Knypersley Spillway Repair – NATCEM® AC

Project – Knypersley Reservoir Spillway Repair

Product – NATCEM® AC

Main Contractor – Kier

Client – Canal & River Trust

Designer – Arcadis

NATCEM® AC was successfully applied in a series of critical repairs at Knypersley Reservoir’s spillway, addressing key safety concerns identified in the latest Section 10 Matters in the Interests of Safety (MIOS) report.

Spillway Repair – the Method

The project required essential maintenance of the reservoir’s spillway and draw-off culvert. Therefore, the Canal & River Trust engaged Arcadis to create a robust design plan. This plan had to meet MIOS recommendations and resolve structural concerns, including missing mortar, cracked surfaces, and displaced masonry blocks affecting stability.

Since the spillway was primarily masonry, it needed thorough repointing and crack filling. Initial inspections revealed widespread missing mortar, fractures, and masonry deterioration. Because long-term durability was critical, every repair had to prevent further structural degradation and withstand extreme weather conditions. Additionally, maintaining the spillway’s functionality was crucial for ensuring overall reservoir performance and safety.

After fully cleaning and preparing the affected areas, the team selected NATCEM® AC for restoration. Since it performs exceptionally well in thin applications, it was the perfect solution. This ensured that the material filled narrow gaps and small voids efficiently, even in high-stress locations. Furthermore, its non-toxic composition made it ideal for use in environmentally sensitive areas near watercourses.

Moreover, NATCEM® AC’s flexibility allowed it to bond securely, even in challenging conditions. Its superior durability reinforced the spillway against future damage, ensuring long-term stability. Additionally, its rapid-setting nature helped accelerate the repair process, minimising downtime. Because the reservoir remained operational, using a high-performance mortar was essential to maintain the structure’s integrity and extend its lifespan.