Comprehensive solutions tailored to meet your engineering needs

• Concrete Repair

Well-designed and properly constructed reinforced concrete structures can have long service lives. But they are not immune to damage because of deterioration over time, foundation movement, chemical or environmental damage, and, on rare occasions, structural damage (e.g., due to earthquakes). The damage is often seen as cracking of the concrete or corrosion of the reinforcing steel, which then causes concrete spalling. Concrete maintenance and early repair of damage are essential to ensure a structure’s long-term structural integrity.

Concrete repairs are, in general, straightforward, but complications due to difficult access, heat, cold, moisture, water seepage, can often occur. Also, concrete repair can be costly, so getting it right the first time is important. Sometimes the repairs are ineffective or fail, and this is usually caused by incorrect material selection and application.

Product selection is key, and this is where Ironstone Civil and our supply partners experience is essential. Nothing is more important than having experienced applicators who understand the importance of working to strict quality procedures.

• Structural relining of tunnels and culverts

Many of today’s culvert and tunnel infrastructure are in need of maintenance or replacement. Replacement is often impractical because it can cause unacceptable downtime or is cost-prohibitive, so structural relining options are increasingly being considered.

Ironstone Civil provides structural relining of tunnels and culverts using cementitious or chemical grouts. For larger diameter culverts of 1.8m diameter and above, we use Geopolymer reinforced grouts that are centrifugally sprayed onto the culvert to create a new culvert within a culvert. Once the Geopolymer sets, the new culvert structurally replaces the old host culvert. The reinforced grout is typically applied at a thickness of around 50mm* thus, hydraulic capacity loss is minimised compared with some other solutions.

* Design thickness will depend on many variables, and engineering designs are recommended for all structural replacement.

• Water stopping and waterproofing

Water leakage can cause significant damage to structures and reduce their economic life. In addition, water leakage can damage stock or seriously reduce the utility of a structure.

Where water is expected to be present, structures are usually designed and constructed to have watertight integrity, that is, to prevent water egress from containment structures or water ingress into structures.

Despite these precautions during construction, unplanned water ingress and egress can still occur. Changing environmental conditions, faulty or inadequate design or construction, damage or simply deterioration of the structure over time can all be contributing factors. In the instance where an asset is ageing, certain materials may have exceeded their lifespans. Stopping water ingress can be very challenging because it is often impossible to know with precision what you are dealing with. This is where know-how and experience come together to solve water stopping problems.

Ironstone Civil, through our supplier partners, has a range of solutions available to stop water leaks in large buildings, large infrastructure and tunnels. Whether it be large water ingress or minor leaks, Ironstone Civil has the experience to solve the problem.

• Concrete crack injection

Crack injection is a precise remediation technique used to restore structural integrity and prevent further deterioration in concrete elements. Using epoxy or polyurethane resins, Ironstone Civil injects cracks under controlled pressure to bond separated concrete, fill voids and stop water ingress. Proper assessment and material selection are critical to ensuring a durable, long-term repair.

• Joint sealant repairs

Joint sealants play a key role in managing movement, preventing moisture ingress and protecting concrete structures from deterioration. Over time, sealants can fail due to ageing, UV exposure, chemical attack or mechanical wear. Ironstone Civil provides joint sealant removal and reinstatement using high-performance products suited to the environment and movement requirements, ensuring continued protection and serviceability.

• HDPE liner repair

HDPE liners can become damaged through impact, wear, UV exposure or installation defects, compromising containment performance. Ironstone Civil carries out specialist repair and welding of HDPE liners to restore impermeability and maintain environmental and structural protection. All repairs are completed in accordance with strict quality procedures to ensure long-term liner integrity.