Investing for control: Needingworth combines concrete production and earthmoving with Liebherr

Arriving at Needingworth Quarry in Cambridgeshire, the scale of the operation is immediately clear. Lorries move steadily in and out, conveyors stretch across the site, and, in the distance, earthmoving equipment works methodically across freshly stripped ground. It is not a typical quarry setting. Producing close to 800,000 tonnes of sand and gravel each year from a relatively shallow seam, Needingworth has long been a key contributor to the region’s construction supply — estimated to account for around 40% of the local market.

Now, under the ownership of Brice Aggregates, the site is undergoing a significant transformation. Since acquiring the quarry in May 2024, the business has moved quickly to embed its own operating model — one centred on control, efficiency and long-term sustainability.

At the heart of that strategy is a dual investment: a new Liebherr concrete batching plant and a fully in-house Liebherr earthmoving fleet.

For Operations Manager Matt Ball, the decision to install a Liebherr batching plant, supported by ten HTM 905 truck mixers, was rooted in experience. “We have a 2.5-F batching plant at Colemans Quarry near Colchester and have found it to be reliable in delivering consistent, high-quality concrete all day, every day,” he explains, standing beside the newly installed New Series Liebherr Mobilmix plant. “We knew exactly what we were getting with Liebherr, so it made sense to invest in the latest version of a batching plant we already trust.”

That familiarity has allowed Brice Aggregates to establish immediate concrete production capacity at Needingworth, strengthening its position across East Anglia and maintaining consistency for its customer base. The addition of the mixers completes the package, ensuring materials produced on site can be delivered efficiently and reliably.

But while the batching plant represents a key step forward in production, it is the decision to bring earthmoving operations in-house that marks the most significant operational shift.

Previously subcontracted, soil stripping and restoration are now being carried out by a dedicated Liebherr fleet — a move designed to give Brice Aggregates greater flexibility across the site, alongside long-term cost benefits.

“We need around 50 acres of land per year to give us around a million tonnes of mineral per year,” says Matt. “By bringing that work in-house, we’ve got much better control over how the site operates — and that gives us flexibility we didn’t have before.”

Out on the quarry face, that change is already visible. A Liebherr R 938 crawler excavator is steadily removing topsoil and subsoil, working in close coordination with the Cambridge Archaeological Unit. Progress is deliberate, with operators carefully exposing layers of material as archaeologists monitor each stage.

The excavator’s role is critical — not only in productivity, but also in precision. “We already have an R 934 at Colemans Quarry and have found that to be a very reliable and productive machine,” Matt says. “Moreso, the fuel economy we are getting is far better than anything else we have in the fleet. That was a big factor in choosing Liebherr again.”

The stripped material is then transported by a trio of TA 230 articulated dump trucks, moving across haul routes that currently stretch to around 650 metres. Despite the variation in ground conditions, the trucks maintain a steady rhythm, aided by wide tyres that minimise ground pressure and a design that balances traction with operator comfort.

The final stage of the cycle takes place away from the main extraction area, where restoration work is reshaping the landscape entirely. Unlike many quarries, where overburden is simply backfilled into worked-out areas, Needingworth is part of a much more ambitious project.

Working in partnership with the RSPB, the site is being developed into what will ultimately become one of Europe’s largest man-made wetland habitats. The scale of that ambition is evident on site, with newly formed landforms gradually taking shape across the low-lying landscape.

Here, a Liebherr PR 736 dozer, equipped with Trimble Earthworks, is at work. From a prepared platform, it pushes and shapes material into a network of islands and contours, following detailed environmental designs.

“We’re given a plan to create these ‘cells’, which include a series of islands formed from the soils we’ve already moved,” Matt explains. “The dozer plays a key role in delivering that — it allows us to be precise, which is essential for this type of restoration.”

The integration of technology with machine performance is clearly visible, as the dozer moves steadily across the site, building up the contours that will eventually support a diverse ecosystem of wildlife.

Across both the production and earthmoving sides of the operation, there is a clear emphasis on consistency — not just in output, but in support. All Liebherr equipment on site is covered by long-term service agreements, ensuring both the batching plant and mobile fleet are maintained to manufacturer standards.

“We’ve been very impressed with the level of service we’ve had,” Matt says. “Having that support gives us real reassurance. It’s an added cost, but when you look at fuel savings and overall efficiency, it more than justifies itself — and it helps us reduce our carbon footprint too.”

Back on site, the interplay between the different elements of the operation becomes clear. Materials are extracted, transported, processed, and ultimately transformed — not just into construction products, but into a landscape with a future purpose.

By investing across both concrete production and earthmoving, Brice Aggregates has created a more integrated and controlled operation at Needingworth. It is a model that brings together performance, efficiency and environmental responsibility — and one that positions the quarry for the long term.