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The Ultracoat system is a structural epoxy coating system used for the rehabilitation and structural reinforcement of a wide range of substrates. Manhole repair, tunnel maintenance, bunds, culverts, and any other surface or structure can be coated. After its single coat application, Ultracoat leaves an exceptionally hard wearing, smooth and waterproof coating, with excellent chemical resistance.

Even in the presence of damp substrates, Ultracoat will effectively adhere to any surface, eliminating and preventing infiltration and leaving a smooth finish with enhanced flow characteristics. Application of Ultracoat is also structurally reinforcing - independent testing showed an increase in compressive strength of concrete pipes of 20%.

After application, for example for bund rehabilitation, the Ultracoat 100% solids epoxy coating system is chemical resistant from pH 2-14. This includes complete resistance to high levels of hydrogen sulphide, up to 40% concentration of nitric acid, acetic acid, calcium chloride and others.

Particularly relevant for manhole rehabilitation and other confined spaces, the Ultracoat system is free from VOCs (volatile organic compounds), meaning breathing apparatus is not required. It is free from solvents and no primer coat is required - application is quick and easy and a manhole chamber or culvert can be back in operation within hours of the project starting.

The Ultracoat epoxy coating system was developed by Danny Warren of Warren Environmental in the USA over 35 years ago and has been used to renovate over 50,000 manholes and kilometres of pipes and tunnels - WITH ZERO FAILURES.

The Ultracoat system is CE marked and complies with the standard BS EN 1504-2:2004 “Products and systems for protection and repair of concrete structures – part 2 surface protection systems”.

Hadlee and Brunton applying Ultracoat to Council Manholes

The following are the key applications for the Ultracoat system:



The Ultracoat system has been used for the rehabilitation of over 50,000 manholes worldwide, each project avoiding the disruption of replacement, reducing immediate costs and bringing whole life cost for the structure down to a minimum. When presented with a corroded surface, perhaps after long term erosion and widespread infiltration, there are two main alternatives; the replacement of the manhole, or the repair of the manhole.



The Ultracoat system has been used successfully on tunnel and subway infrastructure for many years. Replacement of a man entry tunnel or a subway structure is rarely an option, and due to being a confined space and the need to maintain a structural strength, options are limited.



After initial successes with manhole rehabilitation, Ultracoat has more recently been used with great success for culvert surfacing and repair. Below shows a recent success in Tasmania, on a hydroelectric flume. See our Case Study section for more images and additional project details.



Many chambers are by definition confined spaces, and so Ultracoat is the ideal solution when chamber rehabilitation is required. No breathing apparatus is necessary, and so the complexity of a project is kept to a minimum.



Ultracoat is increasingly used for bund lining and other asset management projects.


The ultracoat system has been tested to the following standards

ASTM C297 - Tensile Strength
ASTM D2240 - Durometer Hardness
D2584 – Volatile Matter Content.
D4414 - Wet Film Thickness by Notch Gages
D4541 – Pull-off Strength of Coatings Using a Portable adhesion Tester.
D4541 - Concrete Failure Chemical Resistance to: Sulfuric Acid, 70%
D543 – Resistance of Plastics to Chemical Reagents.
D543 – Water Vapor Transmission of Organic Coating Films.
D543 - Immersion Service
D638 – Flexural Properties of Unreinforced and Reinforced Plastics
ASTM D638 – Tensile Properties of Plastics.
ASTM D638 - Flexural Strength
ASTM D638 - Tensile Elongation
ASTM D638 - Tensile Strength
ASTM D695 – Compressive Properties of Rigid Plastics.
ASTM D695 - Compressive Strength
ASTM D695 - Flatwise Tensile Strength Of Sandwich Constructions
ASTM D790 – Flexural Properties of Unreinforced and Reinforced Plastics.
ASTM D790 - Bond Strength – Concrete
ASTM D790 - Flexural Modulus
ASTM D790 - Flexural Strength
ASTM E84 - Test Method for Surface Burning Characteristics of Building Materials

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