Structural Repair in a Marine Environment with Anti-Corrosion Protection System

Structural Repair in a Marine Environment with Anti-Corrosion Protection System

APPLICATOR COMPANY: Integra Aplicaciones
ARCHITECTURE FIRM: ASB Arquitectura

Structural repair system with PROPAM® TECHNO FLUID MCI and final protection with BETOPAINT

Introduction

Structural repair in coastal areas requires a specialized technical approach due to the aggressive environmental conditions that directly affect reinforced concrete. Constant exposure to sea wind, salinity, humidity, and thermal cycles accelerates carbonation and reinforcement corrosion, compromising structural safety.

In this context, the project carried out in Ferrol addresses the rehabilitation of 5,000 m² of structural concrete surfaces using a certified, high-durability system. The intervention involves 140 tons of PROPAM® TECHNO FLUID MCI, 60 tons of PROPAM® REPAR TECHNO 40, 2,000 kg of BETOPAINT, and PROPAM® REPAR PRIM for the passivation of steel reinforcements, achieving a deep and effective restoration under harsh marine conditions.

Project Description

The project consists of the structural repair of 5,000 m² of concrete elements in a structure severely degraded by marine exposure.
The building shows loss of cover, oxidized reinforcement, and cracks due to carbonation, mainly caused by its proximity to the port and continuous exposure to a saline environment.
The adopted solution combines migratory corrosion inhibitor (MCI) technology, thixotropic repair mortars, reinforcement passivation with specific primer, and a protective coating highly resistant to weather and chlorides.

Reasons for the Intervention

• Stop active corrosion processes in exposed steel reinforcement.
• Repair large volumes of concrete damaged by carbonation.
• Prevent the recurrence of pathologies in a marine environment.
• Improve the aesthetic and functional performance of the structural envelope.

Project Challenges

• Extreme humidity, wind, and salinity typical of the Galician coast.
• Repair work in hard-to-reach areas, including vertical surfaces and ceilings.
• Careful coordination of the treatment, passivation, filling, and finishing stages.
• Strict control of thickness and bonding to ensure long-term durability.

Applied Solution

1. Passivation of affected reinforcement
   🔹 PROPAM® REPAR PRIM
   Corrosion-inhibiting primer applied prior to the repair mortars. It protects oxidized rebar and ensures adhesion and durability of the repair system.
2. Fluid structural repair with corrosion inhibitor
   🔹 PROPAM® TECHNO FLUID MCI
   Compensated-shrinkage fluid mortar with MCI technology, ideal for pouring into formwork and filling large sections. 140 tons are applied to horizontal and vertical elements.
3. Manual thixotropic repair on vertical surfaces
   🔹 PROPAM® REPAR TECHNO 40
   High-performance thixotropic mortar used for volumetric reconstruction and structural regularization. 60 tons are applied to columns, beams, and slab edges.
4. Protective anti-carbonation coating
   🔹 BETOPAINT
   Acrylic waterproof paint with UV resistance and anti-carbonation properties. 2,000 kg are applied as the final protective finish across the entire treated surface.

Added Value of the PROPAM® System

• Fully certified system according to EN 1504 for structural repair.
• Full protection against chloride-induced corrosion thanks to MCI technology.
• Excellent workability on site, even on vertical and overhead surfaces.
• Extended service life of the rehabilitated structural elements.
• Uniform, aesthetic finish resistant to marine weathering.