Photography Commission of Concrete Pouring at NZT Teesworks, Teesside.

Net Zero Teesside (NZT) is a flagship industrial decarbonisation project located at the Teesworks site in the North East of England. The project aims to create the UK's first zero-carbon industrial cluster by capturing, utilising, and storing carbon dioxide emissions from a new power station and other local industries.

Commissioned by Heidelberg Materials, one of the world's largest integrated manufacturers of building materials and solutions, my brief was to photograph and capture the loading of concrete, from production to the pouring at Teesworks for a new storage facility covering 40,000 square metres.

Getting myself to the site at dawn, a cold wind blew in from the east at sunrise. I needed to have all the PPE on and to be ready to start photographing the process. The team at Heidelberg are busy, so I do not want to interfere with their work.

Heidelberg Materials site at Teesworks

The on-site manufacturing of the concrete is carbon-free, which refers to concrete products that either eliminate or significantly reduce the carbon emissions associated with traditional Portland cement production. Conventional concrete is responsible for approximately 8% of global CO2 emissions, primarily due to the high-energy processes involved in cement production.

Concrete pouring is a critical step in construction projects, especially at large industrial sites like Teesworks. This process forms the foundation for buildings, infrastructure, and heavy machinery installations. Understanding how concrete is poured reveals the careful planning, precision, and teamwork required to ensure a strong, durable structure.

Inspection of the concrete sample from delivery before the workers coordinating the pour

Preparing for the Concrete Pour

Before any concrete reaches the site, extensive preparation takes place. At the Teesworks site, this preparation involves several key steps:

• Site inspection and layout: Surveyors mark the exact locations where concrete will be poured. This ensures the foundation aligns with architectural and engineering plans.

• Formwork installation: Steel or wooden moulds, called formwork, are built to shape the concrete. At Teessworks, heavy-duty steel formwork is common due to the scale and weight requirements.

• Reinforcement placement: Steel rebar or mesh is positioned inside the formwork to strengthen the concrete once it sets. This reinforcement is crucial for supporting heavy loads and preventing cracks.

• Equipment setup: Concrete pumps, mixers, and trucks are arranged to deliver concrete efficiently. The layout minimises delays and keeps the pour continuous.

Delivery timing is critical. Concrete must be poured soon after mixing to maintain its workability. At Teesworks, coordination between the batching plant and site ensures the concrete arrives fresh and ready.

The Pouring Process

Pouring concrete involves a coordinated effort between operators, engineers, and laborers. The process includes:

• Positioning the concrete pump: Large boom pumps or line pumps are set up to reach the formwork. The pump’s placement depends on site access and pour size.

• Continuous pouring: Concrete is poured steadily to avoid cold joints, which occur if concrete sets before the next batch arrives. Continuous pouring ensures a uniform, strong foundation.

• Vibration and compaction: Workers use vibrators to remove air bubbles and compact the concrete. This step prevents voids that weaken the structure.

• Levelling and finishing: After pouring, the surface is levelled using screeds and trowels. Finishing may vary depending on the foundation’s purpose, from smooth surfaces to rough textures for better adhesion.

  
  

Safety is a priority during pouring. Workers wear protective gear and follow strict protocols to handle heavy machinery and wet concrete safely.

Challenges and Solutions for Concrete Pouring

Pouring concrete at a large industrial site like Teesworks presents unique challenges:

• Scale and volume: Large pours require precise timing and coordination to keep the concrete flowing without interruption.

• Weather conditions: Rain, wind, or extreme temperatures can affect the pouring and curing process.

• Site logistics: Moving heavy equipment and concrete trucks around a busy site demands careful planning to avoid delays.

  
  

To overcome these challenges, Teesworks employs experienced teams, advanced equipment, and detailed project management. This approach minimises risks and ensures the concrete pour meets quality and safety standards.

Examples of Concrete Pour Projects at Teesworks

Several notable projects at Teesworks showcase the concrete pour process:

• Steelworks foundations: Massive concrete slabs support heavy steel structures. These pours involve thousands of cubic meters of concrete and require continuous pumping over many hours.

• Road and infrastructure bases: Concrete is poured for roads and loading bays, designed to withstand heavy vehicle traffic.

• Industrial building floors: Smooth, level concrete floors are essential for machinery installation and operations.

  
  

Each project highlights the importance of tailored concrete mixes, precise formwork, and expert pouring techniques.

Final Thoughts on Photographing a Concrete Pouring at Teessworks

When on such a large scale site and project such as this one, it's important to have your photographic equipment to hand; the operation happens fairly quickly, and when on-site, you won't have access to your car, where you might have the rest of your equipment. Also, when arriving on-site, you will have to go through the on-site induction, which takes time. You will always have to be accompanied and will not be allowed to just roam around, on your own. There is lots of heavy mashinery moving about and it's quite dangerous. Understanding this process reveals the skill and care behind the scenes of major construction projects, and at Chris J Parker Photography, I was honoured to be commissioned and included to photograph this huge project.