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.
Download file: Solutions for Concrete Repair & Protection - Commercial Buildings
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.
Contact Flexcrete TodayConcrete Repair Problems and Solutions
- Corrosion of Reinforcement
- Chloride Ingress
- Carbonation
- Low Concrete Cover
The Problem
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 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
Extensive 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
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.
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
Low 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.
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.
| Bonding Bridge 842 | Advanced surface impregnant which ennhances bond on high porosity substrates. |  |
| Fastfill | Rapid setting concrete repair mortar. Can be bulked out in deep sections. | |
| Fastfill WP | Rapid setting concrete repair mortar for arresting water seepage and infiltration under pressure. Sets in 2 mins. | |
| Marine Mortar S | General purpose structural concrete repair mortar for use in marine and tidal areas. Early wash-out resistance. | |
| Monolite | Monolite is a lightweight mortar for cosmetic repairs. | |
| Monomix | Low density waterproof mortar for general purpose, structural repairs. | |
| Monomix HD | High strength, structural repair mortar with good abrasion resistance for trafficked areas. | |
| Monomix WS | Modified Monomix to allow wet spray application. Waterproof and low density. | |
| Monopour | Shrinkage compensated, waterproof, polymer modified, pourable grout (PG) or micro concrete (PC6) with excellent flow properties. | |
| Steel Reinforcement Protector 841 | Corrosion preventative flexible coating for steel reinforcement. | |
| Tiefill | Rapid curing mortar for the filling of tie-holes formed by formwork bolts. | |
| Unimatch | Rapid setting mortar for structural repairs to in-situ and pre-cast concrete. Supplied in grey and white for cosmetic colour matched repairs. | |
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.
| Monolevel 250F | Monolevel 250F is a fine grade polymer modified repair mortar for filling blow holes, cracks, surface defects & uneven surfaces. | |
| Monolevel 844SP | Engineering quality fairing coat to reinstate cover and provide a fair faced, waterproof and anticarbonation finish. | |
| Monolevel FC | Fairing coat for filling minor blow holes and defects prior to overcoating. | |
| Monolevel RM | Rendering and profiling of concrete to provide a fairfaced render finish. | |
| Monorub | Fine grade polymer modified mortar for filling blow holes to produce a smooth finish. | |
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.
| Polymer Admixture 850 | Admixture for cement mortars and floor toppings. | |
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.
| Cemprotec MCI® 2020 | Surface applied corrosion inhibitor for the protection of reinforcement in chloride contaminated concrete. | |
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: 10 Market Place, Cirencester
Flexcrete has provided the perfect structural repair, rendering and protective coating solution for this busy high street store.
Project Profile
Project: Hestskjæret Lighthouse, Norway
Monodex based coating chosen to protect Norwegian lighthouse from hostile environment, aggressive weather and constant attack from sea spray & wave action.
Project: 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.
