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Restoring the Pride of an Australian Icon

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Restoring the Pride of an Australian Icon PROJECT PROFILE Restoring the Pride of an Australian Icon Structural Systems (Contractor) 29 metres, it is the second tallest in conjunction with Diagnostech lighthouse in New South Wales. It is (Superintendent) were engaged situated in the picturesque Ben Boyd on behalf of the NSW Office of National Park, 25km south of Eden. Environment and Heritage for the restoration works to the Green Cape The Green Cape precinct is made up Lighthouse in Eden, New South Wales. of the Lighthouse Tower and attached This heritage listed icon of Australia is Oil Store along with two separate well over 100 years old and boasts the living quarters - those being the Head beginning of a construction revolution Keepers Cottage and the Assistant in Australia. Keepers Cottage. Green Cape Lighthouse The existing, corrosion affected The Green Cape Lighthouse was built state of the Lighthouse at the time in 1883 and was the first cast concrete of the works was in principal due lighthouse tower in Australia and also to the harsh Category E environment the largest mass concrete structure of the peninsula and surrounding in New South Wales at the time. At natural reserve. Figure 2 – Lighthouse Tower prior to works. Restoring the Pride Restoration works began in June 2012 and involved a number of repair methods and application designed to ensure the precinct was returned to its former glory. Due to the unusually high exposure levels of salts on the precinct, a completely enclosed / wrapped scaffold system was utilised during the restoration process. This approach helped to minimise the direct line of attack from winds and air-born chlorides when attempting delicate tasks such as that of re-coating the lighthouse. The proprietary system known as Monarflex can be seen in Figure 1. Lighthouse Tower and Oil Store The Lighthouse structure and attached Oil Store, both contained significant areas of cracking and spalling concrete which needed to be addressed. The Oil Store in particular presented a challenge, as large horizontal cracks had developed both internally and externally. The Oil Store stands directly attached to the Western elevation of the lighthouse tower. Given its heritage significance and existing state, an in-depth understanding of its original construction was required prior to determining a remediation method that would best suit this independent Figure 1 – Lighthouse Tower complete with scaffold and encapsulation. element of the lighthouse. p.44 CORROSION & MATERIALS PROJECT PROFILE Having been one of the first reinforced mass concrete structures in Australia, the current state of the Oil Store was evidently exhibiting severe lateral cracking which was occurring at regular intervals around the perimeter of the structure. This cracking was being caused from the severe corrosion of what appears Figure 5 – General View of the Green Cape precinct – Keepers Cottages. to be steel reinforcing bands within the concrete walls of the Oil Store. The Lantern Enclosure – which sits at Keepers’ Cottages Investigation pockets were opened the top of the lighthouse is made up The Assistant Keepers Cottage is used as during the early stages of the works to of a delicately combined steel and tourist accommodation for most part of confirm this – Figure 3 shows the state brass framed structure which includes the year. Tourists from all over Australia of the steel bands effectively causing forty-eight (48) glazing panels. As part and the World are known to frequent these lateral cracks. of the restoration works, the enclosure the Green Cape site. As such the Head was to be de-glazed and the frame Keepers Cottage is currently used as the In order to remedy the Oil Store, these work to be stripped of its numerous Office and permanent accommodation steel bands were partially removed in coatings, corrosion treated, re-coated for the National Parks & Wildlife Service. sections and the voids filled with a and finally re-glazed. The Head Keeper attends to the Assistant suitably high-strength cementitious Keepers’ maintenance requirements repair mortar. Recognising the need for extreme quality along with servicing tours and alike into and environmental control for this work the Lighthouse Tower itself. In addition to the above, crack stitching in particular, a proprietary Peel Away was undertaken on the external face of product was used to remove the existing Over time, both Keepers’ Cottages have the Oil Store as shown in Figure 4. coatings – which, in some areas was up suffered from the effects of significant to 10mm thick. This product ensured corrosion and as a result, required After the Lighthouse and Oil Store minimal reliance was made on capturing numerous repairs both externally facade had been repaired, it was then debris as the existing coating remained and internally. Nearly 5,000 corroded sealed using Ardex WPM 330 an anti- adhered to the Peel Away product and fixings and fixtures had to be removed carbonation waterproof membrane. was able to be bagged immediately and and replaced with new 316 grade This stage was crucial, as it provides appropriately removed off site. stainless steel elements. the structure with a physical barrier to prevent any future corrosion. Again, Corrosion to the framework of the In addition to the stated corrosion the fully wrapped scaffold provided enclosure was evident from two (2) issues, general remedial repairs were excellent working conditions as it not sources - Minor galvanic corrosion undertaken to both cottages to ensure only reduced curing time, but also as a result of direct contact between their future longevity. helped reduce the ongoing build up of dissimilar metals (brass and steel) as well salts and residue on the substrate. as Chloride corrosion due to the existing Re-Birth of an Australian Icon environment and air-born chlorides. With the investment into an Australian Lantern Enclosure icon that is the Green Cape Lighthouse The Lantern of the lighthouse is Once treated, the frame surface was and surrounding precinct successfully known to be an ‘irreplaceable’ primed and coated using a proprietary complete, we can ensure the future of element, as it contains an original first Dulux coating system. It was also our cultural heritage looks just as bright order Chance Brothers Fresnel Lantern. important during this application to as the light that once shone from this As such – protection of this lantern ensure regular washing of the surfaces great treasure. was a crucial element in establishing was maintained, in an effort to stop for these works. any build up of salts or residues. Nour Nwiran, Structural Systems Figure 3 – Corroded steel reinforcing bands. Figure 4 – Lateral cracking on the external walls of the Oil Store. December 2012 www.corrosion.com.au p.45.
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