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INSPEC APR 2013 1 IN SPEC JULY 2013 INSIDE 2 MESSAGE FROM PHIL 2 GRANNY SMITH CONCRETE REPAIR 3 PARMELIA HOUSE 4 DAMPIER SALT DUMP BRIDGE 4 HOPE DOWNS SHED COATINGS 5 565 HAY STREET 5 VICTORIA APARTMENTS 6 Technical - TesTing coaTings 7 DPA PIGGING PLATFORM 7 WOODMAN POINT WWTP 7 ISWA PROJECT FINISHES 8 TECHNICAL AWARD / CONTACT US DAMPIER SALT BRIDGE REPAIRS HOPE DOWNS CONCRETE PROTECTION PAGE 4 RIO TINTO
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INSPEC - Duratec · PDF file2 INSPEC APR 2013 PhIL hARCoURt MANAgINg DIRECtoR A MESSAgE fRoM PhIL Welcome to our winter 2013 edition of InSpec, showcasing some

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Page 1: INSPEC - Duratec  · PDF file2 INSPEC APR 2013 PhIL hARCoURt MANAgINg DIRECtoR A MESSAgE fRoM PhIL Welcome to our winter 2013 edition of InSpec, showcasing some

INSPEC APR 2013 1

INSPECJULY 2013

INSIDE2 MESSAgE fRoM PhIL2 gRANNY SMIth CoNCREtE REPAIR3 PARMELIA hoUSE4 DAMPIER SALt DUMP BRIDgE

4 hoPE DowNS ShED CoAtINgS5 565 hAY StREEt5 VICtoRIA APARtMENtS6 Technical - TesTing coaTings

7 DPA PIggINg PLAtfoRM7 wooDMAN PoINt wwtP7 ISwA PRoJECt fINIShES8 tEChNICAL AwARD / CoNtACt US

Dampier SaltBriDge repairS

hoPE DowNSCoNCREtEPRotECtIoN PAgE 4

riO tiNtO

Page 2: INSPEC - Duratec  · PDF file2 INSPEC APR 2013 PhIL hARCoURt MANAgINg DIRECtoR A MESSAgE fRoM PhIL Welcome to our winter 2013 edition of InSpec, showcasing some

2 INSPEC APR 2013

PhIL hARCoURtMANAgINg DIRECtoR

A MESSAgE fRoM PhILWelcome to our winter 2013 edition of InSpec, showcasing some of our recent projects and contract awards.In this current uncertain and changing market, our company has secured some excellent project works and on-going maintenance contracts. These works are located throughout WA and accordingly we have increased our operational resources to meet this demand for our services. Our excellent team of high quality, experienced remediation engineers and professionals has remained committed to the accomplishment of our stated goals. Meeting the needs of our clients in terms of safe and timely project delivery, right first time, remains our strong focus.

During May 2013, Duratec underwent a Federal Safety audit. It was pleasing to receive positive feedback from the audit team. They commended us for continuing to maintain a robust OH&S management system at both the organisational and project levels.

We thank you for your continued support and we trust you will find the enclosed articles of interest. We welcome any feedback.

WelcOme tO Our July eDitiON Of iNSpec

PRoJECt REVIEwgraNNy Smith cONcrete repair

The bund walls around several sections of the CIL tanks had exhibited cracking. A 20m section was removed and reformed with a further 18m requiring remediation. Similarly, 17 metres of the process water area bund wall was re-aligned to enable retention of a larger volume of water. All new walls were reconstructed using traditional form and pour methods, complete with new reinforcing steel.

The ROM bin exhibited signs of deterioration on the inner faces of the structure, exposing reinforcing steel. This was due to mechanical abrasion and moisture causing corrosion. The front inner wall was 7m long and 4m deep, and was reformed and poured using construction grout. An additional 30m2 of concrete on the back and side walls was drummy. These areas were broken out and shotcreted.

Duratec’s experience in concrete repair on remote mine sites has been utilised again at Barrick Gold’s Granny Smith Operation, near Laverton.

2 INSPEC JULY 2013

Front cover: Duratec specialist performing manual breakout at Dampier Salt’s Lake MacLeod Operations.

CIL bund wallsInner ROM Bin walls

Front ROM Bin wall

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INSPEC APR 2013 3INSPEC JULY 2013 3

Australian City Properties Pty Ltd engaged Duratec to perform a variety of repairs on the 19 storey Parmelia House facade on St Georges Terrace, Perth.

Parmelia House was built in 1968 with extensive use of reinforced concrete. The maintenance works currently being undertaken are designed to address issues of spalling concrete and the repair and strengthening of sun hoods on the north and south facades. The project commenced in April after initial sample panel repairs were approved by BG&E consulting engineers.

Some of the edges of the sun hoods and shades were cracked and at risk of breaking causing safety concerns. The edges of the pre-cast concrete panels are being repaired using form and pour techniques and stainless steel pins. All sun hoods are receiving a four-layer reinforced membrane coating system that will strengthen them and eliminate the risk of further spalls. On the west facade, vertical concrete ribs that were at risk of detaching are being removed and replaced with lightweight ribs to match the originals. All external mastic seals to expansion joints and around windows are being renewed.

Access involves a combination of four swing stages and up to 12 rope access personnel, with extra protection measures and systems in place to provide public protection from any falling debris.

The project is expected to be completed by Christmas 2013 and was selected as the site for a Federal Safety Commission Audit.

PRoJECt REVIEwparmelia hOuSe facaDe reStOratiON

Right: Swing stages were used on the west and south facing facades with rope access utilised on the north facing facade.

Below right: The corner of this sun hood was reformed with a repair mortar and Helifix patching pins used as reinforcing.

Below: Rope access provided a very safe, fast and efficient method of repairing the sun awnings.

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4 INSPEC APR 20134 INSPEC JULY 2013

PRoJECt REVIEw DSl Dry Salt Dump BriDge repairS

Duratec was engaged by Dampier Salt Ltd (DSL) to conduct 60m2 of concrete repairs to the Dry Salt Dump Bridge abutments at Lake MacLeod, during a scheduled shutdown.

With potable water supplies being limited on this remote site, all degraded concrete was removed by jack hammers before reinstatement by form and pour methods. The scope also included erection of temporary structural props (with design and certification), coordination of scaffolding, crack injection and coating the entire structure using Nitoprime DG, followed by Dekguard Elastic. This system protects concrete in saline environments, and being elastomeric, it can accommodate significant substrate cracking and movement.

Duratec conducted post-works quality testing with full reporting to confirm the repairs had been carried out to specification. The project was delivered with commendation from the client for our safety and quality performance.

Top: The completed bridge abutment.

Right: Form and pour methods were utilised to reinstate the concrete.

PRoJECt REVIEw hOpe DOWNS

ammONium NitrateFirm Construction engaged the services of Duratec to complete concrete repairs and coatings to the Ammonium Nitrate shed at Rio Tinto’s Hope Downs, 100kms north-west of Newman.

After an initial survey of the storage facility, all damaged concrete was removed by manual breakout. The pH was continually checked to ensure no contaminated concrete remained. It was then reinstated by form and pour and patch methods, before all surfaces were cup grinded and made ready for coating.

Epigen 4029 was the selected coating system for protecting the concrete. This coating is a high build novalac-based resin that provides excellent chemical resistance.

Also included in the contract was baseplate grouting to column supports.

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INSPEC APR 2013 5

Top: Structural support beam in place after the adhesive had cured. It was held by acro-props during

the curing process.

Right: Duratec specialist applying the Sikadur epoxy adhesive.

PRoJECt REVIEw 565 hay Street Structural StreNgtheNiNg

INSPEC JULY 2013 5

Duratec was engaged by Northerly Constructions to install steel beams and carbon fibre laminates for structural strengthening to concrete elements at 565 Hay Street, Perth.

This project is part of the complete refurbishment of the former Public Trustee Building and will include 11 stories of commercial offices, along with retail outlets at ground level.

Various forms of access were used to complete the installations including EWPs, scaffolding and scissor lifts.

The project included the placement of specially fabricated steel beams at eight separate locations on each of the 10 floors. These provided the columns with additional restraint and protection from seismic movement. The concrete was first prepared by cup grinding before the beams were glued in place using Sikadur epoxy adhesive.

Carbon fibre laminates were used to provide additional strengthening to a new concrete slab on the mezzanine level. In addition, large structural support beams and ”K” bracing on every level required grouting.

Some of the challenges of the project included working around many other trades on the site and minimising dust using vacuum attachments.

At 30 Victoria Avenue in Claremont, Duratec has successfully completed a major makeover to an eight story apartment building that sits on the banks of the Swan River.

The building was completed in sections and with the scaffold erected, repairs were performed to the balconies’ balustrades, which had corroded supports. Any spalling cover concrete was removed and patched, and any broken or cracked tiles were replaced. All rainwater elements, including gutters and downpipes, were also replaced. The facade then received a fresh coat of paint, including two pack epoxies to provide superior corrosion protection to steel elements.

The tenants were kept fully updated of any noisy works required during the 10 week refurbishment.

PRoJECt REVIEwVictOria apartmeNtS

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6 INSPEC APR 20136 INSPEC JULY 2013

Technical arTicle - parT Two prOtectiVe cOatiNg teStiNgAfter thorough surface preparation and subsequent testing (covered in the last edition), the next vital step in ensuring proper asset protection is the correct application and testing of the applied protective coating system.

Most protective coating systems follow a specification and it is to the benefit of all stakeholders that thorough testing of the applied coating system occurs. This protects the contractor from potential re-works, which are usually significantly more expensive to perform than the initial application; the coating manufacturer from potential product warranty claims; and the end client from potential premature failure of their asset’s protection system.

One of the most important factors that affect a system’s performance is film thickness. Specifications are normally formulated to provide a certain life expectancy of a protective coating system, with film thickness directly responsible for meeting these requirements. AS2312 is the Australian Standard that summarises how long and in what type of environments different protective coating systems and their thicknesses should last.

In this electronic age, the dry film thickness (DFT) of paint is easily checked, with Elcometers or Positectors being the two main brands of electronic non-destructive DFT gauges (Figure 1). Checking the wet film is a more useful action for contractors to guarantee their dry film is going to be on target to meet the specification. It is also important that each coat in a system meets its dry film target, especially when galvanic primers are used to provide corrosion protection. Destructive gauges like the PIG gauge can easily determine if film thickness is not achieved in any coat of a multi-coat system.

Another important test for a cured paint system is the ‘spark’ or ‘holiday’ test. This test is designed to locate pinholes, holidays (breaks in the coating system) and areas of low film thickness. By connecting an earth to the substrate and passing a brush (normally brass) running high voltage over the surface, any defects in the paint system will short out or ‘spark’ allowing these areas to be appropriately repaired (Figure 2). This testing is vital in highly corrosive areas and critical assets such as tank internals, where corrosion can be accelerated when bare steel is exposed. All repaired areas should be re-checked until no defects occur.

Adhesion testing is a commonly performed test that ensures the coating system has ‘bonded’ sufficiently to the substrate. Poorly adhered paint is a major cause of premature coating failure. Thin coating systems are

normally checked using a cross-hatch test while thicker systems use a pneumatic pull-off test (Figure 3). Poor adhesion is usually a tell-tale sign of poor surface preparation, suggesting a lack of surface profile from abrasive blasting or contamination on the surface before painting.

The tests conducted during surface preparation and coating application are vital in maximising the performance of your protective coating system to extend the life of your assets. Duratec employs and supports NACE/ACA professionals who understand the details of delivering quality asset protection systems.

figure 1

figure 2

figure 3

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INSPEC APR 2013 7INSPEC JULY 2013 7

PRoJECt REVIEw WOODmaN pOiNt

WWtp

After six months of drilling, inserting over 11,000 anodes, patching and painting, the International School of WA project has been completed.

Duratec has successfully delivered what has been a challenging project. “Carrying out the works while the school has been fully operational was the biggest ongoing challenge,” said Paul Illich, Duratec’s site supervisor.

All parties to the contract were very happy with the outcome, with the reinforced concrete structures being given new life in the coastal environment of City Beach.

The repairs are designed to provide over 20 years of galvanic protection to the concrete steel reinforcement.

PRoJECt REVIEw iNterNatiONal SchOOl prOJect fiNiSheS

The Water Corporation awarded Duratec concrete repair works in a sedimentation tank

at the Woodman Point WWTP.

The scope for the repair included water blasting, concrete breakout and priming, before an epoxy mortar system (Epigen 402) was used to resurface the concrete. A protective epoxy coating was then applied at 500 microns. The repairs were fully spark tested for defects upon completion.

PRoJECt REVIEw Dpa piggiNg platfOrmDuratec was engaged by the Dampier Port Authority to refurbish the pigging platform at their bulk liquid berth in Dampier.

The project involved the application of 700 microns of Interzone 954 epoxy on checker plate flooring and minor repairs along weld margins on the underfloor structural deck beams - a good example of preventative maintenance.

Surface preparation was performed by high pressure water cleaning, power tools and the Torbo wet blasting system (pictured) to eliminate any impact on the surrounding sensitive marine environment.

Above: Stakeholders in the project from left to right: Duratec Site Supervisor Paul Illich, ISWA Business Manager Sue Malcolm, GHD’s Sharon Long, BMW’s Ian Weston and Lena Shaw, Duratec’s Deane Diprose and Spotless’s Steve Fairfield.

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hEAD offICE108 Motivation DriveWangara WA 6065T: (08) 6267 2370E: [email protected]

KALgooRLIELot 33 Yarri RoadParkeston WA 6433T: (08) 9021 5277

KARRAthAU1/3890 Coolawanyah RoadKarratha LIA WA 6714T: (08) 9185 6077

PoRt hEDLAND11 Pinga StreetWedgefield WA 6721T: (08) 9185 6077

SPECIALISt MAINtENANCE AND PRotECtIoN

www.DURAtECAUStRALIA.CoM.AU

• 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

Transfield Services has recently awarded Duratec a contract to provide a technical condition survey on a jetty at Port Denison.

Port Denison, a popular mid-west holiday and fishing destination, is 360kms north of Perth and close to the town of Dongara. The boat harbour was originally constructed in 1979 and is used for commercial and recreational boating.

An additional boat mooring jetty, constructed in 2000, comprises of reinforced concrete that is demonstrating some tell-tale signs of corrosion of the reinforcement by visible cracking and spalling.

Duratec will conduct an investigative survey of the jetty providing a comprehensive technical report detailing remediation strategies that are fit-for-purpose and cost effective.

tEChNICAL SURVEY AwARD

EXtENDINg thE LIfE of YoUR ASSEtS”