Solutions for New Build Structures
New Build Construction Issues
Defects are not just confined to older buildings and structures; challenging problems also occur on new build construction schemes. This can be attributed to the complexity of modern designs, variations to specification or simply because of poor workmanship. Grout loss and damage when removing formwork can result in unacceptable blemishes and poor compaction causes honeycombing. Concrete, often considered as an aesthetic finish in its own right, must meet the required standards if durability is to be assured.
Reinstatement of Cover
Inadequate concrete cover adversely affects the durability of reinforced concrete. Careless fixing of the formwork or incorrect use of spacers can lead to low cover. This undermines the protection of the steel reinforcement, ultimately leading to spalling and expensive maintenance. Flexcrete’s cementitious coatings are engineered so that just a 2mm application is equivalent to a minimum of 100mm of additional good quality concrete cover. Rapidly and easily applied by brush or spray, these coatings offer unparalleled resistance to water, carbon dioxide and chlorides and never need replacing during the design life of the structure.
Solutions for New Build Construction
The structural challenges facing new build projects are an important consideration for designers, engineers and contractors alike. Download this information sheet to find out more about our materials.
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Repairing the Defects
Defects need to be rectified with materials that are visually and structurally compatible. We offer a range of materials to suit all applications from structural mortars for reinstating large areas of honeycombing to colour-matched, fine grade mortars for producing a fair-faced finish.
The Flexcrete range also includes waterproof tie hole fillers, waterproof flooring for basements and a range of high performance coatings to ensure that a watertight seal is achieved in basements and other water retaining structures.
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Solutions for New Build Structures Problems and Solutions
- Grout Loss
- Tie Holes
- Low Concrete Cover
The Problem
Areas of honeycombing, blow-holes and surface voids caused by poor compaction or defects in the formwork placing resulting in grout loss. The surface requires filling to achieve the specified quality of finish.
The Solution
A fine, formed finish is achieved by filling blow holes, areas of honeycombing and grout loss with Monolevel FC, applied using a simple bag-rubbing technique. Available in white and grey formulations, the shades can be blended to match the colour of the parent concrete, resulting in a uniform finish.
Larger defects and areas of honeycombing and grout loss can be filled using Monolevel FC. If such areas need to be cut out, reinstatement can be easily achieved using Monomix.
The Problem
Tie holes left on removal of formwork in new construction must be filled to provide an integral, even finish. In water retaining structures the tie hole must also be made waterproof to prevent leakage.
The Solution
Voids left by proprietary she bolt or through-tie systems can be filled with Tiefill, a rapid setting, non-shrink repair mortar.
The product has WRAS Approval and is totally waterproof, enabling it to be used in water tanks, even those containing potable water.
It can also be employed for sealing grout holes and voids around fixings in pre-cast elements.
The Problem
Low cover to reinforcement from incorrect siting of shutters or positioning of reinforcement. Problems also occur during concrete placement if spacers are not used effectively. Reduced design life and durability is the result.
The Solution
Such low cover problems can be easily overcome by applying two 1mm coats of Cementitious Coating 851 by brush or spray.
The product is a barrier to chloride ions and water, even under 10 bar pressure. It also provides the equivalent of 70mm of additional concrete cover.
Solutions for New Build Structures Products
Find out more below about Flexcrete’s range of products for new build construction:
| Bond-Prime | Single pack epoxy polymer primer to seal and consolidate substrates. |
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| Cementitious Coating 851 | Structural waterproofing. Protection from chloride ingress and carbonation. Reinstatement of cover. |
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| Cemprotec E-Floor | Epoxy and cement modified polymer coating for protecting / waterproofing concrete floors. (2mm) |
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| Cemprotec E-Floor HB | Epoxy and cement modified polymer coating for protecting / waterproofing concrete floors. (3-6mm) |
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| Cemprotec EF Primer | Single component sealer and primer for floors, prior to the application of the Cemprotec range. |
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| Cemprotec GFM | An advanced glass fibre reinforcement matting system. |
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| Fastfill | Rapid setting concrete repair mortar. Can be bulked out in deep sections. |
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| Fastfill WP | Rapid setting concrete repair mortar for arresting water seepage and infiltration under pressure. Sets in 2 mins. |
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| Monolevel 844SP | Engineering quality fairing coat to reinstate cover and provide a fair faced, waterproof and anticarbonation finish. |
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| Monolevel FC | Fairing coat for filling minor blow holes and defects prior to overcoating. |
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| Monomix | Low density waterproof mortar for general purpose, structural repairs. |
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| Monomix HD | High strength, structural repair mortar with good abrasion resistance for trafficked areas. |
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| Monorub | Fine grade polymer modified mortar for filling blow holes to produce a smooth finish. |
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| Tiefill | Rapid curing mortar for the filling of tie-holes formed by formwork bolts. |
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| Unimatch | Rapid setting mortar for structural repairs to in-situ and pre-cast concrete. Supplied in grey and white for cosmetic colour matched repairs. |
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| Cure-Seal WB | Water-based curing compound and clear sealer for Flexcrete Repair and Protection Systems. |
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| Roofdex HB | High build, cold fluid applied liquid roofing system. |
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Solutions for New Build Structures Projects
Take a look below at some of Flexcrete’s latest new build projects, or browse the project profile pages to find more.
Project Location: Pauian Archiland HQ Building, Taiwan
A durable, aesthetic, anti-carbonation coating was required to protect the new concrete walls on this prestigious corporate HQ building.
Project Profile
Project Location: Wastewater Treatment Works, Wellington Dock, Liverpool
Assuring the design life of the new build at Wellington Docks, Liverpool with Flexcrete’s structural mortars and cementitious coatings.
Project Profile
Project Location: Moorgate Shaft, Crossrail Liverpool Street Station, London
Flexcrete’s high strength, waterproofing cementitious mortars were used to enhance the durability of new concrete in the Moorgate Shaft, Crossrail project in London.