Client
Valero Energy
Value
£205k
Sectors & Services
Nuclear & Power Concrete Repair Coatings Corrosion Control Membranes Cleaning & Preparation Projects
The Semlogistics (now Valero) Petroleum Storage Plant at Milford Haven is a critical facility in the UK energy infrastructure, supporting a complex network of storage tanks, pipelines, and distribution systems. Many of the plant’s supporting structures, including 29 concrete pipe-support bridges and the berth infrastructure, showed signs of deterioration due to chloride ingress and long-term exposure to operational and environmental conditions.
CRL was engaged to carry out a phased refurbishment to restore structural integrity, enhance corrosion resistance, and ensure continued operational reliability. The project required careful planning to undertake works safely on a live plant, maintaining uninterrupted operations while addressing complex concrete repair and protection challenges.
Services undertaken
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Concrete repairs to bridges and berth support beams (hand, flowable, or sprayed)
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Hydrodemolition for larger beam repairs
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Hand-placed mortar repairs for smaller areas
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Surface preparation via water jetting
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Application of Sika Ferrogard 903 (MCI) corrosion inhibitor
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Skim coat application of Sikatop 107
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Installation of Mapei Elastic E25 galvanic anode system
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Application of Mapei Elastic cementitious coating
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Bridge deck refurbishment with PMB waterproof membrane and HRA reinstatement
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Pouring of new bitumen joints at abutments
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Suspended scaffold access for berth repairs
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Coordination of works with plant operations and shipping movements
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Compliance with hot work permit systems and plant safety protocols
The project was delivered in multiple phases, each targeting specific structural elements with bespoke methods. For the 29 pipe-support bridges, CRL first undertook detailed surveys to locate repair areas, followed by either hand breakout and placement of repair mortars or hydrodemolition and sprayed repairs for larger beam sections. Corrosion protection strategies were tailored according to chloride levels and structural condition: some elements were prepared with high-pressure water jetting and treated with Sika’s Migrating Corrosion Inhibitor (Ferrogard 903) before a 2 mm skim coat of Sikatop 107 was applied, while others received the Mapei Elastic E25 galvanic anode system, subsequently coated with Mapei Elastic cementitious protection.
Bridge deck refurbishment involved removing existing high-performance surfacing, planing, applying a PMB waterproof membrane, and relaying new surfacing with bitumen joints reinstated at abutment lines. At Berths 2 and 3, concrete repairs were carried out via hand, flowable, or sprayed material techniques. Galvanic anodes were installed into repaired areas, followed by Ferrogard 903 and a protective Sikatop 107 coat. All works were performed under strict plant safety protocols, including hot work permits, plant isolation, and careful sequencing to coordinate with ongoing operations and shipping movements. CRL’s expertise in structural repairs UK, coupled with precise planning, ensured works were executed efficiently without compromising operational continuity.
"The restrictions of working in an operational power plant required detailed planning and co-ordination with the plant management. We are happy to report that the project was completed with no safety incidents, or disruption to the plants activities."
Steve Jones | Southern Regional Director | CRL
Beyond restoring the structural integrity of the bridges and berths, CRL’s interventions provide long-term resilience against corrosion and environmental degradation. The combination of tailored corrosion protection systems, waterproofing membranes, and precise surface preparation significantly extends the service life of critical concrete assets.
Close collaboration with the plant’s operations team ensured that repairs were delivered safely and efficiently, maintaining uninterrupted plant function. The works also contribute to sustainable asset management by reducing future maintenance requirements and supporting operational continuity.
CRL’s meticulous approach demonstrates their ability to deliver complex concrete repair and protection projects within high-risk, operationally sensitive industrial environments, safeguarding long-term performance and reliability.
