Volkerlaser: Delivering precision in complex environments- sprayed concrete works on the M5 Oldbury Viaduct
VolkerLaser recently completed sprayed concrete works across three key phases of work on the M5 Oldbury Viaduct: R181, P80, and P76. The sprayed concrete technique was used to encapsulate and protect embedded titanium mesh as part of an extensive cathodic protection system. Each phase presented unique environmental and logistical challenges that required precision, adaptability, and utilised our in-house expertise.
The three schemes all demanded a unique access strategy and precise control of the sprayed concrete application, with works carried out under live traffic conditions, over canal sections, and within confined viaduct zones. On R181, fully encapsulated scaffolds were installed above the canal to prevent overspray and water discharge from hydro-demolition. P80 required 4,500m² of bespoke V-Deck™ platforms that allowed safe working above the canal without disrupting operations below. Meanwhile, P76 required 66-metre enclosed scaffolding along the viaduct, which was installed under live traffic with narrow lanes and off-site logistics.
Sprayed concrete was selected for its ability to adapt to complex geometries and eliminate traditional formwork. Dry spray was used throughout, with material selection guided by site-specific requirements and specifications- Fosroc DS on R181 and P80, and Webercem Spray DS on P76. Spray trials were conducted on mock beams and panels to validate the technique, followed by inspections under the Inspection Test Plan (ITP). Hammer tap testing at key intervals, reviewed by the client, confirmed application quality across all zones.
All sprayed concrete works were self-delivered by VolkerLaser operatives, each with over 30 years’ experience. This internal expertise ensured full control over programme, cost and quality. Sprayed concrete proved essential, not only for its adaptability to complex geometry and confined space, but for delivering long-term durability. By encapsulating the cathodic protection system, the application helps extend the service life of the structure and minimise future maintenance, strengthening the viaduct for years to come.
