I N S P E CDecemBer 2011

I N S P E C

Maintaining our Heritage at 726HayStreet

WHAt’SinSideMessage froM our MD 2

schools conTracT awarDs 2

726 hay sTreeT 3

Willagee car park 7

Kalgoorlie nicKel sMelTer awarD 8

conTacT us 8

kWinana precision grouTing 4

rail grouTing aT rio TinTo 4

cyaniDe coDe aT Kanowna belle 5

abrasive blasTing MeThoDs 6

02A m e S S A G e F r o m P H i l

throughout the year Duratec has demonstrated their ability to successfully deliver challenging, high risk projects for clients across WA. This has been achieved by our dedicated team that prides itself on appreciating our clients’ needs, meeting the challenges and striving to be the best in the market.

we thank you for providing us with the opportunity to assist you in protecting and maintaining your key infrastructure. it has certainly been a very busy year for everyone.

we wish you a relaxing and safe festive season with family and friends and look forward to working with you in 2012.

phil HarcourtManaging Director

02

Front cover: application of Dulux’s glass flake epoxy to seal the soffit at 726 Hay Street.

DurAtec WiNS tWo mAjor ScHool mAiNteNANce coNtrActSDuratec has been awarded two separate contracts by Programmed Facility management and Spotless to perform a variety of concrete and masonry repair works to 17 schools around the Perth metropolitan area. The south of the river schools include: John curtin college of the arts, Kent street, Thornlie, Kelmscott, Melville, and lynwood senior High schools, north lake senior college, Darling range sports college, and riverton Primary school. The northern suburb schools (spotless contract) include greenwood, carine, girrawheen, Morley, hampton and John forrest senior high schools, Tuart college and the international school of wa.

The program aims to repair highlighted concrete and masonry problem areas improving the overall safety, aesthetics and integrity of the assets. The works will be delivered over the christmas school holidays.

images:examplesofconcreteandmasonryissuesthatrequirerehabilitation.

03F e At u r e r e v i e W

mAiNtAiNiNG our HeritAGe

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Duratec has played an integral role in extending the life of one of WA’s heritage listed buildings.The project required Duratec to tap into the wealth of technical expertise within our team to overcome some of the project challenges. Duratec’s project team worked closely with Diploma (builder), airey Taylor consulting (structural engineer) and Palassis (architect) to gain approval for a technical solution that would deliver the best remediation results.

The building, located at 726 hay street, has been unoccupied for many years and has demonstrated significant concrete deterioration.

Duratec’s solution included alternative membrane systems specific to various levels of required performance and a combination of pour and patch repair mortars to suit individual repair configurations.

over a two month period the scope of works included: 700m2

of waterproofing, application of 1,600 bags of polymer modified repair mortar, installation of over 560 sacrificial anodes and 8,500m2 of glass flake epoxy coatings, Xypex toppings and Mci application. specialist products from Xypex, Dulux, basf, Parchem and sika were used on the project.

our project team consists of a full time project manager/engineer, project supervisor and technical supervisor along with a team of over 20 specialist applicators, carpenters, waterproofing applicators and labourers. a night shift team carried out the application of an epoxy glass flake coating to all the floor soffits to avoid any disruption to the other trades working during the day.

it is anticipated that the majority of repairs will be complete by christmas with the waterproofing continuing into January.

Duratec’s operations Manager, Deane Diprose said, “it has been a very challenging project which included many unique situations. The flexible scope enabled Duratec to adopt a variety of systems to deliver the best solution. a combination of experience and collaboration with all stakeholders enabled the best repair methodologies to be selected”.

Top: all degraded concrete was removed, the reinforcement cleaned,paintedandprotectedbysacrificialanodes.

Above:duratecspecialistpreparingtheexposedreinforcement.

Below: unique formwork built to reinstate the concrete on the structuralsupportsoftheroofsoffit.

Belowleft:aglassflakeepoxywasappliedbyairlessspraytosealtheconcreteofthesoffitbeforeafalseceilingisinstalled.

PreciSioN GroutiNG iN KWiNANA

KeePiNG rio tiNto’S trAiNS oN trAcK

P r o j e c t r e v i e W S04

Duratec was contracted by sister company FormAction to provide grouting solutions for the new Kwinana Bulk terminal’s stacker reclaimer rail line.This rail line consists of approximately 1300 baseplates, each requiring inspection and appropriate precision grouting work. The work methodology involved formwork and a poured epoxy grout. while on site Duratec also undertook additional grouting to the new site hoppers, transfer stations, sampling station and power substation.

The rail line remained operational during the works. Despite being delivered during one of Perth’s wettest october’s, the team completed the project on schedule.

Duratec recently completed the refurbishment of rail crossing panels and baseplates throughout the northwest for rio tinto iron ore.The concrete rail crossing panels were removed from the train crossings and damaged areas were repaired using cement and epoxy based mortars. new 2.5 tonne lifting lugs were installed in the concrete panels into core drilled holes using re 500 epoxy grout. The lugs were then strength tested by independent engineers (see inset photo).

The rail baseplate repairs were completed for Kerman construction at rio Tinto’s newly built locomotive and ore car workshop just outside Karratha. epoxy grouts were installed (as opposed to cement based grouts) as the base plates are required to withstand the constant dynamic forces applied by the heavy locomotives and ore cars. a mobile cool room was on standby to keep the epoxy grout at a temperature compliant with Qa specifications. 242 base plates were grouted with epirez 280s.

both projects were delivered on time and safely.

PreciSioN GroutiNG iN KWiNANA

Duratec was engaged by Barrick Gold’s Kanowna Belle mine to repair concrete and coatings to maintain Cyanide Code compliance.The project involved the manual breakout of delaminated concrete and the replacement of corroded reinforcing bars. sacrificial anodes were installed to further protect the steel reinforcing. Parchem renderoc la55 high strength repair micro-concrete was used to reinstate the repair zones. a new 12 metre wall was installed with traditional form and pour methods with batch concrete supplied by holcim.

upon completion of concrete repairs the entire bund was abrasive whip blasted and epoxy primed in preparation for the application of Polyeuro 5502. This topcoat is a high performance, chemical resistant, instant curing polyurea applied by specialised plural component airless spray equipment. The applied thickness and flexibility of Polyeuro 5502 allows it to bridge cracks and withstand subsequent movement in the concrete floor. The coating was also ideal to seal the tank ringbeam in combination with geotextile providing the bund with a complete monolithic seal satisfying cyanide code requirements.

The specialist application team was required to wear full face respirators and acid protection suits while working in the cyanide bund. The continuity of work was regularly challenged as the bund was required to be completely evacuated during cyanide deliveries.

The project was completed to a high standard within budget and incident free.

KANoWNA Belle comPlyiNG WitH tHe cyANiDe coDe

05P r o j e c t r e v i e W S

top:thebundpriortoapplicationofthetopcoat.

Right:applicationofthepolyureawiththerequirementtowearfullacidsuitsandfullfacemasks.nB:ahardhatisnotrequiredforspecifictaskswhenusedwithafullfacerespirator.

Below:challengesincludedworkingaroundexistingserviceswiththeplantstillinoperation.

Correct surface preparation techniques are vital to ensure your applied protective coating system’s life is maximised. Abrasive blasting is the most common form of preparing a surface for protective coatings. There are many different types of blasting methods and different types of medium to blast with. some of the common types of abrasive blasting are listed below:

Dry Abrasive Blasting – This is the most common form of blasting widely used throughout industry. it is relatively quick, economical and produces a very clean and good profile. The effectiveness of this method depends on many factors including the type, size, shape and hardness of the blast media and the equipment and experience of the operator. it does come with downside issues of excessive noise, dust, airborne contaminants and the clean up of the spent media.

Hydro Blasting – This is commonly called water blasting or water jetting. a high pressure stream of water is very effective at removing existing paint, corrosion and contaminants. water blasting pressures can range from 10,000psi to ultra high of 40,000+psi. water alone will not produce a profile but relies on the original profile that was created on the steel. This method is intrinsically safe and is preferred on offshore rigs and gas production operations. There is no blast media to clean up. The downside of the system is that ultra-high pressure water can be very dangerous. equipment is expensive and it also encourages the steel surface to flash rust very quickly requiring specialised coatings to be applied.

Dry Ice Blasting – This is the process of using air and dry ice (carbon dioxide at low temperature) to prepare the surface without damaging the properties of the substrate. Dry ice blasting leaves the surface completely dry with no residual blast media cleanup. waste disposal is greatly reduced.

Aqua Abrasive Blasting – a relativity new form of wet abrasive blasting that combines the use of water and grit to prepare the substrate. The method is very effective (similar to dry blasting), however produces minimal dust, lower noise levels, is safer and is better for the environment.

Sponge Blasting – a dry blast method that involves the use of media entrapped in polyurethane. The pliant nature of sponge media allows its particles to flatten on impact exposing the abrasive. after leaving the surface, the media constricts and encapsulates what would normally have become airborne contaminants.

Bristle Blasting – unlike other blasting methods, bristle blasting does not use water or blast media. The surface is treated by a brush like rotary power tool made up of dynamically tuned high carbon steel wire bristles which impact

WHAt BlAStiNG metHoD iS riGHt For you?

t e c H N i c A l A r t i c l e06

and rebound to clean the surface. This method is effective on small areas where traditional blasting techniques are impractical.

The type of blasting method that is chosen depends on many factors including the type of substrate, location of the project, the required profile and the paint specification system to be applied.

imagesfromtoptobottom:1.HydroBlastingisaveryeffectivemethodofpreparingconcreteforcoatingorremovingdegradedconcrete.2.AquaAbrasiveBlastingcombinesgarnetandwaterinaslurrymixwhichsignificantlyreducesdustandnoise.3.BristleBlastingissuitableforsmallareas.

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FASt turNArouND At BuSy SHoPPiNG ceNtre

P r o j e c t r e v i e W S 07

Colliers International contracted Duratec to investigate and provide solutions to repair a leaking suspended slab carpark deck at the Willagee Shopping centre, south of Perth.Duratec provided a detailed proposal suggesting a range of waterproofing solutions. This allowed the client to select the option that met their performance and budget criteria.

The works included stripping back the entire south deck to the base concrete slab. any defects and cracks were patched and all points and penetrations detailed.

The entire surface was coated with a durable, elastic, waterproof methacrylate coating system. This technology provides excellent wear and uv resistance, is flexible and has good crack bridging properties. it fully cures within one hour of application minimising down time. all kerbing, fill, paving, line marking and trolley bays were then reinstated to match the existing surrounds.

other works included crack injection repairs, joint repairs, general painting, concrete repairs and light pole grouting. The works were delivered in three stages to minimise disruption to the busy shopping centre, allowing it to remain open at all times.

Duratec completed the refurbishment ahead of schedule, despite a very wet Perth october.

Top: the completed car park.

Right:applicationofthedegacoteC1methacrylate.

Below: all cracks were patched and sealed before the applicationofthetopcoatandlightpolesweregrouted(inset).

Below right: the car park before the refurbishment.

Head Office21 Triumph avenueWangara Wa 6065 P: (08) 6267 2370e: info@duratecaustralia.com.au

KalgOOrlielot 33 Yarri roadParkeston Wa 6433P: (08) 9021 5277

KarraTHaU1/3890 coolawanyah roadKarratha lia Wa 6714P: (08) 9185 6077

POrT Hedland11 Pinga StreetWedgefield Wa 6721P: (08) 9140 2240

“...extending the life of your assets”

Duratec have recently signed a contract with BHP Nickel West for the refurbishment of the sulphuric acid plant at the Kalgoorlie Nickel Smelter.The original plant was built in 1996 and the concrete was coated with novolac epoxy resin and fibreglass matt. The new works involve concrete repair and the application of flexible urethane technology products. Duratec will also install acid bricks to provide the ultimate protection against sulphuric acid attack. The six month program will commence in January 2012.

AciD PlANt ProtecteD

w w w . d u r a t e c a u s t r a l i a . c o m . a u

Right: overview of the sulphuric acid area.

Specialist Maintenance and Protection

“...extending the life of your assets” • AssetConditionSurveys • HighPerformanceCoatings• Concrete Repair • Industrial Flooring• CathodicProtection • MineSiteMaintenance• BlastingandCoating • Tank Maintenance• PrecisionGrouting • Waterproofing• Building Facades • StructuralStrengthening