The installation of the system is generally in three easy steps;
STEP ONE is the set out and fixing of the support structure
STEP TWO is the fixing, cutting and joining of the Flexene sheeting
STEP THREE is the coating and finishing of the surface.
Screw fix the Flexene sheeting using zinc plated 8g 4Omm bugle head dry wall screws (eq. to Buildex) and UPVC washers (Rockcote) to the supporting structure or grid support points provided by the adjustable steel system. The Flexene sheets may be joined together to form a large area of Flexene before lifting and installing to the grid of fixing points or nodes. This large area fixing method allows the installer to determine the best location to form cuts and joins to “tailor” the surface configuration.
Joining the sheets can be achieved by heavy duty crimping staples equal to SW7437 STANLEY BOSTITCH at 5Omm ctrs or using the 9O x 3O perforated plate and screws with UPVC washers.
Large areas of Flexene may be temporarily spot screw fixed to enable more accurate detail fixing to follow. Generally set out from one point, line, floor or edge and adjust the sheeting progressively. Ensure allowance is made for “edge creep” when bending. During the sheeting process, adjustments to the surface shape and contour can be achieved by adjusting the rod on the adjustable clips.
Additional ( intermediate ) fixing points may be required to achieve special features, shapes or just to fine tune the surface contour.
COATING:
After the Flexene sheeting is fixed into the required position the surface is sanded off to remove projections forming a more uniform surface. Hand sanding on a block with medium grade paper will generally remove projections and also slightly roughen the Flexene surface to assist with extra adhesion for the following coats. The finished surface may be slightly flexible at this stage however it will become more rigid after the completion of the scratch coat or lock coat. The coating of render (plaster) may be by trowel or spray application.
Concealed service lines brackets and equipment such as lighting, power, data, water and sewerage etc. must be installed prior to the starting of the next stage. Ensure all service brackets and penetration points are accurately set out and documented for access at a later stage.
LOCK COAT (SCRATCH COAT):
After sanding the surface apply a coat of polymer render equal to Rockcote PM1OO or DULUX Renderwall 2001 to the entire surface. Be sure to force the coating into all grooves so that when cured the coating “locks” the Flexene surface together. Mix and apply in accordance with the manufacturers written instructions and allow to cure.
REINFORCED BASE COAT:
After the lock coat has cured the Flexene surface will generally be a more rigid surface of the required configuration. Modifications and alterations can also still be made at this point to improve the surface and shape if required. Repeat the previous stages as necessary.
Apply an even layer of render equal to Rockcote PM1OO or DULUX Renderwall 2001of 3-4mm thick and embed a layer of Rockcote alkali resistant fibreglass mesh (16Ogsm) overlapping joints MIN 1OOmm or in accordance with the manufacturers written instructions. Work with limited areas to prevent drying before completion. Leave roughened edges with protruding mesh to overlap the next segment of surface working area if work is stopped or left overnight.
FINISH COATING:
After the reinforced coating has cured apply a finish coat equal to DULUX Renderwall 2001or Rockcote PM1OO (MIN 3mm – MAX 10mm thick) to bring the finished surface to the required contour.
The thickness will vary depending on the imperfections in the previous coats. The surface can be finished with a wood or polystyrene float ready to accept a texture finish or floated and soft sponged ready for painting with an acrylic membrane.
Additional reinforced render layers may be required for high use areas to increase strength and durability. Concealed services (previously installed and located) may be installed through to the surface at this stage.
DECORATIVE FINISH:
After the finish coat has cured apply the selected acrylic decorative finish coat in accordance with the manufacturers written instructions.
An acrylic membrane equal to Rockcote Armour is applied in two coats to achieve a finished dry film thickness of 35O microns (min). External surfaces must be coated with a waterproofing membrane system equal to the Laticrete 9235 reinforced system before the decorative finish coats are applied. Make good all defective work and blemishes, install and adjust all fittings and fixtures to complete the installation.
