Concrete structures in the dirty water sector are exposed to demanding conditions with chemical attack from raw sewage, exacerbated by abrasion from solids in the effluent, being just one of them. However it is the bacterial activity in the sewage that causes the most significant problems due to the evolution of hydrogen sulphide (H2S) gas. In enclosed structures, this dissolves in the condensation on surfaces to form sulphuric acid which readily attacks the concrete and significantly reduces the service life of structures.
Flexcrete’s range includes rapid setting, high early strength mortars and water-based cementitious polymer and epoxy modified coatings, which can be applied in damp environments without primers. Suitable for both concrete and steel, the coatings cure to form a waterproof, protective layer with chemical resistance to H2S and sulphuric acid. As our products are water-based and low odour with no hazardous solvents released during application, they can be safely applied when facilities are still in normal operation.
Steel or cast iron in dirty water structures is highly susceptible to corrosion. Flexcrete offers the ideal solution for the protection of ferrous metals with our water-based cementititious and epoxy modified polymer coatings. Cemprotec E942 is applied directly, even onto metal in damp conditions, with minimal surface preparation and cures to form a dense, protective barrier. High alkalinity accelerates the re-passivation of the steel to afford long-term corrosion protection.Download file: Solutions for Dirty Water Structures
Dirty Water Applications
Flexcrete’s products are suitable for the repair and protection of countless structures in the dirty water industry, including those below. They significantly extend durability of structures and enable the original design life to be achieved.
|Final filtration tanks|
|Primary settlement tanks|
|Storm water tanks|
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Waste Water Industry Problems and Solutions
- Wearing of Concrete Surface
- Chemical Attack
- Sulphuric Acid
- Lack of Corrosion Protection
- Concrete or Brick Manhole Chambers
- Degradation of Infrastructure
Cracked or spalled concrete can be repaired with Fastfill. Monolevel 844SP is then spray or trowel applied to rough surfaces to give a smooth, engineering finish with excellent abrasion resistance and durability.
An overall application of Cemprotec E942, incorporating advanced cement chemistry, fibre, epoxy and styrene acrylic copolymer technology protects existing concrete from further deterioration.
Surfaces can be reinstated with Monolevel 844SP prior to overcoating with Cemprotec E942. This unique epoxy and cement modified polymer coating offers excellent resistance to strong acids as well as the aggressive cocktail of chemicals found in sewage.
Cemprotec E942 can be applied to the substrate with minimal preparation. It offers exceptional stand-alone protection, making it ideal where accessibility is limited and working conditions are difficult. It is able to tolerate application to damp surfaces with much lower levels of preparation than conventional coating systems. Cemprotec E942 chemically accelerates the passivation of ferrous metals and provides a barrier to the ingress of water and oxygen — the fuels for corrosion.
Rapid reinstatement of the chamber can be carried out using Fastfill, a fast setting Portland cement based repair mortar with excellent sulphate resistance. A 2mm coat of Cemprotec E942, applied in 2 coats by brush will provide long-term protection from acids and chemicals. Areas can be quickly and effectively treated, minimising disruption.
Flexcrete offers a wide range of repair systems to match the equally wide range of reinforced concrete structures that form an integral part of the water industry infrastructure.
Based on Flexcrete’s core technology: a unique blend of polymers, microsilica and fibres, the products include wet sprayed, dry sprayed, rapid setting, pourable and trowel applied repair mortars: Monomix WS, Fastfill and Monomix.
When repairs have been carried out, an anti-carbonation and decorative finish can be achieved by applying Monodex Smooth.The Flexcrete Concrete Repair and Protection System has BBA Approval.
Waste Water Industry Products
Find out more below about Flexcrete’s range of products for the dirty water industry:
|Biodex Wash||A powerful surface treatment for neutralising active mould, fungal and bacterial growth prior to the application of Flexcrete products.|
|Cementitious Coating 851||Structural waterproofing. Protection from chloride ingress and carbonation. Reinstatement of cover.|
|Cemprotec 2000-BJT||Self-adhesive butyl jointing tape designed to join sections of Cemprotec 2000-S together for waterproofing applications.|
|Cemprotec 2000-S||Elastomeric, waterproof reinforcing tape, giving a highly flexible seal over ‘live’ cracks.|
|Cemprotec E-Floor||Epoxy and cement modified polymer coating for protecting / waterproofing concrete floors. (2mm)|
|Cemprotec E-Floor HB||Epoxy and cement modified polymer coating for protecting / waterproofing concrete floors. (3-6mm)|
|Cemprotec EF Primer||Single component sealer and primer for floors, prior to the application of the Cemprotec range.|
|Cemprotec E942||Waterproofing and protection of concrete where enhanced chemical resistance is needed. Stand alone anti-corrosion coating for ferrous metal.|
|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.|
|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.|
|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.|
|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.|
|Curing Membrane WB||Water based curing membrane / sealer, formulated for use with Flexcrete Repair Systems.|
Waste Water Industry Projects
Take a look below at some of Flexcrete’s latest dirty water sector projects, or browse the project profile pages to find more.