Tailings Management

Concrete Cloth™ (CC) Geosynthetic Composite Cementitious Mat provides a tailings management solution which is fast, easy and cost effective to install. CC has a low alkaline reserve, a low washout rate and a low carbon footprint, characteristics that mean it has been approved for use on large projects by the Environment Agency Biodiversity team.
 
CC has double the abrasion resistance of standard Ordinary Portland Cement and has passed over 200 cycles of freeze-thaw testing with an estimated design life of 50 years in a wet climate. It has been chemically tested according to BS EN 14414 for hydrocarbon resistance, a process involving a 56 day immersion test in a blend of diesel, paraffin and lubricant oil at a temperature of 50°C. CC passed and bend testing proved that many samples actually gained strength following immersion in hydrocarbons.
Ditch Lining

Walter Energy, specified Concrete Cloth™ (CC) GCCM* as a protective liner for a large carrier ditch, directing mining industrial waste water from Willow Creek mine to a nearby settling pond. The lined ditch had to be as water proof as possible, handle freeze/thaw conditions, and be easy to repair. The carrier ditch was 10.5-12 meters wide, between 3 and 5 meters deep and approximately 650 metres long. The overall size, performance requirements of this particular application, as well as the cost potential meant that Ledcor were reluctant to use Shotcrete. The contractors completed the work on schedule in under six weeks, installing over 10,000sqm of CC in a remote site and in difficult weather conditions.
 


Ditch Lining

In September 2012, Concrete Cloth™ (CC) GCCM* was specified to line a tailings containment ditch in the 4th region of Chile. The ditch was needed to ensure that the flow of tailings was directed to specific areas of a dam, resulting in the uniform and safe deposit of sediment. Over 190,000 tons of tailings would pass through the ditch each day, made up of 60% solids, meaning any material used to line the ditch had to have a high level of abrasion resistance. Both Geoweb and shotcrete had been considered for the project, but would require specialist equipment and labor to install. CC could be installed without any specialist labor, training or equipment, ans is proven to have a high level of abrasion resistance during testing, (DIN 52108).


Blow Down Pit

Concrete Cloth™ (CC) GCCM* was used to line a blow down pit at a 250’000 acre oil field in the Middle East, operated by a large petroleum company. Hydrocarbon contaminated water is condensed through pipe manifolds and allowed to collect in an excavated reservoir, referred to as a ‘blow down pit’. Conventional concrete lining of blow down pits involves using in-situ poured concrete and shuttering with re-bar reinforcement. This can typically take anywhere from 9 to 12 weeks, from breaking the ground to completion, depending on the size and accessibility of the site.The speed of install at 3.5 days for the material was significantly faster, with less traffic movement, than using traditional concrete. It was also cheaper and simpler than using traditional concrete.


Ditch Lining

In September 2014, Concrete Cloth™ (CC) GCCM* was used to remediate a drainage ditch at Pogo Mine, Alaska, USA. The ditch prevents surface and storm water coming into contact with the mining tailings field. Due to the location and terrain there are challenges with storm and surface water management. 2 miles of shotcrete lined ditches had been installed in the previous two years. Storm water had undermined the ditch which, with freeze-thaw cycles and heavy rain caused extensive cracking of the shotcrete. CC allowed the installation in weather conditions prevent the use of conventional concrete. Additionally CC will negate the costly maintenance associated with other drainage solutions.


Ditch Lining

In October 2013, Concrete Cloth™ (CC) GCCM* was used to protect two sections of bank that are part of a Dredging Waste Temporary Storage Area (DWTSA) at a landfill site in Northampton. The DWTSA lagoon was constructed on the in situ low permeability clay, which provides secondary containment to the engineered containment structure. The life of the DWTSA is limited because the area in which it was constructed will eventually be excavated to create a landfill void. Concrete Canvas GCCM was specified because of the risk of erosion through tipped debris and minor maintenance trafficking. Furthermore, it will be easier to de-construct and provide a lower mass of material to recover at the end of the lagoon’s life compared to traditional concrete. 675sqm of CC was installed in 5 days.


*Geosynthetic Composite Cementitious Mat



Concrete Cloth Characteristics

 
Concrete Cloth is a flexible cement impregnated fabric that hardens on hydration to form a thin, durable water proof and fire proof concrete layer.

Essentially, it's concrete on a roll Just Add Water.

Easy To Use

Concrete Cloth is available in man portable rolls for applications with limited access or where heavy plant equipment is not available.

There is no need for mixing or measuring, the concrete is premixed and cannot be over hydrated. It will set in fresh and sea water.

Rapid

Once hydrated, Concrete Cloth remains workable for 2 hours and hardens to 80% strength within 24 hours.

Accelerated or retarded formulations can be produced to meet specific customer requirements.

Flexible

Concrete Cloth has good drape characteristics, allowing it to take up the shape of complex surfaces including those with a double curvature. Unset Concrete Cloth can be cut or tailored using basic hand tools.

Hydrocarbon Resistance

CC offers hydrocarbon resistance to BS:14414; based on a 56 day immersion test at 50°C

Strong

The fibre reinforcement prevents cracking, absorbs energy from impacts and provides a stable failure mode.

Durable

Concrete Cloth is chemically resistant, has good weathering performance and will not degrade in UV.

Water Proof

The PVC backing on one surface ensures that the material is completely water proof and chemically resistant.

Fire Proof

Concrete Cloth is a ceramic and will not burn.

CO2 Savings

Concrete Cloth is the only way of laying a thin concrete layer from a prefabricated roll of material.

This enables up to 150 mm of poured concrete to be replaced with just 8 mm for many surfacing applications.

As a result, material savings of 95% can be achieved for a typical construction project.

This directly reduces the CO2 footprint of construction work not only through material savings but also through reduced road transport and time on-site.

Low Wash Out

Concrete Cloth traps dry concrete powder in a 3-dimensional fibre matrix. Testing based on BS8443 to indicate the effect of underwater setting, shows that Concrete Cloth loses only 3% by mass.

By comparison, specialized underwater concretes typically lose between 10-15% while also requiring much larger volumes to be poured.

Alkalinity

Concrete Cloth uses a specialized high early strength concrete with a limited alkaline reserve. Unlike most concretes, it is not classified as an irritant and is less damaging to the environment.

Environment Agency Approval (UK)

Concrete Cloth was approved for use by the Environment Agency (EA) Biodiversity team in 2010 for the Church Village Bypass Project.

Benefits cited included ‘surface roughness to provide diversity in the channel's morphology’ and its ability to introduce ‘sinuosity in the channel line’.

Several projects have since been granted approval on a case-by-case basis and the EA recently purchased Concrete Cloth directly for internal use as a weed inhibitor.

Greening

Untreated Concrete Cloth will naturally ‘green’ over time as the textured top surface allows moss growth, whilst the fibre-reinforced concrete layer will prevent root-growing vegetation, which would otherwise restrict water flow and increase maintenance costs.
 


Nuna Innovations Inc.

Toll Free: 1.855.815.4385
Telephone: 1.604.815.4385
Fax: 1.604.815.0098
Email: sales@nunainnovations.com