Churchfield Water Tower, Cork

Project Overview

Churchfield Water Tower is a critical water storage facility in Cork, standing at 30 meters high. Over time, the structure exhibited signs of weathering, structural wear, and required essential repairs to maintain its integrity and ensure compliance with potable water safety standards. Adrian Queally Ltd (AQL) was engaged to carry out a comprehensive refurbishment of the tower, addressing both external and internal deterioration while applying protective coatings to prolong the structure’s lifespan.

client objectives

• Ensure the longevity and structural integrity of the water tower. • Conduct essential concrete repairs to prevent further deterioration. • Apply protective coatings for weather resistance and long-term performance. • Ensure compliance with potable water safety standards for internal surfaces.

Scope of works

AQL carried out extensive restoration and protection measures, including: • Ground Stabilisation: Constructed a stabilisation platform to provide safe access for MEWPs (Mobile Elevated Work Platforms) required for high-level work. • High-Pressure Cleaning: All external and internal tower surfaces were subjected to a high-pressure clean-down to remove contaminants, debris, and surface deterioration. • External Concrete Repairs: Structural elements suffering from wear and minor damage were repaired using high-performance cementitious repair mortars. • Hydrophobic Coating Application: A weather-resistant hydrophobic coating was applied to the external concrete surfaces, reducing moisture absorption and preventing future degradation. • Roof Surface Protection: The roof received a specialised protective coating to resist environmental damage and extend the life of the concrete. • Internal Concrete Repairs & Coatings: Internal repairs were conducted, followed by the application of a potable water-approved waterproof coating to ensure the structure remained safe for water storage.

Challenges

• Limited Access & Height Considerations: Due to the tower’s 30M height, AQL implemented a ground stabilisation platform to facilitate the safe operation of MEWPs, ensuring safe and effective work execution at elevated levels. • Surface Contaminants & Deterioration: The presence of accumulated grime, biofilm, and pollutants on concrete surfaces necessitated a thorough high-pressure clean-down before coatings and repairs could be applied. • Structural Weathering & Concrete Spalling: External concrete repairs were carried out using industry-approved repair mortars, ensuring structural elements regained their integrity. • Potable Water Safety Compliance: The interior of the tower required the application of a fully compliant, potable water-approved surface waterproofing system to meet regulatory standards.

Results

• Structural Longevity: The repairs and protective coatings significantly enhanced the lifespan of the Churchfield Water Tower, ensuring long-term durability. • Weather Resistance: The hydrophobic coatings and roof protection measures provided long-term resistance against harsh weather conditions, reducing maintenance requirements. • Regulatory Compliance: The potable water-approved waterproofing system ensured the interior met the highest safety and hygiene standards for water storage. • Improved Aesthetic & Functional Integrity: The tower now appears revitalised, with a clean, reinforced exterior that enhances its structural performance.

Conclusion

The successful completion of the Churchfield Water Tower refurbishment highlights AQL’s expertise in structural water infrastructure repairs. Through meticulous planning, industry-leading materials, and specialist application techniques, AQL delivered a high-quality, long-lasting solution that ensures the water tower remains operational and compliant for years to come.

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