Innovative mortar solution to one of Europe's tallest brick-built residential structures
LOCATION
Anchorage Gateway,
Salford Quays, Greater Manchester, M50 2QH
SECTOR
Residential Housing
PRODUCTS USED
GM4 Natural dry mortar, Smart Silo Technology
THE BRIEF
Holcim Mortars was invited to the Anchorage Gateway site by Kinlan Brickwork on behalf of Domis Construction to advise on both ready-to-use (RTU) and dry silo mortar (DSM) options. Due to the constrained footprint and the high volume of brickwork required on such a tall structure, the project team were looking for various guarantees. The main being a high-capacity mortar solution that could keep pace with accelerated bricklaying and zero risk of downtime, given the number of operatives working at height.
The project also needed a system that would require minimal on-ground storage to keep the site clear and operational, as well as a safe and predictable delivery method that would avoid congestion in and around the busy MediaCity environment.
What we achieved in numbers
517
Tonnes of Dry-Silo-Mortar Delivered over 12 months
40
Tonnes of DSM delivered per month
20
Tonne batches of DSM delivered every two weeks between Spet 2022-2023
challenges
Several operational challenges dictated the project’s delivery strategy. The first being the size of the plot which left no room for multiple RTU mortar tubs or frequent vehicle deliveries. Bricklayers were also operating at pace across multiple elevations, using large quantities of material each day so a continuous product supply was critical.
MediaCity has tightly managed delivery windows, pedestrian routes and a nearby school, all of which required careful logistical planning in transporting material to site. With the exterior of the building forming a dominant visual feature, any supply interruption would have had immediate impact on progress at height.
After reviewing the site logistics, Holcim recommended the installation of a single 30-tonne smart silo, capable of delivering a consistent mortar supply while keeping vehicle movements to a minimum. However, the team also needed to identify a safe position for the silo to be installed with correct orientation, vehicle access and a solid base capable of storing 30 tonnes of material.
Solution
After a series of pre-installation site visits, Holcim positioned the smart silo in an agreed upon location on the site in September 2022, delivering GM4 Natural dry mortar. This system offered several advantages tailored to the project’s unique constraints.
Solar powered sonar sensors attached to the silo helped to monitor powder levels in real time, and automatic alerts were sent to Holcim when the silo reached approximately 30% capacity, triggering a planned refill. This ensured no overfills and no risk of wasted loads, a critical factor given the limited amount of space on site.
Powder was delivered in 20-tonne batches to ensure the full load always fit inside the silo over a 12-month period, with the brickwork completed in September 2023. This also removed the risk of return haulage costs and reduced the number of vehicle movements around MediaCity, improving safety and limiting emissions.
With no need for multiple RTU tubs or large storage areas, the ground remained clear for site circulation. This meant bricklayers could simply load tubs beneath the silo and lift them immediately into position at height.
Holcim’s dual capability in DSM and RTU provided a built-in safety net for the project. In the event of the silo becoming temporarily inaccessible, for example through blocked access or mechanical downtime, RTU mortar could instead be delivered to keep work progressing without interruption.
Steven Howitt, Area Sales Manager for Mortar & Screed at Holcim UK, said: “The Anchorage Gateway project allowed us to use both our dry-silo and ready-to-use mortar to the best of its ability. Our ready-to-use mortar provided a genuine safety net that reassured key stakeholders while our dry-silo mortar kept operations running smoothly. The implementation of a single smart silo on site meant we could provide a continuous supply of mortar to match the fast-paced operations of bricklayers, and thanks to close collaboration with both Kinlan Brickwork and Domis Construction, work continued at pace without a hitch.
“This flagship project demanded only the best products, which when combined with state-of-the-art silo technology, showcased the array of possibilities that construction can take advantage of.”
Anchorage Gateway now stands as a landmark within MediaCityUK — one of the tallest brick-skinned residential structures in Europe — and a testament to the value of early planning, intelligent silo technology and close customer collaboration.
"The smart silo system enabled Kinlan Brickwork to work continuously and efficiently on one of the most prominent high-rise residential schemes in Greater Manchester. Despite the constrained footprint and fast programme, Holcim’s proactive planning, technical expertise, and smart delivery systems ensured a smooth, uninterrupted supply of high-quality mortar.”
Ben Douglas, Senior Project Manager,
Relevant Products
Related Case Studies and News
Contact us and get a quote
For more information on about the project or products used in the case study
or to find out how we can help with your next project, please get in touch.
