Industrial Walkways at New Build Recycling Facility, Pernis, Rotterdam, Netherlands

Project Overview

A commercial-scale chemical recycling facility is currently under construction within the Port of Rotterdam — one of Europe’s most significant petrochemical and industrial hubs.

Xycle, a pioneer in advanced recycling technology has commenced delivery of its flagship plant, designed to process 21 kilotonnes of mixed plastic waste annually. Using proven pyrolysis technology, the facility converts non-recyclable plastics into high-quality circular feedstock for reuse in the chemical industry, offering a lower-carbon alternative to traditional incineration.

With an investment of €75–100 million and planned commissioning by the end of 2026, the facility represents a major step forward in demonstrating the technical and commercial viability of chemical recycling at scale. Designed around a flexible, multi-reactor configuration, the plant is engineered to maximise conversion efficiency while supporting Europe’s transition towards a circular plastics economy.

Delivering Industrial Access for a New-Build Facility

As a completely new industrial development, the facility required design and installation of a comprehensive access network across three operational levels.

With no existing infrastructure in place, the project demanded a walkway and footbridge solution capable of supporting safe, reliable movement throughout a complex, process-intensive environment. Key requirements included:

• High load capacity with efficient spanning capability
• Controlled deflection under operational conditions
• Durable, slip-resistant surfaces to support workforce safety
• Lightweight construction to simplify installation at height
• A material solution aligned with the plant’s circular economy objectives

A High-Performance, Low-Carbon GRP Solution

Working in collaboration with BFF Trading and Dura Composites, Buchinhoren BV selected d² Dura Grating 50mm to meet the project’s technical, safety, and sustainability requirements.

As Dura Composites’ official distribution partner in the Netherlands, BFF Trading brings over 12 years of experience supplying composite solutions across industrial, construction, offshore, transport, and marine sectors. Their expertise in specification and application of GRP systems ensured the right solution was selected to meet the demands of a complex, multi-level processing environment.

The walkway product selection decision was driven by the proven performance of the d² range, supported by verified technical data, Environmental Product Declarations (EPDs), and its position as one of the lowest carbon composite walkway solutions available when compared with alternatives.

The combination of structural capability and inherent corrosion resistance made the system ideally suited to Xycle’s multi-level industrial environment, where long-term durability and reliability are critical.

Simplified Installation

Approximately 3,000m² of d² Dura Grating was supplied by BFF and installed by Buchinhoren BV, forming an extensive network of walkways and footbridges connecting key operational areas across three floors of the facility.

Manufactured in standard mesh in Dark Grey colour, the low carbon GRP grating provides a robust, slip-resistant surface while maintaining effective drainage and visibility — essential for safe operation within an industrial processing environment.

Supported by BFF Trading’s local supply capability and technical understanding, the project benefited from efficient product availability and coordination throughout the installation phase.

The lightweight nature of the system delivered clear installation advantages. Panels were easier to handle and position at height, reducing manual handling risk and enabling efficient progress across a large footprint without compromising structural integrity or safety performance.

Supporting Circular Economy Objectives

Located in Pernis, Rotterdam, the facility sits at the centre of Xycle’s ambition to deliver measurable environmental benefits through advanced recycling, including diverting plastic waste from landfill and incineration while enabling the production of circular plastics.

By specifying d² Dura Grating, the project team ensured that supporting infrastructure aligned with these broader sustainability goals. The product’s low embodied carbon design, combined with its durability and corrosion resistance, supports reduced maintenance requirements and long-term environmental performance.

This whole-life approach reflects the growing importance of material selection in delivering genuinely sustainable industrial infrastructure.

Results and Impact

• Industrial walkway and footbridge network delivered across three operational levels
• Approx. 3,000m² of 50mm d² Dura Grating installed
• Enhanced workforce safety through durable, slip-resistant surface
• Low-carbon and fully recyclable walkway solution aligns with circular economy objectives
• Long-life, corrosion-resistant d² reduces maintenance requirements
• Delivered with support from experienced local distribution partner BFF, ensuring effective specification and supply

The Pernis project is a strong example of how d² Dura solutions support modern industrial infrastructure where safety, performance, and sustainability all matter. Working closely with BFF Trading, whose experience in delivering composite solutions across the Netherlands was instrumental, the use of d² Dura Grating provided a lightweight, robust access solution that met demanding load and deflection requirements while aligning closely with Xycle’s low-carbon, circular economy objectives.

Dean Fuller

Overseas Manager, Dura Composites

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