LOCATION:
Berth 3 at Marchwood Port, a key site within the Solent Freeport, had been underutilised due to limitations in its marine infrastructure. Serving both Ministry of Defence (MoD) and commercial operations, the berth required significant upgrades to meet modern operational demands. ABP Solent Gateway appointed Knights Brown to deliver this transformative, £20m, infrastructure project that would extend the life of the jetty and enable year-round berthing for military and commercial vessels.
Key elements of the project included:
The project included:
- Installation of new berthing and mooring dolphins to extend the berth.
- Deepening of the berth from -8m to -11m CD (by others).
- Structural enhancements including fender pile deepening and upgraded mooring equipment.
- Corrosion protection using pile wrapping and cathodic protection to extend the jetty’s lifespan by 30+ years.
- Fabrication and installation of linkspan walkways, precast concrete units and quay furniture.
- Fender pile strengthening, jetty pile repairs and quarter ramp modifications.
- Mechanical and electrical works, including bollard and capstan installation.
Challenges
- Limited as-built data: Required advanced testing and modelling to assess structural capacity.
- Live port environment: All works were delivered while maintaining ongoing MoD and commercial operations.
- Jetty load restrictions: Required innovative logistics and lifting strategies for 40-tonne piles.
- Environmental constraints: Dredging and piling had to be scheduled outside the salmon migratory period.
Solution
Innovative methods and technologies were employed throughout:
- Advanced testing: CAPWAP and static pile testing through the jetty deck enabled safe, uninterrupted operations.
- Computational modelling: Simulated load effects to confirm dredging feasibility without a costly toe wall.
- Retrofit engineering: Smaller diameter piles were inserted into existing fender piles to form composite systems, reducing environmental impact.
- Precision logistics: 32 tubular piles (up to 40m long and 40 tonnes) were delivered by sea and unloaded using bespoke lifting frames, slings and 3D modelling for crane positioning and storage planning.
Outcome
The project has significantly increased the operational capacity of Berth 3, enabling vessels to berth at all states of tide and removing previous tidal and wind restrictions. Knights Brown’s delivery was marked by technical excellence, safety and collaboration, setting a new benchmark for integrated marine infrastructure upgrades. The jetty is now future-proofed for at least 30 years, supporting both national defence and commercial maritime growth.
