ROOFING MODERNISING MANUFACTURING
Russell Roof Tiles first began its journey to net-zero over 10 years ago and last year it announced its £18.5 million investment at its Burton on Trent site. BMJ asks how how this will help it achieve its sustainability goals.
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n the UK, the built environment accounts for 25% of greenhouse gas emissions, making it a focal point for sustainability efforts. Roof tile supplier Russell Roof Tiles started its sustainability journey over 10 years ago with the long-term ambition to reduce emissions that damage the environment and improve its operational efficiency.
Bruce Laidlaw, operations director says: “In 2022, the firm announced its NetZero road map that sets out key projects, targets, and milestones that they are working towards in order to achieve the target by 2040. As part of the commitment to NetZero, the major focus is on direct emissions (Scope 1 & 2), reducing fossil fuel use, energy efficiency, maximising renewables and procuring green energy.” It explained that this will be a process of continual improvement and refinement with all three of its manufacturing sites sharing knowledge and initiatives in the company’s own internal ‘race to zero’.
Last year RRT announced £18.5 million investment in expansion, doubling output at its nine-acre Burton on Trent site. Construction started in 2023 with the new facilities completed, and product output starting later this year. The current site will continue to operate whilst the major project takes place. Laidlaw comments: “The investment will deliver more manufacturing lines and a new 1,600 sq m building which will house a state- of-the-art curing chamber for the concrete tiles, which is a major part of the new plant. “The curing chamber is designed by German
firm KRAFT, who entered the concrete industry by creating vapor curing systems in the early 1990s in the USA. This resulted in a major reduction in energy costs of curing concrete by up to 60%.
“Curing tiles is an essential part of the successful manufacture of concrete roof tiles. This process takes place in a curing chamber, at a temperature of around 37 degrees Celsius. The chamber houses moving tile racks, where the tile temperature is gradually increased from ambient temperature to the target curing temperature in two pre-cure zones.
“After the pre-cure, the tiles enter the main chamber where they gain strength and harden. Moisture is added to the air to optimise the curing environment and to prevent drying. “The more aesthetically demanding the concrete, the greater the importance of consistency of curing, as variations in temperature can lead to a variety of potential issues with the finished product.”
July 2024
www.buildersmerchantsjournal.net
The company is installing the QUADRIX single atmosphere curing chamber from KRAFT, which accelerates the curing process through the controlled addition of heat and humidity. The system allows high air volumes at a low-flow rate, providing a carefully controlled, gentle air- flow across the tiles.
Its highly insulated chamber provides floor to ceiling racking and is very energy efficient and will contribute towards Russell Roof tiles NetZero ambition. The temperature and humidity of the chamber will be closely monitored by AutoCure curing software with integrated touch panel that provides the curing climate data of the chamber in real-time.
By using innovative technologies and streamlining operations, Russell Roof Tiles is not only enhancing the sustainability credentials of the business but also setting new benchmarks for industry excellence.
As the government intensify its focus on climate action, Russell Roof Tiles has continued to evaluate itself and endeavours to put itself on good footing to support the country for a greener future. BMJ
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