Hahn Plastics Ltd

The ChallengeIn 2015 a joint venture of Balfour Beatty, Costain, and Skanksa (A14 integrated delivery team) was awarded £1.5bn by Highways England to improve the A14. These improvements included a new major 12-mile bypass, the widening of the A1 and the existing A14, improving the junctions on the A14, and building new access roads.The A14 carries around 85,000 vehicles per day; 26% of this is HGV traffic. It is frequently congested and traffic is often disrupted by breakdowns, accidents, and roadworks.As part of the A14 major scheme, a new retaining wall was needed to be constructed as new road works were encroaching on the pre-existing embankments. A durable, long-lasting, and low-maintenance wall solution with a Highway Authorities Product Approval Scheme and British Board of Agreement (BBA) certificate was required.The SolutionA vast number of EcoCrib mass gravity retaining walls are now constructed to support the embankments along the A14. The EcoCrib Mass Gravity Retaining Wall began its erection on 24th July and was completed on 10th October 2019. With a design life of over 120 years, EcoCrib is durable, and the most highly sustainable retaining solution. Designed, supplied, and installed by PC Construction, certified by the BBA and HAPAS in 2012.EcoCrib profiles are manufactured entirely from recycled UK plastic (bottle tops, car bumpers, etc) with any wastage or surplus material re-processed to form new EcoCrib profiles. Developed from timber crib technology, the 50mm x 125mm EcoCrib profiles are considerably more durable than treated timber but hold many environmental benefits.EcoCrib can be recycled when it reaches the end of its useful life.When considering solutions for developments of all kinds, the lifetime cost means EcoCrib is the more efficient choice.1838 SQM of EcoCrib was used in the scheme, equivalent to 212 tonnes of plastic waste diverted from landfill.

The ChallengeIn 2018 a joint venture of Bam Nuttall and Morgan Sindall was awarded the £200 million smart motorway scheme by Highways England. These works were to improve the flow of traffic between the M6 and the M60. This involved improving the link road between these two busy Highways which is the M62 J10-12.Many Embankments needed to be retained to fit the new ERAs and to allow room for many of the gantries that are needed on a smart motorway scheme.One of the main challenges with all Highway Schemes is coordinating works around your fellow contractors, this can be tough at times with works spread over such a small distance. With careful planning, this was overcome and the work flowed continuously for the duration of our time on the schemeA durable, long-lasting, and low-maintenance wall solution with a Highway Authorities Product Approval Scheme and British Board of Agreement (BBA) certificate was required.The SolutionA sizeable number of mass gravity EcoCrib retaining walls are now built along the M62 J10-12. A total of 44 structures equating to 1546m of walling is now spread across the 3 junctions. With construction speeds exceeding 50m2 a day and a design life in excess of 120 years, EcoCrib is durable, and the most highly sustainable retaining solution. Designed, supplied and installed by PC Construction, certified by the BBA and HAPAS in 2012.EcoCrib profiles are manufactured entirely from recycled UK plastic (bottle tops, car bumpers etc) with any wastage or surplus material re-processed to form new EcoCrib profiles.EcoCrib can be recycled when it reaches the end of its useful life.When considering solutions for developments of all kinds, the lifetime cost means EcoCrib is the more efficient choice.2984 SQM of EcoCrib was used on the scheme, equivalent to 222 tonnes of plastic waste diverted from landfill.

The ChallengeIn 2015 Kier was awarded the £233 million project to build Cheshire’s first smart motorway to help keep traffic flowing between J16 (Crewe) – and J19 (Knutsford), this included 40 Miles of extra lanes, 21 overhead gantries, 18 emergency bays and 258 electronic signs. Hundreds of metres of retaining walls were needed to allow clearance for the emergency refuge areas (ERA’s) and the overhead gantries to be built within the highway boundaries. “As infrastructures had a major impact on the M6 J16-19 critical path a cost-effective solution was needed to reduce the overall time of installation.” A durable, robust, economical, and sustainable retaining wall solution with a British Board of Agreement (BBA) Highway Authorities Product Approval Scheme (HAPAS) certificate was required to satisfy the Highways Agency.The Solution Several EcoCrib mass gravity retaining walls now support the embankments along the M6 J16-J19 to provide clearance for many of the ERA’s and Gantry Bases. Designed, supplied, and installed by PC Construction. Awarded a BBA HAPAS certificate in 2012 with a design life in excess of 120 years, Ecocrib is structurally robust yet the most highly sustainable retaining solution currently available for highway applications. It was the only retaining option that didn’t need heavy lifting equipment to complete the job which made it the safer option. It also allows the installation to be quicker and cheaper than the other options available. Ian Potts quoted on behalf of Highways England “The savings are easily calculated as the installation was priced by a pilling contractor at £41,975 and the installation cost of EcoCrib was £24,177 delivering a saving of £17,798 (£395.51/m). Total savings for the M6 project is 270m ( gantry bases) plus 390m ERA’s @ a total of 590m x £395.51p = £233,350 saving. However, other savings and benefits included: Installation time is 30% of alternative products i.e. 2 days against 7 days. Eliminates the need for lifting equipment, allows working in limited spacing, is environmentally friendly, improves aesthetics, and has a product life of 120 years. “ Developed from timber crib technology, the 50mm x 125mm Ecocrib profiles are considerably more durable than treated timber but possess many of the environmental benefits. Ecocrib profiles are manufactured entirely from recycled UK plastic waste with any wastage or surplus material re-processed to form new Ecocrib profiles. Ecocrib can be recycled when it reaches the end of its useful life. 1478 SQM of EcoCrib was used in the scheme equivalent to 17 million plastic bottle tops or 86 tonnes of plastic waste diverted from landfill. Highways England is now looking at the possibility of using EcoCrib for step installations and retaining wall heights higher than 1.5m. 

CHALLENGEIlam Park was a popular tourist destination in the Peak District with a parking problem. The main car park is paved with asphalt but their sloped overflow car park suffered from rutted, unsafe and uneven surfaces due to poor drainage and puddling. More asphalt would create water runoff and drainage problems elsewhere so a permanent and durable permeable paving solution was required.SOLUTIONHanpaveTM was chosen as it’s a freedraining system that’s tested to bear almost any vehicle. There are no more problems with rutting or uneven surfaces. It’s also highly durable, weather-resistant and made from 100% recycled plastic. When installed on a properly engineered permeable base (no pipes or ducting required!), it can be in-filled with gravel or grass for an attractive, stable base that becomes virtually invisible to the average user.CONCLUSIONHanpaveTM was installed in 2019. We called in on a very wet day in November 2022 and the HanpaveTM grids were in excellent condition. Surfaces were even, rutting was gone and, even in torrential rain, puddling could only be found in areas paved with asphalt – not HanpaveTM. Despite some extremely hot summers, Hanpave’s unique expansion absorbing design and professional installation have given Ilam Park an effective, longlasting and attractive solution to their overflow parking problems.

CHALLENGE The first of its kind for Quebec, the “living street” required a paving grid that would provide multi-purpose access along the street whilst also allowing for the aesthetically pleasing natural look to be maintained. A woonerf is a living street that is traditionally implemented as a traffic calming aid and to enforce low speed limit areas. They are often shared space streets where equal priority is given to all modes of transportation including automobiles, bicycles and pedestrians; usually with separate rights of way. The province of Quebec was looking to do a “pilot project” in the city of Montreal to create a woonerf that would not only provide the required access, including disabled access but that would also have a long-lasting beneficial impact on the environment. They were looking for an environmentally friendly ground reinforcement product which would provide the strength and durability required for a heavily used area. As a “living street”, the product needed to allow the growth of natural vegetation and contain no harmful preservatives which could affect the environment in which it is placed. The harsh weather conditions in Quebec also needed to be considered. With such extreme conditions in both winter and summer, the material needed to withstand the temperature fluctuations. Ground reinforcement products traditionally used such as concrete are susceptible to cold crack in winter as it is a porous material. As a requirement, the desired product was to absorb only limited heat in order to promote growing vegetation. The only suitable material for a project with such challenging conditions was hanit®’s recycled plastic heavy duty ground girds, with their durability and environmental credentials meeting the requirements.SOLUTIONhanit®’s Heavy Duty Ground Grids are manufactured from a blend of high-quality recycled plastic polyolefins extracted from post-industrial and post-consumer mixed waste plastics. Heavy Duty Ground Grids have a high impact resistance which makes them suitable for all vehicle access. They have an interlocking system which improves stability and also allows for quick and simple installation. As the woonerf needed to provide numerous different access levels it was important that the Heavy Duty Ground Grids were versatile. They can be filled with either grass, seed/topsoil or gravel. For this project, wheelchair access was provided through a gravel filled pathway.The rest of the “living street” was mostly completed with grass filled areas. As hanit® products transfer limited amounts of heat, they dry out the soil less than concrete. This works as a benefit to the vegetation growing through the grids. Recycled plastic material is not porous and therefore does not absorb any moisture. This gives added benefits in the winter as when absorbed moisture freezes in concrete it causes cold crack. Their open structure also allows for quick infiltration of any rainwater into the ground allowing for sustainable urban drainage requirements to be met.hanit® Heavy Duty Ground Grids are strong and durable and require no maintenance. They are not affected by weathering and decay; therefore once in place, they have a much longer lifespan than any other competing products. Made from 100% recycled material, the woonerf has been an extremely sustainable project. Providing Montreal with a living street has not only added more vegetation to the area but also allows the city to contribute to an environmentally responsible sustainable urban drainage solution. As the products are chemically inert they do not affect the environment and are harmless to all flora and fauna. In total the project has used 8,500 units of Heavy Duty Ground Grids. This equates to almost 77 tonnes of recycled plastic waste which has been saved from going to landfill. The woonerf has been an extremely well celebrated project that has won prizes for its conception and green initiatives. “I recommend Les Dalles Vertes (Heavy Duty Ground Grids) to all my clients. We laid out nearly 30,000 square feet of these pavers for the Woonerf project and it took us half the time and resources that were required to install the old concrete grass pavers." - Tony Scirocco, Ventec

CHALLENGE Aylesbury Grammar School needed to have their knee rail fencing replaced in the communal areas of the school. The original fencing made of timber had become unsafe and un-secure making it a liability for the children.You often see timber suffer under harsh circumstances such as being faced with weathering in the challenging outdoor environments in school grounds. Aylesbury Grammar School had faced this issue with the timber fencing they had around the school grounds. The fencing had rotted very quickly due to the poor quality preservatives, which have been used in timber since legislation banning the use of oil based preservatives came into effect.Aylesbury Grammar School instructed Buckland Landscapes to replace and upgrade the outdoor areas of the school grounds. They were looking for products that would require little to no maintenance in order to reduce their annual costs. They wanted strong and durable products that would withstand the heavily used areas and maintain a safe environment for the pupils. The products needed to be long lasting and environmentally friendly.SOLUTIONBuckland Landscapes specified ® hanit as the replacement material for Aylesbury Grammar School. ® hanit Ultra knee rail was chosen to create the boundaries within the school grounds. Knee Rail products are UK manufactured ® using the hanit Ultra formulation which is the strongest of all blends. It offers good impact resistance and is used for high quality profiles. This ensured that Aylesbury Grammar School would be provided the durability required to withstand the high use. The surface has the appearance of timber with a consistent colouring and as the products are weather and rot resistant it will remain aesthetically pleasing for many years to come. The safety of the pupils had been put at risk with the previous rotting fencing. Therefore it was made a priority to looking ® for a new material. As hanit does not rot, is weather resistant and has a smooth splinter free finish. These qualities also ensure the reduction in maintenance costs as ® hanit products require no treatment or maintenance.Aylesbury Grammar School were keen to use a more sustainable product in their school grounds, therefore the environmental ® benefits of hanit made it the perfect choice. Made from 100% recycled plastic it is possible to show the students the benefits of recycling and what products can be re-worked from material that would previously have been a burden on the environment and gone to landfill. Buckland Landscapes were pleased with the ease of installation and they found ® the handling of hanit just as simple as timber. “We are really pleased with the replacement knee rail fencing. The products look really good and most importantly, they are strong and durable and will not splinter or rot making it un-safe for our pupils. The knee rail fencing is also a sustainable replacement as it is made from recycled plastic.” Headteacher - Aylesbury Grammar School

CHALLENGEIn Toronto, ON a large mail sorting facility was having an issue with chemicals coming from a concrete processing plant bordering their employee parking lot. The customer was looking to create both a visual and physical barrier from the equipment and excess dust. The fence had to be 2.4m tall, solid and without worry of material maintenance. They wanted to replace the existing fence that was just chain link with tarps, and an eyesore on their property.SOLUTIONA much more visually appealing and effective solution was found with hanit® 100% recycled plastic tongue and groove boards by HAHN, supported by galvanized steel beams. The 3.6m long beams were sunk 1/3 of the length into concrete, then filled with the 3.8cm x 13cm x 2133cm long T&G boards. Each panel was further reinforced at the base using a small hanit® support. The result was a simple, long-lasting privacy fence that met the customer’s needs. Shown here nearly three years after installation, the privacy fence has been a continued success. After numerous seasonal changes and close exposure to the conditions produced by the concrete plant, this installation demonstrates the durability and potential applications of hanit® 100% recycled plastic products. 

CJ Murfitt were asked to provide an alternative product to replace failing timber products at Castle Special School in Cambridge. The school, which has 165 children attending, was opened in 2006 to replace four existing special schools in Cambridge. The timber had been used to edge planting bays and due to the poor quality of the existing material, large areas are now unusable and unsafe. The recycled rectangular palisade which was used on this project is ideal for challenging outdoor environments. The existing timber had rotted very quickly, due to poor quality preservatives which have been used in timber since the legislation which stopped the use of oil based preservatives came into effect.Recycled plastic products do not absorb moisture, do not rot and are resistant to vandalism. Rectangular palisades look great and their longevity is many times that of timber. There is a great variety of hanit palisades, suitable for creative design in any new development, reconstruction and modernisation project. Strong, durable and weatherproof, the palisades have a smooth splinter free finish. They have strong impact resistance and require little maintenance. The brown textured surface resembles the natural beauty of wood. These products can be easily nailed, cut and screwed. “The square palisades were very easy to install, allowing us to complete the work quickly and efficiently. As the product is maintenance free, we are confident that the project will remain aesthetically pleasing for a very long time.” David Coulson CJ Murfitt Limited - Contractor.