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.
Solutions 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.
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
To 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.
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.
Due 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.
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.
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.
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.|
|Bond-Prime||Single pack epoxy polymer primer to seal and consolidate substrates.|
|Cementitious Coating 851||Structural waterproofing. Protection from chloride ingress and carbonation. Reinstatement of cover.|
|Cemprotec E942||Waterproofing and protection of concrete where enhanced chemical resistance is needed. Stand alone anti-corrosion coating for ferrous metal.|
|Cemprotec Elastic||Waterproofing and protection of concrete where further movement is expected.|
|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.|
|Cemprotec GFM||An advanced glass fibre reinforcement matting system.|
|Monodex Clear||Clear anti-carbonation coating with high diffusion resistance to carbon dioxide diffusion.|
|Monodex Smooth||High build, decorative anti-carbonation coating, which allows damp substrates to breathe.|
|Monodex Textured||Highly textured, flexible waterproof coating for internal and external use.|
|Monodex Ultra||High performance decorative, anticarbonation masonry coating.|
|Monodex Metallic||High performance, elastomeric, water-based anti-carbonation coating with a metallic finish.|
|Monodex UVC||UV cured, waterborne coating which produces a hard wearing, dirt resistant finish with a softer, permanently flexible core.|
|Monodex ICB||Intermediate crack-bridging coating for use beneath Monodex pigmented membranes.|
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.