The combined operation at Tunstead is one of the largest in the UK, extracting between 5 and 6 million tonnes of limestone per annum over recent years. It was established in the 1920s to provide a consistent supply of high purity industrial limestone for use within the chemical and other industries.
Tunstead is the largest supplier of lime and lime-based products in the UK and as such is acknowledged to be of national strategic importance. The powders are manufactured at two sites near to the Tunstead site. The site also produces aggregates for the construction industry.
A new Cement Plant was built in 2004, which now forms part of the UK Tarmac Cement Network. The Plant has a capacity of 1m tonnes, which is shipped all over the country by tanker, rail or in packed bags.
The Tunstead site lies around 4 km east of the centre of the town of Buxton in Derbyshire. It comprises two separate extraction areas – Tunstead Quarry and Old Moor Quarry. The quarries are separated by Great Rocks Dale, a dry valley within which runs a freight railway line serving the two quarries (and others locally) and are connected by a causeway bridge over the railway and stone from both quarries is processed within Tunstead Quarry.
Overall, the operational area is over 340 hectares.
There are around 400 employees working at Tunstead, many living local to the site.
At the head of each operation is a highly qualified and skilled management team.
Lime and Powders
Lime and Powers Director - Viv Russell
Lime General Manager - Peter Butterworth
Plant Manager - Raul Morales
Good environmental management is at the heart of all the operations at Tunstead. The site has achieved the internationally recognised environmental standard (ISO 14001) which demonstrates our commitment to improve our performance.
Here we put the spotlight on Lucy Smith and Nevil Hillton who act as the first point of contact for regulators regarding plant information and ensure the plant complies with its permits, company objectives and community requirements.
Lucy Smith - Environmental Manager
Lucy, 24, joined the company in 2014 as the Environmental Coordinator for the Cement Plant at Tunstead. Lucy studied Material Engineering at Loughborough University and took on summer placements at Bridon International Ltd working in the laboratory as technical support. Following her graduation she joined the company full-time as the site Environmental Coordinator and then after 18 months was promoted to Environmental Manager.
Nevil Hilton - Environmental Manager
Nevil joined the company in February 2014 and is the Environment Manger for Lime and Powders. He has over 20 years experience in environmental related areas, mainly in the Agrochemical and Pharmaceutical industries where he has led a number of projects looking at environmental improvements in the use of energy, waste and water.
Lucy and Nevil’s roles are varied and include ensuring that Tunstead site continues to comply with technical environmental legislation, interacting with the Environment Agency and encouraging and working with all employees to bring ideas on how we can improve our environmental performance.
My name is Hendrik Ratigan I am the new permanent Electrical Engineering apprentice on the cement plant, I have been with the company now for about 2 years. Previously I was with site services and now have been down here on the cement plant for about 8 months. I study at Chesterfield College on day release once a week, I am currently studying for my HNC in Electrical and Electronic Engineering. I enjoy my new role on the cement plant as I am working in a good team of people and the plant offers a wide range of systems to work on for my apprenticeship.
I'm an apprentice mechanical fitter, I am about to start my HNC in Engineering at Chesterfield college. What I enjoy about my position is that every day on site is different and I'm always learning new things about the plant and equipment.
Protecting the safety, health and wellbeing of our employees, contractors and those around us is a core value of our business. We work in potentially hazardous environments so it’s important that everyone understands how to go about their jobs safely.
We believe that no task is so important that it can’t be done safely and through measurement and learning we can continuously improve our performance. Everyone working at Tunstead is expected to work in a safe, responsible manner and to challenge unsafe behaviour.
We give everyone on site a thorough safety induction so they know our behavioural expectations and how to stay safe. We are very careful to separate out traffic and pedestrian movements, and we undertake risk assessments before each activity so that we know the risks involved and can prepare for them.
We measure our safety record by recording everything from a Near Miss (Unsafe Act or Condition), First Aid Treatment, Medical Injuries, and incidents that mean someone has to take time off work, known as a Lost Time Injury (LTI), so we can learn and avoid them altogether in the future. We proudly display the number of days since an LTI and to remind everyone of the need to remain safe.
On site, everyone outside the office buildings must wear Personal Protection Equipment (PPE).
The Mineral Products Association (MPA) is the trade association for the aggregates, asphalt, cement, concrete, lime, mortar and silica sand industries. The British Lime Association is part of MPA and there is extensive health and safety information for the mineral products industries on the Safe Quarry hub site.
Tarmac, a CRH company, is the UK’s leading sustainable building materials and construction solutions business. Our innovative products and solutions not only deliver the infrastructure needed to grow the UK economy today but also help to create a more sustainable built environment for the country’s long term future. We have contributed to some of the UK’s biggest construction projects, including Wembley Stadium, Heathrow Terminal 5, The Shard and London 2012.
The company has over 150 years of experience and directly employs around 6,600 people across a nationwide network of over 330 sites. Our solutions span aggregates, asphalt, cement, lime, readymix concrete, road contracting services, building products and recycling services. This unique combination of people, technology and assets enables us to offer customers unrivalled choice, innovation and flexibility.
Prior to the acquisition of Tarmac by CRH from Lafarge SA and Anglo American Plc the business was known as Lafarge Tarmac. For more details, visit www.tarmac.com
CRH (LSE: CRH, ISEQ: CRG, NYSE: CRH) is a leading diversified international building materials group, employing 91,000 people at c.4,000 operating locations in 37 countries worldwide. With a market capitalisation of c€22 billion (July 2015), CRH is the largest building materials company in North America and the third largest worldwide. The Group has leadership positions in Europe as well as established strategic positions in emerging economic regions of Asia and South America. CRH is committed to improving the built environment through the delivery of superior materials and products for the construction and maintenance of infrastructure, housing and commercial projects. A Fortune 500 company, CRH is a constituent member of the FTSE 100 index and the ISEQ 20 with American Depositary Shares listed on the NYSE. For more information visit www.crh.com