CONCRETE ON A ROLL

Mirny Airport, in Yakutia, is the main means of transport for the Mirna Diamond Mine due to its remote location. A newly excavated drainage channel at the airport required lining to increase its design life and reduce future maintenance requirements.

There are just 3 months of the year when weather conditions allow to take place, so CC was the only possible solution.

1680m² of CC13 were installed in 3 days, compared to approx. 1 month for traditional solutions.

The project was undertaken in an area of Cumbria which was damaged by Storm Desmond in December 2015.

The site had very limited access. The specified bulk and batched rolls of CC8 and CC13 had to be delivered via helicopter where use of the steep, narrow track was not possible.

Installation was carried out by the 7 5 Engineer Regiment on behalf of the Lake District National Park Authority.

In April 2015, the French National Rail Authority, SNCF, specified Concrete Canvas® for a trial installation.

CC was used to line a channel located next to a railway line in Buzy, at the southern end of the Belair Tunnel.

A total of 250m² of CC8 were laid on damp soil, which would not have been possible with alternative solutions, in just 3.5 hours by 5 people.

Steep slopes at the Alcobendas Station in Madrid had been subject to erosion and instability issues, affecting the entrance to the station tunnel.

CC was laid down the slope, into a purpose-built runoff ditch to prevent water running onto the tracks.

2500m² of CC8 were installed in under a week - 70% quicker than shotcrete or gunite - without any interruption to train traffic.

A steep slope in Piazza Armerina in Enna, Sicily required temporary slope protection after a wall, built in the 1900s, collapsed.

CC was the only option for prevention of further collapse as the area is subject to very high temperatures in summer and high winds in winter.

400m² of CC5 were installed in 4 days by a team of three people, including two rock climbers, in temperatures of above 35°C.

CC was installed as an erosion prevention method for a gas pipeline in Abu Dhabi. By exposing the gas pipe, erosion threatened to damage infrastructure and the environment.

CC was specified due to its resistance to UV exposure and wildlife damage, and greater eco-friendliness compared to alternatives.

3000m² of CC5 were installed in 5 days on a remote site.

CC was used to line a series of drainage channels at the Onshore Processing Facility in Chayvo, Sakhalin for Exxon Neftgas Limited.

The client required a channel lining solution which could withstand the extreme cold temperatures experienced in the area in winter.

9250m² of CC8, and 5520m² of CC13 were installed in 3 weeks by a team of 6 people.

CC was used to prevent rain water run-off infiltrating a gulley and causing a land slip at Wadi Laban, Riyadh, Saudi Arabia. CC was specified due to its quick installation times, and lower costs than traditional options.

After installation, the CC was painted to blend in with the surroundings.

750m² of CC8 were installed over a total of 27 hours, across 3 days.

A slope situated between a primary school and residential area, with a busy road running alongside, was at risk of slip due to high levels of rainfall and runoff. A solution was required to prevent a landslide.

CC was specified and over 1000m² of CC5^TM were installed in just 4 days with minimal disruption and no lane possession requirements.

The Brockman 4 mine in Western Australia, owned by Rio Tinto, required a slope protection solution at a Run of Mine. Surface water penetration prevention was required, as well as erosion control and weed suppression.

CC was selected due to its speed, ease of installation and cost-effectiveness.

A total of 810m² of CC5 were installed in 3 days by 3 people in temperatures of up to 43°C.

A section of bridge abutment, initially installed using a geogrid system, required erosion protection. CC was selected as it could be installed quickly, without specialist equipment and labour.

CC5 was specified and cut to length to fit the varying height of the wall, minimising wastage. 

The client was impressed with the ease of installation. 200m² were installed in just over 5 hours.

Willow Creek is a large open-pit mine in northeast British Columbia, producing both hard coking coal and low-volatile PCI coal for steelmaking. 

The channel had to be waterproof, capable of handling freeze-thaw conditions, and easy to repair.

Screws and sealant were used to create watertight joints. The work was completed in under 6 weeks on a remote site, in difficult weather conditions.

The main objective of the installation in Sabang was to replace an existing damaged concrete lining on a slope.

CC8 was specified as it would not require any form works, heavy plant or specialist workers.

The CC was laid down the slope, jointed using Clearfix sealant and screws and fixed with steel pegs.

Urbanisation of the Industrial Park PIA Airport by AM Developers required a rainwater catchment area for infiltration.

The area in need of attention was a storm cistern, and the main aim was to prevent damage to the slopes caused by erosion.

CC5 was specified and laid vertically down the slopes over five days by a crew of 6-8 people.

CC was used as an erosion control measure on a slope adjacent to a section of the Zipaquira-Bogotá Highway in Chinchilla, Colombia.

The slope had suffered from slip and erosion due to adverse weather conditions and leakage from a water pipe on the slope. There was potential for falling debris to cause an accident on the highway or cycle path.

1000m² of CC5 were installed in 13 days in inclement weather by 6 people.

The slope in Recife was located in a residential area and was facing severe erosion problems that had led to a house at the crest of the slope collapsing. CC had already been used on a trial basis within the municipality to assess its suitability.

The slope ranged between 5m-12m and was surrounded by housing. CC8 was specified for the works. 125m² of CC8 were carried out in just 9 hours by a team of six in temperatures of up to 35°C.

The Caserones project was a channel lining project located in the 3^rd Region of Atacama, 800km to the north of Santiago. The aim was to divert glacial melt water that threatened to flood a nearby copper mine.

A total of 53,200m² of CC5 were installed at an average rate of 230m²/hour, by two 6-man teams in a remote environment over 4,000m² above sea level and subject to temperatures ranging between -10°C to 20°C.

Over 11,000m² of CC8™ bulk rolls were installed at the Myra Falls underground zinc and copper mine.

The material was required as a channel lining solution at the Vancouver Island site, and specified instead of shotcrete.

CC was able to accommodate the high waterflow velocities the channel had been designed to manage of up to 20m/s with slopes as steep as 16-20% in some sections.

1375m² of CC8™ were airlifted by helicopter to the Tazin Lake site in Saskatchewan due to very limited site access, which would have made installation of alternative solutions very complex.

CC was used to remediate a weir for SaskPower. CC’s ease of use allowed for quick rectification of a substrate failure during the installation process, preventing costly and lengthy delays.

The United States EPA specified Concrete Canvas® to line a drainage channel at Sheldon Mine, Arizona.

The aim of the project was to prevent surface and storm water coming into contact with mining contaminants, and to protect a nearby residential area and creek.

CC provided a time saving of 50-60% compared to HDPE, with just 9 hours required to install the material.

Agrotek Spa installed 2647m² of CC5™ for the Peralillo Agricultural community in Chile. Lining the irrigation channel with CC prevented water loss and improved the water management system.

The whole project was completed within one month, resulting in 70% more water available to the community. Water now takes just 6 minutes to travel the length of the channel, compared to over 45 minutes prior to the project.

Forestry company Montes del Plata specified Concrete Canvas® as a channel lining solution to create a drainage network series on their industrial site.

CC was installed at a rate of 550m² per day and easily accommodated variations in channel profile, junctions, corners and existing infrastructure such as concrete headwalls.

The project was completed by Pronto Cemento in 23 days.

Concrete Canvas® was used to line sloping walls of two lagoons designed to contain Burlanda Humeda, a bioproduct of bioethanol derived from corn prior to processing for animal feed.

The site is located in a rural area with limited access, ruling out many alternatives.

997m² of CC5™ were installed in five days in high temperatures and despite some rain as CC can be installed in wet weather.

De-Montag Co. Ltd. installed 125m² of CC8™ for the Ghana Irrigation Development Authority to establish its advantages over conventional channel lining methods.

The installation was completed in just 2 hours, minimising disruption to farmers who use it for irrigation.

Time savings, durability, labour reductions and ease of use were cited as advantages of CC over alternatives in this project.

CC was used to reline a section of an existing concrete canal as a trial to establish whether CC could be used for total relining or local repairs.

The project was completed in three hours, with CC providing a durable, effective and neat solution. The client found the joints were incredibly strong and the lined section was completely water-tight, providing efficient protection against any water loss.

Gravity Thickener tanks play a pivotal role in recycling water used for settlement of fines at the Grootegeluk mine in Lephalale, South Africa.

Site owner, Exxaro, opted for the tank floors to be remediation using CC Hydro™ to extend their operational lives. 4000m² of CCH8™ were installed within a strict 3-week window for tank one. This will be repeated in the coming years, with one tanks being remediated each year.

Erosion protection and water loss prevention were required for this unlined irrigation channel at a sugar plantation in Mafambisse.

The lack of lining allowed water seepage into the substrate, reducing its efficiency.  6000m² of CC5™ was specified to line the 4km long channel due to its shallow profile and low flow velocities.

The remediation of a damaged hydroelectric plant water diverting pipe was required on a mostly inaccessible site in Ikizdere.

The pipe’s location made traditional solutions impossible to implement. Instead, CC8™ batched rolls were specified and transported to site using an improvised cable car system. CC provided better abrasive strength compared to traditional repair mortars.

CC was specified along with shotcrete in a trial to establish which was the better solution for slope protection. The aim was to prevent weathering erosion and rockfall onto the road.

3,350m² of CC8™ were installed in 5 days, compared to the 12 required for shotcrete. Time and cost savings were evident with CC, and no lane possession or road closures were required.

CC was specified to line a channel and slope system on a remote, unmanned gas compression station in Wallumbilla, Queensland.

The client, Santos, required a long-term, cost-effective solution for water management, vegetation suppression and erosion protection, while mitigating maintenance requirements.

Just one delivery of CC was required, reducing logistics and the associated carbon footprint.

1020m² of CC5™ was installed as a weed suppression solution alongside a highway in Yamanashi, Japan.

The existing anti-weed fabric had degraded due to UV exposure. CC’s UV resistance, erosion control and weed suppression properties made it the best alternative.

Batched rolls were laid longitudinally, providing a faster install, preventing lengthy lane possessions and breaches of time restrictions.

2600m² of CC5™ was used to cover ballast material in a steel tank cofferdam installed to enclose a construction site in Junk Bay in Tseung Kwan O, Hong Kong.

Due to the cofferdam being at sea, the CC was transported by boat and supplied in batched rolls for easy, two-man handling on site. The project was completed in ten days.

CC was installed at one of Russia’s largest Oil Pumping Facilities as a slope protection measure. The slope is 45m at its highest point, 120m wide and surrounded by sensitive infrastructure.

As a clean and flexible concrete alternative with minimal wastage, CC was specified as it would not damage the infrastructure.

6000m² of CC8™ were installed for Chernomortransneft, JSC with the aid of climbing equipment.

1,000m of CC8™ was installed at a salt storage facility in Novaky, Slovakia in August 2018. CC was used to reline a concrete wall which had corroded as a result of contact with the salt, leading to damage of the steel reinforcement.

The project was completed in 10 days, significantly reducing the outage time for production compared to alternatives, in turn saving costs for the client, Fortischem chemical plant.

Temperatures at Elinoil Hellenic’s Athens petroleum tank farm often reach 48°C in summer, putting vegetated bunds at risk of causing fires.

CC’s weed suppression properties and lack of rebound or requirement for heavy plant meant a guaranteed safe installation.

CC’s flexibility provided a high-quality result and easily accommodated pipework and other infrastructure.

The local commune of Wilster in Germany (Amt Wilstermarsch) specified CC to provide crest protection on sections of a pond embankment which had badly eroded and was losing water as a result.

375m² of CC8™ were installed in just 7 hours by a team with no prior experience of using CC. The installation which was treated as a trial, was deemed a success, with the client looking into using CC for similar projects.

In 2016, CC Hydro™ was installed on a 5000m² berm face as a secondary containment solution at SemLogistics Ltd’s site in Milford Haven, west Wales.

CCH5™ was installed around two of the site’s most critical tanks used to store petroleum products.

CCH reduced construction times, operational disruption and associated costs compared to alternatives.