Why Xypex for Marine Structures

Meeting the Challenge

Protecting Marine Structures

Reinforced concrete marine structures are constantly under attack by the destructive effects of moisture and chloride-induced corrosion. Without proper protection, the structural integrity of a marine structure is soon compromised, leading to expensive remediation efforts and a shortened life span. Once the moisture and chlorides have reached the reinforcing steel, an expansive oxidation process begins to take place causing the formation of cracks and spalling in the concrete. When cracking takes place and is combined with weathering effects such as freeze/thaw damage or accelerated corrosion in hot weather climates, this deterioration takes place at a faster pace.

With over 50 years of experience in 90 countries around the world, Xypex Crystalline Technology has been used in marine structures to waterproof, protect, repair and enhance the durability of concrete subject to water and chloride attack. In this challenging environment, where structures are also exposed to sulphate attack, carbonation, alkali-aggregate reaction, abrasion and freeze thaw cycles, Xypex is a highly respected partner in extending the service life of marine construction.

Xypex products play a key role in the waterproofing and protection of concrete against water penetration, chloride ion attack, cracking, carbonation, sulphate attack, Alkali Aggregate Reaction and freeze/thaw damage – problems typically associated with the reduced service life of marine structures.

 

Water Permeability & Corrosion

The primary purpose of waterproofing concrete marine structures is the protection of reinforcing steel from the damaging effects of corrosion. The nature of concrete and the problems associated with placement and consolidation means having to deal with permeability issues permitting the penetration of water into the substrate and through to the reinforcing steel. With the presence of oxygen this can initiate corrosion.

This permeability facilitates the entry and diffusion of chlorides into contact with the reinforcing steel. The resulting loss of alkalinity and hence the passivating layer allow for an electrochemical process culminating in corrosion of the reinforcing steel and the expansive disruption of the concrete substrate.

Cracking

Cracks in the concrete are the most obvious means by which water and damaging chemicals can enter a structure. These cracks are formed in a number of different ways but the most common are drying shrinkage, thermal cracking, strain formed cracks, settlement cracks and plastic shrinkage cracking in the slab.

Surface Deteroriation

The principal cause of surface degeneration is the impact of silt, sand, gravel and other solids impacting and rolling against the concrete surface. This causes deterioration in the long term, resulting in some form of surface rehabilitation during the service life of the structure.

Carbonation

Carbon dioxide in the air reacts with calcium hydroxide in the concrete to form calcium carbonate which reduces the alkalinity of the concrete. Below a pH of 10, the rebar’s thin layer of surface passivation dissolves and corrosion of the reinforcing steel takes place at an accelerated rate.

Sulphate Attack & Alkali Aggregate Reaction

Where sulphates are present in water or soils, the permeability of concrete and the presence of water allows sulphate ions to diffuse into the concrete and create an expansive reaction causing spalling and deterioration.

A similar effect is caused by Alkali Aggregate Reaction whereby the presence of water in concrete permits a reaction between silica in certain aggregates and the alkalis in cement.

Xypex Crystalline Technology

Xypex products use the natural porosity of concrete and chemical diffusion to penetrate its pores and capillaries. Inside the concrete, Xypex chemicals react with un-hydrated cement particles and the by-products of cement hydration to form a non-soluble crystalline structure deep within the substrate. In this condition, the concrete becomes impermeable, preventing the penetration of liquids and chemicals from any direction even under extreme hydrostatic pressure. The chemical resistant properties of the crystalline structure will mitigate the attack of chlorides and sulfates. In prolonging the durability of concrete, Xypex has also proven to be effective against the effects of carbonation and Alkali Aggregate Reaction as well as having the ability to self-heal static cracks up to 0.5 mm (0.02 in). Xypex also improves the freeze-thaw durability of concrete.

The Xypex Advantage

Xypex Crystalline Technology works inside the concrete, thereby avoiding the problems typical of traditional barrier products.

  • Permanent and reactivates whenever water is present
  • Protects against chlorides
  • Self-heals static cracks up to 0.5 mm (0.02 in)
  • Protects against sulphate attack and Alkali Aggregate Reaction (AAR)
  • Reduces the rate of carbonation
  • Not subject to deterioration problems encountered by surface coatings and membranes

Proven Performance Worldwide

Comprehensive quality systems and standards along with thorough testing in the lab and the field have resulted in Xypex’s highly respected position in the concrete industry. Xypex has been extensively tested by independent testing laboratories in the U.S., Canada, Australia, Japan, Europe and other countries.

Xypex Admix for New Concrete Construction

Xypex Admix is the preferred choice for installing Xypex Crystalline Technology into most new concrete marine structures. Because Xypex Admix is blended into the mix at the time of batching, it becomes an integral part of the entire concrete matrix, thus reducing the potentially damaging effects of water penetration, chloride and sulfate attack, carbonation and Alkali Aggregate Reaction. The addition of Xypex Admix to concrete is a highly effective method of enhancing the durability of concrete structures.

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Xypex Admix Advantages

  • Permanent integral waterproofing
  • Enhances concrete durability
  • Value engineering
  • Non-toxic
  • Non-combustible
  • Resists damaging effects of water penetration and chemical attack

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Rehabilitation & Repair

Xypex’s coating systems and repair products enable owners, engineers and contractors to economically and confidently repair structures that have been damaged due to the effects of chloride attack, carbonation, Alkali Aggregate Reaction or surface deterioration through abrasion and freeze/thaw. Xypex Concentrate and Modified are applied as slurry coatings to the surface of the concrete. Unlike other materials that need a dry substrate, Xypex products require a moist surface – a condition typical of marine structures. This type of environment is conducive to the Xypex Crystalline process. Xypex Patch’n Plug, Concentrate Dry-Pac, and Megamix products are specifically designed to permanently repair concrete defects such as static cracks and faulty cold or construction joints. Xypex Megamix returns structural integrity to severely damaged concrete, whilst maintaining the same protective properties of Xypex-treated concrete.

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Xypex Coating Advantages

  • Doesn’t require a dry surface
  • Apply to either side of the concrete
  • Won’t puncture, blister or tear
  • No costly surface priming or leveling
  • Sealing, lapping or finishing is not required
  • No need for protection during backfilling
  • Permanent waterproofing
  • Enhanced concrete durability
  • Doesn’t contain VOCs
  • Non-toxic and non-combustible
  • Can be applied safely in confined spaces

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COATING: Concentrate & Modified
PLUGGING: Patch’n Plug
REHABILITATION: Patch’n Plug & Megamix
Singapore Marina Barrage
Marine Structures

Singapore Marina Barrage

Singapore
More than 7,000 kg of Xypex Megamix II were used to shape and protect the new fins of the Barrage gates. Specially formulated to produce a high strength, low shrink mortar with high chemical resistance and superior bond characteristics, Xypex Megamix II was the only product available in the market that could applied to the very fine (1 mm) tolerances specified for the barrage, whilst its superior ability to withstand the harsh chemical and mechanical marine environment conditions contribute incrementally to the durability of the fins of the barrage.
Sandy Bay Seawall
Marine Structures

Sandy Bay Seawall

Australia
An existing seawall had become delapidated due to decades of constant, severe exposure to wind, tides and wave action. Xypex Admix was chosen for concrete protection against aggressive chloride attack. Xypex was favoured over other systems due to the ease of application, benefits to the host concrete, longer service life and cost.
Conrad Maldives Resort & Spa
Marine Structures

Conrad Maldives Resort & Spa

Maldives
As durability and protection of the steel reinforcing was a major consideration, 165 kg of Xypex Admix C-1000 NF combined with MS 600 (Microsilica) was specified to provide this protection.
Jacksonville Electric Authority Wharf
Marine Structures

Jacksonville Electric Authority Wharf

USA
Xypex Admix C-1000 NF was used at a rate of 1.5% of cement content for the waterproofing and chemical and chloride protection of the concrete pilings and concrete 'U's. A total of 125,000 lbs of Xypex was used in the concrete mix design.
Lascelles Wharf
Marine Structures

Lascelles Wharf

Australia
With a design mix that included Xypex Admix C-Series, these 20+ tonne, 40 MPa slabs were installed as part of a major upgrade of the Lascelles wharf facility. 
Flinders Ports Berth 8 Outer Harbour Grain Wharf
Marine Structures

Flinders Ports Berth 8 Outer Harbour Grain Wharf

Australia
Xypex Admix C-1000 NF was specified as the most suitable product to effectively protect the concrete structure from the harsh marine environment. Pile plugs, pile caps, rear ramp support walls, wharf beams, deck and ramps were all dosed with Admix C-1000 NF at a rate of 3.9 kg per meter.
Port of Guayaquil
Marine Structures

Port of Guayaquil

Ecuador
During April and May of 2004, the Ports Administration of Ecuador retained Xypex to assist with the repairs of the dock surfaces. The surfaces had characteristics that required Xypex Admix C-2000 to render the concrete impermeable against liquids and other aggressive substances. The Xypex treatment also protected the reinforcing steel and thereby helped prolong the life of the structure.
Australian Marine Complex
Marine Structures

Australian Marine Complex

Australia
Approximately 1,000 m3 of precast product was treated with Xypex Admix C-5000 at a grade of 50 MPa. Besides enhancing durability, benefits of Xypex Admix C-5000 include ease of application into the concrete mix, workability with vertical pours and the long term benefits of the Xypex crystalline process. 
Mayport Naval Station
Marine Structures

Mayport Naval Station

USA
Xypex Concentrate and Patch’n Plug were used to repair 480 ft. of cracks. All concrete surfaces were then coated with Xypex Concentrate and Modified.
Vancouver Seabus Floating Docks
Marine Structures

Vancouver Seabus Floating Docks

Canada
Xypex products were applied to the underside of the two large floating docks after the post-tensioned cables were found to be no more than 1/2 inch from the bottom surface. The Xypex system was used as protection against further chloride attack on the steel and post-tensioned cables.
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