Concrete is widely used in industrial and commercial settings due to its durability and strength. However, its exposure to alkaline solutions can significantly impact its longevity and performance. Whether in chemical plants, manufacturing units, or food processing facilities, concrete surfaces often come into contact with caustic substances like sodium hydroxide (NaOH) and potassium hydroxide (KOH). Understanding the effects of alkaline solutions on concrete and implementing protective measures, such as alkali-resistant flooring, is crucial for maintaining structural integrity.

Effects of Alkaline Solution on Concrete

The effect of an alkaline solution on a concrete surface depends on the concentration, type of alkali, duration of exposure, and the quality of the concrete. Here are the common effects:

1. Surface Deterioration: Prolonged exposure to strong alkaline solutions, such as sodium hydroxide (NaOH) or potassium hydroxide (KOH), can lead to surface etching or softening of the concrete, particularly if the concrete is of low quality or poorly cured.

2. Alkali-Silica Reaction (ASR): Alkali solutions can trigger a chemical reaction between alkalis in the solution and reactive silica in the aggregates, forming a gel-like substance that expands when it absorbs moisture. This leads to:

• Cracking in the concrete.

• Spalling and surface degradation over time.

  

3. Increased Permeability: Alkaline solutions may attack the calcium silicate hydrate (C-S-H) gel, the primary binding component in concrete. This weakens the matrix and increases porosity, making the concrete more susceptible to further chemical attack.

4. Efflorescence: Alkalis can dissolve calcium hydroxide in the concrete and transport it to the surface. When the solution evaporates, it leaves behind white, powdery deposits of salts.

5. Discoloration: Prolonged exposure to alkaline solutions can cause staining or discoloration on the concrete surface, altering its appearance.

6. Loss of Strength: If the alkaline solution penetrates deeply, it can lead to a loss of compressive strength by degrading the internal structure of the concrete.

7. Scaling and Dusting: Exposure to alkaline solutions in poorly compacted or low-strength concrete can result in surface scaling (flaking) and dusting, reducing the durability and aesthetic value of the concrete.

Alkali-Resistant Flooring as a Solution

To combat the  effects of alkaline solutions, industries rely on specialized flooring solutions that offer superior chemical resistance. Rezovate's Alkali-Resistant Flooring provides an effective barrier, protecting concrete from chemical deterioration. Key features include:

Thickness: Available in 1 mm - 3 mm for varying levels of protection.

Form Options: Available in rolls (up to 3 m width) and tiles (300 mm x 300 mm, 600 mm x 600 mm) to suit different application needs.

Testing: Subjected to a 24-hour dip test in caustic soda, ensuring high resistance to alkaline substances.

Performance Characteristics of Alkali-Resistant Flooring

1. Abrasion Resistance: Moderate wear resistance (RDSO-CG-12).

2. Fire Resistance: Does not support combustion or flame spread (RDSO C8515-Rev II).

3. Color Fastness: Retains its color even under harsh conditions (IS: 9766 - Wool Standard

4. Dimensional Stability: No signs of expansion or shrinkage (IS: 3464 - 1986).

5. Curling Resistance: No curling observed, conforming to IS: 3463 - 1986.

6. Insulation Resistance: Provides electrical insulation resistance > 10^13 Ohms, as per IS 2259.

Conclusion

Protecting concrete surfaces from alkaline damage is essential for maintaining structural integrity and operational efficiency in industrial settings. Investing in alkali-resistant flooring not only extends the lifespan of concrete floors but also enhances safety, reduces maintenance costs, and ensures compliance with industry standards. Rezovate’s flooring solutions provide a reliable and durable option for industries dealing with alkaline exposure, ensuring a long-lasting and resilient surface.