BALCONY REPAIRS. inside 2 MESSAGE FROM PHIL 2 WHAT S NEW? 3 COMMERCIAL PROJECTS 4 MARINE PROJECTS 5 MINING PROJECTS ADMIRALTY TOWERS ONE JUNE 2016

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1 JUNE 2016 ADMIRALTY TOWERS ONE BALCONY REPAIRS inside 2 MESSAGE FROM PHIL 2 WHAT S NEW? 3 COMMERCIAL PROJECTS 4 MARINE PROJECTS 5 MINING PROJECTS 6 INFRASTRUCTURE PROJECTS 7 OIL & GAS PROJECTS 7 INDUSTRIAL PROJECTS 8 SPECIALIST ACCESS PROJECTS 8 TECHNICAL SURVEYS 9 FORTEC PROJECTS 10 FEATURED PROJECT 11 SPOTLIGHT ON SURVEYS 12 CONTACT US

2 PHIL HARCOURT MANAGING DIRECTOR Front cover: the 26 storey Admiralty Towers One residential building in Brisbane. A MESSAGE FROM PHIL I am pleased to report that Duratec has experienced another period of outstanding growth whilst consolidating new markets in South Australia and Queensland. This growth has predominantly been organic and is associated with the company s ability to appoint excellent industry experienced personnel aligned, importantly, with our culture and values. The company has managed to increase capacity to meet this growth demand whilst still delivering projects safely, WE ARE PLEASED TO PRESENT THE WINTER EDITION OF INSPEC SHOWCASING SOME OF THE RECENT REMEDIATION WORKS WE HAVE BEEN PERFORMING exceeding quality standards, on time and in line with budget expectations satisfying client needs. I am also pleased to announce a new Construction Products Division as part of the Fortec Australia service offering (see page 9). I trust you will enjoy this edition of InSpec and thank you for the opportunity to be of service. WHAT S NEW? PROJECT VIDEOS FOR A MORE INTERACTIVE LOOK AT WHAT WE DO VISIT OUR WEBSITE, WHERE YOU CAN FIND IN-DEPTH INFORMATION ABOUT OUR PROJECTS AND DOWNLOAD OUR LATEST VIDEOS AND COMPANY PROFILES Rope Access & Drone Capability See our Specialist Access Division in action, utilising a variety of access systems including scaffolding, rigging, rope access and drone. Structures accessed include chimney stacks, cooling towers, flares, bridges, tanks and silos. Crown Metropol Perth Facade Refurbishment Watch Duratec transform the facade of the 397 room luxury Crown Metropol Hotel in Perth. With nearly 30 years of exposure to weathering, the façade was in need of a face lift with the priorities being architectural coatings, window sealing and waterproofing the outside. To view these and our other project videos, visit wwwduratecaustralia.com.au and click on PROJECT VIDEOS on the homepage. 2 INSPEC JUNE 2016

3 COMMERCIAL PROJECTS WAIDE FACADE CONCRETE REPAIRS HERITAGE BUILDINGS ARE UNIQUE PIECES OF OUR HISTORY, SO STRUCTURAL RESTORATION WORK MUST BE PERFORMED IN A WAY WHICH RECTIFIES UNDERLYING CONDITIONS WHILE MAINTAINING THE FACADE S UNIQUE APPEARANCE Built in the early 1900s, the heritage listed WA Institute for Deaf Education required repairs to restore the south façade to its former glory. Weathering had taken its toll over the years and corroded the window lintels to the point where concrete had broken away from the façade. This not only looked unsightly but also posed a public safety hazard. Duratec conducted concrete repairs to most of the window lintels, using custom moulds to replace sections of the trims that were not standard or readily available. Due to the significant heritage value of the building, manual concrete breakout was utilised and to complete the works paint matching was used to blend the old and new finishes. T & G BUILDING REFURBISHMENT BUILDINGS RELY UPON THE INTEGRITY OF THEIR FACADES AND ROOFS TO MAINTAIN PROTECTION FROM THE ENVIRONMENT Built in the 1930s, this historic art deco building in Geelong is being refurbished by Deakin University for use as student accommodation. As part of the renovation, the building will be repainted once repairs have been completed to the facade. Duratec was engaged to perform repairs to large and small areas of delaminated render, steel fixings embedded in render, decorative steel protection coating works, and concrete spall and crack repairs. Duratec has extensive experience in the refurbishment of heritage buildings and structures including: the Old Treasury Building in Perth, City of Subiaco Memorial Clock Tower, Perth Observatory, Customs House Fremantle; and Dumas House, 726 Hay Street and John Curtin College of the Arts in Perth. INSPEC JUNE

4 MARINE PROJECTS SWANSON DOCKS WHARF REPAIRS WAVE SPLASH ACTION LEADS TO CHLORIDE ION INGRESS THROUGHOUT THE UPPER TIDAL AND SPLASH ZONES OF MARINE STRUCTURES Swanson Docks East and West are international shipping facilities at the Port of Melbourne and Duratec has been engaged to perform concrete repairs to the wharf beams, soffit and deck and install water anodes below tide levels on steel piles. Also included in the scope are timber and steel pile repairs using a Denso wrap system, rock revetment, fabriform mattress installation, installation of a new walkway and the application of an epoxy coating system to steel structures. This is Duratec Eastern States second major project for the Port of Melbourne Corporation, following the remediation of two bulk liquid berths - Maribyrnong and Holden. PORT OF BUNBURY BERTH CONNECTION DURATEC HAS DIVERSE CIVIL ENGINEERING EXPERIENCE AND CAN PROVIDE A WIDE RANGE OF SPECIALIST CIVIL SERVICES TO COMPLEMENT OUR CORE CAPABILITIES This project involves the supply and installation of steel connection frames between berth 3 mooring dolphin 2 and berth 5 deck as part of anchor remediation activities on dolphin structures at berth 3, Bunbury inner harbour. The scope includes modifications to existing walkways and access platforms, detailed rebar scanning, coring and installation of anchor bolts, surface finish and installation of steel frame structures, installation of lead rubber bearings and plinths and installation of carbon fibre external reinforcement. We have been working on remediation projects for the Port of Bunbury since our inception in 2010, most notably the five year design and construct contract for the remediation of the outer harbour s berth s 1 and 2. 4 INSPEC JUNE 2016

5 MINING PROJECTS BODDINGTON TANK REFURBISHMENT Duratec has been contracted to refurbish gold processing leach tanks at Boddington Gold Mine. The ongoing contract involves the project management and implementation of the complete refurbishment of the tanks from isolating and emptying to the full application of a protective coating system. After access to the tank internal was gained, a full inspection took place of the protective coating and steelwork using nondestructive testing equipment and coating thickness gauges. All gearboxes, motors and the agitator shaft and downcomers were removed for complete repair. The tank was then hydro-blasted to remove damaged or outof-spec coating areas, before being abrasive blasted followed by the installation of a high performance elastomeric urethane. On completion, all refurbished components were reinstated and the tank filled and tested prior to continuing to extract gold for the client. LEACH TANKS ARE THE HEART OF THE GOLD EXTRACTION PROCESS, SO IT S VITAL THEY ARE WELL MAINTAINED AS ALL ABRASIVE SLURRIES ARE AGGRESSIVE TO PROTECTIVE COATINGS AND THEIR UNDERLYING STEEL STRUCTURES CRACOW ACID BUND COATINGS LONG TERM PROTECTION OF MINING PROCESS PLANTS FROM CHEMICAL ATTACK IS AN IMPORTANT SAFETY, ENVIRONMENTAL AND COMMERCIAL ISSUE Duratec was engaged to complete coatings to the acid wash column bund located at Cracow Gold Mine in Queensland. The concrete bund had significantly degraded due to the hydrochloric acid used as part of the gold recovery process. The project included hydro-blasting the floor and walls, grit blasting elements which could not be contaminated by water, repairing sections of the concrete floor, grinding the walls and installing new falls to sumps using a 30mm average thickness epoxy screed. The screed was then coated with a primer and two coats of epoxy resin and to finish a UV stable polyurethane sealer was applied. INSPEC JUNE

6 INFRASTRUCTURE PROJECTS OBSERVATION TOWER REPAIRS As part of fire remediation building works for the Department of Defence at Lancelin and Bindoon, Duratec is performing a variety of remedial works to the Lancelin observation tower. The tower is a three storey reinforced concrete structure consisting of a ground level used for storage, a level one mess area and a level two observation deck. The scope includes replacement of the viewing windows with armoured glass, survey and repair of exterior and interior concrete, door refurbishment, asbestos removal, access ladder and handrail replacement, water tank inspection and refurbishment, electrical compliance upgrade, signage upgrade and the installation of a new photovoltaic system. The exterior works will be undertaken by our specialist access team, removing the need for scaffolds and cranes. THE REGULAR MAINTENANCE OF BUILDINGS AND PERMANENT INSTALLATIONS THAT SUPPORT OUR ARMED FORCES PLAYS AN IMPORTANT PART IN THE SUCCESS OF THEIR DEPLOYMENT, TRAINING AND OPERATIONS GLENELG TANKS REFURBISHMENT DUE TO HARSH SERVICE CONDITIONS, CONCRETE SURFACES IN WATER TREATMENT INFRASTRUCTURE WILL USUALLY DISPLAY VARYING DEGREES OF DETERIORATION SA Water s Glenelg Waste Water Treatment Plant houses seven primary sedimentation tanks. To increase capacity a new scraper system is being installed inside the tanks. Duratec had been awarded the contract to refurbish both the interior and exterior concrete structures of the tanks prior to the installation of the scrapers. The scope includes hydro-demolition and breakout of defective concrete, concrete repairs and the application of protective coatings, ensuring structural integrity for a further 25 years. 6 INSPEC JUNE 2016

7 OIL & GAS PROJECTS WHEATSTONE COATINGS A PROPERLY SELECTED AND APPLIED COATING SYSTEM WILL REDUCE THE RATE OF CORROSION AND THEREFORE THE COSTS ASSOCIATED WITH CORROSION The Wheatstone Construction General Services #3 Contract commenced in April 2013 and includes the installation and maintenance of underground and aboveground utilities, construction and maintenance of roads and laydown areas, site support and procurement of materials. Duratec was engaged to apply protective coatings to a wide range of substrates including concrete, stainless steel, carbon steel and mild steel. Coatings included organic zincs, epoxies and polyurethanes, many of which were two and three coat systems. Duratec s NACE 2 Inspector ensured the coatings met the quality control requirements outlined within the project s protective coatings specification. INDUSTRIAL PROJECTS YARA PILBARA TANK ROOF COATINGS PREMATURE FAILURE OF COATINGS CAN OCCUR WHEN THE WRONG PRODUCT HAS BEEN SELECTED FOR THE JOB OR THE RIGHT PRODUCT HAS BEEN APPLIED INCORRECTLY Yara Pilbara Nitrates engaged Duratec to repaint two ammonia storage tanks and their support structures, located at their ammonia manufacturing complex on the Burrup Peninsula. The tanks received an abrasive blast with copper slag followed by a garnet blast and a rustproofing primer was applied to the lower steel. After coating with a primer, the tanks were finished with an epoxy barrier coat. INSPEC JUNE

8 SPECIALIST ACCESS PROJECTS RIO TINTO FENDER CHAIN REPLACEMENT Our Specialist Access Division was engaged by Rio Tinto to replace and tension dolphin fender chains at their Cape Lambert operations during a three day planned shutdown. The rope access team started with the worn upper chains, removing and replacing them singularly to retain the fender. The lower chains were replaced with the aid of divers who connected the shackles below the water line. The chains were then tensioned to align them with the dolphin structure ROPE ACCESS IS ONE OF THE SAFEST FORMS OF ACCESS AS WELL AS BEING FAST AND COST EFFECTIVE. WE PROVIDE THIS SERVICE RIGHT ACROSS THE BOARD FROM INITIAL CONDITION ASSESSMENTS TO MAJOR REMEDIATION PROJECTS The team mobilised to site with just two days notice and works were completed on time, so there were no disruptions to port operations. TECHNICAL SURVEYS WA POLICE HQ CONCRETE SURVEY LONG-TERM ENVIRONMENTAL EXPOSURE CAUSES WEATHERING AND DETERIORATION OF FACADES WHICH CAN RESULT IN PUBLIC SAFETY ISSUES Building Management and Works utilised Duratec s technical expertise to undertake an investigation and invasive testing of various concrete elements at the Western Australian Police Headquarters in East Perth. Our survey found widespread delamination and failed previous repairs in multiple locations. Corrosion staining and efflorescence were also identified, indicating that water ingress is causing areas of active corrosion. We produced a comprehensive report for the client, including an explanation of the root causes of the deterioration, remediation options and budget estimates for repairs. 8 INSPEC JUNE 2016

9 FORTEC PROJECTS BRIDGE BEARINGS REPLACEMENT Main Roads WA s Bridge 977 spans the 23km long Leach Highway in Perth s southern suburbs. Fortec Australia was engaged to safely remove the existing bridge bearings at the abutments and piers and replace them with new ones. The set-up included excavation to the top of the concrete footings, installation of a propping system, computerised jacking system and locking ring jacks. Hydro-demolition was then performed below the existing bearings to remove the grout pads and concrete. This was followed by the removal of the existing bearings and installation of new pot and elastomeric bearings. To finish, a form and pour was completed beneath the new bearings. IN MODERN BRIDGE STRUCTURES, BEARINGS AND EXPANSION JOINTS ARE COMMONLY THE MAIN SOURCE OF MAINTENANCE AND PERFORMANCE ISSUES. IN SOME SITUATIONS THEIR PERFORMANCE CAN LEAD TO CLOSURE OR FAILURE OF THE BRIDGE NEW CONSTRUCTION PRODUCTS DIVISION AS WELL AS PROVIDING CONSTRUCTION, ENGINEERING AND GEOTECHNICAL SERVICES, FORTEC IS NOW OFFERING A RANGE OF ENGINEERED CONSTRUCTION PRODUCTS Fortec has extensive knowledge and experience in specialist construction services and understands our clients need for a quality, cost effective and timely solution for their project. The new product range will enable us to add more value for our clients at the concept and design stage of a project as well as the construction phase. The range of engineered products will include: Specialist fixing systems Reinforcement systems Pre-cast accessories Asset integrity To find out more, contact our Construction Products Manager, Iain Baron, on INSPEC JUNE

10 FEATURED PROJECT TARONG POWER STATIONS REPAIRS ADOPTING TIMELY PREVENTATIVE MAINTENANCE SCHEDULES FOR ALL VITAL AREAS OF A POWER FACILITY SIGNIFICANTLY REDUCES FAILURE RATE BY ENSURING SMOOTH OPERATIONAL LEVELS The 1,400 megawatt sub-critical Tarong Power Station is located 45km south east of Kingaroy in the South Burnett region of Queensland. Construction began in 1979, with the first power unit commissioned in Commissioned in 2003, Tarong North Power Station is adjacent to Tarong Power Station. As a result of very good maintenance and the new coal reserves found at Meandu Mine, the power stations are likely to operate until Duratec has been engaged to undertake remedial repairs to deteriorated concrete structures at both the Tarong and Tarong North sites. The scope of works includes: Surface condition assessment Water jet cleaning and cutting Mechanical cleaning and cutting Reinstatement and protective coating of reinforcing steel Reinstatement of structural sections with concrete or mortar Application of coatings to concrete surfaces The purpose of the works is to maintain the integrity of the structures in which they are incorporated through to the station de-commissioning in INSPEC JUNE 2016

11 SPOTLIGHT ON TECHNICAL SURVEYS IN MOST CASES A STRUCTURE LIFE IN EXCESS OF 50 YEARS IS THE EXPECTANCY OF MOST ASSET OWNERS. IN ORDER TO ATTAIN THIS, ISSUES THAT ARISE NEED TO BE ASSESSED BY EXPERIENCED TECHNICAL EXPERTS Duratec Australia s Technical Division employs fully qualified professional civil engineers with the experience and knowledge to provide asset owners with: Technical surveys of reinforced concrete, masonry and steel structures using visual techniques in conjunction with stateof-the-art non-destructive and destructive investigation to determine corrosion states and rates and building element compliance with original design. Laboratory analysis of material samples to determine deterioration causes. Recording of all types and the location of areas of distress. Reporting of all assessment findings in plain, simple language, explaining the type and extent of areas of distress, the root cause of distress and the options for remediation. Accurate budget estimates for the cost to conduct the repairs, which can then be used to support maintenance expenditure requests. Types of surveys and services available include: Waterproofing Penetration Ultrasonic Surveys Ground-penetrating Radar Half-cell Potential Mapping Rope Access Galvanostatic Pulse Surveys Design for Durability Corrosion Surveys Material Selection NACE Coating Inspection Spalling & Crack Investigation Corrosion Rate Prediction Delamination Surveys Containment Bund Audits Cover Meter Surveys Concrete Condition Assessment To find out more, download our new Technical Profile by visiting wwwduratecaustralia.com.au and clicking on OUR SERVICES on the homepage. INSPEC JUNE

12 DURATEC AUSTRALIA IS A SOLUTIONS-BASED CONTRACTOR SPECIALISING IN THE PROTECTION AND REMEDIATION OF STEEL AND CONCRETE STRUCTURES. EXTENDING THE LIFE OF YOUR ASSETS HEAD OFFICE 108 Motivation Dr, Wangara WA 6065 T: KALGOORLIE Lot 33 Yarri Rd, Parkeston WA 6433 T: KARRATHA U1/3890 Coolawanyah Rd, Karratha WA 6714 T: PORT HEDLAND 11 Pinga St, Wedgefield WA 6721 T: DARWIN 30 Muramats Rd, East Arm NT 0828 T: MELBOURNE Remington Dr, Dandenong South VIC 3175 T: SYDNEY U59/7-9 Percy St, Auburn NSW 2144 T: BRISBANE U3/58 Frederick St, Northgate QLD 4013 T: ADELAIDE 8 Walsh Ave, St Marys SA 5042 T: ASSET CONDITION SURVEYS SPECIALIST ACCESS SYSTEMS CONCRETE REPAIR HIGH PERFORMANCE COATINGS JOINT SEALING INDUSTRIAL FLOORING CATHODIC PROTECTION MINE SITE MAINTENANCE BLASTING AND COATING TANK MAINTENANCE PRECISION GROUTING WATERPROOFING BUILDING FACADES STRUCTURAL STRENGTHENING SPECIALIST CIVIL SERVICES