Case Studies

Partnering with you // Strengthening Australia

The work we have done allows us to position ourselves as experts in our field

The case studies you see here are just some examples of what our highly trained staff are capable of. Each of these projects have been successful, not only because of the experience each company has brought with them, but also because of the high standard of professionalism shown by the companies we have partnered with.

Rio Tinto Mission River Bridge

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The Mission River Bridge in Weipa, which is almost 40 years old, has deteriorated due to corrosion of the bridges' underwater supporting piles. Epoxy Solutions has played a major part in the maintenance program where we designed, manufactured, and applied the grout in an underwater situation.

Metal Protection Systems

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Chemical protection systems have been around for a long time. However many are suited to specific purposes. Galvanising is an economical solution that is long-lasting and effective, however it is also limited to certain projects. Acids will quickly penetrate through galvanising and remove the zinc alloy coating. Recently Epoxy Solutions were contacted by a large galvanising plant to provide a long-term solution to protect their carrier beams and oven doors.

Sealing of Gas Bores

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Early in 2011, two gas bores were drilled to a depth of 900 m targeting coal seams. At the time, the bores were plugged using three separate cementitious plugs between the terminal depth and the surface. The drill site area was scheduled for rehabilitation a few weeks after the concreting. However, at the commencement of the rehabilitation, a gas emission was noticed at one of the bores. After conducting several tests, it was determined that methane was escaping from the bores. Epoxy Solutions was contacted to design a system that would seal the bore and eliminate any further gas emissions.

Queensland Rail Ground Stabilisation

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Queensland Rail train drivers reported irregularities on the track going through the Fortitude Valley Tunnel. These irregularities suggested subsidence of the ground support beneath the track slab. In many places, the track and concrete slab had dipped. After careful consideration, the engineers at Queensland Rail contacted Epoxy Solutions to provide a solution to the problem.

Workshop Floor Repairs

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Industrial workshop floors take a beating. If the floor is not being damaged by cleaning chemicals and hydrocarbons, it’s the heavy tracked machines, trucks and tools that so often destroy the concrete surface. This then exposes steel fibre reinforcing or large reinforcing, which oxidises and leads to further decay of the concrete and ultimately failure of the concrete slab. Epoxy Solutions have formulated a grout that is hard wearing, easy to install, chemical resistant and fast curing. The grout is filled with hard aggregates, which improves its wearability. Strengths over 100 MPa are achieved, which in most cases is more than triple that of the concrete floor.

Deep Crack Injection

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Often new, large concrete structures crack as a result of shrinkage and thermal reaction of concrete. Unfortunately, in most cases, the crack is right through the structure resulting in a weak point and an area where water can enter the structure and potentially oxidise the reinforcing that may lead to structural failure. Sealing the surface of the structure is often not sufficient as any movement in the structure will result in cracking through this seal. This means that the entire crack should be sealed with a compound that is strong as or stronger than the concrete. The compound should also have a low viscosity and good pot life so that good coverage can be attached.

Burnett River Bridge Strengthening

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The Burnett River Bridge was constructed about 130 years ago. The bridge is approximately 535 m long and consists of a mix of structural elements made from both steel and cast iron. The steel truss and plate girder bridge is supported by 1 – 2 metre cast iron piles at 33 m centres. It is an integrate bridge that provides a means for trains to pass over the river to travel along the east coast rail line. The Burnett River Bridge carries heritage value and is situated in a sensitive, highly valued ecosystem. A few years ago, Queensland Rail (QR) initiated a process to verify the structural integrity of the bridge. The study revealed that the cast iron piers suffered from corrosion and strengthening was required to extend the usable life of the asset.

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