COATING FOR CONCRETE

BACKGROUND
1. Coating is used on highway Portland Cement Concrete bridge to
reduce the rate of chloride attack on the reinforcing steel corrosion
thereby extending service life and reducing life-cycle structure
costs of the bridge deck (preventative maintenance).
2. By applying coating to existing concrete surfaces, the permeability
of the concrete is reduced by up to one order of magnitude.
3. The permeability of the concrete is one of the most important
factors which will effect the rate of deterioration of rebar
corrosion, alkali-aggregate reaction, carbonation, and the effects of
freeze-thaw cycles of which all could occur at the same time
4. Coatings can be tinted, to an almost unlimited amount of color
choices. One of the most important and fundamental advantages
of architectural coatings is that they beautify the concrete building
or structure to which they are applied.

PURPOSES
1. Corrosion Protection by reducing the permeability of
the concrete, preventing moisture and road salts from
being absorbed into the concrete slab.
2. To prevent water leakage into the space below through
cracks or joints
3. Aesthetics

COATING PROPERTIES
REQUIREMENTS
1.
2.
3.
4.
5.
6.
7.

Water Proofing
Carbonation Resistance
Water Vapor Transmission/Breathe
UV Resistance
Elasticity
Aesthetics
VOC Level

WATERPROOFING
1. The primary function of a protective coating is to keep water
out of the building or structure, and create a protective
envelope for the concrete surface.
2. This resistance to water absorption is a basic, yet critical
function of any architectural coating.
3. Any paint or coating that absorbs considerable amounts of
water will not protect the concrete and will often peel from the
surface.
4. Since chloride ions only enter concrete while dissolved in
water, waterproof coatings will generally keep chloride ions out
of the concrete, further protecting the steel reinforcing.
5. Once chlorides have entered the concrete, they migrate to the
steel, attack the steel surface and instigate corrosion.

CARBONATION RESISTANCE
1. Carbonation is the natural phenomenon that occurs in concrete
when a loss of pH takes place.
2. This occurs when atmospheric carbon dioxide reacts with the
moisture inside the concrete pores and converts high-pH
calcium hydroxide to calcium carbonate, which has a more
neutral pH.
3. At a lower pH level, concretes corrosion protection ability is
reduced (carbonation moves from the outer surface of the
concrete inward, advancing toward the reinforcing steel).
4. Like other exterior coatings, an anti-carbonation coating can still
be water vapor permeable.
5. An anti-carbonation coating forms a cured polymer network, or
"fishnet", that catches the larger carbon dioxide molecules but
allows the smaller water vapor molecules to pass through.

WATER VAPOR TRANSMISSION /

BREATHE
1. Architectural coatings need to let the concrete "breathe" or
allow water vapor to pass from the structure and through
the concrete without building up vapor pressure.
2. This helps protect moisture from building up behind the
coating, which can lead to condensation in the building or
structure and possibly affect the adhesion of the coating to
the concrete.

UV RESISTANCE
1. Sunlight will degrade most polymer materials over a period
of time. In the case of protective coatings and paints, it may
significantly reduce the protective performance that was
expected.
2. While it is expected that a good quality architectural coating
perform for at least 10 years, the life of these coatings is not
unlimited and, after time, their technical benefits will start
to decrease.
3. Ultra Violet light can also cause fading in the organic
pigments used to color many coatings, especially in dark
colors.

ELASTICITY
1. Most concrete structures move thermally and some even
dynamically. This may require a protective coating to have
additional elasticity (the ability to elongate and recover) and
crack-bridging properties, particularly at low temperatures
when coatings become more rigid and cracks become wider.
2. Many coatings are flexible as a free film, but few are
elastomeric, and fewer still are sufficiently elastomeric
enough to bridge recurring fine cracks at low temperatures.
3. Fine cracks, which are often insignificant structurally, are
very significant to the long term durability of reinforcing
steel.
4. These fine cracks can allow water, chlorides, and carbon
dioxide intrusion, which lead to corrosion of the rebar and
subsequently damage the concrete structure.

AESTHETICS
1. One of the most important and fundamental advantages of
architectural coatings is that they beautify the concrete building
or structure to which they are applied.
2. Coatings can be tinted, either by the manufacturer or the local
distributor or paint store, to an almost unlimited amount of color
choices.
3. This makes paints and coatings a very unique product in concrete
protection, because the look of the product is often even more
important to the customer than the technical benefits the
product provides.
4. Architectural coatings are also available in many types of
textures, ranging from smooth to course, which also add to the
aesthetics of the building while helping to hide any imperfections
in the concrete substrate.

VOC LEVELS
1. In the past several years, many states have enacted regulations
aimed at lowering the levels of VOC (volatile organic compound)
in coatings, thereby protecting air quality.
2. Most manufacturers have had to reformulate many products to
water based formulations in order to meet these VOC regulations
and still maintain the products performance.
3. These lower VOC products can also contribute to LEED credits in
building construction.

REFERENCE
1. TECHNICAL LITERATURE ON CORROSION/CARBONISATION
PROTECTION IN CONCRETE STRUCTURES, Goverment of India,
Ministry of Railway
2. BEST PRACTICE GUIDLINES FOR SELECTING CONCRETE BRIDGE
DECK SEALERS, Govermrnt of Alberta, Transportation
3. CONCRETE PROTECTION FOR CONCRETE ADVANTAGES,
Wackers Silicones
4. STUDY ON THE DURABILITY OF SURFACE COATING MATERIALS
FOR CONCRETE STRUCTURES, Iwao SASAKI and Itaru NISHIZAKI

BACKGROUND
1. In the past it was believed that concrete by itself is a durable
material, which needs no protection or maintenance.
2. This belief is no more hold good particularly on account of
environmental pollution, industrial fumes and contamination
of ground water.
3. In addition to the coating of reinforcement by appropriate
material, a surface coating to the concrete member is given
to increase the durability further.
4. The coatings serve the dual purpose of protection and
decoration

CARBONATION DEPTH

INDIA
1. Giving protective coatings to major concrete structures
such as bridges, flyovers, industrial buildings and chimneys
have become a common specification in India as in 22
other countries.
2. Four km long bridge on national highway at Cochin was
recently coated.
3. Almost all the flyovers at Mumbai are being coated for
additional durability

MATERIAL FOR COATING

1.
1.
-

Epoxy based coating material

not resistant to ultra violet rays when exposed to sunlight
not flexible
Not able to breath.
Coating material based on acrylic polymer
resistant to ultra violet rays of sun
flexible.
Retains teh breathing property of concrete

INDIA
SOLVENT/WATER BASED ACRYLIC ELASTOMERIC COATING

INDIA
SOLVENT/WATER BASED ACRYLIC ELASTOMERIC COATING

SURFACE PREPARATION
1. In order to have better bonding, the concrete surface
should be clean, dry and mechanically sound.
2. The surface of the concrete structure to be coated shall
be cleaned of all traces of mould oil, laitance, salt
deposits by mechanized means.
3. The surface should be thoroughly scrubbed using power
tools/sweep blasting. Finally, the surface should be
washed with clean water jet to remove any salt
deposits.
4. The surface should be dried.
5. All the protrusions should be removed and cracks, joints
should be sealed with sealant as per manufacturers
recommendation.

APPLICATION OF COATING
1. Thoroughly mix the entire contents of the packaged tin
prior to use.
2. A primer coating of the coating shall be applied to the
cleaned surface after surface preparation.
3. After air curing, intermediate and top coating should be
applied with time lag as per manufacturers
specification.
4. The coating shall be applied by airless spray or other
approved means

COATING THICKNESS
1. For acceptance purpose, at least 60% of all recorded
total thickness measurement of the coating after curing
shall be 225 20 microns (minimum).
2. Thickness measurement below 225 20 microns shall
be considered cause for rejection.
3. The upper thickness limit does not apply to repaired
areas of damaged coating

FRESH CONCRETE
1.

2.
3.

4.
5.
6.

Freshly made concrete members contain plenty of water in the pore

structures. It takes long time to dry. It should not be coated with epoxy or
other materials, which will seal off and prevent the internal moisture from
going out in consonance with atmospheric conditions.
The moisture trapped inside the concrete can do untold harm to the durability
of concrete in addition to damaging the protective coating itself.
For better durability, the concrete should be able to breathe i.e. water
vapour should be able to migrate from inside to outside and from outside to
inside.
But water as it is, should not be able to enter from outside to inside.
The protective coating given to the concrete should be of the above
characteristics.
Therefore, it is pointed out that the epoxy coating, which does not allow the
concrete to breathe, should not be used for coating concrete members

COATING FOR WET SURFACE

CONCRETE

COATING FOR WET SURFACE

CONCRETE
SURFACE PREPARATION
1. In order to have better bonding, the concrete surface should
be clean, dry and mechanically sound. The surface of the
concrete structure to be coated shall be cleaned of all traces
of mould oil, laitance, salt deposits by mechanized means.
2. The surface should be thoroughly scrubbed using power
tools/sweep blasting. Finally, the surface should be washed
with clean water jet to remove any salt deposits.
3. All the protrusions should be removed and cracks, joints
should be sealed with sealant

COATING FOR WET SURFACE

CONCRETE
APPLICATION OF COATING
1. Mix the base and curing agent in prescribed proportion by
volume thoroughly and allows it to remain in a container for
ten minutes.
2. First and Top Coat should be applied with time lag as per
manufacturers specification.
3. Repair of damaged coating shall be done in accordance with
the patching material manufacturers written
aecommendations within the accepted rates

COATING FOR WET SURFACE

CONCRETE
COATING THICKNESS
1. Measurement of coating thickness shall be made using
thickness measuring gauge and Elcometer. The minimum
total thickness of coating (1st& Top coat) must be 300-350
microns
2. For acceptance purpose, at least 60% of all recorded total
thickness measurement of the coating after curing shall be
300-350 microns (minimum). Thickness measurement
below 300 microns shall be considered cause for rejection.
3. The upper thickness limit does not apply to repaired areas
of damaged coating.

NEXT STEP
1. Comunication with GoldFish for Teh Product we
need
2. Based on Teh Reference (India, Japan, Alberta)