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BCRC at the Cutting Edge of Durability and Inspection Technology

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At BCRC, we pride ourselves on leading from the front—whether it’s designing for durability, conducting structural inspections, or delivering best-practice repair advice. Our work is underpinned by deep technical knowledge and a commitment to staying at the forefront of global developments in concrete technology.

That commitment was recently on display when Dr Jessie Ratcliffe, who leads our Victorian team and holds a PhD in Materials Engineering, travelled to Europe to participate in two major industry events.

International Conference on Concrete Repair, Durability and Technology

Concrete Solutions 2025 | Lisbon, Portugal | 16–18 June 2025

Dr Ratcliffe attended the 9th International Conference on Concrete Repair, Durability and Technology, hosted by LNEC in Lisbon. This leading global event brought together engineers, researchers and asset owners from around the world to share the latest in research, product development and field applications across:

  • Concrete durability and admixture technology
  • Electrochemical repair and NDT diagnostics
  • Repair of fire-damaged structures and heritage conservation
  • Structural health monitoring and surface protection
  • Sustainable repair technologies and service life modelling

The event provided a valuable opportunity to explore cutting-edge techniques for extending the service life of infrastructure, central to BCRC’s mission of helping clients reduce lifecycle costs through better design and maintenance.

During the conference, Dr Ratcliffe also caught up with industry colleagues, including Nick Critchley from Marine & Civil Maintenance, whose team specialises in repairs and chloride extraction. Collaborations like these strengthen our ability to deliver real-world, results-focused solutions.

 

Advanced Training in Non-Destructive Testing and Evaluation

NDT6E-CE Course | Berlin, Germany | 25 June – 1 July 2025

Following the conference, Dr Ratcliffe attended the Non-destructive Testing and Evaluation in Civil Engineering course at BAM—the Federal Institute for Materials Research and Testing in Berlin.

The intensive five-day program provided hands-on experience with state-of-the-art NDT equipment and techniques used to evaluate the condition of civil structures. Dr Ratcliffe is the third person at BCRC to have completed BAM training.

This training reinforces BCRC’s leadership in the use of NDT to assess concrete performance, structural health and long-term durability—crucial for managing ageing infrastructure with minimal disruption and maximum precision.

Engineering Expertise Meets Global Innovation

BCRC continues to invest in the professional development of our team and maintains close links with global leaders in research and practice. Whether we’re applying advanced diagnostics or designing for 100-year performance, we bring the latest thinking to every project.

For expert advice on durability and structural assessment, contact BCRC Durability Consultants today.

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Assessing Structural Integrity: Pitt Street Hotel

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Assessing Structural Integrity: The 372-382A Pitt Street Hotel Redevelopment

In the heart of Sydney, redevelopment projects blend heritage preservation with modern innovation. Well Smart Group engaged BCRC Durability Consultants to assess the structural conditions at 372-382A Pitt Street, an ambitious project involving significant redevelopment while retaining a historic façade.

Project Scope and Purpose

The redevelopment includes the construction of a new 60-storey hotel tower with a 4-storey mixed-use podium. BCRC’s inspection focused on the structural integrity of the retained front 6 metres of the existing buildings, including the façade. Comprehensive site assessments were conducted using a combination of advanced non-destructive (NDT) and destructive testing methods.

Key Inspection Methods

BCRC’s thorough assessment employed:

  1. Visual and thermal imaging inspections
  2. Ground Penetrating Radar (GPR) for concrete cover and reinforcement detection
  3. Core sampling for compressive strength and chemical analyses
  4. Masonry tests, including compressive strength, mortar scratch tests, and bond wrench tests
  5. Foundation assessments through visual inspection and coring

Enhanced Structural Condition Assessment and Targeted Remediation Measures

Façade and Masonry Walls
The façade demonstrates overall structural soundness, constructed using traditional staggered brick bonding. While the absence of modern cavity ties presents an opportunity for moisture control improvements, the structure remains fundamentally intact.
To ensure optimal long-term performance, the following enhancements are being implemented:

·       Façade Upgrades: Immediate repair works include sealing of cracks, selective brick replacement, and the application of advanced waterproofing solutions to prevent moisture ingress.

·       Masonry Wall Rehabilitation: Despite adequate compressive strength, areas exhibiting cracked bricks and deteriorated mortar joints are undergoing repointing and localised brick replacement, reinforcing both strength and appearance.

Concrete Slabs
The concrete slabs exhibit adequate structural capacity, indicating sound original construction.
In order to maximise service life and mitigate isolated issues, the following steps are underway:

·       Contamination Control: Localised remediation is being conducted on the affected unit to address potential contamination.

·       Corrosion Prevention: With chloride and carbonation levels found to be low, corrosion risk is currently minimal; however, monitoring systems are being introduced to ensure early detection of any future changes.

·       Structural Reinforcement Planning: A load-bearing capacity assessment has been conducted to identify potential issues and rectify them.

Foundations
The existing continuous strip footings beneath the retained sections were found to be stable and performing well. Minor cracking has been noted and will be monitored as part of ongoing maintenance, ensuring early intervention if required.

Ongoing Recommendations and Durability Strategy
To support continued structural integrity and long-term resilience, BCRC has developed a proactive remediation and maintenance strategy that includes:

·       Prompt façade and masonry repairs to improve moisture resistance and visual integrity.

·       Localised concrete remediation in the affected unit to eliminate contamination risks.

·       Continued condition monitoring across all critical structural elements throughout the redevelopment phase, ensuring adaptive management of the asset’s condition.

Future Outlook

By proactively addressing these recommendations, the 372- 382A Pitt Street redevelopment will successfully integrate historical architecture with contemporary construction practices. Ensuring structural durability remains paramount for the success of this iconic project.

For expert advice on durability and structural assessment, contact BCRC Durability Consultants today.

Assessing Structural Integrity

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Safeguarding a Sydney Icon: Darling Harbour Structural Investigation

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Safeguarding a Sydney Icon: Harbourside Promenade Structural Investigation

Darling Harbour, one of Sydney’s iconic locations, is undergoing transformation and modernisation. As part of this exciting journey, Mirvac engaged BCRC Durability Consultants to perform an extensive investigation of the Harbourside Promenade, ensuring the safety and longevity of this prominent waterfront structure.

Project Background – Darling Harbour Promenade

The Harbourside Promenade structure, constructed in the late 1980s, comprises steel piles, headstocks, edge beams, precast planks, and cast-in-situ reinforced slabs. Following the demolition of an existing arcade, Mirvac sought BCRC’s expertise to assess structural conditions and durability aspects critical for future redevelopment.

BCRC’s Comprehensive Inspection Approach

Our detailed structural assessment utilised cutting-edge methods:

  1. Visual and Drummy Surveys: Identifying spalled concrete, corrosion, and structural
  2. Ground Penetrating Radar (GPR): Measuring concrete cover and reinforcing steel
  3. Half-Cell Potential Testing: Assessing the likelihood of active
  4. Concrete Core Sampling and Laboratory Testing: Evaluating compressive strength, carbonation depth, and chloride ion ingress.
  5. Corrosion Assessment of Steel Piles: Including Cathodic Protection

Major Findings and Remediation Measures

To enhance the long-term performance and structural integrity of the facility, several targeted remedial actions were successfully designed and implemented:

  1. Concrete Rehabilitation: Deteriorated concrete areas, particularly those exhibiting spalling and exposed reinforcement at critical zones such as headstocks and slab edges, were comprehensively addressed. Damaged sections were carefully removed, cleaned, and repaired using durable repair mortars, restoring both structural function and protective cover.
  2. Chloride Mitigation: In response to localised elevated chloride concentrations indicating potential durability concerns, especially in areas with reduced projected service life, a proactive approach was taken. Surface-applied corrosion inhibitors and chloride-resistant repair systems were introduced to extend the life expectancy of affected zones and mitigate future corrosion risks.
  3. Steel Pile Protection: Significant progress was made in addressing steel pile corrosion, particularly at pile-headstock interfaces. Surface corrosion was removed, and protective coatings were applied. The design also incorporated provisions for long-term durability, including allowance for the future installation of cathodic protection systems where deemed necessary.
  4. Seawall Stabilisation and Structural Review: Observed movement and cracking in sections of the seawall prompted a detailed structural engineering review. Remedial strengthening works were implemented, which included crack injection, joint reformation, and localised structural realignment, ensuring improved stability and reduced risk of further movement.

A Proactive Future

The Harbourside Promenade is poised to remain a cherished Sydney landmark through meticulous assessment and recommended interventions.

BCRC Durability Consultants remain committed to delivering solutions that ensure structural integrity and long-term durability for generations to come.

To explore durable structural solutions or discuss similar projects, reach out to BCRC today.

Structural Investigation Darling Harbour Promenade

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Ensuring Structural Integrity: Narrabri Bridge Inspection Project

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Ensuring Structural Integrity: Narrabri Bridge Inspection Project

Bridges form a vital part of our transport network, and maintaining their structural health is crucial for public safety and infrastructure longevity. BCRC Durability Consultants recently conducted an extensive inspection on the Narrabri Bridge, located on the Newell Highway (HW17) in Narrabri, NSW, at the request of Transport for NSW (TfNSW).

Here’s an insight into the project, its findings, and recommended actions.

Project Overview – Narribri Bridge

The Narrabri Bridge comprises multiple sections constructed at different times, with our investigation focused on the western end completed in 1977. Now 47 years old, this reinforced concrete beam bridge spans Narrabri Creek, supported by prestressed girders on eight piers.

BCRC’s inspections targeted 4No. piers, utilising advanced non-destructive testing (NDT) techniques to identify potential defects without causing harm to the structure.

Advanced Inspection Techniques

To ensure a thorough understanding of the bridge’s condition, our team employed multiple NDT methods, including:

  1. Ground-Penetrating Radar (GPR): To detect reinforcement positions and internal
  2. Ultrasonic Pulse Echo (UPE) and Ultrasonic Pulse Velocity (UPV): To identify voids and cracks and assess concrete quality.
  3. Impact Echo (IE): To detect flaws or defects within the
  4. Rebound Hammer Testing: To evaluate surface hardness and estimate compressive

Structural Assessment Summary and Remediation Plan

The detailed structural investigation of 3No. Piers confirmed their excellent condition, with no significant internal defects or signs of concrete deterioration. These piers demonstrate reliable material performance and structural soundness, affirming the effectiveness of the original construction.

Targeted Remediation Strategy for the Fourth Pier Based on Advanced Diagnostic Techniques

The fourth pier was subject to a comprehensive assessment utilising both visual inspections and advanced non-destructive testing (NDT) methodologies. This integrated investigative approach proved highly effective in guiding a focused and informed remediation plan:

  1. Surface Condition Assessment and Treatment
    Visual inspections identified surface-level changes at the headstock and corbel faces, which provided early indicators for stress-related behaviour. These observations allowed for the timely application of specialised crack sealing techniques, effectively mitigating any risk of moisture ingress and maintaining the element’s long-term durability.
  2. Advanced Internal Diagnostics and Restoration
    NDT methods—including Ultrasonic Pulse Echo (UPE) and Impact Echo (IE)—were instrumental in detecting subtle internal variations near the girder connection zones. These findings informed the decision to conduct targeted core sampling, which validated the presence of isolated voids. As a result, precision pressure grouting (void injection) is being applied to restore internal continuity and enhance structural soundness.
  3. Material Performance Profiling and Strength Optimisation
    The core extraction process not only validated internal observations but also provided valuable compressive strength data. This enabled a tailored strength enhancement strategy, ensuring the pier’s capacity is brought in line with adjacent structures. The findings also support refinement of design assumptions for future asset maintenance and upgrades.

Proactive Structural Health Monitoring
Based on the detailed diagnostic outcomes, a long-term monitoring regime has been established. This includes scheduled inspections, condition tracking, and trend analysis, allowing for proactive maintenance and adaptive management of the pier’s condition over time.

Monitoring Structural Integrity for the Narribri Bridge

Through our comprehensive inspections and detailed analysis, we aim to help Transport for NSW ensure the continued safety and durability of the Narrabri Bridge. Regular monitoring, timely interventions, and advanced NDT methods will play critical roles in maintaining the structure’s longevity.

Get in touch with the BCRC team to learn more about bridge durability solutions or discuss similar projects.

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