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The UK’s commitment to reducing carbon emissions in the construction sector has taken a monumental step forward with the opening of the country’s largest ultra-low carbon cement plant in Wrexham. This innovative facility, built by Material Evolution is set to revolutionise the industry by providing a sustainable alternative to traditional cement production, aligning with the government’s ambitious net-zero targets.

The Role of Ultra-Low Carbon Cement in Sustainable Construction

Cement production accounts for a significant proportion of global CO₂ emissions. The advent of ultra-low carbon cement aims to address this by incorporating alternative materials and advanced technologies. The new plant in Wrexham employs a cutting-edge process to replace a substantial percentage of clinker—a primary contributor to cement’s carbon footprint—with industrial by-products and locally sourced materials.

Material Evolution's new ultra-low cement plant in Wrexham
Image: Material Evolution

Key Features of the Plant:

  • Advanced Manufacturing Techniques: Utilises innovative methods to reduce energy consumption and emissions.
  • Circular Economy Integration: Incorporates waste materials from other industries, reducing landfill dependency.
  • State-of-the-Art Monitoring: Implements real-time carbon tracking and optimisation systems.

Strategic Location and Economic Impact

The plant’s establishment in Wrexham is strategically significant. Its proximity to major construction hubs in the UK ensures streamlined supply chains, reducing transportation-related emissions. Furthermore, the facility is expected to generate numerous local employment opportunities, bolstering the regional economy.

Innovations Driving Change

The plant’s technology portfolio includes:

  1. Alternative Fuels: Reduces reliance on fossil fuels by integrating renewable energy sources.
  2. Carbon Capture Utilisation and Storage (CCUS): Pioneers methods to trap and repurpose emissions.
  3. Digital Twin Systems: Enables predictive maintenance and optimised energy efficiency.

Environmental and Industry Impact

Carbon Footprint Reduction

The plant is projected to cut CO₂ emissions by up to 70% compared to conventional cement facilities, significantly contributing to the UK’s decarbonisation goals.

Industry Leadership

This development positions the UK as a leader in green construction technologies, fostering collaborations across Europe and beyond.

Future Prospects

The Wrexham plant is a blueprint for the future of sustainable construction. It not only aligns with global environmental goals but also sets a precedent for industrial innovation in other high-emission sectors. As the demand for eco-friendly construction materials grows, this facility is expected to catalyse further advancements in sustainable building practices.

Working on behalf of Hyundai Electric UK, in conjunction with National Grid, Collett has successfully delivered two 178Te supergrid transformers from Tilbury Dock in Essex to National Grid’s Biggleswade substation in Bedfordshire.

Each transformer measured 9.0 metres long, 5.4 metres wide and 5.0 metres in height; combining with the trailer for a total vehicle length of 66 metres. Collett utilised their 250Te capacity Goldhofer girder bridge trailer to facilitate the movement of the two transformers to their final destination. The entire project took place over two weeks, with the transport occurring on two consecutive Sundays.

Collett has successfully delivered two 178Te supergrid transformers from Tilbury Dock in Essex to National Grid’s Biggleswade substation in Bedfordshire.
Image: Collett

Prior to the transport, Collett’s Projects and Consulting Departments provided comprehensive planning and site visits to strategise the route.

This included a comprehensive route survey, as well as swept path analysis reports, identifying obstructing street furniture that would require temporary removal. Collett liaised with both Cambridgeshire County Council and Central Bedfordshire Council to ensure that the movement would be successful.

With Collett having undertaken all ship chartering operations, the two transformers arrived at Tilbury Dock. Here, the first transformer was discharged from the vessel onto the girder bridge trailer where it was lowered onto stools in a secure storage area to await future transport.

The second of the two transformers was discharged directly onto the girder bridge trailer, in preparation for the first delivery to commence.

With all preparation in place, Collett began the transport.

Departing from Tilbury Dock, Collett travelled along the 76-mile route in approximately 8 hours.

The load was accompanied by Collett’s in-house escort vehicles as well as police escorts; initially being escorted by Essex police from Tilbury Dock, then handed over to Cambridgeshire Police at the county border.

Upon arrival at the site, Collett was responsible for offloading the transformer. Having previously undertaken detailed planning, including ground bearing pressure calculations, method statements, risk assessments and installation drawings, Collett’s Heavy Lift Team utilised their heavy duty jacking and skidding equipment to skid the 178Te transformer directly from the trailer onto the final plinth.

Collett has successfully delivered two 178Te supergrid transformers from Tilbury Dock in Essex to National Grid’s Biggleswade substation in Bedfordshire.
Image: Collett

With one of the two transformers successfully delivered, the girder bridge was de-mobilised and returned back to Tilbury Dock to load the second transformer. Following the same route, the transformer was delivered to the site where it was once again offloaded onto the final plinth.

The 400kV substation includes two transformers that are needed to power the local area. The substation will initially boost power capacity by 80mW, allowing for future residential and employment growth in the Biggleswade area.

Family-owned Fox Group is taking delivery of four new zero tailpipe emission Volvo trucks which will be used to service a low carbon asphalt plant being constructed at its site in Leyland.

The order comprises three Volvo FMX Electric 8×4 Tridem tippers – to be followed shortly by an FH Electric 6×2 tractor unit.

Fox Group is taking delivery of three new Volvo FMX Electric 8x4 Tridem tippers
Image: Volvo Trucks

Paul Fox, Managing Director of the Blackpool-based business, says: “Electric trucks are no longer on the horizon; they’re here, now, and key to reducing our carbon footprint. At Fox Group we see it as our role and responsibility to make the switch; we’re demonstrating to the whole of the sector that in the right applications, the transition from diesel to electric can be happening now.”

The FMX Electrics will be used to deliver asphalt from a soon to be established low carbon asphalt plant to local construction sites, before backloading sand from Fox Group’s nearby quarry into the plant – with zero tailpipe emissions and minimum noise. It complements the recent re-opening of the former Leyland railhead, which Fox Group is using to bring in enough materials daily to replace 95 eight-wheeler loads. The use of electric vehicles is vital on Fox Group’s journey to net zero, reducing the reliance on fossil fuel.

Fox Group is taking delivery of three new Volvo FMX Electric 8x4 Tridem tippers
Image: Volvo Trucks

Supplied by Neil Crook, Customer Solutions Executive at local dealer Thomas Hardie Commercials, each new FMX Electric is plated at 32-tonnes and benefits from a hydraulically steered tag axle, operating with an insulated aluminium tipper body manufactured by local bodybuilder AJ Hayton.

In a first for the UK, one of the FMX Electrics has been manufactured with fossil-free steel to form the truck’s chassis frame. Produced using a completely new technology based on hydrogen, it ensures a much lower climate impact than conventionally produced steel. It is being gradually introduced to Volvo’s heavy-duty electric trucks, as part of plans to make them both net zero in operation, and when it comes to the materials used in their construction.

Fox adds: “We’re confident that with these electric Volvos, together with our other investments in electric plant and the railhead, we’re showing how we can transport large volumes of materials in a much more efficient and sustainable way.

Fox Group is taking delivery of three new Volvo FMX Electric 8x4 Tridem tippers
Image: Volvo Trucks

“It’s the right thing to be doing for the planet and the communities we operate in, and we’re proud to see Fox Group leading from the front.”

Specified with five traction batteries, each FMX Electric runs on three electric motors, delivering 666hp of continuous power. The massive power is handled by an electromobility traction control system which ensures precision vehicle control even on slippery surfaces, all driven through Volvo’s popular 12-speed I-Shift gearbox – a long-standing favourite with drivers.

The FH Electric tractor unit will feature a matching driveline, but with six batteries, whilst operating at up to 44-tonnes. It will be used in conjunction with a 12m tri-axle tipping trailer, transporting stone from the railhead to local concrete plants.

To support the new vehicles Fox Group has extended its DC charging facilities, with the installation of additional recharging equipment at the railhead. Trucks will operate predominantly during the day, returning to base at night to recharge.

They have been supplied on five-year Volvo Gold Contracts which includes preventive maintenance, repairs, real time monitoring to keep track of the health of the batteries and battery replacements, should performance drop below agreed levels. The trucks are also backed by a full suite of Volvo Connect fleet management services to help boost productivity and energy efficiency.

Fox Group currently operates from 32 locations nationally, specialising in the supply and haulage of aggregates, recycled materials, muck-shift, earthworks and civil engineering projects. It has a fleet of more than 350 vehicles, consisting of six- and eight-wheel tippers, artics, low loaders and road sweepers to work alongside its impressive 4,500 pieces of plant and machinery, and a team of more than 850 people.

New regulations are set to permit the use of hydrogen-powered tractors, diggers, and forklifts on roads throughout Great Britain, excluding Northern Ireland. The consultation period will span four weeks, concluding on April 24th, 2024.

Hydrogen powered JCB digger
Image: JCB

Since 2017, hydrogen-fuelled cars, vans, buses, and trucks have been authorised for road use. However, non-road mobile machinery (NRMM) was omitted from the amendment to the Road Vehicles (Construction & Use) Regulations 1986, commonly referred to as C&U.

In February 2023, JCB secured special dispensation from the Department for Transport to conduct tests on its hydrogen-powered machinery, specifically a backhoe loader, on public highways.

The government is committed to promoting cleaner alternatives to diesel fuel. While battery electric power is suitable for smaller construction machinery, hydrogen is widely acknowledged as the most promising clean alternative for larger machines, provided that the necessary refuelling infrastructure can be established.

Nevertheless, the existing prohibition on hydrogen-fuelled NRMM from travelling on roads between sites poses a significant obstacle to progress in decarbonising the construction industry.

Anthony Browne, the Minister for Technology and Decarbonisation, commented: “Permitting hydrogen-powered tractors, diggers, and forklifts to utilise our roads is a pragmatic step towards reducing emissions. These proposals are integral to our strategy to decarbonise transport in the UK, with skilled jobs in British companies facilitating the widespread adoption of this cutting-edge hydrogen technology, thereby making it more accessible and commonplace.”