Client
National Highways
Value
£1.45M
Sectors & Services
Highway Structures Concrete Repair Condition Surveys Coatings Projects Projects
The Staverton Bridge carries the B4634 Old Gloucester Road over the M5 between Junctions 10 and 11 near Cheltenham. Constructed as a simply supported structure maintained by four piers, it plays a critical role in local and regional traffic management. By the time of the project, concrete deterioration and reinforcement corrosion had begun to compromise the bridge deck, abutments, and piers, necessitating a major refurbishment.
Valued at approximately £1.45 million and delivered over 15 months, the project, led by Concrete Repairs Limited (CRL) in partnership with R&W Civil Engineering for National Highways, focused on concrete reinstatement, corrosion prevention, and structural strengthening. The works aimed to restore the bridge’s integrity, extend its operational life, and ensure safe, uninterrupted motorway traffic throughout phased construction.
Services Undertaken
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Hydrodemolition of defective concrete on bridge deck, piers, and abutments
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Hand-held power tool preparation for precision repairs
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Concrete reinstatement using Strike 4.5 in 13 phased pours
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Installation of 4,058 galvanic anodes (XPT and XP4 types)
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Placement of 554 metres of additional steel reinforcement in channels, damaged areas, and deck extremities
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Repairs to east and west abutment walls, including partial ballast wall removal and reinstatement
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Preformed drip detail installation to soffits behind bridge bearings
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Pier repairs during overnight motorway closures using MEWP access
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Use of Webercem Fivestar and Flexcrete Fastfill for abutment and pier reinstatement
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Laser mapping and ferro scanning to guide pours and locate reinforcement
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Crack monitoring with gauges during the works
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Traffic management for safe phased delivery and overnight closures
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Health and safety management including risk assessments, PPE, and public protection
The Staverton Bridge refurbishment employed a highly structured, phased approach to maintain traffic flow and ensure worker safety. Hydrodemolition was used to remove defective concrete across the bridge deck, piers, and abutments, with hand-held power tools applied where precision was required. Concrete reinstatement utilised specialist Strike 4.5 material, delivered in 13 controlled phases to ensure rapid strength development and consistent curing.
Corrosion protection was achieved with the strategic installation of 4,058 galvanic anodes, including 472 XPT and 3,586 XP4 units, complemented by 554 metres of additional steel reinforcement in channels, damaged areas, and at the start and end of the deck. Preformed drip details were incorporated beneath bridge bearings to prevent future leakage. Laser mapping and ferro scanning guided concrete pours and reinforcement placement with precision.
Repairs to abutment walls involved hydrodemolition and reinstatement using Webercem Fivestar, including partial removal and reconstruction of ballast walls for access. Pier repairs were completed during overnight motorway closures using MEWPs, Webercem Fivestar, and Flexcrete Fastfill. Comprehensive traffic management, safety protocols, and crack monitoring ensured works were delivered efficiently without compromising live traffic or public safety. Collaboration between CRL, National Highways, and engineering partners enabled responsive problem-solving and seamless phased delivery.
Long-term durability measures at Staverton Bridge combine corrosion prevention, structural strengthening, and precise surface protection. Galvanic anodes actively protect embedded reinforcement, while high-performance concrete repairs restore structural integrity across deck, piers, and abutments. Preformed drip details and repaired void formers mitigate future water ingress, preventing damage to the soffits and bridge bearings. Detailed crack monitoring and phased reinstatement ensure controlled curing and continued stability.
Together, these measures reduce ongoing maintenance requirements, extend the bridge’s service life, and enhance resilience under live traffic conditions. The integration of innovative materials, corrosion protection systems, and careful sequencing demonstrates best practice for structural repairs in the UK, supporting effective asset management and safe, long-lasting motorway infrastructure.
