Heidelberg Materials UK is one of the UK's largest suppliers of building materials, including cement – a product responsible for approximately 7% of all global CO2 emissions. As a result, the company is keenly aware of the environmental impact of its operations and has set ambitious goals to reduce emissions from its aggregate, asphalt, concrete and cement production by 15% from a 2019 baseline by 2030 while also reducing raw materials consumption and waste.
While the majority of Heidelberg Materials UK's emissions stem from the production of cement, a small yet significant portion comes from the operation of its quarrying equipment. Recognising this, the company has been scrutinising its fleet of heavy mobile equipment and crushers and planning how it should evolve over the next five years.
The ideal future fleet for Heidelberg Materials UK would consist entirely of zero-emission machines powered by electricity or hydrogen generated from renewable sources. However, transitioning to these technologies requires the development of considerable supporting infrastructures. In addition, many of the company's diesel machines are highly durable and have years of service life remaining.
To bridge the gap, Heidelberg Materials UK collaborated with Volvo dealer SMT to refurbish an older wheeled loader. This avoids the purchase of a new diesel machine that would run for many years to come, as well as the emissions and material consumption associated with its manufacture and transportation. Rebuilding older machines also offers faster delivery times and smoother operations due to the existing machine's known history.
"Rebuilding existing machines is a sustainable practice," says Dominie Carver, a strategic account manager at SMT. "Rebuilds can extend machine life, recycle major components and significantly reduce carbon emissions. Refurbishing a used engine for continued use, for example, can save around 56% in CO₂ emissions, and a transmission of about 60%."
To explore the potential of equipment rebuilds, Heidelberg Materials UK and SMT selected a 14-year-old Volvo L350F wheeled loader used to load limestone into crushers at the Ribblesdale cement works in Clitheroe – one of Heidelberg Materials' three UK plants producing Portland cement for various infrastructure projects. Despite the 21,341 operating hours on the clock, the machine's condition indicated that it could continue to operate reliably and productively with necessary repairs and upgrades.
The rebuild was carried out at SMT's Newcastle depot, with lead engineer Michael Christer and skilled welder Rhys Nixon assigned to oversee the project from start to finish. The L350F was stripped back to the chassis, with new hydraulic pumps, hoses, steering systems and refurbished cylinders installed to factory standards.
Significant work included the replacement of the driveline components (front and rear axles, engine, transmission, dropbox and prop shafts) as well as full line boring and repair of the load frame and bucket, fully overhauled with a new specialised cutting-edge and strengthened wear plates for greater penetration and added protection. Upgrades to the machine to bring it in line with modern Volvo standards also included new lighting and high-intensity decals for better visibility.
Meanwhile, enhancements were made to the cab for greater operator comfort, including a refurbished seat, new floor mats, replacement headlining and an updated switchgear. The Comfort Drive Control system was also installed to reduce operator strain and stress.
"Despite the sheer size and power of the L350F, it's so easy to operate," says Andrew Graham, who operates the loader. "It's just like being in an armchair at home.
"It's got great visibility and, due to the large bucket size, we can reduce the number of trips to the crusher. This efficiency translates to better fuel economy and reduced tyre wear."
The SMT rebuild process typically takes around 12 weeks, with machines selected based on national guidelines, service history, oil samples and component ageing. It also uses genuine Volvo parts, meaning that the machine is covered by a 24-month warranty on major components, offering Heidelberg Materials UK peace of mind with no additional costs for potential issues.
The collaboration between Heidelberg Materials UK and SMT underscores the importance of sustainability and innovation in the construction equipment industry.
"Collaboration with suppliers such as SMT is crucial for achieving Heidelberg Materials UK's sustainability goals," says Elliot Wellbelove, carbon innovation manager at Heidelberg Materials UK. "We can rely on SMT to provide emissions reduction data for rebuilt machines, which is essential for calculating environmental benefits and integrating them into our data systems."
The successful rebuild of the L350F is a testament to the strides Heidelberg Materials UK and SMT are making towards decarbonisation, greater circularity, and improved operational efficiency – and Heidelberg Materials UK now plans to extend the rebuild programme to other sites across the UK. The partnership with SMT is also expected to expand, focusing on innovations such as electrification and hydrogen-powered machinery.
"We have been a Volvo and SMT customer for a long time," says Luke Morgan, Heidelberg Materials' UK fleet manager. "The SMT relationship has developed quite significantly over the past few years.
"We appreciate the professionalism of a structured approach towards the rebuilding of the machines and in the wider way in which SMT operates. Our confidence in the success of the rebuild was due to experience of SMT's expertise and way of working."
This regeneration effort promotes a healthy circular economy and is a crucial step in the transition toward a carbon-free industry. It also exemplifies how strategic collaboration and technological advancements can lead to impactful environmental benefits, without compromising productivity or quality.
