Protective Coatings and Concrete Repair

1. Surface Coatings: Surfaces exposed to the elements, wear and tear or potential chemical corrosion requires surface coating to protect the concrete slab and steel reinforcement. A few different types of coatings include:

   • Epoxy Coatings have excellent adhesion, chemical resist and durability. Floors exposed to wear and tear or exposed to corrosive chemicals. Examples of these are industrial warehouses, manufacturing warehouses for milk, yogurt etc, workshops, and kitchens.
   • Elastomeric Polyurethane Coatings are highly flexible, impact resistant and used for structures that experience dynamic loads and movement. These include bridge decks, car parks and roofs. Also effective in waterproofing applications.
2. Chemical Resistant Coatings for Storage Tanks are crucial as part of the ongoing maintenance and design life requirements of the chemical storage tanks. The tanks storing chemicals, be it for water/sewer treatment, chemical bunds or fuel storage tanks require surface treatment to ensure the storage tank structure be it concrete or steel isn’t corroded or degraded by the chemicals.

3. Structural Repair and Relining of Culverts/Tunnels are required due to the abrasion of the surface caused by continuous flow. There can also be general degradation and/or corrosion of the original liner or structure. Coatings are applied to surfaces like concrete or steel to repair and strengthen existing structures, prevent further degradation, and extend the lifespan of the assets.

   • Cement-Based Protective Coatings are applied to restore, strengthen and protect structures from water intrusion, chemical attack, or environmental degradation. Suitable for rehabilitating deteriorated structures including sewer/water mains and pipelines, stormwater applications, pumping stations, pits and transfer facilities to name a few.

Concrete Repair involves restoring the structural integrity, function, and appearance of damaged or deteriorated concrete structures. Concrete can suffer from various types of damage include cracking, moisture ingress causing steel corrosion and subsequent spalling, chemical and physical weathering. These can be caused by factors such as environmental exposure, wear and tear, poor construction practices, or structural overload. The goal of concrete repair is to extend the service life of the structure, prevent further degradation, and restore its original functionality.

Common Types of Concrete Repairs:

1. Crack Repair:

   • Crack Injection: Low-viscosity epoxy or polyurethane resins are injected into cracks to restore the structural integrity and prevent water ingress.

2. Spall Repair:

   • Surface Repair Mortars: Used to patch areas where concrete has broken away or spalled due to corrosion of reinforcement.

3. Reinforcement Repair:

   • Crack Injection: Low-viscosity epoxy or polyurethane resins are injected into cracks to restore the structural integrity and prevent water ingress.

4. Common Types of Concrete Repairs:

   • Corrosion Mitigation: Involves cleaning and treating corroded steel reinforcement and applying protective coatings or inhibitors to prevent further corrosion.
   • Rebar Replacement or Addition: Damaged or corroded reinforcing bars are replaced or supplemented to restore structural integrity.

5. Overlays and Surface Repairs:

   • Thin-Bonded Overlays: Thin layers of polymer-modified or fiber-reinforced materials are applied over the existing surface to repair and protect against further damage.
   • Full-Depth Replacement: When damage is extensive, a full-depth repair involves removing and replacing entire sections of concrete, and re-tying into larger concrete section.

Repair, remediate or replace.