Aggrecyle Urban Quarry
C&D Waste Recycling & Water Treatment Plant
Leicester, England, UK
MATERIALS
Processing aggregate from construction & demolition projects all year round.
OUTPUT
0-2mm & 0-4mm recycled sand | 10mm, 20mm & 40mm high-quality recycled aggregates
USAGE
Road sub-base, Pipe bedding, Concrete and Asphalt production.
Project Overview
This project delivered a highly efficient, future-ready processing solution that exceeded operational expectations within the first 12 months. With an average uptime of 96%, the capacity to process over 380,000 tonnes of material, including significant volumes of recycled C&D aggregate and the ability to recycle and re-use up to 94% of the water used within the system — the installation demonstrated measurable value from day one.
By enhancing throughput, lowering ownership costs, and simplifying maintenance, the solution not only maximised productivity but also aligned with evolving sustainability goals. Supported by comprehensive engineering expertise and best-in-class after-sales care, the outcome is a robust, scalable system built for long-term performance.
The Challenge
The UK construction sector faces increasing pressure to reduce landfill dependency, lower carbon emissions and maximise the recovery of valuable resources from construction and demolition waste.
AggRecycle identified an opportunity to establish a dedicated Urban Quarry operation capable of processing waste materials generated within the Leicester region and transforming them into high-quality construction aggregates.
The challenge was to design a complete washing and water management system capable of handling variable feed material, achieving high levels of resource recovery and operating efficiently within a constrained urban environment.
Alongside aggregate recovery, the system also needed to minimise water consumption while delivering a sustainable solution capable of supporting future growth.
The Solution
Tyrone International designed and supplied a fully integrated aggregate washing and water treatment plant tailored specifically to AggRecycle’s operational requirements.
The process begins with the washing and classification of incoming construction and demolition waste. Through a combination of screening, scrubbing, washing and classification technologies, the plant effectively separates contaminants while recovering valuable aggregate and sand fractions.
The washing circuit is supported by a high-performance water treatment system that captures and processes process water, allowing it to be reused throughout the plant. This significantly reduces fresh water demand while maintaining efficient production.
From initial design and engineering through to manufacture, installation and commissioning, Tyrone International delivered a complete turnkey solution supported by specialist technical expertise and aftersales support.
The result is a modern Urban Quarry facility capable of transforming site-derived waste materials into valuable recycled construction products fit for reuse within the local construction supply chain.
Results Achieved
The AggRecycle Urban Quarry is now producing high-quality recycled aggregate products from construction and demolition waste that would traditionally have been exported off-site for disposal or lower-value applications.
Key project benefits include:
- Recovery of valuable recycled aggregate products from C&D waste streams.
- Reduced landfill dependency through increased material reuse.
- Reduced transportation requirements through localised material processing.
- Lower carbon emissions compared with the use of primary virgin aggregates.
- Efficient water recovery and reuse through an integrated water treatment system.
- Support for the UK’s growing circular economy objectives.
- Creation of a sustainable source of construction materials within an urban environment.
The project demonstrates how advanced washing and water treatment technologies can unlock significant value from waste materials while helping operators meet environmental and sustainability targets.
As Urban Quarry developments continue to gain momentum across the UK, AggRecycle’s Leicester facility provides a successful model for future aggregate recycling operations.
Gallery
“Our clear focus on customers’ needs, plant efficiency, ease of maintenance and after-sales support is why our business continues to grow at such a rapid rate”
“We are currently in the process of launching a number of innovative new products which will maximise customer production whilst reducing the cost of ownership.
As a company we bring years of industry experience to supply innovative bespoke aggregate washing and water treatment plants which have a clear focus on customers’ needs, plant efficiency, ease of maintenance and after-sales support”