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Aug. 26, 2024
Why choose a Fibreglass (GRP) lining for concrete?
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Concrete is an industry-standard material for many building projects. However, as a porous material concrete is not ideal for waterproofing or water containment. Indeed, extended exposure to water often leads to drastically shortened lifetimes particularly in environments subjected to abrasion, impact and general wear and tear.
Fibreglass (GRP) linings and coatings provide a significant benefit to concrete surfaces and structures. They provide waterproofing, chemical resistance, abrasion and erosion resistance. They also provide protection from physical impact and stress, making them suited to a huge range of applications. Fibreglass (GRP) also bonds extremely well to concrete, making it an excellent substrate for such applications.
Concrete Surfaces: Applications of Fibreglass Linings & Coatings
Linings are designed to protect the internal contents of a structure (such as fish in a pond or drinking water in a storage tank) from leaking or being contaminated by external pollutants from ground soil and porous substrates.
Typical applications of a fibreglass lining or coating include waterproofing for ponds, walls and floors of shower rooms, wetrooms, spray-down rooms, and animal storage rooms. More specialist features centre on chemical containment spill bunds, potable water features, gutters, gullies, storage tanks and drainage channels.
Fibreglass is a high-performance waterproofing barrier. Designed to bond strongly to concrete, it offers protection from liquids and other external stressors like abrasion, impact, UV solar, vegetative growth and aggressive chemicals. Another key benefit of fibreglass is that it can be coated in a variety of topcoat resins, allowing a variety of different pigments and additives (non-slip grit, flame retardants, etc.).
The video below shows a simple overview of the process used to apply a fibreglass covering to concrete. Please note that no surface preparation namely abrasion has not been performed.
The following section provides a detailed guide on how to apply fibreglass to concrete. The first part of this guide details the type of concrete which may be used, its condition and any preparation work which may be required.
In short, concrete must be sufficiently stable, clean, dry and uniform with an absence of excessively rough or sharp edges prior to fibreglassing.
Health & Safety
Fibreglassing, like any other building work, is dangerous and cautions should be taken to ensure a safe working environment is created. The table below shows some of the safety equipment which should be used.
Table 1. Personal Protective Equipment (PPE)
Safety ItemDescription GogglesGlasses offering protection for eyes from hazardous liquids and objects Dust maskProtection from inhaled particulates that may be made during work - particularly during preparation, such as grit blasting or sanding. Chemical maskSpecialist mask designed to protect from the inhalation of hazardous chemicals. Usually used in enclosed or poorly ventilated spaces. Nitrile glovesChemically resistant gloves offering short-term protection for users working with chemicals. Gripper glovesThicker gloves worn when working with glass fibre matting.Please note that the above table is specific to fibreglass (GRP) work. Additional steps may be required for concrete preparation. Working with concrete can cause health problems, so please take care.
Types of Concrete
The type of concrete used can determine the extent of preparation work required. Recommendations on the preparation of concrete for fibreglassing are presented in Table 2.
Table 2. Types of Concrete
TypeDescriptionRecommendation Breeze BlocksEnsure joints are filled in. Apply layer of cement render.Ensure joints are filled in. Apply layer of cement render. Cement RenderCement-based covering applied to base substrate.Allow to dry. Check moisture levels (See Table X). ScreedCement and sand-based coating applied to base substrate.Allow to dry. Check moisture levels (See Table X). Use concrete Existing concreteMay be aforementioned concrete or equivalent.See Table X.1. Concrete Preparation
Before applying fibreglass to concrete, the concrete itself must be amenable to bonding. Loose debris, residual grease, paints and dirt can all interfere with bonding, as can moisture. The surface should present itself as being clean, dry and mildly roughened. A variety of methods are presented in Table 3.
Table 3. Concrete Preparation Methods
MethodDescriptionMicrocracking RiskSkill Level SandingInvolves moving a roughened sheet (sand paper) across the surface to remove surface contaminants, producing a smoother, cleaner surface depending on the paper roughness. Performed by hand for smaller areas or via a rotating disc for larger or more demanding ones. NoneLow GrindingGrinding removes laitance, protrusions, surface contaminants and produces a smooth or polished surface, depending on the roughness of the abrading discs.Note: safety is a big factor here. Care should be taken to avoid exposure to dust and debris via inhalation (use a dust mask), eyes (wear safety goggles) and skin (sharp debris can penetrate the skin).
2. Allow the Concrete to Dry
Unless the concrete is confirmed to be dry, take care to confirm that it has a low moisture content. Fresh concrete is notorious for high levels of moisture and can take 4 6 weeks to fully dry without accelerated drying. Likewise, it is also possible that existing concrete has been contaminated with water or other chemicals. Moisture itself interferes with chemical bonding, particularly for resins and adhesives.
Table 4. Dealing With Moisture in Concrete
ConditionDescriptionPreparation DrynessPrimer required? Existing/DryConcrete is dry and free from sharp edges. It has a good level of roughness.Mild abrading may be required to ensure adequate roughness and the removal of sharp edges. Remove dust/debris.75% relative humidity as per BSYes Fresh/NewDamp, wet or generally recently laidAllow to dehydrate. Use abrading method to shape and remove sharp edges. Remove dust/debris.Yes DamagedCracks, sections missing, splitsRepair cracks and damaged sections. Allow to dry before sanding/abrading. Remove dust/debris.Yes Damp/MoistConcrete has water ingress or moistureRemove source of moisture. Allow to dry out for an extended period. Remove dust/debris.Yes Contaminated Dirt, grease, chemical staining, vegetative growth, etc. Jet washing and abrading (e.g. sanding) may be required to ensure cleanness and adequate roughness and the removal of sharp edges. Remove dust/debris.YesNote: BS Screeds, bases and in-situ floorings details codes of practice related to concrete floors and bases.
Note: to avoid interference with bonding, the concrete should have low levels of moisture. Advice on moisture levels for a standard concrete floor varies according to the measurement system used and the type of concrete. Two tests are available for concrete moisture measurements: the calcium chloride testing and concrete moisture meters.
3. Concrete Repairs
If repairing concrete, cracks may be present on the surface. These should be identified and repaired in advance, prior to any coating with resin. They may need to be smoothed down once cured to create a more uniform surface. Some surface grinding or sanding may be required in this instance.
Note: fibreglass this includes spray-based lay-up applications of creating a composite, often seen in composites used in the aerospace industry and wet-layup installation methods of creating a composite, often used in civil engineering and building industries. This wet layup method is similar to a hand lay-up, which is commonly used on concrete and other surfaces during in-situ application.
4. Clean the Surface: Remove Dust and Debris
Once surface grinding or blasting has been performed, there is likely to be a degree of dust and debris. These should be removed to create a clean surface amenable to resin adhesion. Excess dust will prevent strong adhesion between the GRP and surface, so care must be taken to remove it.
Note: again consider dust protection for your eyes, skin and airways, as outlined above.
5. Primer Application
Concrete is porous and has small cracks by default. The polyester resin used in the laminate is fairly viscous and cannot easily penetrate small pores and cracks. It is preferable to apply a layer of less viscous resin in advance. Whilst this is optional, it does enhance the adhesion of the polyester resin to the concrete. Primer also acts as a moisture-curing layer which also blocks external contaminants from coming into contact with the fibreglass laminate. The primer should be applied using a paintbrush at smaller scales or a foam roller at larger ones.
Quantities of primer required for concrete surfaces are detailed in Table 5.
Table 5. Primer Quantities
PorosityPrimer Coverage (kg per m2)ToolNote Low Porosity0.25 Polyester rollers (larger areas) or a resin brushes (smaller/complex areas) recommended. If porosity is low, coverage should require less primer, since it will adequately cover the surfce. High Porosity>0.5If porosity is high, then more primer is required, since the liquid will enter into the pores.This section details the laminating and topcoating procedures needed to create a fibreglass covering.
If you would like to undertake this work yourself, Resin Library offers a range of fibreglass kits. These kits include both materials and tools required to undertake work across a range of sizes. These include repair kits and roofing kits.
1. Pre-Cut Glass Fibre Matting
The next step is to size and cut the CSM. Concrete protection made from GRP typically requires more robust protection. In most instances, 450 or a 600 gram CSM is recommended. Applicators should cut and size the CSM into manageable sections that fit the designated area. For concrete floors, these should be larger than small repairs. In all instances, the CSM should exceed the area to which it is being applied.
Table 6. Laminate Thickness
DesignDescriptionApplications 1 x 450 gram CSM1 layer of 450 gram glass fibre mattingThin fibreglass flat roofing membrane not suitable for low-level foot traffic. Low-cost flat roof option for sheds and other buildings not expecting foot traffic. 1 x 600 gram CSM1 layer of 600 gram glass fibre mattingStandard flat roofing membrane for low-to-moderate level foot traffic. Flat roofs expecting window cleaners and gutter cleaners. Commonly used on property extensions, garages, orangeries, factories, apartments etc. Suitable for green sedum roofing. Able to tolerate some equipment placement (e.g., air conditioning units). 2 x 450 gram CSM2 layers of 600 gram glass fibre mattingReinforced flat roofing membrane for moderate level foot traffic. Flat roofs expecting window cleaners and gutter cleaners. Suitable for green sedum roofing. Able to tolerate equipment placement (e.g., air conditioning units). 2 x 600 gram CSM2 layers of 600 gram glass fibre mattingReinforced flat roofing membrane for moderate-to-heavy level foot traffic. Flat roofs expecting window cleaners and gutter cleaners. Also balconies, walkways and terraces. Suitable for green sedum roofing. Able to tolerate equipment placement (e.g., air conditioning units).Note: overlapping sections of the CSM requires a level of skill and understanding. This is to ensure that the laminate remains a seamless barrier.
2. Laminate the Glass Fibre
Mix the resin with catalyst and use a polyester roller saturated in this mixture to disperse and drive it into the mat.
Table 7. Resin Quantities per Laminate Design
Laminate DesignGlass Fibre MattingNumber of layersResin Weight per LayerTotal Resin Weight Single Layer450 gram11.1 - 1.3 kg/m21.1 - 1.3 kg/m2 Dual Layer22.2 - 2.6 kg/m2 Single Layer600 gram11.5 - 1.7 kg/m21.5 - 1.7 kg/m2 Dual Layer23.0 - 3.4 kg/m2Note: ensure that the resin-catalyst mixture is carefully but fully mixed. Avoid excessive air bubbles but ensure that the catalyst has been fully dispersed into the resin. Excess air causes bubbles, which weaken the laminate.
Caution: this step should be performed when the weather is dry; water and even low levels of moisture interfere with the curing process. If in doubt, it is better to wait until there is a dry spell.
Note: freshly catalysed resin should be used immediately. Once the catalyst has been added to the resin, it will lose its adhesive and waterproofing capabilities.
3. Consolidate the Laminate
Then use a paddle roller to consolidate the laminate, refining the laminated surface and forcing air bubbles and excess resin out. This is important since air pockets create structural weaknesses in the composite a major cause of defects.
Are you interested in learning more about sourcing fiberglass mesh waterproofing? Contact us today to secure an expert consultation!
4. Allow Laminate Curing
Once the laminate has been consolidated, allow it to harden or cure. This allows time for the resin to crosslink and create a strong structure.
Recommended time: 24 hours (winter) and 12 hours (summer).
5. Prepare Resin Topcoat
Once the laminate has hardened, prepare the topcoat. This involves mixing it with a catalyst and a dye to add colour using a similar process to that used for the polyester resin. For flooring applications, such as those used on terraces, walkways, balconies and in wet or slippery areas, a non-slip coating is desirable. This involves adding a set amount of non-slip aggregate into the topcoat during the mixing process.
Table 8. Concrete Preparation Pre-Fibreglassing
CuringHot weatherWarm weatherCool weatherCold weather Catalyst (%)1 (%)2 (%)3 (%)4 (%) Resin Weight (kg)MEKP Catalyst Volume (mL) 110 mL20 mL30 mL40 mL 220 mL40 mL60 mL80 mL 330 mL60 mL90 mL120 mL 440 mL80 mL120 mL160 mL 550 mL100 mL150 mL200 mLNote: the size of the grit should be selected according to the purpose: for swimming pools where bare feet are common, a finer grit is recommended. Conversely, for
Note: refer to the manufacturers instructions to obtain the optimum amount of non-slip grit per volume of topcoat. Ensure that the grit is well mixed before application.
6. Topcoat Application
Pour a single layer of topcoat resin onto the laminated concrete surface. Take care to avoid applying too much as this will create a brittle outer surface. At the same time, ensure there is adequate resin to cover the glass fibre CSM laminate. Use a foam roller to disperse the topcoat over larger surface areas.
Table 9. Topcoat (Flowcoat Application)
Surface Area (m2)Topcoat Weight (kg) 10.5 21 31.5 42.0 52.5Note: refer to manufacturers instructions for specific quantities of resin per square meter of laminate.
Once the topcoat has been applied, provide adequate time for it to cure and harden. Average cure times range from 2 12 hours (summer) to 24 hours (winter). This can vary from project to project.
Fibreglass linings and coatings have many applications. Weve tried to answer some of these below.
Q. How do I fibreglass a concrete pond?
A. The same procedure as outlined above can be applied to create a fibreglass pond lining.
Q. What is the procedure for fibreglassing concrete?
A. The video below provides an excellent overview on how to create a fibreglass coating for concrete.
Q. What is the best method for measuring concrete moisture levels?
A. Moisture meters are more precise and accurate than calcium tests, which are generally cheap, quick and easy to perform, although less accurate. A more detailed overview of moisture meters has been discussed.
Disclaimer: please note that the information on this site is for general informational purposes. Resin Library is not liable for any outcomes. Please consult professional advice in advance of conducting any work.
If you are having basement seepage and are thinking of installing Interior Drain Tile to keep your basement dry, here are 12 questions you need to ask any contractor whos offering you a solution. These questions will help you discover critical information about the contractor, their solutions and services so you will be well prepared to make a smart buying decision.
12
Questions To Ask Before You Buy Drain Tile
1. What other solutions do you offer besides Drain Tile and why wont they work as well for me?
This question is important because some companies plan to recommend Interior Drain Tile before they even meet you. Their recommendation isnt based on your needs, its based on theirs. So ask them what other options they have for you. Full service waterproofing companies have a variety of effective and complementary ways to correct seepage problems that dont require drain tile.
2. Is your interior drain tile system maintenance free?
A properly designed and installed Interior Drain Tile system doesnt require regular maintenance. You put it in and it works. Some companies install inferior products prone to clogging; then they install cleanouts and offer services to flush out the system. Their return visits are designed as a way to get back into your home to sell you even more services. Be leery of systems requiring maintenance as part of their design.
3. Do you offer a pre-installation walk-through to prepare me for the project?
The installation of Interior Drain Tile is major surgery for your basement. During the initial visit most customers are concerned more with the solution, how soon it can be installed and of course, cost. They arent typically prepared to discuss the logistics and necessary preparation for the job. Thats why we include this walk-through. Weve learned a second visit helps you satisfy questions and concerns you may not have thought about during our first visit.
4. Can you provide me with a list of referrals youve done in my neighborhood in the last few years?
Asking for these referrals will let you talk to a companys previous customers to hear firsthand how their project was handled. When you get the referrals, take advantage of them. Talking to referrals is your best source of unbiased information about a company and how they operate. Make sure the company has done several jobs in your neighborhood.
5. Do you have online reviews I can read?
Another great way to learn about a company is to read their customers reviews on the Internet. There are sites like Yelp, BBB, Angies List, and even Google has reviews. And while youre at Google, another way to dig up dirt on a company is to search the company name, then include a word after it like problem, complaints, scam or ripoff.
When youre reading reviews keep two things in mind; the number of stars and the number of reviews. The average number of stars gives you a preview of how satisfied you can expect to be when working with a company. But also consider the number of reviews. A small number of reviews can indicate that the company is new to the industry or has only a few customers. Any of these should be a yellow flag that you should practice caution when relying on them for expert advice or years of support after the sale.
6. What is the warranty on the solution you are installing for me?
Warranties can be misleading by design. They are used by some honest businesses to reassure you the product you purchase will perform as promised, or it will be fixed if it doesnt. They are also used by shady businesses and manufacturers to give you a false sense of comfort. These are the warranties that seem too good to be true. For example: mechanical pumps with lifetime warranties that will give you unlimited replacements for free after the buy the first one. And then there are the drainage systems that will be serviced for centuries to come, as long as a structure is still standing. These are smoke screens used to distract you so you dont look closer at what youre actually buying. The truth is this. Buy a solution as if it didnt come with a warranty. That way you wont be distracted by the warranty terms and you will spend more time looking at the quality of what youre getting and whos providing it.
NOTE: Waterproofing companies offer a warranty, not a guarantee. What that means is they promise to come back to fix it, but wont pay you if their system fails and causes damage.
7. What kind of sump pumps are you installing?
Basement drainage systems intercept water that wants to get into your basement. It then feeds that water into a basin where a sump pump removes it and the process starts again. The heart of the system is your sump pump. Some companies make the price of their systems lower for unsuspecting homeowners by using inferior plastic pumps that cant properly pump larger volumes of water. Dont be fooled. When the dryness of your basement relies on a pump, dont settle for plastic. Insist on a cast iron primary pump. And ask for a battery backup pump also. Having two pumps with one able to use battery power is cheap dryness insurance for your basement. Remember, pumps are mechanical so you know at some point they will fail. So will the power coming into your home during heavy storms. Dont be caught without a working pump when you need it most!
8. How are disputes resolved if there is an issue with your work?
As much as reputable companies try to do their best, there are times when disputes may arise. When that happens, its important to know your choices for finding a remedy. Can you hire your lawyer and take them to court? Its good to find this out ahead of time because there is at least one waterproofing company that forces you into binding arbitration in order to decide the outcome of their disputes. Going this route can cost thousands of dollars and if their arbitrator rules in their favor, you can also get stuck paying their expenses for the arbitration.
9. Do you offer handyman services to help prepare my basement for the project and put it back together?
Knowing this is helpful because you may have carpeting, drywall, or a washer / dryer that is in the path of where the drain tile will be installed. And while its possible to hire a local handyman to do this prep work, coordinating his schedule with the waterproofers could prove to be difficult. Plus your handyman (if you are lucky enough to find one who will call you back and show up when they promise!) may not know all that is needed to completely prepare your basement, causing potential delays in getting your project started.
10. If I think I have a problem after the installation, will I be charged for the return service call?
While its not common, theres always a possibility that the problem you tried to fix happens again. Sometimes this is a fault in the new system, especially if the work was done incorrectly or you were sold an inferior or imitation drain tile system. At times the continuing problem isnt related to the new system at all, but rather a secondary problem that still exists such as a leaking water heater or furnace. So how do you know? Your first option is to have your waterproofer return to help you determine the source of the problem. Just make sure you pick a waterproofing company who will come back without charging you more if the problem doesnt turn out to be your new system.
11. What type of design is your drainage system?
Experienced waterproofers know that the most efficient way to transport foundation water is through a round drainage piping system positioned next to the footing at the base of the foundation wall. Some companies have designed less effective, but easier to install systems that sit on top of the footing. Others repurpose lawn drainage systems or use a series of mini-tubes in an effort to win business from their systems uniqueness. The problem with all of these unconventional systems is they do a better job at making a profit for the contractor than keeping your basement dry. So make sure you know what companies mean when they use the generic term drain tile to describe their drainage system.
NOTE: Round drainage piping comes in two basic types (PVC and Corrugated) that both do the job well. So dont believe the tired argument that has long since been disproven, that one is stronger and one is prone to collapse.
12. Is your drainage pipe wrapped in a fine mesh, filtration fabric?
One of the simplest, but most important components of a properly designed and installed basement drain tile system is the filtration fabric that is the last line of defense for keeping dirt out of your drain tile and ultimately your sump pumps. When it is not used, it significantly increases the dirt and grit that enters your system which significantly decreases the life of the system. We know because weve replaced many drain tile systems installed by other companies that were only a few years old but were installed without this filter fabric.
There is one more question, and this is one you need to ask yourself
13. How much are you prepared to invest to keep your basement dry?
Too often we see homeowners who use price to guide their solution and ultimately they fall short of all what they truly need.
Remember what John Ruskin said:
Its unwise to pay too much, but its worse to pay too little. When you pay too much, you lose a little moneythats all. When you pay too little, you sometimes lose everything, because the thing you bought was incapable of doing the thing it was bought to do.
At U.S. Waterproofing we are here to help you make an educated decision and welcome you asking us the 12 questions above as well as any others you might have about our company or our solutions.
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