When Concrete Tanks Crack: Why Smart Waterproofing and Structural Repair Matter

When Concrete Tanks Crack: Why Smart Waterproofing and Structural Repair Matter

How Drizoro Mortars Can Prevent Failures — If Applied Correctly

The Incident: A Concrete Tank Suddenly Collapsed

In January 2022, a steel-fibre reinforced concrete tank (SFRC) holding 23,000 L of backwash wastewater catastrophically failed at a Brisbane school’s swimming pool complex. Without warning, the sidewalls gave way. The collapse was total.

WorkSafe Queensland issued an urgent safety alert — highlighting that similar SFRC tanks across schools, public facilities, and homes could be at risk. The core issue? Internal corrosion of embedded steel fibres that weakened the tank from within — invisible until it was too late.

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Key Takeaways

• SFRC tanks are prone to hidden corrosion.

• 

  Perhaps the corrosion was more evident … surface coating possibly designed to protect steel corrosion on the outside. Waterproofing the inside of the tank when this external coating was applied may have been enough to save it!

• Once weakened, walls can fail with no warning, especially under full load.

• Corrosion is often internal — not visible until failure begins.

• Without Structural protection and waterproofing are both critical to prevent the failure of the tank.

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The Role of Waterproofing — and Its Traditional Limitations

Waterproofing is often seen as a way to prevent leaks, mold, or contamination. But in water tanks — especially SFRC — its more critical role is preserving structural integrity. By keeping water and oxygen out of the concrete matrix, waterproofing helps prevent the internal corrosion of steel fibres that ultimately leads to collapse.

However, many assume waterproofing alone is enough. In reality:

Traditional waterproofing doesn’t strengthen weakened concrete.

This is especially true when the tank already shows signs of cracking, spalling, or fibre exposure.

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New Insight: Drizoro Mortars Can Improve Structural Strength

While most cementitious coatings are barriers only, Drizoro’s repair mortars like Maxrest and Maxrite offer real structural reinforcement — when used properly.

According to Our Team Believes and illustrated in the diagram:

• Cracks should be opened from both sides

• Filled with Maxrest or Maxrite, high-bond strength structural mortars

• Embedded with steel reinforcement and covered with at least 25mm of the Drizoro quick set mortar, where necessary, to restore lost structural capacity. See diagram below.

This approach moves beyond waterproofing — it actively restores mechanical integrity.

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Advantages of Using Drizoro for Repair + Waterproofing

✅ 1. Structural Strength + Waterproofing in One

Unlike surface coatings alone, Drizoro mortars:

• Restore compressive and tensile strength in cracked zones

• Can be used to embed steel rods or mesh for added reinforcement

• Seal and waterproof in the same application

✅ 2. Slows or Prevents Further Corrosion

Proper use of Drizoro systems creates a tight bond to existing concrete, cutting off oxygen and moisture pathways that accelerate steel fibre rusting.

✅ 3. Suitable for DIY — With Caution

Experienced DIYers can use Drizoro mortars effectively, especially on small or localized repairs. But structural reinforcement still demands care, skill, and understanding of:

• Crack dynamics

• Load paths

• Bonding techniques

• Correct mixing and curing

No warranty will typically apply for DIY structural repair, but with careful application and prep, meaningful performance can still be achieved.

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Comparison: Repairing vs Just Sealing

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The Smart Repair Process (Using Drizoro)

1. Inspect & Diagnose
   Look for visible cracks, leaks, or exposed fibres. Test structural integrity if in doubt.

2. Open the Cracks
   As shown in the diagram: open the crack fully on both sides to remove loose material and provide bonding area.

3. Embed Steel if Required
   Insert steel reinforcement bars or mesh for significant structural cracks. Bond securely.

4. Apply Maxrest or Maxrite
   These high-performance mortars bond deeply and restore integrity. Cure as per instructions.

   

   The Best way to prep cracks for repair

5. Apply Waterproof Coating
   Use a cementitious waterproof membrane (e.g. Maxseal Flex) to seal the entire interior surface, protecting both old and new areas from future water attack.

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Know What You’re Fixing and the Materials Used

Waterproofing protects — but when corrosion has already taken hold, repairing cracks structurally is essential.

With Drizoro mortars used as shown, it’s possible to restore both watertightness and structural strength — especially if reinforced properly. But remember:

• DIY success depends on skill, not just materials

• No surface coating can save a structurally unsound tank

• Professional inspection is still recommended for large tanks or load-critical situations

Don’t just seal — strengthen.

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Call to Action

🔍 Have a cracked or aging tank?
Inspect it for structural signs — don’t wait for leaks to tell you something’s wrong.

🧱 Use Maxrest or Maxrite correctly — open cracks, embed steel, and build strength back in.

🛠️ DIY or pro — be realistic about risk.
DIY can work on small tanks with care. For large or public systems, consult professionals.

💧 Finish with a Drizoro cementitious membrane waterproofing (e.g. Maxseal Flex) to stop future corrosion and leakage.

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