The Hope Cement Plant in Derbyshire is recognised as the UK's largest. It has been manufacturing cement on this site for nearly 90 years, with a capacity of up to 1.5 million tonnes annually.
The Challenge
Breedon approached Metalis for a critical project at their Hope Valley Cement Works, requiring us to source a contracting team for the complex decommissioning and installation of a new crusher. The old crusher, in operation for 74 years, had to be dismantled in confined spaces, with additional challenges such as managing health and safety risks from toxic fumes and removing 2.1 tonnes of concrete - all while ensuring uninterrupted cement production.
The Solution
Metalis supplied a contracting team to lead the crusher replacement project at Breedon Cement’s Hope Valley Cement Works. This team managed the entire project from start to finish with key responsibilities, such as:
Stakeholder Communication: Maintained clear communication with Breedon’s management and CEO. Contractor & Procurement
Oversight: Managed contractor performance and procurement, making necessary adjustments.
Health & Safety: Enforced strict safety protocols for night-time cutting due to fumes.
Problem Solving & Innovation: Applied advanced methods to dismantle the crusher and safely remove concrete.
Minimising Disruptions: Planning to maintain continuous production without downtime.
The Outcome
Metalis provided a skilled contract team that delivered key benefits for Breedon Cement:
Operational Continuity: The team kept the plant running smoothly, avoiding downtime and ensuring uninterrupted supply.
Cost and Time Efficiency: Effective contractor management kept the project on schedule and within budget, despite challenges.
Enhanced Safety Standards: Strict protocols minimised risks during high-risk tasks.
Successful Project Delivery: The team decommissioned the old crusher, removed concrete in confined spaces, and installed a new crusher to boost capacity