Domestic Xypex Projects

Anderson Point Port Facility

Port Hedland This project will mine and export through the Anderson Point Port Facility, 45 million tonnes per annum (mtpa) of Iron ore to markets in Asia. Xypex Admix C-Series is spec’d into all concrete elements of the berthing facility, to provide enduring protection for this vital asset. As of June 2011, Berths 1 & 2 are complete, with Berth 3 underway.

Australian Marine Complex

Perth Located in Western Australia, 23 kilometres south of Perth, the AMC has been developed to enhance the opportunities created by the clustering of industries and is home to the largest marine industry in Australia. Long term concrete durability is an important factor for any marine structure. This was a key consideration in the decision to include Xypex Admix C-5000 as a component of the precast beams and soffit planks for the “Common User Facility” of the Australian Marine Complex. Approximately 1,000 m³ of precast product was treated with Xypex Admix C-5000 at a grade of 50 MPa. Besides enhancing durability, benefits of Xypex Admix C-5000 include ease of application into the concrete mix, workability with vertical pours and the long term benefits of the Xypex crystalline process. Xypex Admix C-Series enhances the ability of concrete to resist sulphate attack, limits chloride ion penetration, improves the chemical resistance of reinforced concrete and accelerates autogenous healing of cracks.

Ballarat Aquatic Centre

Ballarat, Victoria Ballarat Aquatic Centre upgrade has been jointly funded by the Victorian Government Better Pools Program and Federal Government Better Regions Program. The new redevelopment will cater to 110,000 residents in Ballarat and surrounds. In conjunction with Burn Hamilton and Partners and M.L. Design Architects, Xypex Australia were able to assist with concrete waterproofing the new structure. Xypex Admix C-1000 NF and Xypex Concentrate were used in the new balance tanks, pools, pool concourses and wet areas.

Benelong Point

Sydney Xypex Admix was used throughout this project to waterproof and protect the concrete walls and slabs.

BOC Gases Headquarters

North Ryde Xypex Admix NF was blended with 600 m³ of concrete to waterproof and protect the roof deck of this building.

Bogong Power Station

Bogong Xypex Admix C-Series was specified for use in 12,000 m³ of concrete for this new power station development, designed to provide an additional 140 MW to the Kiewa hydroelectric scheme. The Xypex system was used to enhance long-term durability and provide added waterproofing integrity for this vital infrastructure development.

Brisbane Inner City Bypass

Brisbane Xypex Admix C-1000 NF was dosed into concrete roof elements of the Landbridge, Inner Northern Busway Tunnel and the RNA Tunnel as part of the Brisbane Inner City Bypass project. In excess of 3,000 cubic metres of concrete was dosed with Xypex for waterproofing and durability requirements. Xypex Admix C-1000 NF was dosed into concrete roof elements of the Land bridge, Inner Northern Busway Tunnel and the RNA Tunnel. In excess of 3,000 m³ of concrete was dosed with Xypex Admix C-1000 NF for waterproofing and durability requirements.

Busselton Jetty

Busselton Xypex Admix C-5000 was specified for all concrete used in the refurbishment as protection of concrete used in a marine environment.

Citigroup Headquarters Building

Sydney Xypex Admix C-1000 NF and Admix C-2000 NF were used in the 90 MPa concrete. Xypex Concentrate DS-1 was applied to concrete 150 m above street level.

Cronulla Marina

Sydney Dosed at 4 kg/m³ with Xypex Admix C-2000 NF, this mix was designed to achieve 32 MPa at 48 hours and 50 MPa in seven days. The two-tonne post-tensioned units of this floating concrete structure had to be lifted from their formwork 36 - 48 hours after casting. The marina floats were cast in October 1994, employing a high early strength concrete design that incorporated 530 kg of GP cement and 4.2 kg of Xypex Admix C-NF Series. The 100 mm thick panels are pre tensioned with wire strands and have foam flotation attached to the soffit. The wire strand steel reinforcing is only 40 mm below the top surface of the concrete panel. The top surfaces of the panels are a nominal 350 mm above sea level. 

Crotty Dam Dewatering Outlet Shaft

Queenstown The Xypex waterproofing system was specified by the Hydro Electricity Commission of Tasmania for use in this deep concrete shaft which comprises part of the King River Power Development Scheme. The shaft is approximately 76 metres (250 ft) deep and is adjacent to the Crotty Dam which is located near Queenstown on the West Coast of Tasmania. Internal surface preparation for the Xypex crystalline treatment included the use of Xypex products for repair of structural defects, patching of tie rod holes, and sealing of high pressure leaks. Prior to these repairs, it was estimated that the shaft was taking in over 400 litres (106 US gallons) of water per minute. Once the repairs were completed, a two coat application of Xypex Concentrate was applied to internal shaft surfaces totalling 1,600 m² (17,200 sq ft). Because of the success of this difficult application, the Hydro Electricity Commission has specified the Xypex system on another larger concrete shaft located at the Anthony Power Station.

Dee Why Seawall

Dee Why Xypex Admix was used in the mix design to help achieve greater concrete durability. Durability was one of the most important objectives in the design of this seawall. Aesthetics were also a prime objective and a beige oxide was added to the Xypex Admix used in all visible areas.

Fitzroy Gardens Stormwater Harvesting Tank

Melbourne Xypex Australia and 2Construct were involved in the installation of a 5 mega litre underground concrete water tank in the Fitzroy Gardens. This stormwater harvesting system will include full hydraulics to pump the water through a water treatment bed before it is stored in a separate tank to be used to water plants in the garden. Xypex Admix C-1000 NF has been used in all precast wall panels, tank base slab, and from panel to panel. Once complete garden beds will be planted on top of it so it is not visible from the gardens. Over 6,000 kgs of Xypex Admix C-1000 NF was employed in the construction.

Flinders Ports Berth 8 Outer Harbour Grain Wharf

Adelaide The concrete wharf is a concrete deck and beams on piles structures 228 m long with a roadway along the quay, deep rail support beams and two 36 m wide access ramps. It is designed to berth Panamax and Post-Panamax vessels and will support a travelling shiploader. A total of approx 4,500 cubic metres of concrete was poured. Xypex Admix C-1000 NF was specified as the most suitable product to effectively protect and improve the berth's concrete structures for the specified 50 year structure life. Xypex Admix C-1000 NF is particularly suited to this wharf structure as its chemical composition slows the diffusion of chloride penetration, ensuring protection from the harsh marine environment. Pile plugs, pile caps, rear ramp support walls, wharf beams, the deck and ramps were all dosed with Xypex Admix C-1000 NF at a rate of 3.9 kg per metre. 

Funkers Crossing

Stanthorpe, Southern Downs, QLD As part of flood repairs to New England Highway just outside of Stanthorpe, new culverts were constructed as part of the road upgrade for improved flood prevention. Test results on the 50 MPa concrete failed to meet with compressive strength tolerances of Transport and Main Roads specification. Xypex Concentrate, Xypex Modified and Xypex Gamma Cure were selected to rehabilitate the concrete to increase durability and improve the compressive strength. Raw Worx Pty Ltd were contracted to carry out the surface preparation and application of material to approximately 600 m² of concrete surface.

Hisense Arena

Melbourne Xypex Admix C-1000 NF was blended into the concrete mix to waterproof and protect the precast bleachers for this multipurpose stadium (formerly named the Vodafone Arena). The seating design of this stadium is stunningly innovative and the contractors used the latest technology to ensure that the arena would accommodate a wide range of functions.

Homebush Bay Aquatic Centre

Homebush Bay Before tiles were laid, a coating of Xypex Concentrate was applied to the fine shrinkage cracks in the formed walls of the pool areas throughout the complex.

Iluka Minerals Process Water Tank

Geraldton Built in 1970 with a capacity of 1.4 million liters, the tank is 25 meters wide, 3 meters high and is constructed with steel walls and a concrete foundation. The tank had become unserviceable due to corrosion around the base. Faced with the prospect of a $1.2 million replacement cost, consulting engineer John Montgomery worked closely with Iluka Engineers to develop a strategy for the rehabilitation of the tank which is located at Iluka’s Geraldton, Western Australia facility. Forty-five cubic meters of Admix-treated shotcrete was sprayed up against the existing metal walls and approximately 100 lineal meters of a special waterstop wasplaced at the floor wall intersection. On completion of the repairs, the tank was filled and while initially there were a number of minor leaks, these reduced to zero within 10-14 days as the Xypex crystalline development took place. The structure is now fully ‘returned to service’ and remains watertight. The ultimate result of this collaboration was that through the use of Xypex Admix there was a savings of approximately $900,000, reduced down time of 14 days and an extended service life.

Interactive Underground Restaurant – Darling Harbour

Sydney Xypex Admix was used in 3,700 m³ of concrete to waterproof the hydrostatic slab, pits, tanks, walls and podium.

Lascelles Wharf

Geelong With a design mix that included Xypex Admix C-Series, these 20+ tonne, 40 MPa slabs were installed as part of a major upgrade of the Lascelles wharf facility. Strength, durability and water impermeability were key issues in the design of the slabs, which replaced seriously degraded structures in a very high wear, chemically aggressive, marine environment. In addition to being located in the splash zone, the slabs were subjected to a fallout of bulk chemicals and fertilizers from off-loading of bulk carriers at the wharf and therefore required protection with Xypex products. Dimac Constructions carried out construction and installation of the slabs for the Port of Geelong Authority (now TOLL Geelong Ports).

Melbourne Aquarium

Melbourne The below-ground aquarium tanks and viewing areas (adjacent to the Yarra River) exhibited leakage in various areas due to cracks and defective joints. All leakage was eliminated by using the Xypex concrete repair system (Xypex Concentrate and Patch’n Plug).

Melbourne Zoo – Trail of Elephants

Melbourne The Trail of the Elephants captures the imagination of visitors to the Melbourne Zoo, Parkville, engaging them in a sense of theatre, discovery and wonder, while delivering a serious message about the survival of the ‘endangered’ Asian elephant in its native habitat, and the conservation role of the contemporary zoo. More than two hectares of land were redeveloped with walking trails in a matrix of ‘tropical rainforest’, consisting of a diverse palette of planting material. In excess of 160 m³ of shotcrete and in situ concrete was dosed with Xypex Admix C-1000 NF in the Elephant Pool and the balance tank.

Microsoft Building

Sydney Xypex Admix C-1000 was used to dose 1,200 m³ of concrete on the roof deck of this office building.

Minto Malting Plant

Sydney, NSW The construction of this malting plant consisted of 15 main buildings and many interconnecting steel gantries, towers and linkways that form part of the automated malt processing facility that is expected to outload approximately 110,000 tonnes of malt per annum. Xypex Admix C-Series was specified into the slab and roof sections of the vessels.

Murray Irrigation

Due to the size and scope of the project, application of the concrete repair products needed to be efficient and completed within 10 weeks due to the irrigation requirements of stakeholders. Xypex Concentrate was chosen as the preferred product to meet the engineer’s requirements for an anti-carbonation coating. Furthermore, since Xypex Concentrate is permanent and does not require re-application, ongoing maintenance costs have been eliminated for Murray Irrigation assets. Xypex Megamix II was chosen as the preferred product to meet the engineer’s requirements for a repair render for deteriorated concrete surfaces applied at a rate of 20 kg/m². As opposed to competitors’ high strength repair mortars, Xypex Megamix II contains Xypex’s unique crystalline technology, has high strength yet low shrinkage, and adheres excellently to damp concrete. As a result of using Xypex Concentrate and Xypex Megamix II, 217 structures were repaired and coated in 9.5 weeks.

Olympic Park Train Station

Homebush Bay Xypex Admix C-2000 was used in the concrete mix to waterproof the elevator pits in this train station.

Qantas Domestic Terminal – Kingsford Smith Airport

Sydney Xypex Concentrate and Modified were used to waterproof and protect the footpath and roadway over the arrivals hall of this airport terminal. Xypex Gamma Cure was used to speed the curing process.

Robina Town Centre

Robina To date, 13,000 m³ of concrete have been dosed with Xypex Admix C-2000, including the exposed deck and walls, and fire service tanks. Xypex Concentrate slurry has been used along with Xypex Dry-Pac in the joints. This project is ongoing with plans for Xypex to be used in the sewage treatment plank and rail link to Brisbane.

Sandy Bay Seawall

Tasmania An existing seawall had become delapidated due to decades of constant, severe exposure to wind, tides and wave action. The seawall was rebuilt with the use of Xypex admixture in the concrete elements. The seawall is part of an overall project to provide shore protection and community facilities. Xypex Admix was chosen for concrete protection against aggressive chloride attack. Xypex was favoured over other systems due to the ease of application, benefits to the host concrete, longer service life and cost.

Sea World – Polar Bear Shore

Gold Coast The polar bear enclosure utilised Xypex Admix C-1000 NF and Kuniseal C-31 waterstop for the pool to ensure concrete waterproofing integrity. Xypex Admix C-1000 NF was used to waterproof, protect and improve the concrete's durability for the Sea World Polar Bear enclosure. Kuniseal C-31 was used to prevent the ingress of water through cast in situ concrete construction joints. Xypex prevents the penetration of water and other liquids from any direction by causing a catalytic reaction that produces a non-soluble crystalline formation within the pores and capillary tracts of concrete and cement-based materials.

Stadium Australia

Homebush Bay The ANZ Stadium, also known as Stadium Australia, formerly known as Telstra Stadium, is a multi-purpose stadium located in the Sydney Olympic Park precinct of Homebush Bay. The stadium, which in Australia is sometimes referred to simply as the "Olympic Stadium", was completed in March 1999 to host the 2000 Summer Olympics. The sweeping, slouch-hat shape of Sydney’s Olympic Stadium was built to seat more than 110,000 for the 2000 Games, making it at that time the largest Olympic Stadium ever built as well as the largest stadium in Australia. Xypex Admix was selected to waterproof, protect and enhance approximately 25,000 m³ of the stadium’s concrete. Xypex was used to waterproof and protect numerous areas of the 110,000 seat Olympic Stadium. Specifically, Xypex Admix was utilized in the concrete of four large below-ground water storage tanks, various pits, lift over-run pit and retaining walls, lower tier moveable seating, mid tier seating and suspended slabs exposed on Level 1.

Stumers Creek Culverts

Queensland As part of flood repairs to David Low Way just outside of Coolum, new culverts were constructed as part of the road upgrade for improved flood prevention and tidal overflow. Test results on the 50 MPa concrete of the western-facing wing walls, Apron & Slab failed to meet with compressive strength tolerances of Transport and Main Roads specification. Due to the aggressive nature of the marine environment, Xypex Concentrate, Xypex Modified and Xypex Gamma Cure were selected to rehabilitate with western-facing wing walls, aprons and slab, to increase durability and improve the compressive strength.

Sydney Airport Tunnel – M5 Motorway

Sydney Xypex was used to meet the concrete waterproofing specifications for the freeway (road) tunnel which runs below the Cooks River beside Sydney’s Mascot Airport. The project involved two contracts – one for 5,000 m³ (Cooks River trough section) and another for 1,200 m³ (Turella Shaft Tunnel).

Sydney Harbour Tunnel

Sydney Commencing in September of 1991, repair systems using Xypex Concentrate and Patch’n Plug were used as part of an ongoing program of repair and maintenance of the North and South land driven tunnels and transition tunnels of this renown structure. Xypex products were selected ahead of some 52 others to repair the extensive cracking that has occurred. Xypex Crystalline Technology was chosen primarily because of its unique ability to be applied from the negative pressure side of water affected structures. Extensive crack repair was undertaken using Xypex after other products failed to stop water seepage. Xypex products are applied firstly to shut down the water flow. Repair systems are then installed, giving rise to Xypex crystal growth through the entire depth of the structure, strengthening and waterproofing the concrete as well as protecting the rebar in the repair area. Two work crews spent three months in the tunnel using both Xypex Patch'n Plug and Concentrate to stop leaks.

Sydney Opera House

Sydney The Sydney Opera House is a multi-venue performing arts centre and a modern expressionist design, with a series of large precast concrete "shells", each composed of sections of a sphere of 75.2 metres (246 ft 8.6 in) radius, forming the roofs of the structure, set on a monumental podium. It is supported on 588 concrete piers sunk as much as 25 m (82 ft) below sea level. Xypex Admix was used to waterproof 200 m³ of concrete in this famous Australian landmark.

Sydney’s Taronga Zoo

Sydney Xypex Admix C-1000 was added to the 300 m³ of concrete used in the construction of the clarifier and treatment tanks. These tanks contain potable water for the zoo’s animals.

The Bunnings Warehouse – Manly West

Brisbane Work has recently completed on the new 2-storey Bunnings Warehouse in Manly West, Brisbane. The store includes a main warehouse, indoor timber trade sales area, outdoor nursery, playground, café and undercover parking for more than 280 cars. Xypex Admix C-5000 was specified to 1,800 m³ cubic metres of conventionally reinforced concrete, in the exposed areas of the suspended deck and ramps protecting the car parking underneath. The project highlights the advantages that Xypex Admix C-Series can provide for concrete structures requiring enhanced durability, waterproofing and an extended service life. The project was built by Grindley Construction with concrete supplied by Hanson.

Visitors Marina – Darling Harbour

Sydney Xypex Admix C-2000 was used to waterproof and prevent the ingress of chlorides into these pre-stressed, pre-cast units. The Xypex assisted in providing long-term durability to this floating concrete structure.

Werribee Zoo

Victoria The enclosure’s concrete pools, measuring 170 metres long x 10 - 15 metres wide, and up to 3 metres deep, were dosed with Xypex Admix C-1000 NF, ensuring long term protection and waterproofing integrity. Xypex Admix C-1000 NF forms a non-soluble crystalline formation throughout the concrete matrix which seals the concrete and prevents moisture ingress. Xypex has been thoroughly tested for permeability, chemical resistance, compressive strength, freeze-thaw durability and potable water. Xypex also conforms to AS 1478.1 as a type SN Special Purpose Admixture and is certified environmentally preferable. Additionally, Xypex Megamix I and Megamix II were utilised for spillway repair leaks, which also required the application of Xypex Concentrate, Xycrylic Admix and Xypex Patch'n Plug.