As part of our long-standing support for EDF Hartlepool Nuclear Power Station, CSC Services recently delivered essential concrete repairs within the cooling water intake system. Our team was tasked with restoring the pump eye intake – a key component responsible for drawing seawater into the impeller to maintain safe and efficient cooling operations.
Located underground and exposed to constantly flowing abrasive seawater, they pump eye is a known vulnerability within the system. Over time, the surrounding concrete had deteriorated and small leaks began to form, reducing the pump’s efficiency and posing a risk to long-term performance.
All remedial work needed to be completed within EDF’s regulatory maintenance window, coordinated with the National Grid. With the station supplying power to more than two million homes, completing the repair safely, efficiently and on schedule was essential.
CSC Services has worked with EDF for more than two decades, and our experience allowed us to plan a detailed repair programme alongside other maintenance activities during the nine-week shutdown. Our works included concrete inspection, structural repairs, concrete repair resin, specialist leaking sealing and protective coatings.
The first step was a full assessment of the pump eye structure. Seawater contains magnesium sulphate, which is known to chemically react with the hydrated compounds within hardened concrete. Over time, these reactions weaken the material, cause internal pressure and lead to erosion. As the structure continually experiences wetting and drying cycles, sulphates are repeatedly drawn through the concrete and accelerate deterioration.
Working along the pump intake pipe, our team identified damaged areas and reinstated them using high-performance Intercrete repair mortars supplied by our long-term partner, Flexcrete. The products provided the strength, waterproofing and abrasion resistance required for this demanding marine environment.
To stop active leaks, we used Tampur 100 – a hydrophobic resin that forms a rigid polyurethane foam when it comes into contact with water. Its suitability for saline environments, high expansion ratio and strong chemical resistance made it an ideal solution for this section of the intake system.
Once the repairs and leaking sealing were complete, the entire area was protected with Irathane Aqualine 400, a hand-applied polyurethane coating designed for external waterproofing. Its excellent abrasion resistance and crack-bridging properties ensure long-term durability, even in areas with difficult access or movement. Where required, our specialist dustless abrasive blasting system was used to prepare the concrete and ensure optimal adhesion.
As with a large-scale projects, CSC Services’ director Mark Lemon remained on site to oversee progress and ensure delivery milestones were met. Our operatives, all trained to industry-recognised standards including Confined Space and Water Jetting, also hold NVQ level 2 qualifications in concrete repair.
The completed repairs have restored integrity to the pump eye intake and improved resilience against the harsh marine conditions it faces every day. By completing the work within the planned outage and to EDF’s exacting standards, we supported the safe and reliable operation of a power station that plays a vital role in the UK’s energy network.