Why Xypex for Water Treatment Structures

Meeting the Challenge

Protecting Water Treatment Structures

The structural integrity of holding tanks in water treatment plants depends entirely on the protection of steel reinforcement from corrosion. Inadequate waterproofing, cracking, joint-failure, and chemical attack are problems that will result in the deterioration of concrete. The consequences are costly rehabilitation and significantly reduced service life.

With over 50 years of experience in 90 countries around the world, Xypex has extensive experience in the waterproofing and protection of municipal infrastructure, and is recognized as a key player in the water treatment industry. Our non-toxic Xypex Crystalline Technology has been officially approved around the globe for use with potable water, and has a vast portfolio of international project references. Whether used for new construction or the rehabilitation of water treatment structures, Xypex has gained an exceptional reputation for resisting extreme hydrostatic pressure, chemical attack and protecting the structural integrity of concrete.

Xypex products play a major role in the waterproofing and protection of concrete against hydrostatic pressure, cracks, joint-leaks, chemical attack and surface deterioration – problems typically encountered in the various concrete structures found in the water treatment process.


Hydrostatic Pressure

The waterproofing and protection of concrete in water treatment structures has two primary objectives:

To prevent water held in the structure from leaking out due to the hydrostatic pressure and to protect the reinforcing steel from corrosion.

The nature of concrete and its installation means having to deal with permeability problems created by the natural porosity of the concrete as well as defects (cold joints, honeycombs, rock pockets and tie-holes), joint leaks, freeze/thaw damage and drying shrinkage cracks. These problems typically leave the structure open to active leaks and accelerate the possibility of reinforcing steel corrosion and surface deterioration.

Additional Challenges

Chemical Attack

The addition of coagulants or flocculation chemicals such as iron salts, aluminum salts, or polymers creates an additional long-term problem for the concrete that can lead to surface deterioration. With a loss of concrete cover, the reinforcing steel in the structure becomes more susceptible to corrosion, deterioration, and ultimately results in the failure of the structure itself.

Surface Deterioration

The backwashing process used regularly to clean water filtration tanks is a naturally abrasive process which attacks the surface of the tanks, removing the traditional waterproofing coatings used to protect them. This in turn exposes the concrete to hydrostatic pressure, resulting in reinforcing steel corrosion and leaking.


Water Treatment Structures

  • Raw Water Intake Structures
  • Flocculation Basins
  • Sedimentation Basins
  • Water Filtration Tanks
  • Reservoirs & Distribution Structures

Typical Concrete Problems

  • Concrete Defects
  • Cracks & Joint Leaks
  • Surface Deterioration
  • Chemical Attack
  • Freeze/Thaw Damage

Xypex Crystalline Technology

Xypex products use the natural porosity of concrete and chemical diffusion to penetrate its pores and capillaries. Inside the concrete, Xypex chemicals react with the by-products of cement hydration to form a non-soluble crystalline structure deep within the substrate. In this condition, the concrete becomes impermeable, preventing the penetration of liquids and chemicals from any direction even under extreme hydrostatic pressure. The chemical resistant properties of the crystalline structure prevent the effects of attack by chemicals used in the treatment process.

The Xypex Advantage

Xypex Crystalline Technology works inside the concrete, thereby avoiding the problems typical of traditional barrier products.

  • Resistant to chemical attack
  • Not subject to the deterioration problems encountered by coatings
  • Self-heals static cracks up to 0.5 mm (0.02 in)
  • Permanent and reactivates whenever water is present
  • May be applied on negative or positive side of concrete surface
  • Non-toxic; approved for use with potable water

Proven Performance Worldwide

Comprehensive quality systems and standards along with thorough testing in the lab and the field have resulted in Xypex’s highly respected position in the concrete industry. Xypex has been extensively tested by independent testing laboratories in the U.S., Canada, Australia, Japan, Europe and other countries.

Xypex Admix for New Concrete Construction

Xypex Admix is the preferred choice for installing Xypex Crystalline Technology into new concrete structures for water treatment plants. Because Xypex Admix is blended into the mix at the time of batching, it becomes an integral part of the entire concrete matrix, reducing the potentially damaging effects of water penetration and chemical attack. Flexibility in application means Xypex Admix can be installed in pre-cast elements, cast-in-place structures and added to shotcrete concrete mixtures.

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Xypex Admix Advantages

  • Permanent integral waterproofing
  • Enhances concrete durability
  • Value engineering
  • Non-toxic
  • Non-combustible
  • Resists damaging effects of water penetration and chemical attack

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Rehabilitation & Repair

Xypex’s coating systems and repair products enable municipalities, engineers and
contractors to economically and confidently rehabilitate deteriorating water treatment structures. Xypex Concentrate and Modified are applied as slurry coatings to the surface of the concrete. Unlike other materials that need a dry substrate, Xypex products require a moist surface – conditions typical of existing water treatment structures. Xypex Patch’n Plug, Concentrate Dry-Pac and Megamix products are specifically designed to permanently repair concrete defects such as honeycombs, static cracks and faulty cold or construction joints. These products are also effective at filling tie-holes and sealing around pipe penetrations.

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Xypex Coating Advantages

  • Doesn’t require a dry surface
  • Apply to either side of the concrete
  • Won’t puncture, blister or tear
  • No costly surface priming or leveling
  • Sealing, lapping or finishing is not required
  • No need for protection during backfilling
  • Permanent waterproofing
  • Enhanced concrete durability
  • Doesn’t contain VOCs

Other Accessory Products are also available.

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SURFACE APPLIED COATING: Concentrate & Modified
PLUGGING: Patch’n Plug
REHABILITATION: Patch’n Plug & Megamix
Mao Water Treatment Plant
Water Treatment Plants

Mao Water Treatment Plant

Dominican Republic
Xypex Concentrate and Modified were spray-applied to the floors and walls of this water treatment plant which was built by a Brazilian company. The Xypex products were also shipped from Brazil.
Cardedeu Water Purifying Plant
Water Treatment Plants

Cardedeu Water Purifying Plant

The Cardedeu water purifying plant supplies Barcelona and other towns with drinking water. The filter channels to this water purifying plant were repaired and waterproofed with Xypex products.
Svetly Yakutia Water-Purifying Complex
Water Treatment Plants

Svetly Yakutia Water-Purifying Complex

The epoxy coating that had originally been applied to the surface of the concrete to prevent water penetration, failed. Xypex was selected to remedy the problem. The epoxy surface was removed, and cracks and leaks were repaired with Xypex Patch'n Plug followed by a two-coat application of Xypex Concentrate and Modified.
Hanahan Water Treatment Plant – Clearwell #3
Water Treatment Plants

Hanahan Water Treatment Plant – Clearwell #3

Xypex Concentrate was used to waterproof and protect the wall and slab of this water treatment plant.
National Commission for Water
Water Treatment Plants

National Commission for Water

A two-coat application of Xypex Concentrate was used to repair and waterproof the exterior and interior of this potable water tank. Xypex Patch'n Plug was used to repair concrete cracks and fissures.
Showa Glove Factory
Water Treatment Plants

Showa Glove Factory

Xypex is again selected to waterproof and protect all water tanks, a water treatment plant, and a waste treatment plant of the factory. Total area is approximately 2,400 m2 with 7,054 tie holes, and 694 meters of construction joints. All construction joints are sealed by Xypex Concentrate Dry-Pac method without use of waterstops. Work was completed in July 2004.
Bearspaw Water Treatment Facility
Water Treatment Plants

Bearspaw Water Treatment Facility

Xypex products were used extensively to waterproof and protect the concrete of this water treatment facility: 500 - 50 lb. bags of Xypex Concentrate; 500 - 50 lb. bags of Xypex Modified; 150 - 60 lb. pails of Xypex Dryshake DS-1; and 50 - 60 lb. pails of Xypex Patch'n Plug.
Svobodka Waterworks
Water Treatment Plants

Svobodka Waterworks

Czech Republic
Xypex Concentrate and Patch'n Plug were used on this water treatment plant to seal the joints and against seepage. A hundred meters of crack repair using Xypex products was also carried out.
Potable Water Tanks
Water Treatment Plants

Potable Water Tanks

This water treatment plant supplies three million people with drinking water. The 30-year-old tunnel, 9,000 m in length, was treated with Xypex Megamix II for rehabilitation and to provide waterproofing.
Potable Water Tanks
Water Treatment Plants

Potable Water Tanks

Because of concrete shrinkage, cracks appeared in the walls of this water tank. The cracks were routed out, filled with Xypex Dry-Pac followed by a slurry coat of Xypex Concentrate.