Client
Willis Towers Watson
Value
£2.53M
Sectors & Services
Multi-Storey Car Parks Concrete Repair Coatings Corrosion Control Cleaning & Preparation External Façade Refurbishment Projects
The Greyfriars Multi-Storey Car Park in Ipswich town centre is a mixed-use structure, comprising offices on the ground and first floors, with covered car parking across levels 2–8 and a split-level roof on levels 9 and 10.
Owned by Willis Towers Watson, the building required extensive refurbishment after years of operational use, including concrete degradation, deck wear, and surface deterioration.
CRL was appointed Principal Contractor for a three-year programme, with the objective of delivering structural repairs, corrosion mitigation, and modernisation while maintaining operational continuity. Phase 3 focused on lower-level repairs, external redecoration, and finalising upgrades to ensure a safer, longer-lasting facility for both users and asset managers.
Services undertaken
- Preparation of existing floor decks using concrete floor planers
- Application of Sika Pronto floor coating and decking system
- Concrete repairs to soffits and decks
- Corrosion survey, design, and installation of cathodic protection system
- Jet washing and re-coating of walls, soffits, and external elevations
- Installation of new lighting system integrated with existing sensors
- Scheduling and traffic management to maintain operational use
- Covid-19 safety measures including Track & Trace, PPE, and hygiene protocols
- Coordination with subcontractors for specialist floor preparation and high-pressure cleaning
Phase 3 of the refurbishment involved a comprehensive programme of concrete repairs, surface preparation, corrosion prevention, and modernisation across levels 3 and 4, as well as the external façade. The existing floor decks were initially prepared using specialist concrete floor planers to remove surface contaminants and ensure a clean substrate for the installation of a new Sika Pronto floor coating and decking system. Following a detailed corrosion survey, a cathodic protection system was designed and installed to protect the reinforced concrete from further deterioration.
Concrete repairs to soffits and decks were carried out in accordance with issued repair drawings. Damaged sections were carefully removed, prepared, and reinstated using specialist repair mortars to match the existing structure. Walls and soffits throughout the building, including external elevations, were jet washed to remove ingrained dirt and residues before re-coating, ensuring optimal adhesion and long-term durability. Simultaneously, a new lighting system was installed, fully integrated with existing sensors to enhance safety and visibility across all car park levels.
Work scheduling required close coordination with the car park management team to programme traffic and manage access while keeping the facility operational. Most repair works were completed in-house, with electrical installation carried out by CRL’s sister company, Equilux, and specialist subcontractors employed for floor preparation and high-pressure jet washing. During the Covid-19 lockdown, bespoke risk assessments and method statements were implemented, incorporating Track & Trace systems, PPE protocols, hygiene stations, and social distancing measures to ensure the safety of all personnel on site.
"Delivering Phase 3 of the Greyfriars Car Park refurbishment required careful planning, coordination, and technical expertise, ensuring concrete repairs, corrosion protection, and modernisation were completed safely, efficiently, and to the highest standard."
Kevin Hodgson | Senior Contracts Manager | CRL
The refurbishment delivered enhanced durability, structural resilience, and long-term asset protection. The combination of surface preparation, high-quality repair mortars, floor coatings, and cathodic protection provides effective corrosion mitigation and prevents further deterioration of reinforced concrete elements. Jet washing and recoating of walls and soffits ensured strong adhesion of protective layers, while the Sika Pronto floor system delivers durable wear resistance across the decks.
These measures collectively reduce ongoing maintenance requirements, extend the operational lifespan of the car park, and support effective asset management by safeguarding both structural integrity and user safety for the foreseeable future.
