Steel Marine Structures
Anti-Corrosion Coatings for Steel
Coastal steel structures are more prone to corrosion than inland, due to the aggressive nature of the environment, often exacerbated by a lack of preventative maintenance. There are many products available for remedial works, although a high level of surface preparation is generally needed. This includes the removal of all contaminants and corrosion by-products back to bright metal, a scenario often impossible in marine environments with restrictive tidal windows.
Accelerated Low Water Corrosion (ALWC)
Described as a ‘steel-eating bug epidemic’, the phenomenon of ALWC on marine sheet piling has been recognised since the 1990’s. ALWC is an aggressive form of corrosion, characterised by localised areas of soft orange rusting. Of concern to many Port Authorities and Engineers worldwide, it can pose unexpected engineering and financial challenges. ALWC has been found on structures within just 20 years of operation, requiring extensive and costly repair work on structures which would have otherwise been expected to last 60-120 years.
The most economical solution is to provide protection from ALWC at an early stage, maximising the design life and avoiding the risk of catastrophic, sudden failure. Flexcrete’s waterborne cementitious coating technology offers an effective defence strategy as it forms a dense barrier coating with excellent adhesion to protect from water, oxygen and chloride ion penetration.
Solutions for Coastal Engineering
Used in some of the world’s most hostile environments, Flexcrete products offer outstanding protection for coastal structures. Download this information sheet to find out more about our materials.
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E942 Corrosion Protection
Cemprotec E942 is designed to overcome the shortcomings of traditional corrosion protection products. Surface preparation is typically undertaken by UHP water jetting techniques to achieve excellent bond without a primer.
With fast resistance to wash-out, Cemprotec E942 is applied to damp substrates and will withstand immersion within two hours. The high build, rapid curing properties provide resistance to damage and the waterborne, solvent-free composition poses minimal risk during application.
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Steel Marine Structures Problems and Solutions
- Accelerated Low Water Corrosion
- Corrosion of Steel Membranes
The Problem
Accelerated low water corrosion on sheet piled quays and steel structures in coastal environments. Concentrated corrosion rates can dramatically reduce the design life necessitating immediate action.
The Solution
Cemprotec E942 can be spray or brush applied in tidal zones direct to steel substrates which have been cleaned using UHP techniques. It rapidly stabilises to exhibit good wash-out resistance, enabling it to be immersed soon after application.
Cemprotec Clutch Filler is available for sealing the surface gap at the interlock or clutch to provide complete corrosion protection in these vulnerable areas.
Water based non-hazardous products can be used in confined areas such as limpet or coffer dams.
The Problem
Failure of concrete encased steel sections on jetties. Chlorides have ingressed, resulting in corrosion of steel members and spalling of the protective concrete casing requiring reinstatement to provide protection.
The Solution
Cemprotec E942 can be spray or brush applied in tidal zones direct to steel substrates which have been cleaned using UHP techniques.
On cross members, Monomix can be hand applied although additional reinforcement may be required to provide additional mechanical bond.
Steel Marine Structures Products
Find out more below about Flexcrete’s range of products for protecting steel coastal structures:
Steel Marine Structures Projects
Take a look below at some of Flexcrete’s latest projects involving steel coastal structures, or browse the project profile pages to find more.
Project Profile
Project Location: Creekmoor Sheet Piles, Poole Harbour, Dorset
Corrosion protection of steel piling totalling 480m².
Project Location: Flood Defence Barrier Refurbishment Project, Essex
Flexcrete’s epoxy modified polymer modified coating Cemprotec E942 chosen for the corrosion protection at Flood Defence Barrier Refurbishment Project.
Project Profile
Project Location: Wadebridge Estuary, Cornwall
Flexcrete’s Cemprotec E942 was chosen to provide long lasting corrosion protection of sheet steel piles at Wadebridge Estuary in Cornwall.