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    FCS Concrete Repairs Pty Ltd
    ABN 68 602 061 709

  • Call us 02 8203 4568

  • Email Address info@fcsconcreterepairs.com.au

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    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:


    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.


    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.

    FCS Concrete Repairs’ latest Equipment Addition

    April 4th, 2017 Posted by Blog, Main Feature 1 thought on “FCS Concrete Repairs’ latest Equipment Addition”

    Bunker S8EVM Grout Screw Pump with Mixer

    for small scale spray-cretingin shotcreting and spray applied concrete repair applications.

    The Bunker Grout Pump will be used to apply such products as

    Fosroc Guncrete E: Spray Applied Repair Mortar

    FCS Concrete Repairsstaff are trained and equippedto carryout small scale concrete repair with spray applied repair mortar using the Gunite type process.

    Fosroc Construction Chemicals use Sprayset Chemical,a chloride free liquid based on a blend of inorganic powders, which is added to a sprayed concrete mix to impart properties of high build and low rebound. Its pH level is neutral.

    Fosroc Guncrete E product is a high strength, low shrinkage, high build cementitious spray applied mortar supplied as a ready to use powder for use with standard dry spray or shotcrete equipment.

    The advantages of using the Gunite system with Guncrete E are:

    • High build material
    • High early strength
    • Low drying shrinkage
    • Low rebound
    • Chloride free

    Guncrete E has many applications in the concrete repair industry. Examples where Guncrete E can be spray applied for concrete repair:

    • Bridge Repairs: Concrete cancer type repairs to bridge support columns. Concrete can be reinstated using sprayed mortar such as Guncrete E.
    • Concrete ceilings/soffits. Quality repairs can be achieved using sprayed mortar in small patched areas using the Gunite process.
    • Large area concrete repairs. Concrete repair can be carried out cost effectively on a large scale using spray applied repair mortar.
    • Sea Wall Repair. High build spray applied mortar can be applied to repair deteriorated sea walls because of its quick setting characteristics.
    • Pool Repairs. Ageing concrete pools can be effectively repaired by recoating using the Gunite technology.
    • Concrete Walls. Repair spalling concrete caused by the penetration of water into the concrete can be repaired using the spray applied mortar after removing concrete using torbo-blasting methods.
    • “Drummy” Concrete. Where concrete render has delaminated large areas can be repaired using spray applied mortar.
    • Deteriorating foundations can be repaired effectively using spray applied mortar.
    • Expansion Joint. Overhead repair of spalled expansion joint in a carpark can be repaired effectively using Guncrete.
    • Concrete Beams. Structural concrete beams in suspended decks can be repaired effectively using small scale spray applied mortar methods.

    Before dry-spraying the repair mortar it is necessary prepare the areas before the application of the mortar. This may be achieved by the various preparation methods such as wet grit blasting, torbo-blasting,cleaning and corrosion treatment or replacement of steel reinforcement.

    Steel reinforcement primer may be used with NitoprimeZincrich, a single component zinc-rich epoxy resin specified by Fosroc.

    Guncrete E spray mortar may be used for decks, slabs, horizontal and vertical concrete surfaces to be repaired in one or more layers, each layer 10-150 mm thick where compressive strength >45 MPa compressive strength in 28 days and a low level of drying shrinkage measured to ASTM modified 23°C/50%RH shall not be greater than 500 microstrains at 7 days and 700 microstrains at 28 days is required. The minimum depth for repair shall be 10 mm.

    After applying the sprayed repair mortar the area is finished by striking off with a straight edge and trowelled or floated to achieve a level flush with or slightly proud of the surrounding surface.

    Spray applied repair mortar is cost effective in repairing small scale areas of concrete where hand repairs may be more labour intensive and costly.

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