concrete canvas

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ROAD RAIL AGRO OTHERDESIGNPOWER PETROCHEM MINING

www.concretecanvas.co.uk

12.06.UK

MADE IN UK

www.concretecanvas.co.uk

Concrete Impregnated Fabric...

NATIONAL WINNERmost INNOVATIVE product

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Concrete Impregnated Fabric...© Concrete Canvas Ltd. 2012

The information contained herein is offered free of charge and is, to the best of our knowledge, accurate. However, since the circumstances and conditions in which such information and the products discussed therein can be used may vary and are beyond our control, we make no warranty, express or implied, of merchantability, fitness or otherwise, or against patent infringement, and we accept no liability, with respect to or arising from use of such information or any such product.

[email protected]+ 44 (0) 845 680 1908 www


Concrete Canvas (CC) is a flexible, cement impregnated fabric that hardens when hydrated to form a thin, durable, water and fire proof concrete layer.

The following guide provides useful information for installers, customers and specifiers of CC. It provides an overview of useful data and techniques that can be used across a wide range of applications. The versatile nature of the material means that this document is not exhaustive and is intended for guidance purposes only.

There are 3 CC types available with the following indicative specifications:

CC Type Thickness (mm)

Roll Width(mm)

Dry Weight(kg/sqm)

Batched Roll Coverage (sqm)

Batched Roll Length (m)

Bulk Roll Coverage (sqm)

Bulk Roll Length (m)

CC5 5 1000 7.0 10 10.0 200 200.0CC8 8 1100 12.0 5 4.5 125 113.6CC13 13 1100 19.0 N/A N/A 80 72.7

Concrete Canvas™ User Guide

CC Specification

CC is available in two standard roll sizes; bulk rolls or smaller batched rolls. The quantity per roll differs between the CC types.

Bulk rolls weigh 1.6T and are supplied on 6 inch cardboard tubes which can be hung from a spreader beam and unrolled using suitable plant equipment (see below). Bulk rolls provide the fastest method of laying CC and have the additional advantage of reducing the number of joints required. Contact Concrete Canvas Ltd. for spreader beam hire.

Batched rolls are supplied on 3 inch cardboard cores with carry handles designed as a 2 to 4 man lift. All CC thicknesses can be supplied batched to custom lengths for a small additional charge.

CC bulk rolls are individually wrapped and palletised. A 20ft ISO container can typically hold 1600sqm bulk of CC5, 1250sqm of CC8 or 800sqmof CC13. All CC rolls are provided with a basic hydration guide in English within the packaging.

CC batched rolls are similarly supplied, individually wrapped in airtight PE packaging and palletised. 10 batched rolls fit on a standard 1.2 x 1.0m pallet. A 20ft ISO container can typically hold 1000sqm of CC5 or 500sqm of CC8. CC13 is not supplied as a batched roll as standard.

Bulk Rolls / Batched Rolls

Shipping / Stuffing

CC Types

CC batched rollsCC bulk rolls

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Some examples of applications for the different CC types are given below:

Example CC Applications

Application CC5 CC8 CC13 Comment

Dust Suppression ● ○ Use CC8 if the area is to be regularly trafficked.

Foundation Blinding ● ○ Use CC8 for heavy duty applications.

Weather Proofing /Slope Stabilisation

● ● Use CC5 or CC8 depending on ground conditions.

Ditch Lining ○ ● ○ Use CC5 for light duty applications. Use CC8 for medium duty applications. Use CC13 for heavy duty applications.

Bund Lining ● ● ● All thicknesses may be used depending on level of traffic.

Sandbag / GabionReinforcement

○ ● ● CC8 has been tested by the British Army for sandbag reinforcement.

Trackway / Flooring ● ● Use CC8 to CC13 depending on loading or substrate.

Pipe Protection ● ● ● All thicknesses may be used depending on protection requirements.

Cable Covering ○ ○ ● All thicknesses may be used depending on protection requirements.

CC Ditch Lining CC Slope Protection

CC Pipe Protection CC Bund Lining

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Concrete Canvas™ Hydration Instructions

Storage

CC Hydration at Low Temperatures (<5°C)

SPRAY THE FIBRE SURFACE WITH WATER UNTIL IT FEELS WET TO TOUCH FOR SEVERAL MINUTES AFTER SPRAYING.

Re-spray the CC again after 1 hour if:- Installing CC5- Installing CC on a steep or vertical surface- Installing in warm climates

Notes:- CC cannot be over hydrated and an excess of water is always recommended. - Minimum ratio of water:CC is 1:2 by weight. - Do not jet high pressure water directly onto the CC as this may wash a channel in the material. - CC can be hydrated using saline or non-saline water. - CC will hydrate and set underwater.- CC has a working time of 1-2 hours after hydration. Do not move CC once it has begun to set. - Working time will be reduced in hot climates.- CC will set hard in 24 hours but will continue to gain strength for years.- If CC is not fully saturated, the set may be delayed and strength reduced. If the set is delayed, re-wet with a large excess of water.

1) If the ground surface temperature is between 0 and 5°C and rising, Concrete Canvas should be covered with plastic sheeting immediately after hydration. CC may exhibit a delayed set at very low temperatures.

2) If the surface temperature is expected to fall below 0°C in the 8 hours following hydration then use warm water (>15°C) mixed with CC accelerant and cover with plastic sheeting. It is important to only use accelerant supplied by Concrete Canvas Ltd. as some admixtures may delay set or impair performance of CC. Please contact Concrete Canvas with your specific temperature profile for a recommendation on the dosage of accelerant required.

3) It is not recommended to install CC if the ground surface temperature is likely to fall below -4°C within 24 hours of initial hydration.

4) It is not recommended to install CC on frozen ground as the ground may move significantly when it thaws, creating voids underneath the set Concrete Canvas.

CC should be stored in dry conditions away from direct sunlight and in the manufacturers sealed packaging. If stored correctly CC has a shelf life of 24 months. If stored for longer CC may remain usable in many instances.

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A ‘snap off’ type disposable blade is the most suitable tool for cuttingCC before it is hydrated or set. When cutting dry CC, a 20mm allowance should be left from the cut edge due to lost fill. This can beavoided by wetting the CC prior to cutting.

Set CC can be cut as with conventional concrete, with angle grinders,construction disc cutters or good quality tile cutters.

CC can also be cut using handheld self sharpening powered disc cutters.

CC sheets in all three thicknesses can also be water cut to a fine resolution. Contact Concrete Canvas Ltd. for further information.

Cutting CC

Cutting Unset CC

Cutting Set CC

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CC Mechanical Fixings

The versatility of CC means that a wide range of manual, electric orgas powered staplers are suitable for attaching CC to soft substratessuch as wooden boarding for building cladding. Commercially available hand staplers are suitable for fixing 2 layers of CC together where a small amount of compression force is required - such as with the simple overlap joint described on page 9.

There are a large number of mechanical fixings that are suitable for use with Concrete Canvas. Some of these fixings can be used in conjunctionwith the non-mechanical joining methods described later in this guide to improve the mechanical strength or water proofing properties of joints.

Self tapping screws provide a quick and readily available means of attaching CC to a substrate or to itself. Typical applications include sandbag reinforcement or covering existing wooden or steel structures.

Standard nails can be used to attach CC. Alternatively, a power tool such as the Hilti nail gun, provides a quick and effective method of securing CC to hard surfaces such as concrete or rock. This may be appropriate where CC is being used to recondition an existing concrete surface or for spall lining in mining applications. It is important to ensure that the nail is used with at least a 15mm washer to ensure the head does not penetrate through the surface of the Canvas.

Alternatively large thread ‘self drive’ screws provide an excellent method of securing overlapped layers of CC together. This is ideal where a good mechanical joint is required, for applications such as slope stabilisation, dust suppression or vehicle trackway. Contact Concrete Canvas Ltd. for a recommended supplier and product specification.

Staples Nails

Screws

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Hog-rings are available in a wide range of sizes and can be applied to Concrete Canvas using pneumatic, electrical or hand powered tools. They provide a rapid means of securing CC either to itself or onto a wire mesh substrate such as gabion baskets. Hog-rings can also be used to attach adjacent sheets of CC together by laying the material face to face (fibre side together) and then hog-ringing at intervals along the edge. The spacing will vary depending on the level of mechanical fixing required.

Water Proof Rating : ●●●●○Mechanical Strength : ●●●●○

If a more water proof seal is required, a Bitumen tape can be appliedover the hog-rings, onto the PVC backing, using a blow-torch. Usingthis method, large panels of Concrete Canvas can be prefabricated with relative ease.

Medium gauge wire can be used as a simple alternative to hog-rings where plant equipment is not available. The end of the wire should be cut to a sharp point to aid penetration through the CC layers.

CC Mechanical Fixings cont.

Hog Rings

Hog Rings cont.

Pneumatic hog-ringer fixing CC to a gabion basket

Hog-ringed CC layers opened out showing PVC surface Hog-ringed CC layers opened out showing fibre surface

2 CC layers laid face to face and hog-ringed togetherPneumatic hog-ringer fixing CC to a gabion basket 2 CC layers laid face to face and hog-ringed together

Hog-ringed CC layers opened out showing fibre surfaceHog-ringed CC layers opened out showing PVC surface

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Pegging is recommended for ground surfacing applications such as ditch lining, slope stabilisation or erosion control. Typically pegs are specified every 2m for most applications, but this will vary depending on the ground conditions and application. Pegs should be used at joints where possible to secure adjacent layers together. Pegs are available directly from Concrete Canvas Ltd. in a range of sizes which are suitable for use with CC. The peg must have a sufficiently sharp point to penetrate the surface of the Canvas.

An alternative fixing method to pegging is to bury (anchor trench) the edges of the CC with soil or aggregate. This provides a means of both fixing the material down and also ensures that surface run-off does not undermine the CC. This is particularly suitable for ditch lining, erosion control and slope stabilisation applications. It also provides a more aesthetically pleasing finish.

Pegging

Burying CC Edges

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12 3

Water Proof Rating : ●●○○○ Water Proof Rating : ●●○○○Mechanical Strength : ●○○○○ Mechanical Strength : ●●●●○

Overlapping Concrete Canvas is the simplest method of joining 2 layers together. This is appropriate for the majority of ditch lining, erosion control and ground surfacing applications.

Overlapped joints should be compressed along the entire length while the material sets to ensure there are no voids between layers. This can be done using screws, sandbags, water weights, loose fill, staples etc. Overlapping CC will provide a moderate level of water proofing and is suitable for drainage applications. We recommend overlapping cut edges by a minimum of 100mm and sealed edges by a minimum of 50mm.

Water Proof Rating : ●●●○○Mechanical Strength : ●●○○○

Concrete Canvas can be joined and sealed by applying a bonding sealant between overlapping layers.

Concrete Canvas Ltd. can provide a recommended sealant which bonds to both the PVC backing and fibre surface of Concrete Canvas. A minimum bead size of 6mm should be applied along the length of the joint and the two layers firmly pushed together. The sealant works in both wet and dry conditions so can be applied before hydration or immediately after.

The bonding sealant will fully cure in 24 hours.

CC Non-Mechanical Fixings

Simple CC Overlap Simple CC Overlap (Screwed)

CC Bonding Sealant

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Water Proof Rating : ●●●●○Mechanical Strength : ●●●●○

Concrete Canvas can be joined and sealed by overlapping layers andapplying a grouting compound along the joint.

Concrete Canvas Ltd. can provide a bespoke cementious grout called CC Jointing Grout for use in drainage and ditch lining applications. CC Jointing Grout is based on the same cemetitious mix as Concrete Canvas to create a homogenous joint.

The use of other grouting compounds may retard setting time and reduce set strength, please contact Concrete Canvas Ltd. for further advice.

Grout should be applied after hydrating the two overlapped layers. Ensure that the bottom layer, including the overlapped area is properly hydrated.

CC Jointing Grout has similar setting characteristics to CC and initialset takes place after two hours.

After applying the grout, continue to hydrate as per CC hydration instructions, ensuring not to apply jets of water directly onto the joint to avoid washout of the grout.

Fig. 1 Recommended Minimum Coverage

CC Non-Mechanical Fixings cont.

CC Jointing Grout

When applying the grout, ensure that the coverage on each overlapping edge is at least twice that of the thickness of CC that is used. Also ensure the height of the grout is at least this thickness (see diagram above).

tt

t

2t

2t100mm

CC Layer 1

CC Layer 2

Grout

Fig. 3 CC8 over lapped joint with CC Grout



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The fibre surface of CC can be easily painted once set using standard exterior masonry paint. This provides a quick and simple method of improving the aesthetic appearance of CC. Alternatively, Concrete Canvas Ltd. can recommend a range of copolymer concrete surface treatments which can provide a coloured uniform finish as well as hydrophobic protection against staining and organic growth. Fire retardant paints have also been shown to be effective where thermal performance is critical.

Finishing

A white cement blend of Concrete Canvas is available on request subject to minimum volumes. This blend provides a brilliant white uniform finish and would suit architectural or decorative applications. Contact Concrete Canvas Ltd. for further information.

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© Concrete Canvas Ltd. 2012

Contact Concrete Canvas Ltd. (UK)

Concrete Canvas™ Material Data

Physical Properties*

Setting

Method of Hydration

Working Time 1-2 hours subject to ambient temperature

CC will achieve 80% strength at 24 hours after hydration.

Spray the fibre surface with water until it feels wet to touch for several minutes after spraying.

Re-spray the CC again after 1 hour if:- Installing CC5- Installing CC on a steep or vertical surface- Installing in warm climates

Notes:- CC cannot be over hydrated and an excess of water is always recommended. - Minimum ratio of water:CC is 1:2 by weight. - Do not jet high pressure water directly onto the CC as this may wash a channel in the material. - CC can be hydrated using saline or non-saline water. - CC will hydrate and set underwater.- CC has a working time of 1-2 hours after hydration. Do not move CC once it has begun to set. - Working time will be reduced in hot climates.- CC will set hard in 24 hours but will continue to gain strength for years.- If CC is not fully saturated, the set may be delayed and strength reduced. If the set is delayed, re-wet with a large excess of water. * Indicative values

Freeze-thaw testing (BS EN 12467:2004 part 5.5.2)

Soak-Dry testing (BS EN 12467:2004 part 5.5.5)

Water impermeability (BS EN 12467:2004 part 5.4.4)

Moisture vapour transmission ratePVC ThicknessPVC MVTR range

CC Static Head

Patent ProtectedPat Pend/Granted: AE (932/2006), AU (2005254788), BR (PI 0511408-0), CA (2570532), CA (2655054), EP (1766162), EP (2027319), GB (2455008), IN (20/DELNP/2007), JP (2007-516049), NO (20070245), RU (2386767), SA (12/303,864), US (7721749),US (US-2010-0233417-A1), WO 2010/086618, ZA (2007/0471), ZA (2009/00222) and other patents pending.

Strength

Other

Patent Information

Abrasion Resistance (DIN 52108)- Similar to twice that of OPC

MOHS hardness

CBR Puncture Resistance EN ISO 12236: 2007 (CC8 & CC13 only)- Min. Push-through force- Max. Deflection at Peak

Resistance to Imposed Loads on Vehicle Traffic AreasEN 1991-1-1:2002 (CC8 & CC13 only)- Category G compliant- Gross weight of 2 axle vehicle 30 to 160kN- Uniformly distributed load not exceeding 5kN/sqm

Standard Test Method for Impact Resistance of Pipeline Coatings ASTM G13 (CC13 only)

Very high early strength is a fundamental characteristic of CC.Typical strengths and physical characteristics are as follows:

Compressive tests based on ASTM C109 – 02- 10 day compressive failure stress (MPa)

Bending tests based on BS EN 12467:2004- 10 day bending failure stress (MPa)- 10 day bending Youngs modulus (MPa)

Tensile data

40

3.4180

2.69kN38mm

0.42 mm0.836 - 0.924 g.mm / (m².day)

Passed

Passed**

< 3000mm

Passed

Passed

Max 0.10 gm/cm2

4-5

Tensile strength (kN/m)Length direction Width direction

CC5 6.7 3.8CC8 8.6 6.6CC13 19.5 12.8


** For tanking applications where a 100% waterproof seal is required, it is recommended to use CC as a protective overlay in combination with an appropriate sealed membrane liner. CC is not recommended as the sole barrier layer where 100% impermeability is critical.

Reaction to FireCC has achieved Euroclass B certification:BS EN 13501-1:2007+A1:2009 B-s1, d0

Concrete Canvas Ltd. CF37 5SP, United Kingdom

11EN12467:2004Concrete Canvas:Fibre cement sheetNTOversize sheetsClass 1, Category AReaction to Fire B-s1,d0

© Concrete Canvas 2012

CC Thickness (mm)

Batch Roll Size (sqm)

Bulk Roll Size (sqm)

Roll Width (m)

CC5 5 10 200 1.0CC8 8 5 125 1.1CC13 13 N/A 80 1.1

CC Mass (unset) (kg/m2)

Density (unset) (kg/m3)

Density (set) (kg/m3)

CC5 7.0 1500 +30-35%CC8 12.0 1500 +30-35%CC13 19.0 1500 +30-35%


Address E-mail: [email protected] 3, Block A22, Phone: +44 (0) 845 680 1908Treforest Ind. Estate, Web: www.concretecanvas.co.ukCF37 5SP, UK

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