Zemdrain. Technical Information. Technical & Fixing Guidelines TECHNICAL GUIDELINES

Transcription

1 Technical Information Zemdrain Technical & Fixing Guidelines TECHNICAL GUIDELINES To obtain the best results with Zemdrain, the following should be observed: 1. Zemdrain M can be used with nearly all shapes of formwork. For steel forms special provisions must be made for use of the liner. 2. The form face should be continuous, flat, clean and oil free. With lower grade plywood, the face should be sealed to prevent water ingress/sugar egress. Tape any joints where oil may have concentrated. 3. It is important that Zemdrain liners lie flat on the form. This is aided by fixing during warm sunny periods (the liner expands/contracts when exposed to and shaded from the sun). In times of high daily/weekly temperature variations (>10 0 C), care is required to ensure that the liner remains flat. The use of specially designed fixing tools helps to ensure correct fixation. 4. Release agents should not be applied to the form or to the liner. Take care to avoid all contamination. 5. Zemdrain can be easily cut using a blade cutter or scissors and attached to the form using an industrial stapler and 10mm staples. Once the liner is in place, holes for the tie bolts are cut and stapled. 6. Any damaged areas should be cut out and replaced. Put in a new piece of Zemdrain on top of the old, cut through both, remove damaged area and replace with the new piece. 7. To avoid visible marks on the concrete surface, at tie bolt holes and under spacer blocks the maximum pressure on Zemdrain should not exceed 2 MPa (20 kg/cm 2 ). 8. Concrete should be placed and compacted in accordance with accepted good practice. Pouring and vibration of concrete should be performed consecutively without delay. ensure concrete is not discharged against the liner surface and minimise splatter the slump should be maintained at the mid to lower end of the permissible range avoid concrete wetting the surface of the liner and then being allowed to dry keep the vibrator at least 5-10 cm from the form face avoid fast extraction of the vibrator and also avoid excessive and irregular vibration Failure to observe any of the above may result in prominent pour lines, colour variations, segregation or the presence of blowholes. 9. Primary vibration must be performed using an internal poker vibrator. External vibrators should only be used after completion of primary vibration. 10. Some blowholes and lighter coloured concrete can occur in the upper 5-10 cm of a pour. This can be avoided by revibration of this zone (after mins), followed by tamping and smoothing of the surface. This is especially important for pours with inclined top shutters. 11. Rolls of Zemdrain should be stored in a clean environment, away from contaminants and prolonged exposure to UV light. In cold weather, rolls should be stored indoors. Zemdrain should be protected from flames, welding or steel cutting and kept free from dirt and dust. 12. The number of uses for Zemdrain will depend upon the reasons for liner use (for durability or surface blemish removal) and will be subject to proper handling and cleaning. Checks for possible mechanical damage to the skin of the liner or the tape should be made between uses. 13. The used liner is chemically inert and can be disposed of by burying, earth dumping or incineration. A Material Safety Data Sheet is available upon request. NOTE: a) Zemdrain cast concrete will be slightly darker than traditionally cast concrete reflecting the colour of the cement. Darker coloured spacer blocks may be required for soffits. GGBS lightens the colour. b) Fillets and features should be placed on top of the fitted liner. Larger features, (width > 100 mm) can be lined Zemdrain is DuPont s registered trademark PARCHEM CONCRETE REPAIR FLOORING JOINTING SYSTEMS WATERPROOFING TECHNICAL INFORMATION JUNE Lucca Road, Wyong NSW 2259 Phone ABN Distributed in New Zealand by: Concrete Plus 23 Watts Road, Sockburn Ph: (03)

2 individually. Smaller features are usually left unlined or can be lined using Zemdrain tape. c) Minimise any staple marks in the finished surface by ensuring staples are flush to the liner. Staples and joints can be covered using Zemdrain tape. Some blowholes may occur at the tape. d) Cleaning of Zemdrain with a high-pressure water jet between uses is recommended. Particular attention should be paid to the upper half of the form. The liner should remain fixed to the form during cleaning. e) Surface colour variations may occur due to variable vibration, plywood quality, the mix used and the number of uses of the liner. These colour variations do not effect concrete quality. f) If a Zemdrain lined form is left exposed to full sun for a period of time, it should be left to cool down for several hours before concreting. FIXING GUIDELINES 1. ACCESSORIES - FOR SUCCESSFUL FIXING OF ZEMDRAIN, YOU REQUIRE: staple gun (using 10/12 mm staples) special fixing tool (available in widths of 0.6 m, 1.25 m and 2.5 m) form heights < 2.5 m or special fixing clamps (minimum of 2 No.) all form heights 2. THE FOLLOWING ARE GENERAL NOTES ON FIXING ZEMDRAIN : refer to points 2 to 5 in the Technical Guidelines after unrolling and cutting, allow liner to relax and warm up in direct sunlight the liner will expand and become easier to fix in cold weather (<5 o C), the liner will be difficult to stretch. To aid fixing the liner should not be left outside overnight and should be cut to length and stored in a heated environment before fixing, ensure the liner is square on the form to avoid distortions always ensure staples are securely placed, hammer home if necessary 3. ZEMDRAIN CAN BE FIXED IN TWO WAYS: with the length direction of the roll used in the vertical pour direction - PREFERRED 4. FIXING WHEN THE LENGTH OF THE ROLL IS IN THE VERTICAL POUR DIRECTION: follow points under 2 above, then staple at 25 mm centres (max.) along the top edge at other end, attach a fixing tool or clamps over the full width and stretch the liner flat by rotating the fixing tool against the edge or winding the clamps, then staple down for the cross direction, ensure that the liner lies flat with no folds, pull tight with fixing tool if necessary, then staple down check that the liner is tight with no distortions or folds evident repeat above steps with additional strips of the liner until the formwork is covered strips of liner are butted up and with care tight joints can be achieved, otherwise put sealant in the joint, alternatively Zemdrain tape can be used to mask the joint and the staples form tie bolt holes using a knife, place some staples around the hole for forms (>2.5 m high) the special fixing clamps should always be used 5. FIXING WHEN THE LENGTH OF THE ROLL IS AT RIGHT ANGLES TO THE POUR DIRECTION: the liner should only be fitted this way if the form is less than 2.5 m high, for higher forms, always fix with the length of the roll in the vertical pour direction fixing should be as described in 2 and 4 above in the vertical pour direction a fixing tool should be used to ensure that the liner lies flat and is tensioned. Care is required to avoid distortions at the corners. 6. OTHER FORMWORK SHAPES the liner can be used to line most form shapes, including convex, concave and circular slightly modified versions of the above techniques are applied please consult your local supplier for further details The above fixing details apply to flat timber / plywood faced forms. For steel faced forms, it is recommended that timber inserts be used to permit the liner to be stapled to the form. For unlined panel systems take care to ensure that panels are joined to provide a flat rather than convex surface before fitting Zemdrain. with the length direction of the roll used in the axial direction 2

3 FIXING GUIDELINES - 4 METHODS METHOD 1- FOR FORMS UP TO 2.5 M HIGH - USE FIXING TOOLS Once liner is attached at the base, take up the slack and attach Fixing Tool as shown. To stretch liner tight rotate the Tool against form edge and then staple. The Fixing Tool can also be used for the cross direction when this is used in the vertical pour direction. METHOD 2- FOR FORMS UP TO 20 M HIGH - USE FIXING CLAMPS Either attach clamps directly to shutter or fix clamps to separate timber and then attach to the form. Insert a suitable sized piece of timber (maximum 2.5 m long), ensuring that it sits level with the face of the shutter. Tighten screws to hold timber in place Staple liner to the timber piece joining the clamps, then take up the slack and apply tension evenly, ensuring liner is tight. (see page 5 for full directions) METHOD 3 - FOR FORMS OF ANY HEIGHT An alternative method of fixing involves the use of site available material. At the base, the liner is stapled to the face of the form. At the top the liner is stapled to an appropriately sized timber (max. 2.5 m long). 2 No. threaded bars are then attached to the timber piece. The threaded bar is then attached to a restraint and wing nut and waler plate attached. After taking up the slack, the liner can be tensioned as tightly as required. Note: when a Zemdrain liner is used with the roll length in the vertical pour direction and is tensioned correctly, then tensioning in the cross direction is not usually required. METHOD 4 - FOR CONVEX / CONCAVE / CIRCULAR / FLAT FORMS OF ANY HEIGHT This method of fixing can be used with any shape or size of plywood or steel faced formwork: Attach threaded bars to shutter and then fix timber to form desired shape. Affix liner at top and bottom and then apply tension. For steel forms attach timber at top and bottom to allow stapling. For vertical faces the best results are obtained using a timber insert to allow stapling. Alternatively vertical face can be held with tape, tape may require replacing between uses. 3

4 USING FIXING CLAMPS 1. After ensuring formwork is lying completely flat, either attach clamps directly to the end of the formwork as shown or preferably fix clamps to separate timber and then attach to the formwork. For a 2.5 m wide roll, clamps should be at approximately 1.5 m centres. 2. Insert a suitable sized piece of timber running the width of the shutter/roll (max. 2.5 m), ensuring that it sits level or below the face of the shutter. Tighten screws to hold timber in place. Ensure that the moveable part of the clamp is beside the base plate. 3. Follow points 2 to 4 in the attached Technical Guidelines and point 4 in the Fixing Details sheet. 4. Place Zemdrain square on the form face and at the non-tensioning end staple at 25 mm centres, always staple from centre to the edge of roll to avoid creases. 5. Staple Zemdrain to the timber piece joining the clamps, then take up the slack and ensure liner lies flat across the width. 6. Apply tensioning, approx. 3 mm per metre length, by turning screws as shown until requisite amount of stretch is induced. Now ensure liner is lying flat in the cross direction. 7. Successive 2.5 m wide strips of Zemdrain can be applied to the formwork in the vertical direction. 8. Adjacent strips are simply butted up to each other and if the joint is not acceptable any gaps can be filled with a suitable sealant. 9. If any edges of the liner are exposed in the pour, these should also be sealed to prevent grout ingress. 10. To maximize the life and performance of the liner it is recommended that the liner be given a jet wash between uses. Particular attention should be paid to the upper 25% of the form, which should get an extra pass of the jet wash. 11. The attached FAQ sheet also answers commonly asked questions about Zemdrain use. 4

5 FREQUENTLY ASKED QUESTIONS 1. DAMAGE Repair of damaged areas. For small areas use a short length of Zemdrain tape. For larger areas place a new piece of Zemdrain over the damaged area and cut through both layers to form an infill section. Remove the damaged liner and replace with the new piece using staples or tape. 5. JOINTS For M Series, the two pieces are butt jointed with both stapled down. For good joints no further action is required. For poor joints the gap should be filled with a sealant or covered with Zemdrain tape. 8. STEEL FACED FORMWORK Zemdrain M Series can be used with steel faced formwork. Special fixing techniques may be required depending upon the dimensions of the formwork. It is essential when using Zemdrain with steel faced forms to design in the liner fixing details at the time of manufacture of the form. 2. TIE BARS Holes for formwork ties should only be formed after Zemdrain has been completely fixed to the formwork. Cut a clean hole with a blade cutter and for extra security staple in place. 3. RELEASE AGENTS Release agents should not be used with Zemdrain. They can block the liner pores or cause uneven swelling making the liner unfit for use. Care should be taken to avoid spillage of diesel, hydraulic oil and other contaminants onto the liner. 6. SPACERS In order to reduce visible imprints on the concrete, such as those caused by spacers, the maximum pressure on Zemdrain should be less than 20 kg/ cm 2. Loading caused by reinforcement should be distributed onto as many spacers as possible. 7. DRAINAGE PATH For Zemdrain M Series, it is not essential that the bottom of the liner is open to the atmosphere to permit unimpeded drainage, as there is usually sufficient storage capacity within the net to accommodate all water removed from the concrete. Please ensure that grout cannot penetrate behind the liner. 9. PANEL SYSTEMS Zemdrain M Series has been used successfully with large panel systems without the need for oversheeting with additional plywood. Care needs to be taken to ensure that there are no gaps between panels before fitting Zemdrain. The resulting surface is not completely flat but is acceptable for most non-visual applications. 10. CONCRETE COLOUR The colour of the finished concrete is primarily a function of the type of cement used. Hence for white cement the concrete colour remains white. For GGBS the colour will be light grey, with other cements giving a darker colour. The fine aggregate will also have some influence on the colour, as will the amount and uniformity of vibration and curing. 11. OTHER QUESTIONS If you have any other questions please call us or visit the Parchem s web page at 4. COMPLICATED SHAPES Zemdrain M Series can be used with complicated shapes. The liner has been successfully used with circular, convex and concave formwork. 5

6 ADDITIONAL INFORMATION Parchem provides a wide range of complementary products which include: concrete repair cementitious and epoxy grouts and anchors cementitious and epoxy waterproofing membranes liquid applied, cementitious and bituminous sheet membranes waterstops pvc and swellable joint sealants building, civil and chemical resistant industrial flooring systems cementitious and epoxy architectural coatings filler boards swellable cork, bituminous and backing rod IMPORTANT NOTICE A Material Safety Data Sheet (MSDS) and Technical Data Sheet (TDS) are available from the Parchem website or upon request from the nearest Parchem sales office. Read the MSDS and TDS carefully prior to use as application or performance data may change from time to time. In emergency, contact any Poisons Information Centre (phone within Australia) or a doctor for advice. PRODUCT DISCLAIMER This Technical Data Sheet (TDS) summarises our best knowledge of the product, including how to use and apply the product based on the information available at the time. You should read this TDS carefully and consider the information in the context of how the product will be used, including in conjunction with any other product and the type of surfaces to, and the manner in which, the product will be applied. Our responsibility for products sold is subject to our standard terms and conditions of sale. Parchem does not accept any liability either directly or indirectly for any losses suffered in connection with the use or application of the product whether or not in accordance with any advice, specification, recommendation or information given by it. ancillary products For further information on any of the above, please consult with your local Parchem sales office. PARCHEM CONCRETE REPAIR FLOORING JOINTING SYSTEMS WATERPROOFING TECHNICAL INFORMATION JUNE 09 Zemdrain is DuPont s registered trademark 7 Lucca Road, Wyong NSW 2259 Phone ABN Distributed in New Zealand by: Concrete Plus 23 Watts Road, Sockburn Ph: (03)