Located in Warrington, Cheshire, Daresbury Garden Village is a major Redrow development spanning 120 acres and delivering up to 800 new homes, alongside open spaces, green corridors, play areas and a dedicated village centre with shops and community facilities. The scheme includes a mix of three, four and five bedroom family homes close to Stockton Heath and represents a long-term, large-scale residential investment.
Ecofill was selected by Redrow to transform 18,559 tonnes of onsite clays and subsoils into an aggregate replacement product for reuse across the development. The scope of works covered multiple applications, including trench backfill, adoptable roads, embankments and piling mats, supporting efficient progress across the site while reducing reliance on imported materials.
Ahead of production, almost 20,000 tonnes of excavated clays and subsoils were stockpiled along the eastern perimeter of the site in preparation for the arrival of the Ecofill technology. Under the supervision of an Ecofill Production Supervisor, the Ecofill machine and binders were deployed, enabling consistent onsite processing. Production regularly achieved rates of around 1,000 tonnes per day, with peak outputs exceeding 200 tonnes per hour.
All works were carried out in line with Ecofill’s robust Quality Management Plan. The Ecofill product was periodically sampled to maintain quality and ensure consistency throughout production, supported by a combination of onsite testing and independent laboratory testing. Once produced, the Ecofill material was distributed across the site and used in a range of applications, including trench backfill, adoptable roads, embankments and piling mats.
Laying and compaction were completed using traditional compaction equipment in accordance with the National Earthworks Specification, allowing the rapid curing process to begin and ensuring compatibility with standard construction practices.
The sustainable Ecofill solution delivered a measurable environmental benefit by significantly reducing carbon emissions and pollutants associated with material import and disposal. By treating 18,559 tonnes of onsite material, the project avoided the import of 21,343 tonnes of aggregate and prevented 4,158 lorry movements. This equated to a reduction of 101,699 road miles, 48,705 litres of fuel and 1,695 driving hours. When factoring in quarry distances with zero backloading and the Ecofill Binder production facility, the overall savings amounted to nearly 150 tonnes of carbon.
