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    RECENT PROJECT INVOLVING CRACK INJECTION

    March 12th, 2019 Posted by Uncategorized 0 thoughts on “RECENT PROJECT INVOLVING CRACK INJECTION”

    Description: Repair of Reservoir Tank.

    Elements: Crack Injection, Cathodic Protection and Waterproof Membrane

    Scope of Works

    External crack repair methodology:

    1. Mark out repair areas.
    2. Square cut to a minimum of 10mm
    3. Scabble back to sound concrete
    4. Expose corroding reinforcement
    5. Break out concrete to a minimum of 25mm behind bar.
    6. Grit blast reinforcing
    7. Replace corroded reinforcement if necessary
    8.  Rout non-moving cracks to minimum of 10mm
    9. Install anodes to steel reinforcement at 300mm centres
    10. Check continuity of anodes to steel
    11. Coat steel with primer
    12. Pre-soak concrete substrate
    13. Apply specified bonding agent to concrete only
    14. Apply specified render material to prepared cracks
    15. Re-apply any dried bonding agent
    16. Cure render material immediately after finishing each repair.

    Internal crack repair methodology

    1. V-grind out cracks to 25mm
    2. Brush specified waterproofing system into base of prepared crack
    3. Trowel apply specified mortar to re-profile crack
    4. Damp cure repair material with wet hessian for five (5) days

    Rehabilitation of Internal Floor and Wall

    1. Polymer Modified Membrane to be coated onto internal wall and floor of the Water Tank.
    2. The VersEseal range seals invisible and hard to find leaks in water storage systems with a non-toxic chemical-resistant coating.
    3. VersEseal may be used on already damaged water tanks or can seal new structures to extend the life of the tank or liquid storage structure, protecting metal from corrosion.
    4. Application of VersEseal’s Waterproof Membrane System is straightforward, environmentally safe and free from hazardous fumes.
    5. It can be applied in confined spaces without the heavy duty personal protective equipment that some products require.

    LRM Products VersEseal – Rapid Build

    Heavy-duty textured waterproof sprayable & brushable coating for surface protection

    VersEseal Rapid Build is a single component product that may be applied using a roller, squeegee or aggregate spray equipment. VersEseal Rapid Build is applied in thickness from 1.0 – 2.0mm.

    LRM Products VersEseal – Rapid Build is a fluid applied polymer modified emulsion and is recommended for use in a variety of harsh environments, chemically exposed areas, temperature variations and high traffic areas.

    VersEseal Rapid Build when cured fully adheres to the substrate to which it is applied, providing a flexible long wearing surface and is formulated for application by brush, roller, trowel or squeege.

    Applications include concrete repair, expansion joints, foundation sealing, plumbing applications, retaining walls, roof repair, sewage pump stations, water tank membranes, reservoirs, waste water storage, civil pipe joints, UV protection.

    Galvashield XPT

    Embedded galvanic anodes are designed to provide localized corrosion protection.  When placed at the appropriate spacing along the perimeter of concrete patches or along the interface between new/existing concrete, the anodes mitigate the formation of new corrosion sites in the existing concrete in adjacent areas.

    Description

    The Galvashield XP range of embedded galvanic anode units utilise an innovative zinc anode core design surrounded by an enhanced formulated cement-based mortar to provide corrosion mitigation to reinforced concrete structures. The anode units are alkali-activated (Type A) with an internal pH of 14 or greater to keep the zinc active over the life of the anode while being non-corrosive to reinforcing steel. The anode units utilise 2G Technology™ to provide higher current output. Once installed, the zinc anode corrodes preferentially to the adjacent reinforcing steel, thereby providing galvanic corrosion prevention or corrosion control.

    Applications

     Mitigates incipient anode formation (halo effect) in patch repair applications

     Bridge widening and other structure modifications

     Slab replacements, expansion joint repairs and other interfaces between new and existing concrete

     Repair of prestressed and post-tensioned concrete

     Chloride contaminated or carbonated concrete

    Advantages

     Proven technology – Galvashield has an extensive 10 year track record in the field

     Type A anode – alkali-activated to maintain activity of zinc while being non-corrosive to reinforcing steel

     Cast zinc core – provides high anode utilisation in addition to a secure long-term connection between the zinc and the lead wires

     Integral steel lead wires – allows for quick and convenient anode installation. Provides dependable steel-to-steel contact with no intermediate materials such as galvanising (which can corrode over time) that may compromise the long-term electrical connection

     BarFit™ design – grooved edges on Galvashield XP2 and XP4 anode units assist with secure anode placement

     Economical – provides localised protection where it is needed the most, at the interface of the repair and the remaining contaminated concrete

     Versatile – can be used for both conventionally reinforced and prestressed or post-tensioned concrete

     Low maintenance – requires no external power source or system monitoring

     Long lasting – 10 to 20 year service life* reduces the need for future repairs. *As with all galvanic protection systems, service life and performance is dependent upon a number of

    factors including reinforcing steel density, concrete conductivity, chloride concentration, humidity and anode spacing.

    Galvanic Anode Installation

    1. Install anode units and repair material immediately following preparation and cleaning of the steel reinforcement.
    1. Galvanic anodes shall be installed along the perimeter of the repair or interface at a spacing of (x mm) as specified on the drawings. Anode spacing will vary with changes in the reinforcing steel density, the level of chloride in the structure and the corrosivity of the local environment, etc. 
    Note to Specifier:  Typical spacing for Galvashield XPT ranges from 430-610 mm.  The maximum anode spacing guidelines can be found on the Galvashield XP data sheet.  Anode spacing should be adjusted for aggressive service conditions or for an extended anode service life.
    • Provide sufficient clearance between anodes and substrate to allow repair material to encase anode. 
    • Secure the galvanic anodes as close as possible to the patch edge using the anode tie wires. The tie wires shall be wrapped around the cleaned reinforcing steel and twisted tight to allow little or no free movement.
    1. If less than 25 mm of concrete cover is expected, place anode beside or beneath the bar and secure to clean reinforcing steel.
    • If sufficient concrete cover exists, the anode may be placed along a single bar or at the intersection between two bars and secured to each clean bar.
    • If repair materials with resistivity greater than 15,000 ohm-cm are to be used or the resistivity is unknown, create a conductive grout bridge between the anode and the substrate. Pack Galvashield Embedding Mortar to cover minimum area of 100mm in diameter between the anode and the substrate concrete ensuring no voids exist.  
    • Electrical Continuity
    1. Confirm electrical connection between anode tie wire and reinforcing steel by measuring DC resistance (ohm,W) or potential (mV) with a multi-meter. 
    • Electrical connection is acceptable if the DC resistance measured with multi-meter is less than 1 W or the DC potential is less than 1 mV.
    • Confirm electrical continuity of the exposed reinforcing steel within the repair area. If necessary, electrical continuity shall be established with steel tie wire.
    • Electrical continuity between test areas is acceptable if the DC resistance measured with multi-meter is less than 1 W or the potential is less than 1 mV.

    Concrete Crack Injection

    March 12th, 2019 Posted by Blog, Concrete Repair, Concrete Repairs, Crack Injection 0 thoughts on “Concrete Crack Injection”

    Cracks in concrete need to be repaired as they are a potential threat to the viability of the steel reinforcement within the concrete structure due to the ingress of water. Water quickly causes the internal reinforcement to corrode, expand and cause the encasing concrete to fracture and break away.

    Early treatment will prevent this process from taking place and enable the injection of epoxy resins or polymers into the cracks. Once the process of corrosion is allowed to occur then a costly repair is necessary and the steel reinforcement needs to be treated or replaced to prevent failure of the structure due to a recurrence of the corrosion process or the need for further expensive repairs.

    THE CRACK INJECTION PROCESS

    The surface of the concrete is first cleaned along the crack. Loose material and contaminants are removed. The crack is the cleaned out to remove any material so that the resin or polymer can flow freely into and along the crack.

    Resin is then injected under pressure either into injection ports which have been place at intervals along the crack. Crack injection is a skilled task and should only be undertaken by experienced tradesmen.

    Crack injection may be undertaken using a pump to apply pressure or using a hand pressure gun.

    FCS Concrete Repairs are specialists in Crack Injection and Concrete Repair. There are a variety of repair processes and materials available and FCS Concrete Repairs are experienced in selecting the appropriate process and the specialist material required to carryout an effective repair.

    FEATURED PRODUCTS: Fosroc® Nitofill LV

    May 24th, 2018 Posted by Uncategorized 0 thoughts on “FEATURED PRODUCTS: Fosroc® Nitofill LV”

    Product Description

    Low viscosity, dual cartridge, epoxy crack-injection system

    Uses

    Nitofill LV is designed for injecting cracks in concrete and masonry where there is a need to consolidate a structure or exclude water and air from contact with the reinforcement.

    Nitofill LV is a high strength, low viscosity resin injection system and provides excellent bond to concrete and masonry.

    The Nitofill LV system is ideal for small scale repairs on site and is also suitable for insitu or precast concrete elements.

    Advantages

    • n Suitable for structural crack repairsn Low viscosity allows penetration into the finest cracksn Non-shrink, adheres with no loss of bond

      n System includes everything necessary to complete the crack injection

      n Convenient to use, disposable cartridge pack contains both base and hardener

      n Cost effective and efficient repair

    FEATURED PRODUCTS: Sikadur®-52 LV

    May 24th, 2018 Posted by Uncategorized 0 thoughts on “FEATURED PRODUCTS: Sikadur®-52 LV”

    PRODUCT DESCRIPTION

    Sikadur-52 is a low viscosity, free flowing and fast curing injection resin and primer/coating based on a 2 component solvent free epoxy resin; ideally suited to a wide range of building and civil engineering applications where highly penetrative material is required.  It is available in two grades, Normal and Long Potlife for moderate and high ambient temperatures, respectively.

    Uses

    Sikadur-52 may be used to inject and fill cracks between 0.2 – 5 mm wide in a wide variety of constructions applications.

    Sikadur-52 does not shrink on curing and forms a rigid, high strength product which exhibits excellent adhesion to most construction materials enabling the restoration of structural adequacy to columns, beams, foundations, decks and water retaining structures.

    Due to its highly penetrative nature Sikadur-52 is ideally suited for application as a primer beneath Sikadur epoxy mortars or Sikafloor mortars and coatings on dense substrates.

    Sikadur-52 may also be used to stabilise weak and friable substrates.

    Special high strength grades can be made to order.

    ADVANTAGES

     Shrink free

     Insensitive to moisture during application, cure or whilst in service

     Applicable over wide temperature range

     Low viscosity

     Excellent adhesion to most building materials even when damp

     Proven in service

     High tensile and flexural strength

     Supplied in factory proportioned units

     High early strength  Chemical resistant

    FEATURED PRODUCTS: PRIME FLEX 900 XLV

    May 24th, 2018 Posted by Uncategorized 0 thoughts on “FEATURED PRODUCTS: PRIME FLEX 900 XLV”

    Product Description

    Prime Flex 900 XLV polyurethane resin is a low viscosity, hydrophilic resin that reacts with water and expands to form a closed cell, watertight foam. It is typically injected under pressure to seal actively leaking joints and cracks in concrete structures, including hairline cracks. This product is independently tested and proven to meet NSF/ANSI Standard 61.5 for contact with potable water.

    Recommended Uses

    • Injecting hairline cracks, expansion joints, wide cracks, pipe joints, or pipe penetrations
    • Sealing active leaks in above- or below-grade concrete structures
    • Oil-free oakum or open cell backer rod may be soaked in Prime Flex 900 XLV to create a watertight gasket

    Advantages

    • NSF/ANSI Standard 61.5 compliant for contact with potable water
    • Single-component. No catalyst or accelerators needed. Pump material straight out of the pail.
    • Extremely tough and flexible. Can expand and contract parallel to the crack in varying temperatures.
    • Up to 600% expansion (unconfined)
    • Low viscosity will penetrate tight cracks

     

    Bronte Pool Relining: Bronte Pool Relining

    January 15th, 2017 Posted by Projects 0 thoughts on “Bronte Pool Relining: Bronte Pool Relining”

    FCS Concrete Repairs have successfully co mpleted relining of the Bronte Ocean Pool at Bronte Park adjacent to the Bronte Surf Beach.

    The remediation of this ageing structure presented many problems and challenges:

    FCS Concrete Repairs’ Work Health and Safety Management was an important element in the success of the tender. FCS Concrete Repairs implemented its Integrated Management System covering Management of Human Resources, Sales, Purchasing, Safety and Environment for which detailed procedures were recently certified by JAS-ANZ.

    FCS Concrete Repairs construction programme was greatly affected by tidal and weather influence on surf conditions which often resulted in waves of sea water crashing into the pool work site. However thanks to the support and understanding of our client, the Waverley Council, and our employees the project was successfully completed and ready for the next Sydney summer.

    FCS Concrete Repairs’ works involved relining of the floor, walls and stairs of the Bronte Pool and the nature of our works included:

    • Surface Preparation including excavation, scabbling, scarification, wet abrasive blasting
    • Epoxy crack and joint remediation by low pressure injection
    • Hydrophobic polyurethane resin leak repairs
    • Remediation of any structural failures in the existing pool structure by high pressure injection
    • Application of sealant materials to repair and prevent leaks
    • Inspection and Testing
    • Installation of lane marking
    • Installation of Posts

    Application of a cementitious mortar lining to floor, walls and stairs
    The process for relining of the pool drew upon many of the FCS Concrete Repairs skills and processes developed over many years in the Industry by its experienced Directors and trained workforce. Safety practices were an important feature with fully documented Task Risk Assessments, Safe Work Method Statements implemented through toolbox and pre-start meetings.

    FCS Concrete Repairs have reinstated the structural integrity and appearance of the completed works which now makes the Bronte Pool one of the best ocean pools in the Sydney Region.

    FCS Concrete Repairs are very pleased with the results achieved for what was a very old and structurally compromised pool.

    The end product exceeded all expectations as evidenced by the following photographs:

    The self-healing concrete that can fix its own cracks

    January 15th, 2017 Posted by Insights 0 thoughts on “The self-healing concrete that can fix its own cracks”

    The green technology embeds self-activating bacteria into concrete to make it self-healing, but will it win over a risk-averse construction industry?

    Hendrik Jonkers, a microbiologist at Delft University and a finalist at the recent 10th annual European Inventor Awards, has a plan to increase the lifespan of concrete. His innovation, which embeds self-activating limestone-producing bacteria into building material, is designed to decrease the amount of new concrete produced and lower maintenance and repair costs for city officials, building owners and homeowners.

    self healing concrete

    Jonkers’ self-healing concrete marries two fields: civil engineering and marine biology.

    “One of my colleagues, a civil engineer with no knowledge of microbiology, read about applying limestone-producing bacteria to monuments [to preserve them],” Jonkers said. “He asked me: ‘Is it possible for buildings?’ Then my task was to find the right bacteria that could not only survive being mixed into concrete, but also actively start a self-healing process.”

    When it comes to Jonkers’ concrete, water is both the problem and the catalyst that activates the solution. Bacteria (Bacillus pseudofirmus or Sporosarcina pasteurii) are mixed and distributed evenly throughout the concrete, but can lie dormant for up to 200 years as long as there is food in the form of particles. It is only with the arrival of concrete’s nemesis itself – rainwater or atmospheric moisture seeping into cracks – that the bacteria starts to produce the limestone that eventually repairs the cracks. It’s a similar process to that carried out by osteoplast cells in our body which make bones.

    The invention comes in three forms: a spray that can be applied to existing construction for small cracks that need repairing, a repair mortar for structural repair of large damage and self-healing concrete itself, which can be mixed in quantities as needed. While the spray is commercially available, the latter two are currently in field tests. One application that Jonkers predicts will be widely useful for urban planners is highway infrastructure, where the use of de-icing salts is notoriously detrimental to concrete-paved roads.

    Encouraging as it sounds, Jonkers’ self-healing concrete can’t cure very wide cracks or potholes on roads just yet; the technology is currently able to mend cracks up to 0.8mm wide.

    More Reading: http://edition.cnn.com/2015/05/14/tech/bioconc

    rete-delft-jonkers/

    Youtube: https://www.youtube.com/watch?v=OXkW1q9HpFA

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