Revolutionising Concrete Infrastructure Maintenance Through Innovation 

Introduction

Metrocorp has adopted, invested in and refined advanced technologies to meet the unique challenges of concrete repair. This case study highlights how our innovative approach to concrete preparation sets us apart, offering clients unparalleled safety, efficiency and environmental sustainability. 

The Challenge

The preparation of concrete tunnels for remediation presents distinct challenges. These structures are often degraded by corrosive elements such as sulphuric acid, a byproduct of hydrogen sulphide gas present in urban and industrial wastewater environments. Traditional manual methods of high-pressure blasting posed significant safety risks and were prone to inconsistencies, demanding a more controlled and efficient approach that is also environmentally more sustainable. 

Solution 

Traditional high-pressure blasting systems are managed by a team using Ultra High Pressure (UHP) water blasters. These blasters are operated by teams working in tunnels. 

To eliminate the need for human operators to be in the direct line of high-pressure discharges, we introduced automated high-pressure blasting systems. To achieve this, we started by implementing a two-phase innovation strategy to revolutionise tunnel surface preparation. 

Phase 1: Automating High-Pressure Blasting 

We customised a hydro-demolition robot to automate the cleaning and preparation of tunnel surfaces. This robot was adapted to operate autonomously, mounted on a system of motorised pontoons designed to navigate the cylindrical tunnel space effectively. The robotic system was engineered to withstand harsh environmental conditions and debris, reducing the need for human intervention and enhancing the uniformity of the surface treatment. 

Phase 2: The Rock Wheel Adaptation 

To further enhance our surface preparation techniques, we adapted the Rock Wheel system for use in concrete tunnels. Originally used for more straightforward excavation tasks, the Rock Wheel was modified to work from a floating platform, equipped with rotational capabilities to ensure comprehensive coverage of the tunnel’s curved surfaces. This innovation significantly reduced the use of water and diesel, aligning with our goals for environmental sustainability and reducing the physical footprint of our operations.