Concrete Protection & Repair

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Protection for Concrete Structures in Agriculture

 

Concrete Protection and Repair for Future Value Enhancement

Protection against liquid/semi-liquid manure and biogenic sulphuric acid corrosion

For decades, concrete has been the construction material of choice for agricultural structures. Whether for fodder fermenting silos, slurry tanks, liquid manure cellars, dungwater/ urine channels, water reservoirs or biogas fermenters, concrete constructions fulfil prerequisites essential for commercial success in farming.

With continuous agricultural use, installed concrete is subjected to numerous types of both mechanical and chemical attack (e. g. caused by aggressive fermenting liquids). Such wear and tear can significantly reduce the durability of concrete, leading in extreme cases to the complete failure of an entire reinforced concrete structure. Cracks and leaks may also result in unnoticed groundwater contamination.

 

Surface coatings for reliable protection down to pH 0

The newly developed product system HCR offers comprehensive protection for your concrete structures. Capable of withstanding acid attack down to pH 0.

 

Conserving value with HCR

The reliable and durable protection provided by HCR serves to conserve the value of your agricultural structures:

  • Clamp silo walls and floors
  • Inner walls of biogas facilities
  • Slurry pits, slurry tanks, slurry cellars and much more

 

Flexible, duroelastic surface coating

  • Resistant to organic acids, salt solutions and alkalis
  • Resistant to liquid/semi-liquid manure and fermenting liquids
  • Suitable for pneumatic-tyred vehicle access
  • Easy roller application

 

Durable protection for concrete structures in agriculture

HCR surface coating

  • Two-component, duroelastic, suitable for rolling and trowelling
  • For surfaces exposed to major chemical attack
  • Resistance range pH 14 to pH 0
  • Protection against biogenic sulphuric acid corrosion (BSAC)

 

Priming with HCRprimer

Two-component water-dispersion primer

Clamp Silos

 

Exceptional resistance to organic acids

Clamp silage fermentation is an anaerobic process. In other words, the end product is created by lactic fermentation under air exclusion. This entails not only biopolymer decomposition but also the formation of organic acids.

These organic acids, often termed “silage effluent”, frequently exhibit a particularly low (and thus aggressive) pH value, giving rise to heavy chemical attack on the concrete walls and floors. Depending on the composition of the silage material, pH values of as low as 2 are quite commonplace. Unprotected steel-reinforced concrete is unable to withstand this kind of attack for long.

The solution: HCR. Providing exceptional resistance to organic acids, this duroelastic coating system has been especially developed for this area of application.

 

Part-coating of walls in zones of particularly high attrition

  1. Levelling (on old substrates)
  2. Matched joint
  3. Priming with HCRprimer on swept levelling coat
  4. HCR applied in two coats

 

We recommend that all wall surfaces and floor areas be fully coated.

Impact of silage effluent on the soil-contacted area of the clamp silo walls

 

After just 12 months: Damage caused by silage effluent (chemical attack)

 

Roller application of HCR (first coat)

Biogas Facilities

 

Long-term protection against biogenic sulphuric acid corrosion

Power generation through the fermentation of organic materials in biogas vessels has become a valuable contributor to environmental protection, enhancing energy sustainability based on regenerative resources.

While in the past liquid manure was the primary biomass used in such applications, today biogas generation is relying more and more on renewable raw materials. These include energy maize and residues from the farming cycle, such as solid dung, straw, beet leaves and green waste.

While facilitating simple and efficient energy production in biogas systems, this variety causes a very heavy chemical attack on the concrete of such facilities, particularly in the gas zone. As the concrete is unable to indefinitely withstand this kind of exposure (class XA3), an effective concrete protection is essential to keep such plant running.

The HCR system offers durable protection even against biogenic sulphuric acid.

 

Protection of the full concrete wall surface.

Coating in the upper wall area only (gas zone) is also possible.

 

Preventive concrete protection

  1. Priming with HCRprimer on swept concrete
  2. Sealing pores and blowholes with HCR
  3. HCR applied in two layers

 

Repair and protection

  1. Levelling coat on abrasive-blasted concrete substrate
  2. Priming with HCRprimer on swept levelling coat
  3. HCR applied in two layers

 

 

Slurry-Contacted Concrete Components

 

Enhanced groundwater protection thanks to crack-bridging flexibility

The continuous operation of slurry tanks, slurry cellars and slurry pits gives rise to constant chemical attack on unprotected concrete surfaces.

As a rule, slurry (liquid or semi-liquid manure) is regarded as representing a low to moderate level of organic chemical attack on concrete (exposure class XA1 to XA2). However, the “acid attack potential” of slurries is naturally dependent on their chemical composition, which is never constant, nor entirely predictable. Hence precautions against the possibility of high-level attack are advisable. High attack potentials can even occur in non-covered concrete structures.

And for zones in constant contact with liquid or semi-liquid manure, HCR again offers the ideal protection. The easy-to-apply surface coating remains flexible throughout its service lifetime, thus protecting crack-susceptible substrates or areas with cracking already present close to or at the surface. This is particularly important for the protection of groundwater.

 

 

Slurry-induced chemical attack on the
cement joint of a slatted floor.

Opened slurry cellar below a slatted floor.

Tested for Quality

 

Certified concrete coating system for long-lasting protection

HCR has been developed as a duroelastic coating system specifically for the protection and repair of concrete structures in agriculture.

Outstanding resistance to chemical attack and mechanical wear has been verified in a range of trials and quality assurance tests. As a planner, farmer or property owner, this gives you maximum security for cost-efficient, durable protection and repair works.

 

High chemical resistance

  • Resistant to silage effluent according to DIN 11622-2
  • Resistant to acidic media down to pH 0 according to the KIWA acid test programme
  • Resistant to a wide range of organic acids, salt solutions and alkalis

 

Good crack bridging capacity

  • Crack bridging class A2 according to EN 1504 Part 2

 

Anti-slip properties

  • Sliding friction coefficient determined according to DIN 51131, classified as being of “unrestricted suitability”

 

Fast and easy application

  • Roller application
  • Trowel application

 

European certification

Certified according to EN 1504 Part 2 for methods 1.2 , 2.2, 5.1, 6.1 and 8.1

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