Sources of Stone: Ireland, Part I

  The Celtic Tiger is still roaring; the New European brought unexpected prosperity and opportunity to the south (Republic of Ireland) and the north ( Northern Ireland ). And stone is a strong part of that success.
  The Republic of Ireland´s population in 2005 rose to a new modern high of 4.1 million, thanks in part to immigrants from the newest European Union nations and especially Poland, with whom Ireland shares Roman Catholic traditions and, since 1990, commercial links in banking and the cement industry. Historically, however, the current combined population of the Republic and Northern Ireland (about 5.8 million) remains millions below the estimated 8 to 8.5 million who lived on the island in the first half of the 19th century before the Famine.
  In 2005, Ireland retained its place as the EU´s second richest nation per capita – Luxembourg remained at the top of the list.
  Ireland´s history of stone use is truly remarkable. According to archaelogical evidence, man first arrived in Ireland about 10,000 years ago. Around 4000 B.C., Neolithic settlers began to build stone structures in which the high-ranking dead were buried with elaborate ritual.
  Older than the pyramids in Egypt, the megalithic passage tomb at Newgrange in County Meath is a UNESCO World Heritage site. It was constructed around 3200 B.C. on a scale not witnessed elsewhere in western Europe at that time.The great mound, nearly 328’ in diameter and 39’ high, is retained by a wall of massive horizontal stones. The magnificent entrance stone was probably carved in-situ.
  Round Towers are another Irish stone specialty. They were mainly built between A.D. 800-900, initially to serve as bell towers adjacent to a place of worship. Some towers were also manned to watch out for Viking invaders. The great scriptural High Crosses also appeared around this time; however, the arrival of the Normans in the 12th century trans- formed the Irish landscape.
 
IRISH STONE TODAY
  The Republic of Ireland´s flourishing economy of the last decade has brought significant benefits to stone producers. While the quarrying of Irish granite is in decline, Irish Blue Limestone is in great demand at home and abroad. Marble, sandstone and slate are quarried in Ireland but the volumes are small.
  According to the Construction Industry Federation (CIF), 2004 was a good year for the construction industry in the Irish Republic. A record number of 78,000 housing units were built, overshadowing a more-sluggish performance in the non-residential sector. Houses were produced at a rate of 19.5 units per 1000 population, which compares with the European average of 5 units and the U.S. figure of 6 units.
  Construction output overall was expected to grow 2 percent in volume in 2005, against 6 percent in 2004. Full details are given in the Construction Industry Overview at www.cif.ie.
 
  Irish stone company profiles follow in order of reported annual revenues. (Some companies declined to disclose certain financial information.)
 
STONE DEVELOPMENTS LTD.
  This is the number-one dimensional stone firm in Ireland, with a reported turnover in 2005 of around €25 million ($31.1 million). Founded in 1964, it is a subsidiary of the multinational Sisk Group. John Sisk & Son Ltd. is Ireland’s largest construction firm. Sicon, the holding group for John Sisk companies in Ireland and the UK, had revenues of €1.4 billion ($1.7 million) in 2005.
  Stone Developments is Ireland´s leading producer and supplier of architectural and monumental stonework in its various forms and finishes, and is the largest exporter of Irish Blue Limestone. The company supplies natural stonework to the Irish, continental European, U.K. and U.S. markets, in addition to processing and supplying stone sourced from all over the world, including Europe, India and China.
  Stone Developments operates two main limestone quarries in Ireland at Old Leighlin, County Carlow, and Holdensrath, County Kilkenny. The company also operates a limestone quarry at Ballinasloe in County Galway; a white limestone source in County Cork and a red limestone quarry in County Kerry are worked on demand. The Ballybrew granite quarry in County Wicklow was closed at the end of 2005.
  Demand for Irish limestone, both in the domestic building market and from continental Europe, has been at an all-time high since 1998. In order to meet this demand, Stone Developments commissioned a new €4.35 million ($5.4 million) additional production/ stone-processing facility at Old Leighlin, County Carlow, in 2001.
  Around 15 years ago, the Belgian Courtois group came to investigate Irish Blue Limestone because of its similarity to Belgian Petit Bleu, with concern about their own reserves in the long term. Courtois (trading as Erinstone) subsequently bought the Kilkenny quarry now owned by Stone Developments and a strong business relationship between Courtois and Stone Developments developed.
  In April 2003, Stone Developments acquired the Erinstone quarry in Kilkenny and also the operations of the Courtois Group in Belgium. With the acquisition of the Courtois Group, Stone Developments has a strong presence in mainland Europe. The main operating entities in Belgium are Courtois NV in Hemiksem, just south of Antwerp, and Belgian Stone Supply (BSS) in Basecles. BSS is responsible for the sawing and finishing of raw Erinstone blocks into slabs and tiles.
  The company is particularly proud of its contribution to the More London project. This is a €1.45 billion ($1.8 billion) redevelopment between London Bridge and Tower Bridge which includes a new office block for the Greater London Authority, surrounded by a 13-acre landscaped area.
  The development holds 30,000 m² (322,000 ft²) of Irish Blue Limestone paving. In addition it includes heavy section Irish Blue Limestone for an amphitheatre (“The Scoop”), balustrading, cladding, seating and water features. The first two phases of the project are complete, with a third phase (four are planned) now underway.
  Stone Developments Ltd.:  info@stonedev.ie; www.stonedevelopments.ie
  Erinstone: www.erinstone.com
  
KILKENNY BLUE LIMESTONE
  Kilkenny Blue Limestone is a new name for an old company: Feelystone. An 11th-generation family business, Feelystone decided that the most-prudent way forward is to split their business into Kilkenny Blue Limestone and Feelystone. Kilkenny Blue Limestone is the number-two dimensional stone company in Ireland today.
  The Feelystone factory at Boyle in County Roscommon processes up to 70-percent imported materials, while the Kilkenny Blue Limestone factory (adjacent to Kellymount quarry in County Kilkenny) works 95-percent blue limestone.
  Feelystone, from which Kilkenny Blue Limestone has evolved, was established around 1784, and Patrick Feely, the current CEO, represents the 11th generation to have worked in the stone business. He holds an M.B.A. from the University of California at Berkeley.
  The Kellymount quarry near Paulstown is, in fact, three quarries on the same 75-acre site. By literally moving tons of rock, two of the quarries will soon be converted into a very large one. Extraction at Kellymount was around 47,000 m³ (1.6 million ft³)in 2005.
  The Kellymount factory has six frame saws, two large-diameter circular-blade machines, three diamond-wire sawing machines, a number of secondary saws and a polishing line.
  Apart from the domestic market, there are significant sales to Belgium, The Netherlands, Germany and the U.S. Kilkenny Blue Limestone and Feelystone combined had revenues of around €16 million ($19.9 million) last year.
  Asked to name one project in Ireland and one abroad of which the company was especially proud, Patrick nominated an internal conversion project at Kilkenny Castle – “a contemporary work in a heritage setting” – and the Ireland Park complex in Toronto,  which will commemorate the arrival of 38,000 famine immigrants in 1847. The memorial complex will be inaugurated next by the President of the Irish Republic.
  Kilkenny Blue Limestone: www.feelystone.com
 
McMONAGLE STONE LTD.
  Dan McMonagle & Sons is a Donegal company that owns three sandstone and two quarzite quarries. It also imports sandstone from India and other materials from China, Portugal and other countries.
  Revenues last year totaled approximately €10 million ($12.4 million), and the forecast for 2006 is €12.5 million ($15.5 million). Including the processing factory, 120 people are now employed with the company.
  In business for more than 30 years, McMonagle provided products for many structures in Ireland, the United Kingdom, France, Belgium, Germany, Japan and the United States. Major projects for which the company has supplied stone include the Port Tunnel in Dublin, and the Centre Parcs holiday resorts in the United Kingdom.
  Dan McMonagle & Sons Ltd.:  www.mcmonaglestone.ie
  
McKEON STONE
  Since 1950, McKeon Stone has been supplying natural stone products to Irish and European markets, although the company roots go back to 1898.
  The modern company owns a blue limestone quarry and factory at Threecastles, County Kilkenny, and a processing plant at Stradbally, County Laois. There are three diamond-wire machines and a Fantini chain saw in the quarry. Where appropriate, primary sawing is done at the small works adjacent to the quarry where there are four diamond-wire machines. At the factory, blocks of limestone are slabbed using three frame saws and three single-blade saws. Maximum slab sizes are 106” X 66” with thicknesses from 2cm to 20cm.
  About eight years ago McKeon moved away from the manufacture of monuments because they could no longer compete with imports from India and China. They now concentrate on building products of all kinds, including some sculptured work. Door surrounds with decorative carvings are very popular at present in Ireland, as also are quoins, estate entrances and decorative paving.
  Containers of slabs are exported every week to Belgium, The Netherlands and Germany. McKeon products are in a number of prominent structures, including the Irish blue limestone cladding and glue honed window reveals for the new Hilton Dublin Airport hotel.
  The company recorded 2005 revenues of close to €5 million ($6.2 million).
  McKeon Stone: www.mckeonstone.ie
  
RYANSTONE
  Ryanstone, established in 1850, claims to be the oldest supplier of granite in Ireland. Paul Ryan, M.D., represents the sixth generation.
  Ryanstone describes itself as a leading producer and supplier of granite monuments, building stone, hard landscape materials, stone furniture, fountains and ornaments. Revenues in 2005 were €3 milllion ($3.7 million).
  In 2000, the company supplied a 24’ 6” high Celtic Cross, the tallest in Ireland, to a local authority in Carraigmore, County Tyrone. Over the years, Ryanstone has been commissioned to produce monuments for clients in the United Kingdom, Germany and the United States.
  The granite quarry in the Wicklow Mountains is one of the few still operational in Ireland. When asked if granite quarrying was still viable in Ireland in view of “dumping” imports from China, Paul Ryan replied that delivery from China takes 8-10 weeks – and some clients don’t wish to wait that long.
  Ryanstone is particularly proud of having supplied the architectural and monumental stonework for the Battle of Britain Monument on Victoria Embankment in London.
  J.M.K. Ryan Ltd (Ryanstone): www.ryanstone.com

This article first appeared in the October 2006 print edition of Stone Business. ©2006 Western Business Media Inc.