The project presented several logistical and operational obstacles. Dual carriageways on one side and the canal on the other restricted space for material storage. Mortar also needed to arrive in the afternoon, be moved directly into tubs, lifted up onto mast climbers, and remain workable for bricklaying first-thing in the morning. This meant there was no tolerance for delivery delays, with any missed drops halting bricklayers working at height and creating costly disruption.

As a building that will be seen daily by thousands of commuters and residents travelling football fans, even minor colour variation would have been noticeable and therefore unacceptable. This added an extra layer of importance to the mortar colour, which not only had to be in keeping with the chosen Heritage brick, but also had to remain consistent in its pigmentation.

Holcim provided GM4 Eco 132 ready-to-use (RTU) mortar to the No.1 Old Trafford project, selected from an on‑site colour showcase and approved by the architects for its warm, light straw‑brown tone that complemented the Heritage brick palette.

To ensure uninterrupted progress, RTU mortar was supplied with a 36–72-hour retarder, guaranteeing prime workability when lifted to upper floors. Deliveries were made using Holcim’s pod truck fleet, where the coloured mix is stored in an isolated compartment to protect against contamination and maintain colour consistency. Daily coordination between Holcim’s internal office team and Kinlan’s project managers ensured precise batching, proactive communication, and no missed morning or afternoon delivery windows.

Continuous supply was made from Holcim’s Ellesmere Port plant, strategically located to serve Manchester’s construction corridor. These deliveries supported a smooth build sequence and enabled Kinlan’s bricklayers to work efficiently at height during summer and winter seasons.

Overall operational discipline — including exact pigment dosing and meticulous pod cleaning — ensured a flawless exterior finish across both towers.

Over the 18‑month programme, Holcim supplied nearly 600m³ of RTU mortar, which equates to coverage of approximately 17.5 km² of brickwork.

Sustainability considerations

Holcim incorporated several measures that supported reduced waste and efficiency throughout the project. Pod trucks, for example, enabled multi‑site “milk runs”, reducing the number of single‑purpose vehicle movements. The retarder also ensured full utilisation of each batch, minimising wasted material and avoiding the mortar from prematurely setting off. In addition, consistent batching eliminated the risk of rejected loads or colour mismatch, reducing remediation and embodied carbon associated with rework.