LATEST NEWS FROM FLEXCRETE

In response to strong customer demand, Flexcrete has developed a range of products for the external protection of buildings and other structures under the Monodex brand, and for hygiene sensitive environments, biostatic coatings under the Biodex brand.

Monodex
The Monodex range of coatings provide external or internal protection for buildings and other structures. They are high performance, water based, elastomeric, high build, decorative coatings which provide protection against carbonation and water ingress, yet allow damp substrates to breathe without blistering. They are ultra-fast drying which enables two coat applications to take place on the same day and facilitates year round usage, even in uncertain weather conditions. The products also prevent the growth of mould and fungi, making them ideal maintenance coatings. The Monodex range consists of Monodex Ultra and Monodex Smooth.

Biodex
The Biodex range of coatings are designed for hygiene sensitive environments. The coatings are biostatic and based on the latest encapsulated biocide technology. The range comprises high build surface coatings in a variety of finishes to meet the needs of every hygiene sensitive environment. They are applied to walls and ceilings to prevent the growth of mould and bacteria in food preparation or production areas, brewing and beverage industries, hospitals, the pharmaceutical industry and in kitchens or bathrooms. The Biodex range currently consists of Biodex Sheen and Biodex HB.

Colour Matching
Both the Monodex and Biodex range of coatings are available off-the-shelf in a wide variety of attractive colours.
Flexcrete also offers an exact colour matching service so that all Coatings can be supplied to precisely meet customer requirements.

In July 2010, Flexcrete acquired an additional 2500m² of space in industrial units adjoining the existing Flexcrete powder blending plant in Leyland. Having secured planning permission, the new buildings have been extensively refurbished and extended, and construction is well underway on a dedicated Technical Centre which will house new R&D Laboratories and a Training Suite for the benefit of our fast growing customer base at home and overseas.

The new buildings already house new manufacturing equipment for the production of decorative protective coatings. In response to strong customer demand, Flexcrete has developed a range of products for the external protection of buildings and other structures under the Monodex brand, and for hygiene sensitive environments, biostatic coatings based on the latest encapsulated biocide technology under the Biodex brand. The new Monodex and Biodex products have been produced following extensive in-house research utilising the most modern chemistry available, and sales have already been achieved in Asia and the Americas, as well as to European markets including Cyprus, Finland, Ireland, Italy, Norway and Sweden.

Since its launch in 1989, Sky TV has become a global household name with 10m customers worldwide and a turnover of £6bn. To facilitate further anticipated growth in demand, Sky has relocated to a new state-of–the-art studio complex in Brentford, West London, where programmes will be recorded and broadcast. Not surprisingly, the standards of construction are high, and particular attention was shown to waterproofing requirements.

In the event the fire sprinkler system is activated, to prevent water collecting in the cable ducting channels below raised access flooring, Cementitious Coating 851 reinforced with Cemprotec 2000-S tape has been used at the wall to floor junction to provide a totally waterproof and flexible seal which will not degrade with time. The waterproofing detail was easy to install on to both dry lining plasterboard and the concrete floor, and the non-hazardous nature of the system was a particularly appealing feature as other trades were able to continue working in the environment without exposure to damaging solvent release into the atmosphere.

Cadbury chocolate was exported to Australia as long ago as 1881, and as part of a pioneering international expansion plan, in 1919 their first factory in Australia was built to produce the famous brand. During the war years (1939-1945) Cadbury became the official supplier of chocolate to the Australian Armed Forces. Cadbury ration chocolate in brown-paper wrappers was made from a special formula so that the precious parcel did not melt in the heat of the tropics or the desert.

In 2009, after a detailed appraisal of the options undertaken by Australian Engineering Consultants GHD, Cemprotec E942 was specified for the re-lining of the waste-water tanks during a scheduled shutdown of the plant near to Sydney. An epoxy and polymer modified cementitioius coating with excellent adhesion when applied directly to saturated concrete, Cemprotec E942 provides excellent chemical resistance in this aggressive environment. Cemprotec E942 is CE Marked in compliance with EN 1504, and in total 10 tons were supplied for this high profile project.

Eaglescliffe is a small town in the borough of Stockton-on-Tees in North East England. The bridge at Eaglescliffe was the last crossing point of the tidal section of the River Tees until the Tees Barrage in Stockton made the section non-tidal. The town is divided by railway lines which lead from Yarm to Stockton and can only be crossed by vehicles at the North and South of the town, although there are two pedestrian bridges and an underpass.

Eaglescliffe railway station is approached by pedestrians up a ramp which had become a slip hazard, especially in frosty winter conditions. To upgrade the surfaces and provide a durable non-slip finish, a 2mm layer of Cemprotec E-Floor was applied, finished with Cemprotec EF Grit and sealed with Cemprotec Sandseal 760. The system has the advantage of excellent adhesion to dry or damp cementitious substrates and hydrates to give high early strengths, enabling rapid reinstatement of traffic. It is classified for severe abrasion resistance to BS 8204 Part 2. A further reason for choosing Cemprotec E-Floor is certification to BS EN 1504.

Setin the heart of Sydney on Darling Harbour, Sydney Aquarium boasts the world's largest collection of all-Australian aquatic life featuring a number of spectacular habitat displays occupying sixty tanks and three oceanariums. A major tourist attraction, Sydney Aquarium showcases more than 12,000 aquatic animals from 650 species, from fascinating little penguins to seahorses, sharks and stingrays. Behind the scenes, planned maintenance ensures the ongoing integrity of the structures.

After more than 20 years exposed to seawater, the original timber piles providing structural support had deteriorated beyond refurbishment by traditional methods. An innovative system designed by Corroseal Coatings Pty Ltd was adopted to provide an additional 25 years' life. In order to ensure long term protection from corrosion, Cemprotec E942 was applied directly on the steel headstock housing and on the full length of the steel section of the new pile splice. Cemprotec E942 is applied directly to ferrous metals, curing to form a tough and abrasion resistant finish. It is a complete barrier to chlorides and achieves excellent adhesion in damp or immersed conditions.

Now located in the Faslane Naval Dockyard in Scotland, the newly constructed Valiant Jetty serves as the berthing point for Britain’s modern fleet of Astute Class submarines. Named after the first British built nuclear powered submarine, the 44,000 tonne Valiant Jetty was constructed in dry dock before being floated out on its 12 huge airtight and watertight cells which support this 200 metre long reinforced concrete structure.

Needless to say, it was a key priority for the Ministry of Defence to have the best available seal for the buoyancy chambers. Cemprotec Elastic was the natural choice, as it has excellent bond to concrete in a damp or submerged environment whilst also having the capacity to bridge any cracks which may form in the substrate. Cemprotec Elastic was applied in two 1mm coats by specialist contractor Concrete Repairs Limited using Graco airless spray equipment to achieve a high quality finish. Cemprotec Elastic is CE Marked in compliance with EN 1504-2 for Protection Against Ingress.

With the constant quest for safe and environmentally friendly solutions, together with the need to minimise expense, acting on behalf of London Underground, Metronet have approved the use of Cemprotec E942 for corrosion protection in cast iron shunt tunnels. With strict limitations on working hours and tight control on the use of hazardous products or processes, Cemprotec E942 offers an innovative way of extending the life of ferrous metals in demanding service conditions.

With the need to completely clear the tunnel after each night shift, specialist contractor Quickseal lined the tunnel with 2mm of Cemprotec E942 to significantly extend the anticipated life of the asset. After stripe coating the flanges and boltheads, the application was undertaken without a primer, the high alkalinity of the Cemprotec E942 proving rapid passivation of the surface to stifle further corrosion for decades to come.

With its own unique charm, characterised by fishing boats and the cockle sheds which stretch along the shoreline, Old Leigh is a traditional fishing village in Essex, situated on the River Thames just 50 kilometres to the east of London. Even though the risk of tidal flooding was very low, Southend-on-Sea Borough Council set aside a budget of £145,000 to upgrade the steel sheet pile defences in Old Leigh.

Cemprotec E942 was specified to provide long term protection to the sheet piles which were blast cleaned to remove all contamination back to a sound substrate. Working within the tidal window, Cemprotec E942 was applied by Kieran Lucas Contractors with a PowerSprays PS 1000 pump in two 1mm coats. Cemprotec E942 is favoured for this type of work as it is an environmentally friendly material which can be immersed after as little as two hours following application.

BAFF tanks contain biological aerated flooded filters in which bacteria are grown as a means of treating raw effluent. This creates an environment which is very aggressive towards unprotected concrete, and at the wastewater treatment works at Oldham, all the walls and columns in the BAFF tanks needed reinstating.

With a long history in the dirty water industry, Flexcrete offer a range of CE Marked products for concrete repair and protection in full compliance with EN 1504. In this case, a 60 year design life has been achieved by the application off Monolevel 844SP as an engineering quality faring coat to level the substrate prior to the application of 2mm of Cemprotec E942 to provide long term resistance to chemical attack. Application is on to a saturated concrete and the system is fully water-based, making it safe for use in confined conditions.

Bromley’s Ambulance Station has a staff car park below the main upper deck which the ambulances access via a ramp. Over the years, the fabric of the structure had begun to deteriorate with leakage through the top deck and access ramps causing spalling of the soffits in the staff car park. The Client required a complete solution which provided both concrete repair and protection together with waterproofing beneath asphalt on the ramps and a waterproof friction wearing course for the main deck area.

The Flexcrete specification included Cemprotec E-Floor, a high strength waterproof coating which is applied to saturated concrete. On the main deck, to give appropriate friction properties, Cemprotec EF Grit was broadcast into the Cemprotec E-Floor and sealed in place with Cemprotec Sandseal 760. The concrete repairs below were successfully undertaken with Steel Reinforcement Protector 841 and the lightweight high build mortar, Monolite. White Monolastex Smooth was used for final decoration and long term protection from carbonation.

The platforms which run either side of a train maintenance shed are subject to excessive wear and tear, especially from the loading imposed by the huge hydraulic trolley jacks which are used to lift a locomotive body to expose the running gear for engineering works. The impact of heavy tools dropped on the floor also inflicts localised damage and the inevitable presence of oil and grease demands attention is given to the slip resistance characteristics if accidents are to be avoided.

At Crown Point LMD in Norwich where trains are maintained for National Express East Anglia, time had taken its toll and the platforms were evidently in need of refurbishment. Because of the excellent mechanical properties, thin film nature and slip resistant finish, after localised repairs with Fastfill and general levelling with an initial coat of Cemprotec E-Floor HB, the system was completed with 2mm of high strength Cemprotec E-Floor with a broadcast of Cemprotec EF Grit sealed in place with Cemprotec Sandseal 760.

Q-Park is a strong, highly respected international brand, renowned for its exceptionally high standards. When designing the underground car park at the Stockmann department store in Helsinki, Q-Park needed to take full account of the harsh winter weather in Finland. To cope with snow and ice, vehicles run on studded tyres, causing extensive damage to the concrete deck. Also, the corrosive influence from dripped de-icing salts demands that special precautions are taken to ensure the design life of the structure is not compromised.

Cemprotec E-Floor was specified, a 2mm epoxy and polymer coating which achieves the top Euroclass A2FL-s1 fire rating as part of the CE Marking to EN 1504, a specific requirement for the Finnish market. To provide the contrast which is a design feature for Q-Park, Cemprotec E-Floor was manufactured in a special black colour to give clearly designated parking bays. The system is totally waterproof and is an excellent barrier to chlorides. Cemprotec E-Floor is also inherently tough to resist studded tyres running on the surface.

Lake Margaret Power Station was the first hydro electric facility in Tasmania and back in 1914 it produced an output of 5000hp owing to the reliable rainfall in the area. The water was fed to the turbines via a timber flume constructed of ‘King Billy’ pine, and is still in use today. In 1918, a 17 metre high, 243 metre long concrete gravity dam was added, but after 90 years of service, refurbishment had become essential to maintain the integrity of the structure.

After assessing all the available options, Hydro Tasmania approved the proposal to use the Flexcrete system which is supplied and installed by MRJ Industrial Services. Repairs were undertaken using a combination of environmentally friendly, EN 1504 certified mortars, including Monolevel 844SP for the filling of minor voids, Monomix for larger repairs and Fastfill for areas where time was limited before immersion. Joints were sealed with Cemprotec 2000-S which is adhered in place with Cemprotec Elastic to form a permanently flexible and waterproof seal.

In order to keep pace with increasing demand from the expanding customer base in UK and overseas, improvements in production efficiencies are constantly sought. Flexcrete work closely with the Manufacturing Advisory Service to ensure access to best practice from the wider world of manufacturing, and our significant progress was highlighted during the recent Survive and Thrive Masterclass sponsored by the Northwest Regional Development Agency.

One area that was quickly identified for investment was the process of production planning. After consultation with Datel, the UK’s leading software integration specialist for mid sized companies, Sage Manufacturing was installed. With batch cards produced at the press of a button and full integration with accounting software, our response to the varied customer demands is now even faster. The system was implemented efficiently and quickly, and Datel have produced a Customer Review to publicise the joint success.