Client
National Highways
Value
£ 77k
Palatine Road Viaducts North and South, constructed in 1974, carry the M60 motorway over Palatine Road and the River Mersey. The north viaduct supports the anticlockwise carriageway, while the south viaduct carries clockwise traffic.
Legacy BACO parapet systems with Tugga bolt fixings, installed prior to 1994, were assessed as substandard under CS 461, necessitating full replacement of parapets, transitions, and vehicle restraint systems.
CRL were appointed under the Scheme Delivery Framework as Lot 10 to deliver targeted concrete repairs to stringcourses and bridge deck verges, enabling subsequent structural upgrades by others and supporting long-term asset management objectives.
Services Undertaken
- Concrete repairs to stringcourses and bridge deck verges
- Engineer-led condition surveys to define repair extents
- Surface preparation of concrete substrates
- Working adjacent to live traffic with temporary Vario Guard protection
- Coordination with multiple contractors under the SDF framework
- Night-time working with early morning carriageway reopenings
- Protection and management of existing services including NRTS, power, and communications cables
- Enabling works to facilitate parapet and vehicle restraint system replacement
Operating within a live motorway environment, CRL executed a carefully phased programme of specialist concrete repairs aligned with parapet post locations. Early Contractor Involvement allowed refinement of methodology, sequencing, and target cost, ensuring efficient coordination with the Principal Contractor and other SDF Lot providers. Engineer-led condition surveys were undertaken to accurately define repair extents, enabling a targeted approach to structural repairs and avoiding unnecessary intervention.
Concrete repairs to stringcourses and bridge deck verges were completed using appropriate proprietary repair mortars, selected to match the existing substrate and exposure conditions. Surface preparation was carried out using mechanical methods to achieve the required substrate profile, ensuring optimal bond performance. Particular care was taken around existing services, including NRTS, power, and communication cables, which were protected throughout the works.
Given the constraints of working across two viaducts and both carriageways, activities were undertaken during night-time possessions, with strict deadlines for early morning reopening. Temporary Vario Guard systems were retained as secondary protection, allowing safe working adjacent to live traffic. The phased repair strategy ensured compatibility with forthcoming parapet and VRS installations, maintaining programme continuity across multiple contractors.
CRL’s delivery combined technical precision with logistical control, demonstrating capability in complex structural repairs UK projects. The integration of robust methodologies, collaborative planning, and disciplined execution ensured high-quality outcomes while maintaining safety and minimising disruption.
Durability and long-term performance were central to the repair strategy. All concrete repair areas were prepared and treated to ensure resistance to environmental exposure, particularly in areas susceptible to water ingress and de-icing salts. Repair materials were selected for their compatibility, low permeability, and resistance to carbonation, supporting extended service life.
Attention to detail during surface preparation ensured effective adhesion and minimised the risk of premature failure. By reinstating the integrity of stringcourses and deck verges, the works reduced the likelihood of future deterioration and corrosion of embedded reinforcement. These measures contribute to improved resilience of the structures and reduced maintenance requirements over time.
CRL’s approach reflects a commitment to proactive asset management, ensuring that repairs not only address immediate defects but also enhance whole-life performance. Through careful planning, quality workmanship, and durable repair systems, CRL has helped preserve these critical motorway structures, enabling safer operation and long-term reliability.
