new innovative concrete technology to improve terminal
TRANSCRIPT
New Innovative Concrete
Technology To Improve Terminal Asset Integrity & Safety
DARREN HUGHES
CONCRETE CANVAS LTD, UK
Agenda:
Civil Structures – Providing Environmental & Asset Protection
Challenges of Current Materials in Use
New Material Technology Introduction
GCCM – Erosion Protection
GCCB – Containment Protection
Material Properties
Physical & Chemical Properties
Long Term Durability
Material Use in Application:
Secondary Containment Bund Lining
Case Study:
Valero, Milford Haven (UK)
Summary & Conclusions
Various civil structures protecting
assets and the environment
Typical civil structures present:
Secondary containment
bund & dyke walls
Tertiary containment
lagoons & pits
Fire water storage
reservoirs
Drainage channels
Tank base lining
All need lining to provide containment or protection against erosion
Current Lining Materials
Bitumen sand mix
Compacted engineered clay
Bituminous geomembrane (BGM)
Geosynthetic clay liner (GCL)
PVC / EPDM / Butyl rubber
High density polyethylene (HDPE)
Polymer spray coatings
New Materials
GCCM’s
GCCB’s
Geosynthetic Cementitious Composite Mat (GCCM): a factory assembled geosynthetic composite consisting of a cementitious
layer contained within a layer or layers of geosynthetic materials
GCCM’s are flexible
concrete impregnated
fabrics that hardens
when hydrated to form
thin, durable waterproof
concrete layers
GCCM’s – In essence “Concrete on a roll”
1× Roll of GCCM 200sqm
2 × Concrete Mixer Trucks
Various applications for erosion control
Lining open drainage channels
Saudi Aramco
Yanbu Refinery
Al Madinah, KSA
Weed suppression under pipe tracks
Petro Ineos
Grangemouth Refinery
Falkirk, UK
Various applications for erosion control
Slope Protection
Petroleum Development Oman
Undisclosed Location
Oman
Slope Protection
Transneft
CPC Pipeline Pumping Port
Novorossyisk, Russia
Geosynthetic Cementitious Composite Barrier (GCCB):
GCCB is an extension of GCCM technology
GCCB’s combine a
concrete impregnated
fabric technology with a low
permeability, chemically
resistant geomembrane
liner, which allows joints to
be thermally bonded for on-
site air channel testing.
GCCB key properties – low permeability
Water impermeability (BS EN 12467:2004 part 5.4.4)
GCCB can provide full
containment solution
GCCB key properties – chemical resistance
Rating KeyA – Fluid has little or no effect
B – Fluid has minor or moderate effect
X – Fluid has severe effect
24 hour / 28 day
▲0.1 M H2SO4 pH1.2∆Synthetic according to OECD 303
GCCB key properties - puncture resistance
GCCB key properties – long life durability
Age Testing (minimum 50 year expected life)
Freeze-thaw testing (ASTM C1185) 200 Cycles
Freeze-thaw testing (BS EN 12467:2004 part 7.4.1) Passed
Soak-Dry testing (BS EN 12467:2004 part 5.5.5) Passed
Heat-Rain testing (BS EN 12467:2004 part 5.4.4) Passed
-50°C +50°C
GCCB in application:
Secondary containment bund lining
Comparison: GCCB Vs GCL
Case study: Valero, Milford Haven UK
Mott MacDonald appointed as design consultant
5000m2 berm profile required
lining & protection
Considered traditional
solutions, GCL, HDPE, etc.
Selected GCCB as it provided
an all-in-one solution
Deployment & Lay-Up of GCCB Rolls
Thermal welding process for GCCB
Hydration & Setting of GCCB
Case study: Valero, Milford Haven UK
Summary and conclusions
With an increasing awareness and greater focus placed on
environmental protection and the impact petrochemical assets
have on their surroundings, operators are continually challenged
with the use of traditional materials to ensure compliance and
safe operation.
We should consider new material technologies that can minimize
the contractor burden and provide maintenance free solutions
where available.
GCCM’s and GCCB’s are disruptive material technologies that are
having a dramatic impact on the industry, providing multiple
benefits to terminal operators all over the world.