ROOF TILE manufacturer Russell Roof Tiles’ largest ever investment remains on track at its Burton site, with the final stage of construction and fit out now underway.

Work started on the £18.5m project last year which will double manufacturing output at the 9-acre site. The project is being commissioned in the autumn with full manufacturing to follow, the current plant continues to produce concrete roof tiles whilst the scheme takes place.

Russell Roof Tiles is installing manufacturing processes which support the firm’s net zero ambitions. This immense investment project has already seen the construction of a new batching plant, complete with mixer to facilitate increased concrete roof tile production. A high-tech curing chamber is currently being fitted out and the final piece of the jigsaw will see the new factory extension under construction.   

The new batching plant will increase efficiencies as well as sustainable benefits such as a water reclamation and refiltering system, that allows for recycling of all wash water, including using wash water from the factory. This will reduce the firm’s use of fresh water, and reduce waste.

New Curing Chamber

The project will deliver more manufacturing lines and a new 1600 sq/m building using a 30-ton steel frame which houses a curing chamber for the concrete tiles.

Effective curing is an essential part of the successful manufacture of concrete roof tiles. The process takes place in a curing chamber at a temperature of around 37 degrees celsius and moisture is also added to the air to optimise the curing environment.

The more aesthetically demanding the concrete, the greater the importance of consistency of curing. For example, hot and cold spots in the curing chamber can impact the strength and these variations in temperature will affect the relative humidity in the chamber, leading to colour differences as well as the possible incidence of primary efflorescence.

Russell Roof Tiles is installing a QUADRIX curing single atmosphere chamber from German firm KRAFT, which accelerates the curing process through the controlled addition of heat and humidity. This guarantees a continually uniform environment for curing, the system allows high air volumes at a low flow rate resulting in a higher quality tile.

A team from Germany are currently installing the chamber, which houses floor to ceiling racking providing a carefully controlled gentle air flow (at 32 degrees celsius) across the tiles.

This system generates a constant air temperature and humidity within the chamber, and a consistent and optimum curing climate in a single atmosphere creates a microclimate. Not only will the new facility produce a product which is of higher quality, strength and consistency but it will also speed up the drying process.

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