Concrete Repair Specialist Contractors

Cementitious Coatings

Cementitious coatings to a variety of structures to provide waterproofing of internal and external concrete structures

We use various concrete cementitious coatings designed as a stand-alone coatings that will provide waterproofing to internal and external concrete and steel structures, including DWI-approved coatings in potable water-retaining structures. Using steel float, brush or spray techniques, our state-of-the-art cementitious coatings can be applied in thicknesses ranging from 1mm, giving the equivalent of 100mm of new concrete cover. This aids in helping against water ingress and carbonation that attacks and breaks down concrete and then the steel reinforcing it encapsulates.

Cementitious coatings are also used as fairing coats or sealer coats for old or damaged concrete. The fairing coat is used to fill out blow holes or voids in the surface of the concrete and in some cases to fill out the concrete returning it back to its original profile before a protective coating is applied.

Coatings are available in a range of colours and finishes depending on the exact product, including smooth and textured, with special colours made to order.  We also provide repair services to ensure the level of concrete cover has been restored before the protective coating is applied.

Coating work completed at Biomass Plant

Low cover cementitious coatings

Low cover concrete repair coatings provide a solution for reinstating effective cover on precast and in-situ reinforced concrete, avoiding costly major repair work.

The depth and quality of concrete on bridges and other concrete covered structures is vital to protect its encased reinforced steel. Lack of protection to the re-bars can lead to premature de-passivation of the steel and subsequent corrosion. Inadequate concrete cover will not only speed up the damaging effects of carbonation but also allow even more rapid ingress of chlorides, moisture and oxygen which could have a fatal effect on the structure.

If low cover is identified, remedial measures can often include drastic and costly measures of demolishing sections that fail to meet the required specifications, or partial recasting with new concrete. We offer a more practical and cost-effective means of reinstating cover with protective coating.

Our waterborne, cementitious modified polymer coatings provide structures with additional protection against freeze/thaw cycles, de-icing salts, water and chloride ion penetration.  Being cement based, the coating chemically reacts with the substrate to form an integral part and will have a design life equivalent to that of the concrete to which it is applied.

Low cover concrete coatings

Anti-carbonation Coatings

Concrete structural integrity can become compromised so it is critical to specify anti-carbonation coatings for both new and existing structures. Such products can ensure that buildings remain visually attractive throughout their lifespan and avoid costly and disruptive repair and maintenance work further down the line.

We provide and install a range of weatherproof, anti-carbonation coatings to provide ultimate protection against the ingress of CO2, oxygen and water, whilst allowing damp substrates to breathe without blistering. Fast-drying, water-based formulations allow for quick application, even in inclement weather conditions.

Concrete repair

Why Anti-carbonation Coatings?

In untreated concrete, the process of carbonation is nearly impossible to avoid once exposed to the elements. Carbon dioxide slowly penetrates the surface of the concrete, reacting to the moisture and calcium hydroxide that is naturally found in concrete.

This forms calcium carbonate which initially hardens the concrete raising the compressive strength. Alkalinity then reduces in the concrete and it starts to breakdown. Depending on the permeability, concrete carbonation may advance at a rate of 1 – 5mm per year. As carbon dioxide travels deeper into the concrete it reaches the steel reinforcement embedded in the structure. As the concrete around the steel is broken down by carbonation the corrosive effects of the air and water rust the steel causing it to expand, spall and crack. This in turn causes a high rate of failure to the surrounding area.

Cemementitious coating system at Dungeness B Power Station

Corrosion Control Coatings

Using corrosion control coatings can actively penetrate corroded crevices and protect steel that is vulnerable to pack-rust, micro-cracking, delamination, rust leaking and perforations with traditional coatings.

Corrosion control coatings are specifically engineered to arrest corrosion by:

  • Neutralizing surface acidity
  • Displacing moisture
  • Scavenging oxygen
  • Creating a flexible barrier to prevent further corrosion

Used worldwide on a range of structures, they are environmentally-safe and extremely cost effective, used on bridges and highway overpasses, bolted or plated steel assemblies, water towers and tanks, utility towers, flexible structures and most structural steel applications.

Our expert team will firstly prepare substrates, removing loose paint, loose rust and tightly adhered black oxides, alongside all soluble salts such as chlorides, nitrates and sulphates.

Corrosion control system

Corrosion Control Specifications

Corrosion control coatings are engineered exclusively for encapsulation (overcoat) of existing aged paints, or re-coating of new or prepared structural steel.

The systems are generally recommended for above ground applications but can be used on structures buried in soil such as buried pipes and utility towers following a specialist procedure. Cure times are dependent upon temperature but, at an ambient temperature of about 24 degrees (min temperature 2 degrees), with relative humidity @ 50%, drying time of a typical coating system will take approximately 8 – 12 hours. Our corrosion control coating systems have a 5-year warranty and approximate 25-year service life.

Corrosion control coatings

Offsite Coating Work

We can now carry out repair and coatings work offsite. Structures, pipes or equipment of up to 3m wide can be forklifted in and out of the CSC Services specialist unit, and a range of coatings applied.

CSC Services recently completed a job for Hartlepool Power Station to repair and coat Ferrous Sulphate Tank Lids and Steel Walkway gratings for EDF Energy. The tank lids and walkway gratings were transported from Hartlepool Power Station to the CSC Services work unit for the refurbishment work as part of a plant upgrade. A marine grade coating system was applied to protect against chloride attack at the coastal location of the power station. Read more about this project here.

concrete repair systems
Case Study
We utilised cementitious coatings as part of our work at Hinkley Point B Power Station for client EDF Energy. Over ten tonnes of specialist repair mortars and structural strengthening products were used to rectify the degradation of reinforced concrete at various areas across the station. Cementitious coatings will protect the structures from moisture intrusion and further corrosion, reducing the need for ongoing maintenance work for the life of the station.
Case Study
We installed a Flexcrete cementitious coating system to steelwork in the materials handling facility at Lynemouth Biomass Power Station for client Sir Robert McAlpine. With enhanced chemical and abrasion resistance the coating will guarantee the life-span of the steelwork at the plant for twenty years.

Get in touch

For more information on Cementitious Coatings.