Project Rolling Rock: A Major Milestone for Irving Wallboard!

Irving Wallboard, part of J.D. Irving, Limited’s Construction & Equipment Division, is undergoing a major facility shutdown to upgrade its plant as part of Project Rolling Rock. This five-day, around-the-clock shutdown focuses on significant capital investments and essential maintenance. Once complete, the upgrades will enhance infrastructure, boost operational efficiency and position the business for long-term success.

Key partners in this initiative include CFM, Gulf Operators, and Irving Equipment, all sister companies within the Construction & Equipment Division. CFM is leading mechanical installations and executing shutdown scopes with crane support from Irving Equipment, while Gulf Operators has completed all civil work. Numerous local New Brunswick businesses are also contributing across engineering, construction trades, transportation and catering. The project has created both short and long-term employment opportunities, reflecting Irving Wallboard’s ongoing commitment to its people and community. 

Luke Foster, Maintenance Manager at Irving Wallboard, has been involved from the start. “During this project, there have been several ‘wow’ moments,” he says. “One highlight was the successful execution of all civil work, Laying a strong foundation is crucial and we delivered without compromise. I’m excited to see the full impact of these improvements once they’re operational.” 

The improvements will increase throughput, enhance product quality and consistency, reduce maintenance downtime and eliminate key bottlenecks. "With the first phase set to go live on July 27, including the commissioning of a new dual blend rock hopper fabricated by CFM, the energy at the plant is incredibly positive,” says Foster. “Employees are fully engaged and committed to the project’s success. Despite the constant change and disruption that comes with a capital project of this magnitude, the team’s flexibility and enthusiasm have been amazing.”

When it comes to tracking progress, the team is laser-focused on the safe execution of shutdown-specific milestones. “We hold daily meetings to review timelines and track deliverables,” Foster explains. “Our most critical metric, aside from ensuring everyone goes home safe, is percent completion to plan.” Safety remains a core value throughout the project. 

Planning for Project Rolling Rock began over a year ago through collaboration with JDI’s project engineering team, external firms and frontline staff. Since then, the team has achieved several major milestones, including the completion of all civil work, installation of a new stucco cooler, recommissioning of an overhead crane, and construction of dual blend rock hoppers. Each step laying the groundwork for a more efficient and modernized operation. Phase 1 of the upgrade goes live on July 27, while Phase 2 construction continues and is scheduled for full commissioning in December 2025.

With strong teamwork and leadership, a clear vision and an unwavering commitment to safety, Irving Wallboard is well on its way to delivering one of its most impactful upgrades to date.