Pipes – New & Repair

Cem-Kote systems have over 25 years of field-proven performance worldwide

Gemite’s Cem-Kote protective systems are designed for Internal and External pipe applications, withstand harsh attack by sulfuric acid formed by MIC, and also shield concrete from other chemicals.

Cem-Kote Cementitious Waterproofing membranes excel in buried applications, withstand Positive and Negative hydrostatic pressures exceeding 5 bar (50 m head of water) and provide lasting & reliable performance, even under diverse climatic conditions.

Concrete Pipes – New

System # 2 – H2S up to 50 ppm

1st   coat   =   Cem-Kote Barrier Cote 100 – vapor retarder providing exceptional bond

2nd  coat   =   Cem-Kote Flex CR – waterproofing + protection of concrete against sulfuric acid                                                                                produced by MIC (Microbiologically Induced Corrosion)

Cem-Kote Barrier Cote 100

Cem-Kote Barrier Cote 100 delivers superior bond, even to contaminated concrete & provides super tough surface with high abrasion resistance.

Cem-Kote Barrier Cote 100 is an excellent Vapor Retarder that reduces moisture transfer from ground water, plus is insensitive to moisture in the concrete and high relative humidity – allowing application under conditions which would be impossible for application of polymer coatings.

Cem-Kote Flex CR

Cem-Kote Flex CR has an excellent chemical resistance to acids generated by Microbiologically Induced Corrosion (MCI) – it forms a seamless membrane (without joints) that provides lasting protection for concrete.

Cem-Kote Flex CR is Non-toxic and much easier and safer to apply than polymer coatings. Its inherent flexibility is enhanced with Reinforcing Fabric HD to deliver an excellent bridging of substrate cracks.

Application Procedures

  1. Concrete surface is cleaned and profiled using high-pressure water 34 MPa (5,000 psi)
  2. Active water leaks must be stopped using Fibre-Patch WP, or injection
  3. Cem-Kote Barrier Cote 100 is applied by spraying or brushing
  4. Curing – 2-day air cure is sufficient prior to application of Cem-Kote Flex CR
  5. Clean the surface of Cem-Kote Barrier Cote 100 with high-pressure water 34 MPa (5,000 psi)
  6. Cem-Kote Flex CR is applied by spraying or brushing
  7. Curing – minimum 3-day air cure (under normal conditions) prior to exposure to sludge

Advantages of System # 2

New Concrete

Cem-Kote Barrier Cote 100 can be applied after curing new concrete ONLY overnight

Polymer (epoxy or polyurethane) coatings require concrete to be cured for a minimum 28 days (most recommend 45 days) to prevent debonding. Installation of polymer coatings requires frequent testing to satisfy stringent internal and surface “dryness” and very low Relative humidity.

Insensitivity to Moisture & Humidity

Cem-Kote Barrier Cote 100 and Cem-Kote Flex CR can be applied on Wet Substrate & at High Humidity

Cem-Kote Barrier Cote 100 reduces moisture transfer value (MVT) to levels allowing application of non-breathable coatings, such as epoxy or polyurethanes.

Cem-Kote Flex CR is completely insensitive to surface moisture & high humidity, it stops water penetration from the ground and prevents debonding due to vapor condensation (caused by high capillary pressures at concrete-polymer membrane interface).

Polymer coatings are very sensitive to substrate & surface moisture, high RH and water vapor penetrating from behind – moisture barrier must be used, or 1” depth of concrete must be dried, to allow application. Drying procedures are extremely expensive, and in most underground pipes it is impossible to reduce moisture and RH to levels required by epoxies and polyurethanes.

Excellent Resistance to Acid & other Chemicals

Best system for concrete structures exposed to sulfuric acid generated by MIC (micro-biological oxidation of hydrogen sulfide), such as sewer pipe systems and manholes.

Breathability

Cem-Kote Flex CR is “breathable” = Allows Water Vapor to Escape from inside the Substrate

Polymer membranes act as vapor barriers, preventing water vapor escape – resulting in de-bonding problems.

Flexibility + Crack Bridging

Cem-Kote Flex CR delivers crack bridging, augmented by Reinforcing Fabric HD

Polymer coatings (epoxy, vinyl-esters or flexibilized epoxies) are non-flexible, without (or limited) crack bridging capability.

Easy + Fast Application

Cem-Kote Flex CR is Easily & Quickly Applied without Special Equipment

Polymer coatings are “sticky”, and the tools and equipment are difficult to clean, even with expensive organic solvents.  Application of polymer coatings has to be carried out in a very narrow “application window”, which increase the applied cost.

Resilient

Cem-Kote Flex CR is a very “robust” product

It accommodates large variations in moisture content, relative humidity and temperature, and its “application window” is wide and tolerant to varying site conditions.

Application of polymeric coatings is restricted due to the substrate moisture, RH and temperature conditions required. Expensive heating equipment is needed to dry the application area.

Eco-Friendly & Non-Toxic

Cem-Kote Flex CR is completely Non-Toxic & Not Hazardous

Cem-Kote Flex CR is a water-based, polymerized cementitious coating and does not require any personal protection.  Only disposable dust masks respirators are recommended during mixing.

Polymer coatings are highly flammable, requiring proper ventilation at all times, and emit noxious smell requiring chemical protection (gloves & masks) at all times. Inhalation of epoxy fumes & dust is highly dangerous.

Cost Savings

Cem-Kote Flex CR is less than 50% of the Applied Cost of polymer coatings

Application of polymer coatings is very complex, especially when moisture and higher humidity exist, which significantly increases application time and results in very high applied cost.

Cem-Kote CW Plus

In some situations, when financial restrains do not allow application of the more robust and comprehensive System # 2, Cem-Kote CW Plus is used.

Application Procedures

  1. Concrete surface is cleaned and profiled using high-pressure water 34 MPa (5,000 psi)
  2. Cem-Kote CW Plus is applied in 2-coats to a min. thickness Barrier Cote 100 is applied by spraying or brushing
  3. Curing – 2-day air cure is sufficient prior to application of Cem-Kote Flex CR
  4. Clean the surface of Cem-Kote Barrier Cote 100 with high-pressure water 34 MPa (5,000 psi)
  5. Cem-Kote Flex CR is applied by spraying or brushing
  6. Curing – minimum 3-day air cure (under normal conditions) prior to exposure to sludge

Concrete Pipes – Restoration

In restoration projects the surface of concrete pipe may be seriously contaminated and deteriorated (eroded) to varying depth.  The condition of the surface is sometimes only found after a surface preparation, which is carried out by sandblasting to obtain solid concrete substrate.

Fibre-Prime

Fibre-Prime, rustproofing coating containing migrating corrosion inhibitor must be applied in 2 coats over exposed reinforcing steel (rebar) surface to, to provide protection from future rusting

Levelling & Reprofiling up to 12 mm (1/2”) – Gem-Plast TC

Spray applied and troweled, or hand applied.  Floor reprofiling may require a higher thickness.

Levelling & Reprofiling over 12 mm (1/2”) – Spray-Con WS ST

Wet shotcrete mortar material with a great thixotropy, allowing thick installations in one “pass”.

System # 2 – H2S – up to 50 ppm

1st  coat     =   Cem-Kote Barrier Cote 100 – vapor retarder providing exceptional bond

2nd coat    =   Cem-Kote Flex CR – waterproofing + protection of concrete against sulfuric

                          acid produced by MIC (Microbiologically Induced Corrosion)

Application Procedures

  1. Repaired concrete surface is cleaned and profiled using high-pressure water 34 MPa (5,000 psi)
  2. Active water leaks must be stopped using Fibre-Patch WP, or injection
  3. Cracks are repaired using Reinforcing Fabric HD embedded in Cem-Kote Barrier Cote 100
  4. Cem-Kote Barrier Cote 100 is applied by spraying or brushing
  5. Curing – 2-day air cure is sufficient prior to application of Cem-Kote Flex CR
  6. Clean the surface of Cem-Kote Barrier Cote 100 with high-pressure water 34 MPa (5,000 psi)
  7. Cem-Kote Flex CR is applied by spraying or brushing
  8. Curing – minimum 3-day air cure (under normal conditions) prior to exposure to sludge

Cem-Kote CW Plus

Used in some situations, when financial restrains do not allow application of the more robust and comprehensive System # 2.

Concrete Pipes – Restoration & Strengthening

After the surface preparation – use high-pressure water 34 MPA (5,000 psi), or sandblasting, some pipe sections may be deteriorated so severely that a Structural Strengthening is required.

Highly deteriorated (delaminated) concrete surfaces may require restoration (reprofiling) prior to application of the Structural Strengthening system.

Fibre-Prime

Fibre-Prime, rustproofing coating containing migrating corrosion inhibitor must be applied in 2 coats over exposed reinforcing steel (rebar) surface to, to provide protection from future rusting

Levelling & Reprofiling up to 12 mm (1/2”) – Gem-Plast TC

Spray applied and troweled, or hand applied.  Floor reprofiling may require a higher thickness.

Levelling & Reprofiling over 12 mm (1/2”) – Spray-Con WS ST

Wet shotcrete mortar material with a great thixotropy, allowing thick installations in one “pass”.

Surface cleaning

Reprofiled concrete surface is cleaned using high-pressure water 34 MPa (5,000 psi) or light sandblast

Application Procedures

  1. Concrete Tensile strength must be checked – min. 1.4 MPa (200 psi) with failure in the substrate concrete
  2. Active water leaks must be stopped using Fibre-Patch WP, or injection
  3. Crack are repaired using Reinforcing Fabric HD embedded in Cem-Kote Barrier Cote 100
  4. Cem-Kote Barrier Cote 100 is applied by spraying or brushing
  5. Curing – 3-day air cure is sufficient prior to application of Gem-Wrap Fabric or Gem-Strip Laminate
  6. Clean the surface of Cem-Kote Barrier Cote 100 with high-pressure water 34 MPa (5,000 psi)
  7. Gem-Wrap Carbon Fabric
  8. Apply Gem-Cote W ST Primer, and allow cure overnight – minimum 12 hours
  9. Apply coat of Gem-Cote W ST Resin
  10. Place Gem-Wrap Carbon Fabric into the resin – in the designed direction & work in with a plastic roller
  11. Apply an additional coat of Gem-Cote W ST Resin to embed the Gem-Wrap Carbon Fabric
  12. Gem-Strip Carbon Laminate
  13. Apply Gem-Cote S ST Adhesive to the prepared surface
  14. Apply a coat of Gem-Cote S ST Adhesive to the surface of Gem-Strip Carbon Laminate
  15. Place Gem-Strip Carbon Laminate into the adhesive & use a hard rubber roller to obtain full contact
  16. If the repaired area is exposed to a constant UV light – protect the surface of Gem-Wrap Carbon Fabric or Gem-Strip Carbon Laminate system using Tuff- Flex CA & Primer # 300

Steel pipes – Restoration

Fibre-Prime

Fibre-Prime polymerised cement rustproofing coating employs several corrosion protective mechanisms and is suitable for rusted steel pipes not exposed to severe chemical attack.

Fibre-Prime can be applied to a damp steel surfaces – even under high Relative humidity conditions.

Application Procedures – Fibre-Prime

  1. Use wet or dry abrasive sand blasting, or wire brush, to remove all loose rust, dust and other contaminants that could affect adhesion.
  2. “White metal” surface is not required
  3. Apply a thin coat of Fibre-Prime by spraying, or brushing and allow to dry for 10-15 minutes
  4. Apply second coat of Fibre-Prime to build a total min. dry film thickness of 1 mm (40 mils)
  5. 2-coat application assure that no pinholes are formed + provides a continuous protective membrane
  6. Curing – for approx. 24 hours

Steel Pipes – Restoration (chemical industries)

Protective system for pipes in various chemical industries (exposed to severe chemical attack), incorporates Gem-Cote EP 100 (100% solids epoxy) – to protect against attack by various corrosive chemicals.

1 coat    =   Fibre-Prime – rustproofing coating

2 coat   =   Gem-Cote EP 100 – high-level of chemical protection

Application Procedures:

  1. Fibre-Prime – follow steps 1-3 above
  2. Curing –  24 hours air cure is sufficient prior to application of Gem-Cote EP 100
  3. Apply 2 coats of Gem-Cote EP 100
  4. Allow to dry cure, before exposure to liquids or chemicals