Basement Wall - Repair
Melbourne, Victoria

The walls of a basement-level archive room were experiencing concrete degradation and moisture ingress due to poor concrete placement and compaction during initial construction. NCS were contracted to repair and reinstate the walls using Xypex concrete repair products.

Preparation for the basement wall involved the removal of existing paint and other contaminants from areas that were damaged from water ingress. Additionally, all deteriorated concrete areas were pressure washed to provide an open capillary, clean absorbent surface, and bony and honeycombed sections were chipped out to a square-edged substrate and surface laitance was removed.

Upon completion of surface preparation, the substrate was saturated with water and Xypex Concentrate applied as a slurry coat to treat the exposed steel and reinstate a passive alkaline barrier around the reinforcement. Xypex Megamix II high build mortar was then used to return the repair back to contour with the surrounding concrete.

A Xypex Concentrate and Xypex Modified coating was then uniformly applied to all concrete surfaces with a semi-stiff bristle brush. Xypex Modified chemically reinforces Xypex Concentrate and produces a harder finish, providing enhanced concrete durability and additional waterproofing integrity.

Xypex Gamma Cure was applied as a fine mist spray, both during and after the coating process, to accelerate the crystalline process and assist in product curing for optimum performance..

Reservoir Access Shaft Repair
Regional Victoria

NCS were contracted by a region water authority to repair two construction joints that had failed and allowed substantial water ingress in a reservoir access shaft. The access shaft which is in excess of 125 meters long houses the main offtake pipeline which runs under the reservoir wall. The leakage was resulting in damage to the metal pipeline which could not be maintained whilst subject to water leakage.

A dual repair system was employed and comprised the Xypex Full Crack repair system, which is able to be undertaken against significant water flows in high hydrostatic pressure environments, and as a further precaution a limited amount of Polyurethane resin injection was performed.

The work was successfully completed within two days and the resultant dry shaft was deemed suitable to permit maintenance works of the pipeline to commence.

Dam Repair - Concrete Coverage
Burnett, Queensland

The mini-hydro station at Paradise Dam required remedial repair due to insufficient concrete coverage. Xypex products were specified by Sunwater and applied to the mini-hydro station, under the supervision of NCS . The rectification method was designed to provide protection to the existing steel reinforcing and to enhance long term durability of the structure.

Concrete Coatings - Rail Interchange Bridge
Chatswood, Sydney

The Chatswood Rail Interchange is a post-tension bridge structure that exhibited fine hair line cracking. NCS was contracted to apply the Xypex coating system, which involved brush application of Xypex Concentrate and Modified over the deck area. The Xypex treatment was specified to reinstate service life expectation by eliminating water ingress.

Water Treatment Plant Repair
Richmond Valley Council, NSW

Richmond Valley Council (RVC) operates the Casino Water Treatment Plant. The plant has 4 concrete water filtration tanks with a total surface area of approximately 90m2 each. The surface of the tanks had deteriorated leaving a heavily exposed aggregate finish. NCS were contracted by RVC to repair and reinstate the surface and cut out and replace the existing joint sealant.

Rather than close down the whole plant, the tanks were de-commissioned, one at a time and the work was carried out allowing RVC to re-commission the remediated tank before NCS starting work on the next one. The tanks were prepared and Xypex Megamix II was applied at a thickness of 10mm to the tank walls, floor and baffle trays. Megamix II was selected for its superior bond strength, chemical durabilty and it's use of Xypex's unique crystalline waterproofing and protection technology. The joints were then re-sealed using Sikaflex Tank, polyurethane joint sealant. Sikaflex Tank was selected because of its high chemical resistance and its potable water certification.

Anchor Pad Rehabilitation
Bennelong Pt, Sydney

NCS was contracted to repair and rehabilitate anchor pads and associated works for an underground basement structure located eighteen metres below the Sydney Harbour waterline. The structure exhibited excessive moisture, which in turn was causing corrosion of the steel reinforcing cables.

NCS utilised the Xypex repair system by scabbling the damaged concrete directly beneath the metal base plates and applying Xypex crystalline products to the prepared areas. Coating of the base plate with an epoxy was undertaken seven days after completion of the Xypex repair system.

Sewerage Treatment Tank Repair
Gold Coast, Queensland

NCS was contracted to provide remedial repair to a newly constructed sewerage treatment tank. Cold joint repairs were conducted to the inside and outside of the tank, restoring the concrete back to original contour.

The repair method required the affected area to be scabbled and Xypex Megamix II applied, ensuring long-term concrete waterproofing and durability.

Manhole Remediation
Brisbane Airport, QLD

NCS were contracted to provide a solution to repair two large manholes (3.5m deep x 2.0m diameter) at Brisbane Airport.

The manholes were heavily deteriorated from sulphate attack and required relining and a protective coating. The first manhole was prepared and had a few small patch repairs done before being sprayed with Xypex Megamix II through a specialised pump/spray unit.

Xypex Megamix II was trowelled off and left to cure for several days. The manhole was then coated with 2 applications of Epigen 1311 applied as a protective coating.

The second manhole, which is installed as a 'blind' tank, is used for emergency dumping of waste fuel or kerosene. Xypex Megamix II was applied by spraying and trowelling off. Once cured, Sikagard 62 was applied as a protective coating because of its high level of chemical resistance.

Xypex Megamix II is ideal for use in this situation because of its unique crystalline protection technology, for its concrete durabilty enhancement and proven performance in a sewerage environment.

Bridge Culvert Repairs
Sydney, NSW

The Long Street Culverts exhibited severe corrosion and spalling of 10 joints in two cells. NCS were contracted to repair the culverts which included removal of all damaged concrete, followed by the cleaning and/or replacement of steel reinforcement. The concrete cover was reinstated with Xypex products, with an approximate cover replacement of 50mm. The repair included 7 lineal meters of culvert face construction joint repair.