Inspired by a TV documentary on Stonehenge’s bluestones, Sullivan applied Lean Manufacturing techniques, including root-cause analysis tools like the 5 Whys, to develop the Conveyor System. As detailed in his original Megalithic Portal post, the system uses smaller bluestones arranged in a line or grid as a raised base pathway (6-10 stones, ~2-3 meters long) to elevate and distribute weight, preventing sinking in soft ground. Wooden rollers (2-3 dowels, 10-20 cm diameter) are placed under the load stone (2-5 tons), allowing low-friction rolling. Leapfrogging relocates rear bases and rollers forward after each 1-2 meter advance, creating a continuous, reusable conveyor for distances like Stonehenge’s 240 km bluestone route.
The e-book explains the system’s mechanics, including how friction naturally “dresses” stones through abrasion, and provides step-by-step applications:
- For Stonehenge: Transports bluestones with 5-10 minute cycles, covering 1-2 km/day, outperforming rollers by eliminating resets and saving 50% labor.
- For Egyptian Pyramids: Adapts to ramps and Nile hauls, meeting 1-2 minute takt time for 315 blocks/day with parallels, while rollers fail due to bottlenecks and congestion.
Sullivan’s 3P project prototypes—concrete blocks on grass—confirmed feasibility, with Grok 4 used in 2025 for calculations validating timelines and efficiencies.
“This system challenges us to rethink ancient capabilities,” says Sullivan. “From Stonehenge’s bluestones to Giza’s blocks, it offers a practical, waste-free solution aligned with Neolithic resources.”
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The e-book is available for download.
A youtube video demonstrating the method is available here.
More information can also be obtained at the Megalithic Portal.
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Cover Image, Top Left: Stonehenge. Walkerssk, Pixabay
