SULPHURIC ACID-DAMAGED CONCRETE REPAIR

Sulphuric acid-damaged concrete can be repaired by removing weakened and contaminated material, preparing the remaining sound substrate, rebuilding lost concrete with a chemical-resistant repair material, and applying a protective coating system. In this WA chemical manufacturing project, Belzona 4111 (Magma-Quartz) was used to rebuild the damaged concrete before Belzona 4311 (Magma CR1) was applied as the chemical-resistant protective coating.

Chemical-resistant epoxy coatings such as Belzona 4311 can be used to protect concrete exposed to aggressive chemicals, including sulphuric acid in suitable service conditions. In this application, two 300-micron coats of Belzona 4311 were applied over the repaired concrete to create a durable protective barrier and help prevent further deterioration.

Yes. Where sufficient sound concrete remains, damaged areas can often be restored rather than completely demolished and replaced. This project demonstrated a repair system that rebuilt deteriorated floor and plinth areas, protected them against further chemical attack and provided the customer with a practical alternative to concrete replacement.

The deteriorated concrete was removed until a sound substrate was exposed. The surface was then cleaned using FP29 Safe Solvent before a surface conditioner Belzona 4311 was applied and the damaged areas were rebuilt with Belzona 4111. Correct surface preparation is critical for achieving reliable adhesion and long-term performance of the repair system.

Service life depends on factors including acid concentration, temperature, exposure conditions, substrate preparation and application quality. In this trial, an inspection 16 months after application found the repaired and coated area still in excellent condition, supporting the use of the same repair system for other sulphuric acid-damaged areas at the facility.