Concrete Marine Structures
Protecting Concrete Coastal Structures
Reinforced concrete structures in marine environments often deteriorate prematurely in the early stages of service life. When structures are in their infancy, the high alkalinity of concrete forms a passivating layer on embedded steel reinforcement, providing the required corrosion protection.
However, when concrete structures are constantly submerged in saltwater and exposed to salt spray, chloride ions penetrate concrete, eventually breaking down this passivating layer to initiate corrosion. This process occurs most rapidly in the splash zone where there is sufficient oxygen to facilitate corrosion and the intermittently wet and dry conditions exacerbate chloride penetration. Moisture present in the concrete also increases the electrical conductivity, leading to rust pitting – an aggressive form of localised corrosion. This causes rapid loss of steel sections with consequent cracking and spalling of concrete.
In tidal and submerged zones where the concrete is saturated, oxygen levels are limited as concrete pores are constantly filled with water. However, in areas of low concrete cover, corrosion can still occur, causing a challenge for reinstatement.
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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Chloride and Corrosion Protection
Flexcrete offers technologically advanced reinstatement mortars specifically for marine use and cementitious coatings to provide long-term protection in hostile coastal environments.
Proven worldwide and with CE mark accreditation to the latest BS EN 1504 standards, Flexcrete mortars and anti-corrosion coatings are resistant to early wash-out and afford optimum performance in wet, chloride-laden environments.
Suitable for both remedial works and new build projects, application can be undertaken on damp substrates between tides. Flexcrete products will cure normally under water to form a durable, impenetrable barrier to chlorides whilst also preventing the ingress of oxygen and carbon dioxide in reinforced concrete exposed to the atmosphere.
Contact Flexcrete TodayConcrete Marine Structures Problems and Solutions
- Corrosion Protection
- Splash Zone
- Tidal Zone
The Problem
Chloride Steel and reinforced concrete structures require protection from the corrosive effects of chlorides found in seawater. Any coatings used must be suitable for application in wet environments with less than ideal surface preparation.
The Solution
Cementitious Coating 851 is easily applied to damp concrete with excellent adhesion. It cures to form a dense coating with high levels of protection from water, oxygen and chloride ion penetration.
In terms of water permeability a 2mm coating of Cementitious Coating 851 is equivalent to 1m of good quality concrete and it has a proven track record in some of the world’s most demanding marine environments.
Cemprotec E942, a cement and epoxy modified polymer coating, can be successfully sprayed directly onto steel substrates in damp conditions. Its impressively high resistance to the ingress of the fuels for corrosion and inherent alkalinity will ensure it provides stand-alone anti-corrosion protection.
The Problem
Corrosion of steel reinforcement and spalling of concrete in splash zones due to continual wetting and drying of surfaces and the action of salt spray.
The Solution
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 can be applied to concrete faces and it diffuses through the structure to form a monomolecular protective layer on the reinforcement to protect it from corrosion.
The Problem
Corrosion of steel reinforcement and spalling of concrete in tidal zones due to continual pounding and erosion from wave action. The opportunity to carry out repairs is limited to tidal windows.
The Solution
Marine Mortar S is suitable for the repair of horizontal and vertical surfaces in marine environments. It is perfectly adapted to areas subject to early immersion and provides excellent wash-out resistance against wave action.
Concrete Marine Structures Products
Find out more below about Flexcrete’s range of products for protecting reinforced concrete coastal structures:
| Bond-Prime | Single pack epoxy polymer primer to seal and consolidate substrates. |
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| Cementitious Coating 851 | Structural waterproofing. Protection from chloride ingress and carbonation. Reinstatement of cover. |
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| Cemprotec 2000-BJT | Self-adhesive butyl jointing tape designed to join sections of Cemprotec 2000-S together for waterproofing applications. |
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| Cemprotec 2000-S | Elastomeric, waterproof reinforcing tape, giving a highly flexible seal over ‘live’ cracks. |
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| Cemprotec E-Floor | Epoxy and cement modified polymer coating for protecting / waterproofing concrete floors. (2mm) |
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| Cemprotec E-Floor HB | Epoxy and cement modified polymer coating for protecting / waterproofing concrete floors. (3-6mm) |
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| Cemprotec E942 | Waterproofing and protection of concrete where enhanced chemical resistance is needed. Stand alone anti-corrosion coating for ferrous metal. |
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| Cemprotec EF Grit | Quartz aggregate for abrasion and skid resistance within E-Floor systems. |
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| Cemprotec EF Primer | Single component sealer and primer for floors, prior to the application of the Cemprotec range. |
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| Cemprotec Elastic | Waterproofing and protection of concrete where further movement is expected. |
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| 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. |
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| Cemprotec GFM | An advanced glass fibre reinforcement matting system. |
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| Cemprotec Levelling Coat | Self-levelling cementitious mortar for concrete floors prior to the application of Cemprotec E-Floor or Cemprotec E-Floor HB. |
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| Cemprotec MCI® 2020 | Surface applied corrosion inhibitor for the protection of reinforcement in chloride contaminated concrete. |
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| Fastfill | Rapid setting concrete repair mortar. Can be bulked out in deep sections. |
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| Marine Mortar S | General purpose structural concrete repair mortar for use in marine and tidal areas. Early wash-out resistance. |
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| Monolevel 844SP | Engineering quality fairing coat to reinstate cover and provide a fair faced, waterproof and anticarbonation finish. |
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| Monomix | Low density waterproof mortar for general purpose, structural repairs. |
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| Monomix HD | High strength, structural repair mortar with good abrasion resistance for trafficked areas. |
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| Monomix WS | Modified Monomix to allow wet spray application. Waterproof and low density. |
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| Steel Reinforcement Protector 841 | Corrosion preventative flexible coating for steel reinforcement. |
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| Cure-Seal WB | Water-based curing compound and clear sealer for Flexcrete Repair and Protection Systems. |
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| Monodex Smooth | High build, decorative anti-carbonation coating, which allows damp substrates to breathe. |
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| Monodex Ultra | High performance decorative, anticarbonation masonry coating. |
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| Polymer Admixture 850 | Admixture for cement mortars and floor toppings. |
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| Roofdex HB | High build, cold fluid applied liquid roofing system. |
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Concrete Marine Structures Projects
Take a look below at some of Flexcrete’s latest projects involving concrete coastal structures, or browse the project profile pages to find more.
Project Profile
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.
Project Profile
Project Location: 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.
Project Profile
Project Location: Dawlish Sea Wall, Dawlish Warren, Devon
Flexcrete provided a range of concrete repair and protection products for a 300m long sea wall in the popular holiday resort of Dawlish Warren.