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01772 450950

Home » Solutions » Waste Water Industry

Waste Water Industry

Concrete Attack

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.

Corrosion Protection

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 DocumentSolutions for Dirty Water Structures

Reinforced concrete forms the basis of many dirty water installations, but concrete alone cannot withstand chemical attack.  Download this information sheet to find out more about our materials.

Download File

Dirty water industry

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.

Aeration tanks
Digester tanks
Filter plants
Final filtration tanks
Flume channels
Humus tanks
Primary settlement tanks
Sludge tanks
Spillways
Storm water tanks
Support chambers
Weirs

 

 

Contact Flexcrete Today

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

The Problem

Abrasion Of Scraper Blades And Wheels In Sediment TanksAbrasion of scraper blades and wheels in sediment tanks results in continuous wearing away of the concrete surface.

 

 

 

The Solution

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.

Further protection can be provide by overcoating with Flexcrete’s epoxy and cement modified polymer coatings, Cemprotec E942 and Cemprotec E-Floor.

The Problem

Chemical Attack From Raw SewageChemical attack from raw sewage breaks down the matrix of the concrete below the water level. Abrasion accelerates the deterioration of the surface.

 

 

The Solution

Damaged areas can be effectively reinstated with Monomix or, where rapid reinstatement is required: Fastfill. Both offer long-term durable repairs with excellent chemical resistance.

An overall application of Cemprotec E942, incorporating advanced cement chemistry, fibre, epoxy and styrene acrylic copolymer technology protects existing concrete from further deterioration.

The Problem

Sulphuric Acid Attacking ConcreteBacteria present in sewage form acidic gases which, in confined areas, condense on surface and are broken down to form sulphuric acid which readily attacks concrete.

 

 

The Solution

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.

The Problem

Corrosion Of Ferrous Metals In Aggressive Sewer EnvironmentsCorrosion of ferrous metals in aggressive sewer environments. Lack of corrosion protection from aggressive condensates reduces the life span of the structure.

 

 

The Solution

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.

The Problem

Concrete Or Brick Manhole Chambers Prone To Chemical AttackConcrete or brick manhole chambers are particularly prone to chemical attack due to the build up of gasses and condensates.

 

 

The Solution

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.

The Problem

Cost Effective Concrete Repair And Coating SolutionsGeneral degradation of the infrastructure needs cost effective repair and coating solutions.

 

 

The Solution

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.

Need Help from Our Concrete Repair & Protection Specialists?
Call Flexcrete Today

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. 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 EF Primer Single component sealer and primer for floors, prior to the application of the Cemprotec range. more
Cemprotec E942 Waterproofing and protection of concrete where enhanced chemical resistance is needed. Stand alone anti-corrosion coating for ferrous metal. more
Fastfill Rapid setting concrete repair mortar. Can be bulked out in deep sections. more
Fastfill WP Rapid setting concrete repair mortar for arresting water seepage and infiltration under pressure. Sets in 2 mins. more
Monolevel 844SP Engineering quality fairing coat to reinstate cover and provide a fair faced, waterproof and anticarbonation finish. more
Monolevel FC Fairing coat for filling minor blow holes and defects prior to overcoating. 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
Tiefill Rapid curing mortar for the filling of tie-holes formed by formwork bolts. more
Cure-Seal WB Water-based curing compound and clear sealer for Flexcrete Repair and Protection Systems. more

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.

Project Profile

Concrete Waterproofing and Protection of Wellington Docks

Assuring the design life of a new build extension
Posted on 11-03-2015

Project Location: Wastewater Treatment Works, Wellington Dock, Liverpool

Assuring the design life of the new build at Wellington Docks, Liverpool with Flexcrete’s structural mortars and cementitious coatings.

Read The Project Profile
Project Profile

Concrete Repairs to Columns, Beams, Walls & Tank Floors

Concrete Repair Products Specified for United Utilities Multi-Million Pound Improvement Scheme
Posted on 1-07-2013

Project Location: Clifton Marsh Wastewater Treatment Works, Preston

Flexcrete’s concrete repair and protection system was applied to columns, beams, walls and tank floors at Clifton Marsh Wastewater Treatment Works, Preston.

Read The Project Profile
Project Profile

Fastfill High-Strength Mortar Chosen for Sewage Treatment Works

Tilbury Syphon Sewage Treatment Works, Essex
Posted on 25-12-2012

Project Location: Tilbury Syphon Sewage Treatment Works, Essex

Flexcrete’s Fastfill high-strength mortar chosen for the refurbishment and re-lining of process facilities at Sewage Treatment Works.

Read The Project Profile
View All Projects

Flexcrete Brochure

Find out more about our concrete repair and protection services. Read the Flexcrete product brochure online, or download a copy today

Read The Brochure
Flexcrete 2014 Brochure
Export Champion 2021-2022

Flexcrete Technologies Ltd

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

Telephone: +44 (0)1772 450950

E-mail: web@flexcrete.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

CPD Presentation

Book a Flexcrete CPD Presentation and find out more about our Concrete Repair & Protection Products and discover how our industry leading technology could benefit your next project.
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