P.A. Gascoigne, fixed maintenance contractor at one of Alcan’s aluminium smelting plants, needed to replace the floor slabs in a crucial part of the production line. The use of Toproc Rapid as the in situ replacement for the floor slabs more than halved the period of production downtime at the Alcan plant.
The ultimate early strength concrete
Tarmac Toproc Rapid delivers a range of concretes that provide both rapid setting and high early strength properties resulting in increased turnaround and productivity.
Toproc Rapid is as easy to place as conventional concrete and develops high strength soon after pouring. Unlike other concretes that require between 12-20 hours before formwork can be removed, Toproc Rapid becomes effective in as little as four hours allowing construction to continue.
A range of ready-formulated Toproc Rapid products are available to meet all different types of strength requirements, with setting times ranging from 4 hours to 48 hours.
To view our study that quantifies the use of special concretes including Toproc Rapid in multi-storey and high rise construction projects, please click here.
Less disruption and cost penalties
Attains strength within hours, a crucial consideration when early trafficking is necessary and delays can incur severe financial penalties.
In relation to the rotation of formwork Toproc Rapid 4hr can double the number of daily rotations for walls, columns, slabs on grade and grade beams, significantly reducing project length.
Easy to place
Toproc Rapid is as easy to place as conventional concretes, meaning minimal effort to the contractor.
More flexible construction schedules
Users can choose the specific time the guaranteed early strength is achieved i.e. 24 hours or 48 hours, enabling them to make up lost programme time due to weather, breakdowns etc. This is essential in time critical projects.
Bespoke concrete solutions
To offer further cost and value engineering benefits, Toproc Rapid can also be combined with macro fibres to replace A grade crack-control mesh, providing a very robust concrete solution.
Significant time is saved optimising building processes on all construction sites.
Toproc Rapid works with innovative accelerating systems, enabling good durability, performance and acquisition of long-term strength.
Toproc Rapid achieves both high early strength and high ultimate strength, providing a very durable concrete.
- Car parks
- Access roads
- Floor areas
- Rail networks
- Water control structures
By using Toproc Rapid 48hr the client completed the work on schedule and within a much faster time frame compared to traditional concrete. The newly poured hardstands were able to be trafficked much faster, resulting in a significant reduction in both downtime and subsequent production losses.
The foundation pad for the turbine was successfully poured with Toproc Rapid 48hr. There were no construction joints and the concrete reached the specified strength within two days of pouring. This ensured the project was on schedule and allowed the first stem installation as planned.
A solution was needed to speed up the construction work at the entrance to Loughborough University, a project comprising four buildings covering a total area of 5,900m2 of mixed office and storage space.
The project was a tall order in more ways than one. A 65m control tower to replace the existing one at Manchester Airport, making it the second highest in the UK. The main circular shaft required a 24-hour continuous pour to ensure the shutter levels rose at an optimum rate of 300mm/hour throughout the project.
A precast concrete manufacturing company, specialising in the rail market had been using the same concrete mix for nearly 20 years without any issue in terms of workability, finish and overall strength. Compared to the existing mix, Toproc Rapid offered a time saving as it provided a stronger product in a shorter time frame, as well as being an overall more consistent product.
Tarmac were contacted by the contractor to become involved in the road’s re-instatement and develop a long-term solution.
Following detailed consultation with Sykes House Farm to establish the exact time constraints, strength requirements and aesthetics of the project, Tarmac experts advised the use of Toproc Rapid 48hr.
Toproc Rapid 15hr was developed as a bespoke solution for this project to offer high early strength of 10N at 12 hours, which enabled strip shuttering to happen on the same day and considerably reduced overall construction time.
The required strength for the lintels was 50N/mm2 at 48 hours and Tarmac’s Toproc attained the desired strength comfortably. It achieved 50N/mm2 after just 36 hours and went on to achieve 90N/mm2 after 28 days providing the necessary support and ensuring that deadlines were met comfortably.
When an existing road surface surrounding the train track needed repair work, Tarmac were approached to help supply a solution that would gain sufficient strength in a short window of time to enable these vital links to be quickly back in use.
Manchester Airport required an existing taxiway (Taxiway Juliet) to be replaced with a new concrete slab.