Page 35 - HUB-4 Magazine Issue 94

Quarrying
Innovative Block Wall Design
transforms IMERYS Storage Operations
IMERYS, a leader in mineral-based speciality
solutions, recently undertook a transformative
refurbishment of their Furzebrook facility in
Dorset.
The project included replacing aging, deteriorating steel
columns and wooden sleeper walls, resulting in structural
failures, limiting storage capacity, and cross contamination
between different grades of stored materials, which was
undermining product quality and profitability, threatening
IMERYS’ operational standards.
Assessing the Challenge
Sourcing a solution, IMERYS turned to RSG Structures, with
RSG Director, Gareth Neale identifying several key challenges:
• Complex Building Layout – the facility featured an array of
supporting stanchions, complicating the installation of new
walls
• Uneven Floor Levels – negatively impacting traditional
walling methods
• Heavy Storage Requirements: Ball clay storage material is
exceptionally dense at 1300 kg/m³ and required storage up
to four meters high, with additional surcharge loads
• Existing Steelwork Integration: The new solution needed to
work seamlessly with the in-situ steel frame and
accommodate unique flooring and structural conditions
RSG Structures drew on their extensive experience and
proposed a two-part solution: In-Situ Plinths and Legato®
Walls that included:
• In-Situ Plinths: Providing a stable, even base for the
walling, overcoming the challenges of uneven flouring
• Rubbing Bar Function: Protecting new walls from damage
from shovel bucket material handling
• Customer Fit: The flexibility of Legato® block walling sizes
allowed walls to be positioned close to existing steel
supports, optimising space and structural compatibility
• Engineered Strength: Designed to withstand the immense
loads of storage ball clay, ensuring robust containment
• Structural Cohesion: Where steel supports interrupted the
wall line, a steel plate was installed, enhancing overall
stability and Layalocka straps were used throughout to
increase anchoring
can put designs together for multitude of different loads,
heights and lengths of walls”
With designs finalised, construction proceeded in planned
phases, allowing IMERYS to maintain operations in unaffected
areas, minimising downtime and ensuring continuous
productivity throughout the project.
Delivering immediate and measurable benefits:
• Reducing Cross Contamination: Separating material grades,
drastically minimises contamination, directly improving
product quality and sustainability
• Increased Profitability: Enhanced product integrity means
higher product values and improved margins
• Optimised Storage and Handling: Increased capacity and
durable designs have streamlined material handling and
storage efficiency
• Sustainable Project: The new walling will protect the
column steel from being damaged, due to heavy machinery
manoeuvring inside the shed, ensuring a longer project life
Continuing Gareth emphasised the benefits of Legato®
walling saying: “One of the great things with using blocks and
this is why we do it a lot, is that it’s a very simple system that
can be designed many different ways”.
“Most precast units are designed to take one load, if you want
them to do more, they simply can’t. With Elite Precast blocks I
Collaborative success
Lead by construction solutions specialist RSG Structures the
project’s success is a testament to the effective collaboration
of the team they employed:
• CLP Structures: Design expertise
• TR King: High-quality steelwork
• Evabuild: Groundworks
• Elite Precast Concrete: Legato® walling blocks
Upon completion of Gareth concludes “IMERYS staff are really
happy with the new walls and are already reporting that with
the new walls in place, cross contamination of product is
reduced drastically which is showing an increase in value of
their products”
This project demonstrates the power of innovative engineering
and collaborative expertise in driving business success.
www.hub-4.com Sept/Oct - Issue 94
| p35 |