SubscribeCase Study: Ensus Bio-Ethanol Plant, Wilton International, Teeside. UK.
Glen Jones was approached in 2008 by Simon Carves Ltd, they were in the process of constructing a new bio- ethanol plant for Ensus UK, the project had a requirement for the use of foam concrete as a support medium for the cone bottoms of the tanks which would be used for the bio-ethanol, there were 14 tanks to be infilled ranging from Fermenters to Beerwells.
Uniform Load Bearing Strata
The structural purpose of the foam concrete was to provide a uniform load bearing strata between the steel tank cone bottom and the concrete foundation below. The tanks are of steel construction and fabricated on site. The specification of the foam concrete mix was 1-1 800kgs m3 with 28 day strength of 1.5kgs. GS foam concrete were awarded the contract in October 08, the works were to start November 08 and were projected to finish early 2009.
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The first pour took place and due to the load bearing issues on the tanks it was decided in conjunction with Simon Carves to only infill 700mm per tank per day. The total volume per tank per pour was 18 cm3. Due to the height of the tanks GS foam concrete pumped into the tanks via a mobile concrete pump through a specially adapted pipe. Each tank surround was infilled until the foam concrete was flush with the precast concrete plinth.
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The total volume used in each tank was 56cm3. GS foam concrete completed the works in April 2009. The cube results averaged 2.0n/mm2 @ 28 days; we tested a total of 288 cubes over the course of the works. GS Foam concrete is the first foam concrete contactor in the UK to carry out this type of infill and we are currently speaking to main contractors on similar contracts in the UK and Europe.