ZENITH BRINGS WORLD-CLASS INNOVATION & EXCELLENCE TO A MAJOR CEMENT PLANT PROJECT

Zenith, as part of Coriant Group, is globally recognised for its commitment to innovation and excellence, consistently delivering industry-leading access and repair solutions to the foremost blue-chip companies in the cement sector.

During 2025 and 2026, over two plant shutdowns, Zenith’s long-standing cement industry client, Tarmac, having complete confidence in Zenith’s extensive world-class in-house capabilities for temporary works design, specialist lifting capability, specialist access solutions and mechanical solutions, required the replacement of their Tertiary Air (TA) duct at their Dunbar cement plant.

Tarmac originally faced a major challenge: the only conventional way to replace the failing ductwork was to completely remove the roof and roof structure, then bring in a large crane to lift the old sections out and install the new ones. This approach would have been extremely costly, time‑consuming, and would have blocked key access routes, slowing down the entire shutdown period.

Zenith was asked to explore an alternative. Through careful design work and detailed structural analysis, Zenith’s engineering and contracts teams developed an innovative, safer solution. By installing specially designed runway beams onto the existing roof trusses—and using a combination of specialist lifting techniques, rope access, and traditional scaffolding—the team successfully removed and replaced the entire duct system without cranes and without dismantling the roof.

Zenith delivered all engineering design work, including the new duct sections, support systems, and temporary works. Our in‑house teams carried out every aspect of the operation: rigging, rope access, welding, and scaffolding—completing a complex, high‑risk project with precision and minimal disruption.

From our core values of Innovation & Excellence, our ability to solve technical challenges presented from unusual requests is exemplary. We are, on a day-to-day basis, continually seeking for new ways to overcome the most complex of engineering challenges. From providing industry leading bespoke innovative access solutions for the world’s leading industrial blue-chip companies to designing temporary scaffold access decks, we are continually looking to innovate our designs by utilising industry first access techniques.

Due to our extensive experience and exposure in the industrial sectors we fully understand how down time and outage works affects process and cost. We aim to complete our designs with the minimum disruption at site level and interface closely with the clients’ operations teams to fully understand the design brief from the outset.

In conjunction with our engineering, design and modelling capabilities, Zenith Consultants can offer solutions for complex rigging and lifting projects. As full members of the Lifting Equipment Engineers Association, LEEA, we design and detail bespoke fabrications and solutions to our international customer base. Where precise control, movement and weight measurement is required we are also capable of designing hydraulic lifting and sliding systems.