BulkX: The Story That Transformed Muck-Away

In the late 2000s, large-scale excavation projects were on the rise, with waste equipment such as crane-lifted boat skips and excavator clamshells remaining in widespread use for removing excavated muck and spoil, but they simply could not match the fast pace of modern dig programmes without creating bottlenecks and increasing safety risk.

Contractors repeatedly encountered the same problem:

How can spoil be removed as fast as it is excavated, without compromising safety or programme timelines?

This recurring challenge laid the foundation for what would become BulkX.

Where the Idea Began…

On the Crossrail project, at the major shaft Stepney Green around 2009-2010, Conquip engineers witnessed that excavation outputs were far outpacing muck-away capacity. Excavation teams were working around the clock, but even the highest-output conveyor systems wouldn’t be able to remove spoil quickly enough to keep the programme on schedule.

The contractor’s (Dragados Sisk Joint Venture) initial response was straightforward: request larger skips from Conquip, starting at 4,000 litres up to 8,000 litres. However, this did not address the fundamental issue. Boat skips remained slower as each had to be landed before unloading, causing inevitable delays and increasing the productivity gap.

It became clear the problem wasn’t skip size, it was the methodology itself.

Re-thinking the Process:

Conquip worked with Dragados Sisk Joint Venture and proposed a new method of spoil removal by combining crane-lifted skips with purpose-designed discharge systems to make a new drop-bottom muck-away skip.

This new approach was based on several key principles:

Enable direct discharge into muck-away locations, eliminating double handling.
Maintain a controlled discharge process that avoids the risk of dropped material or unsafe unloading and remove operatives from the discharge zone.
Provide versatile discharge configurations tailored to project and site constraints.

The result was BulkX.

A time-lapse comparison on Stepney Green demonstrated the magnitude of the change:

BulkX cycle: approximately 30 seconds
Boat skip cycle: approximately 2 minutes

Alongside faster cycles, the team significantly improved safety by removing the need for personnel in the discharge area.

Within months, the team accelerated the excavation programme, cutting more than three months from the schedule and returning the project to its planned trajectory.

The Result: Muck Away at Speed

BulkX had introduced a faster, safer, and more predictable method of spoil handling to the market, one that aids project teams in planning and progressing projects with confidence.

Other contractors quickly recognised the benefits:

Significant reductions in dig programme durations by eliminating spoil bottlenecks.
Elimination of double handling, as spoil could be discharged directly into waiting trucks or stockpiled areas.
Reduced requirement for additional plant and machinery, lowering cost and site congestion.
Flexibility across diverse site conditions, from confined city sites to large open excavation zones.
24/7 excavation capability.

BULKX

BulkX System Options

BulkX has evolved into a customisable range of solutions designed to match different site requirements and logistical constraints.

Smart-Release BulkX

Conquip’s latest addition to the BulkX range, remote-operated for enhanced safety and versatility.

Remote-control discharge, reducing plant-people interface.
Versatile discharge locations including muck bays, trucks, barges or stockpiles.
No gantry or landing frame required.
Available in skip capacities from 4 m³ to 16 m³.

Find out more >>

Direct-to-Truck BulkX

A high-efficiency configuration for sites prioritising simplicity and cycle speed.

No gantry or landing frame required, perfect for tight or urban restricted sites.
Skip discharges are spoiled directly into muck-away trucks as soon as the feet land.
Eliminates stockpiles and double handling.
Skip capacities up to 8 m³.

Find out more >>

Gantry BulkX

A gantry-based system suited to large excavation outputs and complex discharge requirements.

Heavy-duty or space-saving gantry configurations available.
Compatible with skip capacities up to 12 m³.
Interlocking gantries eliminate the need for temporary discharge areas.
Different configurations include: Free Standing Gantry, Fixed Gantry and Pit Lane Gantry.

Find out more >>

Improving an Industry Practice

Following its success on Crossrail, BulkX was rapidly adopted on projects around the world, including basement digs, shafts, station boxes and tunnelling projects.

BulkX stands as a testament to Conquip’s customer-driven engineering approach: identify real site inefficiencies, engineer practical solutions, and deliver measurable improvements in productivity and safety.

Conquip’s in-house engineering team continues to tailor BulkX systems to specific projects, integrating skip capacities, crane capabilities and site logistics into customised solutions for maximum performance.

Learn more about BulkX…

Q1: What is BulkX and what problem does it solve?
A: BulkX is a high-efficiency drop-bottom skip, designed to remove excavated material more rapidly and safely than traditional methods.

Q2: How does BulkX improve excavation efficiency?
A: By allowing direct discharge either into trucks, stockpiles or designated zones, BulkX eliminates double handling, reduces cycle times and accelerates dig programmes.

Q3: What configurations are available within the BulkX range?
A: Configurations include Smart-Release BulkX, Direct-to-Truck BulkX and Gantry BulkX with Free Standing, Fixed and Pit Lane gantry options.

Q4: Can BulkX be customised for specific projects?
A: Yes. BulkX is engineered to the site’s dig methodology and needs: crane capacity, skip size and site constraints, and Conquip’s engineering team can further tailor the BulkX for different project types.

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BulkX: The Story That Transformed Muck-Away

Where the Idea Began…

Re-thinking the Process:

The Result: Muck Away at Speed