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    FCS Concrete Repairs Pty Ltd
    ABN 68 602 061 709

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    April 4th, 2017 Posted by Projects, Uncategorized 0 thoughts on “MANLY STRATA UNIT STRUCTURAL STRENGTHENING”


    FCS Concrete Repairs successfully tendered to carryout structural strengthening to the soffit of a strata unit at Manly.

    Our client’s Engineer advised FCS Concrete Repairs that the unit’s soffit required strengthening and provided a marked up drawing indicating where the specified product, Sika Carbodur S1214 strengthening strips, were required to be installed.

    The process of installation was carried out by FCS Concrete Repairs experienced trained staff in accordance with the manufacturer’s specifications and the client’s engineering design.

    Note: FCS Concrete Repairs staff have received instruction from Sika Australia training personnel and FCS Concrete Repairs is a Sika approved applicator.

    The process was as follows:

    • Prior to commencement the soffit substrate quality was established using the Pull-off tests with a minimum requirement of 1.5MPa and tested to ensure that moisture content was less than 4% pbw.
    • The surface to be strengthened was levelled where necessary to provide maximum .
    • The substrata was cleaned of any contaminants and loose material.
    • The substrata was tested to ensure that moisture content was less than 4% pbw.
    • Ambient temperature was between the required 8°C and 35°C.
    • Substrate temperature was atleast 3°C above the dew point.
    • Sikadur 30 adhesive was used to fix the Sika CarboDur S1214 Carbon Fibre Reinforced Polymer strips(CFRP) to the soffit and was mixed as per the Sika product Technical Data Sheet.
    • Sikadur30 is a thixotropic adhesive mortar based on a 2-component solvent free epoxy resin which has the following properties required for the application of the product to the soffit:

    Tensile Properties (ASTM D-638)

    Tensile strength is a measurement of the force required to pull something such as rope, wire, or a structural beam to the point where it breaks.

    7 day Tensile Strength 3,600 psi (24.8 MPa)

    Flexural Properties (ASTM D-790)

    Flexural strength, also known as modulus of rupture, or bend strength, or transverse rupture strength is a material property, defined as the stress in a material just before it yields in a flexure test.

    14 day Flexural Strength (Modulus of Rupture) 6,800 psi (46.8 MPa)

    Shear Strength (ASTM D-732)

    Shear strength represents how hard you can try to cut it without it breaking.

    14 dayShear Strength 3,600 psi (24.8 MPa)

    • Sika CarboDur S1214 CFRP strips were installed in the designated locations on the soffit of the unit using the Sikadur 30 adhesive.
    • Sika CarboDur can be used to strengthen reinforced concrete due to loading increases, structural damage, changes in the structure or design or construction defects.
    • Sika CarboDur S1214 is 120mm wide, 1.4mm thick and can achieve very high tensile and flexural strengths:

    Elastic Modulus           >165,000 MPa

    Tensile Strength          >2,800 MPa

    Mean Value of Tensile Strength at Break  > 3,050 MPa


    • Sikadur 30 was first applied to the soffit to a nominal thickness of 1.5mm and then to the Sika CarboDur laminate also to a thickness of 1.5mm.
    • The laminate was then placed on the surface of the soffit and rolled into the epoxy resin adhesive.
    • Sikadur 30 reaches it’s design strength after 7 days.

    RESULT: The end result was that the soffit of the unit was structurally strengthened to the specifications of the client’s Engineer cost effectively without the need for any costly structural concrete modifications.


    April 4th, 2017 Posted by Projects, Uncategorized 0 thoughts on “BINGARA GORGE WATER TANK REMEDIATION”


    FCS Concrete Repairs successfully tendered to repair the concrete base slab in a water tank at the Bingara Gorge.

    Our client advised FCS Concrete Repairs that there was considerable fine cracking and repairs were necessary to prevent further expansion of the cracking, water leakage and possible failure of the tank base slab.

    Cracking in the concrete base slab floor extended through to the external plinth of the base slab.

    Some key factors considered in determining the most appropriate repair methodology included:

    • Width of cracking in concrete base slab.
    • Structural integrity.
    • Stability of base slab.
    • Degree of movement, if any, in base slab.
    • Need to consolidate the structure.
    • Need to exclude water (or air) from contact with steel reinforcement.
    • Structural or flexible repair required.
    • Chemical nature of liquid stored.
    • Strength and durability of concrete base slab.
    • Old or new concrete in the base slab.

    Based on these key factors FCS Concrete Repairs recommended the use of the Fosroc epoxy injection system TO SEAL AND STRUCTURALLY REPAIR the base slab.

    The materials used were Fosroc Nitomortar AP and Nitofill LV TDS.

    Fosroc Nitomortar AP was used to seal the cracks at the surface while Fosroc Nitofill LV was injected into the underlying cracks after the Nitomortar had cured.

    The detailed repair process carried out by experienced trained FCS Concrete Repairs staff was as follows:

    • Chase cracks with a V-cut blade to 10mm depth.
    • Clean the crack and the surrounding slab surface, remove any loose material from the crack.
    • Cap/Seal the crack using Fosroc Nitomortar AP.

    Fosroc Nitomortar AP is a versatile two-component, epoxy paste consistency, structural adhesive/filler. It cures, with minimal shrinkage, at temperatures above 5°C to a very strong, dense solid.

    The mixed material is applied to a suitably prepared surface and quickly cures to form a complete impermeable repair unaffected by many forms of chemical attack. It is supplied as a two pack colour coded material in pre-weighed quantities ready for on-site mixing and use.

    The pot life at 25°C is 60 minutes, initial hardness is 5 hours at 20°C and the mortar is fully cured at 7 days at 20°C.

    • Apply the mortar along the crack leaving openings at between 20 cm intervals for injection ports to be fixed to the crack. This depends on the crack size along the length of the crack.
    • Smooth the mortar into and along the crack using a spatula ensuring that the mortar penetrates into the crack and that the points for the injection ports are open and clear.
    • Use the mortar as an adhesive to attach the injection ports at each injection point and ensure that the crack is completely sealed and the port is clear and centred over the crack.
    • Allow the mortar to cure for five (5) hours before starting the injection process.
    • Curing is dependent on temperature as noted above. Curing time will be increased at temperatures below 20°C.
    • SAFETY INSTRUCTION: Use protective glasses during the injection process.
    • Fosroc Nitofill LV cartridges were used for the low pressure epoxy crack injection process.

    Nitofill LV is a two part epoxy base and hardener 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.

    Nitofill LV cartridge pack accessory items are available separately and comprise a cartridge gun, static mixer, nozzle hoses, injection flanges, flange adaptors and flange removing tool.

    • The Nitofill LV crack injection system process involves inserting the two part Nitofill cartridge into the cartridge gun after attaching the static mixer hose and adaptor.
    • The adaptor is then connected to the installed port or flange.
    • Nitofill LV was then injected from the cartridge through the port and into the crack until resin flows from an adjacent port.
    • The port is the closed the prevent leakage and the process is repeated at the next and succeeding ports until the entire crack is filled.
    • After the injection resin has set, atleast one (1) hours, the ports/flanges are removed using the removing tool.
    • Nitomortar is then used to fill any remaining surface indentations.
    • Subsequently any excess mortar was removed using a grinder until the original substrate profile was restored.

    RESULT: The end result was that the water tank floor substrate was sealed and structurallyrepaired and the tank repair was completely watertight and structurally sound.

    Use of Carbon Fibre Reinforced Polymer for structural strengthening is a “game changer”

    February 16th, 2017 Posted by Uncategorized 0 thoughts on “Use of Carbon Fibre Reinforced Polymer for structural strengthening is a “game changer””

    The strength of most elements in a concrete structure can be significantly improved by using carbon fibre reinforced polymer (CFRP) plates, rods, fabric and wrap for increasing flexural, compression and shear/tensile load capacity of elements such as beams, columns, suspended floors, penetrations and decks.

    Metal elements can also be strengthened in any load-bearing structure.

    FCS Concrete Repairs uses Sika Structural Strengthening Systems for their proven performance and durability.

    Carbon Fibre strengthening can successfully extend the functional service life of a building or civil engineering structure and accommodate loading changes when function changes impose increasing demands on the structure.

    FCS Concrete Repairs are experts in the use of Carbon Fibre Reinforced Polymers and can provide advice and the expertise required to successfully provide solutions.

    FCS Concrete Repairs recently successfully strengthened the following structures:

    FCS Carbon Fibre Strengthening Projects
    Project: Apartment at 30 Glen St Milsons Point

    Slab strengthening and a new void cut-out was carried out in the following sequence:

    1. Install new Corbel CB1
    2. Install Carbon Fibre Reinforcement plates.
    3. Existing tendon truncation was carried out in accordance with Freyssinet’s method statement.
    4. Cut out existing slab as per Architect’s proposed dimension and position.

    The Sika Carbodur was installed to the structural surface with Sikadur 30 resin in accordance with Sika Cardodur externally bonded reinforcement method statement prepared by Sika Service AG:

    PosiTest Adhesion Testing was carried to ensure a permanent bond
    Sika Carbodur strips were bonded to the slab surface.
    Sika Carbodur strips were bonded to the soffit of the slab

    This strengthening process enabled the void to be cut out and even the post-tensioning tendons to be cut.

    FCS Concrete Repairs skilled tradesmen contributed to a very successful outcome for the client.

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