Flexcrete UK MANUFACTURING AT ITS BEST. Structural Repair & Protection Technology from Flexcrete ESTIMATING GUIDE

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1 Flexcrete UK MANUFACTURING AT ITS BEST Structural Repair & Protection Technology from Flexcrete ESTIMATING GUIDE June 2015

2 introduction As the UK s leading independent manufacturer of engineering quality technical mortars and high performance coatings, Flexcrete offers some of the most technologically advanced and innovative repair and protection materials available today for refurbishment or new build projects. We offer an extensive range of products serving a number of markets, including: Markets Civil Engineering & Infrastructure Buildings & Commercial Construction Utilities Coastal Structures Hygiene Sensitive Environments Products Concrete Repair & Protection Decorative Protective Coatings Structural Waterproofing & Tanking Enhanced Durability for Concrete & Steel Waterproofing of Roofs & Other Deck Areas Ancillaries This Estimating Guide provides an overview of the products we offer, along with useful information such as coverage rates, performance figures and independent certifications. Please Note The information presented in this Estimating Guide is of a general nature and is based on experience in a wide range of applications. It is correct to the best of our knowledge but does not necessarily refer to the particular requirements of the customer. We offer a free advisory service to help determine which Flexcrete products are best suited to individual projects and can provide detailed written specifications on request. Technical Data Sheets, Safety Data Sheets and Application Guides are available on request and can also be downloaded from These documents should be consulted before the commencement of any site works. Should you require any additional support, please do not hesitate to contact us on +44 (0) Flexcrete Technologies Ltd

3 contents CONCRETE REPAIR & PROTECTION REPAIR MORTARS 4 Fastfill Fastfill WP Marine Mortar S Monolite Monomix Monomix HD Monomix WS Tiefill Unimatch FAIRING COATS & RENDERS 4 Monolevel 250F Monolevel 844SP Monolevel FC Monolevel RM Monorub DECORATIVE PROTECTIVE COATINGS ANTI-CARBONATION COATINGS 5 Monodex Clear Monodex Smooth Monodex Textured Monodex Ultra Monodex UVC HYGIENE COATINGS 5 Biodex Sheen Biodex HB WATERPROOFING AND PROTECTION OF CONCRETE & STEEL CEMENTITIOUS WATERPROOF COATINGS 5 Cementitious Coating 851 Cemprotec E942 Cemprotec Elastic Cemprotec Clutch Filler WATERPROOFING OF ROOFS & DECK AREAS HIGH PERFORMANCE ROOF COATINGS 6 Roofdex HB WATERPROOFING OF CONCRETE FLOORS 6 Cemprotec E-Floor Cemprotec EF Primer Cemprotec E-Floor HB Cemprotec Levelling Coat Cemprotec EF Grit CLEAR SURFACE SEALERS 6 Cemprotec Sandseal 75 Monosil Cemprotec Sandseal WB ANCILLARIES PREPARATION & FINISHING 7 Biodex Wash Metal Prime WB Bond-Prime Curing Membrane WB REPAIR ACCESSORIES 7 Bonding Bridge 842 Polymer Admixture 850 Cemprotec MCI 2020 Steel Reinforcement Protector 841 REINFORCEMENTS 7 Cemprotec 2000-BJT Cemprotec GEO80 Cemprotec 2000-S Cemprotec GFM Cemprotec Edge Scrim Cemprotec Scrim Cemprotec Flex-Tape 3

4 CONCRETE REPAIR & PROTECTION REPAIR MORTARS FASTFILL EN (R4), DWI 31, BBA, LUL Rapid setting repair mortar. Can be bulked out for application in deep pockets. 5-50mm (vertical) 5-300mm (pockets) 1 hour 14MPa 1 day 40MPa 28 days 60MPa 13.3 litres 75 packs per m³ Density: 2150kg/m³ FASTFILL WP Rapid setting mortar for arresting water seepage and infiltration under pressure. Sets in 2 mins. 8kg 20mm (min.) 1 hour 4MPa 1 day 11MPa 28 days 26MPa packs per m³ Density: 2150kg/m³ MARINE MORTAR S EN (R4), BBA General purpose structural repairs in marine and tidal areas. Early wash-out resistance. 5-50mm 1 day 15-20MPa 28 days 50-60MPa 14 litres 71.7 packs per m³ Density: 2150kg/m³ MONOLITE EN (R2), LUL Lightweight mortar for cosmetic repairs. 18kg 5-100mm 1 day 13MPa 7 days 24.5MPa 28 days 30MPa 16.7 litres 59.9 packs per m³ Density: kg/m³ MONOMIX EN (R3), DWI 31, BBA, LUL Low density waterproof mortar for general purpose, structural repairs. 5-80mm 1 day 23.5MPa 7 days 35MPa 28 days 42MPa packs per m³ Density: kg/m³ MONOMIX HD EN (R4), LUL High strength, structural repair mortar with good abrasion resistance for trafficked areas. 5-80mm 1 day 33.0MPa 7 days 44.5MPa 28 days 56.5MPa 13.1 litres 76.3 packs per m³ Density: 2100kg/m³ MONOMIX WS EN (R3), DWI 31, BBA Modified Monomix to allow wet spray application. Waterproof and low density. 5-80mm 1 day 20MPa 7 days 30MPa 28 days 40MPa packs per m³ Density: 1750kg/m³ TIEFILL EN (R4), WRAS, LUL Rapid curing mortar for the filling of tie-holes formed by formwork bolts. 8kg 5-50mm 1 hour 8.5MPa 1 day 34.0MPa 28 days 55.0MPa 4.1 litres per 8kg pack Density: 2150kg/m³ UNIMATCH EN (R1) Rapid setting mortar for structural repairs to in-situ and pre-cast concrete. Supplied in grey and white for cosmetic colour matched repairs. 25mm (max.) GREY WHITE 2 hours 15MPa 1 day 20MPa 28 days 41.5MPa 2 hours 9MPa 1 day 23.5MPa 28 days 41.5MPa packs per m³ Density: 2100kg/m³ FAIRING COATS & RENDERS MONOLEVEL 250F EN (R1) Fine grade fairing coat for existing painted surfaces, concrete and mosaics prior to overcoating. 0-4mm 1 day 4-10MPa 7 days 20-30MPa 28 days 25-35MPa 16.2 litres 62 packs per m 3 Density: kg/m 3 MONOLEVEL 844SP EN (R4), DWI 31, LUL Engineering quality fairing coat to reinstate cover and provide a fair faced, waterproof and anticarbonation finish. 6mm (max.) 1 day 23MPa 7 days 46MPa 28 days 60MPa 66.5 packs per m³ Density: kg/m³ MONOLEVEL FC EN (R2), LUL Fairing coat for filling minor blow holes and defects prior to overcoating. 6mm (max.) 1 day 20MPa 7 days 39MPa 28 days 51MPa packs per m³ Density: kg/m³ MONOLEVEL RM Rendering and profiling of concrete to provide a fair-faced render finish. 5-50mm 1 day 8-10MPa 7 days 20-25MPa 28 days 30-35MPa packs per m³ Density: 1900kg/m³ MONORUB EN (R1) Fine grade polymer modified mortar for filling blow holes to produce a smooth finish. 0-2mm GREY WHITE 1 day 25-30MPa 7 days 40-45MPa 28 days 55-60MPa 1 day 5-10MPa 7 days 27-33MPa 28 days 30-40MPa 14 litres 71 packs per m³ Density: 2000kg/m³ 15.9 litres 63 packs per m³ Density: 1950kg/m³ 4

5 DECORATIVE PROTECTIVE COATINGS ANTI-CARBONATION COATINGS MONODEX CLEAR High performance clear, anticarbonation masonry coating. & 1st Coat 200μm 2nd Coat 200μm Overall DFT=150μm Elongation = 164% Water Vapour S D =0.42m diffusion: S c =210mm 0.2 litres/m²/coat 5m²/litre/coat covers 37.5m² MONODEX SMOOTH High build, decorative anti-carbonation coating, which allows damp substrates to breathe. 15 YEAR SYSTEM 1st Coat 200μm 2nd Coat 200μm Overall DFT=240μm Elongation = 279% Water Vapour S D =0.48m diffusion: S c =300mm 0.2 litres/m²/coat 5m²/litre/coat covers 37.5m² MONODEX TEXTURED Highly textured, flexible waterproof coating for internal and external use. 1st Coat 500μm 2nd Coat 500μm Elongation = 172% Water Vapour S D =1.71m 0./m²/coat 2m²/litre/coat covers 15m² MONODEX ULTRA, LUL High performance decorative, anti-carbonation masonry coating. 10 YEAR SYSTEM 1st Coat 200μm 2nd Coat 200μm Overall DFT=130μm Elongation = 125% Water Vapour S D =1.03m diffusion: S c =500mm 0.2 litres/m²/coat 5m²/litre/coat covers 37.5m² MONODEX UVC UV cured system which produces a hard wearing, dirt resistant finish with a softer, permanently flexible core. 1st Coat 300μm 2nd Coat 300μm Overall DFT=312μm Elongation > 870% Water Vapour S D =0.72m 0.3 litres/m²/coat 3.33m²/litre/coat covers 25m² HYGIENE COATINGS BIODEX SHEEN EN Tough, sheen finish, biostatic coating with encapsulated biocide and silver ion technology. 1st Coat 166μm 2nd Coat 166μm Overall DFT=200μm Elongation = 47% Water Vapour S D =1.41m litres/m²/coat 6m²/litre/coat covers 45m² BIODEX HB EN High build, highly flexible, matt finish, biostatic coating with encapsulated biocide and silver ion technology. 1st 250μm 2nd 250μm Overall DFT = 245μm Elongation = 519% Water Vapour S D =1.21m 0.2/m²/coat 4m²/litre/coat covers 30m² WATERPROOFING AND PROTECTION OF CONCRETE & STEEL CEMENTITIOUS WATERPROOF COATINGS CEMENTITIOUS COATING 851, DWI 31, BBA, LUL Structural waterproofing. Protection from chloride ingress and carbonation. Reinstatement of cover. 2 x 1mm 28 days 40MPa Water Vapour S D =0.91m diffusion: S c =100mm Cl- ion: 26 years Euroclass A2-s1,d litres per 2mm Density: 1800kg/m³ ELASTIC WRAS Waterproofing and protection of concrete where further movement is expected. WHITE 15kg GREY 2 x 1mm 28 days 8-10MPa Elongation = 125% Water Vapour S D =1.55m diffusion: S c =135mm 9.4 litres per 15kg 2mm 18.8 litres per 2mm Density: 1600kg/m³ E942, LUL Waterproofing and protection of concrete where enhanced chemical resistance is needed. Stand alone anti-corrosion coating for ferrous metal. 15kg 2 x 1mm 28 days 50-60MPa Water Vapour S D =1.29m diffusion: S c =100mm Euroclass A2-s1, d0 8.1 litres per 15kg 2mm 16.2 litres per 2mm Density: 1850kg/m³ CLUTCH FILLER Mortar for sealing the surface gap at the interlock or clutch between piles. 16.5kg Typically 10mm thick 1 day 21.0MPa 7 days 45.0MPa 28 days 50.5MPa 8. per 16.5kg 85m at 10 x 10mm Density: 1900kg/m³ 5

6 WATERPROOFING OF ROOFS & DECK AREAS HIGH PERFORMANCE ROOF COATINGS ROOFDEX HB High build, cold fluid applied liquid roofing system. System 1 Solar reflective waterproofing. 2 coats Min. coverage rate 0.7/m DFT (μm) Elongation = 500% Tensile Strength = 0.68MPa 1st Coat 0.375l/m 2 or 2.67m 2 /l 2nd Coat 0.375l/m 2 or 2.67m 2 /l Overall 0.75l/m 2 or 1.33m 2 /l covers 20m 2 System 2 Weatherproofing 10 years. 2 coats Min. coverage rate 1.2/m 2 reinforced with Cemprotec GFM 100 Elongation = 10% Tensile Strength = 5.45MPa 1st Coat 0.75l/m 2 or 1.33m 2 /l Reinforce Cemprotec GFM 100 2nd Coat 0.5l/m 2 or 2m 2 /l Overall 1.25l/m 2 or 0.8m 2 /l covers 12m 2 System 3 Weatherproofing 15 years. 2 coats Min. coverage rate 1.7/m 2 reinforced with Cemprotec GFM 225 Elongation = 5% Tensile Strength = 16.60MPa 1st Coat 1.25l/m2 or 0.80m 2 /l Reinforce Cemprotec GFM 225 2nd Coat 0.50l/m 2 or 2.00m 2 /l Overall 1.75l/m 2 or 0.57m 2 /l covers 8.57m 2 WATERPROOFING OF CONCRETE FLOORS E-FLOOR, LUL Epoxy and cement modified polymer coating for protecting/ waterproofing concrete floors. 2mm (min.) 4 hours 8MPa 1 day 18MPa 7 days 33.5MPa 28 days 55MPa 16.2 litres 2mm Density: 1850kg/m³ E-FLOOR HB, LUL Epoxy and cement modified polymer coating for protecting/ waterproofing concrete floors. 3-6mm 1 day 15MPa 7 days 30MPa 28 days 50MPa 3mm Density: 1950kg/m³ EF GRIT FINE & COARSE EF PRIMER Quartz aggregate for abrasion and skid resistance within E-Floor systems. Single component sealer and primer for floors, prior to the application of the Cemprotec range of cementitious coatings and mortars. 2.5kg/m² (retained) 10m² per pack & 15-50m²/ 3-10m²/litre m²/2 LEVELLING COAT EN13813 Self-levelling compound for concrete floors used prior to Cemprotec E-Floor systems. Typically 10mm thick, can be applied up to 60mm 4 hours 4-10MPa 1 day 10-20MPa 7 days 30-40MPa 28 days 45-55MPa 2.0kg/mm/mm 2 A composite pack covers 3m² at 5mm thickness CLEAR SURFACE SEALERS SANDSEAL 75 Clear, hard wearing, single component, polyurethane coating for protecting/sealing Cemprotec E-Floor. 6-7m²/litre/coat (sanded) 10-14m²/litre/coat (smooth) 30-35m²/ (sanded surfaces) 50-70m²/ (smooth surfaces) SANDSEAL WB Water based, film forming polymer sealer with excellent water and oil repellency. Diluted 1:1 with water for walls. 5m 2 /litre/coat (sanded) 10m 2 /litre/coat (smooth) 25m 2 / (sanded surfaces) 50m 2 / (smooth surfaces) MONOSIL Water based silane/siloxane impregnant with excellent water and oil repellency. Can be diluted 1:1 with water for walls. Floors (2 coats) 3-4m 2 /litre Walls (2 coats diluted 1:1 with water) 6-8m 2 /litre Floors (2 coats) 15-20m 2 /pack Walls (2 coats diluted 1:1 with water) 30-40m 2 /pack 6

7 ANCILLARIES PREPARATION & FINISHING BIODEX WASH HSE No BOND-PRIME METAL-PRIME WB CURING MEMBRANE WB BBA A powerful surface treatment for neutralising active mould, fungal and bacterial growth. Single pack epoxy polymer primer to seal and consolidate substrates. Single pack, waterborne, anti-corrosion primer for metal and difficult to adhere to substrates. Water based curing membrane/sealer, formulated for use with Flexcrete Repair Systems. Up to 10m 2 /litre Up to 50m 2 /pack & 2 Cementitious & Masonry 5m 2 /litre Smooth substrates: 10m 2 /litre Non-smooth substrates: 8m 2 /litre 5-7m²/litre/coat Complies with ASTM C309 Cementitious & Masonry treats 25m 2 2 treats 125m 2 treats 50m 2 (smooth) or 40m 2 (non-smooth) 25-35m²/pack REPAIR ACCESSORIES BONDING BRIDGE 842 BBA MCI 2020 Enhances bond on high porosity substrates. Surface applied corrosion inhibitor for the protection of reinforcement in chloride contaminated concrete. 4kg 4m²/kg m²/litre (can be applied in two coats to give above coverage) 2.1 litres - 16m² Density: 1900kg/m³ 2 treats 92m² POLYMER ADMIXTURE 850 WRAS Admixture for cement mortars and floor toppings. & 2 50mm (max.) See data sheet See data sheet STEEL REINFORCEMENT PROTECTOR 841 EN1504-7, DWI 31, BBA Corrosion preventative flexible coating for steel reinforcement. 5kg 2 x 1mm (min.) 32MPa 2.8 litres 45 linear metres of 10mm bar. Density: 1800kg/m³ REINFORCEMENTS PRODUCT DESCRIPTION LENGTH WIDTH PERFORMANCE APPROX. YIELD 2000-BJT WRAS Self adhesive, butyl tape to join sections of Cemprotec 2000-S. 10m 10cm 10 linear metres 2000-S WRAS Elastomeric, waterproof reinforcing tape, giving an impermeable, highly flexible, seal over live cracks and expansion/construction joints. 10m & 50m 50m 12cm 20cm Typically 600% Elongation Impermeable 12cm wide roll 10 & 50 linear metres 20cm wide roll 50 linear metres EDGE SCRIM FLEX-TAPE GEO80 Flexible open textured glass scrim for reinforcing cementitious coatings over welds or on edges. Multi-directional nylon polyamide reinforcing tape for cracks and joints. Thermally bonded, non-woven geotextile for general reinforcement of cementitious coatings. 90m 5cm 90 linear metres 50m 5cm 7.5cm 15cm Light duty Heavy duty Heavy duty 50 linear metres 50m 1.125m 56m 2 GFM 100 Light duty reinforcement for fluid applied roof or wall membrane systems. 100m (approx) 1m 10kg/roll (approx) 100m 2 GFM 225 Heavy duty reinforcement for fluid applied roof or wall membrane systems. 125m (approx) 0.95m 27kg/roll (approx) 120m 2 SCRIM Open textured glass scrim to reinforce cementitious coatings and renders. 50m 1m 50m 2 7

8 INFORMATION All Flexcrete products are manufactured in accordance with the requirements of BS EN ISO 9001: 2008, the international standard for quality assurance. Flexcrete operates a robust Health, Safety and Environmental Management System, with successful accreditation to ISO (Environmental) and OHSAS (Occupational Health and Safety). The Flexcrete Concrete Repair and Protection System is CE Marked in accordance with BS EN The Flexcrete Concrete Repair and Protection System is certified by the British Board of Agrément (BBA). Copies of independent certificates and test reports are available upon request. This Estimating Guide supersedes all previously published Estimating Guides. Please contact us for further information: info@flexcrete.com Flexcrete Technologies Ltd Tomlinson Road Leyland PR25 2DY United Kingdom Tel: +44 (0) Fax: +44 (0) info@flexcrete.com