At CSC Services, we understand that concrete repair in a nuclear environment demands both technical excellence and clear communication. When our client identified failures in the surge chamber’s concrete within their cooling water system exit, we responded swiftly.
Because the site had just achieved a life extension, they needed a robust solution that aligns with stringent operational and safety requirements. Throughout the project, our team worked collaboratively, ensuring transparency and keeping the site’s standards at the forefront.
The client discovered that prior concrete repairs had failed, leaving the surge chamber vulnerable to further deterioration. Since this plays a vital role in cooling operations, any structural compromise could undermine safety and performance. We recognised they needed a long-term fix; one that would withstand the test of time.
KEY FACT: The majority of this work was carried out using an articulated boom platform. All of our concrete repair teams are highly trained and qualified in a number of working methods, including confined space working and working at height.
Working within a nuclear power station carries unique challenges. We had to meet stringent quality standards and ensure all work fulfilled site excellence benchmarks tied to the station’s extended lifespan. Moreover, we had to execute concrete repairs without interrupting critical operations or compromising safety. To achieve this, we designed a repair approach that balanced durability, compliance and sensitivity to site operations.
We began by cleaning the entire surge chamber structure, enabling a full assessment and clear identification of damaged areas. Equipped with that insight, our team set out a structured plan.
Using mechanical breakers, we removed defective concrete carefully. We then installed by hand Flexcrete Monomix HD repair mortar to restore structural integrity. After that, we used Sika Ferroguard as a migrating coating, applying it until it was fully saturated, ensuring the exposed rebar was re-passivated and protected from corrosion.
Following preparation, we applied a Flexcrete Monodex ICB fairing coat to smooth surface imperfections. To ensure protection against carbonation and water ingress, we coated the area with two layers of Flexcrete Monodex Smooth, a high-build, elastomeric finish that resists mould and enables the structure to breathe.
To further reinforce durability, we installed Sika Galvashield XP4 sacrificial anodes for additional corrosion protection. Most of this work took place using an artificitial boom platform, enabling safe, efficient delivery in confined and elevated spaces.
Since the project began in early 2023, we’ve received excellent client feedback regarding our safe, professional and considerate execution. The structure now meets all performance and quality expectations.
Because we delivered a durable and compliant concrete repair, the surge chamber can now safely support the station’s extended operational life. More than that, our collaborative approach bolstered client confidence by preserving continuity, communicating proactively and delivering precisely what they needed. CSC Services reaffirmed our reputation as a trusted technical partner in high-stakes environments.
If your facility requires expert concrete repair, whether in nuclear sites, power plants or other critical infrastructure, CSC Services can deliver reliable, professional solution without disruption. Reach out today to talk with our team.