ScaffFloat Delivers Innovative Modular Pontoon System
Monday, 13th October 2025
ScaffFloat, a leading provider of modular pontoon systems, has successfully designed, manufactured, and deployed a bespoke floating access solution to support corrosion protection and maintenance on a major infrastructure project in Africa. The project highlights ScaffFloat’s expertise in delivering safe, adaptable, and rapidly deployable marine platforms for global civil engineering operations.
The client required a reliable and efficient way to access and maintain a series of newly installed piles supporting a jetty extending nearly one kilometre offshore. The system needed to provide 360-degree working access while being easy to reposition across more than 100 pile locations.
In collaboration with the client, ScaffFloat engineered and built two 8m x 3m self-propelled modular pontoons, purpose-designed for hoisting operations. Each pontoon could be secured on either side of a pile, allowing workers to lay staging boards across the gap and create a safe, full-enclosure work platform. Once maintenance was complete, the pontoon units could be lowered, moved, and re-hoisted onto the next pile in just a few hours — dramatically improving efficiency and reducing downtime.
Engineering and Testing in Cornwall
Prior to deployment, ScaffFloat completed all engineering, fabrication, and testing at its facility in Cornwall, UK. The company conducted a full trial build and load test to confirm the strength and stability of the modular pontoon system, ensuring operational safety before overseas delivery.
The comprehensive verification process included:
– A Category 3 Check from Richter verifying the hoisting system’s structural integrity.
– An inclination test in Falmouth Harbour, overseen by a certified marine surveyor, confirming pontoon stability.
– A detailed lift plan with full engineering drawings and specifications for all lifting equipment.
Global Delivery and On-Site Commissioning
The complete modular pontoon system, including both self-propelled units and all supporting equipment, was efficiently packed into a single 40-foot shipping container for international transport from Cornwall to Africa.
Following delivery, a ScaffFloat engineer travelled to the site to oversee assembly, conduct final trials, and deliver comprehensive training to the client’s team as part of a full operational handover. Ongoing remote support ensures smooth operation and maximum uptime throughout the maintenance programme.
Advancing Modular Marine Engineering
“This project perfectly demonstrates the flexibility and value of modular pontoon systems in complex international civil works,” said Toby Budd, Founder and Managing Director of ScaffFloat. “We didn’t just supply pontoons — we engineered a fully hoistable, modular marine tool that directly met our client’s operational needs.
By managing every stage from design and testing in Falmouth to deployment in Africa, we delivered a turnkey, low-risk solution that is improving safety and efficiency every day.”
About ScaffFloat
Based near Falmouth, Cornwall, ScaffFloat designs and supplies modular pontoon systems and floating work platforms for marine construction, access, and maintenance projects across the UK and internationally. Built from durable, 100% recyclable plastic floats and standard scaffolding, ScaffFloat systems are safe, sustainable, and adaptable to diverse project needs.
With options for pontoon hire, self-propelled units, and skippered services, ScaffFloat delivers reliable, eco-conscious marine access for contractors, engineers, and infrastructure developers worldwide.
