FLEXCRETE NEWS ARchive

Having met the demands of Euroclass A2_fl-s1 (Reaction To Fire in compliance with EN 1504-2), regular orders are now being secured for Cemprotec E-Floor in underground car park applications in Finland.

In this case, the two basement floors below the residential block are host to a car park which required refurbishment owing to water penetration through cracks and general wear from the effects of studded tyres. Cemprotec E-Floor met all the requirements for a thin film waterproof friction wearing course with the appropriate fire classification secured as part of the CE Marking process. Applied as a 2mm layer, Cemprotec E-Floor forms a complete barrier to water and has excellent resistance to deposits of oil and de-icing salts from the underside of vehicles.

Now carrying a CE Mark in compliance with EN 1504-2 in addition to WRAS Approval, Cemprotec Elastic is gaining increasing acceptance within the water industry for the waterproofing of reservoir roofs. Overcoming the challenges encountered with plural component materials, Cemprotec Elastic is a polymer rich cementitious elastomer with excellent crack bridging capabilities. It is easy to apply to a saturated concrete substrate in one or two coats, and a further benefit is that the hazards associated with handling Cemprotec Elastic are no greater than with normal concrete.

An example of work in new construction is the roof at the Barrow Gurney Water Treatment Works for Bristol Water, and Bournemouth and West Hampshire Water have recently chosen Cemprotec Elastic for their Chase Farm and Wood Green Reservoirs. Sales are also expanding overseas, with contracts under negotiation in USA and the Middle East.
 

It was cause for celebration at Flexcrete when the 20 year milestone was passed in an ongoing chloride ion diffusion test at Taylor Woodrow Technology. Since late 1989, a standard 2mm thickness of Cementitious Coating 851 has resisted the ingress of chlorides in this independent evaluation - in stark comparison, the diffusion of chlorides was recorded through the control concrete within the first month of the test starting. This level of performance has no parallel within the industry worldwide, and has led to many international specifications for Cementitious Coating 851, particularly in the Gulf States and in the Far East.

Cementitious Coating 851 provides the base technology for a range of specialist cementitious coatings which are used for structural protection of both concrete and steel in a variety of situations, including sub-structure waterproofing, waterproof deck protection, pipeline coating and the refurbishment of sheet piles in marine environments. For further details, please refer to our Market Sector Brochures.
 

Designed in 1859 and now an important heritage site, the Heugh Gun Battery was built to protect the port and ship building centre of Hartlepool from attack by sea. In 1914 it was engaged in shore-to-ship combat against German battleships and in 1942, the Battery was modified to serve as a combined coastal and air defence station.

During 2008, the Hartlepool Gun Battery Trust confirmed funding for a major refurbishment scheme with the intention of restoring the Battery to as close as possible to its original condition. To achieve this, a range of fully compatible material from Flexcrete was specified, with proven resistance in harsh coastal conditions being one of the main factors in determining the product selection.

Single component repair mortars Fastfill and Monomix were used to reinstate the concrete on the Magazine & Engineering Stores and the Blast Wall, with final protection from the harsh environment being provided by an overall 2mm application of Cemprotec E942. To accommodate any cracks which may form in the future, Cemprotec Elastic was selected as the roof waterproofing for the Battery Command Post.
 

Flexcrete Technologies Limited is proud to announce the award of ISO 9001:2008, the very latest generation of the internationally recognised standard for an internal Quality Management system. Recently assessed by the British Standards Institute under the more rigorous demands of the 2008 standard, Flexcrete is one of the first manufacturing companies in its sector to secure certification to ISO 9001:2008.

The ISO 9000 certification has evolved over several revisions since the initial 1987 version and ISO 9001:2008 moves away from the confines of Quality Assurance to provide a true management standard. By embracing the total business environment, it is an important step towards a sustainable management system which will be the subject of the future ISO 9004.
 

The recent introduction of Cemprotec 2000-S has proved very successful, providing the opportunity to create highly flexible waterproof joint systems by simply embedding a unique composite reinforcing tape into Flexcrete’s unique range of polymer modified cementitious coatings. Already adopted for structural waterproofing applications in civil engineering and residential construction, Cemprotec 2000-S now benefits from potable water certification to enhance the Flexcrete offer for the clean water industry.

Cemprotec 2000-S has been assessed by the Water Quality Centre, meeting the criteria set out in BS 6920 to be listed in the Water Fittings Directory as a WRAS Approved Material. This is the official endorsement to show that Cemprotec 2000-S has passed the tests of effect on water quality, and is suitable for use in contact with potable water.

Nestling in the Tamar Valley in Northern Tasmania, Alinta’s recently completed gas-fired power station was under fast track construction to meet tight deadlines. Under pressure to install high performance bund linings in advance of the erection of chemical storage tanks, specialist contractor MRJ Industrial imported Cemprotec E942 to complete the work on schedule. Within just three days, a total area of 400 m² (including upstands) was prepared and protected with Cemprotec E942 to provide a durable and effective seal.

Cemprotec E942 is a two component epoxy and polymer modified cementitious coating which is applied to damp or ‘green’ concrete to form a waterproof and chemically resistant protective layer with excellent resistance to mechanical damage. It does not require a primer, and in this case, it was applied when the parent concrete was just three days old. Cemprotec E942 is an economic and environmentally friendly alternative to traditional technologies, being water-based and free of toxic or noxious fumes during application. Cemprotec E942 is CE Marked in full compliance with EN 1504-2 which is the latest pan-European standard for Protection Against Ingress.
 

Cementitious Coating 851 has been selected for the structural waterproofing of the lift pits at the new luxurious Macau Diamond Tower, constructed adjacent to the iconic Wynn Macau Casino. Cementitious Coating 851 offers resistance to a 100 metre hydrostatic head, providing complete assurance against water ingress from either positive or negative pressure.

Cementitious Coating 851 is a British Board of Agrement certified, polymer modified Portland cement based coating, which is applied directly to a saturated concrete surface in just one or two coats. Being fluid applied, it eliminates the problems associated with sheet materials whilst being an environmentally friendly alternative to traditional solvent-borne liquids. It is also CE marked in compliance with EN 1504-2, the most up to date standard for Protection Against Ingress.
 

Most products in the Flexcrete range now benefit from CE Marking in compliance with EN1504 - the new pan European standard for concrete repair. EN1504 Part 2 relates to protective coatings and Part 3 covers the concrete repair system.

Flexcrete is the first British manufacturer to achieve registration, and with effect from 1 September 2008, the CE mark will be prominently displayed on technical literature and packaging for all qualifying production. It is a mandatory requirement to use the CE Mark if compliance has been achieved; other manufacturers claiming compliance have not secured the right to CE Mark their production and cannot legally claim to be compliant. If in doubt, a copy of the certificate from the accrediting body should be obtained.

The current list of Flexcrete products which are CE Marked is as follows:

EN1504-2
Cementitious Coating 851
Cemprotec E942
Cemprotec E-Floor
Cemprotec E-Floor HB
Cemprotec Elastic

EN1504-3
Fastfill
Monolevel FC
Monolevel 844SP
Monolite
Monomix
Monomix HD
Monomix WS
Tiefill

Flexcrete Technologies Ltd,
Tomlinson Road, Leyland PR25 2DY England
0086-CPD-530942

EN1504-3: Concrete repair product for structural repair
PCC mortar (based on hydraulic cement polymer modified)

Compressive strength: Class R4 =45MPa
Adhesive Bond: Class R4 = 2.0MPa 
Chloride ion content: = 0.05%
Carbonation resistance: Passes
Elastic Modulus: 26.1 GPa
Thermal Capability Part 1:Class R4 =2.0N/mm2
Capillary Absorption: 0.108kg.m-2.h-0.5
Dangerous Substances: Complies with 5.4
Reaction to Fire: Euroclass A2-s1, d0

Cemprotec Elastic has been awarded “Approved Product” status under the Water Regulations Advisory Scheme. This endorsement follows successful testing at the Water Quality Centre in accordance with BS 6920 Part 2, to access its affect on the quality of water for human consumption. Recently developed in the Flexcrete laboratories in Leyland, Cemprotec Elastic is a cement modified polymer coating that cures to form a tough, permanently elastomeric film with an elongation of over 100% even in immersed conditions. Applied at 2mm thickness, it is totally impermeable to water under 10 bar hydrostatic pressure (100m head of water) in both positive and negative pressure situations. It is ideally suited for waterproofing exposed concrete substrates such as new and existing roofs and water tanks where cracking is an issue. In independent testing it has achieved Class A5 for static crack bridging in accordance with BS EN 1062-7 and can successfully bridge cracks in excess of 2.5mm. It has recently been selected by Bristol Water to waterproof large expanses of new concrete roofing at their Barrow Gurney Water Treatment Works.

In an interview for the BBC at the recent opening of the new Flexcrete facility in Leyland, Digby, Lord Jones of Birmingham, Minister for Trade and Investment, described Flexcrete Technologies as “the Best of British”.

Lord Jones made a rousing and emotive speech in front of assembled dignitaries and senior representatives from the UK Building Research Establishment and leading international consultants Mott MacDonald, before spending time with the workforce who he commended for “buying into the dream” behind the success which Flexcrete has become.

Reflecting on his visit, Lord Jones went on to say, “I completely applaud you, my heart is with you and you’re a great example of what Britain in the 21st century is all about.”

[CLICK HERE TO VIEW UK TRADE & INVESTMENT OFFICIAL PRESS RELEASE]

Fastfill has been successfully used at Manchester International Airport in areas of heavy baggage handling traffic and aircraft movements.  Having found that alternative rapid setting products failed prematurely, Fastfill was chosen as it is a Portland cement based formulation, thus providing total compatibility with the parent concrete. 

Fastfill offers reliable strength development even at low temperature, achieving over 16N/mm² within 2 hours, allowing rapid return to service.  It also benefits from a special shrinkage compensation mechanism to prevent cracking - especially important in exposed airfield applications - and when cured exhibits good chemical resistance and is completely waterproof.  Fastfill can be used as thinly as 5mm, or can be bulked out with aggregate for deep pockets up to 300mm.  Water is used both for priming the substrate and for cleaning tools after use.