Revamping Concrete Trench Drains: A Lasting Fix
Concrete trench drains, often seen as long channels, play a critical role in efficiently draining surface water or housing utility lines and chemical spills. They’re especially vital in industrial settings. Over time, however, these trenches can degrade due to multiple factors, including fire, aggregate expansion, seawater exposure, bacterial corrosion, calcium leaching, physical impact, and chemical wear (such as carbonation, chlorides, sulfates, and even distilled water). These ongoing issues can compromise the structure’s integrity, leading to leaks, reduced strength, and the eventual need for costly repairs or replacements.
Take, for instance, a battery distribution plant less than ten years old. Despite being initially protected by a novolac coating, the concrete started showing severe signs of damage. The coating had failed, allowing the acidic bath from the battery formation process—composed of diluted H2SO4 with a pH of 1-2 and a concentration below 98%—to seep into the concrete. This acidic reaction caused significant concrete corrosion, reducing its thickness by nearly half and leaving around 35% of the concrete compromised. Experts predicted that without timely intervention within six months, the structure would fail within a year.
Fixing concrete corrosion involves removing damaged sections and restoring the substrate to its original, uniform state. At this particular site, HJ3 employed abrasive blasting to clear away loose and deteriorated concrete before applying their CarbonSeal primer and high modulus paste. Next, they installed a CarbonSeal carbon fiber reinforcing fabric up to the 2†x 2†shelf, saturating it thoroughly. To extend the repair’s longevity, they added a chemical-resistant topcoat that extended 1†beyond the edges and onto the shelf. Designed to handle up to 98% H2SO4 concentration, this topcoat ensures the repaired trenches remain robust and reliable for years to come.
Concrete corrosion remains a persistent challenge globally, costing industries trillions annually in both direct and indirect expenses. Replacing trenches at manufacturing sites is not only expensive but also disrupts production schedules. Fortunately, HJ3’s CarbonSeal system provided an efficient alternative, enabling the facility to resume operations within just a week while cutting costs by 85%. With the chemical-resistant coating in place, the trenches now stand strong against constant exposure to the acid bath, guaranteeing uninterrupted operations far into the future.
If your industrial facility has reinforced concrete trenches requiring either reinforcement or chemical resistance, consider exploring HJ3’s CarbonSeal solutions. For more information or to discuss how we can assist, reach out to our project managers at [insert email].
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