Project Location: W2R, Thornton Site (Formerly ICI Site)

Posted on in the category Concrete Repair, Utilities, Corrosion Protection, New Build Construction.

Concrete Reinstatement for Honeycombed Concrete Walls

Reinstating Honeycombed Concrete Walls at Waste Processing Plant


This state of the art £125m waste processing plant has been built in Thornton Cleveleys in Lancashire on the site of the former ICI works by W2R, a partnership between Bovis Lend Lease and Australian firm GRD Minproc Ltd, on behalf of Lancashire Waste Partnership.

It will process waste from Blackpool and the Fylde Coast and is looking to recycle up to 90% of the material received. Problems were experienced when pouring the concrete, which form the walls to the reception bunkers resulting in large voids and areas of honeycombing.

The Solution

Specialist contractor Ram Services proposed a range of CE Marked Products from Flexcrete to reinstate the concrete and ensure the design life is achieved. Areas of honeycombed concrete, voids and blow holes were first filled with Monolevel FC a Class R2 fairing coat. Cemprotec E942, a two component cement and epoxy modified polymer coating complying with EN 1504-2, was applied by spray in 2 x 1mm to all the concrete surfaces to give a durable, abrasion and chemically resistant finish.


Global Renewals & Lancashire County Council Joint Venture


Barhale Construction / RAM Services Limited