Client: Owners Corporation
Sector: Industrial Warehouses
Location: Alexandria, Sydney
Project Value: $250,000
Background: Faced with a heritage facade suffering from deterioration and a leaky roof, the owners confronted critical issues impacting historical integrity, structure and insurance premiums.
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The restoration of the brick heritage facade and roof replacement above a busy council footpath needed rigorous safety measures and a meticulous permit process to protect public well-being and preserve historical value.
The project also demanded innovative weatherproofing techniques to maintain weather tightness and interior protection during the unpredictable roof installation phase.
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We fortified public safety and ensured continuous weatherproofing by integrating overhead protection, securing power lines, and adopting a phased approach to roof replacement.
Overhead Protection:A robust steel gantry provided essential overhead protection, ensuring public safety beneath the worksite.
Power Line Safety:We equipped power lines with tiger tails for heightened electrical safety around the construction zone.
Staged Roof Replacement:Delaying the inevitable repair will always result in more damage that would require more extensive and costly interventions.
Eroded mortar had caused bricks to loosen, some falling onto the public footpath below, presenting immediate safety hazards.
The building's age meant it was constructed without modern movement joints, which led to cracks from thermal expansion and contraction.
The bricks' vulnerability to water only accelerated the degradation. To address this, we applied a clear sealer, providing water protection while preserving the bricks' original heritage aesthetic.
Brick Repointing to Heritage Council of NSW Guidelines
Brick Crack Stitching to reinfoce cracks in brickwork
Clear Brick Sealer to form a barrier that repels water
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Mortar RemovalOld, damaged mortar was delicately removed from between the bricks to prepare for the new mortar application.
Mortar MatchingWe took extra care to match the new mortarto the existing color and texture, thereby ensuring that the wall's historicalappearance was preserved.
ApplicationThe new mortar was carefully applied to thejoints, filling them thoroughly to restore stability to the bricks.
FINISHING TOUCHESEach joint was then neatly finished tomatch the wall's original style, a process known as 'tooling', which also helpsto compact the mortar and seal the joint from weathering.
Acid WashAfter repointing, an acid wash was applied toclean the bricks and highlight the fresh mortar, revitalizing the wall’soverall look.
The installation of Helifix bars reinforces the wall by effectively tying the brickwork together.
Joint PreparationWe carefully remove the old mortar from the brick joints, creating a clean space for Helifix bar installation.
Epoxy Grout Base A bead of high-strength epoxy grout is applied within the cleared joints, serving as an anchor for the Helifix bars.
Helifix Bar InstallationStainless steel Helifix bars are carefully inserted across cracks to structurally integrate the wall sections, akin to reinforcement in concrete
Secondary Epoxy ApplicationAnother bead of epoxy grout is applied on top to encapsulate the bars and ensure they are fully bonded to the brickwork.
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The application of a clear brick sealer not only protects the brickwork but also enhances its durability by imparting hydrophobic properties that repel water.
Surface PreparationBefore sealing, we ensure the brickwork is thoroughly cleaned and dry, removing any dirt or debris.
Sealer Selection We utilised a high-quality, penetrating hydrophobic clear sealer providing a strong barrier against moisture without altering the appearance of the bricks.
Application Technique The clear sealer is applied using a roller, ensuring even coverage for complete protection.
Special attention is given to mortar joints and any areas that are more susceptible to water ingress.
Absorption We allow the sealer to penetrate deeply into the brick and mortar, creating a moisture-repellent layer.
InspectionAfter the sealer has cured, we inspect the coverage to confirm that the protective layer is uniform.
Our approach focused on three pivotal upgrades:
Box Gutter Drainage Upgrades We increased the dimensions of the box gutters, enabling a greater volume of water to be channeled effectively and improve water flow out lets
Timber Purlin UpgradesTo accommodate the upgraded gutters, the roof's elevation was increased using H2 timber purlins.
Colorbond Roof ReplacementCompleting the restoration, we installed new roofing sheets complemented by engineered sarking and insulation to enhance weather resistance and thermal insulation.
Lower Premiums: Reduced Insurance Risk
Enhanced Safety: Create a Secure Environment
Structural Integrity: Extended Lifespan
Peace of mind: Workmanship Guarantee
This sealing process ultimately fortifies the brick structure against the elements, prolonging its life and maintaining its aesthetic appeal.
Heritage Facade Remediation is a skill. Like every other skill, there are amateurs then there are the professionals. The results you achieve depend on the team you choose and the culture they have.
Our team are experts in their craft, they know the difference between a good and great product, they are the first to identify intricate details, utilise new technologies and strategies whenever they appear.
ATOMIC PROJECTS is the ultimate all-in-one building partner guiding you from the first to last day.
There is no one better on the planet to bring your project to life.
Over the last 4 years we have worked exceptionally hard in delivering projects all over Sydney.
We have access to over 1,500 people Sydney-wide, with specialists, experts and professionals in every field imaginable.
All dedicated to the pursuit of excellence.
