Client
Client: BAA London
Value
£4.1 M
Sectors & Services
Multi-Storey Car Parks Concrete Repair Condition Surveys Coatings Corrosion Control Membranes Cleaning & Preparation Projects
The main multi-storey car parks serving Gatwick Airport South Terminal form a vital component of the second largest airport in the UK, facilitating high volumes of passenger movement every day. Due to the age of the structures and their continuous exposure to traffic, de-icing salts and aggressive environmental conditions, significant deterioration had developed within the concrete decks and structural elements.
To safeguard operational continuity and user safety, a comprehensive structural restoration and upgrade was required. CRL was appointed to deliver an in-depth refurbishment, transforming the car parks into a brighter, safer and more legible environment while preserving the long-term performance of this critical airport asset.
Services undertaken
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Detailed structural condition surveys and investigations
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Development of repair specification and scope of works
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Full-scale on-site repair trials and quality control validation
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Hydrodemolition of defective concrete
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Replacement of spalled and cracked concrete to deck surfaces
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Installation of impressed current cathodic protection systems
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Application of conductive anode paint to slab soffits
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Installation of titanium ribbon anodes to in situ beams
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Replacement of all vehicle and pedestrian barriers
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Application of anti-slip waterproof deck coatings to deck surfaces and stairwells
Given the strategic importance of the Gatwick car parks, CRL adopted a rigorous, data-led approach before commencing the main works. CRL Surveys undertook a detailed condition investigation, informing the development of the repair specification and scope of works. A full-scale on-site trial was then completed to validate repair methodologies, materials and quality control procedures prior to full contract delivery. This early-stage diligence ensured the chosen solutions were technically robust and suited to the constraints of a live airport environment.
The original deck construction comprised lightweight concrete decks of approximately 70 mm thickness, necessitating highly controlled concrete repair techniques and extensive temporary propping from two levels below the working area. Hydrodemolition was selected to remove defective concrete accurately while minimising vibration and damage to sound material. Wastewater generated during hydrodemolition was captured, treated through a siltbuster unit and reused, reducing water consumption and supporting sustainable delivery.
In areas where chloride testing and half-cell potential mapping indicated active corrosion risk, CRL installed a combined impressed current cathodic protection system. This comprised conductive anode paint applied to slab soffits and titanium ribbon anodes installed within chases formed in the in situ beams. Approximately 8,000 square metres of deck area is now protected by the ICCP system, arresting ongoing corrosion of embedded reinforcement. Around 1,500 square metres of spalled and cracked concrete were replaced as part of the structural repairs.
Safety and usability were enhanced through the replacement of all vehicle and pedestrian barriers and the application of over 21,000 square metres of anti-slip waterproof deck coatings. These coatings were colour coded to clearly define drive aisles, parking bays, disabled bays, pedestrian routes and luggage trolley areas, with a further 250 square metres treated within escape stairwells. CRL’s integrated capability in complex concrete repairs and structural repairs UK ensured the project was delivered efficiently, safely and to exacting airport standards.
"With the new and brighter colours cheme, coupled with the upgraded lighting system, the car park is now a pleasant place to park and much easier to navigate."
Charles Severn | Project Manager | CRL
Long-term preservation of the Gatwick MSCPs was fundamental to the refurbishment strategy. The combination of precise concrete removal, high-quality reinstatement and targeted cathodic protection provides robust defence against future reinforcement corrosion. The ICCP system actively controls corrosion processes in high-risk zones, significantly extending the service life of the structure and reducing future intervention requirements.
The anti-slip waterproof deck coatings deliver a seamless protective barrier that limits water and chloride ingress while improving safety and durability under heavy traffic. Colour zoning supports efficient traffic management and reduces accidental damage. Together, these measures enhance structural resilience, reduce maintenance liabilities and support Gatwick Airport’s long-term asset management objectives. CRL’s technically assured approach has preserved the integrity of this essential transport asset while delivering a safer, more navigable parking environment.
