WE’VE GOT TUNNEL VISIONCONCRETE PRODUCTS SPECIFICALLY DESIGNED TO PROVIDE BETTER SOLUTIONS FOR TUNNELLING

SHOTCRETE

GROUT

RAPID SETTING CONCRETE

HIGH STRENGTH CONCRETE

FOAM CONCRETE

CEMENT

PFA

HELPING TO BUILD A GREATER BRITAIN HELPING TO BUILD A GREATER BRITAIN

CONTACTSAndrew Bright Dry Silo Manager 07715 160851

Mark Norton National Major Projects Manager 07702 725565

Richard Kershaw National Technical Manager 07703 106348

Christina Ann Mchugh Commercial Development Manager 07879 412627

Map showing locations of CEMEX plants,

the length and breadth of the UK, and the

unparalleled nationwide access this offers.

CONTENTS

INTRODUCTION SHOTCRETE

GROUT SOLUTIONS

CEMEX is a global supplier of building materials with leading

positions in cement, ready-mixed concrete, mortar, screeds

and aggregates.

We believe in building. And building a better future… for all our stakeholders.

That means a commitment to doing things better. From raw materials

supply to pioneering logistics solutions, we have a passion for delivering

quality and value. All backed by industry-leading customer service.

We are also committed to working collaboratively with our customers;

partners and communities to ensure our innovative solutions are more

sustainable and more socially responsible.

CEMEX – Balancing the needs of the built environment and the

natural environment.

Shotcrete is concrete that is pneumatically projected onto a surface at high

velocity. It can be impacted onto any type or shape of surface, including

vertical or overhead areas.

CEMEX has developed a design process for shotcrete using a silo solution.

The blend of separately controlled aggregate sources produce a product

with an ideal grading curve that minimizes rebound and is compliant to the

industry specifications.

» Dry Silo solution for shotcrete - all

materials including admixtures and steel

fibres contained in the silo

» Giga mixer units provided as part of the

solution suitable for mix with outputs of up

to 10.0 m3 per hour

» Water content calibration calculated

based on material flows/specification per site

» Remote silo monitoring of materials linked

to customer PC by web based application

» ISOVEYOR container logistic solution

for road and rail from manufacturing plant in

Doveholes in Derbyshire

» Logistics centre in East London for

deliveries of final product

» Technical support by CEMEX and

TAM admixture

CEMEX has developed a range of piling mixes in silos to meet the needs for

piling and grouting contracts in the UK today. CEMEX products are suitable

for small and large diameter cast in-situ piles, which are frequently used as

an economic way of constructing retaining walls.

CEMEX can also produce specialist grouts using designed applications

such as ground heat source containment grouts. The unique formulations

are capable of grouting at high pressure and flow avoiding potential

washout below the water table.

ADVANTAGES OF GROUT SOLUTIONS

FROM CEMEX

» Soft and hard piles designed on a

maximum 500 mm flow to DC2

ground conditions

» Highly flowing grouts capable of

placement up to 40 bar pressure

» Cementitious solutions

» Can include specialist admixtures such

as corrosion inhibitors

» CEMEX have worked with specialist

drilling companies who can offer their

services for drilling and placement

APPLICATIONS

» Tunnelling operations

» Foundations and piles in primary and

secant piles

» Fills such as backfill to segment

construction

» Containment grouts on ground source

heat pump installations

APPLICATIONS

» Tunnelling-sprayed applications for

primary, secondary and regulating layers

» Embankment stabilisation

» Mine stabilisation

» Shaft construction

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SHOTCRETE

GROUT SOLUTIONS

RAPID SETTING CONCRETE

HIGH STRENGTH CONCRETE

FOAM CONCRETE

CEMENT

PFA

BESPOKE SOLUTIONS: LEE TUNNEL

FOCUS ON HEALTH AND SAFETY

FOCUS ON SUSTAINABILITY

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CEMEX have a number of key products suitable for the tunnelling industry:

ADVANTAGES OF SHOTCRETE FROM CEMEX

ADVANTAGES OF MICROTECH

» High impact and abrasion resistance

providing extremely durable surfaces for

paving and flooring applications

» High strength concrete suitable for use in

heavily loaded applications

» Higher flexural strength than conventional

concrete allowing reduced design

thicknesses for floors and paving

applications

» High early strength allowing rapid access

to the finished structure

» Easy to place and finish with standard

placing techniques

» Enhanced resistance to high temperatures

The technology used in the formulation of CEMEX MicroTech ensures a

high strength, low permeability concrete with enhanced resistance to

sulphate and chloride attack.

Coupled with increased levels of flexural strength and improved resistance

to impact and abrasion, CEMEX MicroTech is the high performance

concrete that will deliver in the most challenging of environments.

In an ever more demanding and extremely competitive environment, with

tight deadlines and even tighter margins, speed and efficiency are critical.

Promptis, from CEMEX, is a new rapid hardening concrete solution that

can help save valuable hours.

ADVANTAGES OF PROMPTIS

» Formwork can be stripped after 6 hours

» Rapid construction programmes are

easily achieved

» Ultimate design strengths are normally

achieved in less than 7 days

» Faster slip form casting times

» The concrete is easy to compact

and finish

» Concrete strengths of up to 40N/mm2

are achievable at just 24 hours

» Concrete poured in winter achieves

the required strength faster to avoid

frost damage

» Promptis can be designed to achieve a

range of end performance characteristics

FOAM CONCRETE

CEMENTHIGH STRENGTH CONCRETE

APPLICATIONS

» Fast demolding in buildings: columns,

walls, beams, slabs, panels and in civil

engineering: high walls, tunnels, roads

» Easy handling – in precast facilities: beams,

panels, specific elements

» Renovation and repair – an ideal solution

where there is limited time to carry out

renovation or repair of structures, slabs or

pavements in a wide variety of applications

APPLICATIONS

» Transport infrastructure

e.g. bridges and tunnels

» Airfields

» Nuclear plants

» Sea defence work

» Effluent treatment plants

» Chemical works

» Recycling centres

» High rise buildings

» Scrap yards and metal handling facilities

» Petrochemical installations

» Ports, dockyards and container

handling facilities

RAPID SETTING CONCRETEADVANTAGES OF FOAMED CONCRETE

» Lightweight (foamed concretes with

densities as low as 300kg/m3 can be

manufactured

» Thermally insulating

» Sound absorbing

» Self-levelling/compacting

» Fire resistant

» Easily re-excavated

» High production rates achievable

» Pumpable

» Good frost resistance

APPLICATIONS

» Fills – e.g. mines, basements and

underpasses

» Trench reinstatements

» Light weight floors and roofs

Foamed concrete is a versatile

solution for fill applications where a

product is designed for a particular

density and strength.

This product is supplied at a lower density than

conventional concretes and placed in difficult

locations where access is difficult and flow is

important. The product can be supplied as a

finished foamed concrete in a truck mixer or a

base mix which is the foamed by a specialist

foam producing company.

CEMEX provides high-

performance, innovative

cementitious solutions to be

the best for customers evolving

needs, drawing on our market-

leading customer service,

technical expertise & logistics

capability.

ADVANTAGES OF CEMENT FROM CEMEX

» Consistency of product

» Third party accredited factory

produced products

» High early strengths

» Consistent chemistry

» Superior levels of service

BULK CEMENTITIOUS SOLUTIONS

CEMEX is proud to manufacture a wide range

of British cements from three UK factories

at Rugby, Warwickshire; South Ferriby,

Lincolnshire and Tilbury, Kent, using locally

quarried materials and additives

CEM 1 (CEMEX Portland)

(Portland cement BS EN 197-1 - CEM I 52,5 N)

CEMEX Rapid

(Portland cement BS EN 197-1 - CEM I 52,5 R)

CEMEX CEM 2 (CEMEX Extra)

(Portland-fly ash cement BS EN 197-1 - CEM

II/B-V 42,5 N)

CEMEX PACKAGED CEMENT

CEMEX is a world leader in packed cement

and other related products. The Rugby brand

is backed with excellent technical expertise in

blended cements and fly ash for more than

20 years.

Rugby Cement Range

Rugby PREMIUM CEMENT

Rugby CEMENT

Rugby SULFATE

Rugby HIGH STRENGTH

Rugby FAST SET

Rugby WHITE

Rugby HYDRATED LIME

CASE STUDY: COMBE DOWN MINES

CEMEX provided 100,000 tonnes of

cement and sand, which was mixed in

a site plant to produce a base mix, to

fill the underground caverns at Combe

Down Mines in Bath.

Propump then foamed the material into a

low density foam suitable to fill the total

6.22 hectare underground area.

The caverns were formed after stone

had been quarried in the 17th and

18th centuries. If the fill had not been

completed there was a danger of the

ground, supporting a 760 strong property

housing site, collapsing into the caverns.

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FOCUS ON HEALTH AND SAFETY

FOCUS ON SUSTAINABILITY

CEMEX has a global framework for health and safety and a detailed UK policy aligned to UK standards.

CEMEX operates to a target of zero injuries and

does not accept unsafe working practices that

could cause accident or ill health to any of our

workers or any member of the public directly

affected by our activities.

Accident prevention, safeguarding employee

health and environmental protection are an

integral part of our company policy. CEMEX

instils into all employees that there is no

production need, competitive advantage, cost

or timesaving measure that is worth an injury of

any kind to any person.

Health and safety is an everyday concern and

should be reflected at all times in employee

behaviours. CEMEX has extended this

commitment to safety beyond the organisation

and is involved with a number of public

initiatives to improve safety and awareness.

CEMEX ensures that products are safe to

transport, store, handle, use and dispose of.

However, some products may carry risks to

people’s health and safety if the appropriate

precautions are not taken.

To prevent such risks, CEMEX has a range

of product safety sheets, which outline any

main hazards and precautions that should be

taken when handling these products. These

are available on request or can be downloaded

from the website.

CEMEX has the best accident rate in the

industry and has won several industry health

and safety awards including the John Crabbe

Memorial Trophy for excellence in health and

safety.

CEMEX is a positive force wherever we undertake our work.

Our philosophy is to continuously improve our sustainability and engage with people inside and outside the business by investing in sustainable initiatives and charities throughout the UK.

CEMEX is committed to sustainable

development and recognises that our success

depends not only on the quality of our

products, service and financial performance,

but also on the way we meet our health, safety,

environmental and social responsibilities.

CEMEX’s environmental record is one we are

proud of as we continue to develop ways to

further enhance our commitment to sustainable

development. Each year the CEMEX Group

produces a global sustainability report detailing

past and present initiatives and successes, as

well as setting future challenges.

Across the UK, CEMEX is committed to

ensuring actions and decisions taken today

do not adversely affect the generations

of tomorrow.

The following are seen

as key areas that we address

to ensure sustainability:

» Management of

Natural Resources » Reducing Energy

Consumption » Reducing Emissions » Biodiversity » Respect for People

RESPONSIBLE SOURCING

All CEMEX products have achieved very good

status under BES6001 the code for responsible

producers. CEMEX has established a

sustainability policy that will continue to improve

our performance and help us achieve our

business goals. Through strong leadership and

organisational cultural change we are working

to improve all areas in our ‘sustainability wheel’.

BESPOKE SOLUTIONS: LEE TUNNEL

PFA

CEMEX provides custom-made solutions for London sewage system

Earlier this year CEMEX provided custom

ready-mix concrete and its industry-leading

logistical expertise for one of the five shafts

for the Thames Water Lee Tunnel project in

Beckton, Greater London. The pour was one of

the longest continual slipform pours in Europe,

spanning 29 uninterrupted days, to avoid the

creation of joints that would compromise the

shaft’s structural integrity.

The Lee sewage tunnel is first of two tunnels

which will capture an average of 39 million

tons of London’s sewage and by itself prevent

more than 16 million tons of sewage mixed

with rainwater overflowing into the River Lee

each year.

Three cranes were used to deliver 11,000

cubic meters of concrete to three skips to pour

into the 80 meter deep shaft. The concrete

was designed specifically for this project’s

demanding requirements and also contained

500 tons of steel fibre as reinforcement.

“This was a tremendous achievement with nine

concrete mixes of different levels of retardation

supplied on a regular and continuous basis

to form an integral part of this vital structure.

The materials have been developed using the

latest technology and challenge our expertise,

to ensure that we can meet the structural

requirements of the tunnel,” said Chris Leese,

Vice President, CEMEX UK Readymix.

FACTS AND FIGURES

» Largest construction site in Europe

» 11,000m3 continuous pour

» 24/7 for 29 days

» Largest single pour by CEMEX UK

» Complex mix requirements

» 45kg/m3 of steel fibre

» Slump retention for two hours

» Multiple levels of retardation to address

ambient conditions

Pulverised Fly Ash is the fine ash produced at coal-fired power plants

that develops cementitious properties when mixed with cement and water.

Widely used in the UK to increase the strength of concrete, fly ash is also

used to improve workability of fresh concrete and reduce water demand,

shrinkage and permeability of the finished product.

ADVANTAGES OF PFA

» Increases the strength of concrete

» Improves the workability and

cohesiveness of fresh concrete.

» Reduces water demand, shrinkage and

permeability of the finished product.

» As it is a waste product, which would

otherwise go to landfill, fly ash can

significantly reduce the carbon

footprint of concrete.

» It is viewed increasingly as a vital

ingredient in low-carbon blended

cements such as CEM II

APPLICATIONS

» Tunnelling

» Shotcrete

» Grouts

» Segments

» Ready-mix concrete

» Concrete block, paving and pipe products

» Blended cements eg CEM II

» Soil stabilisation

» Structural fill

» Waste stabilisation/treatment

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