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

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 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

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.