13.06.UK MADE IN UK ROAD RAIL AGRO POWER PETROCHEM MINING DESIGN OTHER CHAMBER AWARDS 20 11 NATIONAL WINNER Knowledge Transfer Network Modern Built Environment MOST INNOVATIVE PRODUCT AT WORLD OF CONCRETE POZNAN INTERNATIONAL FAIR 2012 R&D 100 Award winner R&D Magazine National Winner Chambers of Commerce Award 2011 Top Innovation BRE Insite 2011 2011 Expert s Choice Winner Most Innovative Product MTP Gold Medal Award BUDMA 2011 2009 Winner Material Connexion Medium Award Material of the Year 2011 Nominee, 2007 Finalist Design to Improve Life Award
Project Info MAY 7 15 / 11 / 2012 CC5 bulk rolls # 25 500sqm Transverse Layers Undisclosed, UK Undisclosed Trant Construction Ltd. i CC installed as protective liner to clay bunds to prevent weathering erosion, provide weed suppression and protect against animal damage. Hydrating CC sections Project Background In 2012, Concrete Canvas (CC) was specified to line refurbished secondary containment bunds at a Marine Terminal Facility in the UK. The bunds surrounded a series of tank farms storing hydrocarbons as part of the larger onshore facility. CC provides hard armour weathering protection of bunds, acts as an effective weed suppressant, protects against animal damage and provides additional levels of containment and fire protection. Trant Construction Ltd were the contractor on these works which started refurbishment of the bunds in October 2012 with a scheduled completion date of July 2013. Concrete Canvas Concrete Canvas is a concrete impregnated flexible fabric that hardens on hydration to form a thin, durable, fibre reinforced concrete layer. CC is available in 3 different grades, CC5, CC8 and CC13 which are 5mm, 8mm and 13mm thick respectively. All three grades can be used to line bunds according to the level of traffic expected. CC8 is also used for lining drainage channels in and around oil refineries as a rapidly installed, cost effective alternative to half cut clay or concrete pipes. Concrete Canvas Ltd. 2013
Concrete Canvas CC can be provided in two formats, man portable batched rolls or larger bulk rolls of up to 200 linear metres. The batched rolls are ideal for areas on site with difficult access and/or where plant equipment isn t available. The project required 25 000sqm of CC5 delivered in 200m bulk rolls, called off in staggered deliveries to match the progress of the installation. Completed junction detail section Completed corner detail section CC Technical Advantages Concrete Canvas provided the following technical advantages for the bund lining works: - Erosion Protection CC provides a hard armour surface protection preventing weathering erosion of the bund. CC is fibre reinforced and has an abrasion resistance twice that of ordinary Portland cement. - Rapid Install CC was installed at rates of 800sqm per day using a 6 man crew. - Weed Suppression CC is an effective weed suppressant, reducing future maintenance costs associated with grass cutting of top soils and negating the risk of fire from dried grasses. - Install in Wet Weather Once hydrated, CC has a working time of 2 hours in a UK climate. This allows for installation in wet conditions which reduces programme disruption due to inclement weather. When the weather was such that refurbishment work on the bunds wasn t possible, the contractors switched to lining the already refurbished sections with CC, meaning that there was a minimum delay in works due to poor weather conditions. - Conformation to Protrusions CC was able to conform to 90 turns, pipe protrusions through the bunds and terminations at buttress walls.
CC Technical Advantages cont. - Protects Sensitive Infrastructure The proximity of sensitive infrastructure meant that shotcreting or spray applied protective finishes were not a feasible option at this site. - Prevents Animal Damage CC preventing rodents from damaging underlying membranes and stopping burrowing animals from compromising the integrity of the bund. - Impermeability and Fire Protection CC has achieved a Euroclass B certification providing an additional level of fire protection in the event of catastrophic failure and subsequent ignition of stored hydrocarbons. - Efficient Material Transportation Concrete Canvas is very efficient in terms of material transport, with over 25 000sqm of concrete surfacing delivered in only 125 pallets in 16 deliveries. CC Installation Grassed soil bunds prior to refurbishment Grassed soil bunds prior to refurbishment The 25 000sqm of CC was supplied in called off staggered deliveries to minimise on-site storage of material and to provide flexibility to the programme of works according to the weather conditions. Following refurbishment of the clay bunds, bulk rolls of 200sqm of CC5 were dispensed onto the bunds from a chain hoisted spreader beam mounted from a 13T tracked excavator. Each CC5 bulk roll was positioned at the crest of the bund, before unrolling the required length down the inside. The bulk roll was then unrolled down the outside edge before being cut to length using utility knives. Subsequent layers of CC were positioned to overlap the previous by 100mm. Once each section of bund had been lined, the CC was hydrated using a fire hose from the nearby water mains. Following hydration, the overlapped edge was then folded back on itself by approx. 50mm to apply CT1 sealant in a continuous 5mm bead along the length using a 600ml applicator sealant gun. The CC edge was then folded back and screwed in position using 30mm screws applied with an auto-fed collated screw driver. The sealant created an impermeable joint whilst the screws provided the mechanical bond between overlapped CC layers. Each layer was anchor trenched at both inside and outside edges of the bund. At approx. 24 hours from the point of hydration, the CC had set to 80% strength and was able to be trafficked as works continued on installing kerb work and drainage details on the inside of the bund.
CC Installation 1Prepare / grade clay bund to desired profile and height 2 Transverse layup of bulk roll CC5 from spreader beam 3 Hydration of CC from on site mains water supply 4 Adhesive sealing of 100mm overlapped joints using CT1 5 Joining of adjacent layers using 30mm autofed screws
TERMINATION OF CONCRETE CANVAS TO CONCRETE OR POLYMER HEADWALL TERMINATION OF CONCRETE CANVAS TO CONCRETE HEADWALL / BUTTRESS TERMINATION OF CONCRETE CANVAS TO POLYMER HEADWALL / BUTTRESS 6MM BEAD SIKA FLEX 1A CONCRETE HEADWALL 6MM BEAD SIKA FLEX 1A POLYMER HEADWALL HILTI X-C47 WITH 30MM WASHER 50mm SELF TAPPING SCREW WITH >14MM WASHER 50mm CONCRETE CANVAS LAYER CONCRETE CANVAS LAYER SOIL SUBSTRATE SOIL SUBSTRATE NOT TO SCALE NOT TO SCALE Buttress wall fixing Buttress wall fixing
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