How Kilkenny Limestone is produced: from quarry to finished product

From 3 million cubic metres of blue limestone reserves at Old Leighlin (Co. Carlow), Kellymount and Holdensrath (Co. Kilkenny), Kilkenny Limestone quarries around 75,000 m³ each year for processing into slabs, tiles, paving, cladding and bespoke architectural elements.

R&D

Advanced geological research, combined with analysis of core samples from future reserves, provides information on colour, texture and fracture zones before extraction begins. This allows us to develop precise planning schedules months in advance, matching material characteristics to project requirements.

Our IT system provides full traceability across quarrying and factory production, so every customer order can be traced back to the specific quarry layer the stone was extracted from.

Equipment

Our production combines diamond-wire saws and diamond-tipped chainsaws to cut through the limestone beds at the quarry, with bridgesaws, frame saws, monoblade saws and a semi-automated tile-cutting line at the production facilities. Cooling water is recycled through settlement ponds on the quarry floors, preventing overheating of the saws and suppressing dust.

The machine park includes equipment for fast texturing and specialist finishing, supporting both standard formats and custom orders including tactile paving, kerbs, steps and bespoke architectural elements.

Production

Extracted blocks are transported from the quarries to our production facilities, where mobile cranes position them onto the cutting equipment. Material is regularly moved between the three quarries, which allows us to match each order to the most suitable block.

During the primary and secondary cutting stages, diamond-tipped equipment produces precision-cut stone with minimal waste. Bridgesaws and tile-cutting lines work in combination to maximise material recovery across the production line. Additional machines handle surface finishes such as honing, flaming, bush hammering and stonewashing, along with specialist operations including custom profiles and tactile paving.

Packaging and delivery

Finished products are packaged for shipment to customers in Ireland, the UK, mainland Europe and international markets. Each pallet or crate is covered with a protective pallet hood to prevent weathering during transport, and strapped for secure handling. Custom labelling and export documentation are handled in-house to support international shipments.

Quality assured 

Every stage of our production is subject to rigorous quality control, from raw material inspection through the manufacturing process to final approval. Kilkenny Limestone products carry CE marking under the relevant European standards for natural stone, including EN 1341 (paving slabs), EN 1342 (setts), EN 1343 (kerbs) and EN 12057/12058 (modular and floor/stair tiles). All products are manufactured from ATG-certified materials under an independently audited ISO 9001 quality management system. Low-waste production methods and the naturally low embodied carbon of Irish blue limestone make it a sustainable choice for projects prioritising lifecycle impact.