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SEPTEMBER 2016
MONASH UNIVERSITY
FACADE REPAIRS
inside 2 MESSAGE FROM PHIL 2 WHAT’S NEW? 3 COMMERCIAL PROJECTS 4 COMMERCIAL PROJECTS 5 MARINE PROJECTS
5 MINING PROJECTS 6 MINING PROJECTS 7 INFRASTRUCTURE PROJECTS 7 INDUSTRIAL PROJECTS 8 SPECIALIST ACCESS PROJECTS
8 TECHNICAL SURVEYS 9 FORTEC PROJECTS9 CONSTRUCTIONPRODUCTS-PIPEWRAP10PROJECTUPDATE-DUMASHOUSE11SPOTLIGHTON-DRONESURVEYS
2 INSPEC SEPTEMBER 20162 INSPEC SEPTEMBER 2016
PHIL HARCOURTMANAGING DIRECTOR
EVERY MONTH WE HOLD A PHOTO COMPETITION TO SHOWCASE SOME OF THE PICTURES TAKEN BY OUR PROJECT TEAMS. THE WINNING SHOTS ARE INCLUDED IN OUR BROCHURES AND ON OUR WEBSITE
It wouldn’t be easy to talk about our remediation projects without good quality images to document each step and we rely on our teams on the ground to capture the full scopes of work as they progress.
Our in-house Photo of the Month competition has been up and running for several years and has produced some really great shots, many of which have graced the front cover of this magazine, and in this isssue, the back page too.
To take a look at some of our recent winners and a few old favourites, visit our Facebook page - Duratec Australia - and click on the Photo of the Month Gallery at the top of the page.
You can also connect with us on LinkedIn, Twitter and YouTube.
Pictured above: diesel tank roof coatings at Rio Tinto’s Parker Point operations photographed by our North West Site Supervisor David Peck
WE ARE PLEASED TO PRESENT THE SPRING EDITION OF
INSPEC SHOWCASING SOME OF THE RECENT REMEDIATION
WORKS WE HAVE BEEN PERFORMING
A MESSAGE FROM PHILThis edition of InSpec highlights the diversity of our specialist infrastructure remediation services and some of the strategies we apply to meet the needs of our clients.
Asset owners are often faced with the challenges of obtaining a preliminary understanding of the integrity of their structures whilst remaining operational or minimising access costs, especially with structures such as high-rise buildings, bridges and chimney stacks.
The enclosed articles on chimney stack surveys using drones and rope access specialists demonstrate safe, efficient and cost-effective means of meeting this challenge.
I trust you will enjoy this edition of InSpec and thank you for the opportunity to be of service.
PROJECT PHOTOSWHAT’S NEW?
Front cover: Monash University, founded in 1958 it is the second oldest university in Victoria
MARITIME MUSEUM WATERPROOFING
IF BUILDINGS ARE NOT ADEQUATELY MAINTAINED, DETERIORATION CAN
BECOME A MAJOR ISSUE, PARTICULARLY WITH WATER INGRESS FROM THE ROOF AREA WHICH CAN CAUSE IRREPARABLE
DAMAGETOTHEFIT-OUTBELOW
225 ST GEORGES TCEFACADE REPAIRSLONG-TERMEXPOSURETOTHEELEMENTSCAUSES FACADE DETERIORATION WHICH CAN RESULT IN SERIOUS SAFETY ISSUES PARTICULARLYWITHHIGH-RISEBUILDINGS225 St Georges Terrace in Perth’s CBD comprises a 20,960sqm office building, with 733sqm of retail space and 3 levels of basement parking.
Duratec will be carrying out repairs to the following façade elements: the realignment of level 2 podium roof parapet capping structures, podium and turret limestone wall cladding, ground floor granite cladding on walls and column pedestals, level 2 flashings, façade aluminium cladding panels and level 19 roof glass balustrading.
The Western Australian Maritime Museum is symbolic of Fremantle’s past, present and future as a coastal city and port and houses several unique galleries that explore Western Australia’s relationship with the sea.
Duratec has been engaged by Building Management and Works to remediate the external roof membrane using our team of specialist applicators and trained rope access technicians.
The scope of works includes a water wash to clean the roof area, replacement of plywood cladding where it has deteriorated, sanding of the existing membrane followed by a prime coat and two top coats of a specialist membrane system that is UV stable and able to withstand the harsh conditions imposed by the building’s location to the sea and elements.
COMMERCIAL PROJECTS
3INSPEC SEPTEMBER 2016
Built in 1981, Capalaba Park Shopping Centre is located 20km south-east of Brisbane. Duratec was engaged by Retail First to remediate the car park expansion joints.
The scope of works included the removal of jointing material to existing expansion joints, cleaning, cutting and repair, build-out using epoxy screed to obtain correct width and installation of 130 lineal meters of expansion joint system and 68 lineal meters of control joints.
The shopping centre remained open at all times and parking bays were blocked off to a minimum and re-opened at peak times to minimise the impact of the works. The installation of the new expansion joint system has completely stopped water ingress into the car park.
COMMERCIAL PROJECTS
CAPALABA CAR PARK JOINT INSTALLATION
WE PROVIDE MAINTENANCE SERVICES TO A WIDE RANGE OF SHOPPING CENTRES
ACROSS AUSTRALIA, SO WE UNDERSTAND THEIR CONCERNS SUCH AS PUBLIC SAFETY
AND LIABILITY ISSUES AND MINIMISINGDISRUPTION TO EVERYDAY OPERATIONS
MONASH UNI FACADE REPAIRSMAINTAINING SCHOOL, COLLEGE AND UNIVERSITY BUILDINGS AND GROUNDS IS A KEY FACTOR IN THE OVERALL HEALTH AND SAFETY OF STUDENTS, STAFF AND VISITORSMonash University is a public research university based in Melbourne. Founded in 1958, it is the second oldest university in Victoria and enrols approximately 47,000 undergraduate and 20,000 graduate students.
The university is utilising Duratec’s expertise to perform facade repairs to building F on Caulfield Campus. The facade and in particular the concrete elements have developed a range of defects over time.
The scope of works will include repairs to the concrete elements and roof at protruding columns, including preparation and recoating of the facades.
4 INSPEC SEPTEMBER 2016
A PROPERLY SELECTED AND APPLIED COATING SYSTEM WILL REDUCE THE RATE OF CORROSION AND ITS ASSOCIATED COSTSPilbara Ports Authority engaged Duratec to complete surface preparation and coating repairs to capstans, located at the Pilbara Port Authority’s Dampier Bulk Liquid Berth.
The scope included a high pressure wash to remove residual contaminants, hand preparation of corroded locations to a minimum class St3 using a pneumatic surface preparation tool, preparation of remaining existing coatings using abrasive paper, application of a light coloured epoxy barrier coat to the bare steel locations followed by a final coat of black acrylic polyurethane finish.
The works were carried out on an operating port facility during shipping breaks utilising Duratec’s experienced local crew. Our in-house local NACE inspection team was utilised for all QA/QC requirements.
PILBARA PORTS CAPSTAN COATINGS
MARINE PROJECTS
A HIGH PERFORMANCE PROTECTIVE COATING SYSTEM WILL SIGNIFICANTLY ENHANCE AN ASSETS PERFORMANCE AND WORKING LIFESPANAs part of our ongoing corrosion remediation contract at Boddington Gold Mine, Duratec was engaged to blast and paint CVR-09 conveyor stringers during a scheduled shutdown. The CVR-09 conveyor is one of the primary conveyors on site and is a major asset.
The scope of works was to spot-blast and paint the stringers, guard rails supports and accessible beams above and on either side of the conveyor.
Works were undertaken on a continuous day and nightshift basis with a designated four man crew operating on each shift.
STRINGER COATINGSMINING PROJECTS
5INSPEC SEPTEMBER 2016
Duratec was engaged to supply and install fencing, located at Rio Tinto’s Cape Lambert car dumper 1 and 2 tail tracks, consisting of 1km of 20 each of 1100mm x 50m sections of chain link fencing fixed to railway sleepers.
The project included both off and on-site works, with the railway sleepers being coated with epoxy and the posts installed at Duratec’s Karratha blast and paint facility.
On-site the scope of works included the installation of a temporary fencing barricade due to the proximity of operating railway lines, laying out of posts, bolting on of post connectors and the twitching and wiring up of the chain link fencing. To complete the works, signage was installed as required.
Previous civil works completed for Rio Tinto at their Cape Lambert operations includes the replacement of five car positioner rail base plates at car dumper 2.
DURATEC HAS DIVERSE CIVIL ENGINEERING EXPERIENCEANDCANPROVIDEAWIDE
RANGE OF SPECIALIST CIVIL SERVICES TO COMPLEMENT OUR CORE CAPABILITIES
ENABLING US TO DELIVER MULTIPLE SERVICES UNDER ONE CONTRACT
RIO TINTO TAIL TRACK FENCING
MINING PROJECTS
THE COATING OF CONCRETE FLOORING IS ESSENTIAL IN PROVIDING PROTECTION, AESTHETICS AND DEMARCATION FOR SAFETY AND OPERATIONAL EFFICIENCYLocated 220km south-west of Kalgoorlie, Independence Group’s Nova nickel-copper project is currently in construction based on a designed 1.5Mtpa underground operation with decline access, 1.5Mtpa processing plant and associated infrastructure and services.
Duratec was engaged to apply protective coatings to a workshop floor at the site.
The scope of works included surface preparation using a dual head floor and manual cup grinder and the spray application of an epoxy coating. Some areas were finished with a non-slip coating.
NOVA WORKSHOPFLOOR COATINGS
6 INSPEC SEPTEMBER 2016
CORROSION IS A SERIOUS THREAT TO THE LONG-TERMFUNCTIONANDSTRUCTURALINTEGRITY OF A STEEL BRIDGEThis heritage listed bridge spans the Parramatta River between Church Street, Ryde and Concord Road, Rhodes NSW and consists of a steel structure with two truss spans, a central lift span and approach spans. The approach spans are of plate web girder design, with five approach spans on the southern side and three approach spans on the north - eleven in total. The bridge is supported at each span by two reinforced concrete piers, octagonal in cross section and tied together by beams at the top and base of the pier.
Duratec has been engaged by DownerMouchel to carry out the rehabilitation works including: abrasive blasting and repainting of all steel surfaces below the bridge deck level, strengthening of steel members subject to section loss and replacement of gusset plates, concrete repairs to the deck soffit, application of anti-carbonation coating to the underside of the bridge deck concrete surfaces, installation of traffic barriers and application of waterproof coating to the footpath surface.
RYDE BRIDGEREHABILITATION
INFRASTRUCTURE PROJECTS
THE LONG TERM PROTECTION OF PROCESS PLANT ASSETS FROM CHEMICAL ATTACK IS AN IMPORTANT SAFETY, ENVIRONMENTAL AND COMMERCIAL ISSUEYara Pilbara is a large ammonia manufacturing complex located in Karratha. The facility hosts numerous bunds for containing processing materials and avoiding soil contamination. Over time the walls of these bunds had become deteriorated and Duratec was engaged to perform repairs to 15 bunds, ensuring their future structural integrity.
The scope included the safe disposal of all residual processing materials followed by pressurised water washing and degreasing. After a thorough inspection of the bunds to identify cracks on the concrete walls and floors, the defects were repaired and a primer and two coats of epoxy applied.
YARA BUND REPAIRS
INDUSTRIAL PROJECTS
7INSPEC SEPTEMBER 2016
Tarong is a coal fired power station located 180km north-west of Brisbane and features a pair of 118m cooling towers and a 210m chimney. The station is due to be de-commissioned in 2035, but will need to maintain its structural integrity until that time.
Duratec was engaged to conduct a rope access survey of the chimney including an external concrete condition assessment by various NDT methods, an ultrasonic thickness survey of the internal flue and removal of samples for laboratory analysis.
An IRATA level 3 supervisor and a team of rope access technicians completed the works. The chimney was inspected whilst online after a shutdown to avoid working above other site crews.
When the investigation was completed the client received a detailed report highlighting all defects which will enable the future works to be accurately priced and the correct methodologies selected for the repair works.
ROPE ACCESS IS ONE OF THE SAFEST FORMS OF ACCESS AS WELL AS BEING FAST AND
COST EFFECTIVE. DURATEC PROVIDES THIS SERVICE RIGHT ACROSS THE BOARD FROM
INITIAL CONDITION ASSESSMENTS TO MAJOR REMEDIATION PROJECTS
TARONG CHIMNEY STACK SURVEY
SPECIALIST ACCESS PROJECTS
WE DELIVER A WIDE RANGE OF TECHNICAL CONDITION ASSESSMENTS THAT ENABLE OUR CLIENTS TO SELECT THE BEST PROTECTION AND REMEDIATION OPTIONSAnglogold Ashanti utilised Duratec’s expertise to undertake a site wide survey at their Tropicana Gold Mine in WA.
Investigations included a visual survey of all structural steel, a ringing hammer survey on all concrete surfaces with noted defects and random micro-cover readings to determine cover concrete thickness to embedded reinforcing steel.
All defects were photographically recorded and site findings summarised in a report for the client indicating the likely cause of defects, commentary on the long term durability of the concrete and steel structures and recommendations and budgets for repairs.
TROPICANA SITE WIDE INSPECTION
TECHNICAL SURVEYS
8 INSPEC SEPTEMBER 2016
RESTORING AND STRENGTHENING PIPES PROVIDES CONSIDERABLE COST SAVINGS OVER REPLACING DETERIORATED ASSETSFortec provides high performance composite repair systems to restore pipe integrity lost to internal and external corrosion, erosion, physical impact and other mechanical damage. These industry-leading pipeline repair solutions are third-party tested and backed by solid composite design engineering and years of performance in on-site installation.
Our systems are engineered in accordance with ASME PCC-2 and ISO24817 standards to withstand harsh elements, high pressure and the effects of exposure over time. Products meet other industry standards such as ABS “Type“ Approval and NSF-61 certification.
With a design life of up to 20 years, the wrap systems are designed to conform to any shape and can be applied to dry or wet surfaces, even underwater. No hot work permit is required for installation, so they are ideal for all working environments. There is no requirement for shutdown and all systems are easy to apply in confined spaces and have a high operating temperature.
To find out more, contact our Construction Products Manager Iain Baron on 0419 620 225.
PIPE WRAP SYSTEMS
St Mark’s is an independent Anglican school in the northern suburbs of Perth and as part of their 10 year campus growth strategy they are constructing a senior academic centre. Fortec was engaged by Perkins Builders to supply and install the post-tensioning to the first and second floor suspended slabs.
The scope included the supply of prestressing materials and the installation, stressing and grouting of the post-tensioned tendons. The two levels were relatively large single 2,000m2 concrete pours placed utilising two concrete boom pumps.
POST-TENSIONEDCONCRETECOMBINESAND OPTIMISES TODAY’S VERY HIGH
STRENGTH CONCRETES AND STEEL TO RESULT IN A PRACTICAL AND EFFICIENT
STRUCTURAL SYSTEMST MARKS POST TENSIONING SLAB
FORTEC PROJECTS
CONSTRUCTION PRODUCTS
9INSPEC SEPTEMBER 2016
In our March issue, we announced that we had been awarded the contract to restore the 50 year old facade and podium of Dumas House, the WA state government’s iconic public service building in West Perth.
Opened in 1966 and Heritage Council of WA listed, the building has a structural steel frame and is clad in concrete and terrazzo. The distinctive exterior of the office block’s long north and south faces feature balcony platforms with concrete columns extending 2 metres forward of the walls and windows from all 14 storeys.
Over the years, the heat, cold, wind and rain have deteriorated the building’s exterior in its exposed position north of Kings Park, the spandrel panels, waterproofing and facade elements have reached the end of their serviceable life and need to be repaired or replaced.
Work is now underway with over 35% of the defects removed and 25% of the repairs complete including the removal of the north-east side spandrel panels and the fitting of replacement ones. All ceramic blocks have been removed from the west side, most spandrel panels removed and concrete repairs are underway.
Asbestos has been removed from 10 of the 13 balconies with the new waterproofing currently being applied to six of the balconies as we work our way up the north-east elevation.
PROJECT UPDATE HERITAGE BUILDINGS ARE UNIQUE PIECES OF HISTORY, SO RESTORATION WORK
MUST BE PERFORMED IN A WAY WHICH RECTIFIES UNDERLYING CONDITIONS WHILE MAINTAINING THE FACADE’S
UNIQUE APPEARANCE
DUMAS HOUSE FACADE RESTORATION
10 INSPEC SEPTEMBER 2016
Case study: BHP Nickel West Kalgoorlie Stack Inspection
Duratec was by engaged to perform a visual inspection of the chimney’s concrete windshield, annulus hood and steel access system.
The UAS inspection was performed whilst the stack was online and Duratec provided the client with:
• A video referencing the defects
• A comprehensive report which was used by the asset owner to price remedial works during the next outage
• Concrete cracks as small as 0.2mm in width were able to be identified with the drone’s camera system
• To complete the inspection two personnel were required over three shifts of eight hours, whereas a rope access inspection would have necessitated three people during four 12 hour shifts
To find out more about our drone capability contact our Specialist Access Manager on 0421 395 171 or email [email protected].
DRONE SURVEYSSPOTLIGHT ON
GROWING NUMBERS OF ASSET OWNERS ARE USINGUNMANNEDAERIALSYSTEMS(UAS)FOR CONDITION ASSESSMENTS AS THEY PROVIDE SIGNIFICANT IMPROVEMENTS IN SAFETY AND DATA QUALITY COMPARED TO TRADITIONAL INSPECTION METHODSOur Specialist Access Division offers a wide range of access solutions for even the most inaccessible structures and in conjunction with our Technical Division we are able to carry out detailed visual inspections of concrete and steel structures using drones to assess the general condition of the asset as a precursor to a more comprehensive physical investigation.
Drones use vertical take off and landing technology and as they use electric propulsion this avoids engine fumes, fuel and heat which is excellent in reducing environmental impact as well as risk in environments such as gas plants.
Our drones accept interchangeable pay loads such as HD digital SLR cameras, HD video cameras and thermal imaging cameras and have the ability to hover in winds up to 20 knots making them ideal for the inspection of chimneys and towers, bridges, oil rigs and pressure tanks.
Duratec Australia has in-house RPAS certified UAS (Drone) pilots and almost five years’ experience in conducting condition assessments.
11INSPEC SEPTEMBER 2016
HEAD OFFICE 108 Motivation Dr, Wangara WA 6065 T: 08 6267 2370
KALGOORLIE Lot 33 Yarri Rd, Parkeston WA 6433 T: 08 9021 5277
KARRATHA U1/3890 Coolawanyah Rd, Karratha WA 6714 T: 08 9185 6077
PORT HEDLAND 11 Pinga St, Wedgefield WA 6721 T: 08 9185 6077
DARWIN 30 Muramats Rd, East Arm NT 0828 T: 08 8901 7760
MELBOURNE 93-97 Remington Dr, Dandenong South VIC 3175 T: 03 8787 5865
SYDNEY U59/7-9 Percy St, Auburn NSW 2144 T: 02 8203 3860
BRISBANE U3/58 Frederick St, Northgate QLD 4013 T: 07 3088 7570
ADELAIDE 8 Walsh Ave, St Marys SA 5042 T: 08 7071 3550
• 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
THE CREW WORKING ON THE HMAS STIRLING LOW LEVEL BRIDGE REPAIRS PROJECT FOR
THE DEPARTMENT OF DEFENCE TAKE A MOMENT TO ENJOY A RAINBOW
DURATECAUSTRALIAISASOLUTIONS-BASEDCONTRACTORSPECIALISINGIN THE PROTECTION AND REMEDIATION OF STEEL AND CONCRETE STRUCTURES
Image captured by our Perth Site Supervisor Paul Illich
