Durability Design in the Circular Economy

BCRC Durability Design and Engineering in the Circular Economy

The built environment encompasses all spaces and structures created by humans for human use, forming a dynamic setting in which assets are continuously built, operated, maintained, and eventually renewed or replaced.

Each asset within this environment undergoes a complete lifecycle comprising five distinct phases: designing and planning, construction, commissioning, operation and maintenance, and ultimately renovation or demolition.

Durability Engineering: Extending Infrastructures’ Design Life for a Circular Economy

Durability engineering plays a critical role in advancing the circular economy by extending the lifespan of infrastructure and reducing the need for resource-intensive repairs, replacements, or demolitions. Central to this approach is the integration of Lifecycle Assessment (LCA), which evaluates the environmental impact of materials and design decisions across the entire asset lifecycle.

By embedding sustainability from the outset, LCA and durability engineering together support resource efficiency, minimise embodied carbon, and reduce overall environmental impact.

Moving away from the traditional “build, use, demolish” model, this strategy prioritises resilient design and material reuse, ensuring long-term performance while aligning with circular economy principles.

The result is infrastructure that remains functional, efficient, and environmentally responsible for generations.

Key points of the low-carbon strategy adopted by Durability Engineers are:

Designing structures for longevity and resilience.

By using tools like probabilistic durability modelling and analysing deterioration mechanisms such as carbonation or chloride ingress, engineers can make informed decisions to minimise risk from the outset and efficiently target the design life of the structures. Concrete mixes with low permeability, paired with supplementary cementitious materials (SCMs) like fly ash or slag, improve durability and reduce carbon emissions. Additional measures like cathodic protection and corrosion inhibitors help safeguard steel reinforcement from long-term deterioration.

Preventative Maintenance and Structural Health Monitoring

Ongoing care is just as important as upfront design. Regular condition assessments ensure that small problems can be addressed before they escalate.

Also, preventative maintenance and the implementation of live monitoring systems such as IoT sensors and AI-driven diagnostics enable early detection of issues, helping to extend service life and reduce the need for major interventions.

3. Adaptive Reuse and Retrofit Solutions

When existing structures start to show their age, adaptive reuse and retrofit solutions offer a sustainable alternative to demolition.

Design solutions like tailored repair strategies or Carbon Fibre Reinforced Polymer (CFRP) strengthening can restore structural performance while adding seismic or fire resilience, ensuring older buildings continue to meet modern standards.

4. Material Recovery and Circular Deconstruction

Finally, durability engineering supports circular outcomes at the end of a structure’s life. Engineers make reclaiming high-value materials like steel and concrete easier by designing for disassembly and material recovery. Recycled aggregates and reclaimed elements reduce the environmental impact of demolition, feeding valuable resources back into the construction cycle.

Together, these strategies extend the life of infrastructure and move us closer to a truly circular and low-carbon-built environment.

BCRC- Durability and the Circular Economy

At BCRC, we are committed to driving innovation in durability engineering, ensuring that the built environment aligns with the circular economy. Our expertise in durability design, material performance, and lifecycle assessment helps future-proof infrastructure while promoting sustainability. As the industry moves towards a more circular approach, durability will remain at the core of resilient and resource-efficient construction.

By integrating advanced materials, predictive maintenance, adaptive reuse, and deconstruction strategies, the industry can significantly reduce waste, lower embodied carbon, and build a sustainable future.

BCRC integrates durability and circular economy principles, shaping a more resilient and environmentally responsible built environment.

February 18, 2025February 22, 2025

Bondi Beach Park Remedial Work

BCRC Bondi Beach Park Remedial Work

Since the mid-1800s, Bondi Beach has been a cherished destination for families, picnics, and beachgoers, evolving into a cultural landmark over the decades. The beach’s popularity soared with the advent of the first tramway in 1884, the construction of surf bathing sheds in 1903, and the opening of the Bondi Pavilion in 1929, which drew a staggering crowd of 200,000. The pavilion, renovated in 2022 by Tonkin Zulaikha Greer Architects (TZG), symbolizes Bondi’s vibrant heritage and enduring charm.

BCRC was engaged to provide inspection services for the concrete elements of the pedestrian bridge and walkway structure leading to Bondi Park and the beachfront.

This article highlights the scope of work and advanced techniques BCRC employs to safeguard this iconic structure.

BCRC-bondi-1930's — Image: NSW State Archives Collection

Comprehensive Inspection and Testing: The BCRC Approach for Bondi Beach

The BCRC team conducted rigorous field and laboratory investigations, utilizing advanced methodologies and tools to evaluate and enhance the durability of the concrete structures.

Visual Inspection and Drummy Survey

Using their proprietary SMART Inspect methodology, BCRC performed thorough visual inspections to identify spalling, cracks, corrosion, and other risks. The Drummy survey, conducted in accordance with ASTM D 4580 standards, identified delaminated areas of concrete that were not visible to the naked eye.

Rebound Hammer Test

The rebound hammer test was employed to assess the concrete’s compressive strength and surface hardness. This non-destructive test provided critical data on the structural durability, guiding further assessments.

Cover Survey Test

BCRC conducted a detailed cover survey to verify the adequacy of the concrete cover over reinforcement bars. This test ensured that the concrete cover met design specifications, a crucial factor in protecting against environmental exposure and corrosion.

Core Sampling

Core samples were extracted to analyze compressive strength and durability characteristics. Key assessments included:

1. Over Reinforcement Coring: This revealed rebar dimensions and allowed visual inspection of reinforcement conditions.

2. Durability Testing: To estimate the remaining service life, chloride and sulfate ion content, as well as carbonation depth, were evaluated.

3. Petrographic Analysis: Concrete quality was assessed, identifying potential alkali-aggregate reactions and other durability factors.

4. Half-Cell Potential (HCP) Survey

BCRC utilized the Proceq Profometer to measure the likelihood of reinforcement corrosion. By analyzing HCP data beyond standard guidelines, the team delivered precise corrosion risk assessments tailored to the structure’s specific conditions.

Data-Driven Solutions and Advanced Reporting

The investigations culminated in a comprehensive report that included:

Detailed observations with photographic evidence.
Compressive strength calculations.
Analysis of degradation rates.
Remaining service life estimations using proprietary and industry-standard models.
This report provided actionable insights and recommendations for the future maintenance and preservation of the structures.

Tailored Repair Specifications for Longevity

BCRC’s EPIC Repair system was employed to identify the most suitable repair methods. These ranged from localized patch repairs to advanced cathodic protection systems, ensuring all repairs aligned with long-term performance goals.

October 27, 2024October 30, 2024

Durability Consulting for $18.5 Million Warehouse Conversion

A stunning transformation is underway as billionaire philanthropist and renowned art collector Judith Neilson prepares for her latest design statement with an $18.5-million warehouse conversion. Colliers Project Leaders was engaged to upgrade the building at 66 Bay Street, Ultimo, from an existing commercial building to a single 5-storey bespoke luxury residence. BCRC is proud to play a crucial role in this high-profile development, providing expertise and durability consulting for the project.

Set in the heart of Ultimo at 66 Bay Street and designed by Atelier Andy Carson, this adaptive reuse project will transform an early 20th-century warehouse into a luxurious contemporary residence.

With extensive experience ensuring the long-term integrity of heritage buildings, BCRC’s involvement highlights the importance of durability assessment when planning substantial upgrades.

A Vision of Adaptive Reuse

The project aspires to be a prime example of world-class adaptive reuse. Originally constructed in 1911, the warehouse has seen significant changes over the years, including a 1980s renovation that added a fourth floor. The current design is ambitious, calling for the complete removal of internal walls and ceilings, as well as excavation to add a basement level. Inside, the residence will feature a new spiral staircase, lift, fire stairs, and bespoke finishes, while the exterior will receive a modern facelift to blend historic charm with contemporary elegance.

Why Durability Consulting Matters

Given the building’s age and the scale of the renovation, the project called for expert durability consulting to assess the condition of the concrete and avoid costly repairs in the future. BCRC’s role in this project underscores the importance of understanding the structural health of existing materials, especially when repurposing older buildings.

BCRC’s Durability Consulting

BCRC is providing comprehensive consulting services throughout the project, including:

• Concrete Mix Design Review and Assessment: Ensuring that the new concrete used in the project meets the highest standards for strength, longevity, and compatibility with the architectural requirements.

• Advice on Construction Processes and Material Selection: Guiding the selection of materials and construction methods to achieve optimal performance, sustainability, and durability of the concrete elements.

• Top-Class Architectural Finishing of Concrete Elements: Providing expertise to ensure the concrete finishes not only meet structural requirements but also achieve top-quality aesthetic standards that enhance the overall design.

• Construction/Engineering Detail Review: Assessing construction drawings and reviewing subcontractor tenders to ensure the project is executed efficiently and according to specification.

• Thermal Modelling and Crack Control Measures: Addressing potential issues like crack development and temperature control in the concrete to prevent long-term damage and ensure structural integrity.

• Quality Inspection and Supervision: Overseeing the on-site work to ensure all aspects of the renovation comply with durability and quality specifications.

Maximising the Life of Your Asset with BCRC Durability Consulting

The warehouse conversion is on track to be completed later this year. Once finished, it will stand as an exemplar of adaptive reuse, blending historical integrity with cutting-edge design. BCRC’s durability consulting will ensure that this luxury residence will not only be visually stunning but structurally sound for generations to come.

BCRC is a trusted leader in construction materials and durability consulting. We provide expert planning-stage durability consulting, asset service life predictions, and repair/remediation solutions for existing structures. Our unmatched expertise ensures long-lasting, resilient buildings.

This project highlights BCRC’s expertise with heritage structures, and we’re proud to be part of a team that’s creating a unique piece of Sydney’s architecture.

Category: Adaptive Reuse