acra awards entries 2014

Email: [email protected]

Phone: +61 2 9645 3692

PO Box 452, Chester Hill NSW 2162

ABN: 41 059 791 374

www.acrassoc.com.au

ACRA

BASF, 2012 ACRA AWARD FOR EXCELLENCE WINNER

Not long now till the ACRA Awards night of nights. As the Judges work tirelessly on

who will be the winners of each category, they have a huge job ahead of them as

the quality of the projects entered become greater with each biannual awards night

that ACRA holds.

Who will win the coveted 2014 ACRA Award for Excellence? Only one way to find

out and that’s to come along and view all the entries which will be on display on

the night, network with your peers, stay for the canapés and drinks and cheer on

all the winners and of course for the BIG winner of the night.

Inside this special edition is all the entries which are all in the running for the main

award on October 16, 2014.

[The following award entries are listed in random order]

http://www.acrassoc.com.au/

http://www.acrassoc.com.au

Warragamba Radial Gates 1, 2, 4 & 5—Warragamba Dam, NSW

Project Background/History:

Hatches over Post-Tensioned Cables on the Warragamba Dam Wall:-The post tension cables were

installed when the dam wall raised by 5 metres in the 80’s. These cables are capped and are

inspected every 10 years; however the inspections had concluded that previous work during the last

inspections had failed and not only was water entering the pits that contain the cable-heads but that

the lids and shoulders had also been damaged during the work. These cables need to be monitored

and remain corrosion free.

The first concrete for the dam was poured in June 1953 and continued for 24 hours until the project

was completed in 1960. More than 2,550 tonnes of sand and gravel were needed, by using a series of

600 buckets, each holding 1,250kg via and aerial ropeway and at 30 second intervals.

Between 1987 & 1989 the dam wall was raised 5 metres to accommodate revised 1:1,000 year storm

events and strengthened using post-tensioned steel cables, which ties the upper portion of the wall

to its base.

Warragamba Dam is Sydney’s largest water supply dam

The dam is made of concrete and took twelve years to build form 1948 to 1960

Lake Burragorang, which formed behind the dam, hold about 4 times more water than Sydney

Harbour

Other ACRA members involved: Sika

Parchem

Categories Entered Into: Historic Structures

Water & Sewer

Final Project Value: $150,000.00

Andersal Pty Ltd

Phone: 02 8437 1800

Level 10, 1 Chandos St, St Leonards NSW 2065

ANDERSAL PTY LTD

http://www.andersal.com.au/

Bunbury Port Authority Wharf Remediation Project—Bunbury WA


The Bunbury Port Authority (BPA) has engaged Duratec Australia in a Design and Construct contract

for the staged maintenance and repairs of Berths 1 & 2 at the Outer Harbour—Bunbury Port.

Berth 1 and Berth 2 are adjoining berths located in the Bunbury Outer Harbour. These two berths

were designed and constructed during the 1960s and remain in service as general purpose berths

with facilities for the offload of methanol from tankers via discharge piping. The berths consist of

conventionally reinforced two-way spanning concrete suspended decks 184m long x 15.8m wide

(Berth 1) and 16.6m wide (Berth 2), supported by three rows of 1067mm diameter reinforced

concrete piles which have been installed within a rock protected embankment forming a

conventional ‘land back’ berth system. The piles are ‘pin’ supported onto the Bunbury Basalt

formation. The height of the deck is 3.6 metres above datum level. Given the berth age is in the order

of 40 years, it has exceeded the original theoretical design life hence requiring appropriate levels of

management including consideration of future berth plans, condition assessment and maintenance

repair efforts. The repair of berths (1 &2) will take place over a staged five year design and construct

maintenance contract, broken down into repairs to piles, approach slab subsidence, general concrete,

steelwork and joint repairs to Berths 1 and 2, with Berth 2 piles and approach slabs taking priority.

The Berth 2 piles, particularly through the inter-tidal and splash zone above low water, are suffering

from varying degrees of deterioration including significant cracking, delamination of cover concrete

and in once case; fully exposed rebar where total spalling loss of the cover concrete has occurred.

The approach slabs and hardstand to the rear of the Berth 2 deck are also suffering varying degrees

of subsidence requiring remediation for safe use of the berth.

Category entered into: Marine

Other ACRA members involved: Parchem

Infracorr Consulting

Final Project Value: $3.5m

Duratec Australia Pty Ltd

Phone: 08 6267 2370

PO Box 1384, Wangara WA 6947

DURATEC AUSTRALIA PTY LTD

http://www.duratecaustralia.com.au/

48a Queenscliff Road, Queenscliff


In early 2004, RM Watson (RMW) was contacted by TJ Taylor Consultants (TJT) to assist in

investigation work at an 8 storey residential block at 48a Queenscliff Road, Queenscliff. The

building’s concrete elements were suffering from severe corrosion related spalling including

numerous instances of failed previous repairs. Trial break out of spalled and apparently sound

concrete exposed extensive active corrosion of the reinforcement in the balcony slabs and columns

as well as internal spalling relating to magnesite floors and leaking windows and doors. Testing of

the external concrete confirmed chloride levels well above the corrosion threshold. TJT had been

advised by the strata managers that several patch repair projects had been carried out on the

building in the preceding 10 years. Considering the chloride levels found during testing, the presence

of failed previous repairs and wide spread insipient anodes, RMW recommended to TJT that the

owners should consider cathodic protection (CP) as a remedial option. The electrochemical repair

would significantly reduce or halt the ongoing corrosion to the reinforcement and give the owners a

long term solution to their chloride problem.

The owners elected to carry out the cathodic protection works as well as the major façade upgrade

which included new windows and doors, rendering of the façade brickwork, new tiles and

balustrades to the balconies and a full façade paint to finalise the works. RMW won a tender for this

work in 2005 with work commencing later that year and completion in February 2007.

Category entered into: Long Term Performance

Other ACRA Members Involved: GHD Australia

Final Project Value: $3,500,00.00

RM Watson Pty Ltd

Phone: 02 9517 3366

18/1 Hordern Place, Camperdown NSW 2050

RM WATSON PTY LTD

http://www.rmwatson.com.au/concrete_repair.htm

Cape Don Lighthouse Rehabilitation— Cobourg Peninsula NT


In late 2012 the Australian Maritime Safety Authority (AMSA) awarded Marine & Civil Maintenance Pty Ltd (MCM) the design & construct contract to repair and protect the heritage listed Cape Don Lighthouse, located 170km northeast of Darwin.

Built in 1916, the lighthouse consists of a reinforced concrete tower 28m high with a circular barrel and an octagonal base. The barrel is 19.5m high and has a wall thickness of 380mm, and the base is approximately 6m wide and 8.5m tall with a tapered upper section. There is a reinforced concrete balcony at the top of the barrel, immediately below the light.

Despite proving its strength by withstanding many cyclones and at least one earthquake, the concrete structure has deteriorated over the years as a result of corrosion of its reinforcing steel.

AMSA’s rehabilitation contract required the repair of the external damage, design and installation of a cathodic protection system including monitoring and maintenance for a fixed period, and coating of the entire structure, all with due regard for the important heritage nature of the lighthouse. Carried out over one dry season, the remote project presented a variety of challenges to MCM.

Category entered into: Buildings

Design and Innovation

Other ACRA Members Involved: Infracorr Consulting Pty Ltd

Parchem Construction Supplies Pty Ltd

Final Project Value: $2.4M

Marine & Civil Maintenance Pty Ltd

Phone: 02 9816 2452

PO Box 2096, Boronia Park NSW 2111

MARINE & CIVIL MAINTENANCE PTY

http://www.marineandcivil.com.au/MCM-NewWebsite/#home


Parmelia House Façade Restoration Project

191 St Georges Terrace, Perth WA


Parmelia House, a 19 storey commercial office building, situated at 191 St George’s Terrace in the

heart of the Perth, WA CBD, was built circa 1968 and was designed by T.P. Bennet & Son Oldham

Boas Ednie-Brown and partners. The building comprises a reinforced concrete frame, reinforced

concrete slabs, exposed white quartz aggregate precast concrete paneling on the eastern and

western elevations and windows on the northern and southern elevations incorporating exposed

white quartz aggregate precast concrete spandrel panels, vertical sunshade fins and horizontal sun

hoods.

Subject to 45 years of atmospheric weathering, the building reinforced concrete elements were

suffering expansive cracking and localized spalling of cover concrete as a consequence of embedded

reinforcing steel corrosion. This was particularly evident on the architectural concrete ribs on the

western elevation and vertical sunshade fin corners. In addition many of the un-reinforced corners

of the 50mm thick horizontal sunhoods contained shrinkage cracks which over time had fallen away

unassisted and it could not be ruled out that further pieces would not fall away without warning.

As a consequence of the poor condition of the building façade in April 2012 the owners consulting

engineers initially engaged Duratec Australia to carry out investigations of the northern, western and

southern elevations to identify and quantify the extent of concrete defects. This was then followed

by confirmation trials of the remediation techniques to be utilized to confirm the suitability of the

repair specification. The façade remediation project was completed in December 2013.

Catergory entered into: Buildings


SIKA



Phone: 08 6267 2370



Geraldton Grain Silos Remediation— Geraldton WA


The CBH Group is one of Australia’s leading grain organisations, a co-operative with operations

including grain storage, handling and transport, to marketing shipping and processing, based in

Western Australia, it has been established for over 80 years and is owned and controlled by more

than 4500 grain growers. The CBH Geraldton base is located in the north of the state’s growing

region and consists of receival, storage and shipping facilities, Geraldton has twenty four (24No)

reinforced concrete grain silos which were constructed around 1960. These silos were constructed

as circular grouped silos in a bank of 8 x 3 No interconnected/adjoining silos, each 36m in height and

12.9m in diameter. This layout formed internal star cells between the main silos which are used to

store boutique grain. The walls of the silos are around 200mm thick and the wall reinforcement

consists only of a centrally placed single mat.

In more recent years evidence of extensive vertical cracking was noted throughout the walls of these

silos and this lead to various investigations and structural assessments. As is typically found for

circular grain storage facilities of this type and age, it was concluded that the original design

understanding was inadequate to cater for the peak loads occurring during grain outflow. The

resulting structural cracking reflected this structural inadequacy, and given the marine environment

in which the silos are located, also raised concern in regard to the long term durability of this

structure.

Categories entered into: Investigation & Diagnosis

Mega projects >$10M


Final Project Value: $30M

Freyssinet Australia Pty Ltd

Phone: 02 9491 7177

Locked Bag 2004, North Ryde NSW 1670

FREYSSINET AUSTRALIA PTY

http://www.freyssinet.com.au/

Prince Henry Hospital—Little Bay Redevlopment, NSW

Delaney House—Now Known as Seaview Building

Heffron House—Now Known as Bayview Building


The Prince Henry Hospital was built in 1881, and the site at Little Bay, NSW was chosen.

This Project calls for the challenging task of restoring and transforming the Hospital into upmarket

apartments, whilst retaining significant elements of its heritage. The redevelopment will include a

series of high end apartments, including 1, 2 and 3 bedrooms, with sea, golf course or park land

views.

Delany House & Heffron House stood unoccupied for many years becoming derelict with many

people in the construction industry believing the buildings could not be repaired to see another life

time.

Although the hospital is considered to be constructed well considering the period of time it was built

and the technology standards available, the costal surroundings have taken its toll on the building.

This makes it even more challenging for NCS to restore.


Other ACRA members involved: Diagnostech

Final Project Value: $1,600,000.00

National Concrete Solutions

Phone: 02 9896 2411

190 Toongabbie Road, Girraween NSW 2145

NATIONAL CONCRETE SOLUTIONS

http://www.ncsaustralia.com.au/

Penrith WRP Overhaul Grit Vortex and Flow Distribution Chamber

Penrith, NSW


“The Penrith ST0046 Water Recycling Plant is owned and operated by Sydney Water and located on

Castlereagh Rd, Penrith. SASTTI Joint Venture was engaged by Sydney Water to carry out an

inspection and condition assessment of the Inlet Works, Grit Removal Tank and Flow Distribution

Chamber. It was identified that the grit removal area has exposed concrete surfaces which are

experiencing up to 30mm of biogenic acid attack and in the flow distribution chamber areas

generally lost 55 mm of concrete cover. This required urgent repairs to both the Grit Removal Tank

and the Flow Distribution Chamber to ensure the structural integrity on these critical operational

assets.

Sydney Water decided to deliver this rehabilitation project through its new NFRP procurement

program. The $890,000 project was awarded to WI Group in February for completion in June 2014.

The majority of the repairs consisted of UHP water blasting to prepare the surface for the application

of a minimum 50 mm thickness of Calcium Aluminate Cement (CAC). The major challenges of this

project were:

It was essential that all works were performed whilst the WRP remained fully operational. Therefore

a fully automated 730 L/s bypass system was required to circumvent both structures and a16 m long

1350 mm diameter large siphon;

The access to both the grit removal vortex and the flow distribution chamber was difficult and

required substantial and complex scaffolding structure to provide a safe working area and access &

egress. Additionally the configuration and size of the structures made if very onerous to complete

the repairs.

Categories entered into: Water & Sewer

Other ACRA members involved: BASF Construction Chemicals

Final Project Value: $895,512.00

Water Infrastructure Group Ptd Ltd

Phone: 02 9895 1578

Level 3, 9 George Street, Parramatta NSW 2150

WATER INFRASTRUCTURE GROUP PTY

http://www.wigroup.com.au/

Midtown Plaza—Façade Remediation—246 Bourke St, Melbourne VIC


Midtown Plaza is a commercial development located in the heart of Melbourne’s CBD. The

development is comprised of two adjoining buildings, namely—

Main tower building-on the corner of Bourke and Swanston Streets, consisting of a 7 storey office

building, over a ground floor corporate foyer, a separate retail mall, and single level basement

mall.

Little Bourke Street building—an adjoining older 2-storey building to the north and with

frontage on Little Bourke Street. A restaurant currently occupies this building.

The main tower building was originally built in 1934, with an additional 3 storeys added in the

1970s. It is of reinforced concrete construction, with the façade being mostly of rendered cast in situ

concrete, with some decorative mouldings. The rendered concrete surface was painted on the south

and west elevations and unpainted on the north and east elevations. The upper 3 storeys (later

addition) are of concrete encased steel construction, with blockwork infills. The Little Bourke Street

Building is largely of brick construction with the exception of a rendered concrete north elevation

facing Little Bourke Street. After reports of spalled concrete and detached render, the building

manager (Knight Frank), on behalf of Building owners (ISPT Pty Ltd), engaged Hyder Consulting Pty

Ltd to inspect and report on the condition of both buildings. This was followed by make safe works

and the preparation of tender documents to address observed building issues.

Category entered into: Commercial

Other ACRA members involved: Hyder Consulting Pty Ltd

BASF


Structural Systems (Remedial) Pty Ltd

Phone: 03 9296 8100

PO Box 1303 South Melbourne VIC 3205

STRUCTURAL SYSTEMS (REMEDIAL) Pty Ltd

http://www.structuralsystems.com.au/

ATP Channel 7— Australian Technology Park, NSW


The area of repair is a 2600m2 suspended post tensioned “Truck Hardstand” slab rated at 20KPa for

the purpose of supporting adjacent filming studio i.e storage, loading equipment and parking for a

fleer of semi-trailers. The area is operated by large media companies Global Television and Channel

7 and experiences high volumes of traffic 24 hours a day and 7 days a week.

Approximately 70% of the suspended slab is exposed to weather and 80% was showing a high level

of cracking only a year after construction. Full section cracking in slab and beams was allowing water

to penetrate directly into the car park or accumulate in between the permanent metal formwork

(Condeck) and concrete in slab areas. Around 100 individual locations were observed to be leaking

into the car park with the entire area often referred to as a ‘sieve’.

The first attempt at repair (by others) chased out cracks in the slab surface then filled with them

epoxy grout. This repair was unsuccessful as the grout was not flexible enough to cope with daily

expansion and contraction of cracks caused by truck loads and thermal movement of the slab. As a

result the grout de-bonded from the substrate and again allowed water to enter the structure and car

park below. This failed repair also introduced a new problem in that approximately 600 large cracks

were now highlighted across the entire hardstand slab.

Categories entered into: Buildings

Design & Innovation


Andersal Pty Ltd

Phone: 02 8437 1800

Level 10, 1 Chandos St, St Leonards NSW 2065

ANDERSAL PTY LTD

http://www.andersal.com.au/

Blacktown Creek Culvert—Concrete Repair & Coating Works

Old Prospect Highway, Seven Hills NSW


The culvert was surveyed and inspected. The four cell, 80m long culvert has reasonable levels of

deterioration of concrete, particularly in the lower half of all walls. There was also some minor soffit

repairs identified. Corrosion was driven by high levels of carbonation and low concrete cover.

A repair specification provided for traditional concrete breakout and repair methodologies, including

an anti-carbonation coating system to all cell walls and the soffits. To increase production, speed up

project delivery, and reduce costs, Preservation Technologies proposed hydro-demolition and gunite

application, which in 2005 were methodologies more associated with larger marine structure repair

projects. Additionally a more cost effective, abrasion and chemical resistant coating system was

offered as an alternative, with the added advantage of also being spray applied. These were accepted

by the client. Over 120m2 of deteriorated concrete was broken out with the majority being between

60-75mm deep. However deeper sections were also undertaken. This was over 50% in greater area

than that specified and tendered. Also the repairs were much deeper resulting in a far greater

concrete repair volumes. Approximately 8,000 litres of concrete repairs in total were carried out.

Notwithstanding the increased volumes and costs associated with this work, had we undertaken the

repairs using hand applied materials and traditional means of breakout, the costs would have been

far greater. Over 250 Galvasheild XP anodes were installed. In 2005 this was still relatively new

technology and a significant quantity of anodes being used. 2000m2 of an epoxy based coating

system was used as an alternative to the Dekguard S system. As part of our quality control system,

testing of the concrete repairs and the coating system was carried out by CTI Consultants.

Categories entered into: Long Term Performance


RMS (RTA) by association

Final Project Value: $250k

Preservation Technologies Pty Ltd

Phone: 02 8565 7777

PO Box 423, Camperdown NSW 1450

PRESERVATION TECHNOLOGIES

http://www.prestech.com.au/

WATER INFRASTRUCTURE GROUP PTY

Rehabilitation of the Main Western Carrier

Wolli Creek & West Botany, NSW


Rehabilitation of the Main Western Carrier was one of the first major spiral wound Panel Lok projects in Australia.

This project involved the lining of approximately 3x1800m of the triple barrel of the Main Western Carrier at Arncliffe. The Panel Lok lining is a uPVC spiral wound lining which was developed exactly 30 years ago by Danby (now Water Infrastructure Group) and has been installed ever since within man-entry sewers to provide structural and biogenic acid attack protection to concrete and brick stormwater and sewers.

This specific project was executed in 1999-2000 and two recent inspections were carried out by two different engineering consultants:

Sewer Traverse Report, Main Western Carrier, KBR, 9 November 2009

Main Western Carrier Surveillance Report No 1, SAS-TTI, 10 May 2013

Sydney Water personnel joined the engineering consultants on both occasions and the feedback from Sydney Water was that the Panel Lok was still in excellent condition. We are currently installing Panel Lok, spiral wound uPVC liner for Sydney Water’s Narrabeen Submain rehabilitation project which further reinforces the reputation that the Panel Lok system has gained from its track record as an excellent, value for money option for the rehabilitation of critical sewer and stormwater conduits assets. This award submission is to highlight the long term performance of Panel Lok as a proven rehabilitation technology. Category entered into: Final Project Value: $2,500,000

Water Infrastructure Group Ptd Ltd

Phone: 02 9895 1578

Level 3, 9 George Street, Parramatta NSW 2150

http://www.wigroup.com.au/

International School of WA Concrete Repair Project

22 Kalinda Dr, City Beach WA


The International School of Western Australia (ISWA) was formally known as City Beach High School.

It was first constructed in 1965. As was popular at that time, the buildings were constructed using

pre cast elements. Our project involved the repair and restoration of these original pre-cast columns,

beams and gutters. Since the original construction a number of extensions were built using similar

construction techniques. These items did not require repair.

The buildings have suffered traditional concrete deterioration caused by chloride induced corrosion

of the reinforcement bars. As the buildings are only 1km from the ocean, air borne chlorides were

always going to present a problem. The buildings have undergone piecemeal minor repairs over the

years but a standard wholesale repair was required. GHD were engaged to propose a repair solution

that had an expected life of over 20 years. Our tender was submitted in November 2012 with the

project being award December 2012 and works commenced immediately as school holidays had just

commenced. The project was completed in June 2013.



GHD



Phone: 08 6267 2370




Magnetic Island Historic WWII Fort Complex Refurbishments—Magnetic

Island, QLD

Restoring the original look with original WW2 materi-als recovered & recycled during the repair process

Remote Location WWII Fort Complex—Magnetic Island, QLD


There are five heritage listed World War 2 Military buildings on Magnetic Island. During 1943, the

Military buildings in Townsville and Magnetic Island reinforced the strategic importance of the

region with a number of battery fortifications such as gun emplacements, ammunition stores, search

lights, observation and signals command posts. These buildings are of historical state significance

All battery structures built during this period were constructed of reinforced concrete, local granite aggregates and were heavily fortified. The superintending engineer from 1942 was Eric T Doig and it was his team that designed and supervised the vital military installations on Magnetic Island during this war stricken period.

Over 70 years of corrosive environmental surrounds contributed to multiple areas of advanced steel degradation and concrete spalling, however they remain among the best preserved Fortifications of their kind in the world.

The Signals command post and Observation Tower on Magnetic island were among the structures

assessed and deemed most in need of repair due to significant corrosion back 2003. The department

of National Parks Recreation Sports and Racing allocated funds for the restoration of the Military

Forts project in 2013.

Restoring the damaged sections of the forts to their original 1943 look was very important aspect of

the works

Category entered into: Historic Structures

Other ACRA members involved: Remedial Technologies Pty Ltd

Final Project Value: $123,000 invoiced + $24,000 donated services

Australian Concrete Repair Group Pty Ltd

Phone: 02 4355 4881

PO Box 5377, Chittaway Bay NSW 2261

AUSTRALIAN CONCRETE REPAIR GROUP

http://acrgroup.com.au/

Old Treasury Building Balcony Remediation Project - Perth WA


The Old Treasury Building, is located in one of the most significant heritage precincts in Perth’s CBD.

Built in 1878, the building has a rich history spanning more than 135 years.

The building had been left vacant for the past seventeen years and commencing in 2013 FJM

Properties commenced restoration of the building into an exciting mix of hotel, hospitality and retail

uses. Built NSW Pty Ltd was the selected main building contractor to manage the works and in turn

they selected specialist restoration sub-contractor Duratec Australia Pty Ltd to undertake the

remediation and restoration of the external balconies. The building balconies were in a very poor

condition prior to commencement of the works. Well developed cracking was evident on the balcony

corbels, convex spandrel beam, floor slabs, longitudinal and transverse beams and columns. Slight

structure movement over time had caused cracking of the outer cementitious encasement allowing

the ingress of moisture and carbon dioxide. This resulted in sections of the coke breeze concrete

becoming carbonated and the pH lowing to a level that supported steel corrosion.

In addition many of the ornate heritage architectural features were cracked, damaged or broken off

completely. This was particularly evident on the convex spandrel beam, column capitals, column

bases, balusters and handrails. Two handrails were completely destroyed as a consequence of

building settlement. Fortunately in all cases there were sufficient undamaged features to enable

accurate moulding, and recasting to be performed using similar cementitious materials and

traditional methods.

Category entered into: Historic Structures


SIKA

Infracorr Consulting



Phone: 08 6267 2370




http://www.kennards.com.au/

http://www.parchem.com.au/

acra awards entries 2014

Documents

warragamba dam wall

acra members

acra basf

acra awards night of

nsw project backgroundhistory

posttensioned cables

adjoining berths

repairs of berths