HOLCIM, BARDON HILL QUARRY – MEMBER SITE VISIT JULY 2025
HOLCIM BARDON HILL QUARRY – MEMBER SITE VISIT
On the 22nd of July, MHEA Members were given the valuable opportunity to tour Bardon Hill Quarry – one of the largest and most technically advanced granite quarries in the UK. Sitting adjacent to Bardon Hill, the highest point in Leicestershire, the visit, kindly hosted by Holcim’s Bart Banks (Assistant Quarry Operations Manager) Richard Miller (Engineering/Maintenance Manager) and Mark Hubbard, (Quarry Supervisor) provided a detailed look into quarry operations, focusing on the site’s processing systems and the innovative RopeCon® overburden conveyor system supplied by Doppelmayr.
Bardon Hill Quarry produces approximately 3 million tonnes of high-quality crushed granite aggregate per year, with plans to scale to over 4 million tonnes following recent site expansions. The site is critical to the UK’s construction material supply and has an operational history dating back over 150 years.
The quarry recently underwent a major extension, unlocking over 130 million tonnes of new reserve, supported by state-of-the-art materials handling systems.
A key highlight of the visit was the RopeCon® aerial conveyor system, developed by Doppelmayr, designed to transport overburden during the extension phase.
The overhead conveyor spans 850 metres across the quarry void with a capacity of up to 1,000 tonnes per hour of material.
The system uses suspended conveyor belts supported by cables, significantly reducing the need for haul roads and truck traffic.
It also allows material to be both extracted and deposited for progressive backfilling and restoration.
The environmental benefits include minimal ground disturbance, reduced noise and emissions and efficient adaptation to varying topography.
This system demonstrates how modern materials handling solutions can drive sustainability and efficiency in large-scale mineral extraction.
The group was also briefed on Bardon Hill’s Biodiversity Action Plan, which includes:
- Translocation of wetland and grassland habitats.
- Species monitoring (including bats, peregrine falcons, and rare insects).
- Progressive restoration using overburden via the RopeCon® system.
The MHEA thanks Holcim and the Bardon Hill team specifically Bart Banks for their warm welcome and detailed insights. The site exemplifies best practice in materials handling, automation and environmental responsibility offering valuable learning for all attendees.
