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Worcestershire Minerals Local Plan Background Document: Concrete Batching and Asphalting

Plants in Worcestershire, May 2015

Worcestershire Minerals Local Plan


Background Document

Concrete Batching and Asphalting


Plants in Worcestershire

Consultation Document
May 2015

Document Details:
Status: Consultation draft 2.0
Date: May 2015
Document Location: www.worcestershire.gov.uk/minerals
Contact: Nick Dean,
Worcestershire County Council, Business, Environment and
Community Directorate, Minerals Planning, County Hall, Worcester,
WR5 2NP
Email: minerals@worcestershire.gov.uk
Tel: 01905 766734

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www.worcestershire.gov.uk
Worcestershire Minerals Local Plan Background Document: Concrete Batching and Asphalting
Plants in Worcestershire, May 2015

EXECUTIVE SUMMARY

1.1. Concrete and asphalt are fundamental to modern built development. The two
materials are different in nature but have many elements in common, not least
because both are major users of aggregates and involve similar environmental
issues. This paper sets out a simple description of the nature of each material
and the environmental and planning issues the Minerals Local Plan will need to
address for both.
1.2. Concrete (a mixture of cement, aggregates and other materials) is our most
widely used construction material and is essential for the sustainable
development of our housing, schools, hospitals, transport networks, energy
infrastructure and our built environment.
1.3. As there are only 12 sites producing cement in the UK, some kind of distribution
network is essential to enable material to be readily supplied to users. That
function is supplied by a network of ready-mixed concrete batching plants,
facilities where builders can buy supplies of concrete in the specifications and at
the time they need it. They are therefore a fundamental element of the
development industry, essential to enabling construction to take place.
1.4. Ready-mixed concrete (RMX) is concrete that is produced in a freshly mixed
and unhardened state. RMX is manufactured from cement, aggregates, water
and other additives as necessary. RMX can be produced (a) in a fixed plant and
distributed to site by a concrete mixer; (b) in a mobile plant at (or near) the
customer site (also known as a ‘site plant’); or (c) in a volumetric truck which
carries the ingredients separately and mixes them on-site (also known as ‘on-
site batching’). In the UK, most RMX is mixed at a fixed plant then delivered to
the customer’s site. The average delivery distance of ready mixed concrete to
the construction site in the UK is 8km.
1.5. Turbid and highly alkaline wastewater, dust emissions and noise are the key
potential impacts associated with concrete batching plants. Where possible
concrete batching plants should be sited such that impacts on the environment
or the amenity of the local community from noise, odour or polluting emissions
are minimised.
1.6. There are 14 RMX plants in Worcestershire at the time of writing. The National
Planning Policy Framework states that in preparing Local Plans, local planning
authorities should safeguard existing, planned and potential sites for concrete
batching (and other sites including those for the manufacture of coated
materials, other concrete products and the handling, processing and distribution
of substitute, recycled and secondary aggregate material). The Minerals Local
Plan will need to set out if and how, these facilities should be safeguarded.

ASPHALT
1.7. Asphalt is a mixture of a bituminous binder with mineral aggregate (stone), sand
and filler, typically containing approximately 4-7% bitumen. Asphalt is primarily
used for road construction, the properties being dependent upon the type, size
and amount of aggregate used in the mixture. Different mixes of bitumen and
aggregate are used to produce the main types of asphalt: asphalt concretes

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www.worcestershire.gov.uk
Worcestershire Minerals Local Plan Background Document: Concrete Batching and Asphalting
Plants in Worcestershire, May 2015

(often known as bitumen macadams); thin surfacings; hot rolled asphalt; stone
mastic asphalt, and warm-mix asphalts used in road construction and
maintenance.
1.8. The production process involves blending the aggregates and then heating
them to a temperature suitable for coating with the bitumen binder. At present
most asphalt is produced in hot mix plants at around 160°C, its strength comes
from the aggregates, the binding agent is normally oil-based bitumen derived
from crude oil. The composition is varied to suit the end use.
1.9. The main use of asphalts is in the construction of roads, from motorways to
private access roads (between 20 and 25 per cent of all aggregates produced in
the U.K. are used for road maintenance and construction).
1.10. The Highways Agency considers that transportation, energy and bitumen prices
are the major influences on variation of costs of highway surfacing material.
Within any given maximum transport radius, cement and energy costs are
understood to be the main influences on the cost for concrete.
1.11. For asphalt and RMX, perishability is an important factor in relation to the
geographic scope of the relevant markets. Asphalt and RMX are best used a
short time after production.
1.12. Wastewater polluted with oil, odours, dust emissions and noise are the key
potential impacts associated with concrete batching and asphalt plants.
1.13. There are 2 asphalting plants in Worcestershire at the time of writing.
1.14. The National Planning Policy Framework states that in preparing Local Plans,
local planning authorities should safeguard existing, planned and potential sites
for concrete batching (and other sites including those for the manufacture of
coated materials, other concrete products and the handling, processing and
distribution of substitute, recycled and secondary aggregate material). The
Minerals Local Plan will need to set out if and how, these facilities should be
safeguarded.

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www.worcestershire.gov.uk
Worcestershire Minerals Local Plan Background Document: Concrete Batching and Asphalting
Plants in Worcestershire, May 2015

CONTENTS
Worcestershire Minerals Local Plan Background Document ........................................................................ 1
Concrete Batching and Asphalting Plants in Worcestershire ........................................................................ 1
Executive Summary ......................................................................................................................................................... 2
Asphalt................................................................................................................................................................ 2
Contents................................................................................................................................................................................ 4
Background information ............................................................................................................................................... 6
Concrete and Cement ................................................................................................................................... 6
Concrete batching plants ............................................................................................................................ 8
Site requirements for a conventional ready-mixed concrete plant ....................................... 10
Asphalt............................................................................................................................................................. 10
Asphalting (Coating) Plants .................................................................................................................... 12
Site requirements for a conventional asphalting plant ............................................................... 14
The scale of the concrete industry in the U.K..................................................................................................... 15
Concrete batching plants in Worcestershire ................................................................................... 16
The scale of the asphalt industry in the U.K. ...................................................................................................... 16
Asphalting plants in Worcestershire .................................................................................................. 17
Combined RMX and asphalting plants ............................................................................................... 18
Environmental considerations................................................................................................................................. 19
Health Issues ................................................................................................................................................. 19
Formal regulatory measures .................................................................................................................. 20
Self-regulatory measures......................................................................................................................... 20
Planning context of concrete batching and asphalting plants .................................................................... 21
Responsibility ............................................................................................................................................... 21
Safeguarding ................................................................................................................................................. 22
National Planning Policy Framework .......................................................................................................... 22
Environmental Issues and controls ..................................................................................................... 23
Air quality considerations ................................................................................................................................ 23
Water management............................................................................................................................................. 24
Noise Management .............................................................................................................................................. 25
Waste management............................................................................................................................................. 26
Landscape and visual impacts ........................................................................................................................ 26
Restoration and aftercare of batching and asphalting plant sites ................................................... 26
Protected environmental sites ....................................................................................................................... 27
Traffic Impacts ...................................................................................................................................................... 27

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Worcestershire Minerals Local Plan Background Document: Concrete Batching and Asphalting
Plants in Worcestershire, May 2015

Summary ........................................................................................................................................................ 27
Climate change................................................................................................................................................................ 29
Environmental impact of concrete ...................................................................................................... 29
CO2 Emissions: transport ......................................................................................................................... 29
Use of recycled materials: Concrete .................................................................................................... 29
Use of recycled materials: Asphalt....................................................................................................... 30
Future Issues ................................................................................................................................................................... 31
Concrete .......................................................................................................................................................... 31
Asphalt............................................................................................................................................................. 31
Conclusions ...................................................................................................................................................................... 33
Appendix 1: The concrete batching process ...................................................................................................... 34
Appendix 2: Bodies consulted on the initial draft Report ............................................................................ 35
Appendix 3: Comments received on initial draft document ........................................................................ 37
Appendix 4: Principal UK Asphalt Specifications ............................................................................................. 38

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Worcestershire Minerals Local Plan Background Document: Concrete Batching and Asphalting
Plants in Worcestershire, May 2015

BACKGROUND INFORMATION
CONCRETE AND CEMENT
1.15. Concrete is a composite material composed of coarse granular material (the
aggregate or filler) embedded in a hard matrix of material (the cement or binder)
that fills the space among the aggregate particles and glues them together. As a
construction material, concrete can be cast in almost any shape desired, and
once hardened, can become a structural (load bearing) element.
1.16. Concrete is widely used today for making architectural structures, foundations,
brick/block walls, pavements, bridges/overpasses, highways, runways, parking
structures, dams, pools/reservoirs, pipes, footings for gates, fences and even
boats. No school, house, road, hospital or bridge could be built without it.
1.17. The cement and concrete manufacturing industries are of major importance to
the national economy and supply an essential product to the construction and
civil engineering industries. It is essential therefore that there should be an
adequate and continuous supply of material to maintain production and an
efficient distribution process to deliver it to end users.
1.18. The RMX industry is well established in the UK. The British Ready-Mixed
Concrete Association (BRMCA) represents members that supply 15 million m3
of concrete a year, around 75% of the UK industry demand. The ready-mixed
concrete industry in the UK has an annual turnover of around £1 billion.1 It is a
crucial supplier to the construction industry which the BRMCA estimates is
currently (2012) worth about £110 billion in the UK.
1.19. The availability of suitable raw materials, particularly chalk and limestone are
the dominant locational factor in the cement industry. The 4 biggest producers in
England and Wales today supply 90% of UK cement demand from only 10
production and 2 grinding/blending plants. Distribution is therefore fundamental
and by far the largest movements within the cement industry are the delivery of
the finished product to the customers who need it to manufacture concrete. That
delivery mechanism is achieved by a network of concrete batching plants across
the whole country. This network is extensive; in the UK the average delivery
distance of ready mixed concrete from batching plant to the construction site is
8 km.
1.20. The main ingredients of concrete are:
 "Aggregate," the large chunks of material in a concrete mix, generally a
coarse gravel or crushed rocks such as limestone, or granite, along with
finer materials such as sand, and
 "Cement"2, commonly Portland cement, and other cementitious materials
such as fly ash and slag cement, serving as a binder or a Ligare (binder)
for the aggregate.

1 http://www.brmca.org.uk/documents/Essential_Ready_Mixed_Concrete_Feb_12.pdf

2
A cement is a binder, a substance that sets and hardens independently, and can bind other materials together.
The word "cement" traces to the Romans who used the term opus caementicum to describe masonry resembling
modern concrete that was made from crushed rock with burnt lime as binder. The volcanic ash and pulverized
brick additives that were added to the burnt lime to obtain a hydraulic binder were later referred to as cementum,

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Worcestershire Minerals Local Plan Background Document: Concrete Batching and Asphalting
Plants in Worcestershire, May 2015

1.21. Water is then mixed with this dry composite, which produces a semi-liquid that
workers can shape (typically by pouring it into a form). The concrete solidifies
and hardens to rock-hard strength through a chemical process called hydration.
The water reacts with the cement, which bonds the other components together,
creating a robust stone-like material.
1.22. "Chemical admixtures" are added to achieve varied properties. These
ingredients may speed or slow down the rate at which the concrete hardens,
and impart many other useful properties.
1.23. "Reinforcements" are often added to concrete. Concrete can be formulated with
high compressive strength, but always has lower tensile strength. For this
reason it is usually reinforced with materials that are strong in tension (often
steel).
1.24. "Mineral admixtures" have become more popular in recent decades. The use of
recycled materials as concrete ingredients has been gaining popularity because
of environmental legislation, cost and reputational benefits and the discovery
that such materials often have complementary and valuable properties. The
most conspicuous of these materials are fly ash (a by-product of coal-fired
power plants) and silica fume (a by-product of industrial electric arc furnaces).
The use of these materials in concrete reduces the amount of primary resources
required, as the ash and fume act as a cement replacement. This displaces
some cement production, an energetically expensive and environmentally
problematic process, while reducing the amount of industrial waste that must be
disposed of.
1.25. The mix design depends on the type of structure being built, how the concrete is
mixed and delivered, and how it is placed to form the structure.
1.26. Concrete batching plants are supplied with raw materials from the
manufacturers and exist to produce and distribute various kinds of ready-mixed
concrete (RMX) at the local scale. These mixes are usually in a freshly mixed
and unhardened state and usually require precise specifications e.g.
compliance with:
- BS EN 206-1 Concrete, Specification, performance, production and
conformity and
- BS 500 Complementary British Standard to BS EN 206-1,
- BS 8500-1 Method of specifying and guidance for the specifier and
- BS 8500-2 Specification for constituent materials and concrete.
1.27. These British Standards for concrete sit at the heart of a network of European
and other Standards necessary for the specification of concrete, concrete
design and concrete construction:

cimentum, cäment, and cement. Cements used in construction can be characterized as being either hydraulic or
non-hydraulic. Hydraulic cements (e.g., Portland Cement) harden because of hydration, a chemical reaction
between the anhydrous cement powder and water. Thus, they can harden underwater or when chemical reaction
results in hydrates that are not very water-soluble and so are quite durable in water. The hydraulic cements do
not harden underwater; for example, slaked limes harden by reaction with atmospheric carbon dioxide. (Source,
Wikipedia)

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Worcestershire Minerals Local Plan Background Document: Concrete Batching and Asphalting
Plants in Worcestershire, May 2015

Figure 1. European and UK specifications for concrete design and construction

1.28. There are many types of concrete available, created by varying the proportions
of the main ingredients above. In this way or by substitution for the cementitious
and aggregate phases, the finished product can be tailored to its application
with varying strength, density, or chemical and thermal resistance properties.
Ready-mixed plants exist to do so on demand, and so are an essential link
between aggregate production and its use in building. They are key to the
efficient working of the development industry.

CONCRETE BATCHING PLANTS


Figure 2. Concrete batching plant (photo courtesy of CEMEX UK Ltd)

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Worcestershire Minerals Local Plan Background Document: Concrete Batching and Asphalting
Plants in Worcestershire, May 2015

1.29. A Concrete batching plant, also known as a batch plant, is a device that
combines these various ingredients to form concrete.
1.30. The specific composition (and resulting properties) of RMX can be customized
to suit different applications. The final product is then discharged into a ready-
mix truck (also known as a concrete mixer). Water is then added to the mix in
the truck and mixed during transport to the job site. A simple summary of the
process is set out in Appendix 1.
1.31. A concrete plant can have a variety of parts and accessories, including but not
limited to: mixers (either tilt-up or horizontal or in some cases both), cement
batchers, aggregate batchers, conveyors, radial stackers, aggregate bins,
cement bins, heaters, chillers, cement silos, batch plant controls, and dust
collectors to minimize environmental pollution.
1.32. A recent development is the availability of the mobile concrete batch plant which
can be designed for the production of all types of concrete, mixed cements, cold
regenerations and inertizations3 of materials mixed with resin additives. The
design can include multiple containers that separately transport all the elements
necessary for the production of concrete, or any other mixture, at the specific
job site. In this way, the operator can produce exactly what he wants, where he
wants and in the quantity he wants through the use of an on-board computer.
Once production is started, the various components enter the mixer in the
required doses and the finished mixed product comes out continuously ready for
final use. Some kinds of plant are also suitable for the recovery of materials
otherwise destined for landfill disposal, such as cement mixtures regenerated
from masonry rubble.
1.33. Mobile batching plants are easy to transport as they can be fixed-mounted on a
lorry, mounted on a truck with tipping box or mounted on an interchangeable
cradle. Plant can be moved to any part of the country and depending on plant
size, can often be set up in less than a week.
1.34. Batching plants can therefore be simple or complex, wet, dry, fixed, mobile,
large, small, vertical or horizontal in design. In practice the main types are:
(a) a fixed plant and distributed to site by a concrete mixer;
(b) a mobile plant at (or near) the customer site (also known as a ‘site
plant’); or
(c) a volumetric truck which carries the ingredients separately and mixes
them on-site (also known as ‘on-site batching’).
For simplicity's sake the term "ready-mixed plants" (RMX) has been used
throughout to describe all of these unless some specific type of plant is being
discussed. The National Planning Policy Framework only refers to fixed plant
and only these will be considered in the Minerals Local Plan.
1.35. The Competition Commission found that the large majority of RMX customers
purchase RMX on a project basis; there are very few fixed outlet customers.

3
Materials to prevent the formation of potentially explosive atmospheres by diluting combustive agents (e.g.
Oxygen present in the air) with inert gases such as nitrogen, argon and carbon dioxide.

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Worcestershire Minerals Local Plan Background Document: Concrete Batching and Asphalting
Plants in Worcestershire, May 2015

However, the size and type of project for which RMX is purchased, and the type
of customers, varies widely. The Commission found that RMX markets were
highly localized in nature, with narrow catchment areas within about 8 to 10
miles of RMX plants, albeit with some scope for variation in catchment area
according to local factors and the means of distribution (since RMX is a
perishable product and can only be transported for a limited time after it has
been mixed)4.
1.36. In the UK, approximately 86% of RMX is mixed at a fixed plant then delivered to
the customer’s site, 9% is supplied by volumetric trucks and 5% is mixed at site
plants and supplied to the same site5. The absence of rail links between the
industry and its customers and the current cost disparity between rail and road
transport means that the industry relies mainly on road transport, even where
both are available. There is currently one site in Worcestershire that transports
aggregates by water, and alternative modes of transport (water, rail) within
Worcestershire are covered in separate background papers.

SITE REQUIREMENTS FOR A CONVENTIONAL READY-MIXED CONCRETE PLANT


1.37. A typical RMX plant requires:
 Approximately 2,500 square metres of hardstanding, including sunken
catchpit, washout bay, and space for aggregate storage as necessary,
 mains power with 300kva 3 phase,
 mains water with a minimum 75mm pipe,
 telephone/isdn lines,
 washout /settlement /drainage facilities, both collection and recycling,
 loading shovel and fuel point, and
 adequate access to the highway for HGVs.
Exact site requirements will vary depending on the job and the specification,
volume and timing of what is needed.

ASPHALT
1.38. Asphalt6 is a mixture of a bituminous binder with mineral aggregate (stone),
sand and filler, typically containing approximately 4-7% bitumen. Asphalt is
primarily used for road construction, the properties being dependent upon the
4
Competition Commission Aggregates, Cement and Ready-mix Concrete Market Investigation Final
Report
http://www.competition-commission.org.uk/assets/competitioncommission/docs/2012/aggregates-
cement-and-ready-mix-concrete/140114_aggregates_final_report.pdf
5
Competition Commission Aggregates, Cement and Ready-mix Concrete Market Investigation
Provisional Findings Report 21st May 2013 (Para 2.75) http://www.competition-
commission.org.uk/assets/competitioncommission/docs/2012/aggregates-cement-and-ready-mix-
concrete/130523_provisional_findings_report.pdf
6
In North America, bitumen is commonly known as “asphalt cement” or “asphalt”. In Europe, the term
“asphalt” is used for the mixture of small stones, sand, filler and bitumen, particularly in its use as a
road paving material. The term ‘asphalt’ is used in this publication and unless accompanied by a
descriptor (for example “Asphalt Concrete” (AC), ‘Hot Rolled Asphalt’ (HRA) or ‘Stone Mastic Asphalt’
(SMA)), is applied in its generic sense to refer to the range of mixtures used in the UK.

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Worcestershire Minerals Local Plan Background Document: Concrete Batching and Asphalting
Plants in Worcestershire, May 2015

type, size and amount of aggregate used in the mixture, all of which are
adjusted to provide the required properties for the desired application. The
waterproofing properties of bitumen binders have been recognised from ancient
times and aggregate mixtures bound with these binders can produce
construction materials having good waterproofing or water-resistant properties.
Different mixes of bitumen and aggregate are used to produce the main types of
asphalt: asphalt concretes (often known as bitumen macadams); thin
surfacings; hot rolled asphalt; stone mastic asphalt, and warm-mix asphalts
used in road construction and maintenance.
1.39. The production process involves blending the aggregates and then heating
them to a temperature suitable for coating with the bitumen binder. At present
most asphalt is produced in hot mix plants at around 160°C, its strength comes
from the aggregates, the binding agent is normally oil-based bitumen derived
from crude oil. The composition is varied to suit the end use.
1.40. The main use of asphalts is in the construction of roads, from motorways to
private access roads (between 20 and 25 per cent of all aggregates produced in
the U.K. are used for road maintenance and construction).7 Asphalt concretes
(often previously known as macadams in the UK) have provided the building
blocks for the road network for many years. They have good mechanical
performance and provide strong, stiff and durable bases on which to lay surface
courses8. The structure of a road comprises several layers and asphalt is widely
used to form the structural layers (or courses) as well as the surface layer.
1.41. There is a wide variety of proprietary asphalts available in the UK designed to
provide specific benefits. The largest non-highway use of asphalt is for surfacing
work on airfields. Most runways on both civil and military airfields in the UK are
surfaced with these materials. Other significant uses are in vehicle parking
areas (from heavy lorry parks to private drives), footways, kerbs, sport and
recreation areas e.g. cycle ways, driver training, motor racing circuits and in a
number of farming applications: agricultural roads and yards where particular
kinds of mud and animal waste accumulation needs special specifications.
1.42. For many years asphalt mixes have also been used for canal lining, reservoir
lining, sea wall construction, coastal groynes and dam construction and even
the lining of leisure lakes. Dams incorporating asphalt mixes are at Dungonnell,
Colliford, Faroe Islands, Marchlyn and Megget. Reservoirs at Shotton,
Leamington and Towey have also incorporated asphalt.
1.43. Another application has been in the lining of liquid waste lagoons and landfill
sites. Asphalt has been used in many parts of the world, particularly in the USA
and Italy, as a base under new railway tracks, asphalt roofing products are also
important in the USA. Neither of these is significant in the U.K. at present.
1.44. Designed asphalts are developed to meet the specific needs of individual
locations or uses. The main generic categories of asphalt are:
 Hot Rolled Asphalt (HRA): Hot rolled asphalt has been used in the UK for
nearly 100 years and has been the most common surface on the
country's road network.

7
Mineral Products Association website http://www.mineralproducts.org/iss_key01.htm 2014.01.09
8
The terminology used in this guide for the structural elements of the surface is that adopted for use
in the European Standards for asphalt mixtures. Surface course was previously known as 'wearing
course', binder course was known as 'basecourse' and base was known as 'roadbase'.

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Worcestershire Minerals Local Plan Background Document: Concrete Batching and Asphalting
Plants in Worcestershire, May 2015

 Stone Mastic Asphalt (SMA): Employing technologies from Germany and


Scandinavia, stone mastic asphalt was developed in the UK initially for
use on high speed, high volume roads and variants are now widely used
in the UK. It has a high resistance to rutting and is extremely durable.
SMA also has good spray and traffic-noise-reducing properties.
 Thin Surfacings: Thin surfacings represent developments in asphalt
materials in more recent years. As their name suggests, they are thin
layers, usually between 20-40mm, compared with traditional surface
course thicknesses of around 30-50mm, and provide good surface
texture and high-quality riding surfaces. They have important cost and
environmental benefits as they employ less material and are quick to lay,
thus cutting installation times.
1.45. Being subject to the combined damaging effects of climate and traffic, all
asphalt materials require maintenance at regular intervals, dependent on their
location and nature of use. Surface courses are fully exposed to those effects
and so need more frequent attention to better protect the structural layers. The
appropriate specification and installation of the right materials for the right site is
key to ensuring the durability of both the materials and the road structure.

ASPHALTING (COATING) PLANTS

Figure 3. Asphalting plant (photo courtesy of Lafarge Tarmac)

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Worcestershire Minerals Local Plan Background Document: Concrete Batching and Asphalting
Plants in Worcestershire, May 2015

1.46. Asphalt, sometimes called "coating," plants are similar to concrete batching
plants; a device that combines aggregates and other ingredients to form a
product used in development or infrastructure. The fundamental differences
between them being that:
 whilst concrete production fundamentally depends upon the addition of
water, asphalt production depends upon bitumen and oil based products
and the use of heat to combine the various constituents and
 gravel aggregates are generally not suitable in their natural state for
asphalt products because they are rounded, (unlike crushed aggregates
which are angular), and therefore do not do not bind in the asphalt matrix
unless crushed9. Natural sand, i.e. less than 3 mm, is however very
suitable and is used in many asphalt mixes10.
1.47. There are two basic kinds of asphalting plant;
 fixed, usually large scale operations producing large volumes for
transportation elsewhere. Fixed plants are supplied with raw materials
from the manufacturers and exist to produce and distribute various kinds
of coated materials at the local scale. In summary the materials are
heated, often to temperatures of 160C (but there is considerable
experimentation to develop cooler production methods) and mixed to
ensure an even coating and consistency. Fixed plants are often situated
in quarries but they may occasionally be 'satellite' plants in urban
locations to serve a specific local market, or even temporary installations
on a major road or airfield site and
 mobile, most commonly used to re-lay road surfaces on site. These are
much smaller in scale and in effect heat and recycle existing materials at
the point of use. Mobile plants are commonly used for highways repairs.
1.48. All asphalt mixtures require precise specifications. Probably the most important
change facing the UK asphalt industry and its customers in recent years has
been the implementation of European Specifications for asphalt, its constituents,
and methods of testing. This process began on 1 January 2002 with introduction
of the European specification for road bitumens (BS EN 12591) which
introduced changes to the available bitumen grades and grade references. The
aggregates used in asphalt have also come under the scope of European
Standards (from 1 January 2004), and in order to accommodate those changes
at that time, the material descriptions for the British Standard asphalts and

9
The Competition Commission considered that the low proportions of use of sand and gravel in
asphalt (11-12% in 2009-10 according to the MPA, compared with crushed rock which accounts for
over 70 per cent of the aggregates used in asphalt) suggest that sand and gravel aggregates are not
.
generally as suitable for asphalt production as crushed rock aggregates http://www.competition-
commission.org.uk/assets/competitioncommission/docs/2012/aggregates-cement-and-ready-mix-
concrete/130523_provisional_findings_report.pdf
10
“Asphalt sand” is a key component in the mix and in some areas is in short supply. This could have
important implications for aggregate supply in the Minerals Local Plan, if it is found in Worcestershire,
natural asphalt sand could be classed as a specialist material in the same way as high non-skid stone
or railway ballast.

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Worcestershire Minerals Local Plan Background Document: Concrete Batching and Asphalting
Plants in Worcestershire, May 2015

macadams were changed11. The Highways Agency's Specification for Highway


Works has adopted these and other consequent changes.

SITE REQUIREMENTS FOR A CONVENTIONAL ASPHALTING PLANT


1.49. A typical fixed asphalting plant requires very similar components as a ready
mixed concrete plant but because of the capital cost of developing asphalting
plants economies of scale are important; the size of fixed plants tends therefore
to be larger and the market area more extensive. Exact site requirements will
vary depending on the job and the specification, volume and timing of what is
needed. There are far fewer fixed asphalting plants than RMX plants in the UK.
The locational requirements for asphalting plants are rather different from those
for RMX plant. The Mineral Products Association (MPA) considers that given
that MPA Members are typically the larger highways construction and
maintenance organisations, the location of a depot as a point of contact may not
preclude it from operating anywhere in the country.

11
As far as asphalt is concerned, the family of test methods (EN 12697 series) for asphalt have been
published as well as the various asphalt mix specifications and conformity assessment procedures
(EN 13108 series). All EU states were required to implement these of standards and withdraw all
conflicting national standards on 1 January 2008. The British Standards Institute (BSI) has published
a National Guidance Document BD6691 to interpret the requirements of the EN13108 series for
implementation in the UK - along with PD6692 for asphalt test methods and BS594987 for installation
of asphalt (to replace the Part 2s of BS594 and BS4987).

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THE SCALE OF THE CONCRETE INDUSTRY IN THE U.K.


1.50. The Competition Commission estimated12 that the following numbers of ready-
mixed plants were operational on 31st Dec 201113:
Operators Number of plant

Fixed Plant
Aggregate Industries 93
Cemex 209
Hanson 180
Lafarge 93
Tarmac 150
Total of above 5 companies 781
All independents (194 companies) 352
( incl. 6 Medium tier independents) (78)
Total Fixed Plant 1,133
Mobile Plant/Volumetric trucks 183
Operators

Total Mobile Plant 183

1.51. The Competition Commission found that the mean volume production by site,
according to BDS data in 2011, was 19,000 m 3 for sites operated by the Major
companies versus 15,000 m3 for sites operated by non-Majors.
1.52. The Commission found that the biggest 5 companies supply 66% of the ready-
mixed concrete used in the U.K. but did not find evidence indicating widespread
problems across multiple local RMX markets in the U.K. (whether as a result of
unilateral market power or coordination) or any features giving rise to concern in
any market in GB for the supply of RMX through unilateral market power or
coordination or from market concentration. It found that the collective share of
supply of RMX in GB held by independent RMX producers had grown from 21
per cent in 2005 to 27 per cent in 2011 (with further growth in 2012) and that
there was no significant evidence of barriers to entry and expansion in RMX 14.

12
Competition Commission Aggregates, Cement and Ready-mix Concrete Market Investigation
Provisional Findings Report 21st May 2013 http://www.competition-
commission.org.uk/assets/competitioncommission/docs/2012/aggregates-cement-and-ready-mix-
concrete/130523_provisional_findings_report.pdf
13
Changes within the industry mean that Tarmac and Lafarge have now merged and a new
company, Hope Materials is now operating in the UK. There is no evidence at the time of writing that
the total number of plant is significantly different.
14
Competition Commission Aggregates, Cement and Ready-mix Concrete Market Investigation Final
Report http://www.competition-
commission.org.uk/assets/competitioncommission/docs/2012/aggregates-cement-and-ready-mix-
concrete/140114_aggregates_final_report.pdf

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CONCRETE BATCHING PLANTS IN WORCESTERSHIRE


1.53. There are 9 companies operating 14 RMX plants in Worcestershire at the time of
writing. A complete list can be found in Appendix 2 under "Bodies Consulted".

Figure 4. Concrete batching plant in Worcestershire

THE SCALE OF THE ASPHALT INDUSTRY IN THE U.K.


1.54. There does not appear to be a central register of asphalting plants in England.
The Mineral Products Association members have 61 fixed asphalt contracting
sites in England at the time of writing15. There are probably more; this list does
not include one of the sites in Worcestershire, for example. The Competition
Commission16 estimates that nationally 7 of the 61 plants were operated by
medium sized aggregates companies17. The MPA recognises that their listings
only include MPA Members and not all contractors, of which there will be
significantly more, it is possible however that these operate mobile rather than
fixed plant.

15 th
Correspondence with the MPA 4 February 2014.
16
Competition Commission Aggregates, Cement and Ready-mix Concrete Market Investigation
Provisional Findings Report 21st May 2013 http://www.competition-

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1.55. The asphalt industry in the U.K. produces approximately 25 million tonnes of
asphalt every year18. The Highways Agency19 estimates that the big 5
aggregates companies accounted for around 90 per cent of the market in terms
of supply of materials.
1.56. According to the data from the MPA, sand and gravel accounted for about 11%
to 12% of primary aggregates used in asphalt production in 2009 and 201020.
1.57. Although there are no definitive figures, the industry considers that between
10% and 20% of new asphalt contains recycled asphalt. The quantity of asphalt
planings arising annually within the UK is thought to be between 5 and 7 million
tonnes. By comparison, the UK aggregate market is around 280 million
tonnes/year, of which 28% is aggregates from secondary and recycled
resources.

ASPHALTING PLANTS IN WORCESTERSHIRE


1.58. At the time of writing the Council has identified 2 fixed asphalting plants in
Worcestershire:
 Lafarge/Tarmac Pershore, Terrace road, Pinvin, Pershore, WR10 2DJ
 Cemex UK Construction Services Ltd, M5 Motorway Compound, Hill
View Road, Upper Strensham, Worcestershire, WR8 9LJ

commission.org.uk/assets/competitioncommission/docs/2012/aggregates-cement-and-ready-mix-
concrete/130523_provisional_findings_report.pdf
17
At 31st Dec 2011. Changes within the industry mean that Tarmac and Lafarge have now merged
and a new company, Hope Materials, now operates in the UK, there is no evidence at the time of
writing that the total number of plant is significantly different.
18
http://www.mineralproducts.org/prod_asp01.htm 2014.01.09
Asphalt sales (GB) 2012 18.5mt, 2011 22.4mt MPA Summary Sustainable Development Report
2013 page 4 (MPA 2013)
19
http://www.competition-commission.org.uk/assets/competitioncommission/docs/2011/anglo-
american-lafarge/111103_summary_of_the_hearing_with_highway_agency.pdf
20
Source; data from ONS, Business Monitor PA 1007 Mineral extraction in Great Britain.

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Figure 5. Asphalt batching plant in Worcestershire

COMBINED RMX AND ASPHALTING PLANTS


1.59. At present, contractors need two different types of production plants to produce
both RMX and asphalt but proposals are in hand to combine both processes in
one plant. The structural components of aggregate with a binder, such as
asphalt cement for making hot-mix asphalt (HMA) or Portland cement for
making concrete are similar. Both materials have broadly similar constituents,
the variable is essentially the addition of either bitumen or Portland cement (with
water or other additives) to create the desired mix and (usually) the use of heat
to melt the bitumen. Every asphalt and concrete plant has components that help
proportion and mix the materials. A "ConAsphalt" plant would manage the
production of both asphalt and concrete with the same group of aggregate bins.
The proposed single plant would have the mechanical devices to make either
product simply by engaging the right controls to move the aggregates to the
appropriate mixer. Such plants are under active development21.

21
"Aggregates Business, Europe" website http://www.aggbusiness.com/categories/asphalt-plants-
equipment-applications/features/technological-advances-in-asphalt-mixing-plants/ 2014.01.09

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ENVIRONMENTAL CONSIDERATIONS
1.60. The manufacture and use of both concrete and asphalt produce a wide range of
environmental and social consequences. Some are harmful, some welcome,
and some both, depending on circumstances. A major component of concrete is
cement, which similarly exerts environmental and social effects. Alongside
energy generation and transportation, the cement industry is one of the three
primary producers in the UK of carbon dioxide, a major greenhouse gas.
Asphalt depends upon bitumen, an inherently polluting material.
1.61. Construction, maintenance and operation of roads only account for 2% to 5% of
the overall energy consumption of road transportation. However, a 2004
European Asphalt Pavement Association report states that "the dominating
activity for the emissions of CO2 and SO2 is in the initial construction of the road,
with maintenance of the road the second largest source of these emissions.
Consequently, reducing greenhouse gas emissions during the production of the
materials used in road construction and maintenance is a very relevant
contribution to reducing the environmental impact of roads22".
1.62. Both concrete and asphalt are used to create hard surfaces that contribute to
surface runoff, which can cause soil erosion, water pollution, and flooding, but
conversely can be used to divert, dam, and control flooding. Concrete is a
primary contributor to the urban heat island effect, though less so than asphalt.

HEALTH ISSUES
1.63. Workers who cut, grind or polish concrete are at risk of inhaling airborne silica,
which can lead to silicosis. Concrete dust released by building demolition and
natural disasters can be a source of dangerous air pollution.
1.64. The presence of some substances in concrete, including useful and unwanted
additives, can cause health concerns due to toxicity and radioactivity. Wet
concrete is highly alkaline and must be handled with proper protective
equipment. The oil based elements of asphalt are potentially both flammable
and polluting and again, need proper protective equipment.
1.65. The latest results of ongoing epidemiological studies by the International
Agency for Research on Cancer (IARC), published in July 2009, confirm that no
evidence was found of an association between lung cancer and exposure to
bitumen fumes23.
1.66. The Minerals Local Plan could include policies to ensure that health issues are
addressed where new plant are proposed as part of wider mineral working
development or are considered for safeguarding. In general however these,
matters fall to the pollution control authorities and should not be duplicated by
the Minerals Planning Authority.

22 Aggregates Business, Europe" website http://www.aggbusiness.com/categories/asphalt-plants-


equipment-applications/features/reduced-temperatures-for-asphalt-production/ 2014.01.09
23 Eurobitume "Health: A Case-Control Study of Lung Cancer Nested in a Cohort of European Asphalt

Workers http://www.eurobitume.eu/publications 2014.01.12

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FORMAL REGULATORY MEASURES


1.67. Ready-mixed concrete and asphalting plant can only be operated in England
and Wales in accordance with a permit issued under section 2 of the Pollution
Prevention and Control Act 1999. The permits set out a pollution control regime
for the purpose of implementing the Integrated Pollution Prevention and Control
Directive (Council Directive 96/61/EC) and for regulating other environmentally
polluting activities not covered by the Directive. In 2007 the Regulations
combined the Pollution Prevention and Control (PPC) and Waste Management
Licensing (WML) regulations and were themselves replaced by the
Environmental Permitting Regulations (England and Wales) 2010. The 2010
regulations extended the controls to include water discharge and groundwater
activities, radioactive substances and provision for a number of Directives,
including the Mining Waste Directive. The Regulations apply to England and
Wales. Enforcement is split between the Environment Agency and local
authorities.
1.68. Blending cement in bulk, bagging it or using it in bulk for batching ready-mixed
concrete, the manufacture of concrete blocks or other cement products and the
production of asphalt except at a construction site, need a specific
environmental permit from the Local Authority24.
1.69. Environmental permits issued under these regulations conventionally include a
conditions and requirements that the Applicant must comply with, notably
relating to dust and air and water emissions, to ensure that the operation does
not give rise to adverse environmental effects on air or water quality.
1.70. The concrete batching and asphalting plants in Worcestershire are regulated
and monitored by Worcester Regulatory Services and the Environment Agency.
At the time of writing, neither has reported that they have concerns about the
environmental conduct of these plants in Worcestershire.
1.71. Like all industrial processes both types of plant are also covered by Health and
Safety and nuisance control legislation.

SELF-REGULATORY MEASURES
1.72. In addition to the statutory Permit, many operations in the UK are accredited
under the International Environmental Management Standard ISO 14001. By
2010 around 86% of BRMCA members' ready-mixed concrete plants were
covered by an EMS (Environmental Management System)25. Accreditation
requires strict compliance with all statutory regulations, planning conditions and
other environmental standards and requires the operator to adopt and
implement a robust environmental management system (EMS) to ensure that
potential risks are properly managed and minimised. Sites are inspected by
independent auditors as well as the applicant’s own in-house auditors, to
determine compliance with the ISO 14001 standards.
1.73. In 2008 the UK concrete industry agreed a Concrete Industry Sustainable
Construction Strategy. This pledge to sustainability objectives was signed by

24
In Worcestershire the role is undertaken by Worcester Regulatory Services.
25
British Ready Mixed Concrete Association
http://www.brmca.org.uk/documents/Essential_Ready_Mixed_Concrete_Feb_12.pdf

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trade associations and companies and included the commitment to publish an


annual report on the sustainability performance of the industry.

PLANNING CONTEXT OF CONCRETE BATCHING AND ASPHALTING


PLANTS

RESPONSIBILITY
1.74. Matters relating to the "winning and working" of minerals are defined as "County
Matters"26 and are the responsibility of the Mineral Planning Authority for the
area; in this case, Worcestershire County Council. In themselves batching and
asphalting plants are not a "County Matter" and unless planning applications for
batching plants are made as part of proposals for a larger mineral development
or are demonstrably subsidiary elements of any such development, are usually
determined by the relevant City, Borough or District Council in Worcestershire..
In general, the pollution control, nuisance abatement and health aspects of
concrete batching and asphalting plants are dealt with by the Environment
Agency, Worcester Regulatory Services and Health and Safety Executive and in
accordance with national planning policy it would not be appropriate for the
county council to seek to control these matters.
1.75. Both kinds of plant are usually considered B2 industrial development and are
often located on land designated for employment, usually industrial, uses. Their
nature readily relates them to mineral workings however and they are often
located at quarries or gravel pits. The National Planning Policy Framework
(NPPF) includes reference to them in the context of mineral development
generally. T should be noted that in an Appeal decision in In a decision in
Staffordshire 15/08/1990 DCS No 041-663-476 an inspector thought that a
ready-mix plant at a sand and gravel quarry could not be incidental to it.
1.76. One of the operators of both concrete and asphalting plants in the county has
identified an increasing trend amongst their customers to require "out of hours"
deliveries and accordingly a need for plant to be operated at night. There is
therefore a potential for conflict between commercial demand and local amenity.
This is an issue which could usefully be addressed in the Minerals Local Plan.
There are no formal mechanisms at present however between the county and
city, borough and district councils in Worcestershire to ensure consultation or
discussion between the two tiers to ensure that the issues are properly
discussed.
1.77. For the Minerals Local Plan two broad matters need particular consideration,
safeguarding existing plant and the environmental impact of new plant. These
matters are set out below to indicate the kinds of issues involved and the
matters which need to be addressed when considering the determination of
applications for new RMX and asphalting plants or the safeguarding and
retention of existing plant. The Minerals Local Plan could include policies to

26
Town and Country Planning Act 1990 schedule 1 defines 'County Matters' in relation to the winning
and working of minerals and related matters and the Town and Country Planning (Prescription of
County Matters) (England) Regulations 2003 prescribe certain classes of operations and uses of land
as "county matters" in relation to waste management.

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ensure that where possible the issues specifically relating to these kinds of plant
are addressed.

SAFEGUARDING

National Planning Policy Framework

1.78. The network of concrete batching and asphalting plants is a key part of the
construction industry in the U.K. an importance recognised in national planning
policy. Paragraph 143 in the NPPF states that:
"In preparing Local Plans, local planning authorities should safeguard […]
existing, planned and potential sites for concrete batching, the
manufacture of coated materials, other concrete products and the
handling, processing and distribution of substitute, recycled and secondary
aggregate material…"
1.79. In order to be found "sound" the emerging Minerals Local Plan will need to
include a policy framework to ensure that both existing and proposed concrete
batching and asphalting plants are appropriately safeguarded. The basic
concepts are that existing plants are part of the essential infrastructure for the
construction industry in Worcestershire but may be seen as relatively low value
land uses and could therefore be vulnerable to redevelopment for other uses.
1.80. Relocating an RMX or asphalting plant could be difficult. The Minerals Local
Plan will need to ensure that existing facilities will be safeguarded from the
development of unrelated uses.
1.81. In order to safeguard existing batching and coating capacity and minimise this
conflict, the relationship between the new and existing land uses will need to be
considered before new permissions for other uses are granted. If the potential
impacts are considered in advance as part of the design and development of the
proposal, it should be possible to minimise conflict between the existing plant
and the proposed development.
1.82. Polices will need to be developed that safeguard existing plant from unrelated
uses where the plant meets local environmental and amenity considerations in
the Development Plan, conforms to the pollution control regime and does not
pose a risk to sites protected at the European or National level.
1.83. They will also need to ensure that development on or adjacent to an existing
planning permission or existing use rights for these plants would only be
permitted where the proposed development would not prevent, hinder or
unreasonably restrict the operation of the batching plant, or in cases where the
proposed development could do so it could be satisfactorily demonstrated that:
 there is no longer a need for the permitted RMX or asphalting plant or,
 suitable alternative provision can be made,
 or the impacts between the two can be satisfactorily mitigated.
1.84. Policies may need to be developed to include that where this is not the case the
County Council would need to oppose the proposed development and would
expect District Councils to refuse permission for the new development. The
policies will need to make it clear that any potential conflicts between users of
the proposed development and existing batching plant must be considered.

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ENVIRONMENTAL ISSUES AND CONTROLS


1.85. Concrete batching and asphalting plants are large, potentially polluting industrial
activities which can have significant and adverse effects on the environment and
local amenities. It is usual for both planning permissions and environmental
permits for them to include conditions to minimise the risk of adverse effects.
The Planning Practice Guidance to the National Planning Policy Framework
outlines specific planning guidelines for aspects of mineral working that could
equally apply to batching and asphalting plants. The following are therefore
material considerations that should be taken into account in developing policies
in the Minerals Local Plan that can be applied to all kinds of plant and
equipment included within or connected with mineral development, including
RMX and asphalting plant. Any such controls would however need to be subject
to the general principle that many such matters are the purview of the pollution
control authorities and should not be duplicated by the Planning Authority.

Air quality considerations

Concrete dust released by batching plants can be a major source of dangerous


air pollution. The presence of some substances in concrete, including useful and
unwanted additives, can cause health concerns due to toxicity and radioactivity.
Cement, sand and aggregates at batching plant and sand and aggregates at
asphalting plant can produce dust which may affect the air quality of the locality.
There is also the possibility of negative impacts from dust on the wider
environment, including heritage, ecology, agriculture and designated nature
conservation sites. The MLP could appropriately include policies to prevent
offsite problems by controlling the release of the dust and control of escaped
material from all kinds of mineral working and related development through
good design and management techniques. The provision of natural or artificial
wind barriers such as trees, fences and landforms may help control the
emission of dust from the plant and could be encouraged.
Road and yard dust
1.86. The most effective means of reducing dust emissions at batching and asphalting
plants is to hard-surface roadways and any other areas where there is a regular
movement of vehicles. Access and exit routes for heavy transport vehicles could
be planned to minimise noise and dust impacts on the environment and amenity
of the locality. Where it is not practicable to hard-surface a site (e.g. at a short-
term location), alternatives to suppress dust emissions from unsealed yards and
roadways could be encouraged, these might include:
 armouring (a thin layer of high quality pavement material is placed on the
pavement surface)
 chemical suppressant products
 regular light watering.
Vehicles
1.87. Dust emissions due to vehicles can be minimised by reducing travel distances
within the site by appropriate site layout and design, the use of wheel and truck
wash facilities at site exits, and the introduction of vehicle speed limits. Policies

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could require all facilities on mineral plant sites to demonstrate good


maintenance practices, including regular sweeping to prevent dust build-up.
Fugitive dust
1.88. Dust emissions from batching and asphalting plant can be both a nuisance and
a source of pollution. Policies could minimise the effects by ensuring that quarry
facilities, including RMX and asphalting plant bunkers and conveyors, are sited
to the leeward of the prevailing wind position and sprays or dust suppression
agents are used to reduce dust emissions and minimise water usage.
1.89. Policies could require aggregate stored on site in stockpiles to be contained
within storage bunkers with windshields that project above the bunker wall and
could require conveyors to be designed to prevent fugitive dust emissions.
1.90. Mixer loading areas could be roofed and enclosed and water sprays, curtains or
air extraction and filtration systems installed to suppress dust generated during
mixer truck loading. There is a potential cross over between the Minerals Local
Plan and Environmental Permits imposed by the Environment Agency or
Worcester Regulatory Services but the MLP could include policies to minimise
pollution risk and that escapes to air are minimised.
Dust Assessments
1.91. The Planning Practice Guidance to the National Planning Policy Framework
makes it clear that, where dust emissions are likely to arise, a dust
assessment27 must be carried out. The key stages of the assessment and high,
medium and low sensitivity land uses are outlined in the National Planning
Policy Framework. The Minerals Local Plan could usefully direct applicants to
these matters
Fumes
1.92. Dust from RMX plants is very fine and can be smelled as well as seen as a
coating on surfaces and can cause respiratory problems. Asphalting plants
produce fumes from heating and melting bituminous materials. These can be
both offensive and a nuisance. Policies could require proper air plume
assessments to be undertaken for proposals to develop new plant to assess the
nature of these effects, their implications and how they might be mitigated.
Steam plumes can be produced from RMX plants and will need to be
considered if likely to be significantly visible.

Water management

1.93. Wet concrete is highly alkaline and needs to be handled with proper protective
equipment. The bituminous elements of the coating process make asphalting
plants potentially very harmful, particularly to watercourses. Potential pollutants
in batching and asphalting plant wastewater and stormwater include cement,
sand, aggregates chemical admixtures, fuels and lubricants. Policies will be
needed to minimise the potential for water pollution from all aspects of mineral
working and processing and for sites to be designed and constructed to divert
clean water away from contaminated areas to stormwater discharge systems.

27
Dust is outlined in the Technical Guidance to the National Planning Policy Framework as particulate
matter in the size range 1–75 μm (micrometres) in diameter.

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Policies could be developed regarding liquids stored on site, which may include
admixtures, fuels and lubricants, to be stored and managed in accordance with
Environment Agency guidelines.
Wastewater collection system
1.94. Contaminated stormwater and wastewater from mineral workings and
associated batching and asphalting plant sites are potentially very polluting and
wastewater collection and policies could require recycling systems to be
designed to collect contaminated water from any:
 agitator washout,
 lorry washing,
 yard washing,
 contaminated stormwater,
 concrete batching area,
 slump stand and
 any other wastewater from the batching plant operation and to divert it
to settling ponds, so that it can be reused.
1.95. Surface and groundwater protection policies in the Minerals Local Plan could
require uncontaminated stormwater to be separated and directed through
interceptors or sediment collection systems to ensure that only clean stormwater
is discharged from the site.
Noise Management

1.96. Noise issues are likely to arise from mineral working and processing sites,
including concrete batching and asphalting plants, particularly if, as referred to
above, there are commercial pressures to operate plants out of conventional l
business hours. The Mineral Local Plan could include policies to lessen these
by:
 Setting noise limits at sensitive properties
 Limiting hours of operation
 Limiting the number or frequency of night operations
 Prescribing certain kinds of reversing alarms.
1.97. Noise levels that may be deemed excessive at mineral workings, and so cause
nuisances, are listed in the Planning Practice Guidance to the NPPF. These
limits are not however prescribed for ancillary operations, such as batching and
asphalting plants at mineral workings, or for industrial premises generally. The
"Noise Statement for England" sets general principles for noise management
but there are no specific limits for concrete batching or asphalting plants per se.
The Minerals Local Plan could consider if policies should be developed to
impose specific levels on new plant. Legislation and common law also exists
regulating the control of nuisances to protect nearby premises from noise from
batching plants.
1.98. Supplying and operating these kinds of plant and transporting materials off site
is likely to cause large amounts of traffic. This will be most acute on the roads
near the sites, as large lorries may be arriving and departing from sites

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regularly. Policies could be developed to control the level of lorry movement or


the routes taken. Policies could reduce traffic noise by controlling hours of
working, screening or the use of other means of transport such as rail, private
haul roads, conveyors or canals to deliver materials to and from batching plants.
Waste management

1.99. RMX and asphalting plants produce waste water, as discussed above, but the
main solid waste generated by batching plants is waste concrete. Waste
generated on site is formally regulated under the Revised Waste Framework
2008/98/EC Waste Framework Directive and the Waste (England and Wales)
Regulations 2011. In Worcestershire the Waste Core Strategy is the principal
mechanism for regulating these matters and waste minimisation is the preferred
approach to dealing with this material. Waste concrete can often be used for
construction purposes at the batching plant or project site (e.g. bunker blocks or
paving unsealed areas). It can also be directed to a washout pit before it
hardens to be dissolved into gravel, sand and sludge, which can subsequently
be collected and reused. Waste asphalt, by contrast, can be more readily re-
used. The Waste Core Strategy encourages all of these and at the time of
writing the council does not anticipate including such polices in the Minerals
Local Plan.
Landscape and visual impacts

1.100. Because of their height, size and mass, batching and asphalting plants
can have visual impacts. Their impact on the immediate surroundings and
wider landscape depends on the:
 Topography and character of the area
 Proximity to main transport links, other business or residential properties or
sites and features of historic importance.
Both types of plant tend however to be tall, identifiably industrial, structures set
on areas of hardstanding with a lot of associated quasi industrial features,
equipment, storage buildings or enclosures with lorry parking and turning areas
around them. They are usually surrounded by high chain link fencing. The
Minerals Local Plan could appropriately include policies to control the height,
mass, colour, materials used, the location of all plant developed in connection
with mineral development and the use of screening, such as tree planting, to
minimise visual impacts.
Restoration and aftercare of batching and asphalting plant sites

1.101. Current government policy is that mineral workings should be restored at


the earliest opportunity28. Restoration and aftercare should provide the means to
maintain or, in some circumstances, enhance the long-term quality of land and
landscapes taken for mineral extraction and to ensure its restoration to a
beneficial afteruse afterwards.. Responsibility for the restoration and aftercare of
mineral sites lies with the operator. Where concrete batching and asphalting
plants are located within a mineral working or plant area the restoration scheme
for the site as a whole should take formal account of its existence and make a
clear decision on whether and how it should be retained or, if appropriate, the
site cleared and restored.
28
National Planning Policy Framework Paragraph 143

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1.102. Unless conditions are imposed on these plants limiting their life to that of a
mineral working, or other development, they are in effect permanent; any
restoration may therefore be limited to if RMX or asphalt plant sites can be
redeveloped for some other use. The Minerals Local Plan is unlikely to include
polices to address such sites.
Protected environmental sites

1.103. Existing and future batching and asphalting plants could adjoin or affect
existing or future species and sites of nature conservation value. Because of
the relatively hazardous and potentially polluting nature of the materials
involved in their use the potential effects of batching plants on protected
species and sites, especially species and sites of national and of European
significance, need very careful consideration.
1.104. The need for extensive hardstandings and access routes mean that
heritage, especially archaeological, features can be adversely affected when
mineral processing plants are constructed. Pollution from their operation could
also, in theory, harm surface or ground features.
The Minerals Local Plan will need to include policies to ensure that all of these
matters can be addressed and that any such features are given appropriate
weight.

Traffic Impacts

1.105. All of the above can have adverse impacts on amenity but one of the most
important impacts they can have on amenity can be from the volume of traffic
generated and plants' hours of operation. RMX and asphalting plants exist to
supply construction projects and so need to be operational relatively early in the
day and generate early HGV traffic. On the basis of the Competition
Commission's finding that the mean volume production by site, in 2011, was
19,000 m3 for RMX sites operated by the Majors versus 15,000 m3 for sites
operated by non-Majors, the traffic generated by RMX plants would be about
3,800- 3,000 10 tonne concrete mixer movements in and out and about another
1,900-1,500 20 tonne HGVs in and out p.a: about 22 – 18 HGV/concrete mixer
movements per day. The council does not have any data on production from
asphalting sites but given that there are relatively fewer numbers of such plants
and that they tend to serve larger areas it is likely that the traffic generation from
them is as high, if not higher. The hours these vehicles enter and leave gravel
pits and quarries can be controlled to some extent and the Minerals Local Plan
could appropriately include policies to do so.

SUMMARY
1. In summary, RMX and asphalting plants can create a wide range of
environmental and amenity problems. Plants are often required to supply
materials outside normal operating hours, notably by the Highways Authority.
During extended hours noise and traffic are potentially more sensitive aspects.
There is a potential conflict therefore between the needs of the market,
particularly for deliveries at unsocial hours, the potential disamenities this can
create and the sensitivities of local people. Mechanisms do exist to control
and limit these however and there is little evidence that as a sector these
plants are perceived as environmentally problematic or their regulation

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unsatisfactory. There is no evidence that the 14 batching and 2 asphalting


plants currently operational in Worcestershire are causing significant problems.
The minerals Local Plan will nonetheless include policies to ensure that where
they are developed as part of gravel pits or quarries or if plants are considered
under safeguarding policies, that amenity, biodiversity, heritage and pollution
control issues are given appropriate weight.

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CLIMATE CHANGE
ENVIRONMENTAL IMPACT OF CONCRETE
1.106. The CO2 emission from concrete production is directly proportional to the
cement content used in the concrete mix. The cement industry is one of the
primary producers of carbon dioxide, a major greenhouse gas. Cement
manufacture contributes greenhouse gases both directly through the production
of carbon dioxide when calcium carbonate is thermally decomposed, producing
lime and carbon dioxide, and also through the use of energy, particularly from
the combustion of fossil fuels. As part of the process of creating concrete,
batching plants contribute to these emissions. On the positive side however the
uses to which the concrete so crested is put can include flood alleviation and
control structures which can significantly ameliorate the effects of climate
change induced flooding.

CO2 EMISSIONS: TRANSPORT


1.107. The local supply network for concrete means that delivery distances are
short and the fuel used during haulage (and the associated CO2 emissions) is
minimised. In the UK the average delivery distance of ready mixed concrete to
the construction site is 8km29. Data collection on transport CO2 is improving by
sector and the industry has published a commitment to focus on the
development of common data collection methodologies and guidelines to allow
the concrete industry to report transport CO2 emissions.

USE OF RECYCLED MATERIALS: CONCRETE


1.108. The use of recycled and secondary aggregates in concrete varies by
sector and the technical specifications for its use. The question of whether the
diversion of larger volumes of recycled and secondary materials into concrete
manufacture would produce a more sustainable outcome, taking into account
transport, production and emissions implications, is difficult to answer in simple
terms and depends upon the circumstances of individual contracts. Generally,
when transported by road, the use of recycled aggregates is only a lower carbon
option when used within 10miles (or 15km) of their source30.
1.109. The Concrete Industry has a Sustainable Construction Strategy to help
manufacturers tackle issues such as energy and resource efficiency and use
building information modelling (BIM). The industry's seventh annual
Sustainability Performance Report (201531), included findings that most
concrete was locally and responsibly sourced, with 91% certified to BES 6001.
Concrete was shown to be a net user of waste: 79 times more waste and
recovered materials were used than were sent to landfill and the proportion of
recycled or secondary aggregates used in concrete production was around 6%
by mass.

29
Concrete Industry Sustainable Construction Strategy.
30
For more information visit www.concretecentre.com
http://www.sustainableconcrete.org.uk/pdf/MB_Performance_Report_Feb2010.pdf
31 Mineral Planning 10th March 2015

http://www.mineralandwasteplanning.co.uk/bulletin/mineral_planning_bulletin/article/1337421/more
-work-needed-concrete-sustainability/?DCMP=EMC-CONMineralPlanningBulletin

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1.110. The initial focus of the industry strategy is on reducing the amount of CO2
emitted for every tonne of concrete produced. Reduction in concrete's embodied
CO2 saw the 1990 figure fall from 103 kilograms per tonne of concrete in recent
years to 79.7kg in 2013. The target for 2020 is to reduce this figure to 71.8kg of
CO2 per tonne of concrete, which equates to a 30% reduction from the 1990
baseline.

USE OF RECYCLED MATERIALS: ASPHALT


1.111. The Highways Agency's Specification for Highway Works permits a
recycled asphalt content of 10% for hot surface course asphalt and up to 50%
for hot binder course and base asphalts within the UK for new roads. Once
constructed however asphalt planings are virtually 100% recycled as
aggregates in unbound (sub-base or capping) or bound (hot or cold process
asphalt) applications. Essential maintenance frequently requires replacement
only of the topmost layer of roads and this can often be stripped, processed
and re-laid on site. Higher-grade surface repairs are therefore one of the most
successful examples of the effective re-use of a finite natural resource: asphalt
road surfaces are 100% recyclable back into asphalt. During more extensive
repair of lower layers, much of the asphalt material extracted can be reused in
lower structural layers. In practice hot base and binder course recycled asphalt
content tends to be in the 10% to 20% range to deal with variability in recycled
asphalt feed stock and asphalt plant production process restrictions but
alternative methods do enable higher amounts of recycled material to be used
and cold process asphalt manufacture using foamed bitumen or bitumen
emulsions can use 100% recycled asphalt as well as generating lower carbon
emissions.
1.112. The reuse of asphalt contributes significantly to reducing the construction
or ‘embedded’ carbon footprint of the materials in roads. In-situ recycling
plants have the additional environmental benefit of reducing the need for
haulage of new or waste material to or from maintenance sites resulting in
fewer lorry journeys. Even where it cannot be reused for highway repairs
recycled asphalt can be used for surfacing relatively lightly-used areas such as
footways, minor or estate roads, playgrounds or car parks. Asphalt recycling
and storage is likely to remain important, the Waste Core Strategy enables this
and specifically directs it, inter alia, to mineral working sites. The Minerals
Local Plan is unlikely to change this unless significant evidence is produced to
the contrary.

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FUTURE ISSUES
CONCRETE
1.113. At the time of writing the council has no information on the likely scale of
demand for ready-mixed concrete, cement production might however be used
as a proxy for ready mix. As well as being an input into RMX, cement is an input
into (among other building materials) the production of concrete and concrete
products. Concrete products include concrete blocks and precast concrete
products, all of which are needed to enable development. Recent sales of
concrete peaked at nearly 13Mt in 2007 after which there was a significant
downturn in sales (a decline of 36%) over the period 2007 to 2009, coinciding
with the UK recession. Sales rose briefly but were at almost the 2009 low point
in 2012. It is widely accepted that the banking crisis of 2008 caused a backlog of
development which will need to be met sometime. It appears reasonable to
assume that this will happen and that at present, there is no case for arguing
that less concrete capacity is needed or that as a corollary, less concrete
batching plant capacity will be needed for the foreseeable future. The need, at
the least, to retain existing concrete production capacity, has been recognised
by the Competition Commission's Aggregates, Cement and Ready-mix
Concrete Market Investigation, which recommended that a 6th major concrete
manufacturer should be formed to operate in the U.K.

ASPHALT
1.114. The same kind of argument, that there is a significant unsatisfied need for
development, justifying the retention of the existing batching plant capacity, also
applies to asphalting plants. The Competition Commission did not however
address this issue in the same level of detail. In the UK, modern asphalt roads
are designed to last at least 40 years before they require major reconstruction
work. However, in practice they last much longer. The Annual Local Authority
Road Maintenance (ALARM) Survey has consistently found that many of
Britain's roads have had no, or only minor repairs in the last 40 years and some
have been unrepaired for 100 years. This is testament to the ability of asphalt to
outperform its design life (although clearly this is not recommended) and the
potential problems being stored up below the surface. The Asphalt Industry
Alliance 18th Annual Local Authority Road Maintenance (ALARM) Survey
(March 2013) of local road network condition and funding, completed by 75 per
cent of councils across England and Wales revealed:
 £829 million annual funding shortfall for highway repairs – England and
London
 £6.2 million annual budget shortfall (per authority, England)
 1 in 5 roads with residual life of less than 5 years
 £338 million – cost of damage caused by 2012 extreme rainfall
 £10.5 billion – estimated “one-off” cost to get roads back into reasonable
condition
 £32 million – amount paid in road user compensation claims
 2.2 million potholes filled across England and Wales

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 £113 million – total spent filling potholes – England and Wales


1.115. It is reasonable to assume that addressing this backlog will require
substantial volumes of asphalt and will put pressure on the capacity of existing
plants. It is not possible to estimate if the current number of plants will be able to
meet this in the West Midlands, let alone Worcestershire. It is however
reasonable to assume that this backlog supports the need for the retention of
existing plant for the present.
1.116. It is possible that other developments will also increase the demand for
asphalt. Modern asphalts can reduce tyre/road surface noise by as much as
11dB(A) more than other road surfaces. The Highways Agency estimates that a
reduction of 3dB(A) is equivalent to either halving the volume of traffic or
doubling the distance of the listener from the road. The Government's 10-year
Transport Plan in July 2000 stated: "quieter road surfaces [will be] installed on
over 60 per cent of the network including all concrete stretches." If implemented
this approach will also support the need for asphalt plant capacity and for
existing facilities to be safeguarded.

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CONCLUSIONS
1.117. RMX and asphalting plants are a fundamental part of the construction
industry, essential for the efficient delivery of new development. The National
Planning Policy Framework identifies them specifically as developments which
should be actively safeguarded and the Minerals Local Plan will need to
ensure they are appropriately safeguarded both from direct redevelopment and
from any possible conflict with new, sensitive, development proposed nearby.
1.118. The nature of the materials involved, particularly dry concrete powder in
concrete and bitumen in asphalt means that RMX plants can have significant
and harmful effects on amenity and the environment. There are however a
number of licensing and regulatory mechanisms to control and limit these
effects and there is little evidence that RMX and asphalting plants in general
are perceived as difficult to manage or significantly harmful in practice.
1.119. There are currently 14 RMX and 2 asphalting plants operating in
Worcestershire at the time of writing, there is no evidence that they are not
operating satisfactorily, both in terms of environmental performance or their
ability or appropriateness in supplying the development industry.
1.120. The Minerals Local Plan could nonetheless appropriately include polices
to ensure that all quarry working and processing related development,
including RMX and asphalting plants, is developed in locations, operated and
safeguarded in ways which do not have unacceptable effects on health,
amenity, the environment or matters of acknowledged importance, particularly
those identified as being of national or international significance.

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APPENDIX 1: The concrete batching process

The process of manufacturing ready mixed concrete is relatively straightforward. It relies


upon having robust quality standards and systems to ensure that the products have the
correct constituents in the correct proportions in the final mix. The following table is a simple
summary of the main elements of the process:

Process
1. In summary, the constituents comprise
1) aggregates, e.g. sand and gravel or recycled materials in different sizes;
2) cement brought onto site in specialist tankers and discharged into silos
and
3) admixtures, which are non-hazardous modified organic materials (liquids)
that are added to concrete to improve its workability when fresh and its
strength and resistance to freeze thaw action when hardened. These are
pumped into the silos from bulk tankers.
4) Water (from mains or drawn from the site)
2. Aggregates will be fed into the hopper, which then feeds aggregate (e.g. by a
belt conveyor) into enclosed bins containing different sized aggregate.
3. Aggregate is then fed into a mixer in the desired proportions where it is
mixed with cement, water and admixtures and discharged (often into the
back of a tipper truck that parks beneath the load out point).
4. The truck mixer then leaves to deliver its load of ready mixed concrete.
5. When the truck mixer returns it may be necessary to wash out the barrel,
which is done by using water that is discharged into a wedge pit to settle out
the solids. The water and solid waste is then placed into a drying bay and
then collected and disposed of to a recycling centre.

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APPENDIX 2: BODIES CONSULTED ON THE INITIAL DRAFT REPORT

Bold text indicates the bodies that made comments on the initial draft. Their comments
have been incorporated in this version of the document.

Minerals Industry:
 Cullimore
 Veolia
 Salop Sand and Gravel
 Smiths and Sons
 Cinetic Sands
 MV Kelly
 Cemex
 Mineral Products Association
 British Aggregates Association
 Aggregates Working Party (West Midlands)
 British Ready Mixed Concrete Association
 Refined Bitumen Association

Conservation organisations:
 Environment Agency
 Natural England

Other:
 Worcestershire LEP
 Greater Birmingham and Solihull LEP
 Worcestershire Regulatory Services

Mineral Planning Authorities adjoining Worcestershire:


 Gloucestershire County Council
 Warwickshire County Council
 Herefordshire Council
 Staffordshire County Council
 Shropshire Council
 Solihull Metropolitan Borough Council
 Dudley Metropolitan Borough Council
 Birmingham City Council

Local Planning Authorities in and adjoining Worcestershire:


 Bromsgrove District Council
 Malvern Hills District Council
 Redditch Borough Council
 Wychavon District Council
 Wyre Forest District Council
 Worcester City Council

Local Planning Authorities adjoining Worcestershire:


 Forest of Dean District Council
 Tewkesbury Borough Council

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 Cotswold District Council


 Stratford-on-Avon District Council
 South Staffordshire District Council

RMX plants

Due to ongoing website updates at the time of consultation, the following companies
were consulted by letter on 1/07/2014 and invited to request a digital copy of the
document by email. BOLD text indicates companies who responded to the consultation
draft.

Company Address
Aggregates Industries (Bardon Grove House Yard, Tewkesbury Road, Upton
Concrete and London Concrete) upon Severn, Worcs WR8 0PW
2 Lisle Avenue Kidderminster, Worcs, DY10
3RD
Cemex Ryall House Farm, Tewkesbury Road, Ryall,
Upton-on-Severn, Worcestershire, WR8 0PU
Ashton Fields Trading Estate, 70 Sherwood
Road, Bromsgrove, Worcestershire, B60 3DR
Vale Industrial Estate, Stourport Road,
Kidderminster, Worcestershire, DY11 7QU
Lakeside, Arthur Street, Redditch,
Worcestershire, B98 8LQ
Terrace road, Pinvin Industrial estate,
Pershore, WR10 2DW
Hanson Heidelberg Cement Sheriff Street, Worcester WR4 9AB

Trumix Concrete Ltd Bonnie Brae, Longdon, Tewkesbury GL20 6AN


Tarmac Unit 7-8 Blackpole Trading Estate, Blackpole
Rd, Worcester WR3 8SG
Freelow Concrete Monkswood Farm Cottage, Droitwich Road,
Hanbury, Worcs, B96 6RA
Ace Minimix/Redditch Concrete Sandhills Farm, Edgioake Lane, Astwood
Bank, Redditch B96 6BG
Accumix Concrete Wildemoor Quarry, Sandy Lane, Bromsgrove
B61 0QR
Breedon Aggregates Huntsman`s/Breedon Aggregates, Bretforton
Road, Weston Subedge, Nr Evesham,
WR11 7QA

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APPENDIX 3: COMMENTS RECEIVED ON INITIAL DRAFT DOCUMENT

Natural England

 We welcome the inclusion of the section on Air Quality Considerations, Water


Management, Landscape and Visual Impacts and Protected Environmental Sites.
 The section on Air Quality should recognise the potential negative effects of dust
on the wider environment, particularly designated nature conservation sites.
(WCC Response, reference added)

Cemex

 Readymixed concrete probably shouldn't be capitalised as this was the full name
of my previous employer RMC and would be a trade name, as referring to
Asphalt as Tarmac would be; (WCC response, change made)
 Within Section 5 generally there are many references to possible policies relating
to the minutiae of pollution control issues which are the province of other
regulatory authorities rather than planning and should be avoided, particularly as
non-quarry plants are not County matters but General Industrial (B2) uses falling
within the purview of the Districts; (WCC response, change made)
 Paragraph 5.7, I'm not aware of any health issues relating to the routine use of
concrete plants beyond those that fall to be discharged pursuant to health and
safety at work legislation. Such policies would be onerous and unnecessary
unless the MPA can point to a body of evidence that substantiates the link
between this type of development and health issues in the wider populous; (WCC
response, change made)
 Paragraph 6.2, see above, I feel there is no confusion regards the status of such
development, off quarry plants are clearly B2 General Industrial developments. I
am less certain regards wharves and rail depots, it may be that these are County
matters where located on a quarry, but B8 distribution uses where stand alone;
(WCC response, noted, to be incorporated in other Background documents)
 Many of the environmental issues identified by Section 6 are controlled by other
regulatory regimes and DP policies would be duplication. One issue not
identified and that isn't controlled directly by other regimes is that of hours of
working. There is an increasing trend amongst customers for asphalt and to
some extent concrete to require 'out of hours' deliveries, and a desire by
operators to deliver raw materials at night. This is an area where policy could
usefully be developed; (WCC response, change made)
 There is no mention of rail or water delivery of aggregates, which should be
included in either the ready-mix or aggregates documents. Clearly CEMEX
deliver aggregates to Ryall Quarry by barge from Ripple Quarry, and wishes to
retain the Ryall facility for future sources of sand and gravel. This site, and
others that may be suitable in the County, should be safeguarded. Although
there are currently no rail depots in the County potential sites should also be
safeguarded. The paper should also seek to safeguard mortar plants, which in
terms of development are similar to concrete plants. Ryall can produce both
products, but stand-alone mortar plants are not uncommon. (WCC response,
change made, note incorporated in other Background documents,
additional research undertaken, no other, specific mortar plants identified
in Worcestershire.)

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Breedon Aggregates

 The document is excessively long and covers technical details and other matters
which are not considered necessary. Added to this there is a marked degree of
repetition. For example there is unnecessary reference to cement manufacture
and matters related to it. Such matters are not relevant in the context of the
circumstances in Worcestershire.
 The text in many instances is alarmist and unwarranted, particularly in respect of
health. Reference is made to ‘toxicity and radioactivity’, and bitumen as a
polluting material. The fact is that many substances, including water, have the
potential to be harmful, but the adoption of recognised practices and controls
means that concrete and asphalt plants operate satisfactorily throughout the
country and in a wide range of situations. Moreover, the products are used in
extensive use, and people come into contact them constantly.
 It seems to me that the main role of the planning policy should be in the
safeguarding of existing sites, particularly from other sensitive development
within the immediate vicinity of operational plants. One of the key points here is
that such plants are often required to supply materials outside normal operating
hours, notably by the highways authority. During extended hours noise and traffic
are potentially more sensitive aspects.
 Finally, I can confirm that Breedon Aggregates now owns the concrete plant at
Evesham (Near Bretforton), but it continues to trade under the name Huntsmans
Quarries.

(WCC response:

APPENDIX 4: PRINCIPAL UK ASPHALT SPECIFICATIONS

1 PD 6691 - Asphalt. Guidance on the use of BS EN 13108 Bituminous Mixtures – Material


specifications. BSI, London.

2 British (European) Standard BS EN 13108-1 Bituminous mixtures - Material specifications


- Part 1: Asphalt Concrete, BSI, London

3 British (European) Standard BS EN 13108-4 Bituminous mixtures - Material specifications


- Part 4: Hot Rolled Asphalt, BSI, London.

4 British (European) Standard BS EN 13108-5 Bituminous mixtures - Material specifications


- Part 5: Stone Mastic Asphalt, BSI, London

5 British (European) Standard BS EN 13108-1 Bituminous mixtures - Material specifications


- Part 7: Porous Asphalt, BSI, London

6 British (European) Standard BS EN 13108-20 Bituminous mixtures - Part 20: Type Testing,
BSI, London

7 British Standard BS 594987 Asphalt for roads and other paved areas - Specification for
transport, laying and compaction and type testing protocols, BSI, London

8 British (European) Standard BS EN 13108-21 Bituminous mixtures - Part 21: Factory


Production Control, BSI, London

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9 British (European) Standard BS EN ISO 9001 Quality Management System -


Requirements, BSI, London

10 National Highways Sector Scheme 14 for Quality Management in Highway Works - the
quality management of the production of asphalt mixes - United Kingdom Accreditation
Service (UKAS).

Source www.ukas.com/informationcentre/publications/pubsforcbaccred.asp

END OF REPORT

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