Precast concrete products manufacturer, Charcon Construction Solutions, part of the Aggregate Industries group, has successfully supplied and installed structural precast concrete materials for the new, state-of-the-art Mount Cook Adventure Centre in Derbyshire.

Set in five acres of grounds, the centre can accommodate 130 guests and includes wheelchair accessible facilities. The eco-building uses solar power to generate hot water and electricity, rainwater collection to flush toilets and air source heat to warm the rooms.

Charcon Constructions Solutions was awarded the contract by Novus, the appointed main contractor, to help deliver the flooring and stairs for the build; a complex hexagonal central core design with two rectangular wings.

Novus specified Charcon Construction Solutions’ bespoke Block and Beam flooring system, composed of pre-stressed concrete beams with standard concrete infill blocks laid in between, for the complicated central core area on the ground floor.

Charcon’s pre-stressed Hollowcore flooring slabs, which range from 150mm to 400mm and achieve a rapid strength of over 60N, at only 28 days, were then used to floor the building’s rectangular wings. A heavy density Hollowcore sound slab was used on the first floor and roof level to effectively meet sound regulations. Two pre-cast staircases, ground to upper floor levels, manufactured using custom built moulds, were also supplied and installed.

Richard Baldry, General Manager for Charcon Construction Solutions, comments: “Due to the complexity of the building’s design, we needed to value engineer a solution that would fast track construction and allow immediate access to following trades.

“Using our precast Block and Beam and Hollowcore flooring systems meant there was no need to wait for concrete slabs to cure. Once grouted, floors formed a ready-to-work base for follow on trades. Additionally, Hollowcore is very easy to transport and handle during construction, and requires less material to manufacture compared to solid concrete slabs. This thereby reduces carbon emissions. Both solutions provide an immediate solid floor surface able to accommodate service pipes and electrical wiring, as well as suspended ceilings. Providing stairs, manufactured offsite, also ensured a cost and time effective alternative to traditional timber built staircases.”

In addition to supplying quality offsite manufactured precast products, Charcon Construction Solutions offered a fully integrated solution on the project, providing Novus direct access to its design and planning expertise.

Dean Povey, Commercial Manager at Novus Solutions, comments: “Charcon Construction Solutions carried out a difficult project in a difficult location under extreme weather conditions and on budget, a job well done.”

The Mount Cook Adventure Centre opened this summer. The centre is using local facilities to provide a range of adventure activities from rock climbing, kayaking and orienteering and will also offer an educational insight into the local history and mining heritage of the area.

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