Formerly home to Royal Doulton Potteries, Cawarden delivered an integrated service to re-engineer a 13.5-acre brownfield site for the construction of 200 new homes in Staffordshire.

In the wake of Stoke on Trent’s pottery industry decline, swathes of land and disused buildings were left behind, emblematic of a fading era. Recognising an opportunity for transformation, Cawarden secured a contract at the former site of Royal Doulton Potteries post its closure in 2005. Our mission: to revitalise this dormant landscape through meticulous demolition and comprehensive remediation efforts.

Initially tasked with the demolition of remaining structures, Cawarden’s success led to a subsequent contract award. The scope was vast, demanding the re-engineering of over 100,000m3 of soil, extensive excavation works reaching depths of 3 metres, and intricate earth profiling. Leveraging cutting-edge GPS modelling technology, our team meticulously created accurate formation levels for new plots and road infrastructure, ensuring precision in every aspect of the project.

Yet, beneath the surface lay a labyrinth of hidden complexities. Dating back to the 1800s, remnants of pottery manufacturing processes lay buried, a testament to the site’s rich industrial history. Collaborating closely with archaeologists, we unearthed a trove of artefacts – kilns, vats, and structural remnants—some spanning over 40 meters in diameter, underscoring the scale of our endeavour.

The site’s history intertwined with coal mining, further complicating our task. Addressing this, we undertook the delicate task of excavating and stabilising old mine shafts, employing advanced grouting techniques to ensure structural integrity.

Preserving the site’s heritage was paramount

A church’s buried remains adjacent to the former Royal Doulton factory shop were excavated and meticulously documented before the shop was demolished.

Sustainability remained a guiding principle throughout

On-site crushing facilitated the recycling of materials, maximising efficiency and minimising waste while backfilling excavated areas in layers.

Innovation was key to overcoming challenges

To address varying site levels, we designed and implemented a pioneering 250-metre-long in-situ retaining wall, tailored to provide stability amidst the terrain’s undulations. Overcoming logistical hurdles, such as poor access, we also collaborated with the client to deploy a pre-cast system lifted in by a 100-tonne crane on the western side of the site.

The walls were backfilled, and a CBR test was taken at different levels to ensure proper compaction.

Delivering Comprehensive Solutions

The culmination of our efforts heralded a new chapter for Stoke on Trent – a landscape reborn, poised to accommodate over 200 new family homes. Our integrated approach, encompassing earthworks, remediation, civils, and groundworks, alongside our core demolition expertise, exemplifies our commitment to delivering comprehensive solutions tailored to our client’s needs.

At Cawarden, we don’t just transform sites; we redefine possibilities. Through value-engineered solutions, streamlined processes, and an expert team, we turn challenges into opportunities, paving the way for progress, one project at a time.