Balvac has delivered complex, critical concrete repair, strengthening, and impressed cathodic protection works to the M60 Palatine Road Bridge, ensuring the bridge's longevity for years to come.
The M60 Palatine Road Bridge, carries thousands of vehicles each day over the River Mersey in Manchester.
Routine inspections of the bridge revealed that the concrete pier crossheads were under capacity due to loss of cover concrete and reinforcement corrosion. Working in collaboration with National Highways, Balvac implemented a temporary propping solution to reduce the loads on the piers while urgent repairs were carried out.
The team successfully repaired seven crossheads using a combination of flowable, sprayed, and hand-placed repair materials, complemented by a titanium mesh anode cathodic protection system. For non-accessible areas, daisy chain anodes were installed through 16m-long precision-cored holes through the centre of the crosshead to a +/- 50mm tolerance.
pier crossheads repaired and protected
million in cost savings
months reduction on programme duration
carriageway closures from the M60 motorway programme
Time and cost saving through innovative trials
A trial conducted with the principal designer demonstrated the efficacy of hydro demolition for precise concrete removal, ultimately reducing the original delivery programme by 11 months and saving £8 million. Additionally, a suspended scaffold access system was developed to avoid the use of cofferdams in the River Mersey, enhancing safety and contributing to the project's time and cost efficiencies.
In May 2023, the project team were awarded the Institution of Civil Engineers (ICE) North West 'Constructability Award' for their innovative approach and successful project outcomes.
Situated in an Environment Agency flood basin, all temporary works were designed to accommodate extreme weather conditions, ensuring minimal disruption to the area.
Social impact
To ensure the project delivered lasting social benefits for the local community Balvac’s teams provided wheelchair-accessible picnic tables for the local park, adjacent to Palatine Road and raised £500 for St Wilfrid’s youth group.
tonnes of spoil removed off-site, thereby eliminating significant earthworks and HGV movements
year record of Zero Harm
year life extension
