Durable Precast Retaining Walls for a 5,000 Tonne Salt Barn
A cost-effective alternative to in situ walls, designed and delivered ahead of winter
Meeting Tight Deadlines with a Smarter Salt Storage Solution
When Central Bedfordshire Council planned a new winter maintenance depot in Houghton Regis, the design included a 5,000-tonne salt storage facility.
Collaborating with Toro Shelters for the main contractor, Morgan Sindall, we were invited to tender for the retaining wall package, delivering a durable, cost-effective solution that could withstand the highly corrosive salt environment.
Project Overview
- Client – Central Bedfordshire Council / Morgan Sindall
- Location – Thorn Turn, Houghton Regis, Bedfordshire
- Sector – Local Authority / Infrastructure
- Services Provided – Structural design, precast installation
- Project – New salt storage facility
- Products Supplied – Cast‑in L‑Shape Retaining Walls
- Installation Duration – 1 week
Project Background
The original salt barn design specified a steel-framed building with in‑situ concrete retaining walls to contain the salt. While effective, this approach required more site labour, longer programme times, and higher costs.
Morgan Sindall were keen to explore alternatives. Our proposal replaced the in-situ walls with precast L-shaped retaining wall units, installed alongside a reinforced concrete floor slab. The building structure was re-engineered as a lightweight galvanised steel lattice frame, clad with a tensioned composite membrane by Toro Shelters.
This combined approach cut construction time, reduced costs, and still met the durability requirements for storing bulk salt.
Our Solution
Why Cast‑In L‑Shape Retaining Walls
The reinforced concrete floor slab in the new salt barn provided the perfect situation for the cast-in wall system. By tying the wall units directly into the slab reinforcement, the cantilever length is extended without the need for a large base, thereby reducing both unit weight and transport costs compared to bolt-down walls.
Key benefits for this project included:
- Reduced foundation size and material use
- Lighter units for easier handling and lower transport costs
- Permanent, self-supporting wall system once cast in
- Faster programme – installation completed in one week
The Results
“The proactive work of JP Concrete has resulted in a smooth-running and cost-effective job that looks very good indeed. From start to finish, everything has gone well, with a great turnaround from an innovative team who quickly understood our deadline and what we needed to achieve.”
Tom Martin, Morgan Sindall
Products Used In This Project
- Heights: 1.0 m to 3.75 m
- Surcharge Capacity: Up to 10 kN/m²
- Concrete Strength: C50
- Corner Options: 90o