• PO BOX 6446 North Ryde NSW 2113

    FCS Concrete Repairs Pty Ltd
    ABN 68 602 061 709

  • Call us 02 8203 4568

  • Email Address info@fcsconcreterepairs.com.au

    Certifications - Jaz AnzCertifications - SafetyCertifications - QualityCertifications - Environmental

    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.

    FCS Anti-Graffiti Solutions

    June 5th, 2018 Posted by Blog, Epoxy Coating, Insights 0 thoughts on “FCS Anti-Graffiti Solutions”

    LATEST DEVELOPMENTS: The very latest in ANTI-GRAFFITI SOLUTIONS.

    IS THIS ART OR SOCIAL VANDALISM?

    Our local Council for the City of Ryde have recently acknowledged the problem of Graffiti Management:

    “Graffiti is a problem everywhere, and the City of Ryde is no exception. This anti-social pastime defaces both public and private property. In NSW, any graffiti on public or private property is a criminal offence unless permission is given by the owner. It is punishable by imprisonment, community service orders or fines of up to $2,200.”

    FCS Concrete Repairs now have the latest solution to the problem!

    FCS Concrete Repairs have rights to a very newly developed coating which enables Graffiti to be easily removed from its surface using a fully biodegradable product.

    The anti-graffiti coating is coloured or clear and can be applied to all surfaces including paint and most other coatings, timber, concrete, brickwork, manufactured surfaces and claddings, and natural materials such as sandstone, granite, marble etc.

    The clear version maintains the appearance of the existing surface, seals and provides protection and enables Graffiti to be completely removed without damage to the surface when any Graffiti attacks are reported.

    FCS Concrete Repairs provide the FULL SOLUTION from coating application to general maintenance and Graffiti removal.

    This is a great development for FCS Concrete Repairs and for the Community, and complements our current range of services in concrete repairs, protective coatings, crack injection and structural strengthening.

    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

     

    De-icing Concrete: the world’s first bridge to incorporate conductive concrete

    October 3rd, 2017 Posted by Blog, Insights 0 thoughts on “De-icing Concrete: the world’s first bridge to incorporate conductive concrete”

    A unique bridge that resides about 15 miles south of Lincoln has given Tuan reason to feel confident. In 2002, Tuan and the Nebraska Department of Roads made the 150-foot Roca Spur Bridge the world’s first to incorporate conductive concrete. Inlaid with 52 conductive slabs that successfully de-iced its surface during a five-year trial run, the bridge exemplifies the sort of targeted site that Tuan envisions for the technology.

    The concrete mix’s designer, UNL professor of civil engineering Chris Tuan, has added a pinch of steel shavings and a dash of carbon particles to a recipe that has literally been set in concrete for centuries. Though the newest ingredients constitute just 20 percent of Tuan’s otherwise standard concrete mixture, they conduct enough electricity to melt ice and snow in the worst winter storms while remaining safe to the touch.

    By replacing the limestone and sand typically used in concrete with a mineral called magnetite, Tuan has shown that the mixture can also shield against electromagnetic waves. Cell phones are unable to receive service for example and the conductive concrete may be useful in shielding against espionage.

    University of Nebraska-Lincoln
    Nebraska Today
    By Scott Schrage
    University Communication

    For morinformation visit news.unl.edu

    Featured Products: Modern Concrete Cracks and Concrete Leaks

    October 3rd, 2017 Posted by Featured Products 0 thoughts on “Featured Products: Modern Concrete Cracks and Concrete Leaks”

    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.

    AR 800 acrylate resin is a super low viscosity, hydrophilic grout that produces an elastomeric gel with variable set times. This three-component resin is used for leak sealing and soil consolidation. It is ideal for geotechnical applications in humid environments. The variable set time range is long—from minutes to more than an hour—and is adjustable in the field. The resin remains fluid until polymerization, allowing for excellent penetration, so it is a great choice for sandy or silty soils.

    When cured at a 50% concentration, it is a white flexible gel that has the consistency of a soft silicone gel with excellent adhesiveness. Humid conditions allow the gel to remain relatively constant. The gel is permanently elastic; these dimensional changes are reversible and do not degrade the gel. All-stainless steel pumps/fittings are required. This product has been independently tested and proven to meet NSF/ANSI Standard 61.5 for contact with potable water.

    Prime Flex 920 is a single-component polyurethane injection resin used to seal gushing leaks, including wide gaps, in concrete where the structure is not subject to movement. This hydrophobic, super low viscosity polyurethane reacts with water and expands to form a closed cell, watertight, rigid foam. Due to its low viscosity, 920 is also used for permeation grouting of loose soils to consolidate soil particles and increase the load-bearing capacity. (For high strength or large void filling, see Prime Flex 985.) This material requires the use of Prime Kat or Kick Fast Kat to adjust the reaction time from 4-13 seconds. (See Material Preparation below.) This product is independently tested and verified to meet NSF/ANSI Standard 61.5 for contact with potable water.

    Prime Flex Hydro Gel SX is a versatile, easy-to-use single-component, water activated, hydrophilic polyurethane injection resin for sealing actively leaking joints and cracks in below-grade concrete structures. It forms either a closed cell, watertight foam or impermeable gel depending on the water to resin mix ratio. Cured material remains flexible and has excellent adhesion. It can also be used for soil binding for slough control. Independently tested and verified to meet NSF/ANSI Standard 61 for contact with potable water.

    Prime Flex 940 polyurethane resin is a very low viscosity, hydrophobic resin that reacts with water and expands to form a closed cell, watertight flexible foam. This grout requires Prime Kat or Kick Fast catalyst, but after mixing is pumped as a single component. The set time can be varied with the catalyst concentration. This resin is used for sealing actively leaking joints and cracks in concrete structures, particularly those subject to movement or vibration. It is verified to meet NSF/ANSI Standard 61.5 for contact with potable water.

    A Truism: Modern Concrete Cracks and Concrete Leaks!

    October 2nd, 2017 Posted by Blog, Concrete Repair, Concrete Repairs, Crack Injection, Main Feature, Projects 0 thoughts on “A Truism: Modern Concrete Cracks and Concrete Leaks!”

    There are four types of concrete!

    Concrete that can crack!

    Concrete that has cracked!

    Concrete that can leak!

    Concrete that has leaked!

    Truism: This observation is obviously true and says nothing new or even interesting about concrete but if you have a problem and need a solution then:

    TALK TO THE DIRECTORS AT FCS CONCRETE REPAIRS.

    They are ready to help you!

    When does concrete crack and leak?

    Shrinkage cracks may occur when water evaporates from the concrete soon after it is layed during the drying process. (that is, the curing process) Hot weather can cause rapid evaporation if curing compound is not properly used to slow the evaporation and cold weather can slow the evaporation process. Fine cracks give the opportunity for water to penetrate the concrete and cause the steel reinforcement to rust and concrete degradation.

    Structural cracks when the concrete structure is over-loaded or subject to design flaws will allow water to penetrate the concrete and cause the steel reinforcement to rust leading to concrete degradation.

    Concrete cancer cracking when water penetrates into the concrete and causes the internal steel reinforcement to corrode, expand and cracks form from within allowing water to leak through the concrete element.

    Concrete cracking when the sub-base is inadequate or a washout occurs allowing water to flow under and through the concrete element.

    Soil movement below the sub-base due to natural movement or the expansion and contraction of the underlying clay earth in times of heavy rain or drought allowing water to flow below and washout the concrete element.

    Cracking due to freezing conditions followed by thawing which may also cause expansion and contraction and allow water to leak through and below the concrete element.

    Hot summers can cause cracking due to expansion of the concrete and allow the ingress of water.

    Washouts behind retaining walls may also result in structural cracking and gushing leaks.

    HEADLINE NEWS!

    Fortunately, experienced Concrete Repair Contractors like, FCS Concrete Repairs, have the solutions. Experienced tradesmen, high-tech equipment and repair materials, and technical knowledge can combine to provide near permanent solutions to concrete cracking and leaking. Early intervention is also critical in enabling effective repair and cost effective solutions.

    What can be done?

    Badly damaged concrete can be replaced BUT this can be costly and involves:

    • Investigation
    • Demolition
    • Removal
    • Replacement

    Modern crack injection methods can provide a cost effective alternative solution:

    • Polyurethane injection

    Single component hydrophobic foam can be injected to stop water infiltration and to stop high pressure flowing water and to fill voids behind the structure or joints or cracking in concrete.

    Two component hydrophobic rapid setting foam can be injected. This foam is highly reactive, high strength and expands up to ten times when in contact with ground water.

    • Polyurea Silicate

    Two component low density foam to fill cavities provides structural strength and flexibility to stabilise strata.

    • Acrylic

    One component water based acrylic joint sealant and gap filler which has low adhesive and compressive strength, but high tear strength.

    • Cementitious Grout

    A combination of cement and water, plus admixes or additives to alter their properties. There are three main types – pure cement mixes (PCMs) composed of cement and water, admixed cement mixes (ACMs) composed of PCM and admixtures, and additive cement mixes (ADCMs) composed of ACM and additives.

    • Epoxy injection

    Two component, low viscosity, solvent free, moisture insensitive, structural epoxy injection resin used to seal cracks and cavities and forms an effective barrier against the infiltration of water and bonds concrete to restore structural integrity. Doesn’t bond as well to wet surfaces.

    FCS Concrete Repairs has the expertise to investigate, test, diagnose and recommend on the most appropriate and cost effective solution to your concrete cracking and leaking problem.

    How to seal leaks in concrete structures

    October 2nd, 2017 Posted by Blog, Concrete Repair, Leak Sealing, Waste Water Treatment, Water Storage, Water Treatment Plant 0 thoughts on “How to seal leaks in concrete structures”

    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 include injecting hairline cracks, expansion joints, wide cracks, pipe joints, or pipe penetrations, or sealing active leaks in above-grade or below-grade concrete structures.

    This can be used for water treatment tanks, dams, below-grade concrete walls, tunnels, manholes and elevator service pits.

    Prime Flex 900XLV is compliant for contact with potable water, can expand and contract parallel to the crack in varying temperatures, can expand up to 600% unconfined and has a low viscosity to allow it to penetrate tight hairline cracks deep into the structure.

    When the material contacts water, it reacts to form a white, flexible gel-like foam that acts as a barrier, sealing the cracks that allowed water to leak. As the foam reacts, it expands to fill the space and bond to the concrete to hold it in place, creating a closed cell mass that does not allow water to pass through or around it. The foam’s flexibility allows it to expand and contract along with the structure it has sealed, so it remains water tight despite temperature fluctuations.

    FCS Concrete Repairs are experts in leak repair and are available to help with your concrete repair requirements. FCS Concrete Repairs are approved applicators for this product in Australia.

    PRIME RESINS VIDEOS

    Prime Flex 900 XLV: Seal leaks in concrete structures

    Repairing an Active Leak in Cracked Concrete with 900 XLV

    Copyright © 2016 FCSConcreteRepairs.com.au. All rights reserved. Website by YourVDesk.com.