Concrete Connections November 2013 edition

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ACRA OFFICERS President, Daniel Rowley Xypex Australia danielr@xypex.com.au Immediate Past President, Andrew Dickinson Parchem Construction Supplies Pty Ltd andrew.dickinson@parchem.com.au Treasurer/Secretary, Henk van den Heuvel Andersal Pty Ltd henk@andresal.com.au Secretary, Peter Johnsson Hyder Consulting Pty Ltd Peter.Johnsson@hyderconsulting.com Executive Officer, Nicole Raymond Australasian Concrete Repair Association Inc. info@acrassoc.com.au ACRA Board of Directors Farhana Jesmin, Roads & Maritime Services farhana.jesmin@rms.nsw.gov.au Greg Zambesi, GHD Pty Ltd greg-zambesi@ghd.com Matthew Ball, Buildcorp Asset Solutions matthew_ball@buildcorp.com.au Grant Dowling, SIKA Australia dowling.grant@aecom.com Diana Solimon, AECOM diana.solimon@aecom.com Editorial contributions are welcomed.

Please contact the ACRA (02) 9654 3692 Email: info@acrassoc.com.au Postal: PO Box 452, Chester Hill NSW 2162 www.acrassoc.com.au Publisher/Editor Nicole Raymond Publications Committee Matthew Ball Grant Dowling Diana Solimon

The information and recommendations in this magazine are provided for use by fully qualified, professional personnel.

The Australasian Concrete Repair Association and the publisher disclaim any responsibility as to their use by readers and shall not be liable for damages arising out of the use of the forgoing information.

All by-lined articles published in this magazine represent solely the individual opinions of the writer and not necessarily those of the association.

Cover Photos: United Dental Hospital, Surry Hills NSW Consolidated Quality Projects

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elcome to the November edition of Concrete Connections In my first message as your Association President, & on behalf of the ACRA Committees & its members, thank you to Andrew Dickinson for the dedication & energy he put in during his time as ACRA President. Andrew has been passionate about seeing the association spread its wings across Australia & abroad.

During his term as President we have seen ACRA’s concrete repair course gain further acceptance as the leading introduction course in concrete repair, to date 12 of these events have been held throughout Australia, & 97% have been sold out. The course feedback has been extremely positive & one industry body actually booked a “tailored inhouse course” for a number of their team members. Andrew’s hard work has seen the Association cross the oceans to become the Australasian Concrete Repair Association, the inclusion of Asset Owners to the membership division, the formation of the WA subcommittee & the ground work laid for future sub committees in VIC & QLD to follow closely, are some of the key areas developed under Andrew’s leadership as president.

I’ve had the pleasure of being involved with a number of industry associations over my 17 years in the construction industry & this is by far the most interesting, rewarding & open association I’ve had the pleasure of being a part of.

I’d like to congratulate the board members who were recently elected onto the board & thank them in advance for their time & support of the association. I hope to see many of you at our Christmas function on November 28 please feel free to contact Nicole directly on info@acrassoc.com.au If there is anything you’d like to have discussed or presented to the board please feel free to contact me directly on 0409 445 270 or danielr@xypex.com.au

-Daniel Rowley, President

Special Thanks…….

Regarding the recent devastating bushfire emergency in NSW, we applaud all RFS Volunteers for what can only be described as an outstanding performance in working to save life & property.

There were several ACRA members who are volunteers and who were under the most testing of conditions during the NSW bushfire emergency is simply inspiring.

Thank you for giving up your time to help out others.

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WA EVENTS ACRA have 2 more events before the end of the year and you’ll have to ACT FAST as time is running out.

CONCRETE REPAIR FROM DESIGN TO CASE STUDY SEMINAR NOVEMBER 6 – DUXTON HOTEL, PERTH 4.30-6.15PM This is the first ACRA seminar in WA to showcase some of the design considerations and case studies of concrete repair projects. We have gathered three industry professionals from design consultant to repair contractors to discuss the challenges in concrete repair works. Rodney Paull from GHD will give an overview of the concrete repair design and specification with considerations from site involvement. Anthony Mesic from Freyssinet will provide a case study for the Geraldton Grain Silos. Chris Oates from Duratec will talk about the challenges on the concrete repair works at International School of WA. SPEAKER# 1 RODNEY PAULL FROM GHD

Rodney is the Materials Technology Service Line Leader with responsibility to assist construction materials development in GHD. Rodney has 34+ years’ experience in construction materials technology including concrete repair projects. He has worked in Australia (16 years), United Kingdom, Singapore/Malaysia (9 years) and Hong Kong (9 years). Rodney is the author of 61+ technical papers/presentations. Rodney will discuss the repair design and specification impact from site involvement.

SPEAKER #2 ANTHONY MESIC FROM FREYSSINET AUSTRALIA PTY LTD

Anthony is the Remedial Manager WA for Freyssinet Australia. He will be speaking about the Geraldton Grain Silos concrete repair and strengthening project. Over the past five (5) years, Freyssinet has been contracted to design and complete repairs and strengthening works to the Geraldton Grain Silos. The repairs included Hydro-demolition, Concrete Repair, Gunite, Shotcrete, Coatings, and External Post Tensioning.

SPEAKER #3 CHRIS OATES FROM DURATEC

Chris is the General Manager at Duratec. He will be speaking about the International School of WA concrete repair and coating project. In December 2012 Duratec were contracted to complete repairs to the International School of WA. The repairs included Concrete Repair, CathodicProtection, Joint Sealing, Coatings.

Cost of seminar: FREE. Although it’s a free event you still need to register.

Email Nicole at info@acrassoc.com.au by November 5.

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2014 ACRA Awards The end of October 2014 will see the 8th biennial ACRA Awards for Excellence held in Sydney.

In past years, we have seen some of the best projects and entries from all over Australia.

Next year, we want to continue the tradition of showcasing our members’ good work.

Following the awards, we will be running editorials in industry magazines as well as other publications to showcase the awards and the winners.

All entries will be acknowledged, with the winners having the opportunity to further promote themselves.

So now it’s time to get your project information and photos together as the categories and entry form will be sent out soon.

Register your interest by emailing info@acrassoc.com.au

2012 winner BASF and our Judges Ian Godson, Sharyn Machin and David Mahaffey

On November 8 we will be holding our last course for 2013 in Perth TECHNICAL TRAINING COURSE ON CONCRETE REPAIR AND PROTECTION This course is limited to only 20 people and only a few spots remain so if you’re yet to register call NOW on 02 9645 3692 or go to our website to register and to get more details on the course www.acrassoc.com.au ACRA’s One Day Course in Concrete Repair offers the most comprehensive training yet available in a single day. The new course is the best independent information available to date for engineers starting out in the specialist area of concrete repair, contractors’ supervisors and foremen, as well as those who just want some basic but detailed knowledge. Asset managers, port and road authorities, councils and ACRA members should consider training their key staff by sending them to a session run around the country. Group bookings can be negotiated by request. The course stresses the importance of thorough diagnosis, covering the basics of concrete and its deterioration, followed by site investigation techniques and how to select an appropriate remedial or protective system. A practical understanding of how repairs should be undertaken is discussed in the last two topics of the day – “Repair Specification”, which covers materials and workmanship; and “How to Do a Repair Properly” which presents a step-by-step guide to undertaking a repair and some common problems with workmanship.

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WA ACRA MEMBERS ONLY CHRISTMAS DRINKS – DECEMBER 5 FROM 6PM

Can you believe that another year is almost over? ACRA members will be getting together for some Christmas cheer at Little Creatures in Fremantle.

All primary corporate members will be sent an invite and they can bring up to 3 guests with them and if you would like anyone else to come along its only $30pp.

Email Nicole at info@acrassoc.com.au to register your interest in attending this year’s ACRA WA Christmas drinks. Close of date is December 2.

If you would like to be added to the WA mailing list for all events send your details to info@acrassoc.com.au or you can subscribe via the ACRA website www.acrassoc.com.au

NSW EVENTS NSW ACRA MEMBERS ONLY CHRISTMAS DRINKS – November 28 from 6pm

ACRA members in NSW will enjoying some merriment on November 28 at The King St Brew House on King St Wharf, Sydney (Darling Harbour). All primary corporate members will be sent an invite where they can bring up to 3 guests and if you would like anyone else to come along its only $30pp.

Email Nicole at info@acrassoc.com.au to register your interest in attending this year’s ACRA WA Christmas drinks. Close of date is November 26.

If you would like to be added to the NSW mailing list for all events send your details to info@acrassoc.com.au or you can subscribe via the ACRA website www.acrassoc.com.au

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Corporate Member News………..

Safety, Health and Environment program wins International Business Awards AECOM recently won two 2013 International Business Awards (IBA) in the Health, Safety and Environment Program of the Year category.

The IBAs recognize organizations' successful implementation of policies to prevent workplace accidents and injuries, increase safety awareness, and meet the requirements of environmental and occupational health and safety laws.

A Gold IBA was awarded to AECOM for Asia and Australia New Zealand, and the Silver IBA for Canada and the United States.

The awards recognize AECOM’s commitment to maintaining a healthy workplace by adopting measures that minimize risk and ensure that the company protects and preserves its facilities, property, environment and, most importantly, its people. As part of AECOM’s global safety, health and environment (SH&E) program, the Safety for Life” initiative was recently introduced, which provides employees with online training and management system assessments, regular communications, an interactive mobile application, access to enterprise-wide safe work method statements, and an incentive reward card that recognizes and rewards proactive safety behaviour. ACRA Congratulates AECOM on wining this prestigious award.

ACRA the wild……

We were recently surprised at the ACRA office when we received this photo from ACRA member Alan Bird from Marine & Civil Maintenance Pty Ltd. “It’s amazing how far and wide ACRA members go in pursuit of projects” said Alan. He was in Zimbabwe, Botswana and South Africa.

Alan, while being sun safe and wearing his ACRA hat, was at a reserve near Victoria Falls where they prepare young lions for staged release into the wild and where people can walk with them through the bush. The lion pictured was more interested in eating the Heron bird rather than Alan, thankfully. www.marineandcivil.com.au

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PRINCE HENRY HOSPITAL TRANSFORMATION PROJECT. While heritage restoration is a challenging sector, National Concrete Solutions (NCS) has demonstrated their expertise and capabilities in assisting in the transformation of the Prince Henry Hospital into upmarket apartments, whilst retaining significant elements of it heritage.

Prince Henry Hospital is currently under redevelopment into a series of high end apartments including 1, 2 and 3 bedrooms, with sea, golf course or park land views.

Built in 1881, the site at Little Bay was chosen because of its isolation from the population of the city, originally to treat smallpox, and the hospital was serviced by horse ambulances.

Once the outbreak was declared over, the hospital was converted to a convalescent hospital, then a fever hospital treating epidemics such as diphtheria, tuberculosis, measles and leprosy. In 1941, with the construction of Delaney House, it became a General Hospital up until 2001 when all services were transferred to the Randwick campus.

“Although the hospital is considered to be constructed well considering the period of time it was built and the technology and standards available, the coastal surroundings have taken its toll on the buildings” commented Brett Zale, NCS Commercial Project Manager.

NCS were engaged by Ganellen to submit solutions for waterproofing and durability that would increase structural integrity and extend the service life of the buildings. NCS recently completed repairing concrete spalling within building columns, soffits and lintels.

Additional coverage was also required to structural and reinforcing internal concrete floors.

Many factors were taken into consideration when selecting the restoration systems including heritage guidelines, limited space, project timeline and age of the buildings. Part of this consideration involved, core samples being taken and analysed. “We worked closely with consulting engineers Diagnostech to ensure all measures were taken to understand the condition of the concrete materials and formulate the Design and Construct methodology. This resulted in a variety of solutions that exceeded engineer specifications and met the client’s needs in extending the service life of the building” commented Brett.

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“NCS have proven themselves to be a professional and competent contractor across all facets of their business operations. They have successfully delivered on their design and construct solution that has allowed the conversion of a heritage building into modern apartments” commented Tim Sachs, Ganellen Project Manager.

In some areas the lentils were severely damaged and required total replacement of steel and concrete (profile was 140 lm of 160mm x160mm). To ensure the historic brick work was preserved HelifixHelibeams were installed in the bottom two courses of façade brickwork to increase the strength of the structure and to support brickwork whilst works were undertaken.

Ultra High Pressure Hydrodemolition was undertaken to remove all concrete in the areas identified as needing repair or replacement.

Due to spalling, and the requirement for steel protection and reinstatement in parts of the structure, NCS repaired columns and soffits back to their original contour through the application of Xypex Megamix II and Xypex Concentrate. This system was approved due to its waterproofing and chloride resistance ability through crystalline technology and Xypex Megamix II’s capability of attaining high compressive strength in a short period of time. Acrylic render was also applied to restore original appearance and provide additional protection.

“This was a very complex project, and NCS ensured they delivered on time and within budget. NCS had an impeccable safety record onsite, performing within the top 5% of contractors consistently through the contract” commented Tim. “Furthermore in the construction industry, it is important to deliver on commitments. NCS have done this and more”.

NCS is proud to be partnering with Ganellen and Diagnostech in restoring Prince Henry Hospital for future generations to enjoy.

www.ncsaustralia.com.au Phone: 02 6040 2444 Email: info@ncsaustralia.com.au

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AECOM Welcomes New Managing Director appointed to lead growth in New Zealand Leading global professional technical services firm AECOM has appointed John Bridgman as Managing Director for New Zealand, with a mandate to steer the company’s continued growth.

Mr Bridgman brings proven strategic, commercial and leadership capabilities to the role, and has led the business in a number of regions and major projects. Mr Bridgman said the future for young New Zealanders considering a career in infrastructure was promising: “The New Zealand government has signalled four key areas of focus; d evelopment of critical national infrastructure, prudent asset management, the rebuild of Christchurch and addressing the national housing shortfall. At the same time, the new Australian administration has signalled its intent to be ‘the infrastructure government’.

“This means the South Pacific is well positioned to become a major draw card for infrastructure and construction skills and investment, providing local and global career opportunities for young New Zealanders. It’s a great time to be part of the industry,” he said.

Mr Bridgman joined AECOM legacy company, Worley Consultants, as a graduate in 1982, and has led several of AECOM’s regional offices in New Zealand. He takes up the role immediately and is supported by a team of more than 560 people in Auckland, Hamilton, Tauranga, Wellington and Christchurch.

Corporate Member Project News……

MOOLOOLABA UNDERWATER WORLD - CONCRETE REPAIR SERVICES MOOLOOLABA UNDERWATER WORLD: STRUCTURAL REPAIR PROGRESS REPORT Located smack bang in the middle of the Sunshine Coast, Mooloolaba Beach is a popular tourist destination for both Australian families and overseas tourists.

After making the decision to improve and update the underwater environments for visitors, management at the facility contacted aquarium designers based in the United Kingdom to redesign the various worlds and pools of the complex. Once plans were approved, the new management appointed Remedial Building Services for the purposes of implementing the proposed new designs as supplied and also address underlying structural issues which had manifested over a number of years.

In summary we were contracted to:  Remove all existing underwater environments (not including marine life)Identify all areas affected by concrete cancer and remove to expose the rusted reinforcing

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     

Hydroblasted existing walls to remove concrete and expose steel reinforcement Build new internal walls as part of the designs Re-render all areas requiring concrete repair Ensure water proof integrity of all surfaces Reinstate marine environments using the plans and schematics provided Associated plumbing works

During the process of removal, our staff identified that many of the marine environments had originally been created using a very dense gunite. This meant that jack hammering was an arduous task. As such, we sought to use a chemical agent manufactured by Tam Australia. Our staff core drilled several 150mm holes into structures requiring removal and inserted the agent, leaving it overnight. Over 12 hours the agent expanded rapidly causing large fissures in the structure, allowing our team to come in the next morning and easily remove the broken segments; all in all enabling our teams to progress as per the original.

CONCRETE REPAIR WORK NEARS COMPLETION Just under 8 months since we were appointed by Merlin Entertainments Group to perform Remediation work to the Mooloolaba Underwater World aquarium, we have completed all works. Completed within the given time frame - allowing the aquarium to prepare ahead of the warmer tourist season - the project was all smooth sailing. Expectations amongst the Sunshine Coast community as regards the aquarium's revamp are at a high with the Sunshine Coast newspaper - the Sunshine Coast Daily - doing a cover story on the concrete repair work which Remedial Building Services have done to prepare the aquarium.

According to Remedial's Jeff Anderson, the company were "very pleased to have overseen and managed such a significant structural repair and waterproofing project. The efforts of all involved, not just Remedial staff, but the work of specialised sculptural and coral teams, have been truly commendable.

The new aquarium will be a wonderful tourist destination for all visitors to the area."

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REMEDIAL REPAIR OF ENFIELD PILAR WATER TANK SYDNEY FOR NSW PORTS CORPORATION, A HERITAGE LISTED STRUCTURE THE HISTORY The pillar water tank is also known as a’ water column’ and ‘parachute tank’ usually of a cylindrical shape, in concrete or steel plate, on a cylindrical column. The Pillar Water Tank appeared on the site in 1918 to provide a watering station for steam powered locomotives. It comprises a cylindrical concrete tank and various concrete mouldings, mounted on top of a reinforced concrete pillar.

The dimensions of water tanks were typically nine feet in diameter, 28 feet high with capacity to hold 4,000 gallons of water. Research undertaken by NSW Ports had identified that this is the only concrete pillar tank surviving from the NSW Government Railway system. As indicate on the drawing “Foundation for Concrete Parachute Tank” originally located in the centre of the Enfield Yard, water tanks are known from the earliest years of steam powered locomotives. These structures gradually become redundant as steam power gave way to electric and diesel powered locomotives in the 1950‘s and 60’s.

THE PROJECT The concrete repair section of the project consisted of traditional steel reinforcement repair methods and coatings on the inside and outside of the structure. What was difficult about this project was that the pillar water tank was not only an odd shaped structure but that it was presented to Andersal in pieces and without a footing to support the structure in its new location. Andersal had to not only remediate the structure but also re-connect the 4 concrete sections that make up the tower & more importantly with this restoration, preserve its historical importance for many more years.

Andersal Pty Ltd was involved in the design the footing along with their consultant MJ Civil and then provided additional information to Sydney Ports, now Ports NSW, with regard to improvements in products selection without increased costs e.g. Wolfin membrane at the base, Sika Carbon-fibre on the inside and some better coating systems for the metal work & the concrete exterior. www.andersal.com.au Phone: 1800 066 327 Email: info@andersal.com.au

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Alt St, ASHFIELD – PROJECT UPDATE

PROJECT: Repair cracking to balcony slab edges and painting to exterior of building ADDRESS: Alt St, Ashfield DATE: May 2013 HISTORY: The building was constructed in the 70’s. The general condition of the building is good. The building is constructed with face brick cavity, concrete floors and a tiled roof

INVESTIGATION: A visual inspection was carried out around the building, which identified numerous locations that required repair. For a building of this age these repairs are very common.

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OUTLINE OF WORKS: Repair cracked render to balcony slab edges Install horizontal control joints to balcony slab edges Replace broken tiles to top of balcony with new brown tiles.

Supply and install 6 new 40mmÆ PVC spout pipes to lower level balconies where spout have broken off.

Pressure clean exterior of ALL balcony brick balustrades to remove staining.

Eaves and Gables- Inspect condition and cause of any damage to eaves Apply water repellent sealer to pebble-crete floor of balcony.

Replacement laundry doors. Includes new locks and hardware

CONCLUSION: With a proactive approach from the owners of the building by organising the remedial works be carried out, then, inturn will prevent more costly repairs in the future. This is the key to maintaining a healthy building.

For more details contact Dapcor Building Services Email: sales@dapcor.com.au Phone: (02) 9316 7866 Website: www.dapcor.com.au

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INDUSTRY CALENDAR OF EVENTS 2013-2014 …………

November 1-2

SCA NSW Convention

Sydney, NSW

Contact Lucy Byers at SCA NSW lucy.byers@stratacommunity.org.au

November 6

Seminar-Concrete Repair from Design to Case Study

Perth, WA

www.acrassoc.com.au

November 8

ACRA Concrete Repair and Protection Course

Perth, WA

Places still available but limited , email info@acrassoc.com.au to reserve your spot today and for more detail

November 10-13

ACA Convention

Brisbane, QLD

www.corosion.com.au

November 28

ACRA Xmas Party

Sydney, NSW

Members Only – invites will be sent out

December 5

ACRA Xmas Party

Members Only – invites will be sent out

January 2014

World of Concrete

Perth, WA Las Vegas, NV, USA

29 January 2014

ACRA Concrete Repair and Protection Course ACRA Concrete Repair and Protection Course ACRA Concrete Repair and Protection Course CONEX Australian Road Engineers & Maintenance Conference ACRA Concrete Repair and Protection Course ACRA Concrete Repair and Protection Course Australian Small Bridges Conference ACA/ACRA Corrosion & Protection of Concrete Structures International Conference on Concrete Repair ACRA Award in Concrete Repair ACA/ACRA Corrosion & Protection of Concrete Structures

Auckland, NZ

www.acrassoc.com.au

Christchurch, NZ

www.acrassoc.com.au

Brisbane, QLD Las Vegas, NV, USA

www.acrassoc.com.au www.conexpoconagg.com

Melbourne, VIC

Scott.matthews@commstrat.com.au 03 8534 5004

Melbourne, VIC

www.acrassoc.com.au

Sydney, NSW

Sydney, NSW

www.acrassoc.com.au Scott.matthews@commstrat.com.au 03 8534 5004 www.corosion.com.au under the Training Calendar tab

Belfast, Northern Ireland

www.rilem.org

Sydney, NSW

www.acrassoc.com.au Open to Corporate Members Only.

Brisbane, QLD

www.corosion.com.au under the Training Calendar tab

30 January 2014 28 February 2014 4-8 March 2014 1-2 April 2014 TBA April 2014 TBA May 2014 27-28 May 2014 19-20 June 2014 1-3 September 2014 October 2014 27-28 November 2014

Sydney, NSW

www.worldofconcrete.com

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NEW CORPORATE MEMBER…………

Sika (NZ) Limited PO Box 19192 AVONDALE, AUCKLAND 1746 NEW ZEALAND Phone: +64 9 820 1434 Contact: Paul Tanner Email: tanner.paul@nz.sika.com Web: www.sika.co.nz

Mulford Holdings Limited 3 Brighton Rd DUNEDIN, 9011 NEW ZEALAND Phone: +64 3 488 4151 Contact: Barrie Clydesdale Email: barrie@mulfordholdings.co.nz Web: www.mulfordholdings.co.nz

NEW INDIVIDUAL MEMBER…………

Devonport, Tasmania - Andrew Buchhorn Phone: 0428250091 Email: merplant@bigpond.com

Dubai, UAE- Hamid Khan Phone: 9 7155 964 699 Email: hamidrahim64@hotmail.com

Darlinghurst, NSW – Wayne Mitchell Phone: 0417 249 228 Email: info@wsbenchmark.com.au

2014 is already looking to be a HUGE year for ACRA with our Victorian sub branch committee almost ready to be announced which will mean more seminars in Victoria and then it’ll be QLD’s turn to form a sub branch committee.

All our committees are made up of corporate members, so if you would like to get on board in one of these states but not yet a member email Nicole and request more information.

Your ACRA Board Members and your Executive Officer, Nicole Raymond would like to wish you all a very happy and safe Christmas break and all the best of health and prosperity in 2014.

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CORPORATE MEMBERS CONSULTANTS ACOR Consultants AECOM Australia ARUP BAAM Consulting Bellmont Faรงade Engineering Costin Roe Consulting Diagnostech GHD Hyder Consulting Infracorr Consulting Integrated Consultancy Group SUPPLIERS BASF Construction Chemicals Australia Parchem Construction Supplies SIKA Australia & NZ Volumetric Concrete Australia Xypex Australia ASSET OWNERS Brisbane City Council Main Roads WA Moira Shire Council Roads & Maritime Services NSW Sydney Ports Corporation VIC Roads Water Corporation of WA

CONTRACTORS Absafe Andersal Australian Concrete Repair Group BCMG Buildcorp Caps Beta Central Systems Consolidated Quality Projects Dapcor Building Services Duratec Australia Eptec Evolution Civil Maintenance Fluid Building Services Freyssinet Australia Hitech Remedial & Construction Interflow Pty Ltd Marine & Civil Maintenance MDP Group Metrocorp Technologies Mulford Holdings Ltd (NZ) National Concrete Solutions Portolesi Structural Preservation Technologies RCW Group Remedial Building Services RM Watson Savcor ART Structural Systems (Remedial) Water Infrastructure Group

Interested in becoming a corporate member of ACRA? Call us today or click on the link to register online for membership and to view all corporate membership entitlements.

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