Proofex Engage protects critical infrastructure for Bluescope Steel Port Kembla, NSW

A challenging project environment

The environment at BlueScope Steel’s Port Kembla facility presents considerable durability challenges.

“It’s an existing industrial area adjacent to a marine environment, so you’ve essentially got salt water in the ground underneath,” explains Fosroc ANZ Specification Manager, Gary Bennett.

With saline groundwater, fluctuating water tables and furnace operating conditions reaching ambient temperatures of up to 200°C, the risk of corrosion to reinforced concrete structures is significant.

“When you combine heat, salt and water, that creates a highly corrosive environment,” Gary adds.

Meeting unique project requirements

To ensure long-term structural integrity, the below-ground waterproofing system needed to perform reliably in extreme conditions.

Key requirements included:

• Preventing saline groundwater ingress under hydrostatic pressure
• Withstanding heavy reinforcement placement and thick concrete pours
• Supporting future installation of heavy furnace equipment
• Allowing efficient repair during construction
• Adapting to complex substrates and construction methods

The project also involved challenging interface conditions, including steel sheet piling with a 'dog tooth' profile, creating an uneven substrate.

“We had a steel sheet pile, which is like a dog tooth profile steel wall, so we had to come up with a system that would work with that,” Gary explains.

Why Proofex Engage?

Fosroc ANZ’s Proofex Engage below-ground waterproofing membrane was selected for its ability to deliver durable, adaptable performance in complex conditions.

The system offers:

• Robustness during installation, withstanding heavy site activity and reinforcement placement
• Repairability, allowing damage to be addressed before concrete placement
• Design flexibility, accommodating different substrates and formwork systems
• Full tanking capability, providing continuous waterproofing across slabs and walls

Fosroc ANZ worked closely with designers and engineers to refine the solution.

“They come to us with the problem, and we work through access, substrate conditions and construction constraints to arrive at the right system,” says Gary.

Product performance

Proofex Engage was installed beneath the slab on a prepared blinding layer, forming a continuous waterproof barrier below the groundwater level.

To address the irregular steel sheet piling, a foam-based lost formwork system was used to create a flat, fully supported surface for the membrane.

“We put in place some foam formwork to support the membrane, because all that heavy concrete would damage it if there are air gaps behind it,” Gary explains.

This approach ensured consistent membrane performance and protection during concrete placement.

The system delivers:

• Resistance to hydrostatic pressure and saline groundwater
• Protection against chloride ingress and reinforcement corrosion
• Reliable performance beneath high-load structural areas

Given the inaccessibility of below-ground waterproofing, installation quality was critical.

“You can’t easily access these areas later - it’s extremely expensive or sometimes impossible - so it has to be done right the first time,” Gary notes.

Project success

Proofex Engage has delivered a robust, long-lasting waterproofing solution for one of Australia’s most demanding industrial environments.

With waterproofing works nearing completion, the structure is ready to support the installation of heavy furnace equipment - operating in high-temperature conditions - confidently protected from saline groundwater ingress.

Fosroc ANZ’s collaborative approach, including ongoing technical support and site engagement, helped ensure a practical and effective outcome aligned with project requirements.

The result is a durable foundation supporting a major national investment, helping secure the long-term performance of infrastructure critical to Australia’s steel manufacturing future.