An epoxy repair mortar was used to repair the damaged concrete substrate in a clarifier tank at a Wastewater Plant in the UK. The system achieved a complete cure despite being completely submerged in water due to a rainstorm during the curing period. In this way, the concrete resurfacing epoxy, Belzona 4131 (Magma-Screed), was an excellent alternative to concrete. It enabled the Customer to bypass the serious problems that would otherwise have arisen had poured concrete been used in the application instead of the epoxy mortar.

Severely Damaged Concrete in Need of Repair 

The clarifier tank, 18 metres (59 ft) in diameter, was suffering from severe deterioration on the concrete base. This had been caused by the combined effects of corrosion and abrasion from the scrapers that run around the clarifier, moving sludge to the centre of the tank. The damaged concrete in the tank had led to a loss of efficiency of the scrapers and premature wear of the rubber scraper pads. In addition, this had caused the pumps operating downstream to become damaged by the pieces of the broken concrete which had been sucked downstream with the sludge. Repouring concrete onto the base of the tank was considered as a repair solution. However, this was deemed inappropriate as the bond to the original concrete would be insufficient.

Specification of Epoxy Repair Mortar, Belzona 4131 (Magma-Screed)

Following an inspection by Douglas Potts, Senior Fields Solutions Engineer at Belzona UK, the epoxy repair mortar, Belzona 4131 (Magma-Screed), along with Belzona 4911 (Magma TX Conditioner), were specified. Belzona 4131 (Magma-Screed) was selected due to its excellent mechanical properties as well as its abrasion resistance capabilities. In addition, as this system can be fully cured in just three days in temperatures of 15°C (59°F), this makes it an excellent alternative to concrete which concrete typically takes around 28 days to achieve a full cure.  

To accompany this specification, case studies and test data were supplied demonstrating the strength and adhesion capabilities of Belzona 4131 (Magma-Screed) to concrete. This, along with the fact that the Customer had used Belzona technology in successful applications before, further cemented their decision to opt for the polymeric technology.

Application of Concrete Resurfacing Epoxy

Firstly, the surface was power washed, and mechanically prepared using grinders and scabblers. Next, the clarifier was marked into sections and each section was then conditioned with Belzona 4911 (Magma TX Conditioner), using a stiff bristled brush. Screed rails were then used to set the level of the Belzona 4131 (Magma-Screed). 4,500 kg (9920.8 lbs) of Belzona 4131 (Magma-Screed) was then applied using metal floats to a thickness of 6mm (0.24 in).  

For more information, please visit: www.belzona.co.uk

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