Loading-Rack and Bund Concrete Rebuild
Spalled loading-rack deck and bund rebuilt and lined chemical-resistant so containment holds a spill instead of soaking into the slab.
The challenge
The concrete under a product loading rack takes a constant beating from spills, drips, and weather, and the surrounding bund is meant to catch and hold any release. Over time the deck and the bund walls spalled and cracked, and the product worked its way down into the open concrete. Once the slab is cracked and porous, the containment can no longer be trusted to hold a release, because anything that lands there soaks into the concrete and finds its way out instead of staying in the bund. Left that way, a routine spill becomes an environmental problem and the loading area is out of compliance.
Our approach
We start by chipping out the unsound, spalled concrete on the deck and the bund walls back to a solid base. Then we rebuild the lost sections with a repair mortar and reprofile the surface so it drains the way it should instead of pooling product. Once the substrate is sound and shaped, we line the deck and the bund with a chemical-resistant coating keyed to the product being loaded, sealing the cracks and tying the deck and walls together under one continuous barrier. The result is a loading area where a spill stays on the surface and inside the bund, where the crew can clean it up, instead of disappearing into the slab.
- Assess and confirm productWe walk the loading rack and bund to map the spalling, cracking, and porous areas, and confirm the product being loaded so the lining is keyed correctly.
- Chip out and prepWe break out the unsound concrete back to a solid base and prepare the deck and bund-wall surfaces so the mortar and lining bond.
- Rebuild and reprofileWe rebuild the spalled deck and bund walls with a repair mortar and reprofile the surface so it drains rather than pools.
- Seal and lineWe seal the cracks and line the deck and bund with a chemical-resistant coating as one continuous barrier over the rebuilt concrete.
- Return to serviceWe confirm the lined deck and bund are sound and hand the loading area back ready to hold a spill instead of letting it soak in.
The result
- Spalled deck and bund walls rebuilt to profile without tearing out and repouring the slab
- Cracks sealed and the surface reprofiled to drain instead of pooling product
- Deck and bund lined chemical-resistant as one continuous barrier keyed to the loaded product
- Containment that holds a release on the surface, delivered by factory-trained and factory-certified Belzona applicators
Belzona systems used
In the field
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