OUR SOLUTION FOR
Sealife Aquarium Sydney
CASE STUDY
Client
sealife sydney
Location
SYDNEY NSW
Challenge
The works took place within an operational, high-traffic public venue housing live marine exhibits. Access was limited, and all tasks had to be carefully coordinated with SEA LIFE’s internal team to avoid disrupting animal care and visitor safety. One of the most critical aspects was the removal and protection of the large curved glass windows, which had to be carefully detached and stored on-site without damage. Severe corrosion was present on steel frames, support posts, and under-deck structures, requiring careful remediation to prevent further structural degradation. Additionally, concrete spalling was identified underneath the tank and walkways, with signs of rust staining and delamination, demanding precise breakout and repair to Australian standards.
Objectives
solutions
Working in close collaboration with the SEA LIFE team, RCR Services began by overseeing the safe emptying and preparation of the L2 coral tank. All curved glass windows were carefully removed and securely stored inside the tank area. Existing seals were stripped back, and the surrounding steel frames were treated thoroughly—corrosion was removed, and the frames were primed with Carboline Rustbond epoxy primer before being finished with two coats of marine-grade protective white epoxy coating. The glass was then reinstated, and all internal and external seals were replaced using high-performance Sika sealant products.
Externally, the existing decking, steel supports, and staircases were dismantled and removed from site. While new fibreglass decking was to be supplied and installed by others, RCR focused on treating all remaining steel corrosion to the structural framing and support posts beneath the tank. These areas were primed and coated with the same marine-grade epoxy system for consistency and durability.
Concrete repair works involved a full inspection using hammer tapping to identify all areas of delamination or spalling beneath the walkway and tank. Damaged concrete was broken back to sound substrate, contaminants removed, and all exposed reinforcement was wet abrasive blasted to AS 1627.4 Class Sa 2½ standards. A Nitoprime Zincrich coating was applied to the steel reinforcement, followed by Nitobond HAR bonding agent, and Renderoc HB40 repair mortar was used to rebuild the concrete with a flush finish. All repairs were carried out in accordance with HB 84 – Guide to Concrete Repair and Protection.
These comprehensive remedial works were delivered safely and to a high standard, ensuring the long-term structural performance of the Coral Cove exhibit while protecting both the built environment and marine life it supports.
