Customer BHP Nickel West
Contractor Minprovise
Sector Mining
Products
- Fosroc Nitoprime Zincrich
- Fosroc Renderoc LA55
- Fosroc Renderoc HB40 Plus
- Fosroc Nitocote EP410
In Western Australia's Goldfields region, the mining town of Kambalda became deserted when the gold ran dry in the early 1900s. But the town 'struck gold' again in 1966 – this time with the discovery of high-grade nickel ore deposits nearby.
Nickel West’s concentrator plant in Kambalda processes nickel ore and nickel concentrate. Fosroc ANZ Account Manager for Greater Perth, Dennis Murray visited the plant to advise on concrete structural repairs.
Break out and rebuild
"A concrete column supporting the sag mill was in need of significant repairs. As is common with structures in splash zones, there was concrete contamination and re-bar damage," Dennis explains.
He recommended a break out and rebuild strategy using four Fosroc ANZ products:
- Fosroc Nitoprime Zincrich was applied to all exposed steel reinforcement before the new concrete pour. It is formulated for use with Fosroc Renderoc repair products. Touch dry after 15 to 45 minutes, this single component primer is an efficient anti-corrosion solution for steel reinforcement.
- Fosroc Renderoc LA55 and Fosroc Renderoc HB40 Plus enabled a complete structural repair. LA55 is a reinstatement mortar ideal for deep section repairs, while HB40 Plus handles angled patch repairs such as chamfers. Both deliver high strength and compatibility with existing concrete.
- The final step, Fosroc Nitocote EP410 was recommended to protect the completed structure from aggressive mining chemicals. It is easily applied by brush, roller or airless spray.
Expert execution
The specialist mining engineers at Minprovise were appointed to execute the repair strategy. The scope of works included the following steps.
Step 1: Break out all contaminated concrete.
Step 2: Cut out and replace the damaged re-bar. Coat all exposed steel with Nitoprime Zincrich to protect against corrosion.
Step 3: Wash down the remaining substrate. Rebuild and pre-soak the column structure with form board.
Step 4: Reinstate the concrete with two pours of Renderoc LA55, a high strength, free-flowing micro-concrete.
Step 5: Clean the area and remove any waste.
Step 6: Recreate the chamfers at the top of the column with Renderoc HB40 Plus.
Step 7: Strip the form board and cup grind the chamfers.
Step 8: A protective coating of Nitocote EP410 will be applied at the final stage of the project. This two pack epoxy coating is highly chemical resistant and ideal for mining environments.
Experienced Fosroc applicators
The Minprovise team has extensive experience using Fosroc products and a longstanding relationship with our specification team in Western Australia.
With 16 years' experience working with the mining industry, Dennis goes above and beyond to build long-term relationships.
"There are long distances involved in mining specifications in WA. But we make the effort to get on site and meet with asset managers, specifiers and applicators," he says. "We always make sure they have full confidence in the products and the application process."
Find out more
- Download our Concrete Repair Solutions brochure
- Scroll down to complete our enquiry form. Our expert team will be in touch to provide a tailored specification.
