Safeguarding Infrastructure: Deep Well ICCP System for Dubbo Bridge

BCRC-Safeguarding-Infrastructure-Dubbo-bridge

Deep Well Impressed Current Cathodic Protection System for Steel Piles of a New Bridge Over a River

The New Dubbo Bridge project represents a major step forward in infrastructure development, aiming to enhance connectivity across the Macquarie River in New South Wales. This 662.59-meter-long bridge, supported by 19 piers extending up to 60 meters underground, relies on tubular steel piles as its foundation.

Safeguarding Infrastructure

Geotechnical surveys revealed a significant corrosion risk in the surrounding soil, leading to the innovative implementation of a Deep Well Impressed Current Cathodic Protection (ICCP) system.

BCRC’s Innovative Approach

In a groundbreaking move, Saeed Ali, Senior Materials and Durability Engineer at BCRC, and Frank Papworth, Director at BCRC, collaborated to design a comprehensive ICCP system to protect the bridge’s steel piles from soil-induced corrosion.

Segmenting the bridge into seven zones, each zone was carefully analyzed based on soil resistivity and pile surface area ratios. SES CDEGS software played a key role in modelling ground-bed resistance and ground potential rise, ensuring a precise and effective design.

The project’s standout feature is the use of deep well anodes strategically placed under the bridge. This not only maximized efficiency but also minimized the need for additional installation space, thereby reducing project costs.

Environmental considerations were also addressed with cased and sealed anode systems, ensuring the sustainability of the design.

Safety and Sustainability at the Core

Step and touch voltage calculations were meticulously conducted to guarantee operational safety. By incorporating industry best practices and a focus on durability, this ICCP system sets a new benchmark in sustainable engineering. It highlights how innovative approaches can ensure critical infrastructure’s longevity and structural integrity.

A Case Study in Excellence

This project is a valuable case study demonstrating the effective application of cathodic protection techniques in large-scale infrastructure projects. It offers methodologies and insights that can be replicated globally, contributing to advancing sustainable engineering practices.

Top Image credit: Construction Review Online

View or download the full paper by Saeed Ali and Frank Papworth for a detailed look into this project’s design, implementation, and methodologies.

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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.

February 10, 2025February 19, 2025

BCRC In Western Australia

Maximise the Life of Your Asset with BCRC

Founded in 2005, BCRC is a technical leader in durability design, structural inspection and repair consulting.

With operations nationally and substantial expertise in Western Australia, our services span the following industries:

Civil Infrastructure, Resources and Mining, Power and Energy, Oil and Gas, Water and Waste-Water, Bridges, Marine Infrastructure, Tunnels, Buildings and Facilities.

BCRC specialists understand the unique challenges asset owners face and what it takes to design and build infrastructure that exceeds its expected operational life with minimal maintenance requirements.

Our multidisciplinary consultants have experience in all materials and applications. Whether it’s concrete, timber, steel, brickwork, corrosion-protective coatings or waterproofing, we offer a range of services to prevent deterioration over the lifetime of a project and help mitigate potential cost overruns due to unforeseen repairs or upgrades.

The BCRC team offers durability design and remedial design, durability plans review, structural investigations, non-destructive and destructive testing, materials selection, corrosion assessments, cathodic protection, repair specification, service life modelling, remedial project management, expert witness and dispute resolution services.

You can reach out to us for any advice on durability.

Contact: Egor Volkov perth@bcrc.com.au 949-951 Wellington Street West Perth, WA 6005

BCRC durability consultant checking with advance ground penetration radar at Sydney Harbour Wharf Project image

Inspection Services

Durability Consulting

Remedial Consulting

Expert Witness Services

BCRC durability consultant discussing about building by viewing in a chart

Project Management

SOME BCRC WESTERN AUSTRALIA PROJECTS

Hamersley Iron

Paddington Gold Mine

Lion Ore Plant

Fortescue Metals Group (FMG) Expansion Project

Ravensthorpe Mine

Boddington Gold Mine

Tropicana Gold Mine

Karara Iron Ore

Dampier Bulk Liquids Berth

Busselton Wharf Aquarium

Narrows Rail Bridge Perth

Kalgoorlie Reservoir

Perth Metro Tunnel

Welligton Street Underground Station

Esplanade Underground Station

Jervoise Bay Wharves

Esperance Port Access Corridor

Esperance Rail Tunnel

Shenton Avenue Interchange, Perth

Merriden Bypass

Twilight Bridge, Esperance

Mt Henry Bridge Duplication, Perth

Orong Road Interchange, Perth

Causeway Bridge, Perth

John Street Bridge, Esperance

Perth Law Courts

Fremantle Port Wharf Deck

Karrinyup Shopping Centre

Leonora Crane Shed

Harbour Town Perth

Cape Lambert Power Station

Cockburn (Coogee Beach) Life-Saving Club

Ocean Keys Shopping Centre (Clarkson)

Century City, Perth

AMP Building, Perth

Parmelia House Perth

ANZ Bank Perth

Carillon City, Perth

Frank Papworth – Durability Consultancy

Frank Papworth is a globally recognised Civil Engineer and Concrete Durability Consultant with over 35 years of experience in the industry. His contributions to concrete durability, inspection, and repair have established him as a leading figure in the field, earning him key leadership roles and prestigious awards.

He has Chaired CIA’s durability committee, Chaired fib COM8 on durability, and Won the Malhotra durability prize.

Egor Volkov – Senior Engineer

Egor’s experience in assessing steel, reinforced concrete, and timber structures, especially for transport, marine, and local government clients, is a valuable skill that further enhances BCRC WA’s expertise.

His experience in remedial design specification and project management enhances our ability to support clients who are committed to extending the service life of their assets.

Herman Jong – Durability Consultant

Herman has over 30 years of experience in construction materials technology in Australia and internationally. Herman has over 10 years of professional engineering experience in Australian inspection and assessment consulting in the building, transport, water, mining and marine infrastructure sectors.

Herman has strong technical consulting skills and in-depth knowledge of structure condition and durability assessments of reinforced concrete/steel structures.

Adam Papworth – NDT Technician

Adam has over fifteen years of non‐destructive testing experience in the field and laboratory.

Adam is experienced in assessing the in‐situ condition of reinforced concrete for both new and existing structures.

Adam is experienced in state‐of‐the‐art techniques to monitor corrosion in reinforced concrete structures and material testing, including non‐destructive techniques.

BCRC Western Australia -Perth

Contact Egor Volkov

perth@bcrc.com.au

949-951 Wellington Street West Perth, WA 6005

At BCRC, you can access a dedicated technical expert aligned with your durability design, remedial management, and construction project requirements.

Whether it’s the design of new structures, the inspection and restoration of older ones, or resolving disputes that may arise, the BCRC team are available to assist at every stage.

November 26, 2024December 3, 2024

Durability and Service Life Modelling for Cobham Bridge

BCRC’s Durability and Service Life Modelling

Understanding design life is essential in building sustainable, safe, and cost-effective structures. By carefully planning for and maintaining a structure’s design life, industries can achieve long-term savings, reduce environmental impact, and ensure safety for generations.

In 2022, BCRC Durability Consultants partnered with Fulton Hogan to extend the design life of the super tee beams on the Cobham Bridge, part of the project to build a section of the Hamilton Ring Road in New Zealand. The project aimed to extend the service life of the beams through a specialised protective coating.

This project highlights BCRC’s approach to durability and service life modelling to safeguard long-term resilience in bridge structures.

BCRC’s Design Life Assessment

During the design life assessment, BCRC evaluated the concrete cover across the Cobham Bridge beams. To meet the required design life of 100 years, BCRC recommended a high-performance coating system—Duralkote 700—that ensures protection against carbonation and environmental factors, which is critical for achieving the desired design life.

Solution for Enhanced Durability and Extended Design Life

Testing of the coating was conducted to verify its performance, which surpassed the minimum required specification by far.

This was determined to be sufficient to achieve a minimum design life of 80 years for the super tees after coating application. Together with a period of 20 years plus propagation as proposed in NZS 3101 Part 2 Clause C3.12.1, this provides the intended 100-year design life of the structure.

Application Process and Quality Assurance in Service Life Modelling

To ensure durability and design life adherence, BCRC developed a rigorous Inspection and Test Plan (ITP) to monitor coating application quality. BCRC specialists went on-site to inspect the initial phase of the coating application and verify its adherence to the ITP.

The whole process was rigorously verified against the NZ standards and industry-accepted best practices.

Achieving the 100-Year Design Life with Durability and Service Life Modelling

After extensive testing, BCRC’s approach to design life modelling on the Cobham Bridge demonstrated the Duralkote 700 coating’s ability to withstand carbonation. This, combined with the concrete’s protective properties, aligns with New Zealand Standard NZS 3101, ensuring corrosion resistance and supporting the projected 100-year design life.

BCRC’s durability and service life modelling strategies, combined with expert application and quality assurance, have fortified the Cobham Bridge’s super tee beams for long-term resilience. This project underscores the value of advanced design life assessment and maintenance in achieving robust, enduring infrastructures.

Category: Bridges