Sectors & Services
Located in East Lothian, the Dunbar Cement Plant, operated by Tarmac, is Scotland’s only cement manufacturing facility, producing approximately 700,000 tonnes annually. The site integrates limestone extraction from the adjacent Dunbar Quarry with on-site processing and dedicated rail infrastructure, enabling efficient distribution across the UK.
Contributing around £8 million annually to the local economy and supporting approximately 130 jobs, the plant is a nationally significant asset. Its private rail network reduces CO₂ emissions, supporting a transition toward net zero. CRL Scotland were engaged to deliver essential structural repairs to the stacker rail system following identification of significant concrete deterioration.
Services Undertaken
- Excavation to expose existing stacker rail foundations
- Hydro-demolition for removal of deteriorated concrete
- Inspection and assessment of existing reinforcement
- Installation of additional reinforcement and steel tie-ins to cross walls
- Shuttering and re-casting of concrete foundations
- Installation, positioning, and welding of new stacker rail system
CRL Scotland were appointed to undertake critical concrete repairs to the plant’s stacker rail foundation, a key component supporting continuous material handling operations. Excavation works were carried out to expose the existing foundation, revealing a greater extent of deterioration than initially anticipated. This required a carefully controlled and adaptive repair methodology to maintain structural integrity and minimise disruption to operations.
Deteriorated concrete was removed using hydro-demolition, a technique selected for its precision and ability to remove unsound material without inducing microcracking or damaging adjacent sound concrete. This method ensured the preservation of the existing structural interface while preparing a suitable substrate for reinstatement. Following concrete removal, the exposed reinforcement was thoroughly assessed to determine its condition and suitability for retention.
Where required, additional reinforcement was installed, including steel tie-ins to the cross walls, enhancing the structural capacity and improving load transfer within the system. This approach ensured the upgraded foundation could accommodate operational demands and future loading conditions. The repair zone was then shuttered and re-cast using appropriate concrete to meet current standards, ensuring durability and compatibility with the existing structure.
Upon completion of the structural repairs, the new stacker rail was accurately positioned and welded into place, reinstating full operational functionality. Throughout the project, CRL applied its specialist expertise in structural repairs UK and concrete repairs, delivering a technically robust solution aligned with best practice in asset management. This approach demonstrates CRL’s capability to adapt methodologies in live industrial environments, ensuring both safety and long-term performance.
The repair strategy implemented at Dunbar Cement Plant was designed to deliver long-term durability and resilience within a demanding industrial environment. The use of hydro-demolition ensured a high-quality bond between existing and new concrete by providing a clean, roughened substrate, critical for the longevity of the repair. Installation of additional reinforcement and steel tie-ins improves load distribution and reduces the risk of future cracking or localised failure.
By re-casting the foundation to modern standards, the upgraded structure offers enhanced resistance to environmental exposure and operational stresses. Careful surface preparation and reinstatement techniques contribute to improved durability, reducing the likelihood of premature deterioration. These measures collectively extend the service life of the stacker rail system, minimise future maintenance requirements, and support the ongoing reliability of this critical asset within a highly regulated and sustainability-focused facility.
