Project Overview

North Sydney Council engaged StoneSet to rejuvenate the aging concrete surrounds at the historic MacCallum Seawater Pool in Cremorne, NSW. Positioned directly on Sydney Harbour and exposed to constant pedestrian traffic, saltwater, and weathering, the existing concrete surface had become worn, visually dated and uncomfortable under foot.

While the original concrete remained structurally sound, demolition and replacement would have created significant disruption, increased costs and extended closure periods for the popular public facility. Council required a solution that would strengthen and modernise the surface while allowing the pool to reopen as quickly as possible.

Following site assessment, StoneSet determined the existing concrete could be retained and overlaid using a reinforced resin-bound paving system. This eliminated the need for major demolition while extending the life of the existing asset.

The completed surface provides a modern natural stone appearance, enhanced pedestrian comfort and long-term durability suited to the harsh marine environment.

Base Preparation

Although weathered and aged, the existing concrete substrate remained structurally capable of supporting a new overlay system. The surface was thoroughly prepared prior to installation to ensure optimum adhesion and long-term performance.

To minimise the risk of reflective cracking from existing joints and movement within the substrate, a reinforcement system incorporating mesh and GO was installed across the surface. This acted as a decoupling layer, isolating movement within the original concrete while providing additional tensile strength to the overlay system.

The reinforced base preparation allowed for the StoneSet system to be installed at an 18mm depth without requiring removal of the original concrete slab.

StoneSet Installation

The new surface consisted of 18mm of 6mm Cudgee Beach StoneSet, selected for its natural coastal appearance and suitability within the surrounding harbour environment.

To maximise consistency, strength and smoothness under foot, the material was compacted and laid using the Glidabull machine laying system. This installation method ensured a highly uniform finish white delivering increased surface density and durability compared to traditional hard installation methods.

The combination of rounded pebble and crushed aggregate created a surface texture capable of achieving a P4 slip resistance rating while remaining comfortable for barefoot pedestrian traffic.

The completed overlay transformed appearance and functionality of the pool surrounds within an exceptionally short construction timeframe.

Lifecycle Extension & Sustainability

By retaining and overlaying the existing concrete surrounds rather than demolishing and reconstructing them, substantial material waste and construction disruption were avoided.

Repurposing the structurally sound base extended the service life of the existing infrastructure while significantly reducing construction waste, transport requirements and embodied carbon associated with replacement concrete works.

This approach demonstrates how aging public infrastructure can be efficiently upgraded using reinforced overlay systems while minimising environmental impact and downtime for the community.

Key Performance Benefits

• P4 slip resistance suitable for wet aquatic environments
• Smooth, barefoot-friendly surface finish
• Reinforced overlay system designed to minimise reflective cracking
• Existing concrete retained, avoiding major demolition works
• Strong and flexible resin-bound paving system
• Rapid installation with only 3 days of pool closure required
• UV stable and suitable for harsh marine exposure
• Modern natural stone appearance enhancing the public space