Full Recoating of Wastewater Treatment Tanks at an Operational Beverage Facility
Hydro Logic was engaged by Asahi Beverages Australia to recoat the internal concrete surfaces of two wastewater treatment tanks at their Western Sydney production facility. The 28-year-old aerobic biological treatment plant processes wastewater generated from the production and packaging of alcoholic and non-alcoholic beverages. The equalisation tank and high BOD tank required full removal of the existing lining, concrete remediation and application of a new protective coating system to maintain design life and ensure ongoing environmental compliance.
Confined Space Works in an Operational Industrial Facility
The tanks form critical infrastructure within an operational industrial facility, introducing a range of environmental, health and safety constraints that required careful management throughout the project. Both tanks required confined space entry, with all personnel required to hold current confined space qualifications and follow strict safety protocols including gas monitoring, permit-to-work procedures and daily toolbox talks.
The existing lining had to be fully removed before the true condition of the underlying concrete substrate could be assessed, meaning the extent of crack repair and mortar patching could not be fully quantified until the tanks were pumped, cleaned and inspected. Works also required coordination with Asahi's site EHS plan, other contractors operating on site and Asahi's own operational program for returning the tanks to service.
High-Pressure Jetting, Concrete Remediation and Advanced Polyurea Coating
Following site induction and establishment of confined space controls, Hydro Logic completed high-pressure water jetting at 5,000 PSI to clean the internal walls and floor of both tanks and remove the existing lining. Gas monitoring was conducted throughout to confirm a safe working environment. Portable scaffolding was installed to provide safe access to all internal surfaces.
A detailed concrete condition assessment was carried out once the tanks were accessible, with crack repairs, void filling and cementitious mortar patching completed across affected areas. All existing expansion joints were cleaned, old sealant removed and treated with an approved polyurethane system before a bandage was applied over each joint.
A primer coat was applied to all masonry surfaces as a bonding substrate prior to the primary coating application. Hydro Logic then applied an advanced polyurea spray coating system, achieving a consistent 3mm to 4mm thickness across all internal surfaces. The polyurea system cures rapidly, allowing a full return to service within 24 hours of application. Adhesion testing was completed upon conclusion of works, with results recorded and reported.
Returned to Service Within 24 Hours. Full EHS Documentation Provided.
Both wastewater treatment tanks were successfully recoated and returned to service within the agreed program. The applied polyurea coating system provides long-term chemical resistance to the aggressive wastewater streams generated by beverage production, protecting the concrete substrate from further deterioration and extending the serviceable life of the tanks. All works were completed in compliance with Asahi's site EHS requirements, with full confined space documentation, SWMS, MSDS records and adhesion test results provided as part of the project handover package.