Structural concrete TOPROC

water-repellentwaterproofhigh-resistance

Overview
Toproc is a high performance, high strength concrete using silica fume technology to deliver optimal strength, extreme toughness and superior abrasion resistance for demanding environments. It is available in a number of standard mixes and can be bespoke-formulated to meet specific project requirements.

Variants

• TOPROC UW – Under Water: a high-consistency, high-strength concrete with washout reduced by up to 50%, scour- and wear-resistant when hardened; for underwater structures, bridges, water defences, wind farms, oil rigs.
• TOPROC MF – Macro Fibre: macro-fibre silica fume concrete providing increased strength and crack resistance; can eliminate ‘A’ grade crack control mesh; suited to heavy industrial floors, external hardstandings, recycling plants and retail flooring.
• TOPROC SY – Scrap Yard: designed for extreme abrasion and impact resistance; allows wide joint spacing and delivers excellent post-crack performance; for scrap yards, recycling plant floors, docksides and loading bays.
• TOPROC ED – Early Drying: quicker drying than conventional concretes; can be walked on after c.18 hours and trafficked by light vehicles after c.24 hours; typical relative humidity at surface reduced to around 75% within 7–21 days, depending on ambient temperature; used for flooring, bridge decks, underpass soffits, resin toppings and tiles, retail spaces.
• TOPROC CR – Chemical Resistant: high resistance to a variety of chemicals and reduced wear in high-abrasion chemical environments; applications include chemical works, effluent treatment plants, waste storage and recycling depots.
• TOPROC HR – Heat Resistant: extreme heat resistance, high bond to concrete and steel, high compressive/flexural/tensile strength and very low permeability; for foundry floors, molten metal splash areas, fire resistant sections and cladding/coating.
• TOPROC ES – Early Strength: highly cohesive dense microstructure with improved bond between paste and aggregate and earlier trafficking access; for heavy industrial use, airport runway repairs and infrastructure under repair.

Applications

• Waste transfer stations and recycling centres
• Industrial yards and external hardstandings
• Factories and heavy industrial buildings
• Sea defences and harbour/port infrastructure
• Cold stores
• Steel works and foundries
• High rise buildings and tall builds
• Supermarkets and retail developments
• Airport runway repairs, infrastructure construction and structures under repair
• Bridges, culverts, discharge pipelines, storage and treatment works

Key benefits

• Exceptional strength and abrasion resistance for long-life performance in the most challenging environments.
• Resists corrosives such as chemicals, acids, seawater and de-icing salts while maintaining durability.
• Faster construction: high early strength and rapid drying cut programme times (gains strength in hours rather than days; many formulations gain substantial strength in 24–48 hours).
• Whole-life savings: proven to outlast conventional concretes in high-impact and high-abrasion applications, reducing maintenance and repair costs.
• Bespoke solutions: range of proprietary formulations to match specific site and application needs.
• Sustainable option: available with lower-carbon formulations and manufactured in accordance with responsible sourcing standards.
• Operational advantages: higher surface strength, low dust properties (often negating need for paint/resin surfacing), pumpable and easier to place than some conventional concretes.

Additional information
Toproc’s performance is achieved through tailored admixtures, primarily silica fume, producing a dense matrix with fewer capillary pores and low permeability. Typical Toproc mixes deliver much higher in-situ compressive strength than conventional concrete and are supplied as ready-mixed concrete from a network of plants. Toproc variants address specific requirements such as underwater washout reduction, macro-fibre crack control, extreme abrasion and heat or chemical resistance.

Technical specifications

• Product family: Toproc (proprietary silica-fume high performance concretes)
• Variants available: TOPROC UW, TOPROC MF, TOPROC SY, TOPROC ED, TOPROC CR, TOPROC HR, TOPROC ES
• Typical early strength: commonly quoted examples include c.20–25 N/mm² at 24 hours (dependent on section size and ambient temperature) and formulations which gain c.25 N in 24–48 hours.
• Typical 28-day strength: average reported >60 N/mm² (product-dependent).
• TOPROC UW: washout reduction up to c.50% (underwater mixes).
• TOPROC MF / SY: designed to eliminate A-grade crack control mesh in many heavy-duty floor applications; high abrasion and post-crack performance.
• TOPROC ED: walkable after c.18 hours; light-vehicle trafficking after c.24 hours; surface relative humidity around 75% within 7–21 days (ambient dependent).
• TOPROC HR: extreme heat resistance, high bond to steel/concrete and very low permeability.
• TOPROC CR: high chemical resistance for effluent/waste environments.
• Durability features: low permeability, dense microstructure, resistance to water ingress, abrasion, impact and chemical attack.
• Delivery form: ready-mixed concrete delivered to site at consistence suitable for application; generally higher consistence than conventional concrete makes placing/pumping easier.
• Typical uses: industrial floors, port and harbour structures, coastal defences, foundry floors, bridge decks, cold stores, airport repairs, high-rise cores and other heavy-duty applications.
• Manufacturing / standards: formulations employ silica fume and tailored admixtures to achieve required performance; produced to responsible sourcing and quality standards.