Structural Concrete Remediation Newcastle

Concrete remediation for Newcastle assets: Concrete cancer and spalling repair to the engineer's specification

• Concrete cancer, spalling and corroded reinforcement repaired
• Work to the engineer's specification and repair drawings
• Propping to the engineer's design before we cut in
• Staged around production, traffic and parking, assets stay in use
• Port of Newcastle, Kooragang, Tomago and the Hunter Valley
• No strata, balcony or homeowner work

Yes, Perfect Remediation repairs concrete cancer, spalling and corroded reinforcement on structures in Newcastle and the Hunter: industrial plants, bridges and culverts, council assets, car parks and commercial buildings. The work is carried out to the engineer's specification and repair drawings, on assets that stay in use, with the aim of extending the life of the asset. Industrial, infrastructure and commercial work only: we do not take homeowner work, and the line is spelt out below.

Call (02) 7912 3054 and ask for the Sydney team, or send the form with the engineer's report.

Call (02) 7912 3054

What we repair

Chlorides or carbonation reach the steel, the steel rusts and expands, the cover delaminates and spalls. It is the same failure on a bridge deck, a bund wall or a hotel column, and we repair it on:

• Bridge soffits, beams, abutments, edge slabs and culverts for councils and government asset owners.
• Bunds, tank slabs, plinths, footings and plant room structures on operating industrial plants.
• Car park decks, podium slabs, beams, columns and loading docks on commercial buildings, hotels and CBD structures.
• Balance tanks, reservoirs and pump station structures, with cathodic protection where the engineer specifies it.

Corroded steel beams and columns alongside the concrete are covered on the structural steel repairs page. Crack injection and protective coatings usually follow the structural repair; the full method is on the concrete cancer repair page.

Where this work happens in Newcastle

Newcastle and the Hunter run on port, power and process plant. The Port of Newcastle, Kooragang Island, Mayfield and Carrington hold the coal terminals, fertiliser and chemical plants, fuel terminals and wharves: bunds, tank slabs, conveyor footings and plant structures in salt air. Tomago, Beresfield, Thornton and Cardiff carry the smelter and manufacturing estates, and the Hunter Valley from Maitland to Muswellbrook carries coal handling plants and power station precincts. Council assets cover the region: bridges and culverts on the Pacific Highway, the New England Highway and the Hunter Expressway, ocean baths and pump stations from Lake Macquarie to Port Stephens, and Hunter Water assets. Newcastle CBD, Honeysuckle and the John Hunter precinct bring car parks and podium slabs.

To be plain about it: our published concrete remediation jobs are in Sydney, and we have no Newcastle or Hunter project on the site yet. The crew, propping, breakers and formwork travel up the M1 from our Marrickville base, and Hunter work is booked as a block so the crew mobilises once and stays.

The concrete remediation jobs on our books are in Sydney, each on its own project page:

• Four concrete bridges over live stormwater channels at Marrickville for Inner West Council: breakout, steel treatment and priming, supplementary reinforcement, crack injection, every patch logged.
• The chemical plant at Wetherill Park: bunds reinforced, formed and re-poured, a tank slab re-topped, tanks braced on temporary props while corroded walkway steel was replaced.
• Lobby columns and slab penetrations at the Sofitel Wentworth for Futuro Capital: spalled concrete removed and reinstated with high strength repair mortars, propped where access was tight.
• The pool balance tank at Wentworthville for Cumberland Council: corbel rebuilt, walls crack injected, reinforcement treated, cathodic protection installed, new suspended slab poured.
• The five storey car park at SBS Artarmon, repaired in stages so it stayed open through the works.

How we do it

The same sequence on a bridge, a bund or a car park:

• Survey and mark out. Delamination survey to the engineer's scope, each area marked and photographed so the breakout extent is agreed before cutting.
• Propping and shoring. Installed to the engineer's design before a beam, soffit or column is cut into, so the structure stays supported.
• Breakout. Square cutting and breakout of delaminated concrete past the reinforcement to sound substrate, with dust and noise controls.
• Steel. Bars cleaned, treated and re-passivated with a zinc rich primer, supplementary reinforcement fixed where the engineer directs it. Lead paint on old steel is dealt with as part of the job.
• Reinstatement. Repair mortars to the specification, or formwork, reinforcement and poured concrete where the section calls for it, as on the Wetherill Park bunds.
• Protection and record. Crack injection, cathodic protection where specified, and coatings to stop the corrosion cell restarting. Every patch logged and photographed against the ITP.

Before you ask for a price

What to send for a price:

• The engineer's report or repair specification, the repair drawings, and structural drawings or as-builts if you have them.
• Photos of the defects and the access to them.
• Operating constraints: hours, permits, inductions, traffic management, how much of the asset stays in use.
• Any test results in hand: cover meter, half cell or chloride.

No engineer's report yet? Send the photos and drawings and we will tell you what an engineer needs to see first. We price against the specification, not a guess.

What we do not do

We do not take strata, owners corporation, apartment balcony, unit or homeowner work. We will point you elsewhere rather than waste your time. Our lane is industrial, infrastructure, council and commercial structures where the repair is engineered and documented.

Common questions

Does the plant, bridge or car park have to close while you work?

Usually not. Repairs are staged around production, traffic and parking, with night works where needed, and propping to the engineer's design keeps the structure supported. The SBS Artarmon car park stayed open through its repairs.

Who specifies the repair?

Your structural engineer. We carry out the repair to the engineer's specification and repair drawings, and propping goes in to the engineer's design. Where a defect is bigger than expected we stop, record it and go back to the engineer.

Do you survey the concrete before you start?

Yes, to the engineer's scope. We tap test and mark out the delaminated areas so the breakout extent is agreed before a breaker is picked up. Cover meter and chloride results come from the engineer's report.

Have you done this work in Newcastle?

Not yet on a published project. Our jobs on the site are in Sydney and we travel to the Hunter from Marrickville with the same crew, method and paperwork.

Related services and other areas

Concrete remediation contractors is the national page for this work. See also concrete cancer repair, bridge structural repairs and structural steel repairs. Other areas: Structural concrete remediation Sydney and Structural concrete remediation Wollongong. All services: remediation services.

What happens next

Call (02) 7912 3054 or send the form with the report, drawings, photos and site constraints. The Sydney team reads the specification, walks the structure where it helps, and comes back with a method, programme and price against the engineer's repair schedule.