Blockwalls Provide Concrete Lego Block Solution To Potters Cullet Bay Dilemma

Virtabloc 1500 x 600 x 600 were used to build the bays. The walls were built straight from the wagon saving the customer money

Potters is the largest producer worldwide of highway safety marking glass beads, metal finishing and polymer additives.

With locations all over the world Potters recycles over one billion pounds of glass each year.


When Potters approached us in 2015, it was to resolve a Cullet issue they had at one of their sites in the North East of England. The bays that were already in place were becoming old and no longer fit for purpose and Potters asked us to design some C shaped Bays to house their cullet on site.

Firstly, a design was composed and communicated to the Group to demonstrate various ways in which they could house the Cullet going forward.

After a couple of iterations and discussions with the client a final design was agreed upon and a delivery schedule was composed and agreed upon.


The final block decided upon was a 1500x600x600 block with some smaller 900x600x600 blocks used to bond the wall together.

Deliveries took place over a 4-week period in January and the team on site at Potters went to work constructing the Cullet Bays to give them a stronger and more sustainable storage facility.


Working in partnership with structural engineers and civil engineering contractors.

We come from the civil engineering sector and have invested in the development of advanced concrete technology and quality assurance. Our mission is to support structural engineers and civil engineering contractor to come up with innovative solutions to common problems. Block Walls are the ideal solution for structural engineers and civil contractors who are seeking cost effective solutions to properly manage their projects.


You send us a basic description or drawing of the area you need to construct and a description of the operation. We will do the rest.


1. Our design team will establish which specification will best fit your environment and calculate the number of blocks required to do the job

2. We quote, you order, we make

3. We deliver


We offer a full design service from simply working out how many blocks you require for your project to full design including drawings and calculations.

Our full design service can include:

  • Planning applications
  • Structural engineering design and calculations
  • 2D and 3D CAD drawings and BIM models
  • Building regulation applications
  • Full project management services

Assistant Plant Manager Stuart Plews said

“The Blockwalls solution just made sense from a design and cost perspective”. “The team at Blockwalls ensured everything went smoothly and we discussed lots of different sized blocks before agreeing on the 1500 x 600 block which is both strong and easy to manoeuvre with the lifting eyes. We’ve been extremely happy with the service and the quality of the blocks and will be speaking with Blockwalls again when future requirements arise for this type of solution”

Block Walls Managing Director Bob Evans adds. “This project has demonstrated the flexibility of what is a simple idea. As a result we are exploring other applications for both our Virtablok and Stackabloc products and testing other waste streams such as glass and ash to produce a geopolymer concrete.”

Each block saves 105kg of carbon due to using recycled material. This is equivalent to an average car journey of 262 miles

Each block saves 105kg of carbon due to usinBlock Walls operate to ISO 9001 2008 quality standards and has won various prestigious environmental awards.g recycled material. This is equivalent to an average car journey of 262 miles

CALL 0800 880 3135

Call today and tell us about your project. We can then design it and give you the quantities of blocks you require together with a quotation. We supply all the method and risk assessments and COSHH data sheets for installation. Opening hours from 9am to 5pm Monday to Friday (except bank holidays).

INTERLOCKING CONCRETE BLOCKS Material, Scrap, Recycling, Silage Bays Call 0800 880 3135 CONSTRUCTION Blast Walls, Bund Walls, Fire Walls, Buildings Call 0800 880 3135 MARITIME Dock, Breakwater, Quay, Harbour Walls Call 0800 880 3135 CIVIL ENGINEERING Retaining Walls, Piling Mats, Temporary Works Call 0800 880 3135