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    FCS Concrete Repairs Pty Ltd
    ABN 68 602 061 709

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    Posts in Water Storage

    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 Flex 900 XLV: Seal leaks in concrete structures

    Repairing an Active Leak in Cracked Concrete with 900 XLV

    Gosford Council Drop Manhole Rehabilitation

    June 23rd, 2017 Posted by Projects, Sewerage Infrastructure, Water Storage 0 thoughts on “Gosford Council Drop Manhole Rehabilitation”

    FCS Concrete Repairs have been engaged by the Gosford Council to rehabilitate two large manholes in the Gosford area.

    FCS Concrete Repairs is experienced and fully resourced to carryout rehabilitation works for Water and Sewerage Infrastructure in confined spaces.
    The Scope of Works for this project includes:

    • Work health and safety management plan
    • Safe work method statements prepared
    • Inspection test plan prepared
    • Task risk assessments prepared
    • Surface cleaning and removal of deteriorated concrete
    • Wet blasting of exposed steel reinforcement
    • Replacement of steel reinforcement, if required
    • Protective coating of steel reinforcement
    • Surface restoration including reinforcement splicing and coating
    • Concrete remediation
    • Tensile or bond strength testing
    • Reinstatement of gatic covers and access ladders

    The project works are carried out in confined spaces within the Drop Manholes over-night and strict safety precautions are required including the closure of the sewer mains.

    The product used: SewperCoat® Wet Spray

    A high performance mortar with superior biogenic corrosion resistance.

    The Problem: Biogenic Corrosion

    When the right conditions exist in a sewer system, Acidophilic* bacteria feed on sulfur from H2S gas and release sulfuric acid that corrodes concrete, mortar, steel, and ductile iron. In the most severe cases, bacterial activity can destroy up to 25 mm of concrete per year.

    The Solution: SewperCoat® Wet Spray

    SewperCoat®’s outstanding durability in the most severe sewer environments relies on the unique “bacterio-static effect” of calcium aluminates. The metabolism of acid-generating bacteria is inhibited on calcium aluminate surfaces, thus maintaining a pH level above 3.


    SewperCoat® Wet Spray is a mortar designed to provide exceptional resistance to the biogenic corrosion environment found in sanitary sewers. The unique biogenic corrosion resistance of SewperCoat® Wet Spray is due to its 100% calcium aluminate composition, i.e. the combination of calcium aluminate cement and calcium aluminate aggregates.

    SewperCoat® Wet Spray can be utilized to rehabilitate sewer infrastructures that have been damaged over years by biogenic corrosion. SewperCoat® Wet Spray can also be utilized to provide a protection lining to new infrastructures that will be exposed to biogenic corrosion conditions.

    SewperCoat® Wet Spray is a cementitious mortar, fully compatible with the moist environment found in sewers.


    The unique properties of SewperCoat® Wet Spray result from the chemical and mineral phases formed during the hydration process. SewperCoat® is unique when compared to other materials such as ordinary portland cement (OPC) concrete, epoxies, poly-vinyl chloride (PVC) or polyethelene because of its ability to inhibit bacterial activity which drastically reduces the production of sulphuric acid. Key advantages of the SewperCoat® Wet Spray are as follows:

    • Inhibits bacterial activity
    • Neutralizes sulfuric acid
    • Readily adheres to damp concrete
    • Easy Monolithic installation
    • Provides Long Term corrosion protection
    • Contains no VOC’s


    Clean the surface and remove any dust, unsound or contaminated material, plaster, oil, paint, grease, corrosion deposits or algae. Where breaking out is not required, roughen the surface and remove any laitance by light scabbling or grit-blasting. The substrate should be thoroughly saturated with clean water prior to the spray application of the SewperCoat® Wet Spray. Under no circumstances shall the material be applied in an area where running water exists.


    In the wet spray process, the mortar is batched and mixed prior to being pumped along suitable hoses to the discharge nozzle. High velocity air is introduced at the nozzle to disperse the mortar and propel it into position. The impact of the mortar ensures excellent contact with the substrate and good compaction. As the material is batch mixed prior to pumping, the water content can be accurately controlled, ensuring a consistent product is applied to the substrate.

    The spraying technique employed for each job will depend on the nature of the work and the materials used. Wherever possible, it is recommended that trials are performed with the material and equipment on elements which exhibit the same features as the job to ensure the spraying technique employed is appropriate. If sagging occurs during application to vertical surfaces, the SewperCoat® Wet Spray should be completely removed and reapplied at a reduced thickness on to the substrate.

    Note: minimum applied thickness of SewperCoat® Wet Spray is 25mm. Equipment used must be clean and free of Portland cement build up to avoid accelerated set. Water addition to be between 2.7-3.00L per 20kg bag of SewperCoat® Wet Spray. Please refer to the SewperCoat® Wet Spray application guide for further information.


    • Compressive Strength (MPa) (AS 1478.2 – 2005)
    • 6 hours >20MPa
    • 24 hours >40MPa
    • 28 days >70MPa
    • Modulus of Rupture (Flexural Strength) (MPa) (AS 1012.11 – 2000):
    • 24 hours >4.5MPa
    • 28 days >8.5MPa
    • Indirect Tensile strength (AS 1012.10 – 2000): 28 days >3.5MPa
    • Dimensional Change (Drying shrinkage) (AS 1478.2 – 2005): 56 days <600 microstrains


    See Product Brochure Here

    Watch This Product in Action Here



    FCS Concrete Repairs are experts in the repair and rehabilitation of Drop Manholes, Digester Systems, Screen Tanks and other Sewage Infrastructure works. FCS Concrete Repairs are on call to provide advice or carryout Specified Rehabilitation Works safely in a professional and cooperative manner.

    Warragamba Pipeline Support Base Slab

    Warragamba Pipeline Support Base Slabs

    March 13th, 2017 Posted by Crack Injection, Projects, Water Storage 0 thoughts on “Warragamba Pipeline Support Base Slabs”

    Client: Water NSW
    Project: Warragamba Pipeline Support Base Slabs
    Location: Orchard Hills NSW
    Scope: Excavate, membrane, steelfixing and place & finish concrete to Pipeline Support Base Slab

    Water Storage Tank Crack Injection

    March 11th, 2017 Posted by Crack Injection, Projects, Veolia Water Solutions, Water Storage 0 thoughts on “Water Storage Tank Crack Injection”

    Client: Veolia Water Solutions
    Project: Water Storage Tank Crack Injection
    Location: Bingara Gorge NSW
    Scope: Tank floor repairs crack injection. Apply Nitomortar AP epoxy paste over the V cut then inject NItofill LV

    Veolia Water Storage Tanks

    January 18th, 2017 Posted by Projects, Storm and Wastewater Infrastructure, The Tasman Tank co., Water Storage 0 thoughts on “Veolia Water Storage Tanks”

    Client: The Tasman Tank Co.
    Project: Veolia Water Storage Tanks
    Location: Bingara Gorge NSW
    Scope: Sikadur-Combiflex SG System (High Performance Joint & Crack Waterproofing System to 2x water storage tanks

    Hezeldenes Chickens, Veolia Water Storage Tanks

    January 18th, 2017 Posted by Projects, Storm and Wastewater Infrastructure, The Tasman Tank co., Water Storage 0 thoughts on “Hezeldenes Chickens, Veolia Water Storage Tanks”

    Client: The Tasman Tank Co.
    Project: Hezeldenes Chickens, Veolia Water Storage Tanks
    Location: Bendigo NSW
    Scope: Sikadur-Combiflex SG System (High Performance Joint & Crack Waterproofing System to 2x water storage tanks

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