Project Overview
SPARK is an 18-hectare brownfield regeneration scheme in the Black Country Enterprise Zone, encompassing the former James Bridge Copper Works and a large domestic and industrial refuse tip. Constrained between the M6 motorway, Walsall Canal, a school and surrounding housing, the site had remained stalled for over two decades due to complex land risks and legacy infrastructure.
Once complete, the project will bring 44 acres of impacted land back into use as a new industrial and business park, delivering up to 1,100 jobs and significant economic uplift to the Walsall area.
Key Project Features
Mine Shaft Remediation
A total of 134 mine shafts were confirmed during site investigations. Each was probed, grouted, and capped with precast slabs or geogrids, depending on structural requirements. This work was crucial to ensuring long-term stability and safe development conditions.
Sustainable Reuse of Impacted Groundwater
At the former James Bridge Copper Works, groundwater impacted by heavy metals and petroleum hydrocarbons was reused within the grout mix for mine remediation. This innovative solution immobilised contaminants and reduced clean water consumption — a sustainable approach validated through pilot trials and approved by the regulator.
Bioremediation of Hydrocarbon-Impacted Soils
Targeted hotspots were treated using bioremediation techniques, allowing impacted soils to be safely reused in earthworks and significantly reducing disposal volumes.
Refuse Tip Earthworks and Materials Reuse
The large refuse tip, separate from the IMI Tip, required extensive earthworks. Approximately 735,200m³ of material was excavated, with rigorous testing and processing enabling over 91% reuse. Only 9,600m³ of material was disposed of off-site due to elevated levels of impact, demonstrating an efficient and sustainable approach to legacy waste.
IMI Tip – Capping and Drainage Strategy
The IMI Tip, a distinct part of the site, was reprofiled and capped with an engineered barrier and drainage layer to sever pollutant linkages. This area is being prepared for future use as Public Open Space, with design measures protecting both human health and controlled waters.
Canal Interface – Engineered Earth Bank
Adjacent to the Walsall Canal, the original plan to install sheet piling was replaced through ECI with a more sustainable engineered earth bank. This alternative reduced embodied carbon, improved visual amenity, and minimised ecological disruption. A licensed fish relocation exercise was carried out in advance of these works to protect aquatic species.
M6 Motorway Interface – Earthworks Consideration
The site is bounded by the M6 motorway, which features an existing retaining wall. Our earthworks design and cut-fill operations were carefully developed with due regard for this structure, ensuring no impact to motorway stability or performance.
Two-Stage Procurement and Regulatory Engagement
Procured under a two-stage contract with a Pre-Construction Services Agreement (PCSA), the project allowed for detailed investigation, collaborative planning, and development of a betterment strategy that was accepted by regulators. This approach enhanced buildability, reduced risk, and improved cost certainty.
Environmental and Stakeholder Considerations:
- Works were conducted in proximity to homes, schools, parks, and the M6, requiring proactive stakeholder engagement and rigorous environmental controls.
- Sensitive ecological measures included habitat protection and the fish relocation exercise prior to canal bank works.
- Materials reuse complied with the CL:AIRE Definition of Waste Code of Practice, aligning delivery with best practice in sustainable development.
Project Outcome
SPARK demonstrates how legacy industrial land can be transformed into future-ready development platforms through technical innovation, environmental leadership, and collaborative delivery.
Key achievements include:
- Stabilisation of 134 mine shafts to unlock previously unviable land.
- Reuse of over 91% of site-won material, reducing off-site waste and carbon.
- On-site bioremediation and reuse of hydrocarbon-impacted soils.
- Sustainable integration of impacted groundwater into the mine remediation process.
- Replacement of sheet piling with an engineered earth bank along the Walsall Canal, with full ecological protection.
- Cut-fill design delivered with full respect for the adjacent M6 retaining wall.
- A Regulator-approved betterment approach, positioning the site for successful long-term redevelopment.
Through this integrated and sustainable strategy, SPARK is delivering measurable social, environmental, and economic value to the West Midlands.