Concrete repairs are vital to the protection of the area damaged. Whether the repair is some simple spalling to a kerb or step or something more comprehensive like a bridge repair or exposed reinforcement our technical team can suggest a vast range of systems to overcome the damaged area or repair the structure giving you peace of mind!

Cemguard 

Products for Concrete Repair and Protection

Deterioration in reinforced concrete structures can commence from the moment the concrete is poured with poor design and/or build quality leading to relatively obvious problems such as ‘honeycomb’ concrete or insufficient cover of the reinforcement bar itself. Added to this, over the following years, a multitude of factors take their toll on the structure and shorten its expected service life.

Of these factors, natural carbonation, freeze thaw action and in particular, chloride attack, are widespread with rebar corrosion and cracking within the concrete itself an inevitable consequence.

Common Causes of Damage and Defects 

• Build Quality
  Poor batching or compaction of concrete - Insufficient concrete cover of steel reinforcement

• Mechanical
  Impact - Vibration - Explosion

• Chemical
  Alkali Aggregate Reaction - Chemical Attack - Bacterial Action

• Physical
  Thermal movement - Freeze Thaw Action - Salt Crystal Expansion - Erosion

• Corrosion
  Carbonation - Chloride Attack - Stray electrical current

A successful and effective repair requires a full appraisal of the situation :-

• What is the cause of the problem?

• What repair scenario is best suited?

• What level of repair needs to be undertaken given the expected design life of the structure?

The answers to these questions provide the basis for the type of repair method to be implemented

The 5 Step Repair Approach Utilising DCP Repair Materials

1. Preparation of the substrate is critical for a long lasting repair. Breaking out, cleaning and protection of the reinforcement is necessary to ensure premature failure of the repair does not occur.

2. Priming the prepared repair area prevents water being drawn away from the mortar into the substrate, resulting in a weaker bond, cracking or possible delamination.

3. The choice of correct repair mortar - lightweight mortars for high build or vertical / overhead applications, heavy duty mortars for horizontal applications. Migrating Corrosion Inhibitor technology for added and ongoing protection.

4. Curing the repair mortar with a suitable curing aid to ensure rapid drying does not occur. If not applied this could lead to shrinkage cracking, possible delamination and the ingress of atmospheric gases and chlorides leading to attack of the reinforcement.

5. Total protection is obtained with the use of an aesthetically pleasing, high performance anti- carbonation coating. Allowing the substrate to breathe, it prevents the penetration of carbon dioxide, stopping the carbonation process repeating itself.

Concrete Repair Mortars

Features and Benefits of DCP’s Concrete Repair Systems 

• Greatly Reduced concrete removal - Reduced labour

• Less noise, vibration and debris - Less inconvenience

• Corrosion of rusted steelwork halted - Further corrosion prevented

• Migrates into concrete - Long term, active protection

• Organic, safe and environmentally friendly - Low hazard products

• Minimal additional maintenance - Ongoing protection system

Cempatch Repair Mortars - Typical Procedure

Stage 1

Spalling concrete and exposed re-inforcing bars were the main problems to rectify using DCP concrete repair and protection system.
This was a result of inadequate concrete cover to steel and years of exposure to atmospheric carbon dioxide which led to the loss of passive protection to the reinforcement.

Stage 2

A critical procedure in the repair process, the affected areas need to be suitably prepared. Breaking out the defective concrete to expose the corroded steel reinforcement and cleaning the rebar is essential for a long lasting repair.

Stage 3

The application of Cempatch Primer has the dual role of  ensuring an excellent bond between the substrate and Cempatch Repair Mortar coupled with inherent Migrating Corrosion Inhibitor technology creating a passivating layer around the reinforcement preventing the onset of further corrosion.
The corrosion inhibitor can also migrate to project adjacent reinforcement - usually the most vulnerable to future corrosion.

Stage 4

Cempatch LW repair mortar was selected due to its lightweight properties for this vertical application. Offering oustanding resistance to weathering it also has good flaxural and compressive strengths.
Cemguard 2020 was then applied to provide long lasting corrosion control.

Stage 5

Repcoat, a tough, elastomeric highly decorative protective coating is applied to not only the completed repair, but to all concrete surfaces.

It offers long lasting protection against the effects of weathering, carbonation and airborne chlorides, effectively stopping the “damage process” from repeating itself.

Stage 6

The completed repair - transformed from a deteriorating structure, this water tower is a prime example, utilising Cempatch and Repcoat products, of how a structured and effective concrete repair can provide long lasting protection from the causes of concrete attack.

Nylofor® Panel Systems
A more and more common product range offering labour reductions in time and therefore cost. A full comprehensive range available on stock. Call our experts to evaluate the contract and advise on the solution!

Radon Membrane
Radon is a naturally occurring radioactive gas formed by the breakdown of uranium and radium. It is crucial that when gas protection is required, the site conditions, design and application are all taken into consideration to provide an impermeable membrane, protecting the most valuable asset, “the building” against the gases that can cause future problems.

C02/Radon Membrane
Carbon Dioxide is a colourless, odourless gas formed as a by-product of decomposing organic matter. It is crucial that when gas protection is required, the site conditions, design and application are all taken into consideration to provide an impermeable membrane, protecting the most valuable asset, “the building” against the gases that can cause future problems.