2023
NEWHURST,SHEPSPED - LEICESTERSHIRE - United Kingdom
Hitachi Zosen Inova
Octopus Building Services
Maccaferri Ltd
Newhurst Energy from Waste Facility Attenuation Pond Lining
NEWHURST ENERGY FROM WASTE FACILITY
Macline GCL W20 patch panels placed to seal the interface around the headwall.
Macline GCL W20 installed and covered with minimum 300mm covering topsoil.
Macline GCL W20 being installed within the attenuation pond located to the rear
Challenge
The Newhurst Energy from Waste Facility, located within the former Newhurst Quarry near Shepshed in Leicestershire, is a major infrastructure project designed to support sustainable waste management in the UK. Construction commenced in June 2020, with completion scheduled for 2023. Once operational, the facility will process up to 350,000 tonnes of residual waste annually while generating up to 42 megawatts of low-carbon energy, enough to power approximately 80,000 homes.
As part of the facility’s critical fire protection system, a large-scale sprinkler network was installed within the incinerator. This created the need for a high-performance attenuation pond capable of capturing and containing firewater runoff in the event of an emergency. In addition to firewater containment, the pond was required to function as part of the site’s wider drainage and stormwater management system.
However, the project faced a significant geotechnical challenge due to the sandy ground conditions at the site. The permeable subgrade increased the risk of water seepage and potential environmental contamination. To ensure effective containment and compliance with environmental standards, a robust and impermeable pond lining solution was required. A geosynthetic clay liner (GCL) was identified as the most suitable approach for achieving long-term performance and sustainability.
Solution
Maccaferri proposed the use of Macline® GCL W20, a high-performance geosynthetic clay liner, to provide an impermeable barrier for the attenuation pond. This solution was approved by the client, Hitachi Zosen Inova, in April 2021, due to its proven effectiveness in landfill lining, water containment, and environmental protection applications.
Macline® GCL W20 consists of a layer of natural sodium bentonite encapsulated between woven and non-woven geotextiles. When hydrated, the bentonite expands to form a dense, low-permeability clay layer, delivering exceptional sealing performance. This eliminates the need for traditional compacted clay liners, significantly reducing material import, construction time, and overall carbon footprint, making it a more sustainable lining solution.
The system was also designed to integrate seamlessly with structural elements such as concrete headwalls. This was achieved by installing the GCL around penetrations and sealing interfaces with bentonite granules, ensuring a continuous impermeable barrier. The liner’s self-sealing properties provide additional resilience, allowing it to recover from minor punctures and maintain performance over time.
Macline® GCL W20 offers excellent slope stability, high chemical resistance, and strong durability under varying climatic conditions. These characteristics make it particularly well-suited for challenging ground conditions such as those encountered at Newhurst Quarry. The solution delivered a reliable, cost-effective, and environmentally responsible attenuation pond lining system, supporting both firewater containment and long-term site drainage requirements.
Used Products
