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01772 450950

Home » Solutions » Anti-Carbonation Protective Coatings

Anti-Carbonation Protective Coatings

The Process of Carbonation

Carbonation of reinforced concrete is one of the most common forms of deterioration in buildings and infrastructure. Untreated masonry is also highly vulnerable to the damaging ingress of water and freeze/thaw cycling. Carbonation is a natural process and is virtually impossible to avoid in unprotected concrete as the process begins as soon as concrete is exposed to the elements. Carbon dioxide from the atmosphere reacts with the concrete, leading to a loss of alkalinity and subsequent corrosion of the reinforcing steel. Structural integrity can therefore become severely compromised so it is critical to specify anti-carbonation coatings for both new and existing structures. Such products can ensure that buildings remain visually attractive throughout their lifespan and avoid costly and disruptive repair and maintenance work further down the line.

High Performance Anti-Carbonation Solution

Flexcrete has developed the Monodex range of weatherproof, anti-carbonation coatings to provide ultimate protection against the ingress of carbon dioxide, oxygen and water, whilst allowing damp substrates to breathe without blistering. With eco-friendly, water-based, low hazard, high build formulations, these weatherproof masonry coatings are ultra-fast drying, enabling two coat applications on the same day even in inclement weather conditions. They also incorporate an active in-film fungicide which inhibits the growth of mould, fungi and lichens and with elastomeric formulations, are able to cover static cracks and bridge dynamic cracks. Able to withstand extreme temperatures of -50°C to +80°C without deterioration, the coatings remain unaffected by exposure to direct sunlight, even in the most aggressive of climates.

Download DocumentSolutions for Concrete Weatherproofing

Reinforced concrete is not as durable as once anticipated and further protection is often necessary in order to achieve the desired design life. Download our information sheet for more details about our materials.  

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Anti-Carbonation Coatings and Masonry Coatings by Flexcrete

Monodex Protection

Designed to last for up to 15 years, Flexcrete’s Monodex anti-carbonation coatings considerably extend the life expectancy of precast and in-situ concrete whilst also protecting new, existing and repaired masonry structures. Monodex coatings have water-based, low hazard formulations so release no hazardous solvents or heavy odour during application. Available with a range of finishes including smooth and textured, they are highly decorative and can be specified in several standard colours, with special colours made to order.

We also offer a clear, water-based anti-carbonation coating, Monodex Clear, which provides exceptional resistance to carbon dioxide diffusion and the effects of general weathering. It allows the original appearance of concrete and masonry substrates to be retained and is ideal for heritage applications and for the protection of decorative concrete finishes, exposed aggregate panels, coloured concrete and other cementitious substrates.

 

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Anti-Carbonation Protective Coatings Problems and Solutions

  • Protection Against Carbonation
  • Corrosion of Reinforcement
  • General Degradation

The Problem

Protection Against CarbonationTo give proven protection against carbonation and so extend the design life of a reinforced concrete structure. Such a barrier prevents further corrosion of steel reinforcement and subsequent spalling of the surrounding concrete.

 

The Solution

Following repair, the complete structure is treated with Monodex Smooth, a coating with outstanding anti-carbonation properties. This highly aesthetic coating also has excellent weathering and UV resistance and a serviceable life of at least 15 years.

The Problem

Anti-Carbonation CoatingsDue to carbonation, localised corrosion of the reinforcement had occurred, resulting in spalling of the concrete cover. Left untreated, the design life of the structure would have been severely shortened.

 

The Solution

Following removal of unsound concrete and preparation of the steel, two coats of Steel Reinforcement Protector 841 are applied by brush. Missing or removed concrete is then reinstated. Where a high build structural repair mortar is required, Monomix is the best choice. For general purpose repairs, Monolite, a low density mortar can be used. Monolite can be applied in thicknesses up to 100mm in a single layer. Afterwards, Monolevel FC may be applied to all surfaces using a bag rubbing technique to achieve a fair-faced finish, prior to the application of a decorative anti-carbonation coating such as Monodex Smooth.

The Problem

Long Term Protective Coating SolutionGeneral degradation of the infrastructure needs cost-effective repair and a long term protective coating solution.

 

The Solution

Flexcrete offers a wide range of repair systems to match the equally wide range of reinforced concrete structures that form an integral part of industry infrastructure. Based on Flexcrete’s core technology: a unique blend of polymers, microsilica and fibres, the products include wet sprayed, dry sprayed, rapid setting, pourable and trowel applied repair mortars: Monomix WS, Fastfill and Monomix. When repairs have been carried out, an anti-carbonation and decorative finish can be achieved by applying Monodex Smooth.

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Anti-Carbonation Protective Coatings Products

Find out more about Flexcrete’s range of anti-carbonation and associated products below:

Biodex Wash A powerful surface treatment for neutralising active mould, fungal and bacterial growth prior to the application of Flexcrete products. more
Bond-Prime Single pack epoxy polymer primer to seal and consolidate substrates. more
Cementitious Coating 851 Structural waterproofing. Protection from chloride ingress and carbonation. Reinstatement of cover. more
Cemprotec E942 Waterproofing and protection of concrete where enhanced chemical resistance is needed. Stand alone anti-corrosion coating for ferrous metal. more
Cemprotec Elastic Waterproofing and protection of concrete where further movement is expected. more
Cemprotec Flex-Tape Covering small, static cracks and joints. Covering larger cracks and joints which are subject to movement and spanning joints between dissimilar substrates. more
Cemprotec GFM An advanced glass fibre reinforcement matting system. more
Monodex Smooth High build, decorative anti-carbonation coating, which allows damp substrates to breathe. more
Monodex Textured Highly textured, flexible waterproof coating for internal and external use. more
Monodex Ultra High performance decorative, anticarbonation masonry coating. more
Monodex UVC UV cured, waterborne coating which produces a hard wearing, dirt resistant finish with a softer, permanently flexible core. more
Monodex ICB Intermediate crack-bridging coating for use beneath Monodex pigmented membranes. more

Anti-Carbonation Protective Coatings Projects

Take a look below at some of Flexcrete’s latest anti-carbonation projects, or browse the project profile pages to find more.

Project Profile

Aesthetic, Protective Coating Provided for Fine Dining Restaurant

Flexcrete coating for Moor Hall
Posted on 18-10-2017

Project Location: Moor Hall, Aughton, Lancashire

Flexcrete has provided a rendering, damp-proofing and protective coating solution for Moor Hall fine dining restaurant in Aughton, Lancashire.

Read The Project Profile
Project Profile

Clear Anti-Carbonation Protection for Civic Centre

clear anti-carbonation coating project
Posted on 16-10-2017

Project Location: Gravesham Borough Council Civic Centre, Gravesend

A transparent anti-carbonation coating was required for the external walls of Gravesham’s Civic Centre in Kent. Monodex Clear from Flexcrete Technologies was selected as the perfect solution.

Read The Project Profile
Project Profile

Protection from the Elements for Norwegian Lighthouse

Monodex coating protection for Norwegian lighthouse
Posted on 15-03-2017

Project Location: Hestskjæret Lighthouse, Norway

Monodex based coating chosen to protect Norwegian lighthouse from hostile environment, aggressive weather and constant attack from sea spray & wave action.

Read The Project Profile
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Flexcrete Brochure

Find out more about our concrete repair and protection services. Read the Flexcrete product brochure online, or download a copy today

Read The Brochure
Flexcrete 2014 Brochure
Export Champion 2021-2022

Flexcrete Technologies Ltd

Tomlinson Road,
Leyland,
Lancashire,
PR25 2DY
United Kingdom

Telephone: +44 (0)1772 450950

E-mail: web@flexcrete.com

Registered: 5401028 England

Products

  • Concrete Repair Products
    • Repair Mortars
      • Bonding Bridge 842
      • Fastfill
      • Fastfill WP
      • Marine Mortar S
      • Monolite
      • Monomix
      • Monomix HD
      • Monomix WS
      • Monopour
      • Steel Reinforcement Protector 841
      • Tiefill
      • Unimatch
    • Fairing Coats & Renders
      • Monolevel 844SP
      • Monolevel FC
      • Monolevel RM
      • Monorub
    • Admixtures
      • Polymer Admixture 850
    • Corrosion Inhibitors
      • Cemprotec MCI® 2020
  • Decorative Protective Coatings
    • Anti-Carbonation Coatings
      • Monodex Smooth
      • Monodex Textured
      • Monodex Ultra
      • Monodex UVC
      • Monodex ICB
    • Hygiene Coatings
      • Biodex HB
      • Biodex Sheen
    • Clear Surface Sealers
      • Monosil
  • Structural Waterproofing & Tanking
    • Cementitious Waterproofing Coatings
      • Cementitious Coating 851
      • Cemprotec E942
      • Cemprotec Elastic
  • Enhanced Durability For Concrete & Steel
    • Corrosion Protection For Steel
      • Cemprotec Clutch Filler
      • Cemprotec E942
    • Protection Against Gas, Chemicals & Chlorides
      • Cementitious Coating 851
      • Cemprotec E942
      • Cemprotec Elastic
  • Waterproofing Of Roofs & Other Deck Areas
    • High Performance Roof Coatings
      • Cemprotec Elastic
      • Roofdex HB
    • Waterproofing of Concrete Floors
      • Cemprotec E-Floor
      • Cemprotec E-Floor HB
      • Cemprotec EF Grit
      • Cemprotec EF Primer
      • Cemprotec Levelling Coat
  • Ancillaries
    • Surface Preparation & Primers
      • Biodex Wash
      • Bond-Prime
    • Reinforcements
      • Cemprotec 2000-BJT
      • Cemprotec 2000-S
      • Cemprotec Edge Scrim
      • Cemprotec Flex-Tape
      • Cemprotec Geo80
      • Cemprotec GFM
      • Cemprotec Scrim
    • Curing Membranes
      • Cure-Seal WB

Sectors

  • Civil Engineering & Infrastructure
  • Buildings & Commercial Construction
  • Utilities
  • Coastal Structures
  • Hygiene Sensitive Environments

CPD Presentation

Book a Flexcrete CPD Presentation and find out more about our Concrete Repair & Protection Products and discover how our industry leading technology could benefit your next project.
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