Client
Associated British Ports (ABP)
Value
£1.8 million
Sectors & Services
Marine Structures Concrete Repair Cleaning & Preparation Projects
Alexandra Dock in Newport, South Wales is a critical operational asset within the port estate, supporting continuous commercial shipping activity on a 24-hour, seven-day basis. Over time, the reinforced concrete underside and supporting dock structures experienced deterioration requiring significant intervention to maintain structural integrity and operational safety.
CRL was appointed to deliver an extensive programme of concrete repairs over an 18-month period, while the dock remained fully operational. The project demanded careful coordination with port authorities and stakeholders to ensure the quay continued to function safely and efficiently throughout the refurbishment works.
Extensive concrete repairs to dock underside and supporting structures
Hydrodemolition to remove defective concrete
Reinstatement of concrete using spray-applied repair techniques
Daily coordination with Harbour Master and Associated British Ports
Programme planning around live port operations
Stakeholder liaison with neighbouring commercial operations
Provision of safe access in restricted tidal conditions
The refurbishment of Alexandra Dock was undertaken in a highly constrained and complex marine environment, requiring specialist methodologies, innovative access solutions and close collaboration with all operational stakeholders. The dock operates as a closed dock with manually adjusted water levels to accommodate varying vessel sizes. Daily liaison with the Harbour Master and Associated British Ports was essential to align repair activities with shipping movements and to maintain safe working conditions for CRL operatives.
Extensive concrete repairs were carried out to the underside of the dock and its supporting structure. Defective concrete was removed using hydrodemolition, a method selected for its precision and ability to remove deteriorated material without inducing vibration or damaging sound concrete. Following breakout, reinstatement was completed using spray-applied concrete techniques, ensuring effective bonding, consistent compaction and long-term durability in the aggressive marine environment.
The proximity of third-party operations added further complexity. Programme projections were shared with a neighbouring scrap metal business to allow works to be phased around their operational requirements, minimising disruption and maintaining positive stakeholder relationships. Careful planning of work zones was also required, as shipping traffic dictated the sequence and timing of repairs.
Access presented a particular challenge, with only approximately one metre clearance between the underside of the dock and the working water level. To overcome this, CRL introduced five steel-framed work barges, each eight metres in length, which were partially submerged to create stable working platforms. This innovative approach provided safe and comfortable access at both high and low tide, significantly improving productivity and reducing programme duration and cost. CRL’s ability to deliver complex concrete repairs and structural repairs UK within a live port environment highlights its technical competence and strength in managing demanding infrastructure projects.
“The repair works carried out by CRL were done in a very professional manner.”
Mark Elliot | Project Engineer | Associated British Ports
The repair strategy at Alexandra Dock focused on restoring structural integrity while enhancing long-term resilience. Hydrodemolition ensured that all defective concrete was fully removed, providing a clean, well-prepared substrate for reinstatement. Spray-applied concrete delivered high-quality repairs with excellent adhesion and durability, well suited to the dock’s tidal and marine exposure.
By carefully sequencing works and maintaining continuous liaison with port operators, CRL minimised the risk of damage to repaired areas during ongoing operations. The restored underside and support structures now offer improved resistance to environmental attack and operational wear, reducing future maintenance demands. Through precise repair techniques, innovative access solutions and rigorous planning, CRL has helped extend the service life of this vital port asset and support effective long-term asset management.
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