Last updated on 13 July 2025
Residents contacted us concerned about the noise and dust generated from the activities taking place at the aggregate and concrete production plant at the Chessington South railhead in Garrison Lane, opposite Chessington South station. In June 2025 CDRA facilitated a meeting with the operators Cappagh/DCRail and Express Concrete.
In attendance were David Fletcher, director, Cappagh/DC Rail; Derek Casey, chairman, Express Concrete; Colin Punch, chairman, CDRA; Rob Robb, member of the TfL/RBK South of the Borough Community Local Business and Residents’ Community Liaison Committee; and a local resident from Garrison Lane.
Background
In May 2022 when the company first took over the site, David Fletcher of Cappagh/DC Rail, attended a Transport for London/RBK South of the Borough Local Community Business and Residents’ Liaison Committee Meeting to explain what was envisaged for the facility. At the time, Cappagh/DC Rail had agreement for three return trips a week between their main depot at Willesden to the Chessington South railhead. The concrete production works was not mentioned at this meeting.
Since then, Cappagh/DC Rail and Express Concrete applied and were granted planning permission from Kingston Council for the operation of the concrete production plant.
Operation
At the June 2025 meeting with CDRA, Derek Casey of Express Concrete explained that railheads hold a special position regarding planning policy. There are few of them and the Government sees them as a major way of getting large vehicles off our roads.
Although Cappagh/DC Rail have a railway track access contract allowing them to use the railway for three round trips weekly, currently they are using just one round trip. This is due to the current lack of demand for cement and aggregate by the construction industry. The train runs on a weekday, arriving on site around 2pm and leaving by 9pm. The trains run in-between the normal train services using the Waterloo to Chessington South line.
The aggregate is unloaded from the train from the top using a large excavator with a grab bucket. The load is then distributed into different bays.
Regarding the concrete, Derek told us that the cement is delivered in specialised cement rail tankers. It is pumped under pressure straight from the tanker into the large silos on the site. It is not exposed to the air. A computer calculates the right quantities of cement, water, and aggregates dependent on the end use. It is then dropped directly into the vehicle from the silo.
Vehicles are washed down afterwards to ensure they do not leave dust on the road network and arrive back at the railhead clean.
Derek explained that the dirty water from the site goes into a settling tank. The solids settle to the bottom and the clearer water from the top is reused in the concrete production process. Water cost is a major issue so it pays for them to recycle as much as they can. The sediment from the tank is emptied from time to time and put into a bay where it is used as part of the process for some products. Derek confirmed that none of the dirty water leaves the site, and it does not get into the Thames Water surface water network.
Concerns about noise, dust, and safety
The Garrison Lane resident said they had seen the numbers of large heavy vehicles including 30-ton trucks and 8×4 concrete mixer lorries increase dramatically and had been keeping records. The resident said lorries park at the end of Garrison Lane by the junction with Leatherhead Road (A243) and sit with the engine running as early as 6.30am. The lorries speed along Garrison Lane, are noisy and create vibration.
Derek said that the site opens at 7am, and they are waiting for the site to open. They suspect the drivers are parking to use the Barwell Café on Leatherhead Road.
The resident told the meeting that the load covers that prevent dust escaping were not being used. Derek confirmed that they should be used both on full loads and when empty. Concern was also expressed about the number of large vehicles and the dust and noise created, particularly within such proximity to Chessington School.
Rob Robb told the meeting he had met with residents from the Garrison Lane and York Way who raised concerns about the noise coming from the site. The noises sound like a large bucket on a JCB or similar vehicle hitting the ground being scrapped along, followed by a loud vehicle reversing signal. Derek said it is the unloading of the train and filling of the hoppers for the concrete production. They cannot stop the vehicle having a reversing alarm, as it is a safety requirement.
Rob raised concerns that the current noise levels would increase as the site gets busier and suggested bund or noise-absorbent fencing. Derek said this would not work as the noise would travel over these fences.
Colin Punch said the local window cleaner had noticed an increase in a dust on windows and windowsills in the area.
Next steps
Since the meeting, we understand that Cappagh/DC Rail and Express Concrete have contacted the drivers to request they adhere to the speed limits and that signage has been installed at the exit of the site. CDRA will monitor ongoing issues and raise any further concerns emanating from the site with Cappagh/DC Rail and Express Concrete. Derek Casey has agreed to keep in contact with the local residents on issues as they arise. We appreciate they have a business to run, but are encouraged by their current engagement. We are hopeful that they will maintain their efforts to mitigate the business’s impact on the day-to-day lives of local residents.
At the South of the Borough Neighbourhood Committee Meeting on 16th July, CDRA raised the issue and asked that Kingston Council planning team, who granted the planning permission for the concrete production plant, revisit the site to see that the operators have adhered to what was agreed as part of their planning consent.
Committee chair, Councillor Lorraine Dunstone, reported that Kingston Council planning team will revisit the site to check what is going on and check the level of compliance with what was agreed when planning permission was granted.
CDRA will contact Transport for London (TfL) and Kingston Council’s Highways team regarding the increasing number of large vehicles on the A243 and the impact on residents. James Kealey, communication engagement officer for TfL was in attendance at the South of the Borough Neighbourhood Committee meeting on 16th July and is now fully aware of the issues with increased heavy vehicle movements at the Garrison Lane/A243 junction.
Are you affected by the activities at the concrete works at the Chessington South railhead? If so, please contact us at chessingtondra@gmail.com.