Ashcourt Group Puts the John Deere 824P Wheel Loader to Work at Manton Quarry

A John Deere 824P wheel loader is the newest arrival at Ashcourt Group’s Manton Quarry in Lincolnshire. It works alongside a freshly installed Kleemann crushing and screening spread. Awesome Earthmovers went to see the setup in action.

The Ashcourt Group is one of the UK’s leading independent suppliers of construction materials and waste management solutions. The family-owned company is based in Humberside, and it has grown massively since its inception in 2012. That growth came from a mixture of organic expansion and strategic acquisitions. As a result, the company has pushed north, south and west from its original Hull base.

Ashcourt’s roots lie in construction, developing commercial and residential properties across the region. Since then the group has added virgin and recycled aggregates and ready mixed concrete. Pumping services, fuel supply and skip hire followed. Even so, it retains a laser focus on the core construction business.

Expanding South Into Lincolnshire

Ashcourt’s strategically located sites now run from Newton Aycliffe in the north to Leeds in the west. Meanwhile a move south into Lincolnshire has seen the company purchase the Brianplant business. That added another quarry and recycling operation to the portfolio.

Manton Quarry sits just off the M180. The recently purchased site is already undergoing a huge transformation. It will become a state-of-the-art aggregate supplier. It will also process many thousands of tonnes of recyclable material every year.

Together, the acquisitions of Brianplant (Humberside) Limited and Manton Quarry mark a pivotal expansion into Lincolnshire. Consequently, Ashcourt can supply high-quality construction materials to a broader clientele.

Standardizing the Fleet at Manton

The move into Manton saw Ashcourt acquire the plant assets held by previous owner Brianplant. The group then moved quickly to standardize the fleet, bringing it in line with its other quarrying operations. A John Deere 824P wheel loader and a new Kleemann spread now anchor that fleet.

A huge, state-of-the-art CDE wash plant is currently under construction. It will separate and clean both virgin and recycled material more effectively. That in turn increases the quantity and quality of material Ashcourt can sell.

For primary crushing and screening, Ashcourt are firm believers in the Kleemann range. Wirtgen UK sells it just a few miles down the A1 at Newark.

Kleemann Crushing and Screening

Manton Quarry has been supplied with several of the German manufacturer’s solutions. Chief among them is a huge Mobicat MC120i Pro jaw crusher. It has an operating weight of around 85 tonnes and can produce up to 650 tonnes per hour. Its fully adjustable 1200mm x 800mm jaw produces material from 200mm down to 70mm. Additionally, the diesel/electric drive keeps the cost per tonne low.

A 55-tonne Volvo EC550E usually loads the crusher, one of two in the Ashcourt fleet. At the time of our visit, however, the excavator was feeding another Kleemann crusher. That machine was reducing material down to 50mm for a specific project.

The Mobirex MR100i NEO Impact Crusher

That machine is the new Mobirex MR100i NEO, a 250 tonnes per hour impact crusher. It combines compact dimensions with high productivity and consistent material sizing. It is also the first in the growing NEO range. That range suits concrete, demolition waste and asphalt as well as medium to hard virgin stone.

The MR100i offers a large impact range with an optimised inlet geometry, so throughput stays high. Ample space allows rapid discharge of material too. Furthermore, unlike many crushers that require specific tooling, the MR100i NEO uses Kleemann’s Lock & Turn Quick Access system. That lets the operator adjust settings and be ready to run in under 30 seconds.

An additional single-deck screen box sits ahead of the output conveyor. Material passes over 4m² of screening media before exiting to stock via the 3.36m high discharge conveyor. Alternatively, it recirculates into the material hopper via the side conveyor.

Finally, a large-capacity MS953EVO multi-deck screener joins the two crushers. It feeds the stockpiles that the John Deere 824P then works. It keeps material sizes constant so the site can segregate and use everything.

Three John Deere 824P Loaders Join the Fleet

Kleemann crushers and screeners play a pivotal role in aggregates production. Alongside them, Wirtgen Group has secured a deal for three John Deere 824P wheel loaders. They will enter service across a number of Ashcourt sites.

Ashcourt has traditionally run Volvo loaders. However, John Deere’s construction machinery is arriving in the UK slowly but steadily. That aligns with the group’s policy of running efficient, top-spec equipment.

The John Deere 824P is a 26-tonne shovel capable of carrying buckets up to 5.2m³. Material at Manton averages 1.6 tonnes per cubic metre, so the shovel is fitted with a 4.7m³ general-purpose rehandling bucket. As a result, Ashcourt’s large 8-wheeler tippers can be sent to the weighbridge in just three passes.

Inside the John Deere 824P

A powerful Stage V, 9-litre PowerTech engine develops 343hp. It drives through a five-speed Powershift transmission with lock-up clutch. The loader also uses a separate hydraulic pump for the steering system, which makes control easier in heavier applications.

Large swing-out mudguards cover the rear wheels and keep the worst of the mess away from the engine access panels. Behind them sits another panel, this time serving the cooling pack. Because the heavy engine and cooling pack overhang at the rear, the loader needs no large counterweight. Instead the John Deere 824P uses a small casting with integrated battery storage, which protects the vulnerable rear of the loader.

John Deere has recently upgraded the P-series cab on the new X-series models. Even so, it remains a light and airy place to spend a shift. Five steps on the nearside lead up to it, and well-placed grabrails aid the climb. Ashcourt has finished those in hi-vis yellow for this quarrying operation.

Inside, a modern black and grey colour scheme sets the tone. The interior is not the largest available, but it offers enough storage for any operator. This machine has joystick steering to reduce operator stress and fatigue. A steering wheel remains an option. John Deere’s SmartWeigh option is available too. It weighs each bucket load dynamically. That gives a total weight per vehicle and totals moved in a day, week or month.

The John Deere 824P at Work

The 824P is the only loader operating at Manton, so it is kept busy all day. Working closely with the EC550E and the MR100i NEO, it clears processed material from under the conveyor belts. It then ferries that material to the relevant stockpiles. In between, the loader keeps the almost constant stream of tippers loaded and moving out.

A spokesperson for Ashcourt Group summed up the decision. “For several years, our fleet has incorporated various John Deere agricultural machinery, and we have consistently found them to be impressive. When the company announced their development of construction equipment, we conducted a trial of the loading shovel. After a successful trial week, its performance demonstrated innovative technology and improved operator efficiency, leading to the deployment of four machines across multiple quarries in the UK.”

Read more about the Ashcourt Group and its operations.

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