Client
Associated British Ports
Value
£1.1M
Sectors & Services
Marine Structures Concrete Repair Condition Surveys Corrosion Control Cleaning & Preparation Projects
Itchen Quays, also known as Berths 30 to 36, are located within Southampton Docks and were originally constructed in 1939 to accommodate dock cranes and freight rail traffic along the quay length. Today, the quays support vehicle loading operations for export shipping.
Following a detailed inspection by Ramboll in 2023, significant concrete spalling was identified, presenting a potential structural risk in a highly operational port environment. CRL Surveys was subsequently appointed to undertake a comprehensive condition survey and investigation, leading to a competitive tender issued by Associated British Ports. In May 2024, CRL was awarded the contract to deliver essential structural repairs and ensure the continued safe operation of this historic maritime asset.
Services undertaken
- Detailed concrete condition survey and investigation
- Design and installation of suspended marine access platform
- Tidal planning and sequencing of marine works
- Hydro-demolition of defective concrete
- Cleaning and preparation of exposed reinforcement
- Application of anti-corrosion primer to reinforcement
- Installation of sacrificial anodes
- Sprayed micro concrete repairs to quay beams
- Coordination with port operations to minimise disruption
The repair works at Itchen Quays presented a series of technical and logistical challenges driven by the marine environment, restricted access, and continuous port operations. To facilitate safe access to the underside of the quay deck and allow concrete beam repairs to be undertaken, a temporary suspended access platform was designed and installed by SCA’s Marine Scaffolding division. The platform was hung from the quay structure using modular beams and perforated metal scaffold decks, providing uninterrupted access to all repair locations while maintaining safe working conditions.
Detailed planning was essential throughout the project, with tidal movements carefully assessed to maximise productive working windows and ensure operatives could work safely around fluctuating water levels. The access system was specifically designed to withstand periodic submersion, allowing the works to progress in line with changing tide schedules. Hydro-demolition was employed to remove damaged and delaminated concrete in a controlled manner, exposing the reinforcement without inducing further damage.
Once exposed, reinforcement was thoroughly cleaned and treated with a protective anti-corrosion primer. Sacrificial anodes were strategically installed within repair areas to mitigate the risk of incipient anode formation and provide long-term corrosion control. Repairs were completed using sprayed micro concrete to achieve durable reinstatement and a seamless finish. Throughout the works, close coordination with Associated British Ports was required to manage interfaces with cruise liners, cargo vessels, and frequent Red Funnel ferry movements, ensuring minimal disruption within one of the UK’s busiest ports.
"It was a challenging project carried out under live conditions, made more difficult by having to undertake the repairs under tidal conditions"
Kevin Hodgson | Senior Contracts Manager | CRL
The Itchen Quays project demonstrates CRL’s ability to deliver complex marine concrete repairs through careful planning, collaboration, and technical expertise. By combining specialist access solutions, corrosion mitigation measures, and high-quality repair techniques, CRL restored the structural integrity of the quay while maintaining port operations.
The installation of sacrificial anodes, application of protective primers, and durable concrete reinstatement provide long-term resilience against the harsh marine environment, reducing future maintenance demands and extending service life. Delivered in close partnership with Associated British Ports and SCA, the project highlights CRL’s professional approach to asset management, safety, and sustainability, ensuring this critical quay infrastructure remains fit for purpose for many years to come.
