A specialist engineering company has saved Tarmac more than GBP750,000 by solving a wearing problem on hoppers at the company's Hilton works..

Ace Arc, of Coalville, has completed the refurbishment of five aggregate storage hoppers and ten trouser leg chutes, which play an integral part in the production of dense aggregate blocks at Tarmac's Wolverhampton facility. The hoppers and chutes transport 500 tonnes of aggregate to the site's concrete mixer each day, and after 18 years of intensive use at the batch plant, they were showing severe signs of corrosion.

Tarmac's project manager, Tim Lovatt, comments: 'We were concerned that the corrosion was making the bins unsuitable for use.

We were already experiencing leakages and wanted to ensure that these did not develop further.' The Hilton plant produces 6,000 square metres of dense aggregate blocks each day for the building industry.

Replacing the batch plant was not an option for Tarmac, as to do so would mean closing the plant for more than a month and an outlay of over GBP500,000 for new equipment.

Ace Arc provided a cost effective solution that enabled the site to remain open and production continue.

Using 8 mm steel, engineers from the Ace Arc team relined the aggregate hoppers.

Four trouser leg chutes were lined with hardened wear plate to increase wear life and a further six chutes were coated with Cera-metalene to prevent aggregate particles from sticking to the sides, causing material build up, potential blockages and corrosion.

Mr Lovatt continues: 'We are really pleased with the work that Ace Arc has carried out for us at Hilton, which was done professionally and safely by experienced people who completed the job on time and within budget.

The work has ensured the lifespan and safety of our equipment for many years to come.' Ace Arc's general manager Scott Bailey said: 'Tarmac is a blue chip company that needed to ensure production at the plant continued while work was carried out.

We were able to provide a safe solution that enabled them to do this effectively.