Wessex Water inlet tank repair and refurbishment

Introduction

A 6 × 6 × 6 metre main sewerage inlet tank operated by Wessex Water required major structural refurbishment following decades of H₂S-induced concrete degradation. Compounded by the structure's coastal proximity, spalling and substrate loss exceeded 100 mm in areas. Overpumping costs at high flow rates made rapid turnaround critical.

Our Solution

UCL Ltd mobilised to carry out full structural reinstatement and protective lining within a 10-day programme. The tank was high-pressure water jetted at 16,000–20,000 psi to remove all degraded concrete and expose corroded reinforcement. Heavily corroded rebar was overlaid with new steel before 14 tonnes of fast-curing spray-applied concrete were applied at 100–120 mm depth to restore full substrate integrity. Within 12 hours of concrete application, surfaces were prepared and a 6 mm build of Ultracoat pure epoxy coating was applied to all internal walls. The coating application was completed within 8 hours and inspected the following day, returning the asset to service within 10 days of mobilisation.

Key Benefits

• Full structural reinstatement of 100+ mm substrate loss across the tank interior
• 14 tonnes of spray-applied concrete applied and cured within 12 hours for coating
• 6 mm Ultracoat pure epoxy lining providing long-term H₂S and chemical resistance
• Total project completed in 10 days, significantly reducing overpumping expenditure
• No requirement for extended shutdown or costly temporary infrastructure

Conclusion

UCL Ltd delivered a fully reinstated and epoxy-lined sewerage inlet tank within a 10-day window, directly controlling overpumping costs for Wessex Water. This project demonstrates UCL's capability in complex, time-critical concrete repair and protective lining within live wastewater environments.