Projects

Project Details

Lake Macquarie Costco – 45,000m²

Increased Concrete Durability

Product Used: DEEPCURE+REPELLER

As part of the construction of the new Costco development at Lake Macquarie, Integra was selected to treat over 45,000 square metres of concrete across aprons, runways, and service areas. The scale and exposure of this high-traffic retail and logistics facility demanded a concrete treatment that would ensure longevity, reduce maintenance, and deliver a clean, safe, and durable surface. DEEPCURE+REPELLER was chosen as the all-in-one solution to meet these rigorous demands.

Challenge:

Large-format retail distribution centres like Lake Macquarie Costco face several compounding concrete performance risks:

High Load and Frequent Traffic: Constant movement of delivery trucks, trolleys, forklifts, and customers puts massive pressure on slab surfaces.
Surface Dusting and Wear: Without the right cure and hardening, slabs degrade over time, creating dust, reducing durability, and increasing safety risks.
Cleaning and Hygiene: Oily residues, tyre marks, and spills from retail and warehousing operations require a surface that is easy to clean and maintain.
Moisture and Environmental Protection: Preventing moisture ingress and surface degradation is critical for structural integrity and long-term performance.

A traditional membrane cure or simple hardener would not meet the long-term needs of the site.

Solution:

DEEPCURE+REPELLER was applied directly to green concrete across the full slab area to deliver:

AS3799-Verified Curing Performance: Moisture retention exceeds standards, ensuring deep, consistent curing and optimal slab strength.
Surface Densification & Dust-Proofing: Forms a rock-hard surface capable of withstanding constant vehicular load without dusting or wear.
Permanent In-Slab Moisture Barrier: Creates a crystalline matrix that blocks moisture ingress from within, safeguarding structural steel and reducing future maintenance risks.
Hydrophobic Surface Protection: The REPELLER technology seals the surface, resisting spills, oils, and grime, and allowing for fast and effective cleaning.
No Need for Surface Grinding or Removal: Applied at time of pour, this one-step system eliminates the need for membranes or additional coatings.

Outcome:

The DEEPCURE+REPELLER system delivered a premium slab finish across the entire Costco Lake Macquarie site:

Perfect In-Slab Cure – No shrinkage cracking or surface map cracking observed
Rock-Hard, Dust-Free Surface – Ready for high load, high frequency use
Exceptional Cleanability – Oil and tyre marks wipe off easily, keeping the site presentation high
Zero Moisture Ingress – Long-term protection against water damage and corrosion
Fast Turnaround for Trades – Slabs were accessible shortly after pour, streamlining project timelines
Extremely Satisfied Contractor and Client – A low-maintenance, high-performance slab that sets a benchmark for large-format retail construction