Concrete Bridge Rehabilitation and Joint Repair
Loch Poowong Rd, Victoria

NCS were contracted to provide concrete rehabilitation and joint repair to a concrete bridge on loch Poowong Road, Victoria. Rehabilitation of the expansion joints was completed by using a Miska system that consists of the use of an elastomeric concrete in conjunction with nitrogen blown closed cell, cross link polyethylene. This stage also required traffic management and was closely linked to the asphalting contractor.

Stage two of the project involved application of the Xypex coating system to the bridge soffits, to provide concrete durabilty enhancement for the structure and an extended service life.

Pedestrian Bridge Repair
Holroyd City Council. Sydney, NSW

The Coopers Creek pedestrian bridge required remedial works to reinstate concrete cover to both the support beams and soffit beams on both sides of the bridge.

Concrete areas requiring treatment were prepared prior to the application of repair materials. This included removal of laitance to provide a clean, open substrate for the application of Xypex repair materials. A solution combining Xypex Concentrate, Xypex Megamix I, Xypex Megamix II, Xypex Xycrylic Admix was provided, and the structure successfully reinstated.

Structural Repairs
Queensland

Due to unforeseen construction issues, a new multi storey building was exhibiting signs of structural weakness in basement areas. This was evident in concrete areas that had subsequently cracked and slumped.

NCS provided a complete structural strengthening solution for the client which involved the installation of support beams and the application of carbon fibre strengthening strips. Repair of the weakened areas by NCS was successful and the treated areas remain correctly positioned.

Rail Culvert Repairs
Queensland Rail

NCS have conducted numerous rail culvert repairs for Queensland Rail across a number of locations, including Mackay, Dalby, Grandchester and Bowenville. After extended periods of use, rail culverts exhibit typical concrete deterioration symptoms, including insufficient concrete cover over steel reinforcement.

Typical rail culvert repair requires high pressure water blasting affected areas, to remove laitance, followed by the application Xypex repair materials to reinstate the concrete and provide long term protection and durability.

The overall cost of repairing culverts equates to less than 10% of the cost of complete replacement,and represents an ideal investment in extending the life of vital rail (and road) infrastructure.

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 Tank Repair
Casino, NSW

A regional council contacted NCS to provide remedial works to four concrete water filtration tanks with a total surface area of approximately 90m2 each.
The surface of the tanks had deteriorated leaving an exposed aggregate finish.

NCS were contracted to repair and reinstate the surface and remove and replace existing joint sealants.Rather than close down the plant, the tanks were de-commissioned, one at a time and the work was carried out allowing the council 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 approximately 10mm to the tank walls, floor and baffle trays. Xypex Megamix II was selected for its superior bond strength, chemical durability and its unique crystalline waterproofing and protection technology. The joints were then re-sealed using a polyurethane joint sealant.

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 at Brisbane Airport. The manholes were heavily deteriorated from sulphate attack and required relining and a protective coating. The first manhole was prepared and was sprayed with Xypex Megamix II through a specialised pump/spray unit. Upon completion of the curing process, it was coated with two applications of a protective coating product. The second manhole, which is installed as a ‘blind’ tank, is used for emergency dumping of waste fuel or kerosine. Xypex Megamix II was applied by spraying and trowelling off.

Once cured, a protective coating was applied to provide chemical resistance. Xypex Megamix II is ideal for use in this situation because of its unique crystalline and protection technology and for its durability 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.