Heidelberg Materials Delivers Challenging Overnight Resurfacing Project in Cheddar Gorge

Heidelberg Materials UK has completed a technically demanding road renewal scheme along Cheddar Gorge, the country’s deepest natural canyon and one of Somerset’s busiest visitor destinations.

The upgrade to the B3135 was delivered under the firm’s long-term maintenance agreement with Somerset Council. To keep disruption to a minimum, all work took place overnight. Crews had to navigate tight bends, sheer limestone cliff faces and gradients reaching 16%, making access and logistics particularly complex.

Roughly 1,300 tonnes of worn road surface were stripped out and sent for recycling, with reclaimed material incorporated back into the fresh asphalt mix where suitable. To cut carbon emissions, transport movements were consolidated by using the same vehicles to take planings to Heidelberg Materials’ Whatley asphalt plant and return with newly produced materials whenever possible.

More than 2,500 tonnes of the company’s Tufflex asphalt were laid along the two-mile stretch. The product is engineered for durability, using a polymer-modified binder to improve flexibility and fatigue strength, and a low-void mix that helps prevent water penetration. Its resistance to deformation also reduces the likelihood of rutting on steep sections where heavy braking is common.

Tim Doyle, Somerset Framework Manager for Heidelberg Materials UK, noted the unique complexities of the job:“Cheddar Gorge is one of the most spectacular driving routes in the UK. Working in such a sensitive environment—adjacent to an SSSI, with steep rock faces and plenty of curious goats and Soay sheep—was far from straightforward. Delivering the project safely, to programme and within budget, reflects the strength of our collaboration with Somerset Council.”

Somerset Council’s Lead Member for Transport and Waste, Councillor Richard Wilkins, welcomed the outcome:“Cheddar Gorge is an iconic landmark, and maintaining the road to a high standard is vital. This was a demanding scheme, and we’re very pleased to see it completed on schedule and within budget.”