Don’t put off your concrete repair project

Many buildings, roads, permanent structures, and storage tanks are made of concrete, which consists of aggregates such as sand, gravel or crushed stone, water and cement. Water and cement combine to form a paste which binds together the aggregates into a rock-like mass.

Concrete can develop cracks due to various processes such as:

• Expansion of corrosion products or rust on steel reinforcement bars
• Freezing of trapped water
• Fire or radiant heat
• Sea water effects
• Bacterial corrosion
• Leaching
• Erosion by fast-flowing water
• Physical damage
• Chemical damage
• Thermal cracks

While cracks are a common problem in concrete, they should not be ignored as they can widen and allow moisture to seep into the concrete, causing further corrosion and affecting the structure’s integrity. They appear unsightly and can reduce the value of your property.

Fortunately, Diamond Protective Coating Services is able to offer a concrete repair service to rectify your damaged concrete through specialist combinations of corrosion removal, protective coatings, and concrete and tank repair systems, including:

Concrete protection and tank lining coatings

Tank linings are integral components of primary and secondary containment systems for corrosion protection. Chemicals and other hazardous substances can penetrate damaged tank linings and concrete substrates, which can lead to contamination and expensive costs of remediation.

Regular inspection of tanks and tank linings are essential for maintenance and safety reasons as linings of concrete tanks can deteriorate over time. To achieve the best possible corrosion protection, they will require appropriate surface preparation, cleaning, and tank lining solutions.

Surface preparation > Sufficient surface preparation is the key to a successful tank lining system. Concrete surfaces must be clean, dry, and free from oil, grease and other contaminants to promote better adhesion of protective coatings. Cracks must be cut out and filled with suitable filler prior to tank lining installation.

Application of tank linings > Specialised coatings and Polyurea coatings are effective materials for concrete tank linings. Two-component epoxy coatings are flexible, tough and have excellent resistance properties to a wide range of chemicals and corrosions. As such, it is ideal for tanks storing petroleum products, brine, salt solutions, detergents, and lubricants.

Polyurea coatings also possess excellent chemical resistance to many liquids. They exhibit high tensile strength, elongation, and impact resistance and have the added advantage of being fast drying.

Concrete refurbishment and sealing

Concrete structures can suffer from cracks on their surfaces for a number of reasons, including cement shrinkage, and the heaving and settlement action of underlying substrate. Cracks are unsightly and can lead to further deterioration and corrosion of embedded steel and other materials and early detection is important for assessing the cause and extent of the damage.

Concrete surfaces require a solution that is tough yet visually appealing, particularly in high traffic areas such as parking areas, retail floors, and showrooms. The polyurethane industrial coatings used by Diamond Protective Coating Services are suitable for refurbishing and sealing visible concrete surfaces due to their:

• Durability
• Substantial ongoing protection
• Water and stain resistance
• Availability in various finishes
• Highly adhesive properties

Conditions such as humidity levels, temperature, and surface preparation are assessed when we apply polyurethane for refurbishing or sealing cracks in concrete and they are applied according to exact manufacturer’s instructions for optimum performance.

Diamond Protective Coatings provides concrete refurbishing and concrete sealing services for concrete structures, particularly floors in a number of settings such as large retail outlets, factories, display showrooms, and other domestic projects.

Concrete repairs and crack injection

Concrete structures need a system of corrosion protection and concrete products and procedures to prolong the life of both the concrete and its embedded steel. Cracks can occur in concrete materials as a result of tensile stresses on the hardened cement mixture, thermal expansion, freezing water trapped in concrete, corrosion of reinforced steel, and water erosion. Monitoring and carefully assessing the causes and extent of cracking are essential in corrosion protection and will help to prevent further deterioration of concrete.

The latest technology in concrete repairs allows cracks to be fixed easily by injecting them with products such as epoxy, polyurethane and polyurea but adequate surface cleaning and preparation must precede crack injection to ensure superior bonding.

In addition to corrosion protection, you can use our crack injection systems for:

• Structural and non-structural bonding
• Concrete and masonry
• Repair of cracks from 0.2 to 5.0 mm
• Vertical, horizontal and overhead cracks

Coatings for potable water tanks

Micro-organisms and chemicals are common threats to water safety and are properly managed by applying adequate barrier systems. Protective coatings minimise the entry and transmission of contaminants and relevant Australian Standards require that these must be solvent-free. There are two types of tank linings approved for use in water tank linings – epoxy and polyurethane.

Epoxy > Epoxy is a two-component coating system which involves the application of an anti-corrosive primer followed by a topcoat of an Epoxy-based paint. Epoxies are brittle and have been known to crack and de-bond when the tank is subjected to stress and some movement.

Polyurethane > Polyurethane coatings have good elongation properties to withstand structural movement. They adhere well to many substrates such as concrete, steel and glass reinforced plastics.

Polyurea > This is a new lining technology which is fast-acting, environmentally-friendly, impact-resistant, flexible, and highly resistant to thermal shock, mild acids, caustic, and hot water. This system can be used for various substrates, particularly concrete tanks.

Damaged concrete tanks need not be replaced and can be repaired using a solvent-free protective paint system. Our advanced barrier system is safe, fast acting, durable and cost effective.

If you are unsure about which protective system for potable water tanks is right for your situation, our team of experts can provide a quote and advice – obligation free.

Concrete roof repairs

Corrosion in concrete roofs can occur when they are constantly exposed to changing weather and temperatures. Rainwater leaves behind acids that can cause corrosion and the reinforced steel embedded within it.

Waterproofing membrane is a key component of corrosion repairs on the roof, and works by keeping water out of the building. While your roof may be protected by a waterproofing system, a regular inspection as part of your maintenance program may reveal damage that will require concrete repair.

Flexible membrane roof systems provide the best protection against corrosion, and they come in two types – thermoplastic and thermoset.

Thermoplastics > Thermoplastics are pre-fabricated flexible membranes which can be reshaped and melted multiple times using heat. The membrane, usually PVC (polyvinyl chloride) or TPO (Thermoplastic Polyolefin), is heated to form a strong bond at the seams. PVC can be reinforced by polyester or fibreglass to withstand breaking under changing temperatures. TPO remain flexible at low temperatures and can be combined with other components such as a fire retardant to withstand harsh elements.

Thermoset > Thermoset membranes such as synthetic rubber require heat to form a tight barrier against rainwater and other elements. Unlike Thermoplastics, Thermoset membranes cannot be melted and reshaped.

We recommend regular roof inspections to detect possible roof damage due to corrosion, and damage to waterproof membranes. As a rule, water stains inside the building, particularly on walls and ceilings, indicate roof problems and must be repaired immediately by a qualified roof repairer.

We offer concrete roof repair services including:

• Inspection
• Sealing with flexible membrane

Concrete waterproofing and sealing

Concrete may be tough but its porous material makes it susceptible to cracking, flaking and chalking due to factors such as chloride-induced corrosion, carbonation and metal corrosion of reinforced steel.

A specialised sealer and waterproofing system prevents concrete damage by creating barriers against moisture and other harmful substances. Various waterproofing systems protect against concrete damage by preventing water and other harmful elements from penetrating the material.

These systems include:

Crystalline concrete waterproofing > A system where a crystalline compound reacts with water to form tiny crystals within gaps in concrete, permanently sealing it.

Concrete sealing > Penetrating sealers enter the concrete material where they form a protective barrier without affecting the external appearance of concrete. Film forming types such as epoxy, polyurethane, and acrylic are applied on concrete surfaces to create a protective barrier and prevent corrosion.

Waterproofing membranes > Used in sheet or liquid form they are protective layers applied on concrete surfaces.

Cementitious waterproofing > This combines cement-based compound, additives and bonding agents to form slurry which is applied onto concrete surfaces.

Diamond Protective Coating Services uses approved concrete sealing and waterproofing products to protect your structures and buildings against corrosion.