FAQs

This section is design to help answer any questions your may have about our products. However we are more than happy to help so please contact us to discuss your requirements further.

Most Commonly Asked Questions

  • What is prestressed concrete?

    The term "prestressed concrete" (also known as pre-tensioned concrete) means that wet concrete is poured onto steel strand which has been tensioned.

     

    The concrete adheres and bonds to the strand and after it has reached the required strength the tension is released.  This tension is transferred to the concrete as compression by static friction.

     

    This gives the panels additional strength and enables them to flex under load without detriment.

     

    Manufacturing using long-line moulds gives economies in the labour required for production and, therefore, cost benefits to our customers.

  • What is precast concrete?

    Precast concrete is the process where concrete is placed in moulds off-site under controlled conditions. The concrete is cast around steel reinforcement bars which add strength to the product.  It offers significant benefits over in-situ cast concrete due to the additional control over the concrete mix used, casting conditions and performance.

  • What is CE Marking?

    How do we mark our products?

    As of 1st July 2013, the Construction Products Regulations (CPR) required producers of construction products who manufacture to a Harmonised European Standard to CE mark their products. In our case, our precast concrete wall panels, floors & stairs are manufactured to Harmonised European Standards and therefore are CE marked.

     

    All necessary information required for CE marking compliance to the CPR is available in our CE Certification section.

     

    What is CE Marking?

    To put a very complex issue simply, CE marking is a European standardised way of informing the customer of key technical and physical properties of the products they are using. This includes any safety information and is intended to enable the user to gain exact comparison of information between manufacturers as well as be assured that the CE marked products comply with all necessary performance standards.  .

     

    As such, we as manufacturers must declare all necessary technical, physical and performance criteria in the same manner as prescribed by the CPR and Harmonized Standards. This information must be made available freely to the customer and to the public and be maintained and kept updated at all times by the manufacturer.

     

    How do we CE mark our products?

    Due to the nature of our products, it is not possible to CE mark the precast products themselves,  therefore we are adhering to the industry-wide standard method of:

     

    • Including the necessary CE information on delivery tickets accompanying our product to site, the customer or to the builder's merchant.
    • The CE information on the delivery tickets instructs the user to visit this section of our website.
    • In this section, all certificates and required CE documentation for our products are available for free download.

     

    Where to find information?

    • The basic CE marking information is shown on our delivery tickets accompanying product sent to sites, directly to customers or to builder's merchants.
    • All CE certificates and Declarations of Performance for all our concrete block products are available to download for free as single-page pdf's. (see below)
    • Any other related information, updates and advice will be found within this section.

  • Prestressed Concrete Floors

    • What sizes are available?

      Block and Beam Prestressed Floors

      At ACP (Concrete) Ltd, our prestressed concrete floor beams are manufactured in a range of sizes to suit various spans and loads, providing flexible and tailored solutions to suit each application. Beam spacing can also be adjusted to suit anticipated loads.

       

      150mm Concrete T-beams

      The 150mm Concrete T-beams are suitable for a wide variety of concrete floor construction such as domestic house floors, flats, nursing homes and commercial developments., Click here for more detailed specification.

       

      215mm Concrete T-beams

      Our 215mm Concrete T-beams are designed for prestressed concrete floors subject to greater loads and larger unsupported spans. Click here for more detailed specification.

       

      Click here to view more information about Block and Beam Flooring

       

      Wide Slab Prestressed Flooring

      At ACP (Concrete) Ltd, our Wide Slab Flooring are manufactured in standard 1200mm wide concrete floor slab maximising transport efficiency and are available in 150mm or 200mm depths.

       

      There also are also available as solid, 3 or 5 poly core floor slabs. The polystyrene core system reduces unit self-weight, increasing safe spans.

       

      Click here to view more information about Wide Slab Flooring

    • How much camber in beams?

      Block and Beam Prestressed Floors

      Units will have a prestressing camber. Camber variation between adjacent units will not exceed length / 250 (in mm).

       

       

      Wide Slab Prestressed Flooring

      Units will have a prestressing camber. Chamber of floor beams to be as detailed in clause E4 of BS EN 15037-1:2008.

    • What loads can be supported?

      A wide variety of different loads can be supported using our products including block walls and point loads, these loads are usually individual requirements and as such would require specific calculations to be produced which is part of our free design and quotation service, please contact the office for more information/assistance.

    • Is a damp-proof course (DPC) needed?

      At ground floor level a damp proof course is required please contact your local building control officer for further details.

    • Is a membrane needed over the floor?

      A membrane is not always required however please contact your local building control officer for advice on this.

    • What infill blocks should be used?

      ACP (Concrete) Ltd's concrete floor beams are ideal for use with standard 440 x 215 x 100 concrete blocks in 7.0N/mm² compressive strengths which are available from Thomas Armstrong Concrete Blocks.

    • What is the fire rating of the beams?

      Our Beams and Wide Slab units have a 30 minutes to 90 minutes rating depending on application.

    • Does it require air ventilation?

      A minimum of 150mm void is required between the underside of the beams and the ground underneath to help air flow and prevent damp issues. Air vents should also be in place.

    • At what stage do I install the ceiling clips?

      Ceiling clips should be installed after the beams have been placed in their final position and the infill blocks have also been installed BUT prior to any grout or floor finish has been applied. For more help please call the office for advise.

    • Is Block and Beam flooring suitable with underfloor heating systems?

      Yes under floor heating systems are very achievable when using beam and block flooring and beam and insulated flooring systems, please advise our staff that this system is being using when sending your enquiries in so we can ask any relevant questions in connection with your project.

    • How is the flooring installed?

      To view the installation process click on the link below

       

      Block and Beam Short Animation and Block and Beam Step by Step Installation Guide

    • What type of grout do I need to use?

      A wet grout system (1:4, cement:sand) can be used to bond the block and beam floor beams together prior to installation of insulation and floor finishes.

       

      A sand/cement screed can be applied to the grouted block and beam flooring system for a robust finished floor or base for ceramic floor finishes. Openings within the floor for service ducts and pipes are easily and cheaply included in the scheme.

       

      Wide Slab Flooring only

      For Wide Slab Flooring  it is a C35 concrete mix not sand and cement like Beam and Block.

    • How are the floor panels delivered?

      Usually deliveries are quoted on flat articulated vehicles with 13 mtr trailers although other vehicles are available on request.

       

      Our products are loaded onto the trailers with timber bearers separating each row to allow for offloading by forklift trucks or using chains depending on the product, please speak to one our staff to confirm the method for your particular product requirement.

       

      Please highlight to our sales team if you require a different vehicle from the one above prior to pricing.

    • What is lead-in time?

      Lead-in periods are product and order take dependant please contact our office to discuss our current timescales.

    • Do you provide a Design and Installation Service?

      At ACP (Concrete) Ltd, we also provide a design and installation service to ensure that your project is designed to the highest standard and provides a cost-effective fit for purpose solution.

       

      Our dedicated in-house team will work closely with you to ensure the final solution meets your specific requirements.

       

      Please contact us for more information.

  • Precast Concrete Stairs and Landings

    • Do you manufacturer stairs with landings or just landings?

      We supply Individual steps, separate Stair flights, Flights with Attached landings and separate landings depending on your needs.

       

      Click on the link to view more information on our Stairs and Landings.

    • What types of stairs do you manufacture?

      There are many different variations in terms of shape and size available please call our team to learn more.

    • Can the stairs / staircases fit with your precast flooring systems?

      Yes we can offer an installation service separately or in conjunction with a flooring system installation.

    • How can the concrete stairs be finished?

      Please contact our office for advice.

    • Can you add lights into the staircase?

      Please contact our office for advice.

    • Do the precast stairs comply with building regulations?

      The responsibility of ensuring that the stairs comply with building regulations is not in our remit however we would always do our best to advise if we thought a customers design did not comply or the makeup of the arrangement was floored in any way.

    • What loads can be supported?

      There are various loads that can be supported by our Stairs and Landings depending on the design please call the office for further information.

    • How are the stairs installed?

      Please contact our office for advice.

    • How do you seal the joints?

      Please contact our office for advice.

    • What is the buying process of purchasing precast stairs?

      Drawings would be required for pricing where we would itemise the required components and price accordingly, if the price is within your budget we would require a purchase order number or letter of intent and we would then produce design drawings for customer approval.

       

      Once the drawings have been checked and approved by the customer or Architect and Engineer we would send the information to our production team for manufacture.

    • Do you hold any precast stairs in stock?

      All Stairs are made to order and specific to the individual project.

    • What is lead-in time?

    • How are the precast stairs delivered?

      Prices are based on delivery using Flat/Curtain-sided Articulated vehicles with 13 meter trailers, if you require a different vehicle size please state this as pricing stage.

    • Do you provide a Design and Installation Service?

      At ACP (Concrete) Ltd, we also provide a design and installation service to ensure that your project is designed to the highest standard and provides a cost-effective fit for purpose solution.

       

      Our dedicated in-house team will work closely with you to ensure the final solution meets your specific requirements.

       

      Please contact us for more information.

  • Precast Concrete Walls

    • Heavy Duty Horizontal Walls  +

      To view more information about our Heavy Duty Horizontal Wall product, click here.

      • What sizes are available?

        The panels are used in combination to achieve the desired overall wall height i.e. 3.6m high use 3 x 1.2m panels.

         

        The tongue and groove joints ensures that the panels sit neatly onto one another. It also allows the stored material i.e. grain/silage load to be shared from the bottom to the top of the wall.

         

        Double Loading panels are available for division walls.

      • What Size Panels Do I Need?

        This is where our expertise is helpful, give the sales office a call to discuss your requirements or to view more information about our Heavy Duty Horizontal Walls, click here.

         

        For Silage:

        The following questions will help to determine the answer.

        • How many tonnes & what crops need to be stored?
        • How many cuts or crops need to be ensiled?
        • What is the feeding strategy for the stored silage? Length of the feeding period? How much required per day?
        • Site restrictions ie. Proximity to watercourses/overhead power lines?

      • Which Thickness Do I Need?

        This is where our expertise is helpful, give the sales office a call to discuss your requirements or to view more information about our Heavy Duty Horizontal Walls, click here.

         

        For Slurry

        The wall panel thickness which is most suitable depends on the following factors:

        • Length of the bay
        • Overall height of the wall

         

        See the table for more information on HDHP Agriculture Slurry Loading Table

         

        For Grain

        The wall panel thickness which is most suitable depends on the following factors:

        • Length of the bay
        • Overall height of the wall
        • The storage type – Level Fill or Surcharged (heaped up)
        • If grain drying equipment are required i.e. stirrers

         

        See the table for more information.

         

        For Silage

        The wall panel thickness which is most suitable depends on the following factors:

        • Length of the bay
        • Overall height of the wall
        • Weight of the vehicle rolling the clamp

         

        See the table for more information, HDHP Agriculture Silage Loading Table.

         

        For King Post - Earth Retaining

        The type of wall panel required depends on the following factors:

        • The span between the piles.
        • Overall height of the wall.
        • Anticipated surcharge loads.

         

        See the table for more information, Kingpost Retaining Wall Panels.

         

        For In Building - Earth Retaining

        The type of wall panel required depends on the following factors:

        • Length of the bay
        • Depth of the retaining wall
        • Overall height of the wall and it’s purpose ie. Non load bearing  or storage building
        • Anticipated surcharge loading on the floor of the building ie stored material, machinery etc.

         

        See the table for more information.

         

        For Biomass

        The type of wall panel required depends on the following factors:

        • Length of the bay
        • Overall height of the wall
        • Storage properties of the biomass material to be stored ie. bulk density & angle of repose

         

        See the table for more information.

         

        For Waste / Push Walls / Bulk Stores / Recycling Bunkers

        The type of wall panel required depends on the following factors:

        • Length/span of the bay
        • Overall height of the wall
        • Storage profile ie. level fill or surcharged
        • Bulk density of stored material & angle of repose
        • Impact loads – Often the impact loads from outloading vehicles are greater than the stored product load. To calculate the impact load we need to know the machine to be used, the bucket size and the maximum speed allowed.

         

        See the table for more information.

         

        For Firewalls

        The type of wall panel required depends on the following factors:

        • Fire rating required.
        • If the wall is to be dual purpose, ie Firewall & retaining wall, then the length of the bay, overall height of the wall and the type of material to be stored need to be considered.

         

        See the table for more information.

         

      • What do the wall panels sit on?

        There are two options:

         

        Option One:

        The panels may bear onto ‘landing cleats’ welded/bolted onto the steel columns with the floor subsequently laid up to the panels.

         

        For Silage/Biomass: If desired the landing cleats can be sited just above the floor to allow the effluent to drain into the outside channel.

         

        For In-building Earth Retaining Walls: Sockets can be cast in at the top of the panels to receive threaded bars for tying into the floor slab.

         

         

        Option Two:

        The panels sit on the concrete floor with a compressible bitumen strip underneath the bottom panel to form a watertight seal.

         

        For In-building Earth Retaining Walls only:

        The above floor level panels can either continue up in line with the floor retaining panels using the tongue and groove joint to keep the panels in line and share the load up & down the wall. Or alternatively they can sit on the concrete floor with a compressible bitumen strip underneath the bottom panel to form a watertight seal.

         

        For Firewalls:

        The panels may sit on the concrete floor with a compressible firestop strip underneath the bottom panel to form a seal. The floor must be designed to take the full line load of the wall panels.

      • Do the panels need to be allowed to flex?

        Prestressed concrete panels are designed to flex under load and it is essential to ensure that the panels are not prevented from flexing.

         

        For Grain: Prestressed concrete panels are designed to flex under load, and it is essential to ensure that the panels are not prevented from flexing and to ensure that the bottom panel is not ‘trapped’ in concrete. Use a compressible strip behind the bottom panels to permit them to flex.

      • How are the wall panels delivered?

        Delivery is on 40’ articulated vehicles, usually curtain siders unless requested otherwise. The wall panels will require off-loading with a forklift, telehandler or a crane.

         

        The panels should be stacked on firm, level ground and separated using the stacking timbers provided.

         

        These should be placed on the panels in accordance with the stacking drawing.

      • How are the panels installed?

        Installation is straightforward using a telehandler or similar farm machinery. The panels are lifted into position using the lifters fitted to lifting inserts located in the top edge of the panels.

         

        For Firewalls please note: The choice of fixing position is dependent on site specific requirements.

         

        With no concrete curing required, installation is largely independent of weather conditions and helps prevent unnecessary delays to your project.

         

        View our Step by step installation guide for more information.

         

        Face Fixed

        Suitable for single side loading only. The panels are clipped to the inside face of the steel columns using the clips and bolts provided with the panels, one at each corner. This fixing system provides a smooth wall face which is easy to clean out and protects the steel columns from damage. It also protects the steel column from contact with the retained materials.

        Fixed between column webs

        For division walls, walls subject to loads on either face or to maximise storage capacity. If possible, the panels are lowered down between the column webs but if this is not possible, because the steel columns are part of a building, the panels can be ‘walked’ into position. The panels are held in position using angle irons bolted into the gap.

      • How are the panels fixed at the Corners?

        The side panels are fixed to the columns in the normal way. At the corners the gable panels are fixed to a corner angle bolted to the side panel using concrete anchors. A stop angle is required to prevent the side wall panels moving.

         

        Alternatively, and particularly for stores over 3m high or high load stores / situations an additional column at the corner is recommended to support the panels.

      • How are the joints sealed to make them watertight / retain content?

        The one-part polyurethane mastic sealant we supply as standard with the panels is applied to the horizontal and vertical joints after the panels have been erected using an applicator gun (if ordered).

         

        Vertical joints should be filled with expanding foam (not supplied) which should then be cut back to give a shallow joint to which the mastic sealant can then be applied.

         

        The mastic requires approximately 24 hours to go off (depending on ambient temperature).

         

        For Firewalls: Intumescent mastic sealant should be used with fire rated expanding foam.

         

        Intumescent sealant should be applied to the horizontal and vertical joints after the panels have been erected using the applicator gun provided (if ordered).

         

        Vertical joints should be filled with appropriate fire rated expanding foam (not supplied) which should then be cut back to give a shallow joint to which the mastic sealant can then be applied. View Everbuild Fire Sealant 400 datasheet.

         

        For Grain: Where the panels are sitting on the concrete floor a compressible bitumen strip under the bottom panel will provide a watertight seal as well as accommodating small unevenness’ in the floor slab.

         

        For Silage: With no concrete curing required, installation is largely independent of weather conditions and helps prevent unnecessary delays to your project. This means that, depending on the clamp size, the time from arrival on the delivery vehicle to fitted with joints sealed and having the clamp ready for filling can be as little as a day or two. However the mastic requires approximately 24 hours to go off (depending on ambient temperature).

         

        For In-building Earth Retaining Walls:  The sealing of the floor to wall requires a hydrophilic preformed strip (not supplied as standard unless part of a design and install package) at least 60mm below floor level and the floor joints need to be sealed in accordance with the floor design.

      • Can you cast in openings?

        Yes, it is possible to cast in openings for ventilation pipes / grain chutes, please ensure you provide us with this information when placing your order.

      • Is Concrete Protection Required?

        Concrete protection is recommended for all concrete surfaces that may come into contact with any aggressive substances or products, such as Silage, Silage or Manure Effluent, Road Salt etc

      • Is additional Fire Protection Required?

        No unless specific requirements are needed. Concrete’s unique fire-resistance properties should provide you with the fire protection required.

         

      • Do I need Effluent Drainage?

        For Silage and applicable to ensiled grass / maize /other green crops.

        A effluent drain must be placed at the bottom of the wall to prevent build up of hydrostatic pressure. Alternatively the landing cleats can be sited just above floor level to allow the effluent to drain into the outside channel.

      • Is it possible to increase the height of the wall at a later date?

        It is possible to increase the height of the wall by the addition of another row of panels at a later date, as long as the post foundations and steel columns have been designed to suit the increased loading.

      • Silage: What Size of Compaction Vehicle Can I Use?

        By law silage clamp design must comply with Water Resources (Control of Pollution Regulations) 2013. These require that all walls must withstand the loads given in BS5502 Part 22 (2003) which has values for  compaction vehicle weights up to 8t and 10t. However increasingly farmers and contractors are using machinery larger than this to compact the silage.

         

        Please contact us if you require a solution for machines over 10 tonnes as we have extensive experience and knowledge to design to meet these requirements.

      • In-Building Earth Retaining Walls: How Do I tie the Floor Slab to the Wall?

        Sockets can be cast in at the top of the panels to receive threaded bars for tying into the floor slab.

      • In-Building Earth Retaining Walls: What happens if I need to use a non-load bearing panel above floor level?

        In this situation we can cast the retaining panels with a flat top. The thinner section panel is then seated on the below ground retaining panel. It is wise to use a compressible strip between them to accommodate any unevenness’s and form a watertight seal.

         

      • Do you provide a Design and Installation Service?

        At ACP (Concrete) Ltd, we also provide a design and installation service to ensure that your project is designed to the highest standard and provides a cost-effective fit for purpose solution.

         

        Our dedicated in-house team will work closely with you to ensure the final solution meets your specific requirements.

         

        Please contact us for more information.

    • 95mm Lightweight Horizontal Walls +

      To view more information about our 95mm Lightweight Horizontal Wall product, click here.

      • What sizes are available?

        The panels are used in combination to achieve the desired overall wall height ie. 2.4m high use 2 x 1.2m panels.

         

        The tongue & groove joint detail ensures that the panels sit together neatly. This joint detail also assists with  fast installation.

      • Is it suitable for deep litter systems?

        Yes, because the tongue & groove joint allows the panels to load share up the wall.  As a general ‘rule of thumb’ the muck build up should be allowed no higher than half way up the total wall height.

         

      • What do the wall panels sit on?

        There are two options:

         

        Option One:

        The panels may bear onto ‘landing cleats’ welded/bolted onto the steel columns with the floor subsequently laid up to the panels.

         

        If desired the landing cleats can be sited just above the floor to allow the effluent to drain into the outside channel.

         

        Option Two

        The panels may sit on the concrete floor. A compressible bitumen strip underneath the bottom panel will form a watertight seal if required.

      • Do the panels need to be allowed to flex?

        Prestressed concrete panels are designed to flex under load and it is essential to ensure that the panels are not prevented from flexing.

      • How are the wall panels delivered?

        Delivery is on 40’ articulated vehicles, usually curtain siders unless requested otherwise.

         

        The wall panels will require off-loading with a forklift, telehandler or a crane. The panels should be stacked on firm, level ground and separated using the stacking timbers provided.

         

        These should be placed on the panels in accordance with the stacking drawing.

      • How are the panels installed?

        Installation is straightforward using a telehandler or similar farm / commercial machinery. The panels are lifted into position using the lifters fitted to lifting inserts located in the top edge of the panels.

         

        View our Step by step installation guide for more information.

         

        Face Fixed

        Suitable for single side loading only. The panels are clipped to the flange of the steel columns using the clips and bolts provided with the panels, one at each corner. This fixing system provides a smooth wall face and protects the steel columns from forklift damage.

        Fixed between column webs

        For division walls or to maximise storage capacity. If possible the panels are lowered down between the column webs but if this is not possible, because the steel columns are part of a building, the panels can be ‘walked’ into position. The panels are held in position using timber packers or angle irons bolted into the gap.

         

        For Security Walls: This option maximises space within the building. The panels are held in position using angle irons bolted into the gap.

      • How are the panels fixed at the Corners?

        The side panels are fixed to the columns in the normal way. At the corners the gable panels are fixed to a corner angle bolted to the side panel using concrete anchors.

         

        A stop angle is required to prevent the side wall panels moving.

      • How are the joints sealed to make them watertight / retain content?

        The one-part polyurethane sealant we supply is to be applied to the horizontal and vertical joints after the panels have been erected using the applicator gun provided (if ordered).

         

        Vertical joints should be filled with expanding foam (not supplied) which should then be cut back to give a shallow joint to which the mastic sealant can then be applied.

         

        The mastic requires approximately 24 hours to go off (depending on ambient temperature).

      • Is it possible to dismantle and relocate the panels at a later date?

        It is possible to dismantle the panels for re-use elsewhere if business requirements alter, particularly useful for tenant farmers.

      • Do you provide a Design and Installation Service?

        At ACP (Concrete) Ltd, we also provide a design and installation service to ensure that your project is designed to the highest standard and provides a cost-effective fit for purpose solution.

         

        Our dedicated in-house team will work closely with you to ensure the final solution meets your specific requirements.

         

        Please contact us for more information.

    • R35 Lightweight Horizontal Walls    +

      To view more information about our R35 Lightweight Horizontal Wall product, click here.

      • What sizes are available?

        Our precast concrete wall panels are available in a range of thicknesses to suit anticipated loadings and surcharge and in any height from 400mm – 3000mm.

         

        Lengths are cast to measure ensuring that the wall panels fit neatly together for fast installation on site.

      • What thickness Do I Need?

        The type of panel required will depend on the height of the wall, any anticipated additional loading on the wall and fire rating requirement.

      • How are the wall panels delivered?

        Delivery is on 40’ articulated vehicles, these maybe curtain siders unless requested otherwise.  The wall panels will require off-loading with a forklift, telehandler or a crane.

         

        The panels should be stacked on firm, level ground and separated using the stacking timbers provided. These should be placed on the panels in accordance with the stacking drawing that should be provided to you when you place your first order with us.

      • How are the panels installed?

        Usually carried out with a telehandler or crane. The panels are lifted into position and fixed to the steel columns. The large section size, up to 10m x 3m high, means that installation is fast.

         

        For Security Walls: Generally panels come with projecting reinforcing bars designed to tie into a 200mm thick floor slab. They are simply lifted into place and propped while the floor slab is placed. Once this has reached the required strength the props can be removed and the joints sealed.

      • What do I use to seal the joints?

        As a standard we supply enough one-part polyurethane mastic sealant (Sika Construction data sheet) to seal the joints on one side. This maybe intumescent (fire rated) sealant if necessary. ACP Staff will be able to recommend an appropriate product.

         

        The sealant should be applied after the panels have been erected and the floor joints need to be sealed in accordance with the floor design.

         

        For Firewalls: Intumescent sealant is required to seal the joints. The fire rating required will dictate the sealing system required. Talk to ACP Staff for more information.

         

      • What do the panels rest on?

        For Firewalls and Blast Walls: The panels can either sit on the floor, which must be designed to take the full line load of the wall. A compressible firestop strip should be placed under the bottom panels to form a seal.

         

        Alternatively the panels can sit on ‘landing cleats’ which should be bolted to the face or in the webs of the columns depending on the fixing position.

      •  Is additional Fire Protection Required?

        No unless specific requirements are needed. Concrete’s unique fire-resistance properties should provide you with the fire protection required.

      • Do you provide a Design and Installation Service?

        At ACP (Concrete) Ltd, we also provide a design and installation service to ensure that your project is designed to the highest standard and provides a cost-effective fit for purpose solution.

         

        Our dedicated in-house team will work closely with you to ensure the final solution meets your specific requirements.

         

        Please contact us for more information.

    • Cantilever Vertical Walls    +

      To view more information about our Cantilever Vertical Wall product, click here.

      • What sizes are available?

        The prestressed concrete panels are available in 145mm, 180mm and 280mm thicknesses which gives our customers a wide range of heights and performance to choose from.

         

        The 145mm and 180mm panels are available in 1m, 1.2, and 1.5m widths, these can be used in combination to give the total wall length required.

         

        The 280mm panels are available in 1.2m widths only.

         

        Heights start at 2.4m above finished floor level (AFFL) using 145mm panels right up to 5m high AFFL using 280mm thick panels with all sizes in between.

         

        For more information view Cantilever Panel Sizes.

      • For Manure and Slurry - What Size Store Do I Need?

        This is where our expertise is helpful, give the sales office a call to discuss your requirements.

      • What thickness do I need?

        The panel type required for your application depends on a number of factors

         

        For Grain

        • The overall height of the wall.
        • The type of crop/product to be stored.
        • The profile of the stored crop, will it be stored level with the top of the wall or will it be surcharged/heaped up above the height of the wall?
        • If grain drying equipment is required i.e. stirrers

         

        For Silage and Security

        • The overall height of the wall.
        • The weight of the compaction vehicle

         

        For Firewalls

        The type of panel required will depend on the height of the wall and fire exposure ratings and any additional loads on the walls for example from stored material.

         

        For Bund Walls

        • The overall height of the wall.
        • Any anticipated impact load

         

        For Retaining Bulk Stores, Recycling Bunkers

        The type of panel required will depend on the height of the wall, the bulk density of the stored product, angle of repose, storage profile and any anticipated impact loads.

         

        For Recycling Waste and Retaining Push Walls

        • Overall height of the wall
        • Storage profile ie. level fill or surcharged
        • Bulk density of stored product & angle of repose
        • Impact loads – Often the impact loads from outloading vehicles are greater than the stored product load. To calculate the impact load we need to know the machine to be used, the bucket size and the maximum speed allowed.

         

        For Biomass

        The type of panel required will depend on the height of the wall and the biomass product to be stored.

         

        For Tanks

        The type of panel required will depend on the height of the wall and the anticipated backfill & surcharge loads.

         

        For more information view Cantilever Panel Sizes.

      • Can you store product/s on either or both sides?

        All our vertical panels are double loading so that you can store product on either or both sides.

         

        Different foundation designs are available for division and perimeter walls but all are double loading meaning another store could be added on the other side in future.

      • What is the fire rating for these products?

        145mm Thickness Fire Rating up to 1.5hrs

        180mm Thickness Fire Rating up to 2.0hrs

        280mm Thickness Fire Rating up to 4hrs*

         

        *Dependant on imposed loads required

      • Is Concrete Protection Required?

        For Silage, Slurry and Manure

        Silage effluent is an aggressive substance,  therefore concrete protection is recommended for all concrete surfaces that may come into contact with silage or silage effluent.

         

        For Retaining Walls Bulk Stores, Recycling Bunkers

        Some stored products ie. Road salt, are known to be aggressive substances, therefore concrete protection is recommended for all concrete surfaces that may come into contact them.

         

        For Recycling Biomass

        Crop effluent are an aggressive substances, therefore concrete protection is recommended for all concrete surfaces that may come into contact.

      • Do I need an effluent drainage?

        For Silage, Biomass - applicable to ensiled grass/maize/other ‘green’ crops

        It is essential to ensure that effluent is not allowed to accumulate at the base of the wall.

         

        An effluent drain must be provided at the base of the wall. It is advisable to slope the floor from front to back to assist with effluent drainage and removal from the clamp.

      • How are the wall panels delivered?

        Delivery is on 40’ articulated vehicles, usually curtain siders unless requested otherwise.  The wall panels will require off-loading with a forklift, telehandler or a crane.

         

        The panels should be stacked on firm, level ground and separated using the stacking timbers provided. These should be placed on the panels in accordance with the stacking drawing that should be provided to you when you place your first order with us.

      • What does Installation involve?

        Briefly installation requires the excavation of a shallow trench with the base given a minimum 100mm thick concrete blinding.

         

        The panels are set up and propped in position with the cradles underneath and the reinforcing bars passed through the cast in holes.

         

        The supporting foundation concrete is poured and when sufficient strength has been achieved the props are removed.

         

        Both standard foundations are double loading, however the foundation is more suitable for perimeter walls.

         

        View Installation Process for Cantilever Wall Panel

      • What and how do I seal the joints?

        As a standard we supply enough one-part polyurethane mastic sealant (Sika Construction data sheet) to seal the vertical joints on both sides. The sealant should be applied after the panels have been erected.

         

        The sealing of the floor to wall requires a hydrophilic preformed strip (not supplied as standard unless part of a design and install package) at least 60mm below floor level and the floor joints need to be sealed in accordance with the floor design.

         

        For Firewalls

        As a standard we supply enough in-tumescent mastic sealant (Everbuild 400 sealant datasheet) to seal the vertical joints on both sides. The sealant should be applied after the panels have been erected. The floor joints need to be sealed in accordance with the floor design.

         

        For Bund Walls

        The joints are sealed with mastic sealant or hydrophilic sealant, the choice of sealant and the application method will depend on the properties of the bunded liquid/material. ACP Staff will be able to recommend an appropriate product.

         

        For Attenuation Tanks

        The joints are sealed with mastic sealant or hydrophilic sealant. ACP Staff will be able to recommend an appropriate product.

      • Is additional Fire Protection Required?

        No unless specific requirements are needed. Concrete’s unique fire-resistance properties should provide you with the fire protection required.

      • Am I able to extend the precast wall at a later date if required?

         

        All ACP vertical panels are made with a double loading strand pattern which means they can never be installed the wrong way round and in addition allows another crop store to be built on the side, sharing the existing wall, at a later date.

         

        Our standard foundation designs are also double loading with this in mind.

      • Do you provide a Design and Installation Service?

        At ACP (Concrete) Ltd, we also provide a design and installation service to ensure that your project is designed to the highest standard and provides a cost-effective fit for purpose solution.

         

        Our dedicated in-house team will work closely with you to ensure the final solution meets your specific requirements.

         

        Please contact us for more information.

      • For Firewalls - Does the firewall panel design cater for fire doors?

        Protection of vital fire escapes require the inclusion of fire doors within the blast wall or firewall panels, these can be designed into the precast concrete blast wall panels often eliminating the requirement for special framing or support structures.

      • For Silage - What Size of Compaction Vehicle Can I Use?

        By law silage clamp design must comply with Water Resources (Control of Pollution Regulations) 2013.

         

        These require that all walls must withstand the loads given in BS5502 Part 22 (2003) which has values for  compaction vehicle weights up to 8t and 10t.

         

        However increasingly farmers and contractors are using machinery larger than this to compact the silage.

         

        Please contact us if you require a solution for machines over 10 tonnes as we have extensive experience and knowledge to design to meet these requirements.

      • For Tanks - Do you supply Lid Panels also?

        Yes, prestressed concrete panels can be used to construct the lid of the tank.

         

        If required these can have a frame for a manhole/inspection hatch cast in for access to the tank.

         

        Precast concrete columns and beams are also available from our Bespoke Department.

    • R35 Cantilever Vertical Walls    +

      To view more information about our R35 Cantilever Vertical Wall product, click here.

      • What sizes are available?

        Our Vertical precast concrete wall panels are available in a range of thicknesses to suit anticipated loadings and surcharge and in any height from 400mm – 3000mm.

         

        Lengths are cast to measure ensuring that the wall panels fit neatly together for fast installation on site.

      • What thickness Do I Need?

        For Bund Walls: The type of panel required will depend on the height of the wall and any anticipated impact load.

         

        For Self Supporting Earth Retaining Walls: The type of panel required will depend on the height of the wall, the profile of the retained soil and any anticipated surcharge loading.

         

        For In Building Earth Retaining Walls: The type of panel required will depend on the height of the wall, the spans between the columns and the anticipated surcharge load on the floor.

         

        For Attenuation Tanks / Below Ground Tanks: The type of panel required will depend on the height of the wall, the anticipated backfill & surcharge loads.

      • Can ACP (Concrete) Ltd also supply Lid Panels?

        Yes, prestressed concrete panels can be used to construct the lid of the tank. If required these can have a frame for a manhole/inspection hatch cast in for access to the tank.

         

        Precast concrete columns and beams are also available from our Bespoke Department.

      • Do they need to be Bolt down or Cast-in?

        For In Building Earth Retaining Walls: Bolt down or Boot walls are quicker to install and enable backfilling and all subsequent trades to be carried out without delay. Casting units are suited to higher surcharge loads and can be a more economical solution if site programme allows for the insitu curing.

      • How are the wall panels delivered?

        Delivery is on 40’ articulated vehicles, these maybe curtain siders unless requested otherwise.  The wall panels will require off-loading with a forklift, telehandler or a crane.

         

        The panels should be stacked on firm, level ground and separated using the stacking timbers provided. These should be placed on the panels in accordance with the stacking drawing that should be provided to you when you place your first order with us.

      • How are the panels installed?

        Usually the panels come with projecting reinforcing bars designed to tie into a 200mm thick floor slab. They are simply lifted into place and propped while the floor slab is placed. Once this has reached the required strength the props can be removed and the joints sealed.

         

        For In Building Earth Retaining Walls: Installation is straightforward using a telehandler or crane. The panels are lifted into position using the lifters fitted to lifting inserts located in the top edge of the panels. Step by step installation guide

         

        Bolt Down

        The panels are positioned on an insitu structural concrete base, levelled and shimmed. Specialist concrete anchors, either simple dowel bars, chemical anchors or concrete self-tapping bolts are drilled and fixed though the panel Boot. Once anchored, grouts and sealant can be applied to complete the wall.

         

        Bolt Down

        The panels are lowered into position onto a simple blinding footing. Temporary propping and kentledge secure the panel whilst the protruding reinforcement bars are encased in the insitu “toe” foundations.

         

      • How Do I tie the Floor Slab to the Wall?

        For In Building Earth Retaining Walls: Sockets can be cast in at the top of the panels to receive threaded bars for tying the wall head into the floor slab.

      • What happens if I need to use a non-load bearing panel above floor level?

        For In Building Earth Retaining Walls: In this situation we can cast the retaining panels with a flat top. The thinner section panel is then seated on the below ground retaining panel. It is wise to use a compressible strip between them to accommodate any unevenness’s and form a watertight seal.

      • What do I use to seal the joints?

        We will be able to recommend an appropriate product and method.

         

        For Bund Walls: The joints are sealed with mastic sealant or hydrophilic sealant, the choice of sealant and the application method will depend on the properties of the bunded liquid / material.

         

        For Attenuation Tanks / Below Ground Tanks / Self Supporting Earth Retaining Walls: The joints are sealed with mastic sealant, hydrophilic sealant and grout.

         

        For In Building Earth Retaining Walls: As a standard we supply enough one-part polyurethane mastic sealant (Sika Construction data sheet) to seal the vertical joints on both sides. The sealant should be applied after the panels have been erected. The sealing of the floor to wall requires a hydrophilic preformed strip (not supplied as standard unless part of a design and install package) at least 60mm below floor level and the floor joints need to be sealed in accordance with the floor design.

      • Do you provide a Design and Installation Service?

        At ACP (Concrete) Ltd, we also provide a design and installation service to ensure that your project is designed to the highest standard and provides a cost-effective fit for purpose solution.

         

        Our dedicated in-house team will work closely with you to ensure the final solution meets your specific requirements.

         

        Please contact us for more information.

    • Arrow Freestanding Walls    +

      To view more information about our Arrow Freestanding Wall product, click here.

      • What sizes are available?

        All Arrow Panels are 1m wide and are available in heights of 2.4m, 3m, 3.6m and 4m.

         

        At 1.55m deep (front to back) the heavy base gives stability and the stem is 200mm thick all the way up (not tapered) and therefore less susceptible to damage from bumps and knocks from compaction vehicles than traditional L Shape panels.

         

        Bespoke heights are available on request.

         

        For Silage/Manure & Slurry: Arrow Panels are all 1m wide and available in standard heights of 2.4m, 3m and 3.6m for silage storage in accordance with BS5502 part 22.

      • What thickness Do I Need?

        For Bund Walls: The type of panel required will depend on the height of the wall and any anticipated impact load.

         

        For Self Supporting Earth Retaining Walls: The type of panel required will depend on the height of the wall, the profile of the retained soil and any anticipated surcharge loading.

         

        For In Building Earth Retaining Walls: The type of panel required will depend on the height of the wall, the spans between the columns and the anticipated surcharge load on the floor.

         

        For Attenuation Tanks / Below Ground Tanks: The type of panel required will depend on the height of the wall, the anticipated backfill & surcharge loads.

      • What Size of Compaction Vehicle Can I Use?

        By law silage clamp design must comply with Water Resources (Control of Pollution Regulations) 2013.

         

        These require that all walls must withstand the loads given in BS5502 Part 22 (2003) which has values for  compaction vehicle weights up to 8t and 10t.

         

        However increasingly farmers and contractors are using machinery larger than this to compact the silage. Please contact us if you require a solution for machines over 10 tonnes as we have extensive experience and knowledge to design to meet these requirements.

      • How are the wall panels delivered?

        2.4m and 3m Arrow Panels arrive on the delivery vehicle ‘standing up’ and are simply off-loaded using a forklift/telehandler via the fork tine slots in the base.

         

        The 3.6m and 4m high panels arrive lying down and are lifted off using chains & lifters attached to the lifting points. The panels are then lifted into the vertical position using a rotating eye lifter attached to the lifting point at the top of the panel.

      • How are the panels installed?

        The panels should be placed onto a structural floor slab or firm level ground. They have fork tine slots in the base to enable them to be easily moved into position using a forklift/telehandler.

         

        A tongue and groove joint detail in the base provides a simple connection that keeps the panels in line at installation and assists with stability.

         

        The corner units are bolted to the standard units on site.

         

        If preferred the panels can be bolted to the floor using removable Excalibur bolts (this is essential for 4m high panels used for surcharged storage). It is possible, if required, to seal the joints with mastic sealant.

      • How are the Arrow Panels fixed to the Floor?

        For Grain and Crops: Arrow Panels can be bolted to the floor using Excalibur bolts. 4m high Arrow Panels must be bolted down to the floor if used for surcharged crop storage.

         

        If preferred the panels can be bolted to the floor using removable Excalibur bolts (this is essential for 4m high panels used for surcharged storage ie grain). It is possible, if required, to seal the joints with mastic sealant.

         

        For Silage / Manure & Slurry: Arrow Panels can be bolted to the floor using Excalibur bolts. Bolt information This is essential for the 3.6m high Arrow Panels. It is optional but recommended for the lower height Arrow Panels.

      • What do you mean by a structural concrete pad?

        Minimum 150mm thick reinforced concrete slab is required. Must be clean and smooth. Clearly the panels will follow any fall in the floor so a valley or a hump will cause a gap between units at the top/bottom.

      • How are the Corners Constructed?

        Sloped corner units are available to enable a full clamp / bunker layout to be installed.

      • How are the panels fixed at the Corners?

        Sloped units to construct 90° corners are available. These arrive separately and require bolting to the standard panel at installation.

      • Can you store product/s on either or both sides?

        Yes the panels can have product stored on either or both sides.

      • Are they easy to clean?

        The 40° sloped base is self-shedding make it for easy cleaning between batches.

      • How are the walls sealed?

        The joints between the panels are generally very tight but if required it is possible to seal them.

         

        For Silage / Slurry and Manure: As a standard we supply enough one part polyurethane mastic sealant (Sika Construction data sheet) to seal the vertical joints on both sides.

         

        The sealant should be applied after the panels have been erected. The sealing of the floor to wall panels is dependent on the site requirements, call ACP to discuss.

         

        For Firewalls: Intumescent mastic sealant should be used.

         

        For Grain and Crops: Provided the floor is even the gaps between the Arrow Panels are minimal (5mm?) however, if required, the joint can be sealed using mastic sealant. This should be applied after the panels have been erected.

      • Is Concrete Protection Required?

        Concrete protection is recommended for all concrete surfaces that may come into contact with aggressive substance such as silage, silage and manure / slurry effluent or rock salt.

      • Is it possible to dismantle and relocate the panels at a later date?

        Arrow Panels are the ultimate future proof design being easily moved to store different products in the future if the requirements of the farm change.

         

        Even if bolted down the bolts can be unscrewed and re-used and the holes filled with resin/mortar.

      • Does the firewall panel design cater for fire doors?

        For Firewalls and Blast Walls: No it is not possible to cater for fire doors.

      • Is additional Fire Protection Required?

        No unless specific requirements are needed. Concrete’s unique fire-resistance properties should provide you with the fire protection required.

      • Do you provide a Design and Installation Service?

        At ACP (Concrete) Ltd, we also provide a design and installation service to ensure that your project is designed to the highest standard and provides a cost-effective fit for purpose solution.

         

        Our dedicated in-house team will work closely with you to ensure the final solution meets your specific requirements.

         

        Please contact us for more information.

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Our Prestressed and Precast Concrete Design and Installation Service