"concrete"

St Vincents Church in Sheffield was to be transformed into a new student accommodation complex. The renovation project required a mass filling of the existing basement with 20N/mm2 concrete. When contractor, Paul John construction approached CEMEX for a suitable voidfill solution, we proposed to use Porofoam, our low density foamed concrete.Using Porofoam enabled the pour to be completed in less than half the time than using a standard concrete. Due to it’s reduced plastic density Porofoam could be placed in much thicker layers reducing lateral pressures exerted on the 165 year old internal walls of the basement.Additionally, Porofoam is self-compacting and self-levelling, which made it much easier for the contractor to place in the network of basement chambers.Porofoam is available in a range of densities and strengths and is manufactured using our proprietary CEMEX admixtures. For this project CEMEX delivered around 60m3 of pre-mixed Porofoam over 2 days to fill the void which achieved the required 20N/mm2 concrete strength.

FlexEJ has designed and manufactured lateral expansion joints with Inconel 625 bellows designed to install in existing pre-cast concrete forms.The London City Airport terminal expansion is being built on a concrete deck supported on over 1000 piles. Between the sections of the deck there can be movement and where critical services pass between sections a fully enclosed expansion joint is required.INSTALLATIONDesigning the expansion joints for installation at site into the existing concrete sections was a challenge. FlexEJ designed and supplied installation tooling which allowed the expansion joint to be inserted into the concrete from one side – complete with internal removable pre-extension bars – and then finally seal welded.FURTHER DETAILSIf you are interested in finding out more about our expansion joint design and manufacturing capabilities, or if you have enquiries for utility related projects, please contact our Technical Sales Team on +44 (0) 1384 881188 or send an email to sales@flexej.co.uk.

Marley's Modern Interlocking Concrete Tiles within the shade of "Smooth Grey" were specified for the roofing of this new and wonderful extension of the Chippenham Care Home, which is opposite to Chippenham's newly built Golf Clubhouse. The Modern interlocking concrete tile is heavily chosen due to its slate-like appearance, ease of installation and due to it being a economical choice.

The 'HOOLA' in Tidal Basin Road in East London, gateway to the soon-to-be regenerated Royal Victoria Docks area, has transformed a brownfield site into two rippling 23 and 24 storey glass towers, that offer 360 apartments with a mix of studios, along with one, two and three-bedroom units.The buildings are super-insulated and the concrete frame will act as a heat sink – absorbing heat on warm days and releasing it back into apartments when it cools. An innovative link-up with the neighbouring ExCel Exhibition Centre will also see excess heat piped directly into the two towers. This will provide all the necessary heating and hot water requirements and significantly reduce maintenance costs by doing away with the need for individual boilers. A critical design requirement for such a super-insulated building was the avoidance of any risk of thermal bridging at the many concrete-to-concrete balcony connectivity points – so highly efficient structural thermal breaks were required throughout. The preferred solution was the Schöck Isokorb® T type K for cantilever balconies.Luke Smerdon-White, Technical Director at Thorp, takes up the story: "We had to design, manufacture and deliver 1410 precast concrete balcony sections that had to then be cast integrally with the in situ concrete structure." "The exposed front-face is curved, with almost 50 different dimensional configurations, while the internal face has a facetted line that had to correlate with the glazing line and opening doors."

The owners of this domestic property in Penn, High Wycombe were looking to decorate their basement garage. They wanted the internal painted in-situ concrete to look like unpainted concrete.Dave Smith, Senior Sales Executive, and Nicola Young, Senior Colourist of KEIM Mineral Paints visited the property in August 2019 to trial samples for the client. It was noted during the visit that the walls were damp and required to be dried out prior to the applying of KEIM Mineral Paints. Pumps and dehumidifiers were installed to help this process.Once the moisture levels in the walls were below 18% by volume, the application of KEIM Design Lasur commenced.A translucent stain was applied to the walls, followed by KEIM Design Lasur sea sponged onto the surface to mimic a concrete appearance.

Say goodbye to Bechtel House and hello to 245 Hammersmith Road. Here the external painted concrete soffit of the undercroft was in poor condition. It needed a solution which would require low future maintenance due to its inaccessible position. Two coats of KEIM Soldalit were applied to the soffit for a long-lasting coverage, and KEIM Concretal Lasur applied to each column to create a uniform finish. 

Outlining the supply of primary spracyed concrete to Bank Station in London

Forum "Gold und Silber" with its impressively unusual facade incorporating a thermally separated steel structure. The unusual facade with its warm golden colouring and square cut-outs is fastened to a steel substructure that, in turn, is anchored to the reinforced concrete building with Isokorb® T types SK and K. The design of the magnificent envelope made from aluminium slabs with gold-coloured coating is testament to the goldsmithing that has been a traditional craft in Schwäbisch Gmünd for more than six hundred years. The concept envisaged strict separation of the core from the envelope: A multi-angled lightweight structure made of square façade panels coated with a substance that is reminiscent of gold leaf encases the five-floor reinforced concrete skeleton structure measuring 19 x 19 metres. The aluminium skin is set at a distance and features more than 1000 cut-outs of various sizes at interestingly different intervals.Getting a grip on thermal bridgesThe aluminium panels are fastened to a steel frame anchored with Schöck Isokorb® T type SK elements to the load-bearing reinforced concrete skeleton structure. In addition, Isokorb® T type K elements transfer the loads from cantilevered concrete slabs into the concrete structure. Without these load bearing thermal insulation elements, it would not be possible to implement such a facade design nowadays, given the thermal bridges at the joints. Schöck Isokorb® T type SK transfers negative moments and positive shear forces from steel components, such as cantilevered facade substructures, balconies and canopies, to concrete components. Whereas Schöck Isokorb® T type K is designed for cantilever reinforced concrete balconies and concrete slabs. This Schöck Isokorb® T variant also transfers negative moments and positive shear forces.Modern precious metal designAccordingly the Schöck Isokorb® T plays a key role in enabling implementation of the unusual facade design, which turns the building into a striking statement of modern architecture. A total of 767 aluminium panels were used. Their unmistakable, warm golden colouring comes from Duraflon coating, which is enormously resistant to bleaching and colour changes. Depending on the angle of the sun and the position of the observer, the Swabian nugget on the banks of the River Rems shimmers in different shades of metallic gold, while at the same time proving "all that glitters is not gold". Nevertheless, the Forum Gold und Silber still knows how to impress, long after the State Garden Show has finished.

Located between St. David's and Aberdour, the tanker terminal at Braefoot Bay is a base for the export of liquefied petroleum gas. The terminal consists of two jetties located on the north shore of Incholm Island. The gas is piped to the Mossmoran Plant in Fife direct from the North Sea, broken down to form ethane and then converted into ethylene, the basic hydrocarbon 'building block' of the petrochemical industry. The products are then piped the final three mile journey to the Braefoot Marine Terminal where they are fed into tankers and gas carriers for markets in Europe and the USA. The terminal is operated jointly by Shell Expro and Exxon.The jetty was suffering from increasing levels of deterioration of the reinforced concrete structure due to the relentless corrosive action of the marine salt environment on the reinforcing steel. A remedial plan was developed to carry out repairs and to introduce a cathodic protection (CP) system to greatly enhance the protection level and therefore extend the life of the structure. The plan was prepared by structural engineers from Shell, led by Hans Verheyde, and Balfour Beatty Construction Services UK (BBCS) was awarded the contract.Two major factors had to be accommodated within the repair programme. Firstly, the tidal flow that submerged the lower part of the jetty twice every 24 hours and secondly, the jetty is a fully live and very active transport hub and shipping schedules had to take precedence at all times. Round-the-clock flexible working maintained delivery of the twelve-month project.Saint-Gobain Weber's specialised repair concrete products were specified for the remedial actions on the Braefoot Bay jetty and technical application advice was provided for the active phase of the project. A suspended scaffold was designed and installed which allowed fast access when the tide ebbed so that productivity could be maintained. Traditional techniques were used to breakout the spalled and cracked concrete and to wash out the surface chlorides and clean the existing reinforcement steels.webercem five star repair concrete CP is a shrinkage-compensated, high strength, low resistivity, flowing repair concrete designed for use in conjunction with CP systems. This pre-blended cementitious concrete fully complies with the Highways Agency Specification Class 29F for high-strength flowing concrete for major structural repairs. It contains non-reactive aggregates with a low soluble-alkali cement content which is particularly important where CP is to be used. The rapid strength development and dimensional stability of webercem five star repair concrete CP – which reaches 27N/mm² in 24 hours – was especially valuable in the tidal conditions in Fife. Tight shuttering was used on the wide beam sections of the jetty to take the poured concrete which reached an integral bond with the original concrete. This process reformed the structural integrity using products with proven durability.An innovative CP system using Duogard® hybrid anodes from CPT was installed to protect the steel reinforcement with the anodes fixed into the soffits with a special CPT mortar. Where the CP installation required chases to carry the cabling, webercem HB40 high-build structural repair mortar was used to fill and seal the chases. webercem bondcoat, a polymer-modified, cementitious bonding aid and steel reinforcement primer, was first applied into the chases to ensure enhanced bonding. webercem HB40 is an acrylic-polymer modified, single component mortar and is lightweight with high build qualities. It can be applied in layers up to 75mm thick vertically, and 50mm on overhead soffits, and can be used without formwork. It was then applied onto the tacky webercem bondcoat primer and finished flush to the concrete surface.The Braefoot Bay terminal project has been completed successfully and Dewi Miller, contracts manager, BBCS, is confident that the jetty protection will extend the working life of the structure. "The products we have used are excellent and the application methods have enabled us to deliver a high degree of protection and reinstatement to the concrete structure. Working on a live site in a tidal zone has required a flexible work schedule but the whole project has worked exactly to plan and the client is very pleased with the result. The Weber materials have been the key to achieving this success."

Date of Project: September 2017Project Owner: Cairns Regional CouncilProject Contractor: Waterstop Solutions Pty, LtdProject Engineer: Cairns Regional Council Market/Environment WastewaterSubstrate: ConcreteSize of Project: 12 x 2m joint replacementTHE CHALLENGEThe joints on a municipal wastewater treatment tank had degenerated to the point where repairing and resealing were necessary. Cairns Regional Council required a product with a fast cure time and rapid compressive strength gains.Five Star® SolutionFive Star Structural Concrete® V/O was selected due to its rapid set and high early strength gains; it reaches 2,500 psi (17.2 MPa) within three hours. This rapid strength gain allowed for the repaired joints to be resealed with minimum turnaround time in preparation for the installation of a joint sealant system.ABOUT FIVE STAR STRUCTURAL CONCRETE® V/OThis is a high-strength, rapid-setting, one-component, permanent concrete repair material for vertical and overhead structural repairs.It produces a repair that is dimensionally stable, develops an integral bond to existing concrete, and restores structural integrity within hours of placement.Provides increased corrosion protection to steel-reinforced structures with migrating corrosion inhibitor technology and very low chloride ion permeability. Moisture-sensitive coatings can be applied in 8 to 24 hours.Can be troweled vertically or overheadOne product for thin and thick placementExcellent freeze/thaw resistanceOutstanding corrosion resistance for protection and rehabilitation

Puma is a German multinational corporation and the third largest sportswear manufacturer in the world.Puma decided to install Amtico Spacia Plaza Concrete across the 3300 sqm space. The combination of evenly coloured, pale greys with a smooth texture creates versatility and durability at the same time.Our Concrete product also removes the challenges presented by poured surfaces and heavy ceramics – offering instead a floor that can be laid quickly and used immediately.

The development district now known as London Docklands is an area alongside the River Thames to the East and South East of London. The Harbour Central project involves the construction of a large single storey reinforced concrete basement, high-rise reinforced concrete cores and frames varying in height from 24 to 41 storeys, plus two low-rise reinforced concrete cores and frames.The product used to prevent punching failure throughout the Harbour Central development is the Schöck Bole® reinforcement system. This widely used and trusted Schöck Bole® solution consists of double-headed studs and anchors, with spacing bars, which enable installation after the bottom reinforcement and before the top layer. The two-spacer rods, which are welded to the vertical studs, ensure the correct distance between uprights and the size of the stud heads guarantee a perfect finishing bond with the concrete. As result, when compared with a typical stirrup reinforcement system, an increased shear force resistance of around 70% is achieved. It is cost-effective and timesaving solution and as the Modebest Senior Engineer on site, Sean Togher commented: “The Schöck Bole® product was easy to understand from a reference point of view and we found it really straightforward to install”.

This Virgin Airlines hangar at Heathrow Airport needed a flooring finish to resist wear and chemical spills, as well as deliver aesthetic appeal – with a light coloured shiny finish that would reflect light and capture the eye to brighten the 4000 square metre area.ExecutionTo ensure the highest quality finish for the hangar the proven standard Resutile ST floor coating system was organised. Specialist resin flooring contractor Datum Flooring first shot-blasted the concrete substrate under vacuum to achieve a Concrete Surface Profile (CSP) 3 to ensure an excellent mechanical key and long term solution with the coating system. Then a primer coat of Resuflor WB was applied which penetrates the concrete and provides a sound surface seal so that an even finish is achieved with the top coats. This was followed by two roller coats of Resutile ST Colour in Light Grey.

ComFlor 80 has played its part in the creation of a strong and efficient solution making the Burj Khalifa the worlds tallest and arguably most iconic building.Over 45,000m³ of concrete weighing more than 110,000t, were used to construct the concrete and steel foundations, which feature 192 piles buried more than 50 metres deep. 4000m² of ComFlor 80 was used in in the floor construction installed to the very top of the 828 metre spiral structure.

For this project, Sandtoft’s Terracotta Concrete Double Roman roof tiles were chosen to reduce costs.

As with all balcony constructions, the issue of cold-bridging (also known as thermal-bridging) must be addressed and minimised to meet the required building standards - Part L of the Building regulations being of particular relevance. The H-BAU ISOPRO® thermal insulation element from J&P solved this problem by providing structural connection between the internal concrete floor slab, and the external concrete (insitu, or precast) balcony, whilst creating a thermal break to minimise cold-bridging.

Cordek were approached for their technical expertise, providing the moulds for the precasting of the concrete parapet units on this striking project.

Contemporary concrete benches and tables are very much at home in the historic King Edward VI Aston School setting.

The refurbishment at Rose Hill Garage in Oxfordshire was required following signs of excessive spalling and degradation on the premises’ concrete walls.

Lewis Deck was chosen, on this particular project in London, for a number of the key benefits the system brings. These being the strength of the system with only needing a thin concrete screed on top, the acoustic qualities & vibration control properties and the speed an ease of installation. This project even requested much longer sheets than standard in an effort to speed up the installation process. In fact you can see from the main photo above that some of the sheets were extremely long. The longest being just over 6.5m.This project was the installation of a new suspended, loadbearing concrete floor above an existing floor below. The space being used as a plant room for the hospital. The Lewis Deck was installed over a suspended steel grid of Light Gauge Steel C-section joists. A thin concrete was then installed over the top.This was a quick installation with the Lewis Deck being installed and then used as a safe working deck ahead of the screed being pumped in.

SENSO UK teamed up with Room Studio to help create this unique space that uses warm tones throughout the property. Senso creating a seamless look that not only unites the rooms seamlessly but creates a sense of warmth, something that we all look for in a home.‘NO LOCATION IS TOO FAR FOR SENSO’ As you can see this project was on the Isle of Skye. Location is no obstacle for us, if you do have a project that is not in London or surrounding area, we can still accommodate you.Senso helps creates an environment that is not only minimalist but sumptuous. Why stop with the kitchen, continue the Senso look throughout the project from the living area to bedroom and even the stairs ( treds' and risers'). The colour dune has two hues together which create a beautiful fusion.Following this we add in our aggregate of recyclable materials from old concrete remains, this creating a look of polished concrete but without the ramifications you get with a concrete.

Concrete foundations of a wind energy plant: Due to the influences of the weather over the years, the following damages were noticed: •Cracks due to movement •Moisture into the structure •Spalling of the concrete •Corrosion of the reinforcement •Flaking paint The first step in the restoration of the foundation was pressure injecting the cracks - through which an elastic closure of the cracks was realized. The total surface was strengthened with a unique sillicate liquid. A waterproof sloped layer was installed; finally, the moving joint between the foundations and the steel tower of the wind energy plant was sealed elastically.

In Vlaardingen Museum, the Netherlands, old meets new. The use of concrete, aluminium and glass creates a powerful sense of open space and transparency. The many level changes and loft-like spaces meant it was important to find a balustrade solution unobstructed by a conventional handrail or metal grip. The Easy Glass Pro structural glass balustrade offered the ability to make fine adjustments to the positioning of each glass panel from the installation side – invaluable when being installed on the various sections of finished concrete flooring levels.

Premcrete assisted BAM Nuttall on the Heathrow Tunnel project to undertake refurbishment work on the main and cargo access tunnels to the airport.The Challenge:Heathrow Airport has awarded BAM Nuttall a contract valued at more than £85m to undertake refurbishment work on the main and cargo access tunnels to the airport.Part of the refurbishment works was to carry out concrete repairs to the spalled concrete using an R4 Structural Mortar in accordance with BS EN1504.The Solution:Premcrete supplied BAM Nuttall with Teknocem S which met the performance specification.

We were approached by a porcelain tile supplier who needed to elevate porcelain tiles around a new build property in Wales. Initially concrete was used to create a base. However the weight of the concrete bent the lintels. The installation proved very challenging due to such a dramtic fall over such a short distance, creating a severe 5% slope. Fortunately our ‘Balance’ self-leveling range of adjustable pedestals provided the answer. Our service team are on call to advise and support installing contractors throughout their project, including site visits.

Fast-Track SolutionClient: Randox LaboratoriesMain Contractor: Corramore ConstructionScreed Installed By: O'Neill Concrete Flooring LtdScreed Supplied By: Robinson ConcreteCemfloor C30F6 was chosen for this project due to the fast-tracked construction of a new laboratory to provide urgently needed Covid-19 test kits.As part of their on-going commitment to produce much needed Covid-19 test kits; Randox Laboratories Ltd invested in a new facility at its existing headquarters in Crumlin, Co Antrim.The specialised laboratory, the development of which was fast-tracked over the space of four weeks, is the first step in a wider diagnostics investment programme from the company.Given the tight construction programme; Cemfloor were contacted and asked to propose a solution for the project.Cemfloor CT C30F6 was specified and over a period of just 2 - days; 3800m2 was installed by O'Neill Concrete Flooring Ltd with the screed being supplied by Robinson Concrete Ltd.Due to the high early strength of Cemfloor C30; the screed was loaded with access lifts 3 - days after installation which ensured that the build programme was able to continue with minimal disruption.A liquid surface DPM was used to allow the vinyl flooring be installed onto the screed only 7 - days after installation.Due to the incredible amount of effort by all parties involved; the entire project finished ahead of schedule with no issues.

This project transforms an industrial site, featuring 11 buildings with up to 44 storeys, offering homes, industrial and commercial spaces.The Challenge:The Malt Street Redevelopment Project marks a significant milestone as the inaugural strategic initiative within the Old Kent Road Opportunity Area. This project is designed to leverage the rich cultural identity of the community while harnessing the industrial character and diverse heritage of the area.The Malt Street Redevelopment Project is segmented into three distinct phases. Construction activities are actively progressing for Phases 1 and 2, with Phase 3 securing outline planning permission, paving the way for its subsequent development.The project features eleven buildings with up to 44 storeys, offering 1,300 homes, industrial and commercial spaces.Groundworkers often face the challenge of achieving thorough concrete compaction within the liner wall, especially to the underside of the capping beam, where proper encapsulation around the water bar is required.When using a letterbox shutter during the concrete pour of the liner wall, it’s particularly difficult to ensure concrete reaches all the way to the underside of the capping beam – which posed a challenge in this situation.The Solution:Our solution involves using a method similar to ‘tremie pipes’. This involves installing vertical pipes with diameters of 100-125mm through the Rebar cage of the capping beam. This technique allows concrete to be poured vertically at various points along the capping beam. By filling up the pipe and using a concrete vibration poker, the concrete can efficiently fill the shuttered liner wall up to the underside of the capping beam.Premcrete Products Used-Maxiprufe Plus-HydrocreteProject DeliverablesPremcrete are proud to be a part of this project, set to bring a great deal of positives to the area including:1,453 high quality homes, including 40% affordable housing50% of the site as new public space, including an important part of the new Grand Surrey Canal Linear Park5,400 sqm safe, new, adventurous play spaces966 cycle spaces as part of phases 1 and 27,000 square metres of commercial and retail space, including affordable workspaces1,250 construction jobs and nearly 70 local construction apprenticeships392 jobs post-construction

A requirement in Corstorphine Wright’s design brief was to avoid horizontal movement joints in the finished façade, which would have been the result had a traditional SFS Infill to concrete frame approach been taken. Working with Willmott Dixon at the early design stages of the contract, Metsec’s in-house design team proposed a continuous walling solution formed from SFS to support glazing and rendered elements that would form the external skin of the façade. Metsec’s solution included the use of fixing cleats to connect the SFS continuous walling to the structure’s concrete frame.

Approximately 5,000 square metres of Marley Edgemere and Marley Concrete Plain Tiles were installed as part of a £44m new-build project by Galliford Try at Wixams Retirement Village. Galliford Try led the Wixams Retirement Village project from start to finish, with NRA Roofing and Marley working together for the installation & manufacture of roofing products. Key reasons for the specification of Marley Edgemere and Marley concrete plain tiles included the cost-competitiveness of the tiles as well as the visual appeal and product attributes which would make the installation process quicker and more efficient.

Buzon UK were commissioned directly by Chelsea Football Club to supply and install the DPH pedestal system to support over 430sqm of EBEMA concrete paving (supplied by Alfresco Floors) to a newly refurbished pitch-side terrace at Stamford Bridge. The terrace areas behind the pitch-perimeter was built up to 200mm to create a raised terrace specially designed for wheelchair users. Buzon pedestals are adjustable from 11 to 1120mm and thanks to their intrinsic strength and reinforced structure are recommended for use with heavier floor coverings such as large format concrete pavers and high live loads.

The Royal College of Pathologists have relocated their London Headquarters to the rapidly changing area of Aldgate, on the Eastern fringes of the city. The new seven storey structure replaces an existing office block, providing a flexible and environmentally efficient building to house their growing needs. The building design includes major conference facilities, meeting rooms, offices, a multi-function auditorium, exhibition space, restaurant facilities and accommodation. Cordek were asked by the specialist concrete frame contractor Oliver Connell & Son to devise a formwork system to allow the construction of ribbed concrete floors.

ADP Architecture’s landscape team specified Artform Urban’s High Performance Concrete (HPC) benches for a new plaza space outside the WMG building at the University of Warwick. WMG (formerly known as Warwick Manufacturing Group) is an academic department at the University.Artform Urban were contracted to supply and install these large units, each weighing up to 1500kg. Our technical involvement in the project simplified the supply and installation process for the main contractor including the experience we have of handling and installing heavy concrete units, saving time when the products arrived on site. 

In dairy industries it's vital that hygiene standards are kept to a high standard. Drainage and kerbing are important products that need consideration. To reduce costs, many may opt for concrete, however over time concrete dries out and is prone to cracking. This can jeopardise a hygienic environment as unwanted bacteria will harbour in the cracks Alternatively, drainage and wall kerbing. Stainless steel is resistant to caustic cleaning materials and lactic acid, which are common elements in a dairy. This resistance ensures that the ss surface does not corrode or weaken making it an excellent long term solution.

Wallbarn worked with a specialist tile installer, working on a new-build in Carmarthenshire. Initially 600mm deep concrete screed was used for a base, but the weight bent the lintels. The concrete had to be broken out and the whole deck repaired. The installation was challenging with falls over 250mm across the deck. ‘Balance’ self-levelling adjustable pedestals provided the answer. Using bespoke pedestal planning software, MegaPro, the Wallbarn service team was able to work out the exact quantity and height of pedestals required for the scheme, colour-coded on the drawing, guiding installers on where to place each pedestal.

Student Accommodation company Urbanest installed Flotex Concrete Planks in their new office for a contemporary and forward- thinking space that encourages flexibility and collaborative working.

Washroom delivered new washroom areas on all levels of this refurbished office building - drawing on a range of high-tech man-made materials including lightweight cast concrete to create a unique, contemporary space which hints at the industrial history of the building. Its full height Alto FENIX toilet cubicles were specified in a crisp white colour to contrast with the grey and stone coloured concrete vanities. FENIX is manufactured in Italy by Arpa Industriale using the latest nano-technology to create a highly durable, tough acrylic resin surface with a host of high-performance properties.