Client
National Highways
Value
£ 350k
Chain Bar Interchange North Bridge is a reinforced concrete underbridge carrying both eastbound and westbound carriageways of the M62 over the A58 Chain Bar Roundabout.
Constructed in 1972, the structure comprises an in-situ reinforced concrete deck slab supported by precast prestressed concrete I-beams, bearing onto cantilever abutments with spread foundations. The original steel P1 (now N2) post-and-rail parapets had reached the end of their serviceable life.
A 2020 CS 461 assessment confirmed the need for parapet and associated vehicle restraint system upgrades. CRL were appointed to undertake enabling works, including scaffolding and localised concrete repairs, to facilitate the wider structural improvements.
CRL delivered a coordinated package of specialist concrete repairs and access solutions within a live motorway environment, where safety, sequencing, and programme certainty were critical. Early engagement with the Principal Contractor, Colas, enabled the development of a fully integrated delivery plan, aligning scaffold installation, repair works, and parapet replacement activities with strict traffic management constraints.
A bespoke temporary works design was implemented to provide safe and efficient access to the stringcourse and parapet zones. Cantilevered scaffold systems and edge protection were engineered to maintain carriageway operations while allowing operatives to undertake repairs adjacent to live traffic. This approach demonstrated CRL’s capability in delivering complex structural repairs UK schemes under constrained conditions.
Detailed engineer-led condition surveys informed the repair methodology, ensuring only defective concrete was removed. Controlled breakout techniques were adopted, particularly in areas with buried and embedded services, to prevent damage and maintain operational integrity. Hydro-demolition was utilised where required, with full encapsulation of the west bridge to contain debris and protect the surrounding environment and live carriageway.
Concrete repairs to the stringcourse and parapet zones were undertaken using compatible repair materials designed to restore structural integrity and durability. The installation of galvanic anodes provided targeted corrosion mitigation, addressing reinforcement deterioration at source. Works were delivered in carefully controlled phases, aligned with lane closures and follow-on activities, reducing interface risks and ensuring continuity across contractors.
CRL’s approach combined technical expertise, disciplined planning, and collaborative working. This ensured high-quality outcomes while maintaining safety and efficiency, reinforcing CRL’s position as a trusted partner in asset management and specialist concrete repair delivery.
Long-term durability was embedded within the repair strategy through the use of corrosion mitigation measures and high-performance materials. The installation of galvanic anodes provides ongoing protection to embedded reinforcement, reducing the risk of future corrosion and extending the service life of repaired areas. Careful surface preparation and controlled removal of defective concrete ensured optimal bond conditions for repair materials, minimising the risk of debonding or premature deterioration.
By addressing localised defects and reinforcing vulnerable zones, the works enhance the bridge’s resilience to environmental exposure, including moisture ingress and de-icing salts. These interventions support reduced maintenance requirements and improved whole-life performance. CRL’s methodical approach to concrete repairs ensures that structures are not only restored but protected, delivering sustainable outcomes and long-term value for critical infrastructure assets.
