Zenith Group We are a multi-disciplined specialist access, maintenance and repair company with an unrivalled focus on bringing innovation, combined with world class engineering and design excellence to the cement industry.
With decades of experience, Zenith offers a comprehensive range of specialist services involving the inspection, maintenance and repair of structures throughout the cement industry. Supported by our in-house world class team of engineers, we provide surveying, assessing and reporting on all types of existing structures. We are industry leaders in temporary works design and installation, bringing safe, innovative, time- saving specialist access solutions to the most complex of issues. We have a wealth of experience in designing, modelling and undertaking complex rigging and lifting projects. As full members of the Lifting Equipment Engineers Association, LEEA, we design and detail bespoke fabrications and solutions to our vast cement industry client base. Where precise control, movement and weight measurement is required, we are also capable of designing hydraulic lifting and sliding systems. With a commitment to excellence in everything we do, Zenith provides all the highly skilled trades required to maintain and repair structures. We have an extremely proactive apprenticeship recruitment and training scheme which keeps us at the forefront of the industry. Through research and development we continue to innovate and improve our specialist access solutions including brining industry leading capabilities unique to Zenith. Zenith Group Cement
Zenith Group Cement
For over 20 years, Zenith has been proud to have developed long- term relationships with our much-valued clients throughout the cement industry delivering world class innovative, engineered solutions. Our total commitment to excellence enables Zenith to remain as industry leaders providing all the engineering capability, specialist access expertise and highly qualified trades personnel to deliver an unrivalled level of service.
CEMENT SERVICES INCLUDE: • Structural Engineering & Design • Temporary Works Design & Installation • Structural Assessment - Surveying, Assessing & Reporting • Specialist Access - Steeplejack & Rope Access • Suspended Platforms • Industrial Scaffolding • Specialist Lifting Design & Installation • Industrial Cleaning • Roofing Specialists - Cleaning, Inspection, Maintenance & Replacement • Building Fabric Maintenance - Extensive Range of Trades & Skills • Industrial Chimneys - Inspection, Maintenance & Repair • Silos - Inspection, Maintenance & Repair • Ducting - Inspection, Maintenance & Repair • Mechanical & Welding • Corrosion Under Insulation (CUI) • Expansion Joint Maintenance, Cladding, & Insulation
CEMENT CLIENTS INCLUDE:
Case Studies
100M SINGLE FLUE CHIMNEY REPAIRS & INSTALLATION TEMPORARY BYPASS STACK Hope Construction Materials
Issue: Following a detailed inspection, a partial failure of the internal refractory brick lining in the main chimney was observed. Due to financial concerns regarding lack of factory production, the client required a minimal shutdown period to carry out the demolition and replacement of the affected brick lining. Therefore, the main chimney required isolation to undertake the urgent work. Solution: Zenith’s world-class engineers working in conjunction with our highly skilled access and heavy lifting specialists, designed, fabricated and installed a temporary steel bypass stack complete with ducting, which was braced to the main chimney windshield. Once the bypass stack was safely jacked and lifted into position, and during a brief shutdown period, the existing flue entries were isolated and the new temporary flue entries were installed to divert the process gases into the new temporary bypass stack thereby allowing factory production to continue whilst the internal brickwork lining repairs were completed in the main chimney. On successful completion of the necessary lining repairs, another brief shutdown period allowed the temporary duct entries to be dismantled and the original flue entries to be reconnected to the main chimney. With the main chimney back in operation and factory production having quickly recommenced, the temporary bypass, structural bracing and temporary works access were dismantled.
Key Factors:
• Design and install all temporary works access including full circumference termination point scaffolding, winches and suspended platforms
• Design, fabricate and install main support steelwork and specialist heavy lifting jacking arrangement below the flue entry points with associated scaffolding
• Design, fabricate and install temporary lateral support bracings positioned to suit the prevailing wind direction
• Design, fabricate and install the temporary sectional 3.80m diameter bot- tom supported steel bypass stack and flue entries
• All the required extensive engineering, specialist access, heavy lifting re- quirements and mechanical services for the entire project were safely and successfully completed in-house utilising Zenith’s world-class, innovative industry leading capabilities.
INNOVATIVE ASBESTOS ROOF REPLACEMENT TO KILN BUILDING DUNBAR Tarmac
Key Factors:
Issue: Asbestos, once a preferred building material, poses serious health risks when disturbed, especially in roofing and other construction materials often found at numerous cement plants. A significant part of the asbestos roof to the kiln hall building at Tarmac’s Dunbar cement plant needed urgent replacement whilst avoiding a shutdown so that cement production could continue unaffected. The asbestos sheeted roof had become overloaded due to an accumulated build-up of product waste. Zenith’s world-class in-house engineers performed a structural assessment of the roof and calculated all potential loadings, considering the potential volume of accumulated product waste observed. Solution: Zenith engineers designed a unique innovative suspended platform to provide safe access to the roof. The platform was supported on a runway system, allowing it to be moved along the length of the building as the roof replacement progressed. The design was tailored to meet the client’s requirements for materials loading and unloading locations, ensuring the safe and economical removal of the existing hazardous roof sheeting. Once the design elements were finalized, Zenith procured the fabrication of the specialist access platforms, which were installed by Zenith specialist access operatives. A trial was conducted on-site to load test the specialist access platforms inside the kiln hall building.
• Structural Assessment Performed by Zenith’s Highly Qualified In- spection Team Overseen by Zenith’s Engineers
• Design and Fabrication of a Bespoke Suspended Access Platform by Zenith’s Engineers
• Testing, Installation & Operation of the Bespoke Suspended Access Platform by Zenith’s Specialist Access Operatives
• Safe Removal & Replacement of the Hazardous Asbestos Roof Sheeting by Zenith’s Roofing Specialists
Following a successful trial, the roof was safely replaced with minimal impact on plant personnel and operations.
DESIGN AND INSTALLATION OF BESPOKE ACCESS PLATFORM TO REPAIR GAS CONDITIONING TOWER DUCTING
Tarmac
Issue: Overseen by our world-class engineers and following an initial detailed inspection of the GCT ducting by Zenith’s inspection team, extensive insulation and cladding repairs were required to the upper section of the ducting at the 127m level. Due to the isolated location of the ducting traditional scaffolding would prove onerous, time consuming and costly. Solution: With decades of excellence and expertise, Zenith’s world-leading engineering team designed a bespoke access platform for the uppermost section of the GCT duct to facilitate suitable access to undertake the insulation and cladding repairs. The platform, with a combined weight of 30 tonnes, provided full working access to the ducting from the 110m level to the 127m level. However, the entire scaffold support loading proved too high for standard tubes and couplers, so Zenith’s engineers designed an innovative fabricated support arrangement which was safely installed by Zenith’s experienced specialist access operatives. Subsequently, Zenith removed and replaced the defective insulation and cladding. As a multi-disciplined experienced contractor committed to excellence, Zenith has the ability to design and install innovative world-leading temporary access solutions as well as having all of the necessary in-house trades and skills to maintain and repair structures throughout the cement industry.
Zenith Group
The Zenith Group is a global leader in providing world-class engineering services, innovative specialist access solutions, specialist lifting capability, and industry leading maintenance and repair solutions.
We bring innovation and excellence to all our activities from initial concept design to successful project completion.
Our in-house research and development department continues to develop and improve our comprehensive range of specialist access solutions, services and products which are unique to the Zenith Group.
Service:
Zenith Group
Specialist Access, Maintenance & Repair
Engineering Consultants
Mechanical & Welding Services
Zenith’s world class engineering expertise allows Zenith to offer a full range of structural and mechanical services, including innovative temporary works design, structural assessment, structural design, mechanical and civil maintenance, repair and specialist lifting capabilities. Zenith Consultants has a global reputation with extensive research and development capability. Our engineering team has a vast range of experience in the fields of mechanical, civil and structural engineering. Several of our engineers are qualified UAV pilots.
Zenith provides extensive mechanical services, project management, access and lifting capabilities including extensive welding capabilities for the refurbishment and even further construction of cement plant structures. Overseen by our world-class team of structural engineers, we have the capability to install additional strengthening and support steelwork to existing structures.
Zenith provides a comprehensive inspection, maintenance, and repair service for cement facilities, including extensive welding, pipe fitting and construction capability. Zenith has a worldwide reputation for providing safe, industry-leading solutions to complex and traditional access issues including resolving complex lifting challenges. Where access or heavy lifting proves to be onerous, Zenith, led by our dedicated team of world class engineers, Zenith can provide safe, innovative solutions that prove to save significant time.
Telephone +44 (0)131 440 3000
Email enquiries@zenithstructural.com
Website zenithstructural.com
Page 1 Page 2 Page 3 Page 4 Page 5 Page 6 Page 7 Page 8 Page 9 Page 10 Page 11Made with FlippingBook Digital Publishing Software