REPORTAgenda Item 14.3.2

Report No. 9/16cncl

TO: ORDINARY COUNCIL - 25 JANUARY 2016

SUBJECT: INDOOR CENTRE TILING REPAIRS

AUTHOR: MARTIN KEMPLAY - MANAGER ASALC

EXECUTIVE SUMMARY

This report provides the Alice Springs Town Council with a review of tiling failure to the Indoor Centre Pools (Leisure and 25m), the proposed remediation plan and resulting impacts for ASALC and the Alice Springs community

RECOMMENDATION

IT IS RECOMMENDED that this report be noted.

REPORT

1. BACKGROUND

CAT Projects was engaged by ASALC and ASTC to manage the review and repair of tiling failure in the Indoor Centre Pools in October 2015.

Refer to attachment "ASALC - Indoor Pools - Tiling Review” page 1 for background information of the tiling failure.

2. DISCUSSION

A joint inspection of the tiling failure was held at ASALC on the 17th of November. Attendees include:

Lyndon Frearson - Cat Projects Mark Huss - Ceramic SolutionsPeter Stewart - Crystal PoolsGeoff Ninnes - Ninnes Fong & Partners

It was verbally agreed on 18 November that within two weeks, that is, by say start of December the contractors would provide:

• Schedule• Work Method Statement that included:

- risk assessment/control measures- plan for drawdown- plan for refill

• Quotation for expansion joint replacement

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Two months later very little information has been provided. Refer to attachment “Works Methodology” provided by Ceramic Solutions

SWMS

Work Method statement and MSDS of products to be used were provided on 22/12/2015. This statement included no reference to risk mitigation nor drawdown/refill procedures.It has been confirmed verbally that SWMS shall be completed on the first day of works.

Timing

All contractors are aware that works are to commence 1 March 2016. The preliminary schedule is:

Activity Start Date Finish Date Duration Responsibility

Draw down lap pool 1 March2016

GNFP

Draw down leisure pool GNFP

Saw cut expansion joint lap pool

1 day ASTC TEA

Inspection of pool tiles 1 day ALL

Remove tiles + surface prep 3 days CS/CP

Replacement of new tile 4 days CS/CP

Caulking and cure 10 days CS/CP

Clean pools 1 day CS/CP

Refill pools GNFP

Temperature increase 10 April2016

GNFP

*GNFP - Geoff Ninnes Fong & Partners*CS - Ceramic Solutions*CP - Crystal Pools*ASTC - Alice Springs Town Council

3. POLICY IMPACTS

As per the section and "Timeframe” in the attachment “ASALC - Indoor Pools - Tiling Review” page 4, the Indoor Centre would be closed for the entire month of March.

Report No. 9/16cncl .13

4. FINANCIAL IMPACTS

As per section “costs” in the attachment "ASALC - indoor pools - tiling review” page 4, ASALC will be responsible for the cost of replacing the expansion joint in the 25m pool. The requested quote fr this work has yet to be supplied by ceramic solutions.

It is estimated that due to the closure of the indoor centre ASALC will suffer a loss of approximately $50,000 in learn to swim revenue.

It is also anticipated that ASALC will suffer further revenue losses from visits to the centre and kiosk sales estimated at approximately $28,000.

5. SOCIAL IMPACTS

Due to the proposed entire closure of the Indoor Centre ASALC is unable to cater for a full complement of Learn to Swim lessons in term 1 of 2016.

The greatest community impact of the proposed closure will be for young families and rehabilitating, the elderly and the disabled.

6. ENVIRONMENTAL IMPACTS

Draining and refilling of both the Leisure and 25m Pools will result in the loss and use of approximately 1,400,000 Litres of water.

7. PUBLIC RELATIONS

A public notice was sent out to all on ASALC’s e-mailing list and uploaded to the ASALC Facebook page. Refer to attachment "Scheduled Pool Repairs”

A public meeting at ASALC has been scheduled for 5.30pm, Wednesday February 10.

The ASTC Media Department will provide further public notices closer to the expected commencement of works via multiple forms of media

8. ATTACHMENTS

Attachment A - ASALC - indoor pools - tiling review Attachment B - Works Methodology Attachment C - Scheduled Pool Repairs

Craig CatchloveDIRECTOR COPORATE AND COMMUNITY SERVICES

SCHEDULED POOL REPAIRS

MARCH 2016

During March our centre will be undergoing scheduled maintenance to repair lifting tiles in our indoor leisure pool and indoor 25m pool. These repairs are vital for safe use of the facility and have been scheduled to occur during a time when outdoor pools are open, so as to minimise disruption. While an exact cause and scope of repair works is to be determined once pool water has been emptied, we can confirm the following

• Engineering assessments in mid-November 2015 have ruled out concrete slab movement as the cause

• Tests indicate tile adhesive failure is not systemic and a full-retile of both pools is not required• Further tests will be conducted once both pools are empty• It is not possible to complete full, lasting repairs with water in the pools• Full works, including emptying the indoor pools, testing, retiling, grouting, cleaning and

reinstallation of expansion joints is expected to take approximately 30 days• Current schedules has this work commencing March 1st and concluding March 30th, however

exact dates will be confirmed at a closer date

During this period of closure, ALL OUTDOOR POOLS WILL REMAIN OPEN. In fact, we will be extending opening hours to accommodate public demand vs a reduced amount of pools. We will open earlier and stay open later. Out team will use pool blankets every night to keep the outdoor pool temperatures as warm as we can. Due to the practicalities of having outdoor pools only, we have made the tough decision to shorten our term 1 learn to swim program to 5 weeks. Learning outcomes have been modified in line with swim and survive program guidelines to ensure all participants receive the best swimming teaching possible in the reduced term time.

We thank all our wonderful pool users, schools, sporting clubs and community groups for their patience while this work goes ahead, and we invite all interested parties to attend a public meeting at 5:30pm on Wednesday the 10th of February to discuss this pool closure and its impacts further.

RegardsASALC Management

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ceramic solutionsfor leisure & commercial applications

Works MethodologyAlice Springs Pool Tiling Rectification, N.T

Pool TilingMaterial to be used on site

• PCI FT Extra + Lastoflex

• PCI Durafug

• PCI Emulsion

• Agrob Buchtal Pool Tile System

Tiling Preparation Works

• Inspect pool tiling for possible loose or delaminated areas and mark up accordingly

• Cut perimeter of loose areas to prevent further transfer

• Remove loose tiles and grind away existing adhesive

• Water blast substrate to remove dust and open the surface of the concrete

Tiling Works

• Ensure substrate is clean from dust prior to tiling

• Mix PCI FT Extra and Lastoflex powder to the correct volumes as per the manufacturers specifications

• Spread adhesives using a 9X6mm Notch trowel in a cris Cross pattern ensuring for total coverage of the substrate, then trowel back over in one direction to give an even coverage of material. Do not spread more adhesive than 1 m2 at a time. Ensure adhesive does not skin prior to the laying of tiles

• Clean surface of tiles of any excess adhesive whilst wet once laid

• Check for overall coverage of adhesive on a regular basis ensuring a minimum coverage of 90%

• Allow curing of tiles for a minimum of 12hrs prior to grouting

Grouting Works

• Inspect joints are clean from dirt and debris, vacuum if required

• Mix PCI Durafug grout as per manufacturers specifications

• Apply grout to joints ensuring all voids are filled

• Allow grout to reach initial set prior to first wash

• Wash excess grout from tiles leaving clean

• Ensure expansion joints are scratched out at the correct spacing’s

Caulking Works

• Ensure all expansion joints clean from residual grout

• Ensure all perimeter areas around affected areas have an expansion joint

• Apply primer coat as per manufacturers instructions

• Apply Otto-Seal S18 silicon as per the manufacturers instructions knifing of to a clean smooth finish

• Final inspection prior to hand over

PROJECTS

Desert Knowledge Precinct PO Box 8044Alice Springs NT 0871 Australia Tel: 08 8959 6240 Fax: 08 8959 6111 Email: enquiries@catprojects.com.

www.catprojects.com

ASALC - Indoor Pools - Tiling Review18 November 2015

BackgroundConstruction was completed of the Alice Springs Aquatic and Leisure Centre (ASALC) indoor pools in February 2011. The construction of the ASALC indoor pools were project managed by CAT Projects, the structural design was completed by GNFP, pool construction was completed by Crystal Pools and pool tiling was completed by Ceramic Solutions. A plan of the indoor pools are as shown in Figure 1.

RAMP

LEISURE POOL

LEARN TO SWIM

POOL

LAP POOL

Figure 1 Plan of Indoor Pools

Pool tiles were observed to have cracked, moved and uplifted in a few areas in the leisure pool in 2014 and subsequently some of these areas were repaired in December 2014. Areas repaired appear to continue to perform well.However over the duration of 2015 further defects in tiling have been observed both in the leisure pool, learn to swim pool ramp and lap pool. Subsequently on the 17 and 18 November 2015 meetings were held to identify defects, postulate causes and determine a remediation plan including suggested preventative works to minimise the risk of potential similar future issues. Major meeting participants included:

• Jesse Mortensen (JM), ASALC• Lyndon Frearson (LF), CAT Projects• Peter Stewart (PS), Crystal Pools• Mark Huss (MH), Ceramic Solutions• Geoff Ninnes (GN), Geoff Ninnes Fong & Partners (GNFP)• Vanessa Ratard (VR), CAT Projects

The major findings of these meetings are detailed following.

ASALC - Indoor Pools - Tiling Review Page 1 of 4

IssuesSince pool repair works on the leisure pool were undertaken in December 2014, the defects listed in Table 1 have been observed. During the meeting these defects were investigated and a suspected cause determined where possible. Ceramic Solutions did a preliminary floor inspection during the meetings and no further areas of drumminess were discovered. A thorough joint inspection however will need to be undertaken upon pool drawdown.

Table 1 Observed Defects and Cause

Location Defect Observed Suspected Potential Causes

Leisurepool

Various localised areas of:- Failure of tile to adhesive.- Failure of adhesive to floor.- Crack in tiles.

The area where the original tile installation mixing occurred, potentially not cleaned properly.Where adhesion is the issue, potentially the minimum 86 % adhesive contact with tile has not been achieved. Cracking of tiles may be due to joints not performing to full capacity.

Learn to swim ramp

Lateral cracking of tiles on the ramp over approximately lm2

The cause is unknown. Possibly from impact (having something dropped on it) or the joint against the wall not allowing movement. It is anticipated that the cause will become evident during investigation when pool is empty.

Lap pool

Along eastern wall diagonal cracking of tiles towards deep end and uplift of tiles towards middle.

The cause is unknown. One cracked tile has a star crack from probably having an item dropped on it and other cracks maybe due to lack of joint movement. It is anticipated that the cause will become evident during investigation when pool is empty.

Tiles on deck level of pool have started to move.

In early 2013 patrons of the pool pulled out parts of the rubber sealant. Subsequently in approximately March2013 Leak Detectors replaced the sealant with an epoxy, with work being conducted underwater. The epoxy of this expansion joint is now rigid not allowing for tile movement.

It should be noted:• Photographs showing a red line where tiles have lifted up in the leisure pool, is a red oxide

marker used during construction and will likely remain under the tiles for the life of the pool. It is of no material concern (pc, PS).

• Tiling joints are at 4.25m grids and AS is 5 m grids (pc, MH).• Tiling joints are 6 mm which allows for approximately 25 % movement ie 1.5 mm (pc, MH).• Tiles are extruded so 100 % adhesion is not possible as tile is not fully horizontal. CSIRO testing

determined that adhesion between 86-96 % is sufficient to achieve required strength (pc, MH).• When tile joints close a little it means that they are doing their job. Excess closing can mean that

other nearby joints are not fully active (pc, GN).• The pool structure will thermally move if heating is not consistent/turned off for periods/large

amounts of cold water are added/pool emptied (pc, GN).• Discolouration of tiles present in leisure pool unlikely to be related to the tile defects due to

nozzles being clean (demonstrating pH levels not an issue) and the dispersion of discolouration is inconsistent with overall pool issue (that is it is only present on the top layers of pool wall and reduces towards the bottom of the pool) (pc, PS).

• The majority of joints were considered to be performing well by preliminary inspection undertaken by Ceramic Solutions however only when a joint is removed will joint defects/contamination be able to be determined. It was observed that the middle longitudinal

ASALC - Indoor Pools - Tiling Review Page 2 of 4

joint of the lap pool was severely stressed being almost closed however this is not currently causing any issues.

Remediation Plan1. Leisure Pool: All existing drummy or cracked tiles to be repaired/replaced. Preventive works

such as increasing the stressed 6mm joint to 10mm and introducing additional joints at selected locations to prevent future potential damage at to be determined.

2. Learn to swim ramp: Cracked tiles to be replaced. Pending further investigation repair or introduce proximate joints as a preventative measure if appropriate.

3. Lap Pool: All existing drummy or cracked tiles to be repaired/replaced and covered with a cementitious latex product. Expansion joint epoxy to be replaced with Maxiseal (major pool sealant in the pools) and cut out within 12 hours of pool drawdown. Additional preventive works such as introducing additional joints where defects occurred to prevent future potential damage to be determined pending further investigation of defect.

RisksInitial risks that have been identified are discussed following. A more comprehensive description of potential risks will be included in the documentation to be provided by Crystal Pools and Ceramic Solutions. It should be noted that although all reasonable efforts would be made to mitigate risks there is potential that further damage may occur in the future.Speed of pool drawdown was identified as one of the greatest risks to these works in terms of potentially causing further damage of the pool tiling. To reduce the potential impact, this process will be managed by Crystal Pools and Ceramic Solutions whom both have significant experience in this area. The drawdown will occur over a number of days and coincide with adjusting of air temperature within the facility to minimise the risk.Conversely filling of the pool may similarly pose a risk to damaging the tiling and will subsequently be done over a number of days with pool water temperature being increased by no more than 0.5 degrees Celsius at maximum per day.There is a potential risk where a joint is underperforming that by recutting and sealing the joint there is a risk that the tension release would allow relatively rapid tile movement to occur and subsequently more tiles to become drummy. This risk could similarly be an issue where new additional joints are installed and of highest concern the cutting out of the epoxy of the lap pool expansion joint. Cutting out the epoxy has been recommended to be undertaken by GNFP/Crystal Pools/Ceramic Solutions as a preventative measure as the rigid joint doesn't allow movement. Although there is this converse risk of movement being allowed causing damage due to release of tension, it is considered a far greater risk to leave the joint rigid and especially during drawdown periods it would be anticipated that the tiles immediately adjacent would be damaged due to this lack of allowance for movement. GN has recommended that Ceramic Solutions seek further expert opinion with regards to this risk of recutting or introducing joints and its potential effect/mitigation measures to be introduced.Tiles are of a standard nature so availability for the proposed works is not considered an issue, however if for example the entire lap pool tiles required replacement the 150m2 or so of stock would be insufficient. The risk of more than 100m2 tiles requiring replacement however is considered low if all proposed mitigation measures are implemented.

OpportunitiesThe pool has been operating for approximately 5 years and thus it would seem an opportune time to undertake required maintenance works if the indoor pools are taken offline, such as:

• Maintenance of pumps, filters, strainers and ancillaries;• Replacing sealant of all major tile joints;• Cleaning of balance tank;• Annual pool cleaning and removal of deposits; and• Boiler room mechanical maintenance.

ASALC - Indoor Pools - Tiling Review Page 3 of 4

TimeframeTiming of the works will be a collaborative process that will be able to be fleshed out more thoroughly upon receipt of a schedule from Crystal Pools and Ceramic Solutions. The general aim is to minimise the impact on the pools operation and so it is noted that preferably works would be completed while the outdoor pools are still open so as to avoid impacting the Learn to Swim programme. Advice from Council and ASALC will be required as to whether there is a preference for the pools to be taken offline concurrently or consecutively, although the general understanding is that the impact on ASALC's overall operations would be minimised by undertaking repair works concurrently. Works are tentatively scheduled to be completed in March 2016.

CostsThe exact liability of costs may only be determined when a joint inspection of these pools and their joints is undertaken by all parties once drawdown is complete due to the uncertainty of causation in some areas. Similarly risks associated with doing the works and cost liability will need to be determined at that time.It has been agreed at this stage that:

• Costs associated with repair of the leisure pool floor and any preventative works will be fully absorbed by Crystal Pools and Ceramic Solutions.

• Crystal Pools and Ceramic Solutions are not considered liable for costs associated with preventative works of replacing the Lap Pool expansion joint epoxy with MaxiSeal and replacing one line of tiles either side of the joint.

Liability for cost of all other repair works is to be determined.

ConclusionThe next phase of this process is that:

• Ceramic Solution/Crystal Pools will provide a proposed schedule and WMS by 3 December 2015 with final scheduling to be completed in conjunction with ASALC.

• Consideration as to whether the opportunities identified in this document are to be undertaken and subsequent initiation of those works.

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