Blockwalls supports the circular economy by manufacturing concrete blocks from waste stress, then using the blocks for segregation bays

Veolia is a global organisation employing 187,000 worldwide who are tasked with contributing directly to the sustainability performance of customers in the public and private sectors. In the UK Veolia provides a comprehensive range of waste, water and energy management services designed to build the circular economy and preserve scarce raw materials.

The Challenge

As a responsible employer Veolia endeavours to protect and care for the welfare and development of their employees so required a sustainable, practical and safe solution for their waste storage bays at the Essar Oil - Stanlow site. The refinery plays a strategic role in the UK economy, supplying 16% of all road transport fuels. It is also a major regional employer with over 900 staff, an additional 500 on-site contractors and a further 5,000 people employed indirectly through the extended value chain. The solution requires a block that is capable to withstand a relentless hammering of the heavy-duty loaders that move waste materials from one area to another.
Blockwalls specialises in turning waste materials into an aggregate that can be used to manufacture concrete blocks. The idea is to use waste kiln ash from the Essar oil Stanlow site as a fine aggregate to manufacture concrete segregation blocks. This saves the waste going to landfill, therefore assisting the circular economy. A win-win for Veolia and Block Walls

Block Walls support two of Veolia’s Risk Management Values, namely:
• Striving for outstanding health and safety performance in the workplace.
• Identifying and limiting industrial and environmental on-site risks.

The Solution

150 eco-BW600 blocks were delivered and installed in a LEGO-style configuration saving valuable build time. Each block weighs over 1,000 KG and was made from eco-mix concrete consisting of 87% recycled materials, 20% of the eco-mix consisted of the kiln ash as fine aggregate replacement. A number of different mixes were tried and tested at our Bromborough site to ensure the strength and quality of the concrete mix.
The interlocking design and overall weight of the blocks provide a robust and solid bay designed to take the constant impact and pressure exerted from the heavy plant. From a health and safety perspective, the BW600 bay has provided a solid and reliable solution, helping keep the site organised.