Concrete Results for Imerys

Pam Reddish | 02 January, 2026

The new storage facility at Furzebrook utilizes Elite Precast Concrete’s Legato interlocking blocks

First published in the December 2025 issue of Quarry Management

Imerys gain capacity, quality, and safety with Legato blocks

Imerys’ Furzebrook facility was recently facing significant operational challenges, as ageing steel columns and wooden sleeper walls were failing structurally, creating reduced storage capacity, causing cross contamination between grades of stored materials, undermining product quality, and increasing operational risk and maintenance costs.

The stored material – dense ball clay weighing 1,300kg/m3 – required containment walls up to 4m high, with additional surcharge load capacity. Further complications included a complex building layout with numerous support stanchions obstructing wall alignment, uneven floor levels that made traditional wall systems impractical, and a need for integration with the existing steel frame and unique floor/structural conditions.

Imerys engaged RSG Structures, led by director Gareth Neale, to develop a robust and flexible solution. Their proposal included Elite Precast Legato interlocking concrete blocks, which offered:

Flexibility – Modular block sizes allowed precise positioning around existing steel supports
Strength – Engineered to handle the immense loads of dense ball clay and operational surcharges
Integration – Steel plates used where supports interrupted wall lines, with Layalocka straps providing secure anchoring
Durability – Manufactured to 50N/mm2, meeting BS EN 1992-1-1 standards and ensuring long service life.

‘One of the great things with using blocks, and why we do it a lot, is that it’s a very simple system that can be designed many different ways. With Elite Precast blocks I can put designs together for a multitude of different loads, heights, and lengths of walls,’ said Mr Neale.

The build was carried out in a phased manner by a team consisting of RSG Structures (project lead and installation), CLP Structures (design expertise), TR King (steelwork), Evabuild (groundwork), and Elite Precast Concrete (Legato interlocking walling blocks). The phased construction allowed Imerys to keep unaffected areas operational, thereby minimizing downtime and ensuring ongoing production.

Post completion, the following has been witnessed:

Minimal cross contamination – Improved separation of material grades has significantly reduced contamination
Higher product quality – Enhanced integrity of stored materials has increased market value and profitability
Optimized storage – Greater capacity and ease of handling has streamlined operations
Extended infrastructure life – Protection of steel columns from impact damage has extended the life of the facility.

The Imerys Furzebrook upgrade is a compelling example of how Elite Precast Concrete’s Legato system, combined with expert engineering and seamless collaboration, led by RSG Structures, can deliver measurable operational improvements. The result is a stronger, safer, and more efficient storage facility, ready to support Imerys’ operations for decades to come.

The robust and flexible storage solution has delivered measurable operational improvements for Imerys