Permeation Grouting, Gushing Leak Sealing, Soil Stabilisation, Chemical Grouting, Curtain Grouting Barriers, Leak Repairs, Slab Lifting, Void Filling

FCS Concrete Repairs Pty Ltd are highly specialised in all aspects of concrete restoration, preservation and protection. We are equipped with the latest technology in fluid containment, chemical or contamination exclusion and the rectification of any type of concrete and masonry based structures.

Vast industry experience and a strong professional team enable us to offer our clients premium remedial and preventative solutions across a broad range of projects from multi residential situations right through to high profile multi-million dollar infrastructure specifically Carbon Fibre Reinforcement is an area we excel in.

FCS Concrete Repairs Pty Ltd have completed Carbon Fibre Reinforcement CFR, externally Bonded Reinforcement projects.

FCS Concrete Repairs Pty Ltd provide a step by step process for the strengthening of structures using Carbon Fibre plate systems of externally bonded reinforcement.

LEAK SEALING REPAIRS

FCS Concrete Repairs use polyurethane resins and acrylate resins to provide reliable and long term results. These are superior products for use in every type of application and every environment.

FCS Concrete Repairs select the appropriate chemical grout and application method to achieve the desired results. FCS Concrete Repairs are able to use Polyurethane Injection Resins for hairline cracks, wide cracks and joints, gushing leaks, dry cracks, manholes, coatings and hydraulic cement.

FCS Concrete Repairs specialist team can stop leaks in balconies, retaining walls, dam and reservoir walls, tank walls, carparks, building walls and concrete floor slabs.

FCS Concrete Repairs methods minimise down-time and will keep your premises open and operating.

FCS Concrete Repairs are able to fix the problem while it is happening using the latest products and techniques.

LEAK SEALING METHODS

FCS Concrete Repairs seal leaks in concrete and masonry structures with crack injection and curtain grouting techniques.

THE CRACK INJECTION PROCESS

The type of product used for crack injection depends on the crack width, wall thickness and conditions present in the area being repaired. The steps in the crack injection process are:

1. Install Injection Ports: Surface ports can be used in low pressure injection situations. The port is placed over the crack and epoxy bonded to the surface. This avoids the need to drill and install injection nipples.
2. Seal the Surface: Seal over the surface ports leaving only the port holes uncovered.
3. Inject the Crack: Inject until the epoxy/polyurethane comes out of the port above. Plug the port and move up to the next port and repeat the process.
4. Remove the Ports: Allow the product to cure and then remove the ports.

Crack Injection is effective where individual cracks in the structure can be effectively sealed to prevent the ingress of water.

THE CURTAIN GROUTING PROCESS

Curtain Grouting involves drilling through the structure and injecting grout into the underlying soil which surrounds the structure (e.g. manhole, retaining wall) and prevents water reaching the structure. The steps in the curtain grouting process are:

1. Drill holes right through the wall of the structure to reach to earth behind.
2. Inject the grout into the lowest injection hole.
3. Move to the next hole when the material comes out of a nearby hole and repeat the process for all holes at the lower level then move up to the next set of holes and repeat.
4. Patch each hole after all the holes are grouted.

Curtain grouting is one of a number of techniques for fighting water intrusion. It eliminates the need to chase water ingress and will protect the structure permanently.

SELECTION OF CHEMICAL RESINS/GROUTS

FCS Concrete Repairs uses chemical grouts for stopping leaks in a variety of structures. By analysing the structure type and the size of the leak, FCS Concrete Repairs can determine which product and process works best for the given problem.

With weeping or small leaks, a major focus is on the viscosity, or thickness, of the resin. Low viscosity resins can easily penetrate the cracks and ensure that all cracked areas are repaired.

Hydrophilic chemical grouts are attracted to water and ‘chase moisture.’ In doing so, the grout follows all paths along the crack in order to reach and seal the leaks. For purposes of sealing leaks with chemical grouts, a hairline crack is considered one that is 1.6mm or less. Several products are independently verified to meet NSF/ANSI Standard 61.5 for contact with potable water, making them ideal for water treatment, transport and storage structures. Other areas of environmental sensitivity, such as seawalls, are also great candidates for our NSF compliant products.

With gushing or large leaks, quick reaction or ‘set’ times are important. This ensures that the resin has the opportunity to react with the water currently present and expand quickly enough to form a watertight, rigid foam before the leak can wash grout away. Set times can be controlled by catalysts or activators. Where hydrostatic pressures are high, a hydraulic cement patching material or oakum can be used to stop or slow the flow enough for the chemical grout to react.

Equally important is the expansion rate. Gushing leaks are caused by larger flows of water, meaning that a large area would need to be sealed in order to stop the leak. Using products with higher expansion rates allows for greater coverage of the void area. In below-grade structures, the large expansion rate also serves to fill any voids behind the structure and thus forms a curtain that serves as a 360-degree shield.

FCS Concrete Repairs selects products which have the necessary properties to repair the leak in the particular application. Such materials include products with the following properties:

• Acrylate, very low viscosity, low toxicity, elastomeric gel, for crack injection in structures
• Acrylate, very low viscosity, low toxicity, elastomeric gel, primarily for geotechnical applications, compliant for potable water use
• Hydrophilic, polyurethane, single-component, extra low viscosity, compliant for potable water use
• Hydrophilic, polyurethane, medium viscosity, single-component, for medium to wide cracks
• Hydrophobic, polyurethane, low viscosity, variable set time, compliant for potable water use
• Rapid cure polyurea non-sag paste for temporary surface seal prior to crack injection of epoxy or polyurethane grouts. Can be peeled off, leaving a clean surface.
• Hydraulic cement product to stop water flow prior to crack injection

FCS Concrete Repairs recommends products supplied by Prime Resins.

Typical structures include:

FCS Concrete Repairs have the required equipment and experience to seal leaks in each of the following structures:

• manholes
• tunnels
• stormwater systems
• sewers
• pipe joints
• retaining walls
• seawalls
• dams
• cooling basins
• footings
• foundations
• tanks
• below-grade carparks
• water treatment tanks
• elevator pits
• box culverts
• below-grade vaults, walls, pits or floors

Uncontrolled Infiltration and Inflow

Water and Sewage Authorities have problems with uncontrolled infiltration and inflows and chemical grouting is a cost-effective solution in controlling such infiltration and inflow in manholes and pipes.