Ironmaster: Case Studies & Proven Results

The Problem

• Consistent clipping overrun of Ironwork on the busy A41 (near right).
• Excavation to sound material is vital to ensure the repair will last (far right).

• The new Proteus ironwork is bedded with Ironmaster bedding compound (left).
• No adjustment or reduction of the gully pot is required. The Proteus gully fits directly over a standard 450mm gully pot (right).

• Infill Mortar surrounds the Ironwork (far left).
• Ironmaster IMP patch applied in layers (near left).

Client: Volker Highways

Site: A busy single carriageway approaching Newbury from Thatcham in West Bershire. The surface is 14mm SMA that had fretted around the gully as the Ironwork had become loose.

Problem: Loose Rattling ironwork in a busy urban environment causing noise nuisance to local residents and a potential hazard for cyclists and other road users

Solution: BBA/HAPAS approved Ironmaster was installed to a selection of Manholes gullies and valve boxes to replace old Ironwork and to re-build the chambers and gully pots to ensure that the repair was to be a permanent solution with no defects guaranteed for 5 years

The historic town of Ironbridge—widely regarded as the birthplace of the Industrial Revolution—faced a modern-day challenge in February 2020, when the area was battered by high winds and severe flooding. Home to the world’s first cast-iron bridge, erected in 1779 and now a globally recognised industrial monument, the town's infrastructure was significantly impacted.

In response, Telford & Wrekin Council, in partnership with the Environment Agency, developed a comprehensive flood resilience strategy. A key part of the works involved upgrading critical highway ironwork along The Wharfage, one of Ironbridge's busiest and most flood-sensitive thoroughfares.

Given the need for durability, speed, and minimal disruption, the council selected Rhino’s Ironmaster™ system—a proven, BBA HAPAS-certified ironwork reinstatement method backed by a 5-year written guarantee.

Over the course of just eight days, Rhino’s specialist crews carried out the full reconstruction of:

29 Single Manholes
3 Double Manholes
2 Triple Manholes
23 Valve Boxes
11 Gullies
1 Double Gully

This installation not only restored functionality but reinforced the town's resilience against future flooding events—delivered quickly and to the highest standard, without compromising the character of this historic location.

“Protecting a site of such heritage while preparing it for the future required a system with absolute reliability. Ironmaster™ delivered.”