Aggregates

Case Study:
The Channel Tunnel Rail Link

Recycled and secondary aggregates saves millions on CTRL project

Key Facts and Figures
In total, over 300,000 tonnes of recycled and secondary aggregates (RSA) were used generating savings of almost 2.5 million Close co-operation between Rail Link Engineering, the various contractors and the Environment Agency proved key in maximising the potential for use of RSA

Photograph courtesy of CTRL/Alan Fuller

The Channel Tunnel Rail Link (CTRL) will be Britain's first major new railway for over a century - a high-speed line running for 68 miles between St Pancras station in London and the Channel Tunnel.

Project background
Work on construction of the CTRL began in 1998. The total project is divided into 15 separate contracts. This case study deals with the use of sustainable aggregates in three of these contracts, C103, C310 and C440.

Why recycled and secondary aggregates were chosen

There were a number of distinct advantages gained from the use of RSA in the three contracts.

Economic
RSA had a lower cost than primary aggregates. Direct savings include:

initial cost of the recycled aggregate (free as they were all available
on site from construction and demolition of future/previous structures, or from nearby sites);

the avoidance of Landfill Tax (currently 2 per tonne for inert

materials or 18 per tonne for non-inert materials) and

the avoidance of the Aggregates Levy applied to primary aggregates

(1.60 per tonne).

Environmental
Use of RSA reduced the demand for primary aggregates, and the re-use of materials created a reduction in the volumes of waste sent to landfill.
Photograph courtesy of CTRL

Performance
Testing of the RSA showed that for some of the uses, performance characteristics were superior to those of the primary aggregates which would have conventionally been used.

Project Specification
Name: Region: Type of project: Timescale: Client: Contractors: Engineers: Channel Tunnel Rail Link (CTRL) London Railway infrastructure 2001-2007 Union Railways North/Union Railways South C103 Kier Nuttall JV C310 Morgan Vinci C440 Balfour Beatty Major Projects Rail Link Engineering Project Manager

AggRegain

the sustainable aggregates information service from

www.aggregain.org.uk

Details of RSA use

Contract C103 Recycled material used C&D wastes from contract C105 C&D wastes from a viaduct situated on contract C103 Concrete rejected for construction from contract C105 and nearby batching plants Second hand rail ballasts (about 6 month old) Applications Type 1A, 6N and 6N1 for unbound and fill applications Granular material, Type 1A Unbound and fill applications Bedding for large water pipes and for temporary railways sidings Construction of the piled slab. Structural fill around structures 144,606 m3 30,000 tonnes Quantity Used 130,000 tonnes

C310 C440

Reject lightweight concrete building blocks Spent foundry sand

Lessons Learnt
Overall, the main lesson learnt from the use of RSA on the various CTRL contracts were that it was economical, sustainable and technically feasible. Close liaison and forward planning between the client and contractors was very important to the effective use of RSA.

Contract 103: Kings Cross Railway Lands

The contractors identified that large quantities of recyclable material was available on a neighbouring contract, which could be recycled as unbound material in the massive earth works taking place at C103. While cost effectiveness and availability where important factors in the decision to use these recycled materials, the deciding factor was that the use of these materials avoided approximately 8,000 vehicle movements in Central London.

Cost effectiveness
Use of recycled aggregate Aggregate cost: 0 Crushing and handling: 3 per tonne Total cost: 3 per tonne
Photograph courtesy of CTRL/Urban Exposure

Use of comparable primary aggregate Aggregate cost: 8 per tonne (including Aggregates Levy at 1.60 per tonne)

Total saving

Quantity used

Total saved

7 per tonne

130,000 tonnes

910,000

Total cost: 10 per tonne

Contract 310: West Thames Ripple Lane to Thurrock Contract 440: Ashford to Cheriton
Over 30,000 tonnes of locally sourced spent foundry sand were used on this contract as fill around structures, providing an alternative to low-grade primary aggregate. The use of spent foundry sand was seen to have a number of performance advantages over primary aggregates as well as providing both economic and environmental benefits A total of 144,606 m3 of reject lightweight concrete blocks were used as a temporary and permanent engineering fill. The decision to use these materials was made because of their cost effectiveness and local availability. The blocks were also seen to have a number of distinct performance advantages when compared to the alternative low grade primary aggregates. The blocks allowed lighter structures to be built, had better weight resistance, reduced settlement and maintenance and excellent compressive strength and interlocking.

Cost effectiveness
Use of recycled aggregate Aggregate cost: 7.37 per m3 (including crushing, handling and transportation costs) Use of comparable primary aggregate Aggregate cost: 18.70 per m3 (including Aggregates Levy at 1.60 per tonne, and crushing,handling and transportation costs) Landfill tax: 2 per tonne 9.81 per m3 144,606 m3 1,417,904 Total saving Quantity used Total saved

Cost effectiveness
The use of spent foundry sand provided direct cost savings in terms of the reduced material costs. In addition, due to the availability of a local supply, transport costs were also significantly lower than for equivalent primary material.

Date of case study: March 2004

Further information
WRAP. The Old Academy, 21 Horse Fair, Banbury OX16 0AH

Please quote reference number 20AGG

Disclaimer: While steps have been taken to ensure its accuracy, WRAP cannot accept responsibility or be held liable for any loss or damage out of or in connection with this information being inaccurate, incomplete or misleading. The listing or featuring of a particular product or company does not constitute an endorsement by WRAP and WRAP cannot guarantee the performance of individual products or materials. For more detail, please refer to our Terms and Conditions on our website www.wrap.org.uk Printed on recycled paper containing at least 75% post consumer waste and 25% mill broke fibres using waterless offset and vegetable based inks.

www.aggregain.org.uk Helpline 0800 100 2040