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.