FORSPEC ACTFLEX FLEXIPLUG flexible joint and crack repair mortar, 10 kg kit
FORSPEC ACTFLEX FLEXIPLUG flexible joint and crack repair mortar, 10 kg kit
Forspec

FORSPEC ACTFLEX FLEXIPLUG Flexible Repair Mortar

$65.00 AUD
$65.00 AUD
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FORSPEC ACTFLEX FLEXIPLUG is a fast-setting, two-component elastomeric mortar for sealing joints, cracks, corner junctions and service penetrations. It bonds to prepared, damp concrete and forms coves, fillets and reglets within ACTFLEX 988 CWP and 989 CWP membrane systems. Its thixotropic consistency suits vertical and overhead detailing, with manufacturer-stated movement capacity up to 15%. Suitable for wet areas and structures requiring immersion after curing. Stop active flowing water with ACTFLEX HYDROPLUG first, then apply FLEXIPLUG to the prepared detail.
  • Flexible sealing for joints and cracks
  • Bonds to prepared damp concrete
  • Thixotropic for vertical and overhead details
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  • Two-component elastomeric repair mortar, mixed 1:1 by weight
  • Bonds to prepared, damp concrete without standing water
  • Thixotropic consistency for vertical and overhead detailing
  • Up to 15% joint movement, as stated by FORSPEC
  • FORSPEC membrane overcoating after 2 hours at 25°C and 50% RH
  • UV-stable, solvent-free and low odour; ventilation remains necessary
  • 1. Confirm the joint or repair detail and required movement with FORSPEC. Use sound, fully cured substrates. Remove dust, laitance, loose material, oil, grease, paint, coatings, curing compounds, efflorescence and release agents; mechanically prepare a clean, open profile.
  • 2. Stop active flowing water with ACTFLEX HYDROPLUG before applying FLEXIPLUG. Pre-wet concrete to saturated surface dry: damp, without standing or ponded water.
  • 3. Saw joints straight and square. General joint width is 5–50 mm. Below 15 mm width, depth equals width; at 15 mm and above, depth is half the width. Install closed-cell polyethylene backing rod 25% wider than the joint to control depth and prevent three-sided adhesion. Movement above 15% requires a FORSPEC-approved engineered detail.
  • 4. Mix equal weights of Part A resin and Part B powder. Add Part A to a clean container, then slowly add Part B while mixing at 400–600 rpm for 2–3 minutes. Rest 1 minute and re-mix briefly. Never add water, cement, sand or aggregates, and never re-temper.
  • 5. Mix only what can be placed within 10–15 minutes at 20°C; working time reduces to 6–8 minutes at 30°C. Apply only between 10°C and 30°C, ambient and substrate.
  • 6. Place by trowel, putty knife or suitable caulking gun, firmly compacting against joint walls and backing rod without voids. Wet-bond both sides of wider joints before placing the central material. Tool immediately with a trowel lubricated with soapy water.
  • 7. Corner details: prepare a minimum 15 × 15 mm rebate or the specified 35 × 35 mm diagonal cove for the FORSPEC membrane detail. Apply a thin bonding layer to both planes, compact additional material fully and tool to a dense finish.
  • 8. Penetrations: install backing rod where the annular gap exceeds 20 mm; below 20 mm place and compact directly as specified. Keep the sealing body at least 20 mm behind the surface line, fully embedded and recessed, never proud, with complete contact around the pipe.
  • 9. Chase cracks to a rectangular profile; use a V-cut only where rectangular cutting is impossible. Clean, maintain SSD, compact to full depth in lifts where needed, slightly overfill and tool flush.
  • 10. Protect fresh work from rain, condensation and water for 24 hours and from early impact, vibration and heavy loading. At 25°C and 50% RH, allow 2 hours before FORSPEC membrane overcoating, 8 hours for pedestrian access, 24 hours for vehicles and at least 72 hours before permanent immersion, with full cure confirmed. The detail must be set, dense, tooled and clean before coating.
  • 11. Clean tools promptly with water; cured material requires mechanical removal. Prevent dust inhalation and skin/eye contact, provide ventilation and use the protective equipment required by the SDS. Keep waste and washings out of drains and waterways.
  • Quantity calculation: for rectangular joints, kg = length (m) × width (mm) × depth (mm) × 0.00128. For triangular coves, halve the width × height cross-section. Add site-specific wastage, divide by the selected 2, 5 or 10 kg kit weight and round up. A 35 × 35 mm triangular cove uses approximately 0.784 kg/m, giving about 2.6 m, 6.4 m or 12.8 m per kit respectively before wastage.
  • Grey, two-component kits: 2 kg, 5 kg and 10 kg; equal weights of Part A and Part B
  • Mixing ratio: Part A : Part B = 1:1 by weight; no added water
  • Pot life: 10–15 minutes at 20°C; working time 6–8 minutes at 30°C
  • Initial/final set: 25–30/50–60 minutes at 20°C
  • Application temperature: 10–30°C, ambient and substrate
  • Joint width: 5–50 mm; depth equals width below 15 mm, or half-width at 15 mm and above
  • Overcoat: 2 hours; pedestrian access: 8 hours; vehicle traffic: 24 hours; permanent immersion: minimum 72 hours, at 25°C and 50% RH
  • Protect from rain, condensation and water for the first 24 hours
  • Rectangular joints: 0.00128 × width (mm) × depth (mm) = kg/m
  • Shelf life: 24 months unopened at 5–30°C
  • Performance figures are FORSPEC characteristic values; the TDS states no accredited test reports currently exist
Technical Data Sheet Safety Data Sheet Installation Guide Warranty Information

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Technical Specifications

Key technical properties of this product. Refer to the Technical Data Sheet for complete installation and performance information.

ClassificationTwo-component elastomeric repair mortar; no accredited classification claimed
Mixing RatioPart A : Part B = 1:1 by weight; do not add water
CoverageRectangular joints: 0.00128 × width (mm) × depth (mm) kg/m. 35 × 35 mm triangular cove: approx. 0.784 kg/m, before wastage.
Hydrostatic ResistanceUp to 10 m water head, positive or negative; FORSPEC characteristic value, not accredited testing
Elongation at Break12–18%; FORSPEC characteristic value on ASTM D412 basis, not accredited testing
Tensile Strength2.5–3.5 MPa; FORSPEC characteristic value on ASTM D412 basis, not accredited testing
Recoat TimeFORSPEC membranes: 2 hours at 25°C, 50% RH, once detail is set, dense, tooled and clean
Suitable SubstratesPrepared concrete, masonry, ceramics, PVC and metals; concrete must be SSD without standing water
Movement CapabilityUp to 15%, manufacturer-stated; greater movement requires an engineered detail
Water ExposureProtect for 24 hours; permanent immersion after minimum 72 hours at 25°C, 50% RH
View Technical Data Sheet

ACTFLEX FLEXIPLUG FAQs

Can FLEXIPLUG stop active flowing water?
Stop active flowing water with ACTFLEX HYDROPLUG first. Then prepare the detail and apply FLEXIPLUG as the flexible sealing mortar. Apply to damp, saturated-surface-dry concrete without standing water. Protect the fresh repair from rain, condensation and water exposure for the first 24 hours.
How do I mix ACTFLEX FLEXIPLUG?
Mix Part A resin and Part B reactive powder in equal weights, 1:1. Put Part A into a clean container and slowly add Part B while mixing at 400–600 rpm for 2–3 minutes. Rest for 1 minute and re-mix briefly. Do not add water, cement, sand or aggregates, and do not re-temper. Pot life is 10–15 minutes at 20°C and working time is 6–8 minutes at 30°C.
How much FLEXIPLUG do I need for joints or coves?
For rectangular joints, consumption in kg per lineal metre = 0.00128 × joint width (mm) × joint depth (mm). Multiply by total length, add a site-specific waste allowance, divide by the selected kit weight (2, 5 or 10 kg) and round up to whole kits. For a triangular cove, halve the width × height cross-section. A 35 × 35 mm diagonal cove consumes approximately 0.784 kg/m, giving about 2.6 m, 6.4 m or 12.8 m per 2, 5 or 10 kg kit before wastage. Joint dimensions must follow the TDS and project detail.
When can FLEXIPLUG be overcoated or immersed?
At 25°C and 50% RH, allow 2 hours before FORSPEC membrane overcoating, with the detail set, dense, tooled and clean. Allow 8 hours for pedestrian access, 24 hours for vehicle traffic and at least 72 hours before permanent immersion, with full cure confirmed. Protect from water exposure during the first 24 hours. These are manufacturer-stated times and depend on site conditions.
What joint sizes and movement can FLEXIPLUG accommodate?
The TDS specifies joints 5–50 mm wide. Below 15 mm width, the mortar depth equals the width; at 15 mm and above, depth is half the width. Use closed-cell polyethylene backing rod sized 25% larger than the joint width to control depth and prevent three-sided adhesion. Manufacturer-stated movement capacity is up to 15%; higher movement requires a FORSPEC-approved engineered detail. Confirm joint width with FORSPEC before application.

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