MARCH 2017

RANGER URANIUM MINE

PROTECTIVE COATINGS

inside 2 MESSAGE FROM PHIL 2 WHAT’S NEW: PRODUCTS 3 COMMERCIAL PROJECTS 4 COMMERCIAL PROJECTS 4 MARINE PROJECTS

5 MARINE PROJECTS 6 MINING PROJECTS 7 MINING PROJECTS 8 INFRASTRUCTURE PROJECTS 9 SPECIALIST ACCESS PROJECTS

9 TECHNICAL SURVEYS 10 FORTEC PROJECTS 10 CONSTRUCTION PRODUCTS 11 SPOTLIGHT: INDUSTRIAL FLOORING12 CONTACT US

PHIL HARCOURTMANAGING DIRECTOR

WE ARE PLEASED TO PRESENT THE AUTUMN EDITION OF

INSPEC SHOWCASING SOME OF THE RECENT REMEDIATION

WORKS WE HAVE BEEN PERFORMING

Front cover: leach tank 3 at Ranger Uranium Mine, 260km south-east of Darwin.

A MESSAGE FROM PHILThis edition highlights the wide range of work we have been performing Australia-wide. This includes our ongoing remediation contracts with Newmont Boddington and FMG, our involvement in new building projects such as the Adelaide Convention Centre redevelopment and major water tank construction in both Western Australia and Queensland.

Duratec prides itself on providing our clients with tailor-made solutions to meet the unique challenges of their remediation programs. With our world-wide network

of suppliers and in-house expertise, we are able to source and install an extensive range of new and innovative products.

An example of this is the lightweight screed we are supplying for the Adelaide Convention Centre, the first time this product has been used in Australia - see below for more details.

I hope you enjoy the magazine and thank you for the opportunity to be of service.

2 INSPEC MARCH 2017

BY REMAINING AT THE FOREFRONT OF NEW TECHNOLOGY, DURATEC IS ABLE TO SOURCE INNOVATIVE NEW PRODUCTS TO MEET TO THE UNIQUE CHALLENGES OF OUR CLIENTS’ PROJECTS

Duratec is playing an integral part in the complex design process on stage 2 of the Adelaide Convention Centre redevelopment, after being engaged to remodel a plaza deck which will sit above live rail, car parking and retail space. Due to the constraints below the deck, the use of traditional strengthening techniques wasn’t viable, which resulted in heavily reduced loading criterias for the finishes above.

Following an extensive investigation our client was unable to source a levelling material that would meet the structure’s loading limits and prove robust enough to be mechanically prepared, waterproofed and trafficked.

Through our international network of suppliers we sourced a fibre-reinforced shrinkage compensated cementitious lightweight screed. With a density of 1.1kg/ltr coupled with a final cure greater than 40MPA the product can be applied using traditional screed pumps at depths ranging from 40-300mm. As it does not require the addition of reinforcement, this again significantly reduces the loading to the existing slab.

PRODUCTSWHAT’S NEW?

301 CORONATION DRWATERPROOFING

MULTI-STOREY AND UNDERGROUND CAR PARKS ARE SUBJECT TO MANY STRESSES INCLUDING MOVEMENT, TEMPERATURE FLUCTUATIONS, WATER, ATMOSPHERIC

CARBONATION, AUTOMOTIVE FLUIDS AND VEHICULAR TRAFFIC

OTTO HIRSCHFELD FACADE REPAIRSALL BUILDINGS RELY UPON THE INTEGRITY OF THEIR FACADES TO MAINTAIN PROTECTION FROM ENVIRONMENTAL FACTORSDuratec has been engaged to complete a full facade refurbishment of the Otto Hirschfeld building at St Lucia Campus, University of Queensland, which houses offices and labs for the Department of Anatomy and Developmental Biology.

The scope of the works will include:

• Dilapidation survey of the façade• Pinning of the precast section to the edge of the

cantilever sunshade slabs on all faces of the building• Concrete repair of the redundant fixings• Repair of drummy render to underside of sun hoods• Pointing of bricks • Repair of construction joints on the beams and

sunhoods• Repair of cracks in concrete• Cleaning of the building facade• Painting of all external concrete surfaces (beams,

sunhoods, soffits, columns etc.)

Bachrach Naumberger enlisted Duratec’s expertise to install 1,040m2 of trafficable waterproof membrane to the upper level of the car park at 301 Coronation Drive, a landmark office building close to the Brisbane River.

The existing failed fibre glass acrylic membrane was removed and crack and slab repairs carried out prior to the application of a flexible polyurethane car park deck coating system.

The coating system is not only waterproof and cosmetically enhancing, but also reduces noise, is slip and fire resistant, 100% UV light stable and has excellent resistance to cracking and chemicals.

COMMERCIAL PROJECTS

3INSPEC MARCH 2017

Duratec has been contracted to remediate the facade of Mineral House, East Perth, which consists of two adjoining buildings housing the Department of Mines and Petroleum.

The scope of works will include concrete, render and joint sealant repairs and the cleaning, preparation and repainting of the façade with a carbonation inhibiting barrier coating.

Duratec conducted the initial inspection of the facade by rope access which highlighted the extent of the repairs required and formed the basis for the schedule of works.

COMMERCIAL PROJECTS

MINERAL HOUSEFACADE REPAIRS

MAJOR FAÇADE REFURBISHMENTS NEED TO BE EXECUTED WITH CRITICAL ATTENTION

TO PUBLIC SAFETY, MINIMAL DISRUPTION TO TENANTS AND VISITORS AND DETAILED

PLANNING AND COMMUNICATION WITH ALL STAKEHOLDERS

PPA WHARF FENDER REPLACEMENTA WELL DESIGNED FENDER SYSTEM IS AN INVESTMENT IN THE LONG-TERM PROTECTION OF A MARINE STRUCTUREThe Pilbara Port Authority’s Dampier Cargo Wharf (DCW) was constructed in 1982 and provides seven berths for the loading and provisioning of vessels servicing the marine industry and offshore oil and gas fields.

The fenders on the western side of the DCW are in poor condition and Duratec has been engaged to replace them with a more modern and durable design for an extended service life.

The scope of works will include the removal of the existing cylindrical fender system, concrete remediation works on the berth face and fender attachment points to reinstate suitable fixing points for the fenders (including remediation of mechanical fastenings) and installation of a replacement cone fender system.

4 INSPEC MARCH 2017

MARINE PROJECTS

Flinders Ports are utilising Duratec’s expertise to carry out remediation works to the concrete capping beam at their Port Pirie operations in South Australia.

Working from both modular floating platform and wharf deck, all defective concrete will be removed and corroded reinforcement replaced, with robust environmental protection measures in place to ensure no waste material enters the marine environment below.

In keeping with Duratec’s commitment to innovation we have designed a bespoke, lightweight formwork solution that protects the workforce from excess manual handling and reduces program duration.

The use of this formwork has enabled us to use a traditional concrete pour technique to reinstate the complex beam layout including the existing sheet pile profile to the underside soffit.

MARINE PROJECTS

PORT PIRIE CAPPING BEAM REPLACEMENT

THE PLACEMENT OF CAPPING BEAMS NEEDS TO BE CAREFULLY ENGINEERED TO

AVOID LATERAL DISPLACEMENT AND TO ALLOW FOR THE TRANSFER

OF STRUCTURAL LOADS

DOCKLANDS WHARF REMEDIATIONWE UNDERSTAND THE CHALLENGES MARINE ASSET OWNERS FACE DURING REMEDIATION PROGRAMS INCLUDING MINIMISING DISRUPTION TO RECREATIONAL WHARVESDuratec has been engaged by Lend Lease to perform remediation works at No.1 Collins Wharf, Victoria Harbour in Melbourne’s Docklands. On the doorstep of the CBD, Victoria Harbour is surrounded by water on three sides and comprises green spaces and Australia’s largest collection of sustainable residential buildings.

The scope of works will include the remediation of existing timber piles, concrete repairs, installation and commissioning of a hybrid cathodic protection system and the application of a silane coating to the underside of untreated concrete beams.

As the wharf is being extended, there is the added challenge of working alongside major civil contractors.

5INSPEC MARCH 2017

WE UNDERSTAND THE MECHANISMS OF CONCRETE DETERIORATION AND PROVIDE TAILORED SOLUTIONS WHICH ADDRESS THE ROOT CAUSES, NOT JUST THE SYMPTOMSDuratec has been engaged to remediate a number of high risk concrete assets at FMG’s Port Hedland operations. From our site-wide audit, it was identified that remediation was required for structural cracks and process-water ponding on the adjoining concrete slab of train unloaders 2 and 3.

The cracks were remediated by injecting them with a low viscosity epoxy. The ponding was remediated by initially conducting a level survey to establish high and low spots on the concrete slab and proposed levels for a new screed.

Using a concrete scarifier, the entire floor area was then profiled to provide a mechanical key but also to reduce high spots. An epoxy binder screed was laid to the new levels to ensure the floor drained sufficiently.

As an added provision, Duratec applied a durable non-slip coatings system to assist with safe footing within the area and extend the working life of the repair and asset.

FMG PORT HEDLANDCONCRETE REPAIRS

MINING PROJECTS

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 Duratec completed the application of coatings to the internals of leach tank 3 at Newmarket Gold’s Union Reef Gold Mine, 225km south of Darwin.

The tank’s internal surface was prepared by high pressure water blasting to remove any contamination and rust, which also allowed for inspection and repair of any worn areas.

Following steel repairs, the tank was abrasive blasted to AS1627.4 class 2.5 and a high build elastomeric urethane applied to the walls, floors, agitator shaft, blades, baffles and launder.

UNION REEF LEACH TANK COATINGS

6 INSPEC MARCH 2017

A HIGH PERFORMANCE PROTECTIVE COATING SYSTEM WILL SIGNIFICANTLY ENHANCE AN ASSETS OPERATIONAL PERFORMANCE AND WORKING LIFESPANDuratec Australia was engaged by Energy Resources Australia to complete the preparation and application of coatings to the externals of leach tank 3 onsite at their Ranger Uranium Mine, located 260km south east of Darwin. The scope included:

• Installation of encapsulation to scaffold

• Abrasive blast of tank externals to remove existing coating and achieve a class 2.5 blast - AS 1627

• Spray application of a zinc epoxy primer by airless spray unit to a minimum of 75 microns DFT

• Spray application of a high solids epoxy by airless spray unit to a minimum of 125 microns DFT

The works were completed successfully and on time with no accidents, injuries or environmental incidents. The degree of difficulty was increased as the works were undertaken with the tank online.

7INSPEC MARCH 2017

MINING PROJECTS

RANGER LEACH TANKBLAST & PAINT

A PROPERLY SELECTED AND APPLIED COATING SYSTEM WILL REDUCE THE RATE OF CORROSION AND ITS ASSOCIATED COSTSAs part of our ongoing corrosion remediation contract at Boddington Gold Mine, 120 km south-east of Perth, we completed the blasting and painting of the structural steel strengthening on the decant station.

The decant station is a large pump station that provides recycled water from the tailings dam back into the gold mine for re-use. The structure sits on two steel tracks so it can be lifted from the water for maintenance and sits off the bottom of the dam so that the sediment is not drawn into the pumps. Due to the highly corrosive environment the existing coating was rusting substantially in some areas.

The scope of works comprised the assessment of the existing coating on the structural steel which was found to be insufficient in some areas.

To remedy this, the existing coating was removed from these areas, grit blasted and then protected with an epoxy zinc phosphate primer and two coats of a high solids epoxy coating, developed specifically for Australasian conditions.

DECANT STATIONREFURBISHMENT

8 INSPEC MARCH 2017

Built in 1910, the Port River Rail Bridge spans the Port River at Port Adelaide and consists of reinforced concrete piling, piers and abutments which support steel girders. The bridge carries 11 spans both on up and downtrack.

Duratec’s scope of work was part of the project programme critical path as it followed span removal and was required to be complete ready for placement of the new spans.

The works included preparation and placement of 80 grout pads poured to a tolerance of +/-1mm, 1m deep coring, anchoring and placement of restraint brackets under the same tolerance constraints.

In addition to the core works, Duratec also completed epoxy crack injection and concrete patch repairs. The programme was completed during a 14 day shutdown utilising our in-house trained and rail certified operatives. The project required both day and nightshift crews for the duration of the works.

RAIL BRIDGE GROUT PAD REPLACEMENT

INFRASTRUCTURE PROJECTS

WATER STORAGE BASIN REPAIRSDRINKING WATER IS VITAL TO COMMUNITIES AND LEAKAGE OF WATER OR CONTAMINANTS INTO OR OUT OF STORAGE STRUCTURES CAN SERIOUSLY AFFECT THE ENTIRE DISTRICTConstructed in 1966, the Daylesford low level potable water storage basin is a 4ML clear water storage facility that supplies the Daylesford Township, 115km from Melbourne.

Duratec was engaged to remediate the concrete basin liner panels and joints to minimise water loss from the structure. The scope of works also included pipework, drainage improvement, under slab void grouting, stabilisation works and miscellaneous civil and structural works.

The basin is a critical component of Daylesford’s water supply and Duratec’s experienced team provided assistance in the revision of repair techniques and material selection, achieving the most cost effective and timely solution for the client.

AN EFFECTIVE BRIDGE MAINTENANCE PROGRAM ADVOCATES REMEDIATION WHILE THE STRUCTURE IS STILL IN A REASONABLE WORKING CONDITION

Located within the historic Bishop See precinct, the nine storey tower located at 235 St Georges Terrace completed in 2009 was one of the first buildings in Perth to achieve a NABERS 5-star environmental rating.

A recent condition assessment of the building revealed that the facades were generally in good condition but some minor maintenance works were required.

Duratec was engaged to perform the facade repairs which included:

• Reinstatement of all dislodged gaskets throughout the facade

• Removal and make safe of all cracked and loose concrete sections on the columns

• Reinstatement of loose trim angles on the north elevation

The works were completed by Duratec’s in-house team of IRATA trained rope access technicians.

SPECIALIST ACCESS

BISHOP SEEFACADE REPAIRS

ROPE ACCESS IS ONE OF THE SAFEST FORMS OF ACCESS AS WELL AS BEING FAST AND COST EFFECTIVE COMPARED TO OTHER METHODS.

WE PROVIDE ROPE ACCESS SERVICES RIGHT ACROSS THE BOARD FROM INITIAL CONDITION

SURVEYS TO MAJOR REMEDIATION PROJECTS

Duratec’s Technical Division will be installing crack gauges to three conveyor tunnels at FMG’s Solomon operations, 60km north of Tom Price in Western Australia.

Five crack gauges will be installed in each tunnel to monitor the movement of cracks caused by loads applied from the stockpile located directly above them.

Movement will be monitored using a remote data logger and wireless 3G modem and the results used to formulate a remediation program for the client, inclusive of realistic budgets for the cost of the repairs.

Other investigations we have conducted for FMG include a full site-wide survey at their port operations in Port Hedland, which consisted of a visual inspection of all concrete elements and random cover meter readings to determine if the observed deterioration had increased the risk of corrosion to the reinforcement.

FMG SOLOMONTUNNEL SURVEY

TECHNICAL SURVEYS

9INSPEC MARCH 2017

CRACK GAUGES ARE A RELIABLE AND ACCURATE WAY TO MONITOR HORIZONTAL OR VERTICAL MOVEMENT ACROSS A CRACK ON A FLAT CONCRETE SURFACE

MASONRY FACADE SUPPORT SYSTEMS

CONSTRUCTION PRODUCTS

10 INSPEC MARCH 2017

HAZ METAL FIXING SYSTEMS OFFER PRACTICAL AND ECONOMICAL SOLUTIONS FOR ALL TYPES OF FACADE CONSTRUCTIONFortec is designing and supplying a high-grade stainless steel brickwork support sub-frame for Duratec’s Dumas House Facade and Podium Repairs Project.

Dumas House in West Perth was constructed in the mid 1960s and is Heritage Council of WA listed. Over the years, the building’s exterior has deteriorated and Duratec has been awarded the contract to complete the repairs.

On the narrow east and west faces of the building, Duratec is removing and replacing the glazed terracotta blocks and the sub-frame will support the new blocks for the entire height of the building on both faces.

Fortec is the exclusive distributor for HAZ Metal products in Australia and New Zealand.

BGC Contracting has been engaged by Water Corporation to construct two 37.5 million litre water tanks west of Cunderdin in Western Australia.

The new tanks will improve the water supply and provide increased storage for WA’s Goldfields and Agricultural Region Water Supply Scheme. Duratec’s sister company Fortec has joined the project as a specialist sub-contractor to BGC Contracting.

The scope includes the design and detailing of the concrete ring beam, base slab, pre-cast walls and roof columns, post-tensioned cables in the in situ base slab and ring beam. Other work includes post-tensioning of the offsite pre-cast wall panels, and the post-tensioned hoop tendons in pre-cast walls, once they have been erected, and in situ stitch joints poured.

WATER STORAGE TANKS ARE CRITICAL ELEMENTS OF WATER

SUPPLY INFRASTRUCTURE AND RELY ON QUALITY DESIGN AND

CONSTRUCTION FOR A LONG AND TROUBLE FREE SERVICE LIFE

WATER TANK CONSTRUCTION

FORTEC PROJECTS

11INSPEC MARCH 2017

INDUSTRIAL FLOORING SYSTEMSSPOTLIGHT ON

INDUSTRIAL FLOOR COATING SYSTEMS PROVIDE PROTECTION, AESTHETICS AND DEMARCATION FOR SAFETY AND OPERATIONAL EFFICIENCYWith the vast range of industrial flooring systems available in the market, choosing the right one for your project can be challenging as every location has its own set of safety, hygiene, durability and aesthetic requirements.

Duratec has the expertise and resources to deliver any size flooring project from large industrial warehouses to specialised food processing areas, mine sites and hygiene-driven, pharmaceutical and anti-static environments.

We provide high quality flooring systems for:

• Abattoirs & Meat Processing• Bakeries & Dairies• Beverage Industry & Wineries• Commercial Operations• Defence• Food Production & Processing• Government & Schools• Healthcare & Pharmaceutical• Hospitality Industry• Industrial Plants• Mines• Retail Premises• Sports & Recreational Facilities

We select the best flooring system for your next project:

Anti-Slip Flooring: Tailored to the working conditions and personnel using the area.

Clear Sealers & Decorative Finishes: Keep decorative or coloured concrete floors looking good by sealing and protecting their surface.

Heavy Duty Epoxy Flooring & Toppings: Ideal for withstanding heavy loads and high impact in mining and industrial workshop applications.

High Build Polyurethane Flooring: Exceptional resistance to aggressive chemicals and extreme mechanical and thermal shock.

Pit, Bund & Sewer Coating Systems: Ideal for environments where constant moisture, aggressive chemicals, traffic patterns or other unique conditions would normally cause damage to untreated and unprotected surfaces.

Rapid Cure Methacrylate (MMA) Flooring Systems: Designed for areas requiring a rapidly installed floor to avoid issues associated with downtime.

Safety Demarcation: Application of lines and symbols enabling staff to avoid hazards when moving around a facility.

Epoxy Flooring Coatings: Quick drying, low odour coatings options suitable for light commercial and industrial areas.

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 ASSESSMENTS • DRONE SURVEYS• SPECIALIST ACCESS SYSTEMS• HIGH PERFORMANCE COATINGS • CONCRETE REPAIR• JOINT SEALING• INDUSTRIAL FLOORING• ACID PROTECTION• CATHODIC PROTECTION • BLASTING AND PAINTING • TANK MAINTENANCE• PRECISION GROUTING • WATERPROOFING• FACADE REMEDIATION • STRUCTURAL STRENGTHENING• MINE SITE MAINTENANCE• MARINE INFRASTRUCTURE REMEDIATION• SPECIALIST CIVIL SERVICES

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OUR CREW ON THE DUMAS HOUSE FAÇADE & PODIUM REPAIRS PROJECT IN WEST PERTH, WHO HELPED TO RAISE NEARLY $1,000 FOR

THE KEVIN BELL REPATRIATION TRUST

DURATEC AUSTRALIA IS A SOLUTIONS-BASED CONTRACTOR SPECIALISING IN THE PROTECTION AND REMEDIATION OF STEEL AND CONCRETE STRUCTURES