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Revitalizing Concrete Trench Drains: A Long-Lasting Fix

Concrete trench drains, often overlooked but essential, serve as critical pathways for managing surface water or safely containing utilities and chemical spills. They are especially vital in industrial environments where efficiency and safety are paramount. However, over time, these structures can suffer from a range of damaging factors—fire, aggregate expansion, seawater exposure, bacterial activity, calcium leaching, physical impacts, and chemical degradation like carbonation, chlorides, and sulfates. These issues compromise the structural integrity of the concrete, leading to leaks, reduced strength, and costly repairs or replacements.

Take the example of a battery distribution plant that had been in operation for less than ten years. Initially protected by a novolac coating, the facility faced a serious problem when the coating failed. The acid bath used in the battery-forming process, which contained diluted sulfuric acid (H2SO4) with a pH of 1–2 and a concentration below 98%, began to penetrate the concrete. This led to severe corrosion, reducing the thickness of the concrete by about half and resulting in approximately 35% of the structure being compromised. Engineers estimated that without immediate action, the trench would fail within a year, and repairs needed to be completed within six months to prevent total collapse.

To address this issue, HJ3 implemented a comprehensive repair strategy. The first step was to remove the damaged concrete using abrasive blasting. Then, they applied HJ3’s CarbonSeal primer followed by high-modulus paste to restore the original shape of the trench. Next, the CarbonSeal carbon fiber fabric was saturated and installed up to the 2” x 2” shelf, providing additional reinforcement. To ensure long-term protection, a chemical-resistant top coat was applied, extending 1” across the entire surface and onto the shelf. This coating is specifically designed to withstand concentrations of up to 98% H2SO4, making it ideal for environments exposed to harsh chemicals.

Corrosion of concrete is a global challenge, costing industries over $6 trillion annually in direct and indirect expenses. Replacing trenches at manufacturing sites can be extremely expensive, involving materials, labor, and significant downtime. In this case, HJ3’s CarbonSeal system provided a cost-effective solution, allowing the facility to resume operations within just one week. Compared to full trench replacement, the company saved 85% on costs while ensuring long-lasting durability. With the chemical-resistant coating in place, the trench is now fully equipped to handle continuous exposure to the acid bath, guaranteeing smooth operations for years ahead.

If your facility has reinforced concrete trenches that require strengthening or chemical resistance, consider HJ3’s CarbonSeal industrial repair systems. Contact our project managers today to learn more about how we can help protect your infrastructure and reduce long-term maintenance costs.

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