Reduce risk, avoid programme delays and make decisions based on evidence – not assumptions.
The Challenge
Structural Repairs was appointed by GEL Engineering to undertake critical concrete repairs within the primary distribution chamber at Ford Water Treatment Works. The active chamber required immediate remediation of deteriorated reinforced concrete surfaces prior to a scheduled stop log installation.
Because the chamber remained fully operational outside the isolated repair zone, preventing debris, dust, spray rebound and wash water from contaminating the live process water was a primary operational constraint. The highly corrosive sewage environment also necessitated strict safety protocols to manage biological hazards, alongside the logistical complexities of working at height from a Mobile Elevating Work Platform (MEWP) during night shifts.
The Structural Repairs Solution
Our engineering team designed and deployed a comprehensive, spray-applied Sika concrete repair system, executing the works under stringent environmental and safety controls.
Our Wastewater Solutions
- Bespoke Environmental Containment: Before breakout commenced, a layered containment system was installed directly over the live process water. Stainless steel fixing hooks were anchored into the chamber walls to support heavy-duty scaffolders’ debris netting, which was then overlaid with an impermeable secondary membrane to create a continuous, secure barrier.
- Controlled Breakout and Preparation: Defective concrete was removed using controlled mechanical breakout to expose the sound substrate and the full circumference of the corroded reinforcement. The exposed steel was abrasive blasted or water-jetted to remove corrosion before being fully encapsulated with Sika MonoTop®-1010 for robust corrosion protection.
- Structural Reinstatement: Following substrate pre-wetting, Sika MonoTop®-4012 structural repair mortar was wet-sprayed to reinstate the required structural profile, accommodating local repair depths of up to 200 mm in multiple controlled layers to prevent slumping.
- Advanced Chemical Resistance: To protect the asset against the aggressive wastewater environment, a final 25 mm layer of Sika MonoTop®-4400 MIC calcium-aluminate mortar was spray-applied over the cured structural repair.
- Rapid Washout Protection: As the chamber required rapid return to service, the repair was sealed with Sikagard®-230 MIC surface hardener, providing immediate protection against early washout and running condensation.
Operational Excellence
The project was executed entirely during planned night shifts to minimise disruption, with all works conducted from a safely positioned MEWP to avoid confined space entry. By isolating the work zone with a custom containment system and utilising advanced composite mortars, Structural Repairs successfully restored the structural integrity and extended the operational life of the primary distribution chamber without interrupting the facility’s vital water treatment processes.
Contact Us
To discuss your next structural engineering project or to learn more about our specialist concrete repair and containment services, please get in touch.
