Hanson Concrete

Thames Tideway Tunnel Capabilities What we can do Hanson UK Hanson UK, a capable business Production sites

Hanson UK is part of the HeidelbergCement Group, Hanson Concrete is the UK’s largest supplier Operations employing 53,000 people across five continents. of ready-mixed concrete from a national network Our UK operations Marine licences HeidelbergCement is the global leader in aggregates of 178 fixed and site-based plants. Aggregates depots and wharves 16 and a leader in cement, concrete and heavy building Asphalt plants 29 products (brick, block and precast concrete). Hanson Asphalt and Contracting supplies and lays asphalt for road surfacing and provides a range Bagged product plants 12 Hanson UK is split into business lines offering the of infrastructure services. Its civil engineering division Block paving plants 1 broadest range of products and services in the heavy specialises in the construction of wind farms and Brick works 7 building products market. waste-to-energy plants. Cement depots and wharves 6 Cement plants 3 Hanson Aggregates produces sand, gravel Hanson Cement is a leading manufacturer of Portland and crushed rock from over 54 quarries in cement, both in bulk and in bags, and produces ground Concrete/aircrete block plants 7 and Wales and includes Hanson Aggregates Marine, granulated blastfurnace slag (GGBS) under the brand Regen plants 3 Europe’s largest producer of marine-dredged sand name Regen – a cement replacement in ready-mixed Marine dredgers 7 and gravel. and precast concrete – and a range of bagged Precast concrete and flooring plants 2 cementitious and aggregate products. Quarries – sand and gravel 29 Quarries – crushed rock 25 Ready-mixed concrete plants 178 Recycling/landfill sites 17 TOTAL 342

All our production sites are certified to ISO 14001 and ISO 9001

Aggregate dredger Arco Dart Ketton cement works in Rutland Ready-mixed concrete delivery

2 | Hanson Concrete Thames Tideway Tunnel Capabilities Hanson Concrete Thames Tideway Tunnel Capabilities | 3 Our responsibility Hanson UK Health and safety Performance and sustainability

Committed to health and safety Upgrading our fleet network Highlights 2012 Industry firsts Not only have we increased our fleet numbers of late, but we • Committed to achieving the highest standards of have also upgraded them to increase efficiency and to help OHSAS 18001 certification achieved 1998 Began creation of Europe’s biggest man-made reed health and safety for all our employees, customers ✓ sustain our excellent health and safety record, which is of across main business lines bed at Needingworth in partnership with the RSPB and third parties paramount importance. • Seek to reduce the number of accidents and ✓ Employee lost time injuries fall by a third 2000 Built floating concrete platform for Canary Wharf incidents year on year, with the goal of eliminating • Our concrete truck mixers have been fitted with sensors to detect cyclists Signed memorandum of understanding with English Nature lost time accidents Waste to landfill target exceeded ✓ (Nature England) and Countryside Council of Wales • Managers involved daily in behaviour and health • They have been fitted with left turning awareness systems and safety observations • Side under bars have been fitted to our tippers to avoid cyclists ✓ Mains water use falls Became UK Habitat Champion for reed bed and fen • Ensure plants and equipment are maintained to or pedestrians being pushed under the wheels More than 100 biodiversity and geodiversity 2001 Castle Cement gained ISO 14001 and ISO 18001 a high standard • Extra signage on vehicles to help make them more visible ✓ action plans now in place • Openly report our performance and constantly review • High percentage of our concrete mixer trucks have a four-way 2005 Joint BAP and GAP action plan for all quarries • Commitment expected from employees to constantly recordable camera system fitted. Energy use per tonne down 11.5 per cent since 2005 ✓ 2006 Purchase of Civil & Marine, sole UK manufacturer of GGBS strive to eliminate hazards and risk of potential injury. Fleet tracking Stakeholder engagement programme broadened 2007 Carbon Trust Certification awarded to building products • Our vehicles have been fitted with tracking devices to help with ✓ division for energy management and planning delivery planning and further increase efficiency ✓ New sustainability department provides increased focus • Vehicles running out of our King’s Cross plant have All Hanson production sites gained ISO 14001 GPS navigation systems fitted, enabling us to find out the exact 2009-11 Achieved responsible sourcing of materials certification for location of the vehicle ready-mixed concrete and aggregates, asphalt, brick, block, • All of our other vehicles have Hanson WAP phones fitted. These precast concrete and cement help provide various updates, including helping determine at what stage of the route the vehicle is 2010 Largest heavy building materials company • Our fleet tracking capability enables us to provide you with more to receive the Carbon Trust Standard accurate delivery times in the event of a delay. Launched the first low energy asphalt – Hanson era Gained first Site of Special Scientific Interest (SSSI) status for a translocation site from Nature England

4 | Hanson Concrete Thames Tideway Tunnel Capabilities Hanson Concrete Thames Tideway Tunnel Capabilities | 5 Hanson UK Products and services Mobile plant capabilities

Delivering product and technical innovation Mobile concrete plants

Construction Asphalt We have invested in a fleet of mobile batch-plants, available for • Hanson Ecohouse® – first • Hanson era® – low energy, high projects both large and small. We have a wealth of experience in Code 4 masonry house recycled content asphalt for all aspects of concrete production and have successfully managed all surface courses a large number of site batching operations throughout the UK. • Stewartby commercial building Our on-site batching delivers the material right where you need it, –BREEAM excellent • Hanson Tuffgrip® – low noise, keeping trucks off the roads and transport costs to a minimum. reduced course thickness Concrete • Our site plant provides continuity of supply throughout the • High rise – leading Cement project’s lifecycle ® concrete technologies and • Regen – the cement • Our modern plants provide highly accurate mixing for quality construction techniques substitute GGBS concrete, batch after batch in high rise construction • Low CO2 cement – introduction • We can formulate bespoke mixes for every type of job including • Hanson EasyPile® – innovation of aggressive alternative fuel high flow/high strength concrete for pumping in concrete piling mixes and material programmes • All our plants are certified by the Quality Scheme for Ready- • Concrete solutions – post • TioCem® – absorbs and reduces Mixed Concrete (QSRMC)

tensioned, high strength, low NOx in the atmosphere • We will provide operational and technical advice through the early permeability, self-compacting site planning process and continuous support through the whole and lightweight concretes of your project’s lifecycle • Sustainable concretes – high • Quick plant set-up. Regen® (GGBS) mixes with recycled aggregates • Power range – specific mix designs for the energy sector

6 | Hanson Concrete Thames Tideway Tunnel Capabilities Hanson Concrete Thames Tideway Tunnel Capabilities | 7 Our locations Hanson, our south-eastern capability Sprayed concrete and grout capability

Our people Our assets Hanson UK sprayed Over the last 15 years HeidelbergCement has developed in excess of 50 different grout variants for tunnel applications • Worldwide expertise gained on • A strong market position in • Rail-linked aggregates storage concrete with cement across Europe. Through the HeidelbergCement Technical projects ranging from the US London and South East England and concrete production facility Centre (HTC), a specialist department was created to federal road building programme in the heart of London at from Ketton develop grout formulations and work with engineers and • Supported by a comprehensive to the Sydney Olympics King’s Cross contractors to deliver tailored solutions for individual projects network of production sites and Hanson UK has 20 years of experience in producing where geological, logistical and formulation issues needed • Our solid asset base and depots for: • Large scale use of rail and water sprayed concrete through its Hanson Cement and to be considered. These are: experienced management team – ready-mixed concrete transportation for raw materials Hanson Quarry Products divisions. From its Ketton makes us an ideal partner for – asphalt ensures we optimise logistics plant Hanson Cement manufactures a unique quality of • Pumpability of grout from batching plant to work location supplying a range of construction – concrete block and maintain the lowest cost and We optimise logistics to cement that is used in sprayed concrete mixes. Hanson • Setting time control materials in London highest sustainability balance “ensure the lowest cost and UK with HeidelbergCement has a technical product • Sites principally supplied by highest sustainability balance. capability that has been proven in tunnelling projects • Resistance to bleeding and segregation • We meet the key sustainability marine sand and gravel dredged • Close links with major ” worldwide. Hanson Cement and Hanson Concrete, criteria of responsible sourcing, from the English Channel and builders’ merchants to offer Luke Smith together with our admixture partners, can ensure the • Reduced heat of hydration/low heat appropriate use of secondary the North Sea and by rail hauled multi-product drops Hanson regional concrete manager – South East final mixes for the primary and secondary coats deliver: • Durability materials, minimised embodied limestone from Somerset • Experience of installing and impact and healthy materials with • Reduced rebound • Easy application through segment annuluses • The largest high quality sand and running site-based concrete minimum exposure to pollution gravel reserves in the South East production plants • Reduced wastage • Shrinkage compensation • Our successful projects in the • Rail-linked aggregates depots at • Mobile concrete plants for • Time saving capital include: Hanson UK with HeidelbergCement can supply formulations, West Drayton and specific projects and portable – Canary Wharf • Rapid and successful adhesion material and expertise for grout used in concrete segment silos for dry mortar – Terminal 5 building, • Six marine wharves on the tunnel lining. This technical knowledge can be translated in • Consistent best quality Heathrow Airport Thames and Medway rivers • Supported by a distribution the UK market through Hanson UK’s: – Channel Tunnel Rail Link including a deep water terminal network of nearly 500 aggregate • Specific mix designs • Asset base – three cement plants and depots into St Pancras. near tipper vehicles and around 250 concrete truck mixers in the • Material supply – Cement, PFA, Regen (GGBS) South East alone. micro silica, limestone and admixtures • Knowledge – Hanson UK Concrete technologists • UK based technical support and quality control • Pumping expertise

8 | Hanson Concrete Thames Tideway Tunnel Capabilities Hanson Concrete Thames Tideway Tunnel Capabilities | 9 Aggregates Aggregate Depot Asphalt Concrete Cement GGBFS Wharf

Acton King’s Cross King’s Cross Abbey Mills Pumping Station Products available: Ready-mixed Products available: Ready-mixed Ketton Cement delivery 54,304 concrete and cement. concrete and cement. point and stock holding Hanson capabilities Output: 100m3 per hour. Output: 180m 3 per hour. TOWER HAMLETS Major projects: Crossrail, Major projects: CTRL 103/105 Contract, Paddington Station. St Pancras International Station, BBC HQ West Drayton Gt Portland St, The Shard. for Thames Tideway Tunnel Delivery by: Delivery by: Foreshore Bekesbourne Beckton Sewage Treatment Works CITY OF WESTMINSTER 32,285 Street NEWHAM Dagenham King Edward Memorial Park Foreshore • The most sustainable transport solutions Acton for ready-mixed concrete and aggregates KENSINGTON Foreshore Silvertown Acton Storm Tanks & CHELSEA available in London 27,808 Shad Thames Pumping Station Chambers Wharf • £20 million investment in concrete & FULHAM 74,067 plants over the last 5 years Greenwich Erith Connection Tunnel Victoria Deep Chelsea Embankment Earl Pumping • Supported by around 250 concrete Foreshore Station HOUNSLOW trucks and 500 tippers in the South East Hammersmith Foreshore Silvertown Pumping Station Heathwall GREENWICH Products available: Ready-mixed concrete. Kirtling Street Pumping Station 3 • Mobile plant capability Cremorne Deptford Output: 120m per hour. Wharf Depot 71,521 Church Street Greenwich Pumping Station Major projects: The Gherkin, Excel, • Use of Hanson’s unique floating platform: Leamouth Peninsular Prescoll Channel. Carnwath Road Riverside LEWISHAM – bulk of raw material river-fed 55,243 Delivery by: Barn Elms – sizeable reduction in lorry movements Pumping Station Bridge – further reductions in carbon footprint Foreshore Wandsworth Other Aggregate supply sites Dormay Street KEY RICHMOND LAMBETH Victoria Deep UPON THAMES Frogmore • Allington • Newhaven Tunnel Hanson production sites Delivery method Connection Tunnel Products available: Ready-mixed concrete, King Georges aggregates and recycled aggregates. Park Tunnel Site Aggregates Barge Output: 85m3 per hour. • Ardingly • Reigate Main Tunnel High Volume Aggregate Site Floating Plant Major projects: North Greenwich Station, Wimbledon Wandsworth The Dome (O2 Building), East London Line, • Beaconsfield • Shoreham WANDSWORTH New Providence Wharf. Connection Tunnels Aggregate Depot Lorry Products available: Ready-mixed concrete. Products available: Ready-mixed concrete. • Gallagher • Theale 3 Delivery by: Asphalt Ship Output: 110 m per hour Output: 14 0m 3 per hour. (Under Construction) Major projects: Harrods, St Georges Train Major projects: Crossrail Station, •Lenham • Wrotham Concrete Development, Imperial Wharf, Brynes at Riverside, Mill Harbour, Blackwall Place, Wimbledon Tennis Club, Reach Canada Square, Heron Quays. Cement Ready-mix Lorry Development and St George’s Hospital • Mortimer GGBS Delivery by: Delivery by: Wimbledon Wharf

10 | Hanson Concrete Thames Tideway Tunnel Capabilities Hanson Concrete Thames Tideway Tunnel Capabilities | 13 Cement Distribution Terminal Existing station GGBS CementNew Distribution station Terminal Existing station Hanson Building Products GGBSSurface line New station Asphalt HansonTunnel Building Products Surface line Concrete AsphaltPortal (tunnel entrance or exit) Tunnel Drystone Concrete Portal (tunnel entrance or exit) Sales Office Drystone Airport Sales Office Shipping/Fleet Airport Shipping/Fleet

Hanson UK Connecting the City, Canary Wharf, the West End and Heathrow Airport to commuter areas east Hanson UK and west of London, Crossrail is a major new rail link project designed to provide a world-class, East London West London Case studies affordable railway with high frequency, convenient and accessible services across the capital. Case studies

West Drayton Dagenham Purfleet Aggregates Aggregates Aggregate Depot Aggregate Depot Asphalt Asphalt Concrete Products available: Ready-mixed concrete, Products available: Ready-mixed concrete, Case study 1: C510 Case study 2: C305 Concrete GGBS manufacturing plant (grinding Cement Cement GGBFS GGBFS Wharf Primary and Secondary aggregates. aggregates and recycled aggregates. Wharf plant with first vertical mill in the UK). Output: 48m3 per hour. Output: 100m3 per hour. Storage: 12,000 tonne capacity. Crossrail contract C510 – Early Access Shafts and Sprayed Concrete Lining Works Eastern Running Tunnels (Limmo Peninsula to Farringdon; Limmo Peninsula Major projects: RAF Northolt, RAF Ruislip, Major projects: CTRL 250/240JV, Major projects: Olympics, CTRL, M1 Central reservation, Windsor Castle, Romford Hospital, Pioneer Point Ilford. QE2 bridge, Canary Wharf, Stratford City, for Whitechapel and Liverpool Street station tunnels to Victoria Dock; Stepney Green to Pudding Mill Lane) Earls Court Ideal Home Exhibition and The Dome (O2 Building). Heathrow Airport. Delivery by: Delivery by: BBMV, the joint venture encompassing Balfour Beatty, ALPINE Material for sprayed concrete Contract C305 is the biggest design-bid-build construction At the Limmo Peninsula site, two 40m deep and 30m diameter Delivery by: BeMo Tunnelling, Morgan Sindall and VINCI Construction, is Hanson UK is supplying BBMV with key components for the contract of the CRL project. The contract includes the eastern shafts were first built. One shaft was sunk using diaphragm walls,

Shoreditch constructing early access shafts and Sprayed Concrete Lining running tunnels of CRL’s central section with launch shafts and SCL the second so called Auxiliary shaft was built utilising the SCL Kings Cross sprayed concrete mix. Ketton works is the approved cement Abbey Mills Shoreditch Pumping Station Kings Cross Abbey Mills Pumping Station TOWER HAMLETS TOWER HAMLETS (SCL) works for both Whitechapel and Liverpool station tunnels. source; the material is railed into our central London cement launch adits for TBMs at Limmo Peninsula, SCL caverns and launch construction method. At the bottom of each shaft two 15m long

West Drayton EALING West Drayton EALING Beckton Sewage Bekesbourne CITY OF WESTMINSTER Blackfriars Bridge Street Treatment Works Beckton Sewage and 8m wide SCL launch adits were excavated and two 55m Acton Bekesbourne adits for TBMs at Stepney Green and 10 SCL cross passages Foreshore NEWHAM Treatment Works distribution depot at Kings Cross, and road delivered direct CITY OF WESTMINSTER Blackfriars Bridge Street CITY OF LONDONActon King Edward Memorial Foreshore NEWHAM Park Foreshore CITY OF LONDON King Edward Memorial Park Foreshore Victoria Embankment Dagenham The major construction works for C510 began in April 2011 KENSINGTON Foreshore SilvertownVictoria Embankment Dagenham Acton & CHELSEA Foreshore between the running tunnels with lengths up to 30 metres. long and 8m wide SCL tunnels constructed in order to connect KENSINGTON Storm Tanks Silvertown to site. The marine sand is supplied via Hanson marine and Acton & CHELSEA StormShad Tanks Thames Chambers Wharf HAMMERSMITH Pumping Station Canary Wharf Blackwall Shad Thames & FULHAM HAMMERSMITH Pumping Station Chambers Wharf Canary Wharf Blackwall and includes the construction of the Crossrail Whitechapel & FULHAM greenwich both shafts. All SCL works at Limmo Peninsula followed a Top connection tunnel Victoria Deep greenwich processed at Dagenham wharf and road delivered to site. connection tunnel Chelsea Embankment Earl Pumping Victoria Deep Foreshore Station Chelsea Embankment Earl Pumping Albert Embankment Foreshore HOUNSLOW Station Hammersmith Foreshore Albert Embankment and Liverpool Street Station SCL tunnels. Associated works According to Crossrail project managers, the Stepney Green HOUNSLOW Pumping Station Hammersmith Foreshore Heathway Erith Kirtling Pumping Station Heading, Bench and Invert excavation sequence and were carried Cremorne Street Pumping Station Heathway Erith Deptford Kirtling Wharf Depot Church Street Cremorne Greenwich Street Pumping Station Pumping Station Deptford Wharf Depot Church Street Greenwich SOUTHWARK Pumping Station Purfleet will include the shafts and adits, platform tunnels, Tunnel Boring caverns are one of the largest mined caverns ever constructed SOUTHWARK Purfleet GREENWICH With limited site storage at both Finsbury and Whitechapel sites, GREENWICH out in London Clay. Carnwath Road Barn Elms Riverside Falconbrook Pumping Station Carnwath Road Barn Elms Riverside Falconbrook Pumping Station Foreshore Wandsworth Putney Bridge Machine (TBM) reception chambers and launch chambers, cross in Europe using a spray concrete lining. The eastbound cavern is Foreshore Wandsworth and the demanding daily sprayed concrete program, weekly and Dormay Street RICHMOND LAMBETH UPON THAMES Dormay Street frogmore RICHMOND LAMBETH connection tunnel UPON THAMES LEWISHAMfrogmore King Georges connection tunnel LEWISHAM Park King Georges Park passages, access passages, escalator barrels, ventilation ducts daily logistics planning between the BBMV site team and Hanson where Crossrail trains will branch towards Stratford or This project has seen Hanson UK supply to date: WANDSWORTH WANDSWORTH and a link passage from Crossrail Liverpool Street Station to and so is scaled to accommodate the two tunnel boring machines orders at Kings Cross and Allington has significantly contributed • Stepney Green – 11km3 spray concrete lining supplied Wimbledon the London Underground Moorgate. (TBMs) – Victoria and Elizabeth. Wimbledon to the overall success to date. Communication and just in time 24/7 over 9 months delivery has reduced vehicle congestion at the vehicle holding Frindsbury Station platforms – the works also include the construction The cavern is 50m long, 13.4m wide and 16.6m high at its widest • Limmo Peninsula – 7.5km3 spray concrete lining supplied Frindsbury areas awaiting discharge to the concrete plants Hanson operates of four compensation grouting sites in the vicinity of Liverpool point. To construct the cavern, the team had to excavate 7500m3 24/7 over 8 months one of the largest Crossrail approved delivery fleets in London, Street Station and one compensation grouting shaft in the of material and apply 2500m3 shotcrete to the walls. with over 150 vehicles and operatives now approved to deliver • Primary lining mix contains retarder, super-plasticiser, vicinity of Whitechapel Station. microsilica and steel fibres Erith Frindsbury to these sites. Due to the site’s urban location, alongside a school and a Products available: Ready-mixed concrete, Products available: technical college, a concrete batching plant was built on • Secondary lining contains poly fibres (for fire retardation) Primary and Secondary aggregates. Ready-mixed concrete Volumes site to manufacture the concrete for the cavern. instead of steel fibres. Output: 48m3 per hour. and aggregates. Major projects: Costain Construction Waste & Recovery Output: 48m3 per hour. • Cement 48,000 tonnes station in Erith, Highertest - Bell Marsh Prison, Lancsville • Marine sand 40,000 tonnes – Woolwich Arsenal, Bexley Heath Town Centre and Farnborough Hospital. Delivery by:

Delivery by:

Hanson Concrete Thames Tideway Tunnel Capabilities | 11 14 | Hanson Concrete Thames Tideway Tunnel Capabilities Hanson Concrete Thames Tideway Tunnel Capabilities | 15 Hanson UK Case studies

Case study 3: C300

Western Running Tunnels (Royal Oak to Farringdon)

Crossrail’s Western Tunnels Contract is one of the largest of Hanson establishes precast facility for tunnel segments Project description the Crossrail contracts. At peak production the TBMs can each The tunnels are being lined with precast concrete fibre • Establishment of precast facility to produce segments advance up to 40 metres in a day excavating in excess of reinforced concrete segments manufactured in a tunnel for Crossrail C300 Western Running tunnels 3,000 tonnes and installing 575 tonnes of concrete tunnel segment manufacturing facility at Old Oak Common. The • On-site QSRMC accredited computer controlled concrete lining rings. purpose built facility has an on-site QSRMC accredited, batch plant with fully automated steel and polypropylene computer controlled concrete batch plant. The purpose built The western tunnels (C300/410) work comprises two 6.2m fibre dispenser equipment factory employs about 60 people and began producing internal diameter bored tunnels, each 6.5km long between the • Heater systems and enclosed aggregate storage to achieve segments in February 2012. The factory produces up to 200 Royal Oak portal, which is west of Paddington Station, and specified concrete temperature segments per day and includes a laboratory to test the quality Farringdon Station, and the sprayed concrete lining (SCL) of the concrete to ensure that the segments have a 120 year • Planetary type mixer for speed to achieve total homogeneity and station tunnels at Bond Street (BOS) and Tottenham Court life. The factory has been built specifically for the production of mixing of product Road (TCR) and the Fisher Street (FS) cross over tunnel, Crossrail’s tunnel segments on a site that will become home to • Full traceability of all batch weights to include fibres, admixtures, including ticket hall shaft construction at TCR. The western a major Crossrail train depot once segment production is powders and aggregates tunnel drive, between Royal Oak and Farringdon is one of five completed. BFK will manufacture more than 75,000 tunnel • Integrated Hydronix system to record m/c of raw materials drives and will be the point at which the existing Network Rail segments at the Old Oak Common site. and concrete services on the western section of the route enter the tunnels under central London. The concrete segments are transported by tunnel locomotives • Dedicated trucks for concrete supply into segment moulds into the tunnels and loaded onto the 1,000 tonne mobile • Specialist concrete mix design to achieve both tensile and underground tunnel factory (the TBM). As the 140 metre long compressive strengths TBM advances forward, the precast concrete segments are • Volume 80,000m3 built into 23 tonne rings to line the tunnels behind the TBM • Traceability – each segment is specifically coded enabling each cutter head. segment of each ring to be traced as to its location in the tunnel lining and that code can be referred back to an individual batch of concrete.

16 | Hanson Concrete Thames Tideway Tunnel Capabilities Hanson Concrete Thames Tideway Tunnel Capabilities | 17 Our companies and products Hanson UK is the leading supplier of heavy building materials to the UK construction industry. We are split into three business lines – Hanson Cement and Hanson Quarry Products. Hanson UK is owned by the HeidelbergCement Group, which employs over 53,000 people and operates worldwide. Hanson UK employs around 3,500 people across over 300 sites.

For detailed information on all areas of Hanson and our products visit: hanson.co.uk

Hanson UK 14 Castle Hill, Maidenhead SL6 4JJ T: 01628 774 100 E: [email protected] W: www.hanson.co.uk