MJ Engineering Projects managed remedial works for a three-level concrete-framed building with brick infill and balconies to sixty-four apartments in Sutherland. The structure had visual indications of severe concrete spalling caused by low cover, water penetration through a ground-floor podium deck into the car park, and texture coating delamination that risked debris falling onto traffic below.
Project background
Site inspections found two root causes. First, the balcony and podium membranes had failed, allowing water to reach reinforcement and trigger corrosion. Second, slab-edge surfaces were not correctly prepared before the original texture coating was applied, leading to widespread debonding. MJ Engineering Projects documented these conditions, produced a remedial works specification aligned with current National Construction Code clauses and ran a selective tender to appoint a specialist contractor. As superintendent we verified workmanship and kept residents informed of scaffold moves, balcony closures and noisy tasks.
Scope of works
- Repair concrete spalling on façade elements
- Remove and replace delaminated texture coating
- Repaint rust-affected bar chairs on balcony soffits
- Repaint previously coated façade and soffit elements
- Waterproof podium deck areas leaking into the car park
Key challenges and solutions
Concrete cancer on slab edges
Spalling along slab fronts threatened structural durability. Loose concrete was broken back to sound material, corroded steel was cleaned and passivated, and polymer-modified repair mortar reinstated cover. Repairs were feather-edged to blend with adjoining surfaces before new coating was applied.
Debonded texture coating
Unprepared slab edges caused extensive peeling. All loose finish was mechanically removed, surfaces were grit-blasted and a bonding primer applied. A flexible texture coating system was then rolled and trowelled to reinstate uniform appearance and protect against weathering.
Podium deck waterproofing
Water ingress from the ground-floor deck reached the car-park ceiling below. The existing topping was removed, a sheet membrane was installed with upturns at balustrade posts and penetrations, and retiled with falls to new strip drains. Water tests confirmed watertightness before the deck reopened.
Balustrade interface
Balustrade posts penetrated the slab and posed a leakage risk. Adequate waterproofing detailing was carried out around each base plate after membrane installation, directing water away from the fixings and safeguarding the new waterproof layer.
Conclusion
The Sutherland remedial works programme restored structural integrity, waterproofing and façade presentation without relocating occupants. Concrete spalling is repaired, balconies and podium decks are watertight, texture coating is secure, and repainted elements give the building a fresh, durable finish. The owner now has a resilient asset with reduced maintenance risk and improved street appeal.
For additional remedial works case studies visit our blog or contact the remedial works team for advice on balcony membranes, concrete repairs and façade maintenance.
