Shoreham Port

Location: Shoreham Port, Southwick Brighton

Client: Lanes Group

Partners: RSM Lining Supplies, VIP-Polymers

The Challenge

Shoreham Port relies on four large-diameter cast-iron pump lines to transfer seawater from a dockside pump house into the dock basin, replenishing water lost during lock operations. Each pipe can convey up to 8,500 tonnes of seawater per hour, making the system critical to the port’s continuous operation.

Condition surveys identified leakage and deterioration within the pipes, increasing pumping costs and placing the long-term integrity of the system at risk. Replacement was not viable due to access constraints, sharp bends, confined working conditions, and the requirement to keep the port fully operational throughout the works.

Conventional CIPP lining methods, including hot water and UV systems, were ruled out due to limited space, multiple 20-degree bends, and tidal constraints within the pump house.

The Solution

Working in close partnership, Lanes Group, RSM Lining Supplies and VIP-Polymers developed a bespoke trenchless rehabilitation approach using the newly launched VIP-WECO Connect system.

VIP-WECO Connect is based on the proven VIP-WECO mechanical seal design and enables multiple rubber sealing elements to be securely connected to form a continuous liner of virtually unlimited length. The system was combined with short CIPP patch liners to accommodate tight bends and geometric changes within each pipe.

In total, more than 500 interconnected VIP-WECO Connect seals were installed to line four pipes ranging from 20 to 42 metres in length, achieving a total rehabilitated length of 126 metres.

During cleaning works, a further challenge was identified: each pipe reduced in diameter by approximately 125mm over a 10-metre section as it exited the pump house. In response, VIP-Polymers designed and manufactured a bespoke stepped sealing arrangement, comprising nine incremental diameter reductions per pipe, allowing the liner to adapt seamlessly to the changing geometry.

To support installation in extremely low-visibility, confined conditions, VIP-Polymers further enhanced the VIP-WECO Connect design to include an integrated locating tab feature.

Developed in response to site constraints and installer feedback, the locating tab provides a clear tactile indication that each seal has been correctly engaged and aligned. This allowed operatives to confirm correct installation by touch rather than relying solely on visual checks, improving confidence, quality control, and installation efficiency in restricted spaces. The locating tab feature has since been incorporated into the ongoing development of the VIP-WECO Connect system.

Installation & Delivery

Installation was carried out by a four-person lining team, supported at all times by a dedicated confined space rescue crew. Two of the four pipes had to remain operational throughout the programme, with work carefully sequenced around tidal movements and live pumping requirements.

Despite these constraints, the full rehabilitation programme was completed in just six weeks, meeting the port’s immovable operational deadline and maintaining uninterrupted cargo movements.

The Outcome

The VIP-WECO Connect system delivered a fully sealed, structurally independent liner with a design life in excess of 50 years, providing Shoreham Port with a long-term, cost-effective solution to safeguard a critical asset.

The project demonstrated the capability of VIP-WECO Connect to overcome severe access, geometry, and operational challenges, where traditional lining or replacement methods are not feasible.

It also highlighted the value of early collaboration between asset owner, contractor, lining specialist, and manufacturer to deliver innovative, site-specific engineering solutions.