The Fort Hills oil sands mining project will be developed as an open-pit truck and shovel mine. It is expected that the mine will process 110 million tonnes of oil sand per year, yielding an average of 180,000 barrels of bitumen per day at full production.
PERI worked with Ledcor, the forming contractor, to construct two 34m diameter circular froth tanks; concrete for the two structures was poured simultaneously.
The RUNDFLEX system designed and provided to Ledcor by PERI for our Froth Tank foundations allowed us to meet our tight schedule, while maintaining our strong commitment to safety. The CB240 Climbing system eliminated the need to erect scaffolding around the tanks, which was a huge benefit in both safety and efficiency. Having a system that can simply be raised and re-set for each subsequent concrete pour means the bulk of the work is completed at the front end of the project. This enabled accurate scheduling, safe efficient production and a decreased crew size compared to conventional forming systems.
RUNDFLEX was used to cast the 1.4m thick walls in three 5m high pours. A complete ring was cast in one pour, requiring over 700m³ of concrete per ring.
The CB Climbing System supported the wall formwork for the upper pours, and it provided a safe working platform for site personnel. Once the platform is built, it can be lifted in conjunction with the wallform.
The whole assembly can be repositioned and set ready for concreting again very quickly. The platform negates the need for scaffolding tower work platforms around the full periphery and at each level, resulting in significant cost savings for labour and material, as well as additional safety.
One side of the tank had a large opening with a 5.4m high wall above it. As a result, a platform could not be anchored into concrete for the next pour. A PERI UP shoring scaffold was used to support the wall during concreting.
As the completed tanks will house liquid, the finished structure is required to be completely watertight. PERI provided their SK Tie System, which is suitable for applications requiring waterproof, gas-proof, fire-resistant or soundproof concrete.