Transforming Difficult Host Material into a Temporary Haul Road Using SMR SoilBind+

Despite challenging ground conditions, environmental factors, and budget constraints, SMR SoilBind+ delivered a cost-effective and environmentally compliant solution.

The Challenge

The project required a temporary haul road capable of supporting heavy vehicles and equipment in the difficult conditions of the brine fields. The existing ground, made up of thick clay and slurry with poor drainage, had very low bearing capacity and would normally be excavated and sent to landfill, requiring costly replacement with imported aggregates. The geology, sitting on layers of salt and minerals from ancient oceans, created further risks of instability and long-term settlement.

Adding to the complexity, the site was home to protected species, including the Great Crested Newt. This meant any works had to be carried out with strict ecological safeguards to prevent contamination of ponds and minimise disruption to sensitive habitats. Together, these factors created a challenge that demanded a solution both technically robust and environmentally responsible.

The SMR UK Solution

SMR UK’s patented binder solution not only allowed for sub-grade stabilisation, but also transformed the excavated material into a structural resource that could be reused up to the formation level.

Using Recycling Aggregates Northwest (RAN)’s mobile mixing facilities, the material was treated to create a Hydraulically Bound Mixture (HBM), which was then re-laid in two compacted layers of 250mm (500mm in total). The result was a strong, stable base that fully met the required load-bearing strengths for heavy traffic.

By reusing up to 100% of the challenging host material, which included clay and slurry, the project avoided landfill disposal, eliminated the need for imported aggregates, and reduced lorry movements, cutting both costs and carbon.

The mobile mixing capability allowed all works to be completed on site efficiently, while ensuring minimal disruption to the sensitive brine field environment and its protected species.

Results

The results were highly impressive given the extremely poor original ground conditions.

The completed haul road demonstrated excellent performance, withstanding sustained heavy vehicle traffic and showing minimal signs of distress or deformation.

By transforming the existing weak materials into a Hydraulically Bound Mixture (HBM) with SMR SoilBind+, the project delivered a structurally robust and durable solution that met all load-bearing and performance requirements efficiently.

Conclusion

The Middlewich haul road project demonstrates how Ex-Situ Stabilisation with SMR SoilBind+ can deliver sustainable and cost-effective infrastructure solutions under highly challenging conditions.

The project maximised material efficiency, eliminated the need for imported aggregates, and avoided landfill disposal.

This approach not only reduced costs and carbon emissions but also enabled rapid construction within budget constraints. The Haul Road provided the required structural performance, while ensuring compliance with strict ecological standards; a critical factor given the waterlogged environment and presence of protected species.

Overall, the project highlights a balanced and innovative solution that successfully addressed environmental, economic, and logistical demands.