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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
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.
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
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.
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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.
Thin film coating (typically 400 microns) - High build coating (2000 microns) - affords
susceptible to early corrosion. superior barrier protection.
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SUPERIOR SOLUTIONS
1 2 3
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…. TO CHALLENGING PROBLEMS
4 5 6
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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.
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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.
♦ 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 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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