Client
Highways England
Value
£900,000
Sectors & Services
Highway Structures Concrete Repair Cleaning & Preparation ECI (Early Contractor Involvement) Projects Projects
Ashflat Lane Bridge is a highway overbridge spanning the M6 motorway within Highways England Area 9, carrying local traffic and pedestrians over one of the UK’s busiest strategic routes. The cast in-situ concrete parapet edge beams had reached the end of their serviceable life and required full replacement to maintain structural integrity and safety.
Following an extended Early Contractor Involvement process and a competitive bid, CRL was appointed to deliver the works. The project was significant due to the requirement to maintain live motorway traffic beneath the bridge and pedestrian access above, demanding an innovative, safety-led approach consistent with best practice in structural repairs UK and asset management.
Services undertaken
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Early Contractor Involvement and collaborative solution development
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Night-time lifting and installation of modular over-slung protection units
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Hydro-demolition of concrete to expose reinforcement
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Installation of new steel reinforcement cages
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In-situ recasting of concrete parapet edge beams
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Bridge deck waterproofing works
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Laying of new carriageway surfacing
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Installation of new vehicle parapets
CRL worked closely with its supply chain to develop an innovative access and protection solution that allowed the parapet edge beam replacement to be carried out while keeping the M6 fully operational. A bespoke cantilevered support and protection system was designed to create a fully enclosed working environment beneath the bridge deck. The primary support frame was assembled on the bridge deck using kentledge, while modular over-slung sections were fabricated on the M6 hard shoulder and lifted into position during planned night-time closures. This approach eliminated the need for prolonged motorway closures and significantly reduced disruption to road users.
The enclosed and sealed system enabled safe use of hydro-demolition to remove the upper layer of concrete and expose the existing reinforcement without risk to traffic below. Ring saw cutting was then employed to section and remove the existing concrete parapet in controlled, manageable blocks. Once removed, a new steel reinforcement cage was installed, followed by recasting of the parapet edge beam in situ.
Subsequent works included re-waterproofing of the bridge deck, laying new surfacing and installation of a new vehicle parapet. Throughout the scheme, CRL managed all aspects of health, safety and workforce welfare. A strong safety culture was maintained through regular briefings, toolbox talks and senior management inspections, resulting in zero reportable or major accidents. The project was delivered adjacent to residential properties, over a live motorway and with pedestrian access maintained, demonstrating CRL’s ability to deliver complex concrete repairs safely, efficiently and collaboratively while preserving critical infrastructure.
"By developing a bespoke cantilevered access system, we were able to safely replace the parapet edge beams while keeping the M6 fully operational. The works were delivered to a high quality standard with zero reportable accidents, reflecting the strong safety culture and commitment of everyone involved. This scheme clearly shows CRL’s ability to deliver complex concrete repair solutions safely, efficiently and with minimal disruption.”
Adrian Pike | Global Framework Director | CRL
The completed works provide long-term durability and resilience for Ashflat Lane Bridge by addressing both structural condition and future protection. Recasting the parapet edge beams with new reinforcement restores structural capacity, while deck re-waterproofing prevents the ingress of water and de-icing salts that can lead to reinforcement corrosion. The use of hydro-demolition and controlled cutting ensured sound substrates and high-quality bond conditions for new concrete, supporting long-term performance.
The installation of new surfacing and a compliant vehicle parapet further enhances safety and reduces ongoing maintenance demands. By delivering a solution that protects the structure while maintaining traffic flow, CRL has helped extend the service life of this key asset, supporting effective asset management and reducing the need for future disruptive interventions on the motorway network.
