Surge Chamber Concrete Repair at UK Nuclear Power Station

Project Requirements

Our ongoing nuclear power client had identified concrete damage to the surge chamber within the cooling water system exit.  Previous repairs had failed and they required a long-term, durable solution for the structure – the site had recently received an extension to its operating lifetime and it was key that the work met site excellence requirements in order to contribute to the extension conditions.

Work Completed

All defective concrete was identified, repaired and protected to strict quality standards in line with site excellence requirements through the following process:


  1. The full structure was cleaned down to enable thorough inspection prior to repair planning. The structural concrete was analysed and any defective or damaged areas identified.  A plan was then formed for the repair and strengthening of the structure.
  2. Mechanical breakers were then used to remove the defective concrete and create a suitable surface for the repairs to take place.
  1. The initial concrete repair was then carried out using hand-applied Flexcrete Monomix HD repair mortar.
  1. A migrating coating of Sika Ferroguard was then applied until the point of refusal and the team was confident that it had reached depths adequate to repassivate and protect the rebar and any other steel elements at risk of corrosion.
  1. Flexcrete Monodex ICB was then applied as a fairing/smoothing coat to fill in any small imperfections and give a fair finish to the surface prior to the final coatings.
  2. To anti-carbonation coatings of Flexcrete Monodex Smooth were then applied.  These layers of coating are key to providing an, elastomeric, high-build, decorative coating that ensures protection against carbonation and water ingress, while allowing the structure to breathe.  It also resists the growth of mould and fungi and is ideal both for new construction and refurbishment projects.
  3. As part of the concrete repair and refurbishment process we also installed Sika Galvashield XP4 sacrificial anodes.

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.

Structure repaired and in the process of coating applications

Project Outcome

This project, started in early 2023, is almost at completion and we have received excellent feedback from the site for the approach of our team for the safe, professional and considerate approach they have shown on site.

Team qualifications & specialist skills

  • CSC Concrete Repair Team Specialist Skills and Training
  • Confined Space Working Qualified
  • ISO-certified (9001, 14001, 45001)
  • Members of the Institute of Water
  • Quality Approved Contractor
  • Award-winning members (2021,2022) of the Concrete Repair Association
  • Concrete repair in accordance with BSEN1504
  • EUSR National Water Hygiene card
  • Scottish Water DOMS card
  • Achilles UVDB
  • COSHH Awareness
  • Ultra High-Pressure Water Jetting Trained
  • Abrasive Blasting Trained
  • Airless Spray Painting Trained
  • Gold-level Constructionlinemembership
  • Corrosion specialist trained

Can we help with your next concrete repair project?

Talk to the team today