Coastal Engineering Brochure

8/8/2019 Coastal Engineering Brochure

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Flexcrete is committed to providing innovativesolutions 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 thoseauthorities, engineers and specifiers responsible for maintaining the

integrity of coastal defences, wharfs and pier deck structures. Highchloride levels in seawater, combined with the aggressive action ofwaves and currents, push structural integrity to the limits, whilst, atthe same time, offering only fleeting opportunities for repair andrefurbishment. Structures in service need to withstand extremeloading variations from wind and water movement, as well asabrasion damage from waterborne debris. Flexcrete has long beenrecognised as a foremost supplier of high performance repair andprotection systems for marine structures and currently offers its

widest ever range of specialist products for use in some of the mosthostile environments in the world.


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REPAIR AND PROTECTION SYSTEMSfor coastal engineering

Flexcrete coastal engineering systems

Flexcretes range of purpose designed marine mortars, sprayed mortars and uniquecementitious coatings are based on the Companys own highly advancedmicrosilica, polymer and fibre technology. This affords optimum application andperformance in wet, chloride-laden environments and offers excellent resistance towash-out. Flexcrete marine products can be installed between tides to dampsubstrates and will cure under water to form a resilient, durable finish that resistsabrasion and chloride ion diffusion. All Flexcrete products are manufactured withsustainable development in mind and the Company is committed to providingenvironmentally aware solutions.

ADVANTAGES

High performance, specially formulated

products for coastal structures. Quick to apply and to cure.

Outstanding resistance to wash-out, enablingplacement between tides.

Excellent adhesion in permanently wet orimmersed conditions.

Resistant to chloride ion diffusion.

Protection against structural deterioration.

Resilient and durable even in extremeconditions.

Solvent-free and environmentally friendly. Highly impact resistant.


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The Cemprotec range consists of a series of high performance, water-basedcementitious coatings that extend the durability of both steel and reinforced concrete

structures, offering excellent protection from the ingress of chlorides, water andoxygen, and thereby minimising the risk of corrosion.

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

Cementitious Coating 851 is specifically designed for the protection of reinforcedconcrete and incorporates Flexcretes unique technology to offer excellent

resistance to wash-out. Independent tests show that it is a barrier to chloride iondiffusion and a 2mm coat provides nearly 1000mm of additional effective cover toboth new and existing reinforced concrete structures.

Cemprotec MCI 2020 is a surface applied migratory corrosion inhibitor that doesnot need to be directly applied to the steel reinforcement. Based on a patented,proven corrosion inhibitor, it migrates through the densest concrete to form aprotective film on the reinforcement to help prevent further corrosion. It isparticularly effective in marine environments. MCI

technology has been proven to

provide over 10 times the natural resistance to corrosion in steel reinforced concretestructures.

MCI is a registered trademark of Cortec Corporation

THIN-FILM CEMENTITIOUS TECHNOLOGY


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ANTI-WASHOUT REPAIR MORTARS

The Companys concrete repair materials, specifically developed for marineapplications, include hand placed mortars, spray applied mortars and pourableconcrete.

Marine Mortar, a high strength hand placed repair compound, is cement based andwill provide outstanding resistance to wash-out when immersed in water; showingno loss of cement or fines. It has high build characteristics, develops key physicalproperties extremely quickly and offers good mechanical qualities, thus assuringexcellent long-term durability.

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

after just one hour.

Flexcretes pre-bagged Monogun sprayed mortar enables rapid high buildapplications in either open or enclosed locations, whilst its enhanced polymericproperties ensure high adhesion, low shrinkage and good resistance to freeze/thawcycles. It exhibits minimal dusting and rebound losses and only the addition ofwater at the spray nozzle is required to achieve a mortar that is easily placed andfloated 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

ADVANTAGES: E942 v COAL TAR EPOXY

Accelerated low water corrosion (ALWC) has become an increasingly worryingphenomenon since it was first identified in the 1960s. ALWC, or concentrated corrosion

as it is often known, is a form of bacteriological corrosion and is primarily found on sheetpiled quays and flood defences. It is characterised by localised areas of soft orangecorrosion residue, overlaying a black organic sludge containing colonies of several typesof bacteria. At least one of these, sulphate-reducing bacteria (SRB), is capable ofchanging sulphates in seawater to sulphuric acid.

Typical annual corrosion rates on sheet piling in the UK are estimated to be approximately0.1mm. However, in ALWC affected areas, this rate can be as high as 1mm per annumand worldwide rates of up to 8mm have been reported. Typical sheet piles of 12mmoriginal thickness have therefore seen their design life dramatically reduced from 120years to just 12 years.

Traditionally, the onset of corrosion has been delayed by the application of a coatingsystem such as high build coal tar epoxy. However, the use of these types of products iswidely being precluded due to concerns over their carcinogenic nature and high solventcontent.

Flexcretes solution is unique. Cemprotec E942 is perfectly suited to combat theproblems associated with ALWC and has a number of benefits over traditional applicationsystems.

PROBLEM: COAL TAR EPOXY SOLUTION: CEMPROTEC E942

Abrasive blast cleaning essentialGenerally SA

2 or SA3.

High tolerance of lower forms of surface

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 7days.

Extremely durable after 24 hours.

Barrier protection onlyprimer coat (zincphosphate) normally required.

Self-priming systemvery high alkalinity activelypassivates corrosion.

Thin film coating (typically 400 microns) -

susceptible to early corrosion.

High build coating (2000 microns) - affords

superior barrier protection.

Generally solvented. Water based.


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SUPERIOR SOLUTIONS

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problem

Steel and reinforcedconcrete structures requirepro tec t ion f rom thecorrosive e f fects of chlorides found in seawater.Any coatings used must besuitable for application in wetenvironments with less thanideal surface preparation.

solution

Cementitious Coating 851 iseasily applied to dampconcrete with excellentadhesion. It cures to form adense coating with high levelsof protection from water,oxygen and chloride ionpenetration. In terms of waterpermeability a 2mm coating of851 is equivalent to 1m ofgood quality concrete and it

has a proven track record insome of the worlds mostd e m a n d i n g m a r i n eenvironments. CemprotecE942, a cement and epoxymodified polymer coating, canbe successfully sprayeddirectly onto steel substrates indamp condit ions. Itsimpressively high resistance tothe ingress of the fuels forcorrosion and inherentalkalinity will ensure it provides

stand-alone anti-corrosionprotection.

problem

C o r r o s i o n o f s t e e lreinforcement and spalling ofconcrete in splash zones dueto continual wetting and dryingof surfaces and the action ofsalt spray.

solution

Monogun pre-bagged sprayedmortar has excellent lowrebound losses and is suitablefor high build repairs over largeareas.

Monomix can be hand appliedto re-profile small areas ofdamage and a special gradeMonomix WS, is available forapplication by wet process in

larger areas.

Cemprotec MCI 2020 can beapplied to concrete faces and itdiffuses through the structure tofo rm a monomolecu la r protective layer on thereinforcement to protect it from

corrosion.

problem

C o r r o s i o n o f s t e e lreinforcement and spallingof concrete in tidal zonesdue to continual pounding anderosion from wave action. Theopportunity to carry out repairsis limited to tidal windows.

solution

Marine Mortar is suitable forthe repair of horizontal andvertical surfaces in marineenvironments. It is perfectlyadapted to areas subject toearly immersion and providesexcellent wash-out resistanceagainst wave action.

Monogun sprayed mortar ishighly adhesive and, with its

rapid curing properties, can beapplied between t ides.Monopour, a pourable groutor micro-concrete, can beeasily applied to re-cast largeareas of damaged concreteand offers long term, highstrength properties.


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. TO CHALLENGING PROBLEMS

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problem

Erosion of coastal defencessuch as jetties, harbour andsea walls due to continualonslaught from the wavesand exacerbated by theaction of waterborneshingle.

solution

Fastfill, a rapid setting mortarcan be applied into large voidson vertical and horizontalsurfaces and consequentlyprovides a resilient, durablerepair solution (compressivestrength of 10N/mm after onehour).

Marine Mortar improvesi m p a c t s t r e n g t h f r o m

waterborne shingle and can beused to re-profile damagedareas.

Monogun sprayed mortar canbe applied in situations wheretime is a critical factor and itsrapid cure properties make itan extremely effective solutionwith excellent wash-outresistance

problem

Natural stone structuresrequire superior pointing andbedding to ensure the integrityof the structure is maintained.

solution

Monolevel 844SP andPolymer Admixture 850 canbe combined to provide a highstrength pointing and beddingm o r t a r w i t h e x c e l l e n twaterproofing and wash-outresistance properties.

Marine Mortar can be handapplied to reinstate large jointsin masonry and pre-cast

concrete units in tidal zones.

Admix 50 can be added topointing mortars to produce acohesive, high strength materialwith enhanced adhesion andwash-out resistance.

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problem

Accelerated low watercorrosion on sheet piled quaysand steel structures in coastalenvironments. Concentratedc o r r o s i o n r a t e s c a ndramatically reduce the designlife necessitating immediateaction.

solution

Cemprotec E942 can be sprayor brush applied in tidal zonesdirect to steel substrates whichhave been cleaned using UHPtechniques. Rapidly stabilisesto exhibit good wash-outresistance, enabling it to bei m m e r s e d s o o n a f t e r application.

Cemprotec Clucth Filler is

available for sealing thesurface gap at the interlock orclutch to provide completecorrosion protection in thesevulnerable areas.

Water based non-hazardousproducts can be used inconfined areas such as limpetor coffer dams.


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SYSTEM SELECTIONVOIDS &CAVITYFILLING

MIGRATORYCORROSIONINHIBITOR

ANTICORROSIONPROTECTIONFOR STEEL

PROTECTIONFROM

CHLORIDEATTACK

ANTIWASHOUT

MARINEMORTARS

WATERPROOFDECK

PROTECTION

PAGENUMBERS

Monolevel844SP

6, 9

CemprotecMCI 2020

5, 8

CemprotecE942

5, 7, 8, 11

CementitiousCoating 851

5, 8, 11

CemprotecE-Floor

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MarineMortar S &HD

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LOWSLUMPREPAIR

MORTAR

RAPIDSETTINGMORTAR

SPRAYEDCONCRETEFOR LARGE

AREAS

POURABLEGROUT/MICRO

CONCRETE

ANTICARBONATIONDECORATIVE

COATING

POLYMERADMIXTURES

PAGENUMBERS

Monomix 8

Monomix WS 8

Fastfill 6

Monogun 6, 8, 9

MonopourPG & PC6

6, 9

MonolastexSmooth

8

PolymerAdmixture850

9

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 meetindividual requirements. Key Flexcrete systems are independently certified by the British

Board of Agrment (BBA). BBA certificates are available on request. Technical datasheets 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 reinforcementon 70 supporting pillars due to chloride penetrationand water-borne pollutants.

SOLUTION: Following concrete repairs, Cementitious Coating851 was chosen on the basis of its ability to form adense, impermeable matrix with excellentresistance to chloride diffusion, water ingress and

chemical attack. It can be subjected to totalimmersion in water within only an hour ofapplication without exhibiting any signs of wash-out.

PROJECT: Deal Pier, Kent

PROBLEM: Deterioration of steel and concrete due to theaggressive saline environment, changes in waterlevel and attack by sea spray.

SOLUTION:Spalled concrete was repaired using Flexcreterepair mortars and the exposed flanges of steelbeams were protected with Cemprotec E942. Ableto withstand early immersion, E942 has excellentresistance to impact and water ingress andprovides 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 protectivecoatings, Cementitious Coating 8521 was speci-fied to form a waterproof surface. The product canbe applied to damp substrates in temperatures be-tween 5C-35C with minimal surface preparation.


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OTHER FLEXCRETE SYSTEMS

Flexcrete offers an extensive range of highly advanced repair mortars and specialistcoatings, 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

The information herein is correct to the best of our knowledge, but it does not necessarily refer to the particular requirementsof 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

Flexcrete Technologies LimitedTomlinson Road Leyland Lancashire PR25 2DY England

Tel: +44 (0) 845 260 7005Fax: +44 (0) 845 260 7006Email: [email protected]

www.flexcrete.com

Coastal Engineering Brochure

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