PMB Defence’s new $21M production facility at Osborne is a 26,000 m² high-security defence engineering site built by Sarah Constructions. The facility manufactures battery systems for Australian submarine programs and was delivered under strict defence industry security protocols and tight specification tolerances. Floortek was engaged by Sarah Constructions to perform concrete remediation works within the production building prior to the final floor system being laid.

The existing slab had suffered significant delamination and structural cracking — conditions that rule out any surface-applied coating or topping without first resolving the underlying substrate integrity. Floortek’s scope was to stabilise and remediate the slab, then install an industrial trafficable cementitious overlay to bring the floor back to specification.

Scope of Works

• Scabbling of the delaminated surface — mechanical removal of the failed concrete layer across the affected area to expose sound substrate
• Structural crack repair — full crack mapping, routing, and epoxy injection/repair to address structural movement cracks before overlay application
• Surface inspection and CSP sign-off — prepared surface vacuumed, inspected, and CSP documented before handover to the overlay trade
• Industrial trafficable cementitious overlay — self-levelling topping applied to the remediated substrate, reinstating a flat, sound, and trafficable surface to the required specification

Defence facilities have tight tolerances and compliance requirements. The remediation scope here went beyond standard surface prep — structural crack repair prior to an overlay is a technically demanding sequence that requires the right read of the substrate before committing to a system. Floortek managed the full remediation-to-overlay process as a single scope for Sarah Constructions.