CASE STUDY: Clever & Co SBS TSN – Shotcrete Repair
Project Background
Absafe, a leading specialist access contractor, delivers a range of remedial engineering services across industrial and infrastructure projects. Their reputation for tackling difficult-to-access locations was key in securing the contract to repair a 140-metre-tall concrete chimney in Victoria’s LaTrobe Valley. Built over 50 years ago, the chimney was suffering from extensive concrete spalling near its capping. As part of a scheduled maintenance program, the goal was to find a safer, faster, and more cost-effective solution than traditional repair methods. In collaboration with Absafe, CGS Equipment developed a specialised shotcrete repair solution.
Challenge: Concrete Spalling at Height
Concrete spalling—also referred to as concrete cancer—occurs when the reinforcing steel within concrete rusts, expands, and causes the surrounding concrete to crack and flake. Over the years, the Hazelwood Power Station had relied on patching and form-and-pour techniques to repair the damage. However, these methods were labour-intensive, slow, and costly—especially during major shutdowns. Absafe requested a new approach to improve safety, speed and cost efficiency.
CGS Equipment’s Specialist Solution – Shotcrete Repair
To address the complex repair challenge, Absafe partnered with CGS Equipment, Australia’s exclusive distributor for Clever & Co. shotcrete systems. CGS recommended the SBS Type TSN Shotcrete Machine, paired with a PANDA high-pressure water pump, as the optimal setup for vertical concrete remediation.
The TSN machine pumped BASF MasterEmaco S820CI repair mortar and water through separate lines to the chimney’s capping, 140 metres above ground. The materials were mixed at the nozzle by an experienced operator to achieve a smooth, trowel-finish shotcrete application.
System Features and Performance
The SBS TSN Shotcrete System incorporates an intelligent SBS Control Chamber, which ensures accurate dosing and long-distance material transport—up to 1,500 metres. For this project, the system reliably conveyed dry mortar and water to the nozzle without pulsation, even under winter conditions and restricted access.
A 52mm OD, 32mm ID material hose and a 12mm, 160-bar-rated high-pressure water hose transported materials from ground level. A 25mm Clever & Co. nozzle, selected for its compact size, enabled precise spraying despite only 600mm of clearance from the repair face.
The PANDA high-pressure pump delivered consistent water flow at 2,000 psi, while the TSN’s electric-hydraulic drive allowed stepless adjustment of output. This high level of control produced minimal material waste and ensured reliable daily performance. The ground team and nozzle operator communicated via two-way radios to monitor and adjust system pressures in real time.
Results: Efficient, High-Quality Shotcrete Repair
The repair operation ran for two weeks and achieved remarkable results:
-
One pallet of material was applied per hour
-
Bags were broken and prepped every 90 seconds
-
Daily performance was consistent with minimal machine maintenance
-
Air pressure and material feed were set once and required no major changes
The standout feature was the TSN’s “set and forget” capability, removing the need for manual adjustments and allowing the team to focus on quality and safety.
Outcome
The damaged chimney capping was successfully repaired on time and within budget. The advanced shotcrete solution enhanced operational efficiency and extended the structure’s service life for many years.
Looking for reliable solutions for challenging concrete repairs? Explore our range of shotcrete machines for sale or hire. Alternatively, speak to one of our friendly team today to learn how our shotcrete systems can meet the needs of your next project.
1300 581 984
sales@cgsequipment.com.au
