We delivered extensive concrete repair and cathodic protection works on the A50 River Dove Bridge, a critical section of the strategic route between Staffordshire and Derbyshire.
Originally constructed in 1976, the three-span reinforced-concrete A50 River Dove Bridge had deteriorated due to water ingress through failed deck joints. This resulted in damage to the abutments and half-joint areas, creating the need for extensive repairs and long-term protection. Planning and delivery demanded careful management of environmental constraints, landowner permissions and uninterrupted traffic flow on the heavily trafficked A50.
Commissioned by Balfour Beatty and Connect A50 Limited and delivered by Balvac Ltd, the £2.05 million scheme overcame these challenges while maintaining network performance. The project won the Concrete Repair Association (CRA) “Large Project of the Year” award and was highly commended by the Corrosion Prevention Association.
Located in Uttoxeter, the works were carried out in two phases between April 2023 and October 2024 to avoid the salmon spawning season.
We applied our 4D approach – Detect, Diagnose, Develop and Deliver – to shape project decisions from the outset. Early Contractor Involvement (ECI) was key, with our teams working closely with Balfour Beatty, Connect A50 and WSP to develop a buildable, risk-reducing repair strategy. This collaborative approach provided continuity from design through to delivery, improving programme efficiency.
The works included phased concrete repairs to the half-joints and abutments, alongside the installation of impressed current cathodic protection (ICCP) systems (discrete nodes; mesh and overlay; sting anodes) to the half-joints and hybrid galvanic protection (Galvashield Fusion T2) to the abutments. Several innovative solutions were introduced, including flood-resilient access designed by our temporary works team and reduced drilling requirements with the use of string anodes through the half joints.
Environmental stewardship was integral to the project. Work phases were carefully planned around salmon spawning periods and comprehensive biodiversity surveys were undertaken to protect local species. With the access to the half joints and abutments set with in the flood zone of the river, ongoing river-level monitoring was instigated to safeguard the workforce and the environment as part of a Flood Action Plan.
Pollution risks were mitigated through fully contained hydro demolition, while ultra-high-pressure techniques reduced water consumption. Further benefits were achieved through trials of Instagrid portable rechargeable battery generators for site tools, and by powering the site compound using an energy-smart generator and battery storage solution – reducing overall energy use and cutting emissions by nearly 50%.
Alongside environmental performance, health, safety and sustainability were at the forefront throughout delivery, with Zero Harm embedded across all operations. Operator exposure to vibration was minimised through the adoption of string-anode techniques, while the impressed current cathodic protection (ICCP) design reduced drilling, noise, dust and vibration risks.
A key achievement of the project was maintaining full traffic flow on the A50 throughout the programme, with no lane closures required. Optimised sequencing shortened the programme by two and a half weeks, enabling delivery ahead of schedule and within budget. In total, 17,787 hours were worked without a single reportable safety, environmental or lost-time incident. The project’s success was driven by close collaboration between five organisations, practical innovation and strong environmental governance, earning recognition from the CRA.
