Exoline Protector I Waterproof-Breathable Concrete

Exoline® Protector SG-55 - watertight concrete admixture

How does it differ from a waterproofing layer?

Bituminous membranes, polymer coatings and sheet membranes create an external protective interface on the surface of the concrete and try to keep water away from the outside. Their effectiveness depends fundamentally on the continuity, adhesion and ageing resistance of the surface layer.

If such a coating is damaged, cracks, is punctured or fails at the joints, water can get behind the waterproofing. From that point on, the internal capillary system of the concrete continues to conduct moisture, because the material structure itself has remained unchanged.

Protector SG-55 reverses this logic. The protection is not carried by a separate layer; the modified pore system itself becomes the basis of watertight performance: the concrete does not receive a vulnerable protective layer from the outside, but becomes - from within - a material structure that is more resistant to water, frost and corrosion risks.

≤ 0.1

Capillary water absorption
kg/(m²·min^0.5)

10–18 mm

Depth of water penetration
XV3(H) requirement: ≤ 20 mm

μ = 80–120

Water vapour diffusion resistance
EN ISO 12572

11.5–12.5

pH - alkaline pore environment
supporting passivation

01 - Hydrophobic pore modification

This is the basis of the whole system. The fine, hydrophobic ExoBase™ particles with their positive surface charge anchor onto pore walls, capillary channels and micro-voids, and change the behaviour of these internal surfaces towards water. The modified pore system: •reduces the wetting of the pore walls •limits capillary water absorption •establishes an internal structure that slows ion transport The aim is not to physically fill every pore, but to make the pore surfaces behave differently towards liquid water.

02 - Protection at crack surfaces

The active component is present throughout the entire volume of the concrete. When a microcrack forms, the surfaces exposed along the crack are not untreated concrete surfaces, but part of the very same modified material structure. It follows that: •the newly exposed surfaces are also hydrophobic in character •a microcrack does not automatically become a water-conducting channel •no subsequent crystal growth is required - the protection is already there The essence of the mechanism is not that every microcrack mechanically disappears, but that even inside the crack the wetting conditions required for capillary water movement do not develop.

03 - Selective vapour permeability

The technology does not create a closed, vapour-tight layer. The capillary movement of liquid water becomes restricted, while the diffusion of water vapour out of the structure can be retained - the μ = 80–120 range allows controlled vapour release. This selective behaviour: •reduces the water load arriving from outside •preserves the drying capacity of the structure •reduces the frost risk associated with pore moisture One of the basic preconditions of frost damage is liquid water present in the pores. If less freezable water can be present, the risk of internal stress caused by freeze–thaw cycles also decreases.

04 - Alkaline pH and transport inhibition

Protector SG-55 does not coat the steel reinforcement; it makes the concrete a more durable protective medium around the reinforcement. The effect works through two mutually reinforcing principles. The two operating principles: •the modified pore system slows CO₂ and chloride ion transport •the calcium oxide-based mineral carrier supports the persistence of the alkaline pore environment •together they can extend the period before corrosion initiation The technology does not replace the requirements of concrete cover, reinforcement detailing and design according to the relevant durability class.

05 - Stability of the active component

Organic surface waterproofing systems are exposed to hydrolysis, oxidation, UV degradation, thermal cycling and plasticiser migration. These processes can be slowed down, but they cannot be eliminated entirely. Within the concrete matrix, the ExoBase™ particles: •are not exposed to direct UV radiation •do not act as a standalone external membrane •do not behave according to classical polymer-chain ageing mechanisms The durability of the protection is therefore not determined by the ageing of an external layer, but by whether the particles retain their surface function within the internal pore and void system of the concrete.

Conventional waterproofing vs. Protector SG-55

Property	Organic surface waterproofing	Protector SG-55 / ExoBase™
Material family	Bitumen, polymer, acrylic, polyurethane, epoxy	Calcium oxide-based mineral carrier with functional surface treatment
Place of action	On the external surface of the concrete	In the internal pore and void system of the concrete
Service life limit	Ageing, cracking and delamination of the surface layer	Not tied to an external layer; the particles are anchored in the concrete matrix
UV sensitivity	Can be significant on external surfaces	Not decisive - the active component works inside the concrete
Thermal cycling	Fatigue, cracking, loss of adhesion	Does not act as a membrane; cyclic surface stresses are less relevant
Maintenance logic	Periodic inspection, repair or renewal	Part of the material structure; requires no separate surface-layer maintenance

What happens if the concrete cracks?

Crack type	Expected behaviour
Microcrack ≤ 0.3 mm	The hydrophobic surface character also applies to the freshly exposed crack surfaces. The conditions for capillary water ingress are significantly restricted.
Wider crack 0.3–1.0 mm	The modified surface condition is still present, but under hydrostatic pressure, and depending on crack geometry and sustained water load, water can pass through mechanically.
Structural macrocrack	Conventional structural crack repair is required. Protector SG-55 does not replace the repair of structural or load-bearing defects.

Limits of the system: Protector SG-55 improves the concrete's own watertightness. It does not replace correct concrete mix design, concrete cover, the design of movement and construction joints, compaction and curing - it complements them.

Physical and chemical properties

Physical formUltra-fine, off-white mineral powder, dosed into the dry mix during concrete production.

Particle sizeApprox. 4 µm - a micropore-filling size that supports distribution within the capillary channels and the interfacial transition zones.

Bulk density0.65 kg/dm³ - a light, highly active powder with a large functional surface area relative to its mass.

Specific surface area (BET)Large reactive internal surface. The exact value for a given production batch can be certified on a certificate of analysis (CoA).

pH value11.5-12.5 - strongly alkaline character, supporting a pore environment favourable to the passivation of reinforcing steel.

Surface chargePositive. This ensures uniform dispersion without agglomeration, and strong adhesion to hardened cement paste, sand, ballast and gravel.

Chemical characterMineral, solvent-free, VOC-free powder - compatible with LEED / BREEAM requirements and low-emission specifications.

Integrated material effectThe active component is distributed within the concrete matrix; its performance does not depend on the adhesion, UV resistance or ageing of an exposed membrane.

EN 206EN 12390-8EN ISO 12572MSZ 4798Project mix validation

Engineering qualification: the values given are nominal values according to the production specification, and are to be interpreted for a validated concrete composition, correct dosage and standardised laboratory testing. Performance must in every case be verified as a function of the specific concrete recipe, water/cement ratio, aggregate grading, compaction and curing.

Fire and thermal data: the reaction-to-fire classification, the behaviour under thermal load and any degradation temperature can only be established on the given application build-up, by testing to EN 13501-1 or another accredited fire test. We make no generalised heat-resistance or “A1/A2 non-combustible” type claims; such a classification can only be given on the basis of a valid test report, tailored to the project.

Fields of application

Base slabs, basement walls

Structures exposed to ground moisture and hydrostatic load, where the external surface is inaccessible after construction.

Bridges, tunnels

Load-bearing concrete exposed to precipitation, de-icing salts, freeze–thaw cycles and sustained moisture loads.

Underground car parks

Reinforced concrete structures simultaneously affected by water, salts, temperature fluctuation and corrosion risk.

Channel elements, U-drains

Precast hydraulic engineering elements and industrial elements of lower concrete class, under sustained water load.

Industrial concrete

Floors, shafts, channels and structural elements where long-term moisture resistance is critical.

Dosage guidelines

The dosage should not be matched to the cement mass alone, but primarily to the fines content of the concrete. The 0–4 mm fraction is particularly important, and within it the proportion of the < 0.125 mm range, since this determines the size of the internal surface to be covered by the active component.

The higher the proportion of fines, the greater the internal specific surface area of the concrete, and therefore the greater the quantity of active component required. The values below are initial engineering guide values.

Concrete class	Coarser / Danube-type	Medium grading curve	Finer / Maros-type
C12/15 – C16/20	5–6 kg/m³	6–8 kg/m³	8–10 kg/m³
C20/25 – C25/30	4–5 kg/m³	5–6 kg/m³	6–8 kg/m³
C30/37	3–4 kg/m³	4–5 kg/m³	5–6 kg/m³
C35/45	2.5–3.5 kg/m³	3–4 kg/m³	4–5 kg/m³

Increasing the dosage does not automatically mean better performance. An excessive quantity can affect the consistency, air content, strength and setting behaviour of the concrete. Above C30/37, laboratory validation is mandatory; class C35/45 may only be used after laboratory validation, technologist approval and performance testing.

Frequently asked questions

How does it differ from crystalline admixtures?With crystalline systems, the aim is for new crystalline phases to grow in the presence of water and partly seal the crack or the capillary channels. Protector SG-55 is not based on subsequent crystal growth: the ExoBase™ particles are already present throughout the entire volume of the concrete, so when a crack opens, no new protection has to form - the already modified material structure is what becomes exposed.

Does the concrete still breathe, or does it form a vapour barrier?It does not form a vapour barrier. The capillary movement of liquid water becomes restricted, while the diffusion of water vapour out of the structure is retained. This matters because moisture trapped in the structure can cause internal stress during freeze-thaw cycles and, in reinforced concrete, an unfavourable corrosive environment.

How long does the effect last?The protection is not based on an external coating system that ages over time. The active component is anchored within the internal material structure of the concrete, so the service life of the protective function is linked to that of the cement matrix and of the structure as a whole, not to the classical coating ageing curve.

How can the performance be verified on our own mix?The performance values depend on the concrete composition, so project mix validation is required. For load-bearing applications, higher concrete grades, and in every case where the project mix differs significantly from the reference range, accompanying laboratory testing is mandatory.

A material-structure level approach, not another coating

Exoline® Protector SG-55 addresses the most important durability risks of concrete within a single integrated material system: capillary water ingress, the water-conducting role of microcracks, freeze–thaw damage and the corrosion exposure of the reinforcement.

The protection is not tied to a vulnerable layer created on the external surface of the concrete; it is formed within the internal pore and void system of the concrete. The active component becomes part of the concrete together with the structure, and rather than sealing off the natural material behaviour of the concrete, it modifies that behaviour in a favourable direction.

Have Protector SG-55 tested on your own project mix.

Request technical documentation Project mix testing

FAQ about Exoline® Products

If you have any questions about the Exoline® product family or our other solutions, you can find answers here or ask your question now, and our experts will be happy to assist you!

We remain at your disposal at any time of the day and are committed to providing you with prompt, professional, and tailored assistance. Should you have any questions, requests, or require further information, please do not hesitate to let us know how we may best support you.

Exoline LTD.

5 Round House Dormans Park Road East Grinstead England RH19 2EN

+44 79 040 28 064

exoline@exoline.co.uk

07853326

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EXOLINE PROTECTOR SG-55

Watertight concrete - from within, not by coating

The protection is created inside the material structure of the concrete

Exoline® Protector SG-55 is not applied to the surface of hardened concrete; it is built into the material as part of the fresh concrete mix. Its effect does not depend on the integrity of a separate coating - it acts within the internal pore and void system of the concrete.