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Home » Solutions » Concrete Marine Structures

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.

Download DocumentSolutions 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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Concrete Repair & Corrosion Protection of Reinforced Concrete Coastal Structures

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.

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Concrete Marine Structures Problems and Solutions

  • Corrosion Protection
  • Splash Zone
  • Tidal Zone

The Problem

Protection From The Corrosive Effects Of Chlorides Found In SeawaterChloride 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 ConcreteCorrosion 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 ZonesCorrosion 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.

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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. more
Cementitious Coating 851 Structural waterproofing. Protection from chloride ingress and carbonation. Reinstatement of cover. more
Cemprotec 2000-BJT Self-adhesive butyl jointing tape designed to join sections of Cemprotec 2000-S together for waterproofing applications. more
Cemprotec 2000-S Elastomeric, waterproof reinforcing tape, giving a highly flexible seal over ‘live’ cracks. more
Cemprotec E-Floor Epoxy and cement modified polymer coating for protecting / waterproofing concrete floors. (2mm) more
Cemprotec E-Floor HB Epoxy and cement modified polymer coating for protecting / waterproofing concrete floors. (3-6mm) more
Cemprotec E942 Waterproofing and protection of concrete where enhanced chemical resistance is needed. Stand alone anti-corrosion coating for ferrous metal. more
Cemprotec EF Grit Quartz aggregate for abrasion and skid resistance within E-Floor systems. more
Cemprotec EF Primer Single component sealer and primer for floors, prior to the application of the Cemprotec range. more
Cemprotec Elastic Waterproofing and protection of concrete where further movement is expected. more
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. more
Cemprotec GFM An advanced glass fibre reinforcement matting system. more
Cemprotec Levelling Coat Self-levelling cementitious mortar for concrete floors prior to the application of Cemprotec E-Floor or Cemprotec E-Floor HB. more
Cemprotec MCI® 2020 Surface applied corrosion inhibitor for the protection of reinforcement in chloride contaminated concrete. more
Fastfill Rapid setting concrete repair mortar. Can be bulked out in deep sections. more
Marine Mortar S General purpose structural concrete repair mortar for use in marine and tidal areas. Early wash-out resistance. more
Monolevel 844SP Engineering quality fairing coat to reinstate cover and provide a fair faced, waterproof and anticarbonation finish. 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
Steel Reinforcement Protector 841 Corrosion preventative flexible coating for steel reinforcement. more
Cure-Seal WB Water-based curing compound and clear sealer for Flexcrete Repair and Protection Systems. more
Monodex Smooth High build, decorative anti-carbonation coating, which allows damp substrates to breathe. more
Monodex Ultra High performance decorative, anticarbonation masonry coating. more
Polymer Admixture 850 Admixture for cement mortars and floor toppings. more
Roofdex HB High build, cold fluid applied liquid roofing system. more

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

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

Repair and Cathodic Protection for St Peter Port in Guernsey

St Peter Port Docks, Guernsey
Posted on 8-07-2016

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.

Read The Project Profile
Project Profile

Concrete Repairs for 1970s Seaside Wall in Devon

Dawlish Sea Wall Flexcrete Project
Posted on 10-08-2015

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.

Read The Project Profile
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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

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Export Champion 2022-2023

Flexcrete Technologies Ltd

Tomlinson Road,
Leyland,
Lancashire,
PR25 2DY
United Kingdom

Telephone: +44 (0)1772 450950

E-mail: flexcrete@akzonobel.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

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