Corrosion Protection
Innovative Corrosion Solutions
Flexcrete specialises in corrosion protection and offers anti-corrosion products for steel reinforcement protection and polymer epoxy modified cementitious coatings for the protection of steel and other ferrous metals. Corrosion damage may not always be visible to the eye, but at worst it can lead to structural failure and therefore needs to be rectified in order to ensure public safety. Steel structures such as bridges and tunnels are susceptible to corrosion, as is steel reinforcement in concrete, so effective anti-corrosion measures are needed to extend the lifespan of infrastructure and buildings for the next generation and beyond.
Deterioration of ferrous metals typically occurs in onerous environments, such as access shafts and tunnels. Repairs often need to be carried out in confined and difficult conditions, where the atmosphere is damp and acidic with strict limitations in place regarding working hours and the use of hazardous products and processes. Furthermore, environmental constraints limit the amount of surface preparation that can be carried out and the use of solvents and grit blasting is strictly forbidden.
E942 Corrosion Protection
Our Cemprotec E942 coating can be applied with only the minimum surface preparation and a primer is not required. It exhibits excellent adhesion even when surface dampness is present, and rapidly cures to form a dense barrier designed to keep out all the fuels for corrosion.
Due to its non-hazardous, waterborne composition, Cemprotec E942 is completely safe to use in confined spaces. In addition, as it is compliant with London Underground Limited (LUL) standard 1-085 for Fire Safety Performance, the product has surpassed stringent criteria for fire, smoke and toxic fume emissions required for products applied to sub-surface rail networks.
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Corrosion Protection Problems and Solutions
- Corrosion Under Insulation (CUI)
- Anti-Corrosion Pipeline Coating
- Microbial Induced Corrosion
The Problem
Degraded, damp and wet insulation under metal cladding or on bulkheads leads to rapid corrosion and deterioration.
The Solution
CUI can be effectively controlled and prevented by coating the pipes and steelwork with two layers of Cemprotec E942. This stand-alone anti-corrosive system is equally effective when applied to steel where full preparation to Sa2½ is not possible. Independent tests have documented its performance even when subjected to temperature cycles which typically pass repeatedly through the dew point
The Problem
To protect pipes, sheet piling and other ferrous metal substrates from corrosion.
The Solution
An effective barrier to corrosion is provided by two coats of Cemprotec E942. This product is applied direct to ferrous metals and chemically reacts to provide complete anti-corrosion protection in the form of a dense film. This keeps out the fuels for corrosion without the need for a special priming system. Application can be carried out under either factory or site conditions; both are equally suitable.
The Problem
Microbial induced 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. Rapidly stabilises to exhibit good wash-out resistance, enabling it to be immersed soon after application.
Cemprotec Clucth 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.
Corrosion Protection Products
Find out more about Flexcrete’s range of anti-corrosion products below:
| Cemprotec Clutch Filler | Mortar for sealing the surface gap at the interlock or clutch between piles. |  |
| Cemprotec E942 | Waterproofing and protection of concrete where enhanced chemical resistance is needed. Stand alone anti-corrosion coating for ferrous metal. | |
| Metal-Prime WB | Single pack, waterborne, anti-corrosion primer for metal and difficult to adhere to substrates. | |
Corrosion Protection Projects
Take a look below at some of Flexcrete’s latest corrosion protection projects, or browse the project profile pages to find more.
Project Profile
Project: Lynemouth Power Station, Northumberland
High performance, anti-corrosion coating provided for sheet piling in new rail offload areas.
Project: Norfolk & Norwich University Hospital, Norwich
Flexcrete has provided waterproof, anti-corrosion treatment and surface protection for trafficked floor areas at the Norfolk and Norwich University Hospital.
Project Profile
Project: St. Peter Port Docks, Guernsey
At St Peter Port Docks in Guernsey, Flexcrete’s products were used on one of the largest marine repair and cathodic protection systems ever installed in Europe.