MJ Engineering Projects acted as superintendent and adviser on remedial works at a three-storey complex of thirty-two apartments in Vaucluse. The concrete-column and beam structure with brick infill displayed mortar fretting, water ingress through balconies, delaminated render, non-conforming brick balustrades and extensive concrete spalling caused by low cover. The client requested a cost-effective remedial works programme that would address these defects, extend service life and keep apartments fully occupied.
Project background
A facade and balcony survey confirmed that inadequate waterproofing membranes allowed persistent moisture to enter the concrete matrix, promoting chloride attack and reinforcement corrosion. Mortar joints had eroded in several brick panels, and many balcony balustrades failed modern safety requirements. MJ Engineering Projects documented these conditions and produced a remedial works specification that aligns with current National Construction Code provisions. A competitive tender process selected a contractor specialising in remedial works, and our team supervised quality, budget and sequencing. Weekly notices distributed through the strata manager kept residents informed of scaffold moves, balcony closures and noisy trades.
Scope of works
- Repair concrete spalling
- Remove and replace balcony balustrades
- Tile balcony slabs after waterproofing
- Apply render to slab edges
- Remove and replace podium-level balustrades
- Apply high-build acrylic coating to concrete elements
- Apply low-sheen acrylic paint to brickwork
- Repaint timber and metalwork
- Remove and replace garage doors
- Repair construction joints
- Apply the Vandex waterproofing system to selected areas
- Apply sealant at joints and penetrations
Key challenges and solutions
Balcony waterproofing
Leaking balconies were the primary water source inside the building envelope. Works involed removal of existing finishes, installed a sheet membrane and retiled with slip-resistant porcelain set to compliant falls.
Concrete spalling
Low cover and chloride contamination caused widespread spalling. Damaged concrete was broken back to sound material, steel was cleaned and passivated, and polymer-modified repair mortar reinstated cover. A high-build acrylic coating now protects repaired areas and adjoining concrete.
Non-conforming balustrades
Brick balustrades no longer satisfied current impact-load requirements. They were demolished and replaced with powder-coated aluminium systems on the balconies, while stainless-steel balustrades were installed at podium level.
Brickwork deterioration
Fretted mortar joints reduced weather resistance. Masonry teams repointed the affected panels with a suitable mortar compatible with existing bricks, restoring structural integrity and appearance.
Garage door upgrade
Original tilt doors were corroded and poorly sealed. New aluminium roller doors with integrated weather strips were fitted, improving security and reducing wind-driven rain ingress to the parking level.
Conclusion
The Vaucluse remedial works programme rectified balcony waterproofing, concrete spalling and balustrade non-compliance without exceeding budget or schedule. Balconies are now watertight, repaired concrete is protected by high-build coating, brickwork mortar is sound and new balustrades comply with safety standards. Fresh coatings across concrete and brick surfaces provide uniform appearance and long-term weather resistance, while upgraded garage doors improve amenity.
MJ Engineering Projects draws on more than twenty-five years of remedial works experience across Sydney. For additional case studies visit our blog or contact the remedial works team to discuss balcony membranes, concrete repair or façade maintenance for your strata property.
