Flexcrete
01772 450950
Akzo Nobel
  • About
    • Accreditations
    • Sustainability
    • Research & Development
    • Policies
    • Concrete Repair Association
    • UK Distributor Map
  • Sectors
    • Civil Engineering & Infrastructure
    • Buildings & Commercial Construction
    • Utilities
    • Coastal Structures
    • Hygiene Sensitive Environments
    • Interactive Illustration
  • Solutions
    • Concrete Repair
      • Concrete Repair
      • Corrosion Protection
      • Concrete Floor Repair
    • Protective Coatings
      • Anti-Carbonation Protective Coatings
      • Hygienic Coatings
      • Cementitious Coatings
    • Waterproofing
      • Basement Waterproofing
      • Concrete Waterproofing
      • Structural Waterproofing
      • Flooring Systems
      • Roofs & Podium Deck Waterproofing
    • Specialist Solutions
      • Asbestos Encapsulation
      • Concrete Bridge Repair & Maintenance
      • Steel Marine Structures
      • Concrete Marine Structures
      • Clean Water Industry
      • Waste Water Industry
      • Oil & Gas Industry
      • Power Generation & Renewables
      • Solutions for Heritage Structures
      • Solutions for New Build Structures
  • Products
    • Concrete Repair Products
      • Repair Mortars
      • Fairing Coats & Renders
      • Admixtures
      • Corrosion Inhibitors
    • Decorative Protective Coatings
      • Anti-Carbonation Coatings
      • Hygiene Coatings
      • Clear Surface Sealers
    • Structural Waterproofing & Tanking
      • Cementitious Waterproofing Coatings
    • Enhanced Durability For Concrete & Steel
      • Corrosion Protection For Steel
      • Protection Against Gas, Chemicals & Chlorides
    • Waterproofing Of Roofs & Other Deck Areas
      • High Performance Roof Coatings
      • Waterproofing of Concrete Floors
    • Ancillaries
      • Surface Preparation & Primers
      • Reinforcements
      • Curing Membranes
    • Product Estimating Guide
    • A-Z Product Listing
  • Projects
    • Projects
    • Construction Focus Newsletter
  • Support
    • Technical Support
    • CAD Drawings
    • CPD Presentations
    • Product Estimating Guide
    • UK Distributor Map
    • Videos
    • Interactive Illustration
    • My Flexcrete
      • Research & Development
      • Specialist Distributors
      • Structural Engineers
      • Whitelist Instructions
  • News
    • News
    • In the Press
    • Construction Focus Newsletter
  • Contact
  • Login
    • My Account
    • Recover Password
01772 450950

Home » Solutions » Solutions for New Build Structures

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.

Download DocumentSolutions 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.

Download File

Flexcrete solutions for new build construction

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.

 

Contact Flexcrete Today

Solutions for New Build Structures Problems and Solutions

  • Grout Loss
  • Tie Holes
  • Low Concrete Cover

The Problem

Honeycombing, Blow-Holes And Surface Voids 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 HolesTie 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 Positioning Of ReinforcementLow 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.

Need Assistance with Your Next Project?
Speak to Flexcrete's Technical Experts Today

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. more
Cementitious Coating 851 Structural waterproofing. Protection from chloride ingress and carbonation. Reinstatement of cover. more
Cemprotec E-Floor Epoxy and cement modified polymer coating for protecting / waterproofing concrete floors. (2mm) more
Cemprotec E-Floor HB Epoxy and cement modified polymer coating for protecting / waterproofing concrete floors. (3-6mm) more
Cemprotec EF Primer Single component sealer and primer for floors, prior to the application of the Cemprotec range. more
Cemprotec GFM An advanced glass fibre reinforcement matting system. more
Fastfill Rapid setting concrete repair mortar. Can be bulked out in deep sections. more
Fastfill WP Rapid setting concrete repair mortar for arresting water seepage and infiltration under pressure. Sets in 2 mins. more
Monolevel 844SP Engineering quality fairing coat to reinstate cover and provide a fair faced, waterproof and anticarbonation finish. more
Monolevel FC Fairing coat for filling minor blow holes and defects prior to overcoating. more
Monomix Low density waterproof mortar for general purpose, structural repairs. more
Monomix HD High strength, structural repair mortar with good abrasion resistance for trafficked areas. more
Monorub Fine grade polymer modified mortar for filling blow holes to produce a smooth finish. more
Tiefill Rapid curing mortar for the filling of tie-holes formed by formwork bolts. more
Unimatch Rapid setting mortar for structural repairs to in-situ and pre-cast concrete. Supplied in grey and white for cosmetic colour matched repairs. more
Cure-Seal WB Water-based curing compound and clear sealer for Flexcrete Repair and Protection Systems. more
Roofdex HB High build, cold fluid applied liquid roofing system. more

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 Profile

Durable, Decorative Anti-Carbonation Protection for Corporate HQ Building

Pauian Archiland, Taiwan - Flexcrete project
Posted on 12-06-2017

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.

Read The Project Profile
Project Profile

Concrete Waterproofing and Protection of Wellington Docks

Assuring the design life of a new build extension
Posted on 11-03-2015

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.

Read The Project Profile
Project Profile

Flexcrete’s Waterproof Mortar Chosen for Crossrail

Flexcrete's Waterproof Mortar Chosen for Crossrail
Posted on 9-02-2015

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.

Read The Project Profile
View All Projects

Flexcrete Brochure

Find out more about our concrete repair and protection services. Read the Flexcrete product brochure online, or download a copy today

Read The Brochure
Flexcrete 2014 Brochure
Export Champion 2021-2022

Flexcrete Technologies Ltd

Tomlinson Road,
Leyland,
Lancashire,
PR25 2DY
United Kingdom

Telephone: +44 (0)1772 450950

E-mail: web@flexcrete.com

Registered: 5401028 England

Products

  • Concrete Repair Products
    • Repair Mortars
      • Bonding Bridge 842
      • Fastfill
      • Fastfill WP
      • Marine Mortar S
      • Monolite
      • Monomix
      • Monomix HD
      • Monomix WS
      • Monopour
      • Steel Reinforcement Protector 841
      • Tiefill
      • Unimatch
    • Fairing Coats & Renders
      • Monolevel 844SP
      • Monolevel FC
      • Monolevel RM
      • Monorub
    • Admixtures
      • Polymer Admixture 850
    • Corrosion Inhibitors
      • Cemprotec MCI® 2020
  • Decorative Protective Coatings
    • Anti-Carbonation Coatings
      • Monodex Smooth
      • Monodex Textured
      • Monodex Ultra
      • Monodex UVC
      • Monodex ICB
    • Hygiene Coatings
      • Biodex HB
      • Biodex Sheen
    • Clear Surface Sealers
      • Monosil
  • Structural Waterproofing & Tanking
    • Cementitious Waterproofing Coatings
      • Cementitious Coating 851
      • Cemprotec E942
      • Cemprotec Elastic
  • Enhanced Durability For Concrete & Steel
    • Corrosion Protection For Steel
      • Cemprotec Clutch Filler
      • Cemprotec E942
    • Protection Against Gas, Chemicals & Chlorides
      • Cementitious Coating 851
      • Cemprotec E942
      • Cemprotec Elastic
  • Waterproofing Of Roofs & Other Deck Areas
    • High Performance Roof Coatings
      • Cemprotec Elastic
      • Roofdex HB
    • Waterproofing of Concrete Floors
      • Cemprotec E-Floor
      • Cemprotec E-Floor HB
      • Cemprotec EF Grit
      • Cemprotec EF Primer
      • Cemprotec Levelling Coat
  • Ancillaries
    • Surface Preparation & Primers
      • Biodex Wash
      • Bond-Prime
    • Reinforcements
      • Cemprotec 2000-BJT
      • Cemprotec 2000-S
      • Cemprotec Edge Scrim
      • Cemprotec Flex-Tape
      • Cemprotec Geo80
      • Cemprotec GFM
      • Cemprotec Scrim
    • Curing Membranes
      • Cure-Seal WB

Sectors

  • Civil Engineering & Infrastructure
  • Buildings & Commercial Construction
  • Utilities
  • Coastal Structures
  • Hygiene Sensitive Environments

CPD Presentation

Book a Flexcrete CPD Presentation and find out more about our Concrete Repair & Protection Products and discover how our industry leading technology could benefit your next project.
Book A Presentation
Facebook Icon Twitter Icon Linkedin Icon
  • Cookie Policy
  • Privacy Policy
Structural Repair and Protection Technology

Made with by We Manage Web

Akzo Nobel
We use cookies on our website to give you the most relevant experience by remembering your preferences and repeat visits. By clicking “Accept All”, you consent to the use of ALL the cookies. However, you may visit "Cookie Settings" to provide a controlled consent.
Cookie SettingsAccept All
Manage consent

Privacy Overview

This website uses cookies to improve your experience while you navigate through the website. Out of these, the cookies that are categorized as necessary are stored on your browser as they are essential for the working of basic functionalities of the website. We also use third-party cookies that help us analyze and understand how you use this website. These cookies will be stored in your browser only with your consent. You also have the option to opt-out of these cookies. But opting out of some of these cookies may affect your browsing experience.
Necessary
Always Enabled
Necessary cookies are absolutely essential for the website to function properly. These cookies ensure basic functionalities and security features of the website, anonymously.
CookieDurationDescription
_GRECAPTCHA5 months 27 daysThis cookie is set by Google. In addition to certain standard Google cookies, reCAPTCHA sets a necessary cookie (_GRECAPTCHA) when executed for the purpose of providing its risk analysis.
cookielawinfo-checkbox-advertisement1 yearThe cookie is set by GDPR cookie consent to record the user consent for the cookies in the category "Advertisement".
cookielawinfo-checkbox-analytics11 monthsThis cookie is set by GDPR Cookie Consent plugin. The cookie is used to store the user consent for the cookies in the category "Analytics".
cookielawinfo-checkbox-functional11 monthsThe cookie is set by GDPR cookie consent to record the user consent for the cookies in the category "Functional".
cookielawinfo-checkbox-necessary11 monthsThis cookie is set by GDPR Cookie Consent plugin. The cookies is used to store the user consent for the cookies in the category "Necessary".
cookielawinfo-checkbox-others11 monthsThis cookie is set by GDPR Cookie Consent plugin. The cookie is used to store the user consent for the cookies in the category "Other.
cookielawinfo-checkbox-performance11 monthsThis cookie is set by GDPR Cookie Consent plugin. The cookie is used to store the user consent for the cookies in the category "Performance".
viewed_cookie_policy11 monthsThe cookie is set by the GDPR Cookie Consent plugin and is used to store whether or not user has consented to the use of cookies. It does not store any personal data.
Functional
Functional cookies help to perform certain functionalities like sharing the content of the website on social media platforms, collect feedbacks, and other third-party features.
Performance
Performance cookies are used to understand and analyze the key performance indexes of the website which helps in delivering a better user experience for the visitors.
Analytics
Analytical cookies are used to understand how visitors interact with the website. These cookies help provide information on metrics the number of visitors, bounce rate, traffic source, etc.
CookieDurationDescription
_ga2 yearsThis cookie is installed by Google Analytics. The cookie is used to calculate visitor, session, campaign data and keep track of site usage for the site's analytics report. The cookies store information anonymously and assign a randomly generated number to identify unique visitors.
_gat_UA-3540151-11 minuteThis is a pattern type cookie set by Google Analytics, where the pattern element on the name contains the unique identity number of the account or website it relates to. It appears to be a variation of the _gat cookie which is used to limit the amount of data recorded by Google on high traffic volume websites.
_gid1 dayThis cookie is installed by Google Analytics. The cookie is used to store information of how visitors use a website and helps in creating an analytics report of how the website is doing. The data collected including the number visitors, the source where they have come from, and the pages visted in an anonymous form.
Advertisement
Advertisement cookies are used to provide visitors with relevant ads and marketing campaigns. These cookies track visitors across websites and collect information to provide customized ads.
CookieDurationDescription
IDE1 year 24 daysUsed by Google DoubleClick and stores information about how the user uses the website and any other advertisement before visiting the website. This is used to present users with ads that are relevant to them according to the user profile.
NID6 monthsThis cookie is used to a profile based on user's interest and display personalized ads to the users.
test_cookie15 minutesThis cookie is set by doubleclick.net. The purpose of the cookie is to determine if the user's browser supports cookies.
VISITOR_INFO1_LIVE5 months 27 daysThis cookie is set by Youtube. Used to track the information of the embedded YouTube videos on a website.
YSCsessionThis cookies is set by Youtube and is used to track the views of embedded videos.
Others
Other uncategorized cookies are those that are being analyzed and have not been classified into a category as yet.
CookieDurationDescription
bynderNo description available.
CONSENT16 years 6 months 8 days 9 hours 10 minutesNo description
DEFAULTLOCALEThis cookie is used for determining the visitor language preference.
yt-remote-connected-devicesneverNo description available.
yt-remote-device-idneverNo description available.
SAVE & ACCEPT
Powered by CookieYes Logo