From stockpile to valuable aggregate: the MB Crusher cost-saving solution
Turning waste into a valuable construction material is nothing new for Fortis. For more than 20 years, the company has been producing IBA aggregates, marketed as Fortistone®, through the thermal treatment of municipal, commercial, and industrial waste. What was once a disposal problem is now a proven resource for the construction industry.
But even well-established processes have their pressure points. For Fortis, that pressure came in the form of oversized material building up during production — a challenge that was solved by introducing the MB Crusher BF90.3 jaw crusher bucket. The solution turned out to be simpler, smarter, and more efficient than expected.
From waste ash to working infrastructure
Incinerator Bottom Ash, or IBA, is the residue left after waste is burned. Historically, it was seen as difficult and low value. Today, it is widely recognised as a reliable secondary aggregate, suitable for road sub-bases, footpaths, car parks, and structural platforms.
By diverting IBA from landfill and processing it into a saleable product, Fortis has created a clear win-win: reduced landfill dependency and a new revenue stream. Over the past decade alone, the company has recycled, processed, and supplied more than four million tonnes of IBA aggregates to the UK construction sector.
No one can avoid the stockpile problem.
Like all IBA processors, Fortis faces a natural challenge during the maturation phase. Heat and moisture can cause parts of the material to harden and bind together, forming oversized clumps. Anything above 65mm cannot be used directly in the final product.
At first, the oversize material was simply stockpiled. Over time, those stockpiles grew. Recirculating the material back through the plant was an option, but it came with drawbacks: extra handling, increased wear on equipment and rising operating costs. It was clear that a more efficient approach was needed.
Enter MB Crusher
Fortis fitted an MB Crusher BF90.3 jaw crusher bucket to its Volvo EC220 excavator. The impact was immediate.
The BF90.3 crushes the hardened clumps down to 40mm, the ideal size to reintroduce into the production process. Instead of sitting idle in a stockpile, the oversize material becomes usable product again.
There was another bonus. Crushing the material also releases trapped metal, allowing it to be recovered more effectively. The result is a cleaner, higher-quality secondary aggregate and improved recycling performance overall.
A shift from problem to process advantage.
Luke from Fortis explained how the MB Crusher attachment changed day-to-day operations.
What had once been a growing logistical headache became a controlled, on-site process. Oversize material was no longer a burden but a manageable part of production.
“The BF90.3 has reduced recirculation of oversize, with subsequent reductions in processing plant wear and OPEX costs,” Luke said.
By handling material directly at the stockpile, Fortis cut unnecessary movements, reduced strain on the main plant and simplified stockpile management.
Why secondary aggregates matter.
Secondary aggregates, such as IBA, are by-products from other industrial processes that would otherwise go to waste. Their use in construction reduces reliance on virgin materials and helps preserve natural resources.
Fortistone® offers an additional advantage: it is more cost-effective than virgin aggregate and carries no tax levy. For contractors, that means lower material costs. For the industry, it represents a tangible step towards lower environmental impact and potential carbon reduction.
As Luke put it: “IBA Aggregate, marketed as Fortistone®, is a more cost-effective and sustainable solution than virgin aggregates. Its use in construction demonstrates a clear commitment to the environment and the preservation of natural resources.”
Designed for the operator too.
The benefits are not just measured in tonnes and costs. Operators quickly noticed the difference in the cab.
“You can hardly hear it,” said one operator. “It is not silent, you know it is working, but it is very bearable. It is operator-friendly and does not shake you around.”
A practical investment with lasting results
Fortis’ decision to invest in MB Crusher technology was driven by a simple goal: reduce stockpile pressure without adding complexity or cost. The result has been improved efficiency, better material recovery, and a more resilient production process. For companies facing similar challenges with oversized aggregates, Fortis’ experience shows that the right attachment can turn an unavoidable by-product into a controllable, value-generating part of the operation.