Transforming C&D waste into high-quality recycled sand and aggregates

L. Behan Aggregates transforms C&D waste into high-quality recycled sand and aggregates with a custom Terex Washing Systems plant, meeting Dublin’s growing demand for sustainable construction materials.

Problem

L. Behan Aggregates & Recycling, a family-run business in South Co. Dublin, set out to lead sustainable construction in the region by investing in advanced wash recycling.

 

Challenges included:

  • Diverting C&D waste from landfill
  • Producing recycled sand and aggregates equal in quality to virgin materials
  • No existing plant to meet modern recycling standards
  • A need for a 200tph system offering reliability and full support

 

After years of planning, Larry Behan's long-held vision for a high-performance recycling facility in Dublin moved from concept to reality.

 

Solution

L. Behan Aggregates & Recycling worked with Terex Washing Systems to install a fully integrated Feeder to Filterpress wash plant tailored to their material and capacity needs. After visiting UK installations and the TWS factory in Dungannon, they commissioned a custom solution to deliver sustainable, high-volume recycling.

 

Installed system includes:

  • H12 Live Head Hopper with scalping mesh and overband magnet
  • AggreSand 206 with three decks and dual-sand output via split catch box
  • Aggrescrub 150 for scrubbing and removal of organics
  • MPS MC1000 Cone Crusher in a closed recirculating loop
  • Static 16x5 three-deck dry screen for aggregate classification
  • TC5032 Radial Conveyors for stockpiling
  • Water treatment system with 3000L floc dosing unit and 12m rake thickener
  • Centralised control room with full plant touchscreen management

 

The plant recovers construction and excavation waste into high-quality dual sands and four clean aggregate sizes, supporting sustainable construction across Dublin.

Results

  • Just weeks after commissioning, the plant struggled to keep up with demand from pipe-laying contractors and construction projects across Dublin
  • The installation fulfilled Larry Behan’s long-held vision of introducing advanced wash recycling to Dublin’s construction sector
  • Now producing clean, consistent recycled sand and aggregates that match virgin materials in quality and performance
  • Thousands of tonnes of C&D waste are diverted from landfill, reducing environmental impact and supporting the circular economy
  • The fully integrated Terex Washing Systems setup ensures reliable performance and scalable growth
  • Recycled products have opened a new revenue stream, establishing Behan as a leader in sustainable construction solutions