Water Damage Restoration Case Study] What is a “membrane” that creates a concrete surface just by pouring water on it?

In Japan, typhoons and torrential rains occur every year, sometimes leaving large traces of damage. Rivers, waterways, and mountain roads are especially vulnerable to damage, and in some cases, large-scale repair work using concrete is required, leaving the government agencies in charge to deal with the situation. Damage caused by typhoons and torrential rains is often directly related to people’s daily lives, and disaster recovery efforts are therefore urgent. However, it is sometimes difficult to respond with a sense of speed because construction using secondary concrete products takes time, requires large heavy machinery, and requires workers with specialized skills. The solution to this problem is “Concrete Canvas,” a “membrane” that creates a concrete surface simply by pouring water on it.

• short delivery time
• No need for large heavy machinery
• No technical expertise required

and can create concrete surfaces, enabling rapid repair work. This article details the performance of concrete canvas and actual examples of its use. It is especially useful for civil engineering project managers in government and transportation-related businesses. Please take a look at this article before the arrival of the typhoon and heavy rain season.

What is a concrete canvas?

Concrete Canvas is a “composite material of concrete, fabric, and impervious material” developed in the UK. By simply laying a thin fabric of 5mm to 13mm thick on the ground and sprinkling water on it, a durable, watertight, and fire-resistant concrete surface can be created. It can also be used underwater in both seawater/freshwater. The structure consists of specially formulated dry concrete sandwiched between a fiber matrix weave (surface) and a PVC sheet (back).

 

The following issues that have been a problem in concrete construction have been resolved,

• take time
• Large heavy equipment required
• Need workers with specialized skills.

It has been adopted by many governments for its ability to make quick repairs in urgent situations such as typhoon damage response. Please watch this 2-minute video for an overview of Concrete Canvas.

 

 

 

Four features of the concrete canvas

Concrete canvas has four characteristics: high workability, durability, environmental friendliness, and fire resistance.

 

Feature 1: High workability

All that is needed to create a concrete surface is concrete canvas and water. Since the fabric can be transported in a rolled form, there is no need for mixer trucks or other large heavy equipment, no need for measuring or mixing, and no need for workers with special expertise since there is no need to worry about excess water.

Before curing, the product is in a flexible cloth-like form, allowing it to be applied to complex shapes, even in wet weather and underwater.

 

There are “batch rolls” that can be transported by hand and “bulk rolls” that can be constructed at high speed on a large scale by heavy machinery.

 

Feature 2: Durability

Concrete canvas materials are chemically and weather resistant and are not degraded by ultraviolet light. It also has approximately twice the abrasion resistance of ordinary concrete and has demonstrated a life expectancy of over 50 years in accelerated deterioration tests in the United Kingdom. In this test, concrete canvas withstood 200 repeated freeze-thaw cycles.

 

Feature 3: Environmental

Concrete canvas is characterized by low abrasion and exhibits the following environmental properties

Reduction of CO2

Concrete canvas saves approximately 95% of materials for a typical construction project. Material savings translate directly into reduced road transportation and time spent on site, thus reducing the total amount of CO2 emissions from the construction process.

Fewer outflows

In a runoff test in water, Concrete Canvas showed a mass loss of only 3%, while typical concrete showed a mass loss of 10-15%. With little runoff and no need for casting, the amount of material required can be significantly reduced.

Low free alkali

Concrete Canvas uses a special fast-strength concrete with low free alkali content. This product is not classified as an irritant like ordinary concrete and is less harmful to the environment.

tree planting

The concrete canvas has a coarse surface fiber surface due to its non-treated nature, and over time, moss grows on it, giving it a “green” color that naturally blends in with rivers and mountain paths.

 

Feature 4: Fire resistance

Concrete canvas has excellent heat resistance and can also be used as a fireproof layer in some applications, achieving Euro Class B in BS EN 13501 flame reaction testing and has been approved by the U.S. Mine Safety and Health Administration (MSHA) as meeting 30 CFR Part 7, Section B, Section 7.24. The product has also been approved by the U.S. Mine Safety and Health Administration (MSHA) as meeting 30 CFR Part 7, Section B, Section 7.24. Because the flame does not spread to the surface, smoke generation is kept low and emissions of toxic gases are minimized.

Concrete Canvas Applications

Concrete canvas, which can be used to create concrete surfaces quickly, flexibly, and with ease, can be used for a variety of purposes and in a variety of situations. The following are some examples.

Disaster recovery (sandbag covering)

 

Erosion prevention (surface protection)

 

Waterway maintenance and expansion

 

irrigation channel construction

 

weed prevention

 

slope protection

 

Concrete Repair

 

Outlet/residual water discharge

 

basket protection

Concrete Canvas Case Study Introduction

Concrete Canvas has already been adopted in many areas due to its performance, and in some cases, a letter of appreciation has been sent for its outstanding effectiveness. The following are just a few examples.

Example of emergency restoration of the Suemasa River embankment break in Kurashiki City (Mabi-cho)

 

In the summer of 2018, Mabi-cho, Kurashiki City, Okayama Prefecture, was severely damaged by the so-called “torrential rainstorm in western Japan. Both banks of the Suemasa River collapsed, flooding the town. A rapid restoration response was required, and temporary restoration had to be completed in about two weeks to minimize the damage. However, it was not an easy task due to the following issues.

• The entire neighborhood was affected by the disaster, and there were no builders with spare capacity.
• The initial plan to construct the concrete surface using fabric formwork would take more than one month and would not be completed in time.
• Inability to secure workers capable of performing special construction.

Construction began on July 26 and was completed by the evening of August 3. The concrete canvas was highly appreciated by Okayama Prefecture for its significant results.

Other examples of introductions include

Aomori Amamabayashi Land Improvement District, Aomori Repair of aging farmland canals

Tohoku Expressway, Towada District, Kodan Drainage Ditch Improvement Work

Weeding and weed control work associated with Hikari no Mori Station

Repair of drainage pipes, etc. at Minamisawa Bridge on Chuo Expressway

FY 2008 Maintenance and repair work between Nakatsugawa IC and Sonohara IC on Chuo Expressway

Yokohama Line Furubuchi – Fuchinobe 27k500m to 27k760m weed control work

Northwest road construction road removal and restoration peripheral maintenance work

summary

While concrete work is an essential part of disaster recovery, it is not always easy to implement in some situations due to the following challenges.

• Time-consuming pouring work
• Large heavy equipment required
• Requires workers with specialized skills

Concrete Canvas solves these problems and allows for quick and flexible concrete construction. Consider it for typhoon and torrential rain disaster recovery, waterway and slope protection, and weed control. To request more information or inquire about concrete canvas, please click on the links below.

> Taiyo Kogyo “Concrete Canvas

>> Click here to contact us.