INSPEC OCTOBER 2012 ROPE ACCESS FACADE INVESTIGATION PLUS ACID PROOFING HYATT HOTEL PAGE 4 INSIDE 2 MESSAGE FROM PHIL 2 BUND PROTECTION AT KCGM 3 TECHNICAL SURVEY - 996 HAY ST 4 ACID PROTECTION - HYATT HOTEL 4 CIL TANK REFURB - CAROSUE DAM 5 CONCRETE REPAIRS - GRANNY SMITH 5 CRACK INJECTION IN WELSHPOOL 6 WATERPROOFING ARTICLE 7 SUPPORTING COMMUNITIES 7 RIO TINTO DOZER 8 ACRA AWARD WIN 8 CONTACT US INSPEC OCT 2012 1
A MESSAGE FROM PHIL PHIL HARCOURT MANAGING DIRECTOR WELCOME TO OUR SPRING EDITION OF INSPEC Welcome to our October edition of InSpec highlighting recent asset investigation and remediation projects and providing some recent company achievements. We are delighted to announce Duratec Australia, in conjunction with Rio Tinto Dampier Salt Ltd, has received the Australian Concrete Repair Association (ACRA) award for excellence in concrete repair and protection, in excess of $3M category, for its Dampier Salt Mooring Dolphin concrete repair and hybrid cathodic protection project submission. This prestigious award was presented at the eighth biennial Awards of Excellence function held at Darling Harbour, Sydney on the 11th October 2012. A newly constructed company web site was launched in late September 2012 and this provides improvements in presentation and navigation to those who access it along with clarification of our capabilities and markets we operate in. We encourage you to view this on www.duratecaustralia.com.au We look forward to being of service meeting our customers needs and expectations. PROJECT REVIEW CYANIDE BUND PROTECTION AT GIDJI ROASTER KCGM s Gidji Roaster has built a new Cyanide Destruction Area. FormAction provided all the concrete civils with Duratec installing a high performance membrane to protect the 400m 2 of concrete from the process liquors. The selected topcoat was Polyeuro 5502 - a plural component rapid set polyurea. This coating system has excellent flexibility to accommodate substrate movement and excellent chemical resistance and waterproofing properties. To prepare the 28 day old cured concrete, Duratec specialists abrasive blasted and patched the bund with Nitomortar 903 before the polyurea primer was applied. All corners were coved to assist the performance of the coating system. One of the commons problems with painting new concrete is outgassing. The crews worked at night when the substrate temperature was falling to reduce the issue of outgassing. 2 INSPEC OCT 2012 Overview of the 400m 2 bund. Right: Duratec specialist solvent wiping the surface in preparation for the polyurea topcoat.
PROJECT REVIEW TECHNICAL SURVEY AT 996 HAY STREET The owners of 996 Hay Street - a large residential and commercial complex in the heart of Perth has engaged Duratec to complete a full external survey of their building. Most of the external survey was performed by rope access professionals who noted and photographed any visible defects. Rope access is a nationally accredited skill and is regarded as one of the safest forms of access as well as being fast and cost effective. The owners received a detailed report highlighting all defects which will enable the project to be accurately priced and the correct methodologies ascertained for the repairs works. In the building carpark, Duratec engineers also provided some diagnostic surveying of water leaks from the complex s swimming pool which were causing chloride contamination of one of the reinforced concrete support beams. A Corromap instrument was used to measure and record the corrosion rate of the reinforcing steel, the half-cell potentials and the resistance of the cover concrete, key information required to enable informed decision making on recommended remediation techniques. Top: Rope access specialists inspecting all potential problem areas. Right: Photographing defects on the southern facade. Below: Duratec engineer mapping the corrosion rate of the steel reinforcement in the underground car park. Below right: Rope access is a fast and efficient way of performing facade investigations. INSPEC OCT 2012 3
PROJECT REVIEW ACID PROTECTION AT THE HYATT HOTEL When you think of acid proofing you normally think of remote mine sites and chemical bunds. The Hyatt Hotel in Perth s CBD however needed to protect the concrete in their pool plant room from exposure to pool chemicals. The plant room is adjacent to offices, so all noisy works such as the preparation of the floor with grinders had to be completed outside of normal working hours. After the preparation was finished, a three coat high performance Steuler acid protection system was installed to provide long-term protection of the concrete from the aggressive pool chemicals. Some repairs on the roof soffit were also completed. Top: application of the Alkadur HR - a self-levelling, seamless, chemical resistant flooring system. Right: Duratec specialist applicator installing the intermediate coat of the three coat process. PROJECT REVIEW COMBATING SRB S AT CAROSUE DAM 4 INSPEC OCT 2012 Sulphate Reducing Bacteria (SRBs) are nasty critters that can quickly accelerate the corrosion of steel assets, in particular storage tanks. Duratec was called upon by Saracen Mineral Holdings Ltd to refurbish a CIL tank that tested positive to SRBs at their Carosue Dam operation. The successful removal of SRBs is vital in maximising the life of the tank and to achieve this, the full internal epoxy coating was removed by ultra high pressure water jetting. This method removes the coating fast and efficiently and also thoroughly cleans the steel substrate. After mechanical repairs were completed, the tank surface was also sandblasted before a holding primer and 3000 microns of an ultra high build epoxy was applied.
PROJECT REVIEW GRANNY SMITH CONCRETE WORKS Duratec s Kalgoorlie Division specialise in servicing our remote gold mines and was again engaged by Granny Smith gold operations to perform remedial works. Two teams mobilised to the mine site located 20km south of Laverton to refurbish the hydrochloric acid area and perform concrete repairs in the stockpile tunnel. The HCl area required an upgrade to meet new safety standards including the placement of new concrete walls, replacement of the joint sealant and the application of Epigen s Chemproof novolac epoxy lining system to the exposed concrete bund and truck unloading area. The stockpile tunnel repairs were performed over a scheduled eight day shutdown. Concrete was removed manually by jackhammers before the steel reinforcement was blasted and painted for protection. Due to tight working environments, a combination of methods (form and pour, grout pumping and shotcreting) and products (Renderoc s Guncrete E and LA55) was required to repair the degraded areas. To meet the shutdown deadline, two six man teams worked rotating shifts around the clock to complete the 65m 2 repair area. Top: HCL truck unloading area. Middle: Stockpile tunnel entrance wall after concrete breakout and reinforcement repair and protection. Right: the completed wall. PROJECT REVIEW CRACK INJECTION Duratec regularly perform concrete crack injection repairs and was called upon by Knight Frank to repair tilt form slab walls at Hazelhurst Street in Welshpool. The damage and expensive repairs required when water enters cracks in pre-cast concrete panels can be simply avoided. Injection of water tight material into the crack is simple, efficient and very cost effective in comparison to repairing in the later stages of concrete cancer. Using AKWASEAL LV Duratec was able to complete the sealing of the cracks in the pre-cast tilt up concrete panels. INSPEC OCT 2012 5
TECHNICAL ARTICLE WATERPROOFING TECHNIQUES Since the early Roman times the importance of waterproof construction and attention to detail has been recognised, albeit the materials applied today are quite different. Waterproofing of building structures is an integral part of good construction practices and building codes, as when correctly specified and installed, importantly prevents water ingress through building materials such as concrete that, inherently, are not waterproof. There are a large number of proprietary waterproofing products on the market and the choice of product is very much dependent upon the application and service conditions. Some of the commonly used waterproofing products used by Duratec are presented as follows: Liquid Applied Membranes: are normally polyurethane based two component asphalt modified products, which being liquid applied conform to irregular profiles, are seamless, chemically cure and are appropriate for a variety of applications including basements, flat decks, balconies and for use in conjunction with sheet membranes. Spray Applied Membranes: these are generally polyurea/ elastomeric urethane membrane systems spray applied with specialist plural component equipment. They have the benefits of: rapid curing and fast application; high flexibility to accommodate substrate movement; and one coat application at any thickness providing a seamless, tough, resilient film. This makes them excellent waterproof coatings for large areas such as secondary containment bunds and tank linings. Torch Applied Membranes: generally these are elastomeric polymer-bitumen multi-layer reinforced composite sheet membranes, up to 4mm thick applied on top of a previously applied bituminous primer using a gas torch-on method. These types of membranes supply uniform thickness, excellent temperature stability, durability, flexibility, adhesion and resistance to substrate cracking. They are ideally suited to waterproofing lift pits, basement slabs, wall tanking, cut and cover tunnels, podiums, balconies, roof slabs, car parks, bridge decks and all suspended slab landscaped areas. Self-Adhering Blind Side Sheet Membranes: these sheet membranes comprise multi-layered composite sheets of HDPE and specially formulated synthetic pressure sensitive adhesive and protective coating. This type of membrane is specifically suited to blind side waterproofing applications where the positive side waterproofing is desired but the positive side of the structure is not accessible once the concrete is poured. These types of membranes are applied in under slab and below grade split slab applications and on correctly prepared soil retention systems where the concrete is cast against the membrane. Self-Adhering Sheet Membranes: these sheet membranes are multi-layered composite sheets of HDPE and specially formulated synthetic pressure sensitive adhesive and protective coating or rubberised asphalt composite. They are applied to the accessible positive external face of structures such as double face formed retaining walls, box culverts, flat decks, roof slabs and plaza decks. Apart from the correct selection of a waterproofing system fit for the intended service, one of the most critical factors associated with waterproof membrane installation is attention to detail at termination points, expansion joints, reentrant corners, laps (in the case of sheet membranes), and penetrations. Failure to attend correctly to these critical issues will ultimately lead to leakage into the building structure. Duratec key personnel possess many years experience of successful installation of waterproof membranes in new construction and rehabilitation works ensuring watertight construction and extending the life of key infrastructure. Polyurea applied in a containment bund in the gold industry. Torch-on membrane applied at Haddon Place, South Perth. Liquid membranes with sheet reinforcing applied at King Edward Memorial hospital. 6 INSPEC OCT 2012
NEWS SUPPORTING LOCAL COMMUNITIES As a goodwill gesture and to help support local community organisations, Duratec provided a helpful hand to Kalgoorlie s Golden Mile Paceway. The trotting club s water cart was in desperate need of saving from corrosion and our Kalgoorlie division came to the rescue. Performed in our yard on Yarri Road, the water cart was fully sandblasted and painted bringing it back to new condition. The two-pack anti-corrosive paint was kindly donated by Dulux Protective Coatings. CHECK OUT OUR NEW WEBSITE AT www.duratecaustralia.com.au PROJECT REVIEW PROTECTING MINING EQUIPMENT FOR RIO TINTO The fully completed D10 ready for many more hours of work. Duratec was engaged by Rio Tinto Iron Ore to completely refurbish a D10 Dozer. The project was completed in Karratha s fully encapsulated blast and paint yard. The dozer was showing signs of corrosion and required spot abrasive blasting with the remaining intact surfaces lightly blasted. All areas to be protected were masked prior to treatment and Cameleon Camprime PS200 primer was applied at 45 microns. After the primer cured, a coat of Camsafe IF898 in the colour Westrac Yellow was applied by airless spray. INSPEC OCT 2012 7
EXTENDING THE LIFE OF YOUR ASSETS ACRA AWARD WIN Duratec is pleased to announce we have won an ACRA award for excellence. The award is for outstanding achievement in the provision of remedial concrete diagnosis and repair services. The Australian Concrete Repair Association s award was presented to Duratec s Managing Director Phil Harcourt at the biennial award gala dinner held in Cockle Bay, Sydney on Thursday 11 October. Duratec nominated two projects - the Rio Tinto Dampier Salt Mooring Dolphin Repair Project and the BHP Billiton Nickel West Kalgoorlie Acid Protection Project for the awards. It was the Dampier Salt Mooring Dolphin repair project that was the successful winner of the marine/ industrial large project category up to $3mil. Phil Harcourt said, the success of this project was due to all stakeholders working collaboratively together and we would like to thank our project team, Dampier Salt and Infracorr Consultants for their commitment to the project. SPECIALIST MAINTENANCE AND PROTECTION ASSET CONDITION SURVEYS HIGH PERFORMANCE COATINGS CONCRETE REPAIR INDUSTRIAL FLOORING CATHODIC PROTECTION MINE SITE MAINTENANCE BLASTING AND COATING TANK MAINTENANCE PRECISION GROUTING WATERPROOFING BUILDING FACADES STRUCTURAL STRENGTHENING HEAD OFFICE 21 Triumph Avenue Wangara WA 6065 P: (08) 6267 2370 E: info@duratecaustralia.com.au KALGOORLIE Lot 33 Yarri Road Parkeston WA 6433 P: (08) 9021 5277 KARRATHA U1/3890 Coolawanyah Road Karratha LIA WA 6714 P: (08) 9185 6077 PORT HEDLAND 11 Pinga Street Wedgefield WA 6721 P: (08) 9140 2240 WWW.DURATECAUSTRALIA.COM.AU