The challenge
The Rookery South Energy Recovery Facility (ERF) is built in a disused clay pit at Stewartby, Bedfordshire. It processes around 550,000 tonnes of non-recyclable waste a year and produces over 60 MW of electricity, enough for about 112,500 homes and businesses. The concrete floors needed a wear-resistant surface for constant truck and loading shovel traffic.
The DCP solution
DCP supplied TIBMIX, a non-oxidising, chemically inert, metallic dry shake topping for monolithic floors. It is a premixed blend of graded aggregates, additives and ordinary Portland cement. It gives a dense, tough surface that resists abrasion, wear, oil and grease, which suits heavy industry and power plants. The London-based contractor uses either Monoshake or TIBMIX from DCP when a dense surface and high wear resistance are needed.
DCP products used
How it was applied
- Place a well compacted, smoothed concrete slab and let the bleed water rise and evaporate.
- When light foot traffic leaves a 3 to 6 mm imprint, apply TIBMIX.
- On large areas, spread and trowel TIBMIX in one stage with mechanical spreaders.
- For manual work, spread two thirds of the TIBMIX first and let it absorb moisture until the colour is even.
- Float, spread the remaining third, then float for a final time.
The result
TIBMIX raised the surface wear capability of the new concrete by 300 to 500%, into a special wear class suited to heavy industry. The facility completed commissioning and was handed over to the operator within the agreed schedule, after less than three years of construction.
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