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VERSION FOUR • DEC 2006

REPAIR AND PROTECTION SYSTEMS


FOR COASTAL ENGINEERING

Flexcrete Technologies Limited


“Flexcrete is committed to providing innovative
solutions to the rigorous demands facing the
Marine Industry today.”

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RISING TO THE CHALLENGE
Marine environments impose rigorous and unique demands on those
authorities, engineers and specifiers responsible for maintaining the
integrity of coastal defences, wharfs and pier deck structures. High
chloride levels in seawater, combined with the aggressive action of
waves and currents, push structural integrity to the limits, whilst, at
the same time, offering only fleeting opportunities for repair and
refurbishment. Structures in service need to withstand extreme
loading variations from wind and water movement, as well as
abrasion damage from waterborne debris. Flexcrete has long been
recognised as a foremost supplier of high performance repair and
protection systems for marine structures and currently offers its
widest ever range of specialist products for use in some of the most
hostile environments in the world.
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REPAIR AND PROTECTION SYSTEMS
for coastal engineering
Flexcrete’s range of purpose designed marine mortars, sprayed mortars and unique
cementitious coatings are based on the Company’s own highly advanced
microsilica, polymer and fibre technology. This affords optimum application and
performance in wet, chloride-laden environments and offers excellent resistance to
wash-out. Flexcrete marine products can be installed between tides to damp
substrates and will cure under water to form a resilient, durable finish that resists
abrasion and chloride ion diffusion. All Flexcrete products are manufactured with
sustainable development in mind and the Company is committed to providing
environmentally aware solutions.

ADVANTAGES
Flexcrete coastal engineering systems
• High performance, specially formulated
products for coastal structures.
• Quick to apply and to cure.
• Outstanding resistance to wash-out, enabling
placement between tides.
• Excellent adhesion in permanently wet or
immersed conditions.
• Resistant to chloride ion diffusion.
• Protection against structural deterioration.
• Resilient and durable even in extreme
conditions.
• Solvent-free and environmentally friendly.
• Highly impact resistant.
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THIN-FILM CEMENTITIOUS TECHNOLOGY

The Cemprotec range consists of a series of high performance, water-based


cementitious coatings that extend the durability of both steel and reinforced concrete
structures, offering excellent protection from the ingress of chlorides, water and
oxygen, and thereby minimising the risk of corrosion.

Cemprotec E942, a cement and epoxy modified polymer coating, is applied directly
to steel substrates to offer exceptional stand-alone protection against corrosion.
The cement based formulation results in the formation of a dense, highly alkaline
coating, which chemically passivates the steel enabling it to tolerate application to
damp surfaces with lower levels of preparation than conventional coating systems.

Cementitious Coating 851 is specifically designed for the protection of reinforced


concrete and incorporates Flexcrete’s unique technology to offer excellent
resistance to wash-out. Independent tests show that it is a barrier to chloride ion
diffusion and a 2mm coat provides nearly 1000mm of additional effective cover to
both new and existing reinforced concrete structures.

Cemprotec MCI ® 2020 is a surface applied migratory corrosion inhibitor that does
not need to be directly applied to the steel reinforcement. Based on a patented,
proven corrosion inhibitor, it migrates through the densest concrete to form a
protective film on the reinforcement to help prevent further corrosion. It is
particularly effective in marine environments. MCI® technology has been proven to
provide over 10 times the natural resistance to corrosion in steel reinforced concrete
structures.
® MCI is a registered trademark of Cortec Corporation

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ANTI-WASHOUT REPAIR MORTARS

The Company’s concrete repair materials, specifically developed for marine


applications, include hand placed mortars, spray applied mortars and pourable
concrete.

Marine Mortar, a high strength hand placed repair compound, is cement based and
will provide outstanding resistance to wash-out when immersed in water; showing
no loss of cement or fines. It has high build characteristics, develops key physical
properties extremely quickly and offers good mechanical qualities, thus assuring
excellent long-term durability.

Fastfill rapid setting mortar offers an outstanding compressive strength of 10N/mm²


after just one hour.

Flexcrete’s pre-bagged Monogun sprayed mortar enables rapid high build


applications in either open or enclosed locations, whilst its enhanced polymeric
properties ensure high adhesion, low shrinkage and good resistance to freeze/thaw
cycles. It exhibits minimal dusting and rebound losses and only the addition of
water at the spray nozzle is required to achieve a mortar that is easily placed and
floated to finish.

The Monopour range - available as a grout or micro-concrete - is ideal for re-


casting large areas of damaged concrete, whilst Monolevel levelling mortars are
designed for repairs to voids, cavities and honeycombing.

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ACCELERATED LOW WATER CORROSION
Accelerated low water corrosion (ALWC) has become an increasingly worrying
phenomenon since it was first identified in the 1960’s. ALWC, or concentrated corrosion
as it is often known, is a form of bacteriological corrosion and is primarily found on sheet
piled quays and flood defences. It is characterised by localised areas of soft orange
corrosion residue, overlaying a black organic sludge containing colonies of several types
of bacteria. At least one of these, sulphate-reducing bacteria (SRB), is capable of
changing sulphates in seawater to sulphuric acid.

Typical annual corrosion rates on sheet piling in the UK are estimated to be approximately
0.1mm. However, in ALWC affected areas, this rate can be as high as 1mm per annum
and worldwide rates of up to 8mm have been reported. Typical sheet piles of 12mm
original thickness have therefore seen their design life dramatically reduced from 120
years to just 12 years.

Traditionally, the onset of corrosion has been delayed by the application of a coating
system such as high build coal tar epoxy. However, the use of these types of products is
widely being precluded due to concerns over their carcinogenic nature and high solvent
content.

Flexcrete’s solution is unique. Cemprotec E942 is perfectly suited to combat the


problems associated with ALWC and has a number of benefits over traditional application
systems.

ADVANTAGES: E942 v COAL TAR EPOXY


PROBLEM: COAL TAR EPOXY SOLUTION: CEMPROTEC E942
Abrasive blast cleaning essential—Generally SA High tolerance of lower forms of surface
2½ or SA3. preparation.
Dampness affects adhesion. Damp tolerant.
Early immersion difficult. Tolerates early immersion.
Coal tar pitch is a carcinogen. Solvent free and low hazard in use.
Susceptible to mechanical damage for up to 7 Extremely durable after 24 hours.
days.
Barrier protection only—primer coat (zinc Self-priming system—very high alkalinity actively
phosphate) normally required. passivates corrosion.

Thin film coating (typically 400 microns) - High build coating (2000 microns) - affords
susceptible to early corrosion. superior barrier protection.

Generally solvented. Water based.

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SUPERIOR SOLUTIONS

1 2 3

problem problem problem


Steel and reinforced Corrosion of steel Corrosion of steel
concrete structures require reinforcement and spalling of reinforcement and spalling
protection from the concrete in splash zones due of concrete in tidal zones
corrosive effects of to continual wetting and drying due to continual pounding and
chlorides found in seawater. of surfaces and the action of erosion from wave action. The
Any coatings used must be salt spray. opportunity to carry out repairs
suitable for application in wet is limited to tidal windows.
environments with less than
ideal surface preparation.

solution solution solution


Cementitious Coating 851 is Monogun pre-bagged sprayed Marine Mortar is suitable for
easily applied to damp mortar has excellent low the repair of horizontal and
concrete with excellent rebound losses and is suitable vertical surfaces in marine
adhesion. It cures to form a for high build repairs over large environments. It is perfectly
dense coating with high levels areas. adapted to areas subject to
of protection from water, early immersion and provides
oxygen and chloride ion Monomix can be hand applied excellent wash-out resistance
penetration. In terms of water to re-profile small areas of against wave action.
permeability a 2mm coating of damage and a special grade
851 is equivalent to 1m of Monomix WS, is available for Monogun sprayed mortar is
good quality concrete and it application by wet process in highly adhesive and, with its
has a proven track record in larger areas. rapid curing properties, can be
some of the world’s most a pp li ed be tw een t id es .
demanding marine Cemprotec MCI® 2020 can be Monopour, a pourable grout
environments. Cemprotec applied to concrete faces and it or micro-concrete, can be
E942, a cement and epoxy diffuses through the structure to easily applied to re-cast large
modified polymer coating, can form a monomolecular areas of damaged concrete
be successfully sprayed protective layer on the and offers long term, high
directly onto steel substrates in reinforcement to protect it from strength properties.
damp conditions. Its corrosion.
impressively high resistance to
the ingress of the fuels for
c o r r os io n a nd i nh er e nt
alkalinity will ensure it provides
stand-alone anti-corrosion
protection.

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…. TO CHALLENGING PROBLEMS

4 5 6

problem problem problem


Erosion of coastal defences Natural stone structures Accelerated low water
such as jetties, harbour and require superior pointing and corrosion on sheet piled quays
sea walls due to continual bedding to ensure the integrity and steel structures in coastal
onslaught from the waves of the structure is maintained. environments. Concentrated
and exacerbated by the corrosion rates can
action of w aterborne dramatically reduce the design
shingle. life necessitating immediate
action.

solution solution solution


Fastfill, a rapid setting mortar Monolevel 844SP and Cemprotec E942 can be spray
can be applied into large voids Polymer Admixture 850 can or brush applied in tidal zones
on vertical and horizontal be combined to provide a high direct to steel substrates which
surfaces and consequently strength pointing and bedding have been cleaned using UHP
provides a resilient, durable mortar with excellent techniques. Rapidly stabilises
repair solution (compressive waterproofing and wash-out to exhibit good wash-out
strength of 10N/mm² after one resistance properties. resistance, enabling it to be
hour). immersed soon after
Marine Mortar can be hand application.
Marine Mortar improves applied to reinstate large joints
impact strength from in masonry and pre-cast Cemprotec Clucth Filler is
waterborne shingle and can be concrete units in tidal zones. available for sealing the
used to re-profile damaged surface gap at the interlock or
areas. Admix 50 can be added to clutch to provide complete
pointing mortars to produce a corrosion protection in these
Monogun sprayed mortar can cohesive, high strength material vulnerable areas.
be applied in situations where with enhanced adhesion and
time is a critical factor and its wash-out resistance. Water based non-hazardous
rapid cure properties make it products can be used in
an extremely effective solution confined areas such as limpet
with excellent wash-out or coffer dams.
resistance

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SYSTEM SELECTION
VOIDS & MIGRATORY ANTI PROTECTION ANTI WATERPROOF PAGE
CAVITY CORROSION CORROSION FROM WASHOUT DECK NUMBERS
FILLING INHIBITOR PROTECTION CHLORIDE MARINE PROTECTION
FOR STEEL ATTACK MORTARS
Monolevel √ √ 6, 9
844SP
Cemprotec √ 5, 8
MCI® 2020
Cemprotec √ √ 5, 7, 8, 11
E942
Cementitious √ √ 5, 8, 11
Coating 851
Cemprotec √ 8
E-Floor
Marine √ √ 6,9
Mortar S &
HD
LOW RAPID SPRAYED POURABLE ANTI POLYMER PAGE
SLUMP SETTING CONCRETE GROUT/ CARBONATION ADMIXTURES NUMBERS
REPAIR MORTAR FOR LARGE MICRO DECORATIVE
MORTAR AREAS CONCRETE COATING
Monomix √ 8

Monomix WS √ 8

Fastfill √ 6

Monogun √ 6, 8, 9

Monopour √ 6, 9
PG & PC6
Monolastex √ 8
Smooth
Polymer √ 9
Admixture
850
Admix 50 √ 9

TECHNICAL SERVICES
Flexcrete offers a complete range of technical services including:
• Contractor Training • Specifications
• Test Reports • Site Inspections
• On-site Technical Support • Quality Assurance
• CPD Presentations

Flexcrete products are available with a range of guarantees which can be tailored to meet
individual requirements. Key Flexcrete systems are independently certified by the British
Board of Agrément (BBA). BBA certificates are available on request. Technical data
sheets are also provided on request.

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PROJECT PROFILES
Flexcrete products have an outstanding national and international track record in
coastal environments.

PROJECT: Tranmere Jetty, Merseyside

PROBLEM: Concrete spalling and corrosion of reinforcement


on 70 supporting pillars due to chloride penetration
and water-borne pollutants.

SOLUTION: Following concrete repairs, Cementitious Coating


851 was chosen on the basis of its ability to form a
dense, impermeable matrix with excellent
resistance to chloride diffusion, water ingress and
chemical attack. It can be subjected to total
immersion in water within only an hour of
application without exhibiting any signs of wash-
out.

PROJECT: Deal Pier, Kent

PROBLEM: Deterioration of steel and concrete due to the


aggressive saline environment, changes in water
level and attack by sea spray.

SOLUTION: Spalled concrete was repaired using Flexcrete


repair mortars and the exposed flanges of steel
beams were protected with Cemprotec E942. Able
to withstand early immersion, E942 has excellent
resistance to impact and water ingress and
provides a total barrier against corrosion.

PROJECT: Doha Corniche, Qatar

PROBLEM: Protection of a 500m sea wall from the damaging


effects of salt-laden winds, salt spray, tidal action,
currents and impact damage.

SOLUTION: Following consideration of a number of protective


coatings, Cementitious Coating 8521 was speci-
fied to form a waterproof surface. The product can
be applied to damp substrates in temperatures be-
tween 5°C-35°C with minimal surface preparation.

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OTHER FLEXCRETE SYSTEMS
Flexcrete offers an extensive range of highly advanced repair mortars and specialist
coatings, all designed to combine maximum performance with ease of application.

The following are available on request:

♦ Interactive CD-Rom
♦ Full Range Corporate brochure
♦ Repair and Protection Systems for the Water Industry brochure
♦ Repair and Protection Systems for Civils & Building Structures
♦ Repair and Protection Systems for Floors & Trafficked Areas brochure

Flexcrete Technologies Limited


Tomlinson Road • Leyland • Lancashire • PR25 2DY • England
Tel: +44 (0) 845 260 7005
Fax: +44 (0) 845 260 7006
Email: info@flexcrete.com
www.flexcrete.com

The information herein is correct to the best of our knowledge, but it does not necessarily refer to the particular requirements
of the customer. If customers have any particular requirements, they should make them known in writing to Flexcrete
Technologies Limited, and obtain further advice accordingly.
12/06
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