Legato® Interlocking Blocks Provide Concrete Results for IMERYS Furzebrook Facility

IMERYS' Furzebrook facility was facing significant operational challenges, as ageing steel columns and wooden sleeper walls were failing structurally. As a result this was causing reduced storage capacity, cross contamination between materials, increased operational risk and higher maintenance costs.

The stored material, dense ball clay, required containment walls up to four metres high, with additional surcharge loads. Further complications included a complex building layout, uneven floor levels and a need for integration with the existing steel frame.

IMERYS engaged RSG Structures, led by Director Gareth Neale, to develop a robust and flexible solution. Their proposal included Elite Precast Legato® interlocking concrete blocks.

The modular blocks offered both flexibility and strength. They were also easy to integrate with steel plates being used where supports interrupted wall lines. Manufactured to 50N/mm² and meeting BS EN 1992-1-1 standards, would also ensure long service life.

The build was carried out in phased construction, enabling IMERYS to keep unaffected areas operational. This minimised downtime and ensured ongoing production.

Gareth Neale, Director, RSG Structures commented - "With Elite Precast blocks I can put designs together for a multitude of different loads, heights, and lengths of walls."

The Results

After completion the following has been achieved:

• Reduced Cross Contamination - Improved separation of material grades

• Higher Product Quality - Enhanced integrity of stored materials.

• Optimised Storage - Greater capacity and ease of handling streamline operations.

• Extended Infrastructure Life - Protection of steel columns from impact damage.

A team effort

• RSG Structures - Project lead & installation

• CLP Structures - Design expertise

• TR King - Steelwork

• Evabuild - Groundworks

• Elite Precast Concrete - Legato® interlocking walling blocks

The IMERYS Furzebrook upgrade is a compelling example of how Elite Precast Concrete's Legato® system, combined with expert engineering and seamless collaboration, led by RSG Structures, can deliver measurable operational improvements. The result is a stronger, safer, and more efficient storage facility, ready to support IMERYS' operations for decades to come.