CONCRETE PROTECTION AND REPAIR PROJECTS

CPR Services is proudly the leading Concrete Repair service provider in New South Wales and Victoria. We are continuously engaged by large and medium commercial, industrial and government organisations to plan and implement major concrete repair projects on concrete assets and structures as well as public roads, bridges and other public works. Our recent projects include:

“Epoxy injection to North West Rail Link”

NORTH WEST RAIL LINK

Client: Salini Impreglio.
Method: Epoxy Injection.
Case: Epoxy Injection of elevated rail segment joints.
Implementation: Epoxy injection to segment joints on the new North West Rail Link. An ongoing project, CPR has currently successfully injected 10 full spans, with a further 140 to follow. The project thus far has used 2,500 injections ports, 105 kgs of special flexible epoxy resin, 200 kg of high strength epoxy paste and two of CPR Services custom built epoxy pumps. CPR was the only contractor in the country who could offer a cost effective and high quality solution.

“Structural Crack Repair to concrete surface above dock. Gunite Dry spray concrete repair to beams/bents beneath the dock for structural integrity”

WEBB DOCK

Client: Freyssinet.
Method: Epoxy Crack Repair and Concrete Repair – Gunite Dry Spray.
Case: Port of Melbourne’s largest dock remediation package this century.
Implementation: CCPR Services were engaged as the only contractor to be able to achieve the volume of concrete required to make sure the program stayed on track for this time critical project. Using custom made CPR Gunite systems CPR Services installed more than 145,000 litres of concrete repair within a 10 month period. CPR Services also installed over 6000m of epoxy crack repair using an in house cut and fill technique.

“More efficient, cleaner and faster concrete repair with Dry – Dust Free – Gunite”

BONDI PACIFIC

The project entailed the redevelopment of the former Swiss Grand Resort Spa into a mixed use development combining luxury residential apartments with a boutique hotel and retail tenancies.

Client: Hutchinson Builders.
Method: Concrete Repair, Gunite Dry Spray, Epoxy (Structural) Crack Injection.
Case: CPR Services were awarded for all concrete repair for the redevelopment of the old Swiss Grand Hotel in Bondi into the Bondi Pacific Precinct. 150 tonnes of concrete repair and over 200m of epoxy injection.
Implementation: CPR developed and used dustless dry spray gunite to install high volume repairs faster, cleaner & more efficiently than competitors in this industry.

“Installation of Proofex membrane and waterstop to 2 kilometres of cold joints and Sika Swell & profile to 7 kilometres of steel and concrete piling”

LEVEL CROSSING REMOVAL

Client: John Holland.
Method: Water Bar and Proofex Subgrade Water Proofing.
Case: To seal and waterproof expansion joints and construction joints below base slabs and between pile walls and base slabs.
Implementation: CPR Services was engaged to install 7000m of Sika Swell and 2000m of Proofex and Back Stop Waterbar to both Bentleigh and McKinnon Stations on behalf of John Holland for Metro Trains. This was achieved in a 10 day window as part of a greater 37 day greater occupation. CPR had 24 men onsite on 12 hour rolling shifts, 24 hours per day. CPR achieved our outcome on time.

“Surface preparation and installation of protective coating on large water tank”

MCG UNDERGROUND WATER TANK

Client: Asset Rehabilitation Services.
Method: Protective Coating – Intercrete 4841.
Case: Protective coating to decaying underground concrete tank.
Implementation: Via Asset Rehabilitation Services CPR Services were engaged to coat and existing A Class Water tank under the MCG. Timing on this project was key as the tank had to be operational prior to the opening round of the AFL Season. CPR was called to nominate a product and system that was both an affordable and achievable solution given the time frame. CPR Services completed 1500m2 of remediation works in a three week period and the tank was operational for the beginning of the AFL season.

“Use of customised injection equipment to seal major diversion and permanent plugs”

COTTER DAM

Method: Polyurethane Injection.
Case: Installation of sealing major diversion plug.
Implementation: CPR Services carried out Polyurethane Injection with customised injection equipment. This enables CPR to seal the major diversion plug and permanent plug in a single session of works for each item. Works were completed over two, four days sessions of work. This was done in conjunction with Professional Diving Services and this operation was deep diving (up to 50m), at altitude and cold.

“Repair and reinforcement of Strathfillan Bridge which was affected by alkali silica reaction – also known as alkali aggregate reaction”

VLINE STRATHFILLAN BRIDGE

Client: VLINE.
Case: The implementation os this project required installation of:

  • Over 1200kgs Epoxy resin injection for structural crack repair.
  • 186 lineal metres Carbon Fibre Plates into concrete internally for structural integrity to the railway bridge.
  • 270 m²Carbon Fibre wrap around piers.
  • 292 m² Anti-carbonation protective coating.

“Continuous maintenance providing leaking crack injection and Anti-Chemical Growth Epoxy Coating”

M5 MOTORWAY – CITY CROSS TUNNEL

The Cross City Tunnel runs for 2.1 km and gives airport travellers speedy access to the CBD and Darling Harbour. It was built with prediction to carry up to 90,000 vehicles per day.

Case: Continuing maintenance contract providing Polyurethane (leaking) crack injection & anti-chemical growth epoxy coating.
Implementation: CPR Services were awarded contract to carry out maintenance works to leaking cracks throughout the Cross City Tunnel itself, as well installing a protective coating for the sandstone walls of the access tunnels. These works are carried out over a foud night occupation/shut downs of the tunnel.

“Epoxy injection to segment joints on the new North West Rail Link”

REGIONAL RAIL LINK – NORTH MELBOURNE

The Sydney Metro Northwest Rail Link is Australia’s largest public transport infrastructure project and a priority rail project for the NSW Government.

Method: Epoxy Injection.
Case: Epoxy Injection of elevated rail segment joints.
Implementation: Epoxy injection to segment joints on the new North West Rail Link. An ongoing project, CPR has currently successfully injected 10 full spans, with a further 140 to follow. The project thus far has used 2,500 injections ports, 105 kgs of special flexible epoxy resin, 200 kg of high strength epoxy paste and two of CPR Services custom built epoxy pumps. CPR was the only contractor in the country who could offer a cost effective and high quality solution.

“Raising and levelling of concrete slabs using Polyurethane Foam Injection on an old hanger as it was being converted to a new car park”

ESSENDON AIRPORT

Late in 2014 CPR Jacking was contacted by a civil engineering firm seeking solution to the problem of sinking and unstable slabs in the carpark at Essendon Fields Airport.
Water ingress through unsealed joints in the carpark had caused erosion of the fill beneath. The weight of vehicles travelling over the unsupported joints further exasperated the problem by creating a pumping effect, resulting in liquefaction and displacement of the saturated fill material. Left untreated deterioration would have continued at an exponential rate causing the slabs to crack and break, ultimately necessitating full replacement at great cost and disruption to the client.

A site inspection by CPR identified significant voiding under the slabs and Slab Jacking, along with sealing of the joints, was proposed as the most effective and efficient solution.

During a 4 day occupation the CPR team injected over 1000kg of polyurethane resin, filling over 12,000 litres of void. The non-disruptive nature of the application allowed for the car park to remain in operation throughout the works.

The installation successfully levelled and stabilised the slabs; water ponding on the surface was also significantly reduced as storm water falls were returned to their intended levels.

“Yarra River closure & underwater Armour Grouting to essential services below 15 metres of water”

YARRA RIVER PROTECTION SYSTEM

This was completed in association with Waterways Construction and Professional Diving Services. CPR Services carried out specialised underwater grouting to provide Armour Protection to essential mains in an urgent work schedule.

The implementation of this project required the bay to be closed to all commercial and private vessels. The bay closure and the use of additional resources and pre-planning provided for completion of the project 40% earlier than initially scheduled.

“CPR carried out Leaking Crack Injection to 18 kilometers of tunnel”

MELBOURNE UNDERGROUND RAIL LINK

Client: Metro.
Method: Leaking Crack Injection.
Case: To repair serious leaking cracks and water ingress into the Melbourne Underground Rail Loop.
Implementation: CPR carried out Leaking Crack Injection to 18kms of tunnel at over 700 locations affected by cracks at an average of 6.5 meters totalling over 4,500 lineal meters. Over 2,500 litres of product was injected over five work sessions of three occupation/shut-down weekend periods.