FAQ’s

Tarmac is proposing to develop a state-of-the-art production facility at the Cotesbach site. This plant will take non-recyclable waste from regional waste management partnerships, and convert it into a high-quality, sustainable fuel known as Solid Recovered Fuel (SRF). This SRF will then be transported using biomethane- or electric-powers HGVs and used as a cleaner alternative to fossil fuels at Tarmac’s cement manufacturing facility in the Peak District, creating an efficient, circular-economy solution for managing waste and energy. The facility is designed to process approximately 200,000 tonnes of imported waste per year.

The proposal is to build an advanced recycling facility, known as a wash plant, at the Cotesbach site. The plant’s purpose is to take locally collected inert soils, construction and demolition (C&D) waste and process it to create high-quality, reusable construction materials, such as sharp sand and different sizes of gravel (10mm and 20mm).

This facility represents a significant investment in the circular economy, turning materials that might otherwise be considered waste into valuable products for Tarmac to use in applications like concrete production.

A new gas purification plant would capture the gas produced by decomposing waste within the landfill and convert it into green energy. This landfill gas, which would otherwise be wasted or flared, will be transformed into biomethane—a renewable equivalent of natural gas. This clean, green gas can then be used to heat homes and power businesses across the country via the national gas network, a connection to which already runs through the Cotesbach site.

Currently, Tarmac collects a liquid known as ‘leachate’ from the Cotesbach landfill site. This liquid, a by-product of rainwater filtering through the waste, needs to be treated. At present, this involves loading the leachate into tankers—around 10 lorry loads per day—and transporting it off-site for disposal. This process is costly and has a significant environmental footprint due to the vehicle emissions and traffic. The proposed solution – an on-site treatment facility.

To create a more sustainable and environmentally friendly solution, the proposal is to build a self-contained, on-site water treatment facility. This facility will clean the leachate to a high standard, allowing it to be re-used in other on site processes (e.g., in the aggregate washing plant) or safely discharged through a wetland reedbed system and then into a local river, a plan which we would discuss and agree with the Environment Agency before adopting this approach. The new system is designed to treat up to 300 cubic metres (300m3), or 300,000 litres of leachate every day.

The project will completely eliminate the need for daily tanker transport, reducing traffic on local roads, as well as noise and carbon emissions. The chosen solution uses a combination of two proven technologies: a biological treatment plant and a specially constructed wetland ecosystem.

An electric concrete plant is a batching facility that mixes cement, water, and aggregates into concrete using electric-powered mixers, conveyors, and pumps. It works like a traditional plant, but is cleaner, quieter, and more sustainable, especially when powered by renewable electricity as is proposed at Cotesbach.

Think of a ready-mix concrete plant as a large, automated kitchen for baking a cake, but instead of flour and sugar, it uses cement, sand, and gravel.

AA concrete block plant is a modern, automated facility that mass-produces concrete paving blocks, bricks, and kerbstones used in driveways, pavements, and public spaces. The process is similar to an industrial bakery—precise recipes of aggregates, cement, water, and pigments are measured and mixed to form a stiff concrete “dough.” This mixture is compacted into steel moulds under pressure and vibration to create dense blocks, which are then cured in controlled, humid chambers to achieve their full strength. Once hardened, the finished blocks are automatically packed and shipped to construction sites.

What makes this operation particularly sustainable is its integration within a circular system of materials, water, and energy. Recycled aggregates from the proposed wash plant replace the need for virgin sand and gravel to be quarried, while treated water from the proposed on-site leachate facility would reduce the reliance on mains water supply. Meanwhile, waste heat from the proposed renewables and SRF plant will be able to be used to warm the curing chambers, cutting both energy costs and emissions. Together, these interconnected systems form a “circular construction hub,” where local waste is transformed into high-value building materials, with minimal environmental impact.

Our proposals for the next chapter at Cotesbach represent a UK-first, sector leading approach to sustainable waste management and circularity. The proposal represents a multi-million-pound private investment in Leicestershire, demonstrating Tarmac’s long-term commitment to the site and to Leicestershire more broadly, whilst also offering a real opportunity to position the region as a centre of excellence for high skill jobs and training opportunities within the circular economy.

The proposal demonstrate Tarmac’s long-term commitment to the site and to Leicestershire more broadly, whilst also offering a real opportunity to position the region as a centre of excellence for high skill jobs and training opportunities within the circular economy.

At a glance, the benefits of the project include:

• A UK-first in Leicestershire – pioneering a new approach to waste management, recovery, and reuse.
• Less landfill – The Solid Recovered Fuels (SRF) Plant will turn non-recyclable household waste into a cleaner fuel (SRF) instead of sending it to landfill—around 200,000 tonnes a year
• Reduced HGV traffic – it is anticipated that the proposals will lead to a reduction in the number of HGV movements compared to the existing planning permission for the site.
• Cutting fossil fuel use – replacing the use of coal at Tarmac’s cement plant.
• Economic growth – a substantial investment and long-term vote of confidence in the local and regional economies.
• Green jobs – new skilled roles and training for local people.
• Nature recovery – an enhanced nature reserve open to the community, supporting nature restoration and enabling biodiversity to thrive.

For over 50 years, this site has served as an important economic asset for the region and wider economy, supporting jobs and supply chains across Leicestershire. Tarmac’s vision for the next chapter at Cotesbach would represent an investment into Leicestershire, and would help to position the region as a sector-leader in circular waste management and sustainable energy production.

It is also estimated that the proposals will create and support temporary jobs and training opportunities during construction and around 50 new full-time jobs once the site becomes fully operational.

During the construction process, the project will also provide economic support for local industries, specifically construction and hospitality. We are committed to using local suppliers during construction where possible, and would be keen to hear from interested parties during the planning process to discuss potential procurement opportunities.

We are committed to working with residents, businesses, and suppliers to identify how best the project can support local jobs and training opportunities and deliver value for the wider supply chain and economy.

Our Solid Recovered Fuel (SRF) plant will divert residual waste away from landfill and convert this into useable fuel, which will be transported to our cement works in the peak district and replace the use of coal.

Tarmac will also be transitioning to a fleet of EV or biomethane-powered HGVs powered by on-site green energy generation, minimising the site’s immediate and wider CO₂ footprint. The circularity hub will have its own lorry and vehicle EV charging area, incorporating a driver co-ordination centre, offices, and depot.

At the centre of our innovative plans to modernise the Cotesbach site is clean, green, and sustainable renewable energy generation. Driven by the integration of a 30MW solar installation and 10MW BESS facility, our proposals would not only ensure that on site operations can be self-sustaining, but would also have the potential to be exported directly to neighbouring economic hubs (e.g., Magna Park) via direct connections as well.

Generating sustainable, reliable, green energy on-site from waste materials and renewable sources will enable the proposed development to relieve pressure on the national grid, freeing up capacity for other industries to grow. Whilst the on-site solar farm will provide a resilient combined energy system to power the new on-site plants, the SRF and gas purification facilities would produce alternative sources of fuel. This would replace the burning of coal at our cement works in the peak district and enable cleaned biomethane to be plugged directly into the gas network to help power and heat people’s homes.

Through a careful and deliberate design, our plans for Cotesbach will therefore provide a roadmap for reducing the reliance on fossil fuels and imported energy, whilst also providing an exemplar for decarbonisation across waste management and construction.

The project is anticipated to create 50 new jobs and safeguarding more locally and indirectly in the wider supply chain. The jobs and training opportunities which would be created by the scheme will be specialist, skilled positions that will contribute significantly to the local economy.

A proposed enhanced nature reserve is at the heart of our vision for the next chapter at Cotesbach. This will promote access to nature for local people through a network of connected new footpaths and recreation opportunities and will bring the site back into public use. Extensive planting of trees, hedgerows and wildflowers is also proposed within the nature reserve, and across the entire site, ensuring that the future for Cotesbach is driven by nature-led recovery and support biodiversity.

The Cotesbach site is situated in south site is situated Leicestershire, near the villages of Cotesbach and Shawell, to the north-east of Rugby. The site extends to approximately 146 acres, although the development area itself will cover a small portion of the site, and will be contained on already developed land – no previously undisturbed land is proposed to be developed as part of this project.

For over 50 years, the site has served as an important asset for the region and wider economy, supporting jobs and supply chains across Leicestershire. The site is nearing the end of its operational lifespan as material reserves reduce, with all quarrying operations currently set to end in 2044. With local planning policy making it clear that no new landfill sites will be permitted in Leicestershire, our proposals present a unique opportunity to set out a new model for circular waste management within Leicestershire and to act as a benchmark for the delivery of a sustainable and productive future life for similar sites across the UK.

We are proposing a suite of complementary facilities, co-located on the existing site footprint, including:

• Solid Recovered Fuel (SRF) plant to divert residual waste from landfill and replace fossil fuels at a nearby cement works.
• Advanced aggregate washing and concrete plants to recover construction materials and support local, regional and national building projects.
• Gas purification plant to turn landfill gas into biomethane for 8,000 homes and catering-grade CO₂ for industry.
• Leachate plant to treat byproduct from the existing landfill, leaving water which will be able to reused in the aggregate washing plant.
• Solar farm and battery storage providing resilient, renewable power for on-site operations.
• An enhanced nature reserve which will be opened up to the local community, which will promote nature-led recovery and support biodiversity.

Together, these facilities will cut waste going to landfill, generate clean energy, and reduce HGV trips by processing, recovering, and re-using materials on-site.

Cotesbach is uniquely situated as one of the few sites in the UK with the right infrastructure, history, and strategic transport links to host this type of sector-leading project.

With local planning policy outlining that no new landfill sites are planned in Leicestershire, Cotesbach is the county’s long-term solution for managing waste responsibly. Our vision for the next chapter at Cotesbach will transform the quarry and landfill into an exemplar circular economy hub for recycling, clean energy, and nature recovery.

Its central location, within easy reach of the M1, M6 and A5 strategic road network, offer an opportunity to deliver significant investment and support innovation and job creation on an already well-connected site which is ideally placed for a project which requires connectivity. We are also proposing to utilise Rugby railhead as the central transport hub within our plans, and we will look to use this to minimise HGV movements to the site from the wider UK market.

Our proposals would mean fewer lorry trips, lower carbon emissions, and better use of local supply chains.

No. The Cotesbach project is unrelated to the proposed new quarry at Misterton and serves a distinct and separate function, both economically and within the wider Tarmac business.

A circular economy is an economic model designed to reduce waste and make the most of resources. Instead of the traditional linear economy (“take → make → use → dispose”), the circular approach keeps products, materials, and resources in use for as long as possible.

At its core, it’s about closing the loop of production and consumption. This involves:

• Designing out waste and treating pollution – creating products that can be reused, repaired, or recycled.
• Keeping products and materials in use – through reuse, sharing, remanufacturing, and recycling.
• Regenerating natural systems – for example, returning nutrients to the soil or using renewable energy instead of fossil fuels.

A simple example: instead of throwing away an old phone, parts could be repaired, refurbished, or recycled into new devices—keeping valuable materials like metals and plastics in circulation.

No. All the energy generated by the solar farm will be used to power our operations on site, with excess energy stored via a Battery Energy Storage System (BESS), meaning the proposals require no grid connection.

The site currently has planning permission up to 2044, and with this application, we are seeking to extend this into the 2060s, securing the site’s role as an important asset in Leicestershire’s sustainable waste management for the next 40 years.

Our proposals are designed to avoid adding pressure to the Gibbet roundabout and surrounding area. HGV trips will still be required, but by co-locating and combining plants and processes which complement each other and enable circularity between plants and processes on-site, the proposals will aim to significantly reduce the number of HGV trips required to and from the site compared to the existing planning permission for the site.

We are aware of residents’ concerns about traffic at Gibbet roundabout and are engaging with relevant parties to understand future highways plans for the area. To support this, we have instructed specialist highways consultants to carry out assessments that will inform our planning application.

Should planning permission be granted Tarmac would agree a Construction Traffic Management Plan (CTMP) with Leicestershire County Council. This document will set out traffic management procedures for the duration of the construction period, including strict guidelines for contractors to ensure that disruption to local residents is kept to a minimum.

The CTMP will also set out the number and type of construction vehicles expected throughout the construction period, as well as the designated construction routes.

Prior to the commencement of construction, we will carry out a road condition survey on the proposed construction route which will be used to assess any impact from construction vehicles. We will seek to work closely with officers in Leicestershire County Council’s Highways Department to identify where any financial contributions may be required in order to offset the impact of the proposed development on the highways network. If approved, and once fully in operation, we anticipate a lower overall impact on local highways.

Should planning permission be approved we are keen to bring forward the new chapter for Cotesbach as soon as we can. We expect that construction would take 12-18 months to complete. As part of the preparation of our planning application, we will outline how many HGV movements we would anticipate would be required each day during the construction period.

We are focused on utilising Cotesbach’s unique, strategically important location to reduce the environmental impact of these journeys as part of our proposals. Rugby railhead is central to our plans, and we will look to use this important transport hub to minimise HGV movements to the site from the wider UK market.

Whilst we recognise that HGV trips will still be required, by co-locating and combining plants and processes which complement each other and enable circularity between plants and processes on-site, our proposals will aim to significantly reduce the number of HGV trips required to and from the site compared to current levels. This will play a role in reducing congestion on the local highways network and ensure the amenity of local residents is further protected. Equally, where HGV movements ae required, we will be transitioning to a fleet of EV or biomethane-powered HGVs, thus minimising the site’s immediate and wider CO₂ footprint.

A detailed Transport Assessment will be prepared to support the submission of a planning application for the site, which will set out the expected number of trips associated with the proposals, particularly at peak times in the morning and evening.

Should planning permission be granted, we will agree a Construction Management Plan with Leicestershire County Council to set out how access around the site will be retained during construction. We will also work closely with the relevant Public Rights Of Way (PROW) team regarding any necessary footpath diversions or temporary closures.

Ensuring a healthy and safe environment extends across our supply chain and to every aspect of our business – from the way we manage sites and the way we train and equip our employees and contractors – to the safety features we innovate across our fleet to protect road users.

Tarmac is proud to work with experts in the field of Health and Safety, such as the British Safety Council and The Health and Safety Executive and is also one of the founding partners of a mental health programme for people working in the construction sector called Mates in Mind.

We also operate our National Skills and Safety Park. Dedicated to operational onboarding, professional operational training, assessments and health and safety learning. This industry-leading facility demonstrates our ongoing commitment to a culture of safety excellence.

Our approach is no different at Cotesbach. The site has been quarried for over 50 years, and has been operating as a landfill for 16 years, and the safety of our neighbours has always been, and will continue to be, absolutely paramount. Should planning permission be granted we would agreed a Construction Management Plan with Leicestershire County Council ahead of any construction commencing on the site – this will set out the measures we would take in order to protect our immediate neighbours and surrounding communities from the impacts of construction. Once operational, by diverting waste from landfill and recovering this via our innovative combination of new on site processes, issues such as odour and pests would also be significantly reduced, which will help to address concerns which are commonly raised by local communities.

An assessment of the potential construction noise and vibration effects will be undertaken when the construction programme is known. Construction noise and vibration is temporary in nature, and it is anticipated that, with the implementation of measures to be outlined in the Construction Environmental Management Plan (‘CEMP’), the impacts will not be adverse. In terms of the operational noise impact, it is likely that, with the use of required mitigation measures, the noise levels will not exceed proposed noise limits and should result in a negligible impact.

Based on the traffic generation, the impacts from construction traffic on local air quality will be negligible and occur for a transient period of time. All existing dust and air quality management plans which Tarmac has in place for the Cotesbach landfill site will remain active, therefore, it is reasonable to conclude that the overall effect on local air quality will not be significant.

The proposed Solid Recovered Fuels Plant (SRF) will not be accepting ‘wet’ domestic waste streams that have the potential to promote flies, which will help to address concerns which are commonly raised by local communities.

Should planning permission be granted for the proposals all existing pest management plans which Tarmac have in place will remain active, ensuring that this issue contains to be dealt with as effectively as possible.

Under the existing planning permission and permit application the Local Planning Authority and the Environment Agency retain responsibility for monitoring the landfill site.

Landfill and waste sites like those operated by Tarmac are highly regulated in the UK under the Environmental Permitting Regulations (EPR) and Health & Safety law.

Fire Prevention Plan (FPP): Every landfill and waste management site must have a fire prevention plan approved by the Environment Agency. This sets out:

• How fire risks are reduced (separating combustible wastes, limiting stockpile sizes, rotating waste to avoid heat build-up).
• Fire detection and alarm systems.
• Location of fire-fighting equipment (hydrants, hoses, extinguishers, fire water lagoons).
• On-site trained fire marshals and emergency drills.

Tarmac recognises the use of batteries (including lithium-ion) as Energy Storage Systems (ESS) is a new and emerging practice in the global renewable energy sector. We are consulting with Leicestershire Fire and Rescue (LYFR) to better understand any risks that may be posed and develop strategies and procedures to mitigate these risks.

To protect the battery energy storage system, it will be equipped with an FFSS (Fire Fighting Suppression System) inside each container. An FFSS includes a smoke detector, control panel, alarm device, exhaust pipe and bump head. Before gas blow-out, the system controller will send a signal to the HVAC main power switch to stop working as well as isolating the fans and thus achieve fire suppression process. Tarmac will continue to monitor developments in technological and regulatory advancements for BESS to ensure that the final design of the BESS complies with any future amendments to fire and safety standards.

A surface water drainage strategy will be implemented on site, which will manage the impact of the development on surface water run-off. It will prevent erosion and the release of silt-laden run-off from entering surface water drains, watercourses and ponds without treatment (e.g. earth bunds, silt fences, straw bales, or proprietary treatment) under any circumstances.

Surface water run-off from panels, equipment and access tracks will be directed to permeable Sustainable drainage systems (SuDS) features.

Further surveys will be undertaken and used together with comments received from relevant consultees to further refine and improve the proposals.

Our approach to delivering an exemplar site for sustainability at Cotesbach has been to place nature recovery and biodiversity at the heart of our proposals. As part of our focus on the remediation and repurposing of the existing quarry and landfill at Cotesbach, our plans would deliver a new nature reserve, extending to around 146 acres.

Tarmac is unwavering in our commitment to ensuring that our positive vision for the future of Cotesbach – with the proposed nature reserve at its heart – also promotes access to nature for local people. Through a new network of connected new footpaths and recreation opportunities, we will open up part of the site and bring it back into public use. In so doing, we hope to improve the health and well-being of our neighbours and surrounding communities. Our plans include extensive planting of trees, hedgerows and wildflowers, not only within the proposed nature reserve, but across the entire site. This will help to sensitively reintegrate the site back into the local landscape and create a pleasant environment for people to spend time, exercise, and enjoy themselves.

The proposals will deliver at least a 10 per cent Biodiversity Net Gain, in accordance with the provisions of the national policy, but will seek to deliver much greater improvements to existing, and creation of new, habitats for a range of species – ensuring that the site becomes a fertile haven for local wildlife.

Biodiversity Net Gain (BNG) is a conservation approach used in planning and development that ensures a project leaves the natural environment in a measurably better state for biodiversity than it was before the project took place.

Instead of just compensating for environmental damage, BNG requires developers to enhance habitats and ecosystems, delivering more biodiversity overall.

As part of the preparation of our planning application, we will be preparing a comprehensive drainage strategy for the site. By including extensive planting and green spaces across the proposed nature reserve and wider site, rain water will be able to be better retained on site and released steadily into local watercourses.

Our public consultation ran from 11 November 2025 until 11.59pm on 11 December 2025.

We held in-person events in Cotesbach and Shawell where local residents, stakeholders, and other interested parties could learn more about the proposals, ask questions, and provide their feedback.

We are grateful for all the feedback and questions received. The views expressed by all stakeholders, along with the outcomes of environmental assessments and technical studies, will now be carefully considered and where possible will inform our plans for the project.

Following engagement with local stakeholders and communities, we will be submitting our planning application to Leicestershire County Council as relevant authority responsible for minerals and waste matters. It will then be for the County Council’s Development Control and Regulatory Board to decide whether the planning permission should be granted.

Once submitted, we will work closely with officers and statutory consultees and look to respond positively to comments and feedback received. We are hopeful for a decision from Leicestershire County Council in mid-2026.

Tarmac is committed to holding an accessible and transparent consultation, which reaches a wide audience of local residents.

You can get in touch with us in a number of ways, including:

• Email at info@cotesbach-development.co.uk
• Call the project’s freephone line on 0800 699 0081 (Monday-Friday, 9am-5pm, excluding Bank Holidays) and leave your contacts details for one of our team to call you back.
• Freepost at FREEPOST TC CONSULTATION (no further address or stamp required)