A511 Junction & Level Crossing Works

This project formed part of the Bardon Hill Quarry Extension Project – Phase 1. The requirement was for upgrade works to the A511 highway and upgrade of the existing Level Crossing.


Aggregate Industries

Date Completed

May 2019


Highway, Bridges & Structures

Project Overview

Bardon Hill Quarry is a four million tonne a year granite quarry located just north of Leicester, with important rail links to London and other strategic locations across the country. The quarry has been in existence since the 1800s. The current reserves of the existing quarry planning permission are ending, and planning permission has been granted for a new quarry extension which lies approximately 2km East of the existing quarry.


The Challenge

As part of the Bardon Hill Extension Project – Phase 1 there was a requirement for upgraded works to the A511 highway and an upgrade to the existing level crossing.

Cairn Cross worked as Principal Contractor to deliver the relevant upgrades to the highway while allowing the road to remain operationally open.


The Solution

After the clearing of vegetation, works began with: the set up of the Cairn Cross compound, widening of the footpaths or road, sub-base was laid and compacted where required, tactile paving, islands, edgings and kerbs were installed, followed by resurfacing works later on in the project. This work was required to increase the visibility splays for vehicles exiting the junction on to the A511.

Civil highway works for Bardon Hill Quarry Entrance Junction Road Works

The Result

A major part of the works was to upgrade the existing outdated level crossing with a new barrier level crossing. The biggest challenges were to undertake the works whilst maintaining minimal disruption to the highway. The permanent way works consisted of removal of the existing track, excavation to 200mm below sleeper bottom, laying of new 200mm bottom ballast and compacted, installation of new track comprising serviceable concrete sleepers and rails.

The next phase was to supply and install a 16m long, heavy-duty rubber level crossing deck matching to the newly installed rail. New crossing barriers were installed along with new signage and lights.

A511 highway new highway Civil works

Bardon Hill Quarry Entrance Junction Road Works