Client: PJ Careys The Tilbury Grinding Station, located at the Port of Tilbury in Essex, is a cutting-edge cement production facility. This nine-acre plant represents a strategic investment to address the growing demand for sustainable building materials in London and the South East. The facility specialises in low-carbon and circular cementitious products, including GGBS (ground granulated blast-furnace slag) and materials derived from construction waste, helping to reduce carbon emissions in the construction industry. The station is equipped with five loading heads to supply customers with conventional and low-carbon cement around the clock, positioning it as a key player in the UK’s shift toward greener construction practices. Services we provided Civil & Infrastructure Engineering Building Surveying Geotechnical & Ground Engineering Ground Investigation & Land Quality Structural Engineering Transport Planning & Traffic Engineering Our Role BWB was appointed to provide civil, geotechnical, and structural engineering services, as well as highway design for Tilbury Grinding Station. Our involvement began with extensive site surveys, including an Unexploded Ordnance (UXO) survey, to ensure the site was safe for development due to its history of being bombed during World War II. Complex geotechnical profile Given the site’s complex geotechnical profile, we designed a comprehensive piling solution that provided the necessary stability for the new structures. We collaborated closely with international subcontractors and suppliers from across Europe to integrate the foundations with the Vertical Roller Mill, ensuring that the design addressed the unique vibrational characteristics of this equipment without compromising structural integrity. Highways expertise Our highways and infrastructure team developed innovative solutions to manage site access and traffic flow, given the confined space and heavy industrial nature of the surrounding area. Our highway designs facilitated smooth logistics and transport operations, supporting the grinding station’s role as a key node in the supply chain for low-carbon cement products. Overcoming challenges The primary challenges involved the site’s soft ground conditions and its historical use as a working dock. The site required a robust piling solution to ensure stability, and our engineers designed a comprehensive foundation system capable of withstanding the heavy loads and vibrations of the Vertical Roller Mill. Another significant challenge was conducting the UXO survey to check for unexploded ordnance from wartime bombings, which added complexity and required careful planning before commencing groundworks.