Asset Resilience and Containment — Clay Mills

Introduction

Clay Mills in Staffordshire is the Midlands' largest filter works, serving a population equivalent of 400,000. During refurbishment, movement and dummy joints within the water treatment beds were found to be failing and leaking to ground, requiring an effective containment solution across a five-football-pitch-sized area.

Our Solution

UCL Ltd developed a solution to reinstate watertight integrity using a specialised proprietary polyurea spray coating. Damaged soft joints were removed and high-pressure water used to expel contamination and surface laitance. Once dry, joints were fitted with backing rods and a 5mm recess cut, with a quick-setting primer and fine grit applied to enhance adhesion before a liquid soft joint was applied. The specialised polyurea, offering over 300% elasticity, was then sprayed over each joint, allowing it to flex with concrete movement while avoiding the cost of lining the entire structure.

Key Benefits

• Over 2,000m of movement joints and 2,000m of dummy crack repairs completed within four months
• Specialised polyurea provides over 300% elasticity to accommodate structural movement
• Rapid application and drying times enabled a fast return to service
• Environmentally friendly solution with no VOCs
• Significant cost reduction compared to full-area lining or concrete replacement
• 50-year guarantee provided for the completed works

Conclusion

UCL Ltd delivered this project on time and within budget. By utilising specialised polyurea overbanding, UCL Ltd reinstated immediate watertight integrity and provided a long-term, guaranteed solution that outperformed traditional lining methods in both flexibility and cost-effectiveness.