Holcim UK supplies 35,000 tonnes of aggregates to Luton Airport runway resurfacing

 

Holcim UK, a leading supplier of sustainable building materials, has successfully delivered 35,000 tonnes of high-quality aggregates for the resurfacing of the main runway at London Luton Airport.

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Working in partnership with specialist contractor Lagan Aviation & Infrastructure, Holcim supplied approximately 28,000 tonnes in aggregates from its Bardon Hill quarry in Leicestershire and a further 7,000 tonnes of sand from its Grovebury Quarry in Leighton Buzzard to accommodate this large-scale, time-sensitive project.

Lagan Aviation used the aggregates delivered by Holcim to produce specially engineered Marshall asphalt, which it then applied to the runway for creating the new surfacing.  

The planings removed from the old runway surface were transported to Holcim’s Croft Circular Construction Hub, to be recycled and used in its circular asphalt products. As part of its commitment to circularity within the construction industry, Holcim recycles construction demolition materials (CDM) for reuse in new sustainable products, thereby maximising resources, minimising waste, and reducing carbon emissions.

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The £18 million runway resurfacing programme, which began in November 2025 and was completed in March of this year, marks the first full renewal of the 1.3-mile runway since 2006. Under UK aviation safety requirements, major runways typically require resurfacing every 20 years to remain compliant and safe for aircraft operations.

Because London Luton Airport operates around the clock, the construction team worked within a nightly window of only five hours and 44 minutes before the runway was returned to service for the first departures of the morning. This limited access required meticulous planning, precise execution and consistent supply reliability.

Each night, approximately 15 centimetres of the existing surface was removed and replaced with a new high-performance asphalt layer engineered to withstand heavy aircraft loads and varying weather conditions throughout the year.

Holcim has previously worked with Lagan Aviation, having supplied materials from its Bardon Hill site to several other major runway resurfacing projects across the UK, including at London Stansted Airport and RAF Wittering.

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Gareth Pugh, Regional Director of Aggregates for the Midlands at Holcim UK, said: “This project is a powerful example of how our sector-focused approach is delivering real results.

“Supplying the materials on a just-in-time basis, we’ve supported Lagan’s tight project schedules while minimising risk. Our approach has also halved CO₂ emissions through smarter haulage and kept old planings in use, contributing to a more circular construction process.

“Both our Bardon Hill and Leighton Buzzard sites have been outstanding throughout, and this success shows exactly what our teams and partners can achieve collaboratively”

Brandi Davey, Project Manager at Lagan Aviation & Infrastructure, said: “Holcim had a clear understanding of our project goals, and worked with the Lagan team to meet our tight deadlines.

“Challenging weather brought change, which Holcim was able to react to in a positive way. The reuse of planings, and using the same vehicles for delivering aggregates, reduced the number of vehicles travelling in and out of the local community.

“The quality of the service, and the products used for the asphalt, remained high throughout the project, enabling us to finish on time.”

To find out more about Holcim UK, click here: https://www.holcim.co.uk/