Mining Infrastructure (Form, Reo, Pour)

FSC has been involved in the delivery of numerous mine construction projects ranging from supply of skilled labour for FIFO projects to delivering FRP contract scopes.
FSC has been involved in the delivery, including, but is not limited to the following mine processing structures:

• Crushers
• Plant conveyor systems
• Train load-out facilities
• Bore mills
• Thickeners
• Rom walls
• Scavenger feed tanks
• Transformer and switch rooms

Precast Supply and Installation

Our expertise includes, but is not limited to:

• Supply and install precast concrete structures
• Supply and install precast concrete tilt up panels

Services and Communications Infrastructure

FSC ION Groups’ multi-skilled personnel enables us to provide not only quality electrical services, but also a range of civil works in all aspects of day-to-day operations. Utilising these resources we can provide a range of services from basic earthing systems, to underground pit and pipe, valve installations, draining, and detailed excavation. Our team is well equipped to validate concepts and scope projects to provide cost-effective and efficient solutions for our clients.

Core competencies within the civil sector include:

• Earthing systems

• Underground pit and pipe

• Cable management

• Conduit supply and installation

FSC ION Group provides ongoing support for the installation and maintenance of communication infrastructure within the mining, rail, communications and industrial sectors. We can also provide experienced expert labour personnel to support client requirements.

Mining, rail and general industrial:

• Rail network asset protection system installation and maintenance

• Cable installation and removal

National Broadband Network:

• Mark up plans of proposed cross chamber

• Connection unit sites for design teams

• Rod, roping and proving of existing ducts

• Cleaning out pits and blocked ducts

• Red line drawings of proposed builds to support NBN infrastructure

• Non penetrating excavations

FSC ION Group is well positioned to develop and manage renewable energy projects and assets for clients. Our qualified and professional tradespeople are capable of renewable energy projects both large and small for all commercial and industrial applications.

Core competencies within the renewable energy sector include:

• Installation of solar inverters, arrays and location cases

• LV switch gear installation

• Cable support systems

• Control panels

• Power system assessment

• Installation of infrastructure and equipment

FSC ION Group provides commercial and industrial services support for local and large-scale commercial and industrial projects.

Commercial & industrial services include:

• Compliance testing & tag (AS/NZS 3760)

• General electrical inspection maintenance

• Lighting and power upgrades

• Safety switch installation and testing

• Main Distribution and Switch Board design & build / installation / replacement

• Temporary site power installations

• Residual current device testing

• Emergency lighting testing and repairs

• LV distribution systems

Earthworks

• Bulk earthworks

• Detailed earthworks

• Backfill & compaction

• Spillways

• Gabion basket construction

Remedial Work to Concrete Structures

Concrete Crack Injection/Repair

Injections are a good choice because they help avoid expensive costs of structural repairs and reduce operational downtime. They can be used for all types of leak-sealing applications in concrete, masonry and natural stone structures and are able to form a new permanent watertight seal.

Products – FSC has experience using the following products:

• • Sikadur Crack Injection System
• • ARDEX Concrete Crack Repair
• • Permatech Crack Injection System – Capsules

CONCRETE CANCER REPAIRS

FSC utilise two main techniques to repair structures affected by concrete cancer,

1. Concrete cancer caused by carbonation

Polymer modified repair system – This is a treatment used for concrete cancer caused by inadequate concrete cover over the reinforcement. This leads to corrosion of embedded steel reinforcements, also known as concrete carbonation. All the spalled and cracked concrete is removed to show the steel within, which is then cleaned and freed from corrosion using different techniques.

Once the reinforcement has been restored or replaced, it is then painted with a polymer emulsion bonding agent, such as Fosroc Nitobond HAR. It is then encased with concrete, ensuring cover is maintained according to specified recommendations.

As an extra level of protection, the finished surface of the repair can be treated with a primer such as Fosroc Nitoprime DG, followed by an anti-carbonation protective coating such as, Fosroc Dekguard Elastic, which provide ultimate protection against the ingress of carbon dioxide, oxygen, and water, whilst allowing damp substrates to breathe without blistering.

2. Concrete cancer caused by chlorides

Concrete repair with electrochemical treatment – This treatment is used for concrete cancer caused by structures exposed to marine environments or water spray. Concrete contains an alkaline environment that provides some protection against corrosion. The introduction of chloride and sulfate ions, present in marine environments, will weaken this protection as the water soaks into the concrete, and once the protection is breached, then the corrosion process begins to work on the steel itself.

This repair starts with the removal of chloride-contaminated concrete.
After the defective concrete is removed, the rebar is made corrosion-resistant by the application of protective coatings. It is then encased with concrete, ensuring cover is maintained according to specified recommendations. To reinforce the protection from chloride contamination, a surface treatment in the form of cathodic system can be applied.

Crack Stitching

FSC utilise two main techniques to improve concrete crack repair.

1. Crack stitching using rebar and epoxy

Holes are drilled at 45O angle (or similar) to the crack line and should start and finish at least 200mm from the centre line of the crack but on opposite faces of the wall/structure. Once the preparation is complete and free of dust, reinforcement is placed in the drilled hole and the hole is filled with injectable adhesive such as Hilti HIT-RE 500 V3 EPOXY ANCHOR or similar. Once installed, the reinforcement and epoxy permanently bonds both sides of the crack together

2. Carbon-fibre crack bridging stitch

FSC utilise the Rhino Concrete Crack Lock (CCL), supplied by Ardex which was developed to improve concrete crack repair.

The CCL is made from carbon-fibre and resembles a dog bone with a slender centre cord and two larger circular ends. The CCL is installed by making a single blade-width cut across the crack and drilling two holes along the cut at the appropriate locations. Once the preparation is complete and free of dust, it is filled with an approved ARDEX Epoxy Paste such as ARDEX RA 88 (for vertical applications) or ARDEX RA 142, ARDEX RA 144 or ARDEX RA 146 (for horizontal applications) and the CCL is inserted. Once installed, the CCL permanently bonds both sides of the crack together

Protective Coatings

There are many concrete protective coatings on the market for a wide variety of applications. These include products to increase the durability of the concrete by preventing water ingress and products to seal and accommodate surface cracks.

Products – FSC has experience using the following products:

• XYPEX CONCENTRATE

• XYPEX MODIFIED

• Vandex Concrete Grey

Joint Sealing

Only correctly specified and professionally applied high quality joint sealants will manage to keep your building or structure sustainably tight during its entire lifespan.
FSC has experience with a range of joint sealing options for new and existing joints, which include:

• SILICONE SEALING – for non-porous substrates like metal and glass

• POLYURETHANE SEALING – for porous substrates like concrete, bricks and masonry

• SILANE-MODIFIED POLYMER SEALING – where a wide adhesion range is required like for installations of doors/window

• SIKADUR-COMBIFLEX – allows variable and high levels of movement in one or more directions, whilst maintaining a watertight seal

• ELASTOMERIC EXPANSION JOINT SEALING – used where there is a lot of movement between structures such as bridges & approach slabs

• WATERSTOP or WATERBAR – a centrally placed seal between joints within concrete to prevent water from passing through the joints

• HYDROPHILIC PROFILES AND SEALANTS like SIKASWELL – waterstop which is applied to a construction joint and can swell when concrete is poured against it. They are used in watertight concrete structures for systematic sealing of construction joints.