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01772 450950

Home » Solutions » Concrete Repair

Concrete Repair

Concrete Repair Excellence from Flexcrete

At Flexcrete we manufacture and supply a comprehensive range of concrete repair systems, perfectly suited to both new build and refurbishment construction projects. We have a vast range of specialist products that are designed to solve complex structural problems and reinstate structural integrity whilst causing the minimum of disruption during application.

Our concrete repair & protection products include structural repair mortars which can be applied up to 100mm in a single application, fast setting mortars designed for rapid reinstatement of heavily trafficked areas and cementitious coatings designed to reinstate low concrete cover; a simple 2mm application provides the equivalent of 100mm good quality concrete cover and offers low permeability to water, even at 10 bar positive and negative pressure. For a decorative finish, we offer a range of Monodex weatherproof anti-carbonation coatings which provide the ultimate protection against the ingress of carbon dioxide, oxygen and water and are available in smooth, textured and clear variants.

As our concrete repair and protection products have environmentally friendly, water-based, low hazard formulations, they are ultra-low odour and release no hazardous solvents during application. Daily routines can continue as normal and there is absolutely no disruption to other trades during new construction or refurbishment work. Our products are CE marked and comply with the demands of EN 1504, the pan European standard for concrete repair, so they can be relied upon with absolute confidence. They have an outstanding track record of use on buildings and commercial construction all around the world.

 

Flexcrete Concrete Repair and Protection Information Sheet

Download DocumentSolutions for Concrete Repair & Protection - Commercial Buildings

At Flexcrete, we have extensive expertise in the concrete repair and protection of all types of buildings and structures.  Download this information sheet to find out more about the benefits that our materials offer.

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Concrete Repair Flexcrete

The Need for Periodic Maintenance

Today, reinforced concrete is one of the most common building materials in the world. However, when subjected to the elements and environmental attack, even the most well-designed structures, constructed using the best quality concrete, need repair and protection.

Factors such as carbonation, water penetration, chemical attack, freeze/thaw cycling and chloride attack can all lead to significant deterioration of precast and in-situ concrete. Steel reinforcement can quickly corrode and compromise structural integrity. It is therefore essential to carry out periodic maintenance in order to guarantee the original design life of buildings and, above all, keep the people and contents within them safe.

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Concrete Repair Problems and Solutions

  • Corrosion of Reinforcement
  • Chloride Ingress
  • Carbonation
  • Low Concrete Cover

The Problem

Spalling Of Concrete CoverDue 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 shortened.

The Solution

Following removal of unsound concrete and preparation of the steel, 2 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

Loss Of Steel Section And Large Areas Of SpallingExtensive corrosion caused by chlorides, resulting in loss of steel section and large areas of spalling. The source can be chlorides which are cast-in, or those which ingress from external sources such as de-icing salts.

The Solution

Unsound concrete is removed and the prepared steel is given 2 coats of Steel Reinforcement Protector 841 by brush.

Monomix can be hand applied to re-profile small areas of damage and a special grade, Monomix WS, is available for application by wet process in larger areas.

Cemprotec MCI® 2020 will diffuse through the concrete structure to form a protective layer on the reinforcement to protect it from corrosion in chloride contaminated structures.

The Problem

Carbonation

Spalling Of ConcreteTo 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.

Where aesthetics are of lesser importance, two 1mm coats of Cementitious Coating 851 will also provide long term protection for the design life of the structure.

The Problem

Low Concrete Cover

Insufficient Corrosion ProtectionLow cover to reinforcement provides insufficient corrosion protection to the reinforcement. Reduced design life and durability is the result.

 

The Solution

Such low cover problems can be easily overcome by applying two 1mm coats of Cementitious Coating 851 by brush or spray.

The product is a barrier to chloride ions and water, even under 10 bar pressure. It also provides the equivalent of 70mm of additional concrete cover.

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Concrete Repair Products

Concrete Repair Mortars

Flexcrete offers an extensive range of engineering quality, waterproof concrete repair mortars for both structural and cosmetic repairs. Primers are not required and packs can be split and simply mixed with water. Our range includes Monomix mortars, easily applied up to 80mm in a single application, Fastfill which is designed to allow rapid return to service especially in heavily trafficked areas and our lightweight mortar Monolite.

Browse Flexcrete's Concrete Repair Mortars

Fastfill Rapid setting concrete repair mortar. Can be bulked out in deep sections. more
Fastfill WP Rapid setting concrete repair mortar for arresting water seepage and infiltration under pressure. Sets in 2 mins. more
Marine Mortar S General purpose structural concrete repair mortar for use in marine and tidal areas. Early wash-out resistance. more
Monolite Monolite is a lightweight mortar for cosmetic repairs. more
Monomix Low density waterproof mortar for general purpose, structural repairs. more
Monomix HD High strength, structural repair mortar with good abrasion resistance for trafficked areas. more
Monomix WS Modified Monomix to allow wet spray application. Waterproof and low density. more
Monopour Shrinkage compensated, waterproof, polymer modified, pourable grout (PG) or micro concrete (PC6) with excellent flow properties. more
Steel Reinforcement Protector 841 Corrosion preventative flexible coating for steel reinforcement. more
Tiefill Rapid curing mortar for the filling of tie-holes formed by formwork bolts. more
Unimatch Rapid setting mortar for structural repairs to in-situ and pre-cast concrete. Supplied in grey and white for cosmetic colour matched repairs. more

Fairing Coats & Renders

For a decorative, protective finish our Monodex anti-carbonation coatings are water-based, environmentally friendly and available in a wide range of attractive colours. With a design life of 10-15 years before first maintenance, Monodex coatings provide years of protection against general weathering, carbonation and water ingress, yet allow damp substrates to breathe without blistering or delaminating. Our clear anti-carbonation coating, Monodex Clear, also demonstrates exceptional resistance to carbon dioxide diffusion.

Browse Flexcrete's Concrete Repair Fairing Coats & Renders

Monolevel 844SP Engineering quality fairing coat to reinstate cover and provide a fair faced, waterproof and anticarbonation finish. more
Monolevel FC Fairing coat for filling minor blow holes and defects prior to overcoating. more
Monolevel RM Rendering and profiling of concrete to provide a fairfaced render finish. more
Monorub Fine grade polymer modified mortar for filling blow holes to produce a smooth finish. more

Admixtures

Flexcrete’s versatile admixture products are specifically designed to enhance cementitious mixes in order to achieve improved mechanical characteristics with excellent resistance to oil, water and abrasion.

Browse Flexcrete's Concrete Repair Admixtures

Polymer Admixture 850 Admixture for cement mortars and floor toppings. more

Corrosion Inhibitors

Flexcrete offers various anti-corrosion measures which can extend the lifespan of infrastructure and buildings. For example, our surface-applied corrosion inhibitors are specially formulated to migrate through concrete on existing structures to seek out and help protect the steel reinforcement.

Browse Flexcrete's Concrete Corrosion Inhibitors

Cemprotec MCI® 2020 Surface applied corrosion inhibitor for the protection of reinforcement in chloride contaminated concrete. more

Concrete Repair Projects

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

Project Profile

Complete Repair & Protection Solution for Façade of Retail Outlet

concrete repair Cirencester
Posted on 20-03-2017

Project Location: 10 Market Place, Cirencester

Flexcrete has provided the perfect structural repair, rendering and protective coating solution for this busy high street store.

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
Project Profile

Assuring the Design Life of the Bloomberg Development in London

Structural Repair System for Bloomberg Development, London
Posted on 3-11-2015

Project Location: Bloomberg Office Development, City of London

Flexcrete’s Class R4 structural repair mortar and render have been chosen for slab edge trimming and remedial works at the Bloomberg development in London.

Read The Project Profile
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The Latest Cementitious Technology

Technical innovation is key at Flexcrete and our investment in Research and Development means that we can offer the most technologically advanced and innovative repair and protection materials. Our concrete repair products incorporate a unique blend of polymers, microsilica and fibres, and are simply installed using spray-applied, trowel-applied and pourable techniques.

Flexcrete’s concrete repair products are used to solve complex structural problems and are widely respected by designers, engineers and contractors alike. They offer the ultimate protection against chemicals, chloride ions, carbonation, water penetration and other aggressive forms of attack and have a long track record of success in some of the world’s most hostile environments.

Repairing Concrete Structures in Key Market Sectors…

Flexcrete can call upon decades of knowledge and experience to offer high performance, long-lasting concrete repair solutions for a variety of market sectors. Simply hover your mouse over the various hot spots in the illustration below and then click to find out more…

[litetooltip_hotspot id=”6577″]

Do You Have a Concrete Repair Problem?

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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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