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Heavy duty fibre reinforced concrete for agricultural hardstanding

Heavy duty fibre reinforced concrete for agricultural hardstanding

Tarmac

A private landowner wanted to develop a large multi-purpose agricultural facility for both arable and potential livestock use at their farm in Leicestershire. Part of the requirement was external surfacing, which would need to be hard wearing and deliver long lasting durability in this demanding environment, including regular use by heavy agricultural vehicles. After discussions with the contractor, the solution proposed was Tarmac’s TOPFORCE fibre reinforced concrete with a combination of synthetic macro and micro fibres. TOPFORCE is a fibre reinforced, high performance concrete, that eliminates the need for some traditional reinforcement. Quicker and easier to place than traditional steel mesh reinforced concrete, TOPFORCE concrete offers excellent long-term durability and performance. This makes it ideal for heavy duty flooring or hardstanding applications. This solution would deliver a saving in both labour and material costs and avoid the budget impact of the rising cost of steel. As well as improving the durability off the finished concrete, the use of macro fibres would also improve sustainability significantly by reducing embodied carbon compared to traditional steel reinforcement. 
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Tough, fibre reinforced concrete for busy transport hub

Tough, fibre reinforced concrete for busy transport hub

Tarmac

A busy Leeds Freightliner container terminal located to the South East of Leeds needed replacement of a number of sections of the external paving. The site is subject to constant traffic and extreme loading, with loading vehicles weighting up to 100 tonnes when carrying a container and daily use by HGV’s. Tarmac’s TOPFORCE fibre reinforced concrete offered the ideal solution. Although TOPFORCE concretes can be used instead of conventional steel reinforcement in some applications, in this case it would be used for added durability and crack resistance in a pavement design containing two layers of steel reinforcement mesh within a 300mm slab. The fibres within TOPFORCE provide three-dimensional reinforcement throughout the full depth of the pavement. This delivers improved abrasion, impact and crack resistance and enhanced flexural strength.Find out more at: https://tarmac.com/case-studies/fibre-reinforced-concrete-for-busy-transport-hub/
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Fibre reinforced concrete for container terminal

Fibre reinforced concrete for container terminal

Tarmac

This major expansion of the deep-water container terminal at Liverpool docks would significantly increase the footprint and capacity of the site. The site handles the world’s largest container ships and connects road, rail and canal networks directly to the heart of the UK mainland. As part of this project, external concrete surfacing was needed that would deliver long term resistance to the high volumes of HGV traffic using the terminal. After discussions with the contractor, the solution proposed was Tarmac’s TOPFORCE fibre reinforced concrete with a combination of synthetic macro and micro fibres. TOPFORCE can eliminate the need for some traditional steel reinforcement, making it quicker and easier to place. It offers excellent longterm durability making it ideal for commercial and industrial sites used by HGV traffic. This solution would deliver a saving in both labour and material costs and avoid the budget impact of the rising cost of steel. As well as improving the durability and structural performance, the use of macro fibres also improved sustainability significantly by reducing embodied carbon compared to traditional steel reinforcement. 
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Fast, sustainable construction of fibre reinforced floor slab for London academy school

Fast, sustainable construction of fibre reinforced floor slab for London academy school

Tarmac

This major redevelopment of Charlton Park Academy school involved replacing temporary mobile classrooms and a single storey building with a two-storey steel framed brick building to better meet the needs of students, teachers and carers. A structural flooring solution was required for use over precast planks, covering 800m2 on the ground and upper floor at a depth of 75mm to 120mm. Space and access would be challenging, due to the small footprint of the site, proximity to the existing school building and access from a busy main road. Given the large floor area, a traditional sand cement screed would have been very time consuming to place. Tarmac’s TOPFLOW SF a self compacting steel fibre reinforced concrete was chosen as the solution. Its flowing nature would allow it to be quickly pumped into place and adapt to the variable thickness criteria. TOPFLOW SF is designed to act as a structural topping with both, steel mesh & fibre reinforcement. The steel fibres added to the TOPFLOW SF gave its robustness and flexural strength as it was being placed over a precast plank system that could flex with loadings. They also reduced the risk of cracking. By replacing steel mesh reinforcement, it helped avoid problems with access, storage and handling and kept the site open for parallel trades. Using TOPFLOW SF rather than a sand cement screed or reinforced concrete, improved productivity and saved time. This saved 13 days or just over 2.5 weeks on the programme. 
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Weight saving structural concrete for hotel rooftop extension

Weight saving structural concrete for hotel rooftop extension

Tarmac

The challenge was to construct a roof top extension on top of the luxury hotel NOBU in Shoreditch. The plan was to add an additional 1 storey of hotel rooms, suites, dining areas and open terraces that would replace the existing planted roof. The chosen solution was Tarmac Toplight C lightweight structural concrete in a pump mix with the addition of steel fibres, ensuring maximum weight loss of 35% with no compromise on structural concrete performance.By adding steel fibres into the lightweight mix the composite metal deck system could be installed without the need for traditional expensive and slow steel reinforcement across the deck. The use of lightweight concrete, furthermore, reduced the load by 35% which meant the existing structure did not need to be reinforced or under pinned. The construction programme time was also reduced considerably.
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Fibre reinforced concrete for supermarket distribution centre - Cardiff

Fibre reinforced concrete for supermarket distribution centre - Cardiff

Tarmac

As part of its UK expansion program Aldi was building a new £59 million regional distribution centre and offices at Wentloog near Cardiff.Over 10,000 m3 of TOPFORCE fibre reinforced concrete was supplied over a period of 13 months for the external floor slab. The TOPFORCE concrete reduced the effects of shrinkage and settlement cracking, while enhancing the surface properties and durability of the hardened, cementitious product. 
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Cannon Green Staircase

Cannon Green Staircase

Lazenby

Cannon Green’s RC cast in situ polished concrete staircase is an Ocubis project in conjunction with John Robertson Architects (JRA), Civic Engineers and Six Smith Build. Lazenby built and installed the 21m long, 7m high and 7.5m wide (at the top) inverted amphitheater cast in situ Pewter concrete staircase. This staircase was designed by JRA and structurally engineered by Civic Engineers, incorporating BIM modelling due of the intricacies of the reinforcement design. This self-supporting staircase is tied into the structure with a steel stringer to convert the loads and moments down through the steel columns.Lazenby installed traditional formwork to create the stepped soffit that leads up to the inverted amphitheatre steps. Lazenby then installed a false work system (from Ischebeck Titan/Inform UK) enabling the formworkers to create the radius former inverted amphitheatre undercarriage that is visible from the restaurant (Drake & Morgan). The reinforcement was then added to the soffit and steps; the carpenters then added formers and attached nearly 700 DDA studs to the formwork prior to the casting of concrete.Lazenby’s integral-coloured Pewter polished concrete was batched on site into a C32/40 concrete supplied by London Concrete. The project used approx. 24 cubic meters of concrete and 6 tonnes of steel reinforcement. Ground floor to the top landing and seating area is just over 4m high, 21m long and 7.5m wide with 24 shallow risers and 3 functional landings. The first 3m wide step widens to a 7.5m inverted amphitheatre style landing featuring single and double height steps.Lazenby’s 8 master craftsmen were onsite for the duration of this 12-week project. Lazenby won the Cannon Green project based on the ability to deliver unrivalled experience for projects of this scale and magnitude. Engineering from Civic Engineers, design by JRA and experience and know-how from Lazenby’s master craftsmen created a steel and concrete masterpiece of exacting standards.
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Apartment Renovation, Raised Steel Acoustic Floor - Båstad, SE

Apartment Renovation, Raised Steel Acoustic Floor - Båstad, SE

Floor Levelling Systems Ltd

SubFloor flooring was used to help renovate, raise and acoustically dampen concrete floors in apartments.The acoustic feet simply click onto the SubFloor screws and dampens any step noise up to 28 dB, this helps reduce; step noise, rebound noise and flanking transmission.This simple and elegant solution raised and levelled the floor to allow for installations and insulation underneath. The joist and screw system allows for quick and easy assembly so that the floor can reach the desired height.Products:Steel Joist 45x30x3800 mmSubFloor Screw 100 mmSubFloor Acoustic FootHeight Variation: 58 - 112 mmJoist separation: c/c 600 mmSystem Weight - c/c 600 mm: 2.21 kg/m²Materials:Steel, Z100 GalvFibre-reinforced polypropylenePolyamide + Rubber damping elementPoint Load Limit (50 x 50 mm):Between screws over joist - 6.78 kNOver screws over joist - 10.54 kN
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Christ Church URC, Chelmsford

Christ Church URC, Chelmsford

Sika Limited

Christ Church URC in Chelmsford, Essex provides a hub for the whole community, hosting mother and toddler groups, social meetings and youth based events as well as traditional religious services. The church’s brick-clad structure includes exposed concrete columns which were showing signs of deterioration due to carbonation together with other factors causing the steel reinforcement to corrode and the surface to crack and spall, leaving the reinforcement bar exposed in areas.Sika supplied the long-term concrete repair and protection solution for a church façade which had displayed signs of deterioration due to long-term exposure to air pollutants.
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Forum "Gold und Silber"

Forum "Gold und Silber"

Schöck Ltd

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.
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KINGS CROSS R8

KINGS CROSS R8

Ambar Kelly Ltd

As part of a mixed-use commercial development in King’s Cross, Ambar Kelly have supplied bespoke riser flooring system. The rise flooring is providing to an ideal riser flooring solution for a complex construction project involving reinforced concrete frame and steel frame buildings, to improve buildability and safety.
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Restoration of the foundations at a wind energy plant

Restoration of the foundations at a wind energy plant

Koster Aquatecnic Ltd

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.
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Alltech

Alltech

Canal Architectural

Canal designed and installed and impressive steel and glass feature staircase for a commercial setting. This bespoke design comprised of four joint free, smooth helical staircases, connected by an intermediate landing fabricated from reinforced concrete. The Canal team designed each staircase to comply with BS5395: Part 2, 1984 (spiral and helical staircases) and Building Regulations Approved Document K.
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Braefoot Jetty - Fife, Scotland

Braefoot Jetty - Fife, Scotland

Saint-Gobain Weber

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."
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Landmark Art Deco building in Malta fitted with new Clement steel windows

Landmark Art Deco building in Malta fitted with new Clement steel windows

Clement Windows Group

The Brewhouse, formerly known as Farsons Brewery was one of the first and finest examples of concrete-reinforced Art Deco buildings on the island of Malta. The building was founded and designed by Lewis V Farrugia and William Binnie and originally opened 73 years ago in June 1950.Now a Grade II listed building The Brewhouse has been part of a €86 million redevelopment project, reimagined by world-renowned London based ritchie*studio. Covering over 7,000 sq m of industrial space, the building now includes a unique mix of office, food and beverage, retail, visitor experience, and events space over seven floors.In a building of such historical and architectural significance the new windows not only had to look as close to the originals as possible, but also meet stringent requirements for thermal efficiency, as the building was designed to meet the strictest of environmental codes. Clement was thrilled that over one hundred white Clement EB24 steel framed windows were specified, featuring T bars and multi point locking.Robert Abela, the Prime Minister of Malta, was among around 400 people who attended the inauguration ceremony of Trident Park and The Brewhouse, one of the most iconic regeneration projects in Maltese history.ritchie*studio director, Ian Ritchie said: “Clement Windows provided the perfect steel window profile and workmanship solution to help restore this beautiful and iconic Maltese industrial Art Deco building."
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Wright Place

Wright Place

Schöck Ltd

Outdoor life tends to take place inside the perimeter of block buildings in towns and cities. An inner courtyard becomes the outdoor area of choice, shielded from the noise from the roads that surround the building. The Wright Place project involved the installation of 60 balconies that were also planned as design elements. Schöck Isokorb® type KS was used for both structural stability and thermal insulation.Precast balconies as design elementsA total of 300 Schöck Isokorb® elements – between four and six per balcony, depending on size – were installed in the building structure, with some welded to the reinforcement to prevent tipping during concrete application. The Isokorb® used was type KS from Schöck's standard range, which functions as a load bearing thermal insulation element, eliminating thermal bridges between reinforced concrete and steel structures and thus preventing mould formation at the critical joints. The Schöck Isokorb® allows steel and metalworkers to prefabricate to a large degree, thus reducing installation times to a minimum. Its superb load bearing capacity offers enormous scope for balcony design while ensuring outstanding structural stability.
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South West Lands

South West Lands

Schöck Ltd

It is anticipated that when completed in the next ten years or so, the regeneration of Wembley Park, in North West London, will provide up to 7000 new homes. Schöck is supplying its Isokorb structural thermal break systems across a number of different sites on this vast scheme, but one of the largest is South West Lands. This private rented sector residential-led mixed-use neighbourhood will account for around 12% of the new homes on the entire Wembley Park development, up to 900 in total.South West Lands is spread across four separate blocks, which all share a communal basement car park.The reinforced concrete frame buildings, up to 18 storeys high, are finished using traditional brickwork and standing seam metal cladding. To create valuable amenity space at higher levels, as well as offering far-reaching views across London, there are communal roof terraces and a considerable number of private balconies throughout the development.Schöck Isokorb® T type SK products were used on two of the phases at South West Lands for thermally connecting the cantilevered steel balconies to the reinforced concrete slab. The Isokorb® T type SK units were positioned accurately using re-useable balcony width steel jigs.
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Concrete Worktops - Chef’s Kitchen

Concrete Worktops - Chef’s Kitchen

LIVING CONCRETE LTD

The Living Concrete team provided design consultancy and were selected to project manage the delivery of a new kitchen for a celebrity chef.The glass fibre reinforced concrete central island, table-come-workbench was manufactured using our special GRC BTX concrete, which is lighter and stronger than traditional concrete. We used our unique eco concrete mix technology with a hydrophobic agent to limit moisture absorption. The individual elements were precast in our workshop for assembly on site and then hand polished and treated with a specialist sealant. Large format GAP wall panels with concrete caps in Mist Rough finish completed the design.Living Concrete’s worktops and tables are extremely strong and durable and can be used indoors or outdoors. By using the best of modern technology, we have created a contemporary and elegant space that demonstrates how concrete can be both good looking and functional.
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Fitzwilliam College, Cambridge

Fitzwilliam College, Cambridge

Sika Sarnafil

Sika's full suit of products helped with waterproofing the scalloped roof at the campus. A combination of Sike Sarnafils waterproof Single Ply membrane, as a flexible and robust membrane, and Sikalastic- 621, as a highly-durable elastic liquid polyurethane system, was used. As well as the roof refurbishment, concrete repairs were also carried out with the use of Sika MonoTop-615 and Sikagard - 550. For the steel reinforcement Sika FerroGard-903 was also used. The refurbishment of the buliding was a great project for Sika to work on as it had solutions for each aspect of the project.
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Concrete Worktops, Penthouse Flat in Shoreditch

Concrete Worktops, Penthouse Flat in Shoreditch

LIVING CONCRETE LTD

On this redevelopment project we worked closely with McLaren.Excell Architects to manufacture and supply bespoke concrete kitchen worktops and concrete cladded central island in a newly renovated penthouse flat at a warehouse in Shoreditch.The glass fibre reinforced concrete central island, splash backs and worktops were manufactured using our special GRC BTX concrete, which is lighter and stronger than traditional concrete. We used our unique eco concrete mix technology with a hydrophobic agent to limit moisture absorption. The individual elements were precast in our workshop for assembly on site and then hand polished and treated with a specialist sealant. Living Concrete’s worktops are extremely strong and durable and can be used indoors or outdoors. By using the best of modern technology, we have created a sleek contemporary look that demonstrates how concrete can be both eye catching and functional.
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Concrete Lamp Shades

Concrete Lamp Shades

LIVING CONCRETE LTD

Project: Manufacture and installation of 10 bespoke concrete pendant light fittings for newly refurbished London gym and changing rooms. Materials used: Hand-cast concrete sphere shaped lamp shades with hand applied metallic internal finish and stainless steel fittings. We were asked to manufacture 10 bespoke extra large sphere-shaped concrete pendant lamps with hand applied metallic internal finish and stainless steel fittings. Product Spec: Size: diameter 47cm, shade height 28cm, maximum suspension height 120cm Weight 6.25kg Finish/ Colour: Rough finish – GREY Cable / cord : Herringbone brown linen Ceiling rose : Concrete GREY Colour temperature: 3000k LED WARM WHITE
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Olympic Village

Olympic Village

Schöck Ltd

The Olympic Village consists of 11 blocks, each block comprising between six and eight individual buildings, which are eight to twelve storeys high. Of the many amenities in the Village, by far the largest usage is for apartments, of which there are around 3000 units.Despite the height and density of the scheme, it has a surprisingly open feel, aided by the glazed winter gardens and mostly generous sized balconies, which are very much in evidence throughout the entire development. There was a huge demand here for the Schöck Isokorb®, with around 10,000 thermally broken structural connections to be considered. For podium slabs and pre-cast balcony applications the Isokorb® T type K, for concrete-to-concrete connectivity was used. The T type S, T type Q-P and Schöck SLD dowels combined to meet the requirement for securing the winter garden balconies. Types SK-MM1 and SK-MM2 for steel-to-concrete, provided the solution for connecting the various concrete frames to steel balconies.Some of the steel balconies had a cantilever length of approximately two metres and in most cases SK-MM2 units offered the ideal solution. However, in certain locations – concrete edge beams for example – the reinforcement bars had to be shaped to suit and for these applications special SK-MM1 modules were utilised.The unusual T-shaped winter gardens provided one of the greater challenges. Remarkably, the winter garden concrete slabs are designed to span two building blocks – approximately seven metres – and it was essential to allow for movement of the slabs by combining the Isokorb® T type Q-P at one end and SLD dowels at the other.Exceptionally strong steel-to-concrete thermal break connections were required and usually the Isokorb® T type SK would be the natural choice. On this occasion however, the forces involved exceeded even the capabilities of the SK units and it was necessary to design a T type S configuration, in combination with a specially developed steel bracket. Back at ground and first floor levels a huge number of T type K concrete-to-concrete thermal breaks were required for the large slab sections. In some cases the extreme dimensions of the slab sections resulted in thermal movement beyond the Isokorb®'s capability and SLD dowels were used in their place.
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Awnings and Fit-Box roller blinds in Estudio B76 Headquarters

Awnings and Fit-Box roller blinds in Estudio B76 Headquarters

Bandalux Industrial SA

Estudio B76 designed its new headquarters in an industrial warehouse built in the 50s. They kept and revealed reinforced concrete trusses and the perimetral walls made of bricks. The design focuses on using glass and steel to maintain the industrial atmosphere.Thanks to active and passive sustainable measures, such as photovoltaic panels, aerothermal energy, and efficient shading solutions, the project achieves high sustainability.From Bandalux, we proposed a combination of systems suitable for both the working and residential parts of this mixed project:, but Veranda Plus is particularly convenient as it completes without denaturing the former structure of the building.
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Concrete Reception Desk, Eastcheap Court

Concrete Reception Desk, Eastcheap Court

LIVING CONCRETE LTD

Eastcheap Court has been newly re-designed by Trehearne Architects and Fletcher Preist, to provide best-in-class office space within a smart controlled environment.We manufactured and installed a precast concrete reception desk for the newly redesigned reception area. The desk was constructed from two large precast sections, and we used our special eco mix of glass fibre-reinforced concrete for this project. It was created in a White Smooth finish and was had-polished and assembled onsite. We also added LED lighting strips to provide evenly distributed lighting around the area. It was a successful build that the client was very happy with.
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Nobu Shoreditch RubberBond FleeceBack EPDM Single Ply

Nobu Shoreditch RubberBond FleeceBack EPDM Single Ply

Flex-R

Nobu Hotel is a new development in Shoreditch, East London, and was opened by Hollywood legend Robert De Niro and Japanese chef Nobu Matsuhisa in May 2018.The design of the five-storey building – which has 150 hotel rooms and suites – is a nod to the area’s industrial past with a ‘frayed edge’ look of stepped balconies formed with glass fibre, reinforced concrete and cantilevered steel beams. The design has also been likened to that of a cruise ship and received much critical acclaim.The roofing system covered 1500 sq. m, which included a green roof area and tiered balconies.
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Reinforced Concrete Restoration - Omni Centre Car Park, Scotland

Reinforced Concrete Restoration - Omni Centre Car Park, Scotland

C-Probe Systems

Challenge: C-Probe's LoCem® +chase® anode mortar has been installed at the Omni Shopping Centre Car Park in Edinburgh, Scotland to 4 levels of underground car parking as part of a comprehensive corrosion management strategy. Overtime the popular car park had succumbed to structural damage and corrosion caused by the ingress of chlorides from de-icing salts from above.Solution: This system comprised of 42 ICCP zones and 7 additional monitoring zones forlevels protected using surface-applied corrosion inhibitors. In addition to this, some 6000 C-Puck galvanic anodes were used to protect newly repaired areas to 2 levels. All the anodes and monitoring could be controlled and data accessed remotely throughoutthe car park with AchillesICP and AchillesIES, helping to extend its service life for 100+ years.Outcome: This ESG compliant approach meant there was no need for demolition or extensive reconstruction using new materials, helping to reduce waste and harmful emissions. Reconstruction was also a near-impossible strategy due to underground facility and electric tram on land, meaning something non-invasive like cathodic protection was essentialto minimise social disruption. 
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Entrance Concrete Cladding

Entrance Concrete Cladding

LIVING CONCRETE LTD

Project: Manufacture and installation of bespoke 3D GRC cladding panels in Tempest Grey colour and Silk finish Client: Morgan Lovell Materials used: Panels were produced using BTX GRC high performance concrete in 3 meter length and only 20mm thickness. Bespoke 3D BTX GRC high performance concrete cladding panels were installed by Living Concrete to the famous 10 Old Bailey entrance. The panels were 3 meters in length each but only 20mm thick. Panels were double fixed to a steel frame and sealed in a Silk finish.
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New Victoria, Manchester

New Victoria, Manchester

Schöck Ltd

Sitting adjacent to Manchester Victoria station, the £185m New Victoria development is a two-phase scheme initially involving two residential towers of 20 and 25 storeys providing 520 one, two and three bed apartments. The second phase being a 13-storey office block. The façade concept is a ‘hooped envelope around a glass box’ with the ‘envelope’ consisting of vertical panels from the first floor to roof level. As with any reinforced concrete slab design, the project is at risk of punching shear failure. Which traditionally has been resolved by adding further concrete, such as downstand beams or localised thickened column heads. However these measures require complex formwork and significantly reduce the benefits of the flat slab design. By incorporating the Schöck Bole shear rail system – with its ready-to-install reinforcement element consisting of double-headed studs with spacing bars to ensure correct positioning – installation is cost-effective and significantly faster than traditional loose links. In fact, Shaun Farrell of Mayo Civils, the concrete frame contractor, comments: “We were pleased to find that by using the Bole shear rail system on the project, installation was four times faster than if we had used shear links.” Shaun goes on to explain that: “when using traditional links the installation time is increased because twelve ties are involved, six of which have to be tied to the bottom steel matt, which involves getting your hands between the rebar. With the Schöck Bole six-stud shear rail, it only involves two ties to the top matt”. 
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Chiswick Point

Chiswick Point

Schöck Ltd

The Chiswick Point development, at Bollo Lane, in West London, is a £20m contemporary mixed-use residential scheme offering 124 one, two and three bedroom residential apartments, including three penthouses. A sustainable approach was important, with all of the units designed to meet Level 4 of the Code for Sustainable Homes, and the Lifetime Homes code. Constructed in two blocks of six and nine storeys, the frame is mainly reinforced concrete, with the concrete frame floors and cladding providing thermal mass, which absorbs energy and slowly releases it to help reduce temperature fluctuations.Long continuous ribbon balconies provide solar shading to the two blocks and provide the residents with a very pleasant outlook across the London Wildlife Trust nature reserve at the rear of the development. The continuous balconies are a major feature of the scheme and with several hundred metres of them winding across the two blocks, effective thermal insulation was imperative if thermal bridging is to be avoided. To minimise any condensation problems and subsequent mould growth as a result, plus the avoidance of thermal outflow, Schöck Isokorb® T type K heat-insulating load-bearing elements are installed at various strategic positions along the large expanse of balconies. The Schöck Isokorb® T type K provides high thermal resistance by using stainless steel bars to act as tension and shear reinforcement, plus high-strength HTE pressure bearing modules.
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Shard Place Riser Install, London

Shard Place Riser Install, London

Dura Composites Ltd

Dura Grating Riser Installation | Case StudyShard Place is the third phase of the £3.5 billion redevelopment of the estate next to London Bridge station, known as Shard Quarter. Reinforced concrete frame and groundwork specialists Getjar were appointed as the formwork contractor by the principal contractor Mace and chose the Dura Composites Riser Install team to take on some of the complex install challenges of the service risers.Dura’s unrivalled expertise and full install capabilities meant they could deliver a bespoke solution for a large triangular shaped riser on all 26 storeys that required the use of galvanized steel supports and bracketing in conjunction with GRP Dura Grating to allow for cutouts to be performed whilst maintaining the integrity of the riser.
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Privacy Fence

Privacy Fence

Hahn Plastics Ltd

CHALLENGEIn Toronto, ON a large mail sorting facility was having an issue with chemicals coming from a concrete processing plant bordering their employee parking lot. The customer was looking to create both a visual and physical barrier from the equipment and excess dust. The fence had to be 2.4m tall, solid and without worry of material maintenance. They wanted to replace the existing fence that was just chain link with tarps, and an eyesore on their property.SOLUTIONA much more visually appealing and effective solution was found with hanit® 100% recycled plastic tongue and groove boards by HAHN, supported by galvanized steel beams. The 3.6m long beams were sunk 1/3 of the length into concrete, then filled with the 3.8cm x 13cm x 2133cm long T&G boards. Each panel was further reinforced at the base using a small hanit® support. The result was a simple, long-lasting privacy fence that met the customer’s needs. Shown here nearly three years after installation, the privacy fence has been a continued success. After numerous seasonal changes and close exposure to the conditions produced by the concrete plant, this installation demonstrates the durability and potential applications of hanit® 100% recycled plastic products. 
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SOLUTIONS | Cairns Regional Council Vertical Expansion Stormflow Joints Replacement Project

SOLUTIONS | Cairns Regional Council Vertical Expansion Stormflow Joints Replacement Project

Five Star Products

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
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3D Concrete Tiles

3D Concrete Tiles

LIVING CONCRETE LTD

Manufacture and installation of bespoke white concrete kitchen worktops and concrete cladded central island. The large format concrete panels were wrapped around the central island with 3D concrete tiles completing the design. All worktops and tiles were fitted using mechanical and chemical fixings.
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Concrete Outdoor Furniture

Concrete Outdoor Furniture

LIVING CONCRETE LTD

On this fast turnaround project we worked closely with Apteriors; Interior Design and Furniture Specialists and McLaren Construction to manufacture and supply outdoor concrete furniture for new multipurpose recreation and study area for New Regent’s College in London. Living Concrete supplied 4 large Let’s Dine Concrete Tables and 12 concrete cube seats with oak cladding which were assembled on site and finished with a specialist sealant. Product Spec: Let’s Dine Table Size: height 70cm x length 200cm x width 100cm Finish/ Colour: Mist Hand-cast GRC concrete Indoor and outdoor use
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Concrete Kitchen Worktops

Concrete Kitchen Worktops

LIVING CONCRETE LTD

On this fast turnaround project we worked closely with Clarke Penman Architecture to manufacture and install polished concrete kitchen worktops and splash-backs.Concrete worktops are extremely strong and durable and designed to withstand busy family use. These were cast to the client’s individual and unique specifications using our BTX Ultra High Performance Concrete mix with a hydrophobic agent to limit moisture absorption. The worktops were cut to fit various kitchen appliances and then treated and sealed to make them stain proof.Spanning over 6 metres, separate large BTX concrete panels were carefully assembled on site and fitted with brass sink and taps by our experienced team. The finished effect is a modern, industrial look that complements client’s design style and blends perfectly with the raw plastered walls and concrete floors, which together create a truly unique and highly functional kitchen.
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Sport at the highest level

Sport at the highest level

RENOLIT Cramlington Ltd

RENOLIT ALKORPLAN scores high on Deltion College! CHALLENGE A sports field on top of the roof. A surprising and exceptional RENOLIT achievement that absolutely draws the attention… Deltion College in Zwolle (NL) really is an exceptional case. This college offers amongst others education courses to prepare for service in the Armed Forces - Navy, Army as well as the Air Forces. No doubt sports are an important part of life on the campus. Then came the inspiration to install an artificial grass sports field on top of the roof of the newly constructed multifunctional building. Space-saving and functional! The choice to specify RENOLIT ALKORPLAN as roofing material was a shrewd decision, as RENOLIT ALKORPLAN offers a solution not only for mechanically fixed roofs but also for ballasted roof systems… SOLUTION The highest rooftop, a steel frame construction, has been installed with a PES-reinforced mechanically fixed RENOLIT ALKORPLAN F roofing membrane. For the lower concrete roof – the sports field to be – a different product was required: RENOLIT ALKORPLAN L! A glass fleece reinforced membrane with an excellent resistance to microorganisms, specifically conceived for ballasted roofs. Before installing the insulation, a bituminous vapour barrier was placed on top of the concrete. Next came a first layer of 70 mm thick aluminium-faced PIR insulation, followed by a second layer of 100 mm thick unfaced polystyrene insulation. To avoid direct contact between the roofing membrane and the PS insulation a glass fleece separation layer was added. Afterwards the RENOLIT ALKORPLAN membrane was loose laid and hot air welded. In accordance with the RENOLIT installation instructions the seams were sealed with RENOLIT ALKORPLAN seam sealer. A little bit of effort for extra security! 

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