The O鈥橩eefe Group is using cement stabilisation techniques to prepare the site of a decommissioned power station for its redevelopment as a container storage facility for the Port of Tilbury.聽
Known as Tilbury2, the new 拢200m port terminal, which is adjacent to the existing 930-acre site in Thurrock, will become the UK鈥檚 largest unaccompanied freight ferry port and the country鈥檚 biggest construction processing hub.
O鈥橩eefe is working on the part of the site located on the north bank of the River Thames at Tilbury. The area was previously part of a coal-fired power station that was taken out of commission and finally demolished in 2017.
Now, principal contractor Graham is transforming this part of the development into a storage facility for containers at Tilbury2鈥檚 roll-on/roll-off container terminal.
The extensive brownfield site, covering approximately 250,000m2, must be levelled and compacted to a 30% CBR value before a layer of quarried type-1 aggregate can be laid as a base for the final reinforced concrete paving slab.
The task is complicated by the presence of numerous underground structures, namely concrete foundations that supported the now-demolished buildings.
鈥淲e are excavating all the obstructions and crushing them down for reuse as aggregate,鈥� says O鈥橩eefe鈥檚 contracts manager Brian Doogue. 鈥淭hat material is then used to back-fill drainage and service trenches.鈥�
Ground conditions on the site are very variable and O鈥橩eefe is using a fleet of specialist machines to treat the soil and produce a consistently stable base.
The main technique being employed is cement stabilisation which involves mixing cement powder with the soil in-situ. Once incorporated and evenly mixed into the soil, the cement cures, effectively stiffening the soil and increasing its bearing strength.
鈥淪oil improvement and stabilisation is especially useful at this time of year when the weather鈥檚 bad and aggregate stockpiles are getting low,鈥� says Doogue. 鈥淎 major advantage of the process is that by improving the existing soil, you don鈥檛 have to take so much of it off-site.聽
鈥淲e use it frequently for all sorts of applications, such as piling mats and to create sub-base for car parks, roads and cut-and-fill earthworks,鈥� he adds.
O鈥橩eefe operates three German-made Wirtgen soil stabilisers 鈥� highly-specialised machines that work rather like enormous rotavators to mill the soil while mixing the cement into it. Once the Wirtgen machines have done their work, the ground is levelled and compacted using a Cat D6 dozer.聽
All three of O鈥橩eefe鈥檚 Wirtgen mixers are of the integrated type 鈥� that is, they spread the cement or lime binding agents and simultaneously mix them into the soil as they travel over the site.聽
A simpler method is to spread the binding material over the site first, and then use a tractor-towed stabiliser to mix it into the soil.
Integrated mixers are very expensive pieces of kit, but they give better results, says Doogue:聽
鈥淲e only use integrated mixers because they鈥檙e more efficient and better for the environment. An integrated mixer mixes the cement powder into the ground as it goes; if you鈥檙e spreading cement powder over a site before you mix it in, the wind can often blow it around.鈥澛�
This is not only messy 鈥� and potentially hazardous 鈥� but also wasteful and can deliver inconsistent results, explains Doogue.
鈥淭he main advantage of soil stabilisation on this project is that it has allowed Graham to use site-won material and import less aggregate,鈥� he says.
Alongside the Wirtgen soil stabilisers is a fleet of 30-tonne tracked excavators, fitted with breakers and pulverisers, which are used to dig out and break up the buried concrete. This is then fed into a Pegson crusher which processes it into another source of reusable aggregate.
The company started work on the site in April 2019 and is on schedule to hand it over to Graham this month.
How it works
Soil stabilisation uses a combination of mechanical and chemical processes to transform a poor, weak soil into a granular material that can be compacted to a known strength and used for structural purposes.
The fact that this is done in-situ has obvious cost and efficiency benefits. In some cases it can even be used to process contaminated soil for reuse, cancelling the need to remove it from site for disposal at significant cost elsewhere.
However, cautions O鈥橩eefe鈥檚 Brian Doogue, 鈥渢he whole point of this method is that you鈥檙e technically improving the ground. It鈥檚 not a cure for contamination. That鈥檚 a completely separate activity鈥�.
In heavy clay soils, lime is mixed into the ground first. As it hydrates, it removes water from the soil allowing it to be reduced to a friable material. Cement is then mixed into the soil to complete its transformation into a stable, granular material.
The process, dependent on both chemical and mechanical processes, needs to be carefully managed, says Doogue:
鈥淲e go to site and collect soil samples which then go to our in-house laboratory in Borough Green where we produce trial mixes. The samples are then sent to a UKAS-accredited lab where they are tested for organic matter and sulphates so we can ensure that it is suitable for stabilisation.鈥�
This technique is now widely used to improve soils in all sorts of applications where it is deemed advantageous from an environmental, cost or practical point of view.聽
Although primarily employed as a means of improving soils in-situ in order to improve stability and bearing strength, it is also a useful way of improving excavated material for reuse.
This article was first published in the聽
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