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Product Design

ã ç ë í é ê ç ÇìÅíëinnovative

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2014 Fast Track 100 16th fastest growing company in the UK.

www.concretecanvas.com

Concrete Impregnated Fabric

®

ROADRAIL AGRO DESIGNUTILITIESPETROCHEMMINING DEFENCEMUNICIPAL

1511.EN.CP

© Concrete Canvas Ltd. 2015The information contained herein is offered free of charge and is, to the best of our knowledge, accurate. However, since the circumstances and conditions in which such information and the products discussed therein can be used may vary and are beyond our control, we make no warranty, express or implied, of merchantability, fi tness or otherwise, or against patent infringement, and we accept no liability, with respect to or arising from use of such information or any such product. Patent and Trademark information can be found here: http://www.concretecanvas.com/patent-and-trademark-info/

[email protected]+44 (0) 345 680 1908 www®

CC produces no back spray, eliminating problems associated with using sprayed concrete or resin based lining and reinforcement systems around sensitive infrastructure.

Reduces maintenance and repair work by eliminating the risk of membrane or structural damage from burrowing animals.

The following pages contain a collection of case studies highlighting the advantages of using CC to line bunds.

Concrete Canvas® User Benefits

Concrete Canvas® Key Properties

Erosion ProtectionCC provides high level protection against earth bund surface erosion from wind, rain and freeze thaw. CC significantly extends the operational life span of the bund, reducing through-life maintenance and rebuild costs.

Weed SuppressionCC acts as an effective weed inhibitor, eliminating the maintenance required with grassed or earth bunds whilst providing a safe surface for trafficking.

Conforms To ProtrusionsCC has excellent drape characteristics, allowing the material to conform in and around existing infrastructure, form sealed joints around pipe protrusions and negotiate sharp bends and variations in bund profile.

Prevents Animal Damage

No Rebound

Hydrocarbon ResistanceCC has been tested to BS14144 standard and passed a 56 day immersion test at 50°C.

Concrete Canvas® is a Geosynthetic Cementitious Composite Mat (GCCM), part of a revolutionary new class of construction materials. It is a flexible, concrete impregnated fabric that hardens on hydration to form a thin, durable, water proof and fire resistant concrete layer. Essentially, it’s concrete on a roll. Concrete Canvas® GCCM (CC) is predominantly used for erosion control applications such as bund lining, ditch lining, slope protection and the lining of tertiary containment lagoons.

Rapid Install

Easy To Use

Low Project Cost

CC can be laid at a rate of 200sqm/hour, up to 10 times faster than conventional concrete solutions. CC has a working time of 2 hours after hydration and can be installed in wet weather conditions, reducing programme disruption.

CC is available in man portable rolls for applications with limited access. The concrete is pre-mixed so there is no need for mixing, measuring or compacting. Just add water.

The speed and ease of installation mean CC is more cost-effective than conventional concrete, with less logistical complexity.

Eco-FriendlyCC is a low mass, low carbon technology which uses up to 95% less material than conventional concrete for many applications. Up to 200sqm can be delivered on a single pallet; enough to replace two full mixer trucks.



Project Info

CC5TM bulk rolls

15 / 11 / 2012

25,500sqm

Transverse Layers

Undisclosed, UK

Undisclosed

Trant Construction Ltd.

CC installed as protective liner to clay bunds to prevent weathering erosion, provide weed suppression and protect against animal damage.

i

#

7MAY

The finished project

In 2012, Concrete Canvas® GCCM* (CC) was specified to line refurbished secondary containment bunds at a Marine Terminal Facility in the UK. The bunds surrounded a series of tank farms storing hydrocarbons as part of the larger onshore facility. CC provides hard armour weathering protection of bunds, acts as an effective weed suppressant, protects against animal damage and provides additional levels of containment and fire protection. Trant Construction Ltd were the contractor on these works which started refurbishment of the bunds in October 2012 with a scheduled completion date of July 2013.

Concrete Canvas® GCCM is a concrete impregnated flexible fabric that hardens on hydration to form a thin, durable, fibre reinforced concrete layer. CC is available in 3 different grades, CC5TM, CC8TM and CC13TM which are 5mm, 8mm and 13mm thick respectively. All three grades can be used to line bunds according to the level of traffic expected. CC8TM is also used for lining drainage channels in and around oil refineries as a rapidly installed, cost effective alternative to half cut clay or concrete pipes.

Project Background

Concrete Canvas® GCCM

*Geosynthetic Cementitious Composite Mat

Rapid Installation

CC can be provided in two formats, man portable batched rolls or larger bulk rolls of up to 200 linear metres. The batched rolls are ideal for areas on site with difficult access and/or where plant equipment isn’t available.

The project required 25,500sqm of CC5TM delivered in 200m bulk rolls, called off in staggered deliveries to match the progress of the installation.

CC provided the following technical advantages for the bund lining works:

- Erosion ProtectionCC provides a hard armour surface protection preventing weathering erosion of the bund. CC is fibre reinforced and has an abrasion resistance twice that of ordinary Portland cement.

- Rapid InstallCC was installed at rates of 800sqm per day using a 6 man crew.

- Weed SuppressionCC is an effective weed suppressant, reducing future maintenance costs associated with grass cutting of top soils and negating the risk of fire from dried grasses.

- Install in Wet WeatherOnce hydrated, CC has a working time of 2 hours in a UK climate. This allows for installation in wet conditions which reduces programme disruption due to inclement weather. When the weather was such that refurbishment work on the bunds wasn’t possible, the contractors switched to lining the already refurbished sections with CC, meaning that there was a minimum delay in works due to poor weather conditions.

- Conformation to ProtrusionsCC was able to conform to 90° turns, pipe protrusions through the bunds and terminations at buttress walls.

Technical Advantages

Completed corner detail sectionCompleted junction detail section



- Protects Sensitive InfrastructureThe proximity of sensitive infrastructure meant that shotcreting or spray applied protective finishes were not a feasible option at this site.

- Prevents Animal DamageCC preventing rodents from damaging underlying membranes and stopping burrowing animals from compromising the integrity of the bund.

- Impermeability and Fire ProtectionCC has achieved a Euroclass B certification providing an additional level of fire protection in the event of catastrophic failure and subsequent ignition of stored hydrocarbons.

- Efficient Material TransportationCC is very efficient in terms of material transport, with over 25,000sqm of concrete surfacing delivered in only 125 pallets in 16 deliveries.

The 25,500sqm of CC was supplied in called off staggered deliveries to minimise on-site storage of material and to provide flexibility to the programme of works according to the weather conditions.

Following refurbishment of the clay bunds, bulk rolls of 200sqm of CC5TM were dispensed onto the bunds from a chain hoisted spreader beam mounted from a 13T tracked excavator. Each CC5TM bulk roll was positioned at the crest of the bund, before unrolling the required length down the inside. The bulk roll was then unrolled down the outside edge before being cut to length using utility knives.

Subsequent layers of CC were positioned to overlap the previous by 100mm. Once each section of bund had been lined, the CC was hydrated using a fire hose from the nearby water mains. Following hydration, the overlapped edge was then folded back on itself by approximately 50mm to apply CT1 sealant in a continuous 5mm bead along the length using a 600ml applicator sealant gun. The CC edge was then folded back and screwed in position using 30mm screws applied with an auto-fed collated screw driver. The sealant created an impermeable joint whilst the screws provided the mechanical bond between overlapped CC layers. Each layer was anchor trenched at both inside and outside edges of the bund.

At approximately 24 hours from the point of hydration, the CC had set to 80% strength and was able to be trafficked as works continued on installing kerb work and drainage details on the inside of the bund.

Installation

Grassed soil bunds prior to refurbishment Grassed soil bunds prior to refurbishment



Joining of adjacent layers using 30mm autofed screws

Hydration of CC from on site mains water supply

Prepare / grade clay bund to desired profile and height

Completed section

Adhesive sealing of 100mm overlapped joints using CT1

Transverse layup of bulk roll CC5TM from spreader beam1

3

5

2

4



Buttress wall fixingButtress wall fixing

50mmHILTI X-C47WITH 30MM WASHER

CONCRETE CANVAS LAYER CONCRETE CANVAS LAYER

6MM BEADSIKA FLEX 1A

NOT TO SCALE NOT TO SCALE

TERMINATION OF CONCRETE CANVAS TO CONCRETE OR POLYMER HEADWALL

TERMINATION OF CONCRETE CANVASTO CONCRETE HEADWALL / BUTTRESS

TERMINATION OF CONCRETE CANVASTO POLYMER HEADWALL / BUTTRESS

CONCRETEHEADWALL

6MM BEADSIKA FLEX 1A

50mmSELF TAPPINGSCREW WITH >14MMWASHER

POLYMERHEADWALL

SOIL SUBSTRATE SOIL SUBSTRATE



Summary

Completed section

Completed section

Completed section





In May 2011, Concrete Canvas® GCCM* (CC) was used in a trial bund lining project carried out as part of reinforcement works at the CPF-2 Meta Petroleum Corp. oil field facility in Colombia. The bunds were graded to profile and CC5TM was batched to specific profile length to avoid wastage. The CC matting was laid transversely across the bund and adjacent layers were overlapped by 100mm. Ground pegs were used to fix the CC to the substrate and staples were applied along the overlaps at roughly 200mm intervals.

The trial demonstrated that CC could be installed on site without the need for heavy plant equipment, which was critical for a site with limited access and within a hazardous environment. The works were also completed in wet weather conditions which would have halted conventional concreting works.

Meta Petroleum Corp. were impressed with the simple and rapid installation method of CC as well as its immediate effectiveness after laying. Topography studies were completed in preparation for larger CC projects in other areas of the oil field, including drainage works and more extensive bund lining.

CC5TM bulk rolls

26 / 05 / 2011

100sqm

Transverse Layers

Meta Petroleum Corp. oil field, Colombia

Meta Petroleum Corp Staff

CC trialled as a bund lining solution.i

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7MAY

Hydrating CC sections


Infrastructure Protection



Initial ground inspection and preparation Cutting CC to length from batched rolls using basic hand tools

Hydrating of the fixed CC layersFixing into the substrate and jointing using ground pegs and staples

The CC lining was tailored to fit in and around existing pipe workCompleted section of bund



Project Info

CC5TM Bulk Rolls

27 / 10 / 2014

5200sqm

Transverse layers

Mount Vernon Washington, USA

Western Refinery Service (WRS)

CC5TM was used as a hard armour capping for a secondary containment berm

i

#

7MAY

Completed section of bund

In October 2014, Concrete Canvas® GCCM* (CC) was used as a hard armour capping and erosion prevention method at a refinery site in Washington, USA. Industry safety protocols state that berms must maintain a minimum height and erosion leads to time consuming re-profiling and re-coating of the berms to ensure they meet this standard.

Previously, asphalt had been used to protect the berm, however this incurred huge maintenance costs. Not only did the berm need to be re-coated every 5-7 years, but it required regular and costly maintenance throughout the year. CC has a 50 year life-span and requires little to no maintenance, resulting in huge cost savings. Additionally CC offers hydrocarbon resistance to BS:14414; based on a 56 day immersion test, some CC samples were found to actually gain strength upon exposure to hydrocarbons. Furthermore CC’s weed suppression characteristics prevent vegetation growth (and therefore the costs associated with vegetation removal) and prevent the fire hazards that result if the vegetation dies off. The concrete layer stops any UV degradation of the PVC backing, unlike asphalt which cracks with long term exposure to UV, compromising the integrity of the bund.


RapidInstallation

Unrolling the CC down the bund

Spooling the CC down the bund

Cutting the CC to length with a utility knife

WRS (Western Refinery Services) completed the installation over a period of 7 days with a team of 8. Bulk rolls of CC5TM were placed at the crest of the berm and spooled down one side before being unrolled down the other. This process was repeated along the berm, with a 100mm overlap being created between layers. Each overlap was screwed and sealed using 20mm self tapping screws placed at 300mm intervals and Sika 1-A sealant. On the inside of the bund, the cut edges of the CC were placed into an anchor trench before being captured with concrete paving. On the outer edge of the bund, masonry bolts were used to fix the CC to the existing concrete infrastructure. In areas where the bund had eroded to the extent it no longer met the height requirements, sandbags were used to fill any voids before the CC was deployed. Infrastructure such as pipework was easily accommodated due to the drape characteristics and flexibility of CC. Holes were cut for the pipes, and where needed an extra layer of CC was fitted around them and sealed. The CC was hydrated using a high volume mounted hose attached to a water hydrant.

Installation

Refinery Site

Cracked asphalt



Hydration from the water mainsSealing the overlap with CT1 Sika1-A sealant

Piping detail

CC accommodating infrastructure

Sealing around piping

Piping detail



5200sqm of CC5TM were installed by a team of 8 in just 7 days. The completion of this project has resulted in drastically reduced maintenance costs, improved impermeability and an improved fire resistance of the berm. Infrastructure, corner details and pipe protrusions were simple to accommodate resulting in an easy and rapid install. The client has said they are “very happy” with the outcome of the project and they are looking to install CC on other bunds in their vast oil and gas network.

Concrete Impregnated Fabric...


Corner detail

Summary


Stair detail



07.06.11 Bund Lining Case Study : Classified

In May 2011, Concrete Canvas® GCCM* (CC) was specified as the surfacing material for a 2.3m high bund surrounding a remote storage facility. A total of 2900sqm of 5mm thick CC (CC5TM) was installed on a sand base in order to protect the bund against the effects of wind, rain and long term environmental degradation.

CC was specified over conventional lining solutions such as shotcrete or reinforced concrete due to the cost and time savings offered as well as additional site specific benefits.

The traverse batters were excavated to a maximum of 30º to the vertical ensuring surface flow was directed into the 600mm wide spoon drains at the base of the bund. A 50mm sand base course was applied to the traverse prior to the installation of the CC to allow free drainage. The CC was supplied as 200sqm bulk rolls and installed on site using plant mounted spreader beams. The material was unrolled into position and fixed into the batters using 500mm soil pins with washers. Each CC layer was anchored top and toe of the batter by a minimum of 300mm and overlapped 100mm between adjacent sheets. Weep holes were drilled into the base of the CC at 3m centres once the CC had set.

Corner detail of CC lined traverseTraverse prior to CC lining

Completed CC lined traverse






Concrete Canvas Ltd. CF37 5SP, United Kingdom

11

EN12467:2004Concrete Canvas:Fibre cement sheetNTOversize sheetsClass 1, Category AReaction to Fire B-s1,d0

Post Set Concrete Canvas® GCCM Properties

Pre-Set Concrete Canvas® GCCM Properties

Concrete Canvas® GCCM Physical Properties*

Setting

Method of Hydration

Working Time 1-2 hours subject to ambient temperatureCC will achieve 80% strength at 24 hours after hydration.

Spray the fi bre surface with water until it feels wet to touch for several minutes after spraying.

Re-spray the CC again after 1 hour if:- Installing CC5TM

- Installing on a steep or vertical surface

* Indicative values

StrengthVery high early strength is a fundamental characteristic of CC. Typical strengths and characteristics are as follows:

Compressive tests based on ASTM C109 – 02 (initial crack)- 10 day compressive failure stress (MPa)

Bending tests based on BS EN 12467:2004 (initial crack)- 10 day bending failure stress (MPa)

Tensile data (initial crack)

40

3.4

Age Testing (minimum 50 year expected life)Freeze-Thaw testing (ASTM C1185)Freeze-Thaw testing (BS EN 12467:2004 part 7.4.1)Soak-Dry testing (BS EN 12467:2004 part 5.5.5)Heat-Rain testing (BS EN 12467:2004 part 7.4.2)Water impermeability (BS EN 12467:2004 part 5.4.4) Passed**

PassedPassed

200 Cycles

Passed

Abrasion Resistance (ASTM C-1353)Approximately 7.5x greater than 17MPa OPC

Manning’s Value (ASTM D6460)

Root Resistance (DD CEN/TS 14416:2005)

Chemical Resistance (BS EN 14414)- Acid (pH 1.0) (56 day immersion at 50°C)- Alkaline (pH 13.0) (56 day immersion at 50°C)- Hydrocarbon (56 day immersion at 50°C)- Sulfate Resistance (28 day immersion at pH 7.2)

Impact Resistance of Pipeline Coatings ASTM G13 (CC13TM only)

Permissible Shear & Velocity CC8TM (ASTM D-6460)- Shear (Pa)- Velocity (m/s)Product exceeded large scale testing capabilities and was not tested to failure.

To achieve these permissible values, the CC material must be properly anchored with a system designed to meet or exceed these values.

Other

PassedPassedPassedPassed

Passed

n = 0.011

Length direction (kN/m) Width direction (kN/m)CC5TM 6.7 3.8CC8TM 8.6 6.6CC13TM 19.5 12.8

The information contained herein is offered free of charge and is, to the best of our knowledge, accurate. However, since the circumstances and conditions in which such information and the products discussed therein can be used may vary and are beyond our control, we make no warranty, express or implied, of merchantability, fi tness or otherwise, or against patent infringement, and we accept no liability, with respect to or arising from use of such information or any such product.

** For containment applications it is recommended to use CC HydroTM

Based on Concrete Canvas GCCM ® hydrated in accordance with the Concrete Canvas® Hydration Guide.

Passed

Reaction to FireCC has achieved Euroclass B certifi cation:BS EN 13501-1:2007+A1:2009 B-s1, d0Flame Resistance: MSHA ASTP-5011Vertical and Horizontal Certifi cation

Other Information

Product Thickness (mm)

Batch Roll Size (sqm)

Bulk Roll Size (sqm)

Roll Width (m)

CC5TM 5 10 200 1.0CC8TM 8 5 125 1.1CC13TM 13 N/A 80 1.1

Product Mass (unset) (kg/m2)

Density (unset) (kg/m3)

Density (set) (kg/m3)

CC5TM 7 1500 +30-35%CC8TM 12 1500 +30-35%CC13TM 19 1500 +30-35%

* Occasionally there will be a Beam Fault (fabric imperfection under 100mm wide running across the width) in a Bulk Roll. This fault is unavoidable due to the manufacturing process and the fault will be clearly marked with a white tag, there will be a maximum of (1) one Beam Fault in any Bulk Roll. A joint may need to be made on site where there is a Beam Fault as the material at a fault will not reach the performance specifi ed in this Data Sheet. The maximum un-useable material due to any Beam Fault will be 100mm. There are no beam faults in standard batched rolls.

An excess of water is always recommended. CC will set underwater and in seawater.CC must be actively hydrated. For example do not rely on rainfall or snowmelt. Use a spray nozzle for the best results (see CC equipment list). Do not jet high pressure water directly onto the CC as this may wash a channel in the unset CC. CC has a working time of 1-2 hours after hydration. Do not move or traffi c CC once it has begun to set. Working time will be reduced in hot climates and increased in very cold climates.CC will set hard in 24 hours but will continue to gain strength over time.If CC is not suffi ciently wetted, or dries out in the fi rst 5 hours, the set may be delayed and strength reduced. If the set is delayed avoid traffi cking the material and re-wet with an excess of water.

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-

-

-

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-

Notes:

Refer to the Concrete Canvas Hydration Guide for installation in low temperatures or drying conditions.

Low Temperature Conditions occur the ground surface temperature is between 0 and 5°C and rising or is expected to fall below 0°C in the 8 hours following hydration.

Drying Conditions occur when there is one or more of: high air temperature (>22oC), wind (> 12km/h), strong direct sunlight or low humidity (<70%).

-

-

Passed

120010.7

Concrete Canvas® GCCM Material Data

Passed

Documents

Concrete Impregnated Fabric - perendes.comperendes.com/product_catalog/articles/44/uploads/3.1.3-Bund-Lining... · with grassed or earth bunds whilst providing a ... control applications