PD Ports
Hartlepool
Heugh Breakwater Repair
MARINE ENGINEERING | CIVIL ENGINEERING | STRUCTURAL ENGINEERING | PROJECT MANAGEMENT
PROJECT OVERVIEW
Simpson Coulson was commissioned by PD Ports to develop a comprehensive engineering solution for the repair, strengthening and cavity fill of Heugh Breakwater in Hartlepool. This is a historic coastal defence structure protecting the harbour from the exposed conditions of the North Sea.
Originally constructed in 1853, the approximately 400m long breakwater had suffered significant deterioration and storm damage, including the displacement of substantial precast concrete blocks at its seaward head.
Following detailed engineering assessments and a Front End Engineering Design (FEED) study, we developed an innovative repair strategy to stabilise the existing structure, strengthen the vulnerable pier head and improve resilience against wave action.
SOLUTION
The proposed solution incorporated a reinforced concrete bulkhead and concrete cavity filling. This was achieved with a structural overlay, specialist reinforcement and dowel connections. Alongside these, we also improved the access to the infrastructure, security gates and protective hand railing.
EXPERTISE
By evaluating alternative marine construction techniques and developing a practical land based strengthening strategy, our team demonstrated its ability to combine technical engineering expertise with construction led problem solving. This resulted in the delivery of a safer, more economical approach to complex coastal infrastructure repairs.
400m
Total breakwater length
70m
End section identified for structural strengthening
400mm
Designed reinforced concrete overlay thickness
6 months
Phase 1, 2 and 3 construction duration
ENGINEERING CHALLENGE
The principal engineering challenge was to stabilise and protect an ageing breakwater. The Heugh was suffering from substantial damage from repeated exposure to severe marine conditions. The existing structure comprised large precast concrete blocks arranged in overlapping tiers, relying on their collective mass to resist wave action. Storm damage had displaced several blocks at the breakwater head, leaving the remaining structure increasingly vulnerable to further movement.
Conventional reconstruction would have required extensive marine operations. This includes heavy lifting from jack-up barges, underwater working and the repositioning of individual concrete blocks weighing more than 30 tonnes. Simpson Coulson therefore needed to develop an alternative repair methodology capable of strengthening the existing structure while minimising the risks, logistical constraints and costs associated with working in an exposed tidal environment.
SCOPE OF WORKS
Simpson Coulson’s scope encompassed specialist marine structural design, reinforced concrete strengthening, coastal infrastructure repairs and construction planning. We delivered an integrated engineering solution to address storm damage and improve the resilience of Heugh Breakwater.
Structural Engineering & Design
• Front End Engineering Design (FEED) study
• Structural condition and damage assessments
• Reinforced concrete bulkhead design
• Structural slab and reinforcement detailing
• Dowel connections to existing precast blocks
• General arrangement and construction drawings
• Structural load and stability assessments
Marine & Coastal Engineering
• Assessment of storm damage and wave exposure
• Breakwater head stabilisation strategy
• Evaluation of land-based and offshore repair methods
• Protection against block displacement and undermining
• Grouting and stabilisation of damaged concrete blocks
• Marine access and tidal working considerations
• Coastal infrastructure rehabilitation
Civil Engineering & Concrete Works
• Site preparation and temporary access works
• Specialist formwork and shuttering installation
• Drilling and installation of structural dowels
• Reinforcement fabrication and installation
• In-situ reinforced concrete slab construction
• Cavity grouting and concrete repair works
• Security gate and protective handrail improvements
Construction & Project Management
• Temporary works design and methodology
• Construction sequencing and programme development
• Plant access and ground-bearing assessments
• Site mobilisation and logistics planning
• Coordination of specialist construction activities
• Health, safety and marine risk management
• Site reinstatement and demobilisation
ENGINEERING DESIGN & DELIVERY
AN ALTERNATIVE APPROACH TO MARINE CONSTRUCTION
A defining aspect of the project was Simpson Coulson’s development of a land based strengthening strategy. The initial engineering assessment considered recovering and reinstating the displaced concrete blocks using jack-up or floating barges. However, the significant weight of the blocks, exposed tidal conditions, restricted access and potential requirement for underwater operations presented safety and logistical challenges.
Rather than reconstructing the breakwater head block by block, we developed a solution focused on retaining and strengthening the remaining structure. The proposed design incorporated a reinforced concrete bulkhead connected to the existing precast blocks. Together with a structural concrete overlay designed to distribute loads and improve the structure’s resistance to wave induced movement.
Specialist dowel connections and reinforcement arrangements were designed to tie the new concrete into the existing structure. This created a more unified structural system capable of resisting the forces generated during severe coastal storms. This approach significantly reduced the reliance on offshore plant and specialist lifting while providing PD Ports with a targeted repair strategy for the most vulnerable sections.
PROJECT OUTCOME
PROTECTING HISTORICAL COASTAL INFRASTRUCTURE
The Heugh Breakwater repair scheme demonstrates our capability to develop practical engineering solutions for complex marine structures. We achieved this through detailed structural assessment, innovative repair design and construction methodology development. This project established a targeted approach to stabilising the damaged breakwater head and improving the resilience of the existing infrastructure.
The engineering solution prioritised the retention and strengthening of the historic structure. This results in reducing the need for extensive reconstruction while addressing critical structural vulnerabilities. Simpson Coulson provided PD Ports with a coordinated solution focused on safeguarding Hartlepool’s coastal infrastructure. This was achieved by integrating marine engineering, reinforced concrete design and specialist construction planning.
PROTECTING HISTORY THROUGH INNOVATION
The Heugh Breakwater project highlights Simpson Coulson’s specialist expertise in marine structural engineering and the rehabilitation of critical coastal infrastructure, combining detailed technical assessment with practical, construction solutions.
By challenging conventional offshore repair methods, we developed an alternative strengthening strategy that addressed complex structural vulnerabilities while reducing anticipated construction risks, marine plant requirements and associated costs. The project demonstrates our ability to assess ageing marine assets, develop technically robust repair solutions and coordinate specialist engineering disciplines within demanding coastal environments.
An example of Simpson Coulson’s commitment to engineering innovation, protecting existing infrastructure and developing sustainable, long term solutions for the UK’s marine and port industries.