On‑Site Crushing And Screening: The Quick Answer
Picture a midlands housebuilder with 2,500 tonnes of slab and foundations to clear, school next door and a quarry 12 miles away: do you cart it off or crush and reuse on site? If you manage sites, contracts or estates in the UK and need a clear, practical guide, this article is for you. In our experience, the difference between saving five figures and wasting time is knowing which levers to pull: tonnage, distance, access and reuse plan. Read on for fast decision rules, compliance must‑dos, kit choices and a short checklist to take to tender meetings.
A common issue we see is teams assuming crushing always saves money. It doesn’t. We supply frank, site‑level advice and reliable delivery across Shropshire, Staffordshire, Cheshire and the Midlands. For availability and examples, view our crushing solutions.
The Cost Equation: Compare Off‑Site Vs On‑Site Properly
Keep the maths simple. Off‑site costs: load‑out, haul distance, gate fees and the cost to import aggregate back in. On‑site costs: mobilisation, plant hire (crusher, screener, excavator), fuel, water/dust controls and operators. Don’t forget programme risk and waiting time — these are real costs on live projects.
Quick formula: On‑site £/t = (mobilisation + hire + fuel + controls) ÷ tonnes. Off‑site £/t = haul per tonne + tip fee + imported aggregate cost. If you want a rapid desk appraisal, use our aggregates calculator and check typical muck away rates before you estimate.
Break‑Even By Tonnage And Distance: Worked Examples
- Small (1,000 t, 10 miles): off‑site ~£35–£45/t; on‑site ~£14–£18/t. Marginal if access or space is limited.
- Medium (4,000 t, 12 miles): off‑site ~£38–£48/t; on‑site ~£10–£14/t. Typical saving ~£24–£34/t — payback in days.
- Large (12,000 t, full reuse): off‑site ~£36–£46/t; on‑site ~£8–£12/t. Savings stack to tens of thousands and cut carbon and delivery congestion.
These figures assume 20‑t payloads and realistic tip fees; they are guides, not quotes. If you need grading to Type 1 or 6F2, see our screening services.
This image was generated with AI and may not always represent the product or service exactly.
Distance Sensitivity And Quick Rules Of Thumb
Every extra mile each way raises off‑site £/t; every percentage point more reuse reduces on‑site £/t. The levers are steady feed rate, short internal moves and clean stockpiles. If you can reuse >70% and the tip is over 5 miles each way, on‑site usually wins. If you have under 500–700 t or only 2–3 miles to the tip, it is often marginal.
What Most People Get Wrong
Most teams overlook programme risk and neighbour costs. Waiting for a slot at a tip, extra traffic management or night works can erase apparent savings on paper. In our experience, factoring these operational costs changes the decision more often than variations in tip fees.
Quick Checklist
- Tonnage and target product (6F2, Type 1)
- Distance to nearest inert tip and typical gate fee
- Site space for crusher, screener and stockpiles
- Contamination risk (tar, asbestos, plaster)
- Access, neighbours and permitted hours
When This Doesn’t Apply
If arisings contain asbestos, high tar or significant organic contamination, on‑site crushing is usually unsuitable and may require specialist disposal. Also, next to a very low‑cost quarry with cheap delivered materials, off‑site imports can be the lower risk option.
Compliance, Permits And Paperwork (UK)
Operators should hold a Local Authority Part B Mobile Plant permit and supply RAMS. On‑site reuse can sit under a U1 exemption in some cases; screening or blending may touch T5 regulations. Always check with the Environment Agency and the local authority for your site.
Controls to plan: water suppression, wheel wash, road sweeping, a simple Dust Management Plan and Duty of Care records including Waste Transfer Notes. Noise may need Section 61 consent or restricted working hours. We provide templates and help with paperwork — see Documents & Downloads.
Fleet Options: Matching Kit To Your Material And Space
Compact jaw crushers suit tight urban sites and mixed loads at 20–80 tph; mid‑size jaws handle 120–300 tph for bulk concrete. Impactors are better for softer materials and a uniform product. Use magnets for rebar and use 2–3‑deck screens to hit Type 1 gradings. Support plant — excavator, loading shovel, water bowser and stackers — matters as much as the crusher itself.
A steady, consistent feed improves throughput more than a bigger crusher. If you’re unsure which kit fits your sequence, send site photos and tonnage via contact us for a practical recommendation.
Sample ROI Scenarios By Sector
Housebuilder (2,500 t): crush slabs to 6F2 and reuse for plots and haul roads. Saves on deliveries and nuisance to neighbours.
Civils (8,000 t): produce Type 1 on site to cut imports and simplify sequencing, reducing delivery conflicts and programme exposure.
Farm/Estate (1,200 t): crush hardcore for tracks and yard consolidation — often cheaper than delivered stone and kinder on farm tracks.
This image was generated with AI and may not always represent the product or service exactly.
When On‑Site Crushing Does Not Pay
If you have under 500–700 tonnes, no safe space for plant and stockpiles, live buried services that limit access, or cannot reuse any product, the numbers rarely stack up. Contaminated arisings with tar, asbestos or excessive plaster/wood usually need specialist removal.
Planning Your Programme: Step‑By‑Step
- Survey arisings and sample for contamination. Agree target products and volumes.
- Plan compound, vehicle routes and stockpiles. Arrange water and neighbour notices.
- Mobilise, pre‑sort steel and timber, maintain steady feed, test gradings and log reuse volumes.
We support RAMS, permits and align crushing with earthworks to keep the programme moving and reduce hand‑offs.
Why Choose A R Richards: One Provider, Reliable Delivery
A R Richards is a 40‑year family‑run firm with modern kit and trained operators. We combine waste management, plant hire and delivery to reduce risk and simplify logistics. For a fast desktop price or site visit, send tonnage, photos and reuse plans via crushing solutions or contact us.
FAQs
Is My Project Big Enough To Justify On‑Site Crushing?
As a rule, under 500–700 t with short tip distances and limited space is unlikely to justify mobilisation. If you exceed 1,000 t and can reuse a high proportion, it often does. Send details and we’ll run the numbers.
How Do I Calculate Break‑Even Quickly?
Use the simple formula: on‑site £/t = (mobilisation + hire + controls) ÷ tonnes versus off‑site £/t = haul + tip fee + imported aggregate. Our aggregates calculator and muck‑away rates help you plug in real numbers fast.
What Permits Or Paperwork Will I Need?
Expect Part B permit requirements for mobile plant, RAMS, Duty of Care records and possibly a Dust Management Plan or Section 61 for noise. Local rules vary; we assist with templates and local applications.
How Quickly Can You Start On Site?
Mobilisation and set‑up commonly take half a day to a day, subject to access and controls. With clear access and permits, production often starts on day one.
How Do You Manage Contamination And Rebar?
We pre‑sort visible contaminants, use magnets for rebar and advise on testing for tar or asbestos. Contaminated loads change the approach — we’ll recommend disposal routes if reuse isn’t safe.
Who Do I Contact For A Practical Quote?
Send tonnage, photos, tip distance and target products via our contact page. We offer desk‑top appraisals, site visits and firm quotes tailored to your programme.
