Storm-Proof Zappshelter Keeps Tarmac’s Clinker Dry

The Company:

Tarmac, a subsidiary of CRH, is the UK’s leading provider of sustainable construction materials and solutions. With over 150 years of experience, Tarmac supports infrastructure development across the UK, supplying a wide range of products such as aggregates, asphalt, cement, concrete, lime and building materials. These materials are used in essential projects, including, housing, schools, roads and flood defenses, as well as in industries like steel and water purification.

The company operates more than 400 sites across the UK, including quarries, cement and asphalt plants.

The Challenge:

As production volumes grew at Tarmac’s cement plant in Tunstead, the need for additional clinker storage became urgent. 

Leaving clinker stock piles exposed to the elements led to crusting, requiring costly and energy-intensive reprocessing. Steven Cox, Cement Grinding Production Coordinator at Tarmac, explained, “When it’s been left outside before, it gains a crust on it, and we have to end up re-crushing it, so we’re actually processing it twice, which is quite a cost to the business.”

Tarmac also needed to have the ability to build significant stock piles, ensuring sufficient stock levels during kiln shutdowns. 

Tarmac needed a fast, durable and sustainable storage solution that could handle increased capacity without the need for extensive groundwork or long lead times. 

Located near the Peak District, the facility faces challenging weather conditions including high winds, heavy rain and snow. Tarmac also  required a storage solution that was storm-proof and durable. 

The Zappshelter Solution:

Tarmac selected two 17m wide x 56m long Zappshelters, mounted on concrete blocks. They opted to leave both ends open for easy stock rotation and selected custom grey-coloured canopies. Installed on existing ground with no additional groundwork required, the Zappshelters were operational within just a few weeks, providing a quick and cost-effective turnaround.

The Zappshelters ensured that clinker stockpiles remained dry and ready for use, eliminating the need for re-crushing. This significantly reduced energy consumption, machinery usage and emissions. 

Most importantly, when put to the test in challenging weather conditions, the Zappshelters were able to withstand storms without any issues. Every Zappshelter is manufactured in the UK, using steel that’s 50% stronger than competitors and engineered to be permanent. Commenting on their durability, Steve Cox said, “In terms of Zappshelters themselves, they’ve weathered some storms up in Buxton! We’re renowned for being quite high up, with constant weather impact and with the resilience of them, they’ve not moved an inch.”

The Result:

• Increased productivity: with Zappshelter, Tarmac could plan kiln shutdowns more effectively, maintaining a reliable clinker supply and ensuring uninterrupted cement production. Steven Cox, explains, “It just allows us to plan for a longer window throughout that shutdown, so that we’ve always got clinker for cement production, therefore are always able to satisfy the customers needs.”
• Environmental benefits: Zappshelter eliminated the need for reprocessing clinker, resulting in lower energy consumption, fewer emissions and reduced machinery usage.
• Cost savings: avoiding re-crushing clinker lowered operating costs and improved efficiency.
• Speed and flexibility: the shelters were installed rapidly and provided immediate value, ensuring Tarmac had materials ready to meet customer needs.
• Reliability: the shelters demonstrated exceptional durability in extreme weather conditions, providing long-term protection for stored materials.

Steven’s final thoughts:

“I think anyone that’s after additional storage for something that’s quick to turn around, great support, then it’s certainly an avenue you should look down. Zappshelter have been great for us and something that we’d look to use in the future again.”

Steven Cox, Cement Grinding Production Coordinator

Needing to keep your stockpiles away from the elements, with a fast, flexible and durable storage solution?

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