In the heart of Sydney’s innovation corridor, the SBS Studios Headquarters in Artarmon stands as a hub of media, culture, and public broadcasting. But beneath its modern façade lay a hidden threat: widespread concrete cancer in its 5-storey car park—used daily by employees, contractors, and visitors.
Left unaddressed, the deteriorating structure posed serious safety, compliance, and operational risks. Yet shutting down the car park for months was not an option. The client needed a specialist remediation contractor who could deliver high-quality, minimally disruptive, and compliant concrete repairs—without compromising daily operations.
Enter Perfect Remediation and Refurbishment.
This case study details how our team executed a complex, phased concrete remediation project at SBS Studios Artarmon—overcoming logistical, technical, and environmental challenges to extend the asset’s life by 25+ years while maintaining full functionality throughout.
Project Overview
- Client: SBS (Special Broadcasting Service)
- Location: Artarmon, NSW
- Asset: 5-storey operational car park
- Primary Issue: Advanced concrete cancer (reinforcement corrosion) causing spalling, delamination, and exposed rebar
- Scope: Full-depth concrete remediation across all levels, including rebar treatment, structural repair, and protective coating systems
- Key Constraints:
- Car park remained fully operational during works
- Zero tolerance for dust, noise, or safety incidents
- Strict adherence to AS 3600, AS 5100, and WHS regulations
- Minimal visual impact on adjacent office spaces
The Challenge: Concrete Cancer in a High-Traffic Urban Environment
Concrete cancer doesn’t announce itself—it silently expands from within. At SBS Artarmon, years of water ingress through expansion joints, drainage failures, and Sydney’s humid climate had triggered aggressive rebar corrosion.
Visual signs included:
- Rust staining on soffits and columns
- Spalling concrete exposing rusted rebar
- Hollow-sounding delaminated zones
- Cracks widening over time
Left untreated, the deterioration would have:
- Compromised structural integrity
- Created falling debris hazards
- Triggered council repair notices under NSW building laws
- Required emergency closure—costing SBS tens of thousands in disruption
But traditional remediation approaches—scaffolding, full shutdowns, noisy demolition—were not viable in this sensitive, occupied environment.
“As PMs ourselves, we understand the pain of being let down… We’re committed to responsible, flexible personnel.”
— Our Approach
Our Solution: A Phased, Precision Remediation Strategy
Rather than a one-size-fits-all fix, we developed a tailored, engineer-led remediation plan built on three pillars: safety, minimal disruption, and long-term durability.
Phase 1: Comprehensive Diagnostics & Planning
Before a single tool was turned on, we conducted:
- Half-cell potential testing to map active corrosion zones
- Cover meter surveys to assess rebar depth
- Ultrasonic pulse velocity (UPV) to detect internal voids
- Moisture and chloride testing
This data informed a Remediation Method Statement (RMS) approved by structural engineers—ensuring every action was justified, safe, and compliant.
Phase 2: Containment & Safety Setup
Given the car park’s constant use, safety was non-negotiable. We installed:
- Debris netting and edge protection (AS 4546 compliant)
- Dust suppression systems (wet cutting, HEPA vacuums)
- Silica control measures aligned with new Australian legislation (Silica Guide )
- 24/7 signage and traffic management
As an AS/NZS 4801-certified company, we embedded safety into every workflow. (Certifications )
Phase 3: Precision Concrete Removal
Using low-vibration, high-precision equipment, we removed unsound concrete without damaging sound structure:
- Hilti and Brokk robotic demolition units for overhead soffits
- Husqvarna wall saws for clean edges
- Tyrolit diamond blades for minimal dust
All removed material was segregated and recycled, supporting our 60%+ waste recycling target. (Sustainability Commitment )
“With three comprehensive workshops and mobile technicians on call 25/8, ‘downtime’ is almost irrelevant.”
— Equipment Philosophy
Phase 4: Rebar Treatment & Structural Repair
Exposed rebar was:
- Abrasive blasted to SA 2.5 (near-white metal)
- Treated with corrosion inhibitors
- Coated with anti-rust epoxy primers
Structural voids were reinstated using:
- Polymer-modified, shrinkage-compensated repair mortars
- Shotcrete stabilisation for deep sections (Shotcrete Guide )
All materials met AS 3600 standards for structural repair.
Phase 5: Protective Coating System
To prevent recurrence, we applied a dual-layer protective system:
- Cementitious crystalline waterproofing (for negative-side protection)
- Elastomeric topcoat (for UV resistance and crack-bridging)
This integrated approach aligns with our concrete protective coatings philosophy—shielding against water, chlorides, and carbonation. (Coatings Blog )
Phase 6: Phased Execution & Minimal Disruption
Rather than shutting down entire levels, we worked in 20m² zones, rotating weekly:
- Repairs completed after business hours (6 PM–6 AM)
- Temporary parking rerouting coordinated with SBS facilities team
- Daily cleanup ensured zero debris or dust in operational areas
The car park remained 95% accessible throughout the 10-week project.
Technical Highlights & Innovations
Non-Destructive Testing (NDT) Integration
We used real-time NDT data to adjust repair depth on-site—avoiding over-excavation and saving 12% in material costs.
Sustainable Waste Management
- 68% of demolition waste recycled (exceeding our 60% target)
- Zero landfill for concrete fines (reused as sub-base)
- Low-VOC coatings reduced environmental impact
This earned recognition under our Excellence in Sustainability Award. (Awards )
Tier 1 Equipment Reliability
- Volvo and Isuzu support vehicles for rapid mobilisation
- Hilti and Milwaukee tools for precision
- Digital reporting provided real-time progress tracking to SBS stakeholders
“Reliability can make or break a deadline… and eventually—a relationship.”
— Our Approach
Results & Client Impact
| Structural Integrity | Fully restored; 25+ year design life extension |
| Operational Disruption | Zero full-day closures; 95% parking availability maintained |
| Safety Record | Zero incidents, near-misses, or WHS breaches |
| Compliance | Full adherence to AS 3600, AS 5100, and NSW building codes |
| Client Satisfaction | SBS praised our “professionalism, precision, and flexibility” |
The project reinforced our core promise:
“Extending the life of your assets.”
Why This Project Exemplifies Perfect Remediation’s Approach
Client-Centric Flexibility
We didn’t just follow a scope—we collaborated with SBS’s facilities and risk teams to tailor every detail.
Technical Excellence
Backed by 12+ years of Tier 1 experience (Westpac Kent Street, Town Hall Station), our engineers ensured every decision was data-driven.
Sustainability in Action
From waste recycling to low-emission equipment, we embedded ESG principles into execution—honouring our Reconciliation Action Plan and Workplace Inclusion Award. (Diversity & Inclusion )
Reliability Through Investment
Our three workshops, 25/8 mobile technicians, and trusted brands (Volvo, Brokk, Hilti) ensured on-time, on-budget delivery—no excuses.
“Time and again, we have stretched ourselves to go above, to go beyond, to do more and to be better.”
— Our Ethos
Lessons Learned & Industry Insights
1. Early Intervention Saves Millions
Had SBS waited 2 more years, full structural replacement would have cost 3–5x more and required a 3-month shutdown.
2. Phased Works Are Possible—With the Right Partner
Many assume “occupied = impossible.” But with smart planning, night works, and containment, even complex remediation can coexist with operations.
3. Compliance Is Non-Negotiable
From silica dust to edge protection, cutting corners risks lives and licenses. Our ISO 9001, 14001, and AS/NZS 4801 certifications ensure every box is ticked. (Certifications )
4. Sustainability = Smart Business
Recycling waste, reducing emissions, and protecting community health isn’t just ethical—it builds long-term client trust and brand value.
How This Project Fits Into Our Broader Portfolio
The Artarmon car park is one of dozens of commercial concrete remediation projects we’ve delivered across NSW, including:
- Sofitel Sydney Wentworth – Lobby and balcony repairs (Project )
- HJ Daley Library – Civic infrastructure restoration (Project )
- YMCA Camden – Gym and facility upgrades (Project )
We serve all sectors—commercial, industrial, heritage, infrastructure—with the same commitment to quality. (Explore Sectors )
FAQs: Concrete Remediation in Operational Buildings
Q: Can you work in a fully occupied car park?
A: Yes. We specialise in low-disruption, phased, after-hours works with full containment.
Q: How long does a multi-level car park remediation take?
A: Typically 8–14 weeks, depending on scope. Artarmon took 10 weeks with zero full closures.
Q: Do you provide warranties?
A: Yes—5–10 years on materials and workmanship, backed by ISO-certified processes.
Q: What about insurance and licences?
A: We hold full NSW building licences, public liability insurance, and WHS compliance. (Licences & Insurance )
Q: How much does it cost?
A: Costs vary by extent of decay. We provide transparent, no-obligation quotes. (Contact Us )
Final Thoughts: Remediation Done Right
The SBS Studios Artarmon project wasn’t just about fixing concrete—it was about preserving safety, function, and value in one of Sydney’s most active media hubs.
It showcased how technical expertise, operational flexibility, and ethical integrity converge to deliver outcomes that exceed expectations.
At Perfect Remediation and Refurbishment, we don’t see concrete as just a material. We see it as the backbone of Australia’s infrastructure—worthy of respect, protection, and expert care.
Whether you manage a commercial tower, industrial plant, or public asset, our team is ready to bring the same precision, reliability, and results to your project.
Need a professional concrete remediation assessment?
Email :- info@perfectremediation.com.au
Contact us :- 02 7912 3054 | 1300 737 332
Concrete Repairs & Remediation Services
Perfect Remediation and Refurbishment acknowledges the Aboriginal and Torres Strait Isander people as Traditional Custodians of the country on which we live and work. We pay our respects to the Traditional Custodians and Elders past, present and future, and honour their connection to the land and ongoing contribution to society.