Bombardier Aerospace

New Facility For The Manufacture Of Wings For New C-Series Aeroplane

Project Key Facts

  • Project Type - Manufacturing Facility
  • Location - Belfast Harbour Complex
  • Products - Permaban Alphaslide & Quartz Dry - Shake With Surface Sealer
  • Client - Bombardier Aerospace
  • Engineer - Scott Wilson
  • Main Contractor, John Sisk & Son
  • Duration : 3 months
  • Value : £750,000

After a very onerous tendering process, Konfloor Ltd were awarded the contract to install 35,000m² of floor slab to FM1 tolerance at the new Bombardier C-Series facility in the Belfast harbour complex by John Sisk & Son.

As the floor was piled and reinforced with two layers of tied steel the use of our laser screed was not possible, and all the tied steel reinforcement was to be carried continuously through joints. As part of our tender we had to outline how we would achieve the specified floor tolerance & form these joints.

After much thought and deliberation we designed a bespoke joint specifically for the Bombardier project (visible on image to the right) which not only allowed the re-bar to pass through it uninterrupted but also was capable of being adjusted to the exact height, capable of carrying heavy loads & also was retrievable after each pour had been completed allowing re-use throughout the contract.

To achieve the FM1 tolerance we proposed the use of our Razorback truss screed (please see image right) which was met with some reservations. However, when we were designing the bespoke joint to be specifically for piled slabs where the re-bar must be continuous through the joint, it was also designed specifically to carry the truss screed also. We then performed a 180m² trial pour which was surveyed by FACE Consultants and proved compliant with the FM1 floor tolerance requirement.

The floor slab also required a quartz dry-shake to achieve abrasion resistance AR1. This was applied during the power floating stage using a Tremix spreader, and was cured using Permaseal Aquacure applied using a mist sprayer to prevent the appearance of arcing when it had dried.

With the addition of a dry-shake surface hardener the composition of the mix design and in particular the sand became a critical issue. Most concrete suppliers in Belfast and the greater area use lough sand dredged from the nearby Lough Neagh. However, lough sand could not be used on this project as it is too fine and de-lamination issues would arise with the application of a dry-shake. Konfloor were insistent that a pit sand could only be used that met the correct grading curve for compatibility to our preferred dry-shake.

Utilising our bespoke joints and Razorback truss screed we were able to undertake pours of 1,200 m² with 360m³ per pour which was all pumped into place. Before any power floating commenced the floor was bump cut using a highway float to identify any humps or hollows and rectify before the surface of the concrete became too hard. This process was repeated on each individual pour.

The floor was completed in 29 pours over a period of 3 months to suit the construction programme and all to FM1 tolerance with no requirement for remedial grinding.

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