Client
Sutton & East Surrey Water
Value
£430,000
Sectors & Services
Water Industry Concrete Repair Condition Surveys Coatings Membranes Cleaning & Preparation Projects
The Rusper and Betchworth Water Towers in Surrey, constructed in 1930 from conventionally reinforced concrete, are key assets within the Sutton & East Surrey Water network. While these structures had withstood decades of exposure remarkably well, their internal and external concrete surfaces were beginning to show signs of age, including spalling, cracking, and deterioration of protective coatings.
Sutton & East Surrey Water commissioned CRL to carry out a comprehensive refurbishment to extend the service life of the towers, improve operational efficiency, and ensure compliance with modern health and safety standards. The project required careful planning to maintain structural integrity while upgrading critical elements such as the water bowls, roof, and access systems.
Services undertaken
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Internal and external concrete repairs to walls, floors, and columns
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Surface preparation, cleaning, and fairing coat application
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Spray application of Sika Sikagard 550W Anti-Carbonation System externally
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Roof repairs and cleaning, followed by waterproof coating
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Removal and replacement of internal asphalt lining
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Reprofiling and overbanding of internal cracks
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Protective coating application to roof soffits and beams
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Detailed condition surveys and assessment of concrete integrity
CRL began the refurbishment with a detailed condition survey to identify areas of concrete degradation and structural concern. Spalled and cracked concrete on the external walls, roof parapets, and enclosed areas beneath the bowl was carefully repaired using DWI-approved repair mortars and reinstatement techniques. External surfaces were then cleaned and coated with a fairing layer to create a smooth substrate for the spray-applied Sika Sikagard 550W Anti-Carbonation System, providing a long-term barrier against carbonation and environmental exposure.
Roof refurbishment included repair and cleaning of the existing asphalt membrane above the bowl, followed by the application of Irathane’s Aqualine 400a waterproof coating to protect against water ingress. Internal works within the water bowls involved removal of the existing asphalt lining on walls, floors, and columns, concrete repairs, surface preparation, reprofiling, and overbanding of cracks.
The walls and floors were then relined with Irathane Aqualine 650 to provide a durable, water-tight finish. Roof soffits and beams underwent inspection, repairs, and the application of a protective coating to ensure structural longevity. To meet modern health and safety requirements, CRL replaced the original 1930s wooden internal access staircase and roof ladder with new compliant systems, enhancing safe access for maintenance and operations.
“Now that the final phase of these works is completed we are confident that, thanks to the specialist advice and quality workmanship we received from CRL, the life of both towers has been extended by some 25 years and they will continue to operate safely and efficiently to provide clean, high quality potable water to the local community for a long time to come.”
Simon Thompson | Project Engineer | Sutton & East Surrey Water
The combined refurbishment measures significantly enhanced the durability, resilience, and service life of the Rusper and Betchworth Water Towers. The use of anti-carbonation coatings externally and high-performance waterproofing internally protects reinforced concrete against moisture ingress, carbonation, and chemical attack, minimising future maintenance requirements.
Surface preparation, reprofiling, and crack overbanding ensure optimal adhesion of protective systems, while upgraded access and safety features align with contemporary standards. CRL’s expertise in structural repairs UK and water asset management ensured that both towers are now fully protected, operationally efficient, and positioned to provide decades of reliable service.
