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Controlled
Permeability
Formwork (CPF)
liners for high
quality durable
concrete surfaces
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Zemdrain®
Summary of Contents

Properties and actions

Why use? ...............................................................................................................Page 4
Improving the concrete cover zone .........................................................................Page 5
How it works .............................................................................................................Page 6
What it does..............................................................................................................Page 7
Visible Benefits ..........................................................................................................Page 8

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Measurable Benefits................................................................................................Page 10

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Impact of formwork .................................................................................................Page 12
Impact of cement types ..........................................................................................Page 13
Impact of admixtures & mix strength .......................................................................Page 14
Impact of coatings & penetrants..............................................................................Page 15
Performance with time ............................................................................................Page 16
Performance in extreme / harsh climates.................................................................Page 17
The economic benefits of using...............................................................................Page 18

Practical applications:
Zemdrain® MD or Classic ........................................................................................Page 19
Transport / Marine / Waterway Structures ...............................................................Page 20
Potable Water / Wastewater Structures...................................................................Page 21
Practical applications on formwork..........................................................................Page 22

Tender specification clauses and product range

Specification clauses...............................................................................................Page 24
Zemdrain® MD product range ................................................................................Page 25
Zemdrain® Classic product range............................................................................Page 26

Instructions for use

Technical Guidelines ................................................................................................Page 27
Fixing details - Zemdrain® MD ...............................................................................Page 28
Fixing details - Zemdrain® Classic ...........................................................................Page 29
Frequently Asked Questions....................................................................................Page 30

Reports:
Test certificate / report summary .............................................................................Page 31

Zemdrain® is DuPont’s registered trademark.

www.zemdrain.com

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Zemdrain®
Why use?
The outer surface (up to 20 mm)
is usually the poorest quality
concrete in the structure due to
“process“ problems(1).
Problems that can arise due to the use
of oiled impermeable faced formwork
and to workmanship include:
■ excess air and water trapped at the
formwork /concrete interface
■ reduced cement contents
■ surface contamination
■ improper / ineffective curing
■ insufficient cover
(2)
Air trapped at the surface results
in blowholes and pinholes. Although
attempts are made to fill these in, over
the longer term they reappear and look
unsightly.
Water (2) trapped at the surface can
cause other blemishes:
■ a weak surface laitence
■ segregation
■ scouring
■ bleeding
■ some forms of cracking
4
Water gain(1) in the outer 20 mm of
the surface leads to an increase in
w/c ratio and a decrease in cement
content.
Decreases in cement content of up
to 40 kg/m3 have been measured,
irrespective of mix strength, cement
type, admixture use or formwork orien-
tation.
The resulting surface has higher porosi-
ty and is more liable to degradation
from abrasion, acid attack and other
aggressive elements
Release Agents(3) prevent full hydra-
tion of the surface concrete, with
dusting a sign of incomplete hydration.
Residues of biological release agents
contaminate the concrete surface and
encourage bacterial growth in all
wet/dry environments.
The performance of coatings and pe-
netrants can also be reduced by these
residues.
Curing(4) is beneficial in improving the
performance of the cover zone concre-
te to a depth of 20 to 50 mm.
Properties imporved by curing:
■ resistance to dusting
■ resistance to abrasion
■ risk of cracking reduced
■ reduced surface porosity
Curing is rarely carried out correctly. It
is often not applied early enough and
for too short a period.
Higher surface porosity due to the
water gain from the use of oiled imper-
meable faced formwork causes an
immediate loss of moisture on form-
work removal. The result is reduced
concrete performance.
Insufficient Cover(5)
Several extensive surveys have shown
that deficiencies in cover of over 15 mm
are common. The need for high quality
surfaces is therefore very important.
The reality is that the outer 20 mm of
the concrete surface is the poorest in
the structure. The combination of redu-
ced cover and poor quality concrete
ensure a reduced structural life in any
aggressive environment.
The Solution: The use of Zem-
drain® CPF liners to overcome the
majority of “process“ problems.
Zemdrain®
Improving the concrete cover zone
Zemdrain® use results in improved
quality and durability of the cover
(16)
zone concrete . cing a virtually blemish free, dense,
By replacing oiled plywood and steel as
the formwork face contact material,
Zemdrain® overcomes many “process“
problems by:
■ removing excess air
■ removing excess water
■ not using release agents
■ acting as a curing membrane
Using conventional formwork
Concrete formed with Zemdrain® offers the following benefits:
■ surfaces free of blowholes and
other blemishes
■ increases in cement content
of up to 100 kg/m3 in the outer
20 mm of the surface
■ decreases in w/c ratio
■ surfaces that are hostile to
growth of microorganisms
■ durability benefits equivalent
to an extra 15 - 20 mm of cover
The resulting concrete surface is of
higher quality and more resistant to all
aggressive elements such as chloride
salts, carbon dioxide acidic water and
freeze/thaw action.
Laboratory and in-situ testing has
shown Zemdrain® to be effective with
all concrete grades, cement types, ad-
mixture types and to work irrespective
of formwork orientation and height of
pour. Zemdrain® use in hot climates is
also very beneficial, particularly the
curing benefits(7).
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Using Zemdrain®
■ a well cured surface
■ release agents are not used
■ minimal formwork cleaning costs
■ liner can remain on concrete
surface to protect from dirt and
damage
■ longer service life of highly-
loaded concrete structures
■ significant reduction in upkeep
costs for structures
Zemdrain® formwork liners provide a
simple and effective method of produ-
low permeability cover zone. The result
is increased protection of the steel
reinforcement and the concrete core
from attack by aggressive elements.
Recent research(8) has concluded that
if a CPF liner is used correctly, the
resulting durability benefits can be
equivalent to having an extra 15 mm to
20 mm of cover.
The result is a virtually blowhole-
free, low porosity, uncontaminated,
high quality concrete surface which
is highly resistant to aggressive
environmental agents
■ provides an ideal surface for
coatings without the need for
preparatory work
■ reduction in costs which arise
due to operational downtime
caused by refurbishment of
structures
■ improvement in concrete
appearance
■ the use of less expensive
concrete mixes is feasible
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Zemdrain®
How it works

Zemdrain® acts as the formwork face
(9)
contact material . Both sides of the
formwork liner are different and have
unique functions.
The formwork side has a drainage/
storage function. It ensures that air and
excess water are collected at the
contact surface with the formwork and
are removed using a textured surface
with coarse fibres or a grid.
20 mm of the cover zone. This encour- The result is a denser, more compact
ages quicker and more complete and more durable concrete cover zone,
hydration of the cement with reduced which protects the concrete core
pore formation. The resulting higher and the reinforcement from attack by
concentration of fine constituents and aggressive elements.
cement reduce surface porosity and
the formation of blowholes.
Vibrator
Formwork Panel

The concrete side, with its controlled

pore structure, retains the cement
fines, which leads to a denser and
Concrete
less porous surface. Zemdrain® only
permits removal of excess quantities of
water and air, and there is no vacuum
effect. Water removal is by gravity, Enlargement of the filter layer which
ensuring an ideal w/c ratio in the outer Zemdrain ® retains the cement particles.

Conventional formwork w/c ratio

Air and excess water in the concrete
are expelled to the formwork surface
Formwork without Zemdrain®
0.7
by vibration energy. The result is
blowholes, other surface blemishes,
W

an increased w/c ratio and decreased

it h
ou

cement content in the concrete cover

Ze
t

zone. It is easier and quicker for harm- m

dr
a in ®
ful substances to penetrate this more
Formwork face

- in
porous concrete. Aggressive agents cre
a sin
can begin their destructive work earlier gw
/c ra
ti o
and more intensively.
0.5 w/c = 0.5
®
Zemdrain ti o
Formwork with Zemdrain® w /c ra
sin g
Zemdrain® CPF liners remove excess rea
ec
water and air from the concrete sur- ® -d H2O: excess water taken up
a in
face in a controlled manner. Cement dr
em
fines are retained at the surface. The
Z
ith

result: an almost blemish free and low

W

H2O: water required for hydration

porosity surface with significantly redu- given back
ced w/c ratio and increased cement w/c = 0.4
content. The dense, hard, low perme- Formwork with Zemdrain®
ability concrete in the outer cover zone
gives improved protection to the rein- Concrete Cover

forcement.

6
Zemdrain®
What it does
The fine pore structure of the Zemdrain®
filter facilitates removal of excess water
from the surface zone during and after
vibration. The quantity of water removed
will be a function of initial w/c ratio, any
admixtures used, type of cement and
vibration efficiency. Tests carried out
worldwide confirm this conclusion.
Water removal and the water/
cement ratio
Reductions in w/c ratio of 0.05 to 0.25
are common with between 0.3 and
2.0 litres/m2 of water drained off. The
greater the initial w/c ratio of the mix,
the greater will be the quantity of water
removed.
Absorbency and Drainage
Too much absorbency and too little
drainage capacity can reduce the effec-
tiveness of a formwork system:
■ absorbent timber can remove only
0.2 litres/m2 of water on first use.
Further uses cause pores to block,
reducing drainage. This type of tim-
ber is not effective in this application.
■ thick fleece liners absorb around
0.8 litres/m2 of water. Such a small
amount of water can already be
absorbed by a fleece liner prior to
concreting due to for example light
rainfall.
Excess water drained out by Zemdrain® is evacuated to the outside via the formwork.
■ Zemdrain® liners have low absorb- a dense and compact concrete cover
ency, relying upon vibration and con- with a high pH-value.
crete head to force out excess water.
Classic requires positive drainage, Mass ratios
while MD has enough capacity TU Munich tests
Mass ratios in 12 cm test wall
(1.5 litres/m2) to function without with/without Zemdrain®
w/c value
drainage for most mixes. 0.6
Does the weather influence 0.5
®
Zemdrain performance?
0.4
In contrast to absorbent timber
and thick fleeces, the weather 0.3
cement/sand
has no influence on the way
Zemdrain® performs, which al- 0.2
ways remains the same.
0.1
Any water resulting from rain
showers immediately before 1 2 3 4 5 6 7 8 9 10 11 12
concreting is not absorbed Distance from surface (cm)
by Zemdrain®, so that its full With Zemdrain® Without Zemdrain®
water-draining capacity is still
Denser concrete boundary zones
available for the excess water
The ideal ratio of water to cement en-
in the concrete.
courages quicker and more complete
Water will only pass through cement hydration. As there is minimal
Zemdrain® under the influence excess water available, there are few
of concrete pressure and vibra- pores remaining after evaporation. The
tion.
result is a high concentration of fine
constituents and cement and thus a re-
Higher cement concentrations on duction of porosity.
the surface
Removal of the excess water leads to a Petrographical images
flow of cement particles which concen-
trate in the surface zone, thus forming
Without Zemdrain® porous texture
With Zemdrain® denser structure
7
Zemdrain®
Visible benefits

Surface Hardness(3,8) The problem: Vibration moves air and

water to the formwork face. The resul-
ting concrete surface is weak and
porous.
Such concrete surfaces are liable to
degradation from abrasive action. They
also require costly preparatory work
prior to coating application.
Benefits of Zemdrain®
By removing the excess air and
water, an optimum w/c ratio is
achieved in the cover zone. Com-
plete hydration of the cement re-
sults in a surface with increased
hardness and tensile strength.
The dense, blemish free surface
provides an ideal base for coa-
tings without extensive substrate
preparation.

Carbonation(3,8,13,20)
The problem: Carbonation reduces
the alkalinity of the concrete, removing
the protection to the steel. Carbonated
concrete encourages quicker pollutant
entry and results in reduced concrete
durability.
The rate of absorption of carbon dioxi-
de and other harmful gaseous sub-
stances from the atmosphere is signifi-
cantly increased by the porous surface
formed by oiled steel or plywood faced
formwork.
Benefits of Zemdrain®
Significant reduction in the rate of
carbonation due to a dense cover
zone - resulting from increases
in cement content of up to 100
kg/m3 in the outer 20 mm of the
surface.

Water / Chloride The problem: Most coastal and trans-

port structures are subject to wetting Benefits of Zemdrain®
Ingress(3,8,13,20,25)
Reduced w/c ratio and higher ce-
and drying cycles in the presence of
ment contents at the surface
With Without water borne chlorides.
Zemdrain® Zemdrain® combined with better curing lead
The quality and permeability of the sur-
to a concrete cover zone with
face concrete governs surface chloride
lower porosity and permeability.
levels and chloride diffusion rates. The
Resistance to water borne ag-
surfaces produced by conventional
gressive agents such as chlorides
formwork increase the rates of chloride
is increased.
ingress and water penetration.

Freeze / Thaw Resistance(10) The problem: Expansion of capillaries

caused by ice pressure, also under the Benefits of Zemdrain®
Zemdrain® improves the frost
influence of de-icing substances, leads
resistance of concrete with or
to spalling of the concrete surface.
without air entrainment due to re-
The porous surface, which results from
duced surface porosity.
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the use of traditional formwork face

The improved weathering re-
contact materials, can readily display
sistance of the surface leads to
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spalling after relatively few freeze/thaw

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increased durability for transport

cycles.
structures subjected to de-icing
substances.

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Zemdrain®
Visible benefits

Microbiological Growth(1,3,11) The problem: Micro-organisms can

reproduce and live in blowholes, large Benefits of Zemdrain®
The uncontaminated, virtually
capillary pores and imperfections in the
blemish free surface with its in-
carbonated outer concrete surface.
creased hardness and resistance
Modern biologically degradable release
to carbonation provides a hostile
agents, residues of which can penetra-
environment resistant to micro-
te up to 5 mm into the surface, provide
organism growth.
nutrients for further organic growth.
Potable water reservoirs made of un-
treated concrete, with the use of relea-
se agents pose a danger for hygienic
and problem free drinking water.

Acid / Chemical Attack(26,27) The problem: The acid resistance of

concrete depends upon the cement
content and porosity of the surface.
The greater the cement content the
longer the surface will resist degrada-
tion.
Surfaces produced by oiled impermea-
ble formwork have significantly redu-
ced cement contents and increased
porosity.
Benefits of Zemdrain®
Zemdrain® use results in an in-
crease in surface cement content
of up to 100 kg/m3 and reduc-
tions in surface porosity of around
30 %.
The result is a surface with signifi-
cantly increased resistance to
acid/chemical attack.

Curing Effect(1,4,20) The problem: Water gain in the outer

cover zone results in a porous surface, Benefits of Zemdrain®
Zemdrain® retains drainage water
which on formwork removal allows a
in its structure and acts as a cu-
rapid escape of moisture into the at-
ring membrane until the formwork
mosphere. This has a negative influen-
is removed.
ce on the hydration process.
Lower porosity in the cover zone
Unless curing is applied immediately
minimises moisture loss.
and is maintained, the result can be
Zemdrain® use largely desensi-
significant reductions in concrete quali-
tises concrete to the effects of
ty and a rapid drying out of the surface. poor quality curing.

Surface Blemishes(12) The problem: Water and air trapped

by the use of oiled steel and plywood Benefits of Zemdrain®
Water and air removal results in a
faced formwork cause blowholes and
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virtually blemish free surface for

other blemishes. These blemishes are
both inclined and vertical surfa-
not only an aesthetic problem, but also
ces. Sandblasting exposes few
reduce long term durability. Repairs are
further blowholes.
usually cosmetic and have a short life.
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Many more blowholes are present just

beneath the surface and are easily re-
vealed by grit blasting.

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Zemdrain®
Measurable benefits

Important concrete properties are measurably improved by using Zemdrain® in differing con-
crete compositions.

1. Surface strength MPa

Without Zemdrain®
Measured according to BS With Zemdrain®
2.5
1881 (pull-out test at 28 days) 2.35 2.32 2.34 2.32
2.17 2.13 2.13 2.13
2.1
2.0
Up to five times stronger surfa-
ce strength has been achieved 1.5 1.56

®,
through the use of Zemdrain
thanks to optimum cement 1.0 0.98
0.87 0.87 0.87
hydration. 0.76 0.72
0.59 0.59 0.55
0.5 0.52

0
Without With Without With Without With Without With Without With
curing curing curing curing curing curing curing curing curing curing
Definition 100% PC 70% PC/30% PFA 50% PC/50% GGBS 30% PC/70% GGBS 100% PC-AEA
to EN CEM I CEM II/B-V CEM III/A CEM III/B CEM I + AEA

2. Surface absorption ml/m2

Two hours cumulative Initial 4000

Surface Absorption Test (ISAT) 3618

according to BS 1881, after 28 3000

days. 2493 With Without
2106 Zemdrain® Zemdrain®
2000 2061 1872 1872

Surface of the concrete is up

1103
to ten times less permeable 1000
779 806
540
due to a denser structure and 306
518
194 279 180
0 113 126 81 86 54
fewer capillaries left by evapo-
Without With Without With Without With Without With Without With
ration of excess water. curing curing curing curing curing curing curing curing curing curing
Definition 100% PC 70% PC/30% PFA 50% PC/50% GGBS 30% PC/70% GGBS 100% PC-AEA
to EN CEM I CEM II/B-V CEM III/A CEM III/B CEM I + AEA

3. Carbonation mm

Accelerated test, for 12 weeks, 12 12

4% CO2, 50% RH, 23°C, at 28 Without Zemdrain®
days age With Zemdrain®
10 10

9 9 9
8.5
Up to ten times greater resi- 8 8

stance to carbonation has be- 7

en measured at the surface, as 6

a result of the reduced porosity 5

4
of the concrete cover.
3 3

The surface of a C20 concrete 2 2

1.5
cast against Zemdrain® form- 1
0.5 0.5 0.5 0.5 0.5 0.5
work liner is more durable than 0
Without With Without With Without With Without With Without With
that of a conventionally cast curing curing curing curing curing curing curing curing curing curing
Definition 100% PC 70% PC/30% PFA 50% PC/50% GGBS 30% PC/70% GGBS 100% PC-AEA
C50 concrete. to EN CEM I CEM II/B-V CEM III/A CEM III/B CEM I + AEA

10
Zemdrain®
Measurable benefits

4. Chloride diffusion Years

Without Zemdrain®
Accelerated test, extrapolated With Zemdrain®
400
according to the Second Law 361 353
345
of Fick (at 28 days): AASHTO T 300

227-831
217 210
200 191

When Zemdrain® is used, the 147

time necessary to activate cor- 100 97 85

67 65 77
60
rosion of steel reinforcement 34 35 40 35 33 40
27
0
by reaching a specified con-
no cure wet cure no cure wet cure no cure wet cure no cure wet cure no cure wet cure
centration of chloride (0.4 % Definition 100% PC 70% PC/30% PFA 50% PC/50% GGBS 30% PC/70% GGBS 100% PC-AEA
to EN CEM I CEM II/B-V CEM III/A CEM III/B CEM I + AEA
Cl / cement) is two to ten times
longer.
High surface porosity explains the poor cubes and cylinders. The use of Zemdrain®
performance of the control mixes with enabled concrete to achive outstanding
GGBS, compared with results of tests on resistance to chloride diffusion in all mixes.

5. Frost resistance Scaled Material, kg/m2

Without Zemdrain®
According to Swedish SS 137 With Zemdrain®
6
244: freeze / thaw cycles with
solution of sodium chloride 5

Thanks to a denser, less 4

porous cover, up to one hun-

dred times less material scaling 3

has been measured on surfa-

2
ces cast with Zemdrain®.

1
NB: done on a different mix:
C65; w/c = 0,42; AEA 2,2%,
0
M 5% no cure with cure no cure with cure no cure with cure no cure with cure no cure with cure
No. 7 14 28 42 56
of cycles

6. Curing effect Effect (%) relative to control

sample without Zemdrain® With Zemdrain®, without curing
and without curing
All properties of a concrete Without Zemdrain®, 3 days curing
200
surface cast against Zemdrain®
163
formwork liner, and left without 150
136
cure in the lab, are better than
117
those obtained on a surface 100 100 100 100 96 95 95

cast again conventional forms

57
followed by an ideal wet cure. 50 50
38 38
18
5 10
0
hot-dry hot-wet hot-dry hot-wet hot-dry hot-wet hot-dry hot-wet
2 hours cumulative ISAT Surface hardness Accelerated carbonation Chloride diffusion

11
Zemdrain®
Impact of Formwork

The types of formwork face contact
material used will vary between sites
and countries. The most commonly
used facing materials are oiled
plywood, timber and steel.
The orientation of the formwork de-
pends upon the application and can
be vertical, inclined top, inclined bot-
tom, soffit and top horizontal.
The types of face contact materials
and release agents used, and the qua-
lity of workmanship can cause:
■ surface blemishes due to trapped air
and water
■ surface contamination due to the
use of release agents
■ increased w/c ratio and decreased
cement content in the outer 20 mm
of the surface
These problems can be magnified by
the use inclined shutters. Trapped air
shows up as blowholes and pinholes.
Their size and frequency increasing as
the inclination of a top shutter gets
shallower. On any formed surface, a
light grit blasting will reveal many more
blemishes.
Zemdrain® can be used with all form-
work types. Irrespective of the backing
material and formwork inclination,
Zemdrain® use will normally result in:
■ a virtually blemish free surface
■ a surface uncontaminated by relea-
se agent residues
■ improved early age curing
■ decreased w/c ratio and increased
cement content in the outer 20 mm
of the surface
Any Zemdrain® cast surface will after
light grit blasting reveal significantly
less blowholes than a non CPF cast
surface.
For top horizontal surfaces Zemdrain®
will only work to remove air and water
if there is sufficient pressure from head
of concrete and vibration to do so.
Panel formwork systems can give un-
sightly joints unless they are overshee-
ted with plywood. Zemdrain® can re-
place this plywood layer to save weight
and to improve concrete quality and
durability.

As-Struck Surface

Grit blasted Surface

Cement Contents in outer 20 mm of Surface(8)
100

50
Cement
Content 0
Variation
(kg/cu.m)
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Sloping Sloping
Vertical Soffit
(T) (B)
Control -40 -44 -24 -30
It is recommended that trial panels be cast to con- CPF 61 54 69 60
firm performance for any site.

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Zemdrain®
Impact of Cement Types

Different cement types and additions
like Pulverised Fly Ash (PFA), Ground
Granulated Blast Furnace Slag (GGBS),
Meta Kaolin (MK), Condensed Silica
Fume (CSF), can help to improve over-
all concrete durability. This is particu-
larly the case in terms of resistance
to chloride ingress. However, blended
cement concrete can:
■ be more prone to carbonation
■ have an initial surface strength gain
that is generally less than that for a
PC concrete.
■ be more sensitive to the quality of
site curing
Research(8) has shown that when cast
against formwork using oiled plywood
or steel as the face contact material,
the cement content in the outer 20 mm
of the surface can be reduced by up to
3
40 kg/m . This occurs irrespective of
the type of blended cement used.
When Zemdrain® is used as the form-
work face contact material with blen-
ded cements, the following is noted:
■ cement contents in the outer 20 mm
of the cover zone can be increased
3
by up to 100 kg/m
■ w/c ratio is reduced
■ early age surface hardness and ten-
sile strength are increased signifi-
cantly
■ early age and longer term carbonati-
on are minimised
■ a better cured surface results
■ surface porosity is reduced
®
Zemdrain and Blended Cements
The synergism between Zemdrain®
and blended cements enhances the
(13)
durability of concrete . on several projects. The following is
The benefits in the outer 20 mm from
using Zemdrain® and the improve-
ments to the mass of the concrete
from the blended cements ensure a
longer structural life.
Improved curing is a major benefit
when using Zemdrain® with blended
cements. Keeping the liner in contact
with the concrete surface for prolon-
ged periods and ensuring that the net
(MD) remains filled with water can en-
hance this effect further.
Zemdrain® and White / Pigmented
Cements
Interest in white and pigmented con-
cretes increases as dissatisfaction
grows with shades of grey concrete
and the pseudo white colour given
by release agent retardation of the sur-
face.
Zemdrain® has been used with diffe-
rent pigments and with white cement
noted or recommended:
■ the pigmented colours will be slightly
darker for Zemdrain® cast surfaces
■ trials should be performed to ensure
that pigments perform correctly with
Zemdrain®
■ with white cement there is a slight
reduction in the whiteness factor
and care should also be taken to
choose light coloured fine aggre-
gate(14).

Cement Contents in outer 20 mm of Surface(8)

100

50
Cement
Content 0
Variation
(kg/cu.m)
-50

-100

PC PFA GGBS MK CSF

Control -45 -30 -60 -35 -60

CPF 55 45 65 40 45

It is recommended that trial panels be cast to con-

firm performance for any site.

Bridge cast using Zemdrain® and white cement

13
Zemdrain®
Impact of Admixtures & Mix Characteristics

Admixtures: ■ cement contents in the outer 20 mm Mix strength:

A range of admixtures have been de-
veloped to improve concrete durability,
including:
■ water reducers (WR)
■ superplasticisers (SP)
■ waterproofers (WP)
■ pore blockers (PB)
■ air entrainment (AE)
■ fibres
These improve overall concrete quality.
However, for the outer 20 mm of the
surface, workmanship and the type of
formwork face contact material used
can negatively affect concrete perfor-
mance.
(8)
Research has shown that in this criti-
cal zone the use of oiled plywood or
steel as the face contact material can
cause reductions in cement content of
up to 40 kg/m3 and increases in w/c
ratio. As a result of this and the other
“process“ problems, the full benefits of
admixtures are never realised.
When Zemdrain® is used as the form-
work face contact material with admix-
tures, the following is noted:
are increased by up to 100 kg/m3
over those for the oiled plywood /
steel face
■ w/c ratio is reduced by 0.2
■ increased early age surface
hardness and tensile strength
■ increased resistance to all aggressive
agents
■ surface is better cured
■ surface porosity is reduced
Air entrainment is widely used to im-
prove the frost resistance of concrete.
Results of research have shown that:
■ Zemdrain® modifies the air void sy-
stem close to the formed surface.
The total amount of air entrained in
the cement paste is increased, but
both the spacing factor and specific
surface measurements remain within
accepted guidelines(10)
■ the frost resistance of concrete with
and without air entrainment is impro-
®.
ved by using Zemdrain
■ for freezing/thawing In the presence
of deicing salts, Zemdrain® and non
air entrained concrete perform better
than conventionally cast air entrained
concrete
Increased mix strength is often viewed
as a way of improving durability. But
the use of higher strength mixes can
increase the likelihood of surface ble-
mishes and other process problems.
The surface problems of air and
water gain are also evident for all mix
strengths. The result will be decreased
durability performance. The need for
better curing is also apparent with
increasing mix strength.
The improvements resulting from Zem-
drain® use, also apply irrespective of
mix strength.
Zemdrain® - Admixtures & Strength:
The synergism between Zemdrain®
and admixtures enhances the durabili-
ty performance of concrete.
The benefits in the outer 20 mm from
using Zemdrain® and the improvements
to the mass of the concrete from the
admixtures and/or higher strength
concrete ensure a longer structural life.
Zemdrain® ensures that the maximum
performance benefits are derived from
the use of admixtures and higher
strength (lower w/c ratio) concretes.

Cement Contents in outer 20 mm of Surface(8) Cement Contents in outer 20 mm of Surface(8)

100 100
80
50 60
Cement 40
Content 0 Cement 20
Variation Content
(kg/cu.m) 0
Variation
-50 (kg/cu.m) -20
-40
-100 -60

C25 C37 C45 PC WR SP AE WP

Control -20 -45 -70 Control -45 -45 -45 -38 -40
CPF 75 55 45 CPF 55 65 70 88 50

It is recommended that trial panels be cast to con-

firm performance for any site.

14
Zemdrain®
Impact of Coatings & Penetrants

Coatings and surface penetrants are
usually applied to concrete to protect
the surface from the harmful effects of
the environment. Coatings for architec-
tural reasons are also becoming com-
mon.
Problems affecting coatings and
Penetrants
■ contamination of the surface from
release agents, curing agents, spil-
led oils etc., will inhibit absorption of
penetrants and adhesion of coatings
■ physical defects such as cracks,
blowholes, laitence and general
roughness can effect coating perfor-
mance
■ life expectancy of a coating will be
influenced by the quality of surface
preparation. The majority of coatings
fail due to substrate problems
■ environmental degradation of con-
crete surfaces can reduce effec-
tiveness of penetrants like silane as
they sometimes penetrate only 1
mm into the surface
■ the need for specialist applicators to
apply coatings and penetrants
■ for penetrants like silane the need
for strict Health & Safety precautions
to protect the public and the envi-
ronment. This is particularly the case
for watercourses
■ a life expectancy shorter than that of
the structure they protect, so the
need for several reapplications du-
ring the life of a structure
Benefits of using Zemdrain®
■ surface has a tensile strength of over
1.5 N/mm2
■ surface is uncontaminated by relea-
se agent residues
■ surface is virtually blemish free
■ surface porosity reduced by up to
35%
■ depth of effect is up to 20/30 mm
and lasts the life of the concrete
■ surface is well cured
■ grit blasting of the surface is not nor-
mally needed
■ increased cement content and redu-
ced permeability give a surface that
is more resistant to graffiti and from
attack by acids, chlorides, abrasives
and other environmental agents
■ with Zemdrain® you can see that it
has been used, this is not the case
with the majority of penetrants
Zemdrain® & Coatings
■ the improved quality of the concrete
may mean that a coating is not re-
quired
■ if coatings are required the only pre-
paratory work prior to primer appli-
cation will generally be a surface
cleaning
■ the avoidance of grit blasting and fa-
ring coats can ensure considerable
savings
■ unlike coatings the improvements to
the concrete from using Zemdrain®
have a long life
■ it is always advisable to perform a
trial to confirm that the coating has
good adherence to the Zemdrain®
cast surface
■ putting a coating onto a Zemdrain®
cast surface will enhance the projec-
ted coating life
Zemdrain® & Penetrants
■ the quality of concrete may mean
that use of a penetrant is not neces-
sary
■ laboratory and field results show
that a Zemdrain® cast surface has
lower absorption rates than a control
surface with silane(16)
■ with the absence of release agent
residues and the low porosity of a
Zemdrain® surface, the effectiveness
of silane is improved

M2 Bridge, Belfast - Surface Absorption

7

6
Sorptivity Index

4 Control
3 Zemdrain®
2

0
Lab Field Lab/Silane Field/Silane

It is recommended that trial panels be cast to con-

firm performance for any site.

15
Zemdrain®
Performance with time

The performance of concrete with time permeability and sorptivity and increa-
is very important. The actions of aggres- ses in surface strength. The level of im-
sive environmental agents will cause provements was not affected by silane
surface deterioration and eventually application.
reinforcement corrosion. Extensive
laboratory and in-situ testing of new “The test report concluded that after
structures has shown the significant 7 years in service, that the durability
benefits to concrete of using Zemdrain®. properties of concrete cast against
Zemdrain® remain considerably better
Recent in-situ tests on 6 to 7 year old than those of the concrete cast against
structures have confirmed that the be- normal formwork.“
nefits predicted by laboratory tests are
achieved in concrete exposed to de- Concrete Average Average Air Average Carbonation
icing salts and in a marine environment. Surface Surface Permeability Sorptivity (mm)
(1999) Strength Index Index
(MPa)
The extension to Dock Street bridge in
Belfast, N.Ireland was constructed in Control 7.28 0.0717 0.499 5 - 10
1992. Testing was performed at the end
of construction and repeated in 1999(17). Zemdrain® 9.21 0.00229 0.073 0

At the end of construction, test results Improvement

1.27 1/31 1/7 Very good
Ratio
showed significant reductions in air

At Brighton, England, several kilome-

tres of sea wall were constructed in
three sections between 1992 and
1996. Zemdrain® was used on the
sea ward facing faces of the vertical
and wave-return sections of the wall(18).

In this very aggressive environment the

concrete used was C45, 70% PC / 30%
GGBS with polypropylene fibres. After
6 years exposure to the aggressive en-
vironment of the Channel, the Univer-
IMF (Steel Faced Formwork) Zemdrain®
sity of Dundee carried out a program-
Test method (3 yrs. Exposure) (6 yrs. Exposure)
me of in-situ and laboratory testing.
Inter Tidal Splash Zone Inter Tidal Splash Zone
The concrete facing the walkway was Surface Hardness
42 41.6 52.0 55.3
cast without Zemdrain® and the growth (rebound number)
of algae on this face is very prominent. Pull Off Tensile
0.8 1.0 2.4 2.2
Strength (N/mm2)

Test results have shown the significant Capillary Porosity

4.865 5.958 3.203 3.391
(%)
benefits derived from the use of Zem-
ISAT – 10
drain®. 46.1 36.4 16.1 11.4
(m2/sec x 10-2)
Surface Chlorides
7.7 10.4 2.3 3.3
(% weight of cement)
Apparent Chloride
12.0 27.9 8.1 9.2
diffusion coefficient

16
Zemdrain®
Performance in extreme / harsh climates(19,20,21,28)

Climate extremes, hot or cold and wet

or dry conditions, pose a significant
threat to the life expectancy of con-
crete.

Reinforced concrete structures in hot

climates often deteriorate much more
rapidly than structures in more tempe-
rate regions. Whilst in some cases, this
accelerated deterioration is a result of
unavoidable use of poor quality or con-
taminated materials, the climate itself is
a significant factor.

High initial concrete temperatures lead

to rapid cement hydration, producing
a weak porous microstructure of re-
duced strength and increased perme-
ability. The difficulty of achieving effec-
tive site curing in hot climates is also
well known, with the initial rapid mois-
ture loss after formwork removal par-
ticularly detrimental to long term dura-
bility.
Careful specification of the mix can
enhance the bulk properties of the con-
crete. However, the performance of
the cover zone is significantly effected
by “process“. “Process“ factors include
the type of formwork face contact
material, quality of curing and general
workmanship.
The cover zone is even more important
to long term durability in extreme/harsh
climates.
The use of Zemdrain® has already been
shown to enhance the surface proper-
ties of concrete.
Laboratory and field tests have shown
that Zemdrain® consistently improves
concrete durability in hot/wet, hot/dry
and cold conditions. Perhaps the most
significant finding was that using Zem-
drain® desensitises the concrete against
the effects of inadequate curing.

In hot/wet and hot/dry climates the in-
creased presence of chlorides in the
atmosphere is particularly harmful to
concrete. The effective chloride diffu-
sion coefficient of concrete cast against
Zemdrain® is generally reduced by
more than 50%.
Results for blocks of 50% PC / 50%
GGBS (0.4 w/c ratio) concrete exposed
in the United Arab Emirates are shown.
CI (% of cement content)
chloride binding by the uncarbonated In extremely cold climates the quality
surface concrete. This will consequent- of the cover zone remains important,
ly reduce the risk of reinforcement especially when de-icing agents are
corrosion in structures exposed to salt being applied.
spray or marine splash zone conditions
in hot climates. This is particularly im- Zemdrain® use in all extreme/harsh
portant in hot/dry climates. environments is essential for an
increased structural life.
Jebel Ali Port Quay 10 16
3.5 14
Carbonation, mm

3 12
Levels of surface chlorides and ingress 2.5 10
rates are significantly reduced. The 2 8
1.5
result is an improved service life for all 6
1 4
reinforced concrete structures.
0.5 2
0 0
The use of Zemdrain® prevents sig- 5 17.5 37.5 62.5 87.5 No Cure Cure
Sample Depth (mm)
nificant carbonation, and thus allows HOT / DRY
Control Zemdrain®
Control Zemdrain®

17
Zemdrain®
The economic benefits
Investment decisions
When making investment decisions ab-
out the need to construct structures
such as bridges, drinking water reser-
voirs, sewage treatment works etc., it is
critical to take account of not only the
investment costs, but also the opera-
ting costs.
Maintenance bills are often a major pro-
portion of the operational budget.
Costs associated with minor mainten-
ance work are usually included in the
annual running costs. However, major
refurbishment projects which increase
asset valuations and prolong service life
are handled separately and, in the case
of e.g. sewage treatment works, must
be capitalized.
Initial and ongoing costs
According to current findings - practical
experience since 1989 and test investi-
gations - the time between construc-
tion of a given concrete structure and
Economic benefits of concrete
formed with Zemdrain®
The technical benefits give increased
structural durability. The result is a lon-
ger service life with increased intervals
between any necessary maintenance.
Over the entire service life of any
structure, increased economic be-
nefits result from the use of Zem-
drain® (taking into account a finan-
cial calculation for advance finance
of extra costs).
This was confirmed by a study carried
out by Prof. Seyfried at the University of
Hanover in accordance with LAWA gui-
delines. The adjacent simplified graphic
shows the results(22).
18
its first renovation doubles under the ced in advance from reserves. The mo-
same exposure conditions if the con- re expensive and more often that refur-
crete surface has been formed with bishment is required, the higher the
Zemdrain®. costs which have to be passed on to
the customer. This is often the cause of
Zemdrain® Classic and MD liners intense public discussions.
give significant benefits at relati-
vely low costs. Construct economically
The extra costs to double the When talking about cost reduction, we
time to renovations are consider- generally mean investment costs. This
ably less than the cost of remedi- way of looking at things is, however,
als. rather short-sighted.
The values mentioned therein apply for The crucial factor is not the in-
a well-organised construction site and vestment costs but the whole life
costs, which result from the in-
a working team experienced in fixing
vestment costs and the operatio-
Zemdrain® on the formwork.
nal costs over the service life of a
structure. Here the refurbishment
Costs become charges
costs of any structure are of ma-
In the case of public structures for drin-
jor significance.
king water supply or sewage treatment,
The use of Zemdrain® helps to
major renovations are often financed
minimise future refurbishment
via charges, connection fees or additio- costs.
nal one - off premiums - or even finan-
3/m2
Costs of 1 m2 concrete surface in sewage
treatment woks during 35-year operational
life including construction and renovation
to "basic standard" 237,25 3/m2
3rd renovation
{ 109,95 3/m2
savings
127,30 3/m2
2nd renovation
2 renovation
nd
1st renovation
1st renovation
Construction investment
Extra investment
with Zemdrain®{
with Zemdrain®
15,35 3/m2 Construction investment
without Zemdrain®
Years
10 20 30 35
Zemdrain® MD or Zemdrain® Classic
There are two different styles of Zemdrain®.
The differences between them are:
a) Zemdrain® MD (Type III CPF liner*):
■ a composite filter/net liner
■ 2.2 mm thick
■ formwork side - a special drainage grid
■ concrete side - a white engineered filter
■ one roll size at 2.5 m wide and 35 m long
When should you use Zemdrain® MD?
■ for multiple use with minimal risk of folding
■ for reduced costs per m2 of concrete surface
■ for easy application with simple tensioning devices
■ for applications with special formwork or in precast plants
■ for completely sealed formwork - intermediate grid space
serves as additional storage
■ easier to use with circular, concave, convex and complica-
ted formwork shapes
Both types of Zemdrain® produce concrete of equal
quality and durability(23,24) - the skilled work required and
application to the formwork are different, however.
*as defined by CIRIA Report C511 “Controlled Permeability Formwork“
b) Zemdrain® Classic (Type II CPF liner*):
■ a single layer combined filter/drain
■ 0.7 mm thick
■ formwork side - black
■ concrete side - a grey engineered filter
■ various roll widths between 1.6 m and 5.2 m,
standard roll length 50 m
When should you use Zemdrain® Classic?
■ if only one use is necessary
■ when round steel formwork is used in monolithic con-
struction
■ if specifications demand that concrete is cured with Zem-
drain® formwork liner remaining on the concrete face
■ if steel formwork is used which may require wide sheets
■ for applications with special formwork or in precast plants
■ for soffit formwork for bridges
Ask our support department to advise you on the opti-
mum solution.
19
Zemdrain®
Transport / Marine / Waterway Structure

Brighton, England Donegal, Ireland

Freeport, Bahamas Doha Corniche, UAE

King George V Dock, London; UK Skullerund Bridge, Norway

Oresund Link, Sweden/Denmark Charles de Gaulle Airport, Paris, France

20
Zemdrain®
Potable Water / Wastewater Structures

Spillway, Alabama, USA

Dam, Ireland

Service Reservoir, England

Dam, Germany WTW, Germany

21
Zemdrain®
Practical applications on formwork

Lining steel formwork for bridge pier with Zemdrain® MD Formwork element for bridge lined with Zemdrain® Classic

Frame formwork for a drinking water reservoir lined with Soffit of bridge over a canal lined with Zemdrain® Classic
®
Zemdrain MD

Round convex steel formwork lined with Zemdrain® Classic Formwork for a bridge pier curving in two directions lined
with Zemdrain® MD

22
Zemdrain®
Practical applications on formwork

Featured bridge pier formwork lined with Zemdrain® MD Steel formwork for a sea wall lined with Zemdrain® Classic

Bridge parapet formwork lined with Zemdrain® MD Steel formwork for outflow cone in sewage purification basin
lined with Zemdrain® Classic

Lining a small detail shutter - gaps between the individual Internal flexible formwork lined with Zemdrain® Classic
shutter panels are bridged with Zemdrain® Classic

23
Zemdrain®
Specification Clauses

Zemdrain® MD

1. All formed surface finishes are
to be achieved using a Type III
controlled permeability formwork
(CPF) liner, comprising a filter
fabric bonded to a backing grid,
Zemdrain® MD or equal approved.
2. The approved Type III CPF liner
shall have the following properties:
■ a maximum compression of less
than 10 % under a pressure of
200 kPa
■ a maximum pore size of less
than 0.050 mm
■ a minimum water retention capa-
city of 1.30 litres/m2
■ a maximum absorbency of 0.1
litres/m2
3. The approved CPF liner shall have
supporting test data certified by an
independent testing organisation,
such as the Board of Agrément, to
confirm the achievable improve-
ments to concrete.
4. Certification and independent
testing shall demonstrate that the
use of the CPF liner improves the
performance of a CPF cast concre-
te against that for conventionally
cast concrete. The outer 20 mm of
the CPF cast surfaces shall have
cement contents of over 75 kg/m3
greater than the control. A mini-
mum improvement of 50 % for sur-
face tensile strength, ISAT, carbo-
nation and chloride ingress is also
required. Liners without an Agré-
ment Board Certificate and inde-
pendent tests to establish the liner
performance shall not be approved.
5. The CPF liner shall be installed and
used in accordance with the manu-
facturer's recommendations. The
use of release agents is not permit-
ted.
6. Type III, CPF liners can be reused,
subject to inspection between
pours. Before approval for liner reu-
se is given, evidence that durability
benefits are maintained with reuse
must be submitted.
7. A trial panel shall be cast to confirm
the suitability of the liner for use
with the design mix and formwork
8. Type III, CPF liners are as defined
in the Concrete Society / CIRIA
Report “Controlled Permeability
Formwork“ CIRIA C511.

Zemdrain® MD and/or Zemdrain® Classic

1. All formed surface finishes are to
be achieved using a controlled per-
meability formwork (CPF) liner,
Zemdrain® MD, Zemdrain® Classic
or equal approved.
4. Certification
2. Approved CPF liners shall have the
following properties:
■ a maximum compression of 10 %
under a pressure of 200 kPa
■ a maximum pore size of 0.050
mm
■ a minimum water retention capa-
city of 0.35 litres/m2
■ a maximum absorbency of 0.1
litres/m2
3. The approved CPF liner shall have
supporting test data certified by an
independent testing organisation,
such as the Board of Agrément,
to confirm the achievable improve-
ments to concrete.
and independent
testing shall demonstrate that the
use of the CPF liner improves the
performance of a CPF cast concre-
te against that for conventionally
cast concrete. The outer 20 mm of
the CPF surfaces shall have ce-
ment contents of over 75 kg/m3
greater than the control. A mini-
mum improvement of 50 % for sur-
face tensile strength, ISAT, carbo-
nation and chloride ingress is also
required. Liners without an Agré-
ment Board Certificate and inde-
pendent tests to establish the liner
performance shall not be appro-
ved.
5. The CPF liner shall be installed and
used in accordance with the manu-
facturer's recommendations. The
use of release agents is not permit-
ted.
6. Single sheet CPF liners can be
used once. Composite sheet/net
CPF liners can be reused up to
three times, subject to inspection
between pours. Before approval for
liner reuse is given, evidence that
durability benefits are maintained
with reuse must be submitted.

24
Zemdrain®
Zemdrain® MD product range

Product
Article
Roll width Roll length m2/roll weight/roll
number

ZEMMD2 2.50 m 35 m 87.5 59 kg

Zemdrain® MD can be reused subject to correct handling and cleaning

Article
Desription
number
ZEMSCHNITTQ Cross cutting rolls to shorten roll length
Cuts
ZEMSCHNITTL Cutting the complete roll to reduce roll width

ZBBAND MD fixing tape 50 mm x 1.0 mm x 10 lin. m/roll

ZBBAND25 MD fixing tape 25 mm x 1.0 mm x 10 lin. m/roll
Double-side adhesive tape, for fixing and sealing of Zemdrain® MD to formwork (it is possible that
some isolated small blowholes will occur in the vicinity of the adhesive tape due to the impermea-
bility of the adhesive film.

ZABAND Zemdrain® cover tape 50 mm x 0.5 mm x 10 lin. m

ZABAND25 Zemdrain® cover tape 25 mm x 0.5 mm x 10 lin. m
Zemdrain® laminated self-adhesive tape for covering formwork joints, stapled Zemdrain® joints,
for repair of any damaged Zemdrain® areas or for edge coverage of lined used formwork elements
(it is possible that some isolated small blowholes will occur in the vicinity of the adhesive tape due
to the impermeability of the adhesive film).

Special adhesive tape 50 mm x 0.5 mm x 50 lin. m

ZDSSKB Double-sided adhesion for preferred fixing of Zemdrain® MD formwork liner to formwork faces
when staples should not be visible

Tools for working with Zemdrain® MD

Article
Description
number

Tensioning tool MD 2.5 m

ZSZMD2500
for tensioning of Zemdrain® MD (also available in 0.6 m and 1.2 m)

Adjustable stapler, hand-operated for fixing Zemdrain® MD to formwork surfaces

ZTAKMD1
for staple size 8 and 10 mm

Additional staples
ZTEK08 Model 053-8 mm long, 1400 no./pack. for coated plywood panels
ZTEK10 Model 053-10 mm long, 1200 no./pack. for plywood panels

ZSTMKL Steel Knife with blade

General accessories for Zemdrain® MD and Zemdrain® Classic

Article
Description
number

Zemdrain® pre-fixing tape 50 mm x 2 mm – 10 lin. m

ZVBAND
for sealing formwork joints and formwork elements joints

Foam plastic waterstop 19 mm x 6 mm – 10 lin. m

FKBANDS
for sealing formwork element joints

Serrated grinding wheel SIC 24 - Ø 180 x 22.2 mm – 80 m/sec.

ZFSS180
Special grinding wheel for grinding off large burrs and corners on hardened concrete

Serrated grinding wheel SIC 24 - Ø 115 x 22.2 mm – 80 m/sec.

ZFSS115
Special grinding wheel for grinding off large burrs and corners on hardened concrete

Protective goggles
ZSBRILLE
Essential eye protection for carrying out concrete grinding work

Dust protection mask

ZSFMASK used as respiratory protection when carrying out grinding work on dry concrete,
packaging unit 10 pcs.

25
Zemdrain®
Zemdrain® Classic and accessories
Product
Article
Roll width Roll length m2/Roll weight/Roll
number
ZEM1600 1,60 m 50 m 80,0 28 kg
ZEM1900 1,90 m 50 m 85,0 33 kg
ZEM2250 2,25 m 50 m 112,5 39 kg
ZEM2600 2,60 m 50 m 130,0 45 kg
ZEM2900 2,90 m 50 m 145,0 50 kg
Zemdrain®
Classic roll ZEM3200 3,20 m 50 m 160,0 55 kg
ZEM4000 4,00 m 50 m 200,0 70 kg
ZEM4500 4,50 m 50 m 225,0 78 kg
ZEM5200 5,20 m 50 m 260,0 89 kg
Special widths are available on request, subject to a minimum quantity and increased delivery time

Article
Description
number
ZEMSCHNITTQ Cross cutting rolls to shorten roll length
Cuts
ZEMSCHNITTL Cutting the complete roll to reduce roll width

Welding for increasing roll width

ZEMSCHWEIß
Welding seam length

Special adhesive tape 50 mm x 0.5 mm x 50 lin. m

ZDSSKB Double-sided adhesive, for fixing rear face and sealing butt joints on
Zemdrain® Classic

Tools for working with Zemdrain® Classic

Article
Description
number
Tensioning tool
ZSZKAZ Wide-area clamping and tensioning of Zemdrain® Classic across smaller formwork areas.
Fix subsequently using staples.

Stapler, hand-operated for fixing Zemdrain® Classic to 8/10 timbers and to formwork
ZTAKHAND
skin or sub construction for staple sizes 6 and 8 mm

Additional staplers
ZTEK06 Model 053-6 mm long, 1800 no./pack for playwood panels
ZTEK08 Model 053-8 mm long, 1400 no./pack for timber and softwood

ZSTMKL Steel Knife with blade

ZHWSCH Heavy duty scissors for simple cutting and shaping work with Zemdrain® Classic

Accessories
Article Tensioning Weight
Description Size No. reqd./m
number length cm kg/item
ZSH050 50 from 20 – 25 4–5 0.05
ZSH100 Tensioning hooks 100 from 35 – 45 2–3 0.06
ZSH150 150 from 40 – 50 2–3 0.08

Article
Description Size Packaging unit
number
ZEG050 50 50 pcs./bundle
ZEG100 Spare rubber band 100 50 pcs./bundle
ZEG150 150 50 pcs./bundle

Article Weight
Description
number kg/item
Tensioning Frog
Fix approx. 1 per meter to formwork surface, and place 8 x 10 timber in
ZSF0810 tensioning frogs - length depends on formwork element length. Pretension 2,8
tensioning frog, staple Zemdrain® Classic to timber, release lock and
Zemdrains® Classic remains tensioned

26
Zemdrain®
Technical Guidelines
To obtain the best results with
Zemdrain®, the following should be
observed:
1. Zemdrain® Classic is best suited to
use with flat, convex or soffit forms.
Zemdrain® MD can be used with
nearly all shapes of formwork. For
steel forms special provisions must
be made for use of the liner.
2. The form face should be conti-
nuous, flat, clean and oil free. With
lower grade plywood, the face
should be sealed to prevent water
ingress/sugar egress. Tape any
joints where oil may have concen-
trated.
3. It is important that Zemdrain® liners
lie flat on the form. This is aided by
fixing during warm sunny periods
(the liner expands/contracts when
exposed to and shaded from the
sun). In times of high daily/weekly
temperature variations (>10° C), ca-
re is required to ensure that the liner
remains flat. The use of specially
designed fixing tools helps to ensu-
re correct fixation.
4. Release agents should not be ap-
plied to the form or to the liner. Take
care to avoid all contamination.
5. Zemdrain® can be easily cut using
a blade cutter or scissors and atta-
ched to the form using an industrial
stapler and 10 mm staples. Once
the liner is in place, holes for the tie
bolts are cut and stapled.
6. Any damaged areas should be cut
out and replaced. Put in a new pie-
ce of Zemdrain® on top of the old,
cut through both, remove damaged
area and replace with the new piece.
7. To avoid visible marks on the con-
crete surface, at tie bolt holes and
under spacer blocks the maximum
pressure on Zemdrain® should not
exceed 2 MPa (20 kg/cm2).
8. Concrete should be placed and
compacted in accordance with ac-
cepted good practice. Pouring and
vibration of concrete should be per-
formed consecutively without delay.
■ ensure concrete is not dischar-
ged against the liner surface and
minimise splatter
■ the slump should be maintained
at the mid to lower end of the
permissible range
■ avoid concrete wetting the surfa-
ce of the liner and then being al-
lowed to dry
■ keep the vibrator at least 5-10
cm from the form face
■ avoid fast extraction of the vibra-
tor
■ avoid excessive and irregular vi-
bration
Failure to observe any of the above,
may result in prominent pour lines,
colour variations, segregation or the
presence of blowholes.
9. Primary vibration must be perfor-
med using an internal poker vibra-
tor. External vibrators should only
be used after completion of primary
vibration.
10. Some blowholes and lighter colou-
red concrete can occur in the up-
per 5-10 cm of a pour. This can be
avoided by revibration of this zone
(after 20-50 mins), followed by tam-
ping and smoothing of the surface.
This is especially important for
pours with inclined top shutters and
when using Classic.
11. Rolls of Zemdrain® should be sto-
red in a clean environment, away
from contaminants and prolonged
exposure to UV light. In cold weat-
her, rolls should be stored indoors.
Zemdrain® should be protected
from flames, welding or steel cut-
ting and kept free from dirt and
dust.
12. The number of uses for Zemdrain®
Classic and MD will depend upon
the reasons for liner use (for durabi-
lity or surface blemish removal) and
will be subject to proper handling
and cleaning. Checks for possible
mechanical damage to the skin of
the liner or the tape should be ma-
de between uses.
13. The used liner is chemically inert
and can be disposed of by burying,
earth dumping or incineration. A
“Material Safety Data Sheet“ is
available upon request.
Note:
a) Zemdrain® cast concrete will gene-
rally be slightly darker than traditio-
nally cast concrete reflecting the
colour of the cement. Darker colou-
red spacer blocks may be required
for soffits. GGBS lightens the
colour.
b) Fillets and features should be pla-
ced on top of the fitted liner. Larger
features, (width > 100 mm) can be
lined individually. Smaller features
are usually left unlined or can be
lined using Zemdrain® tape.
c) Minimise any staple marks in the
finished surface by ensuring staples
are flush to the liner. Staples and
joints can be covered using Zem-
drain® tape. Some blowholes may
occur at the tape.
d) Cleaning of MD with a high-pres-
sure water jet between uses is
recommended. Particular attention
should be paid to the upper half of
the form. The liner should remain
fixed to the form during cleaning.
e) Surface colour variations may occur
due to variable vibration, plywood
quality, the mix used and the num-
ber of uses of the liner. These
colour variations do not effect con-
crete quality.
f) If a Zemdrain® lined form is left ex-
posed to full sun for a period of ti-
me, it should be left to cool down
for several hours before concreting.
These Technical Guidelines and
the Fixing Details overleaf are a
condensed description of factors
having a direct effect on the perfor-
mance of Zemdrain® CPF Liners
and are based on the present state
of the art. It may be necessary to
alter these recommendations, as
more information becomes availa-
ble. If in doubt consult your local
supplier.
27
Zemdrain®
Fixing Guidelines - MD
1. For successful fixing of Zem-
drain® MD, you require the follo-
wing:
■ Staple gun (using 10/12 mm staples)
■ Special fixing tools (available in
widths of 0.6 m, 1.25 m and 2.5 m)
2. The following are general notes
on fixing Zemdrain® MD:
■ before using refer to the Technical
Guidelines
■ after unrolling and cutting, allow liner
to relax and warm up for at least 10
minutes
■ in direct sunlight liner will expand
and become easier to fix
■ before fixing, ensure liner is square
on the form to avoid distortions
■ always ensure staples are securely
placed, hammer home if necessary
■ in cold weather MD should be sto-
red in a heated environment prior to
fixing
3. Zemdrain® MD can be fixed in
two ways:
■ with the length direction of the roll
used in the vertical pour direction -
PREFERRED
■ with the length direction of the roll
used in the axial direction
Zem
dra
in M
D
2-3
28
4. Fixing when the length of the roll
is in the vertical pour direction:
■ follow points under 2 above, then
staple at 25 mm centres (max.)
along the top edge
■ at other end, attach a fixing tool over
the full width and stretch MD flat by
rotating the fixing tool against the
edge, then staple down
■ for the cross direction, ensure that li-
ner lies flat with no folds, pull tight
with fixing tool if necessary, staple
down at 30-50 mm centres
■ check that liner is tight with no di-
stortions or folds evident
■ repeat above steps with additional
strips of liner until the formwork is
covered
■ strips of liner are butted up and with
care tight joints can be achieved,
otherwise put sealant in the joint
■ Zemdrain® tape can be used to
mask the joint and the staples
■ form tie bolt holes using a knife, pla-
ce some staples around the hole
■ for forms ( >2.5 m high) - pull liner
flat and staple axially at 2.5 m inter-
vals over the height, reattaching the
fixing tool and pulling flat each time.
■ for forms (>2.5 m high) - tensioning
clamps may be used to avoid the in-
termediate rows of staples
cm
3 -5
5. Fixing when the length of the roll
is at right angles to the pour di-
rection:
■ liner should only be fitted this way if
the form is less than 2.5 m high, for
higher forms, always fix with the
length of the roll in the vertical pour
direction
■ fixing should be as described in 2
and 4 above
■ in the vertical pour direction a fixing
tool should be used to ensure that
liner lies flat and is tight. Care is re-
quired to avoid distortions at the
corners.
6. Other formwork shapes
■ liner can be used with most form
shapes, including convex, concave
and circular
■ slightly modified versions of the abo-
ve techniques are applied
■ please consult your local supplier for
further details
The above fixing details apply to flat
timber / plywood faced forms. For steel
faced forms, it is recommended that
timber inserts be used to permit liner to
be stapled to the form. For unlined pa-
nel systems, take care to ensure that
there are no gaps between panels be-
fore fitting the liner.
Zemdrain®
Fixing Guidelines - Classic

Before using Classic refer to the D. Either trim off the excess liner
Technical Guidelines. or fold over the edge and staple A.
down. Form tie bolt holes after Zem
dra
A. Classic must be tensioned in both tensioning is complete, using a in
directions to avoid folds in the con- knife and stapler.
crete. Due to its thermal expansion
properties, the liner should always Notes:
be left in the sun for at least 10
minutes before fitting and where 1. In cold weather Classic should be
possible be fitted during the war- stored in a heated environment
mest part of the day. Wherever prior to fixing
possible the length of the roll 2. Use scissors or a knife to cut Clas-
should be fitted in the vertical pour sic
direction. 3. Use an industrial staple gun and B. tensioning
device
5 mm/metre
length
8 to 10 mm staples
B. Unroll Classic, cut to the required 4. When stapling, always work from
length from the roll and place squa- middle of section to end
re on the form. Allow a minimum 5. Staples around edge of form
overhang of 50 mm all round, with should be at maximum 25 mm cen-
approx. 200 mm at the end where tres (lengthways tensioning) and at
principal tensioning is performed. maximum 50 mm centres (crosswi-
Always tension in the length of the se tensioning)
roll first, followed by the cross di- 6. Special tools and techniques are
rection. The smooth grey side faces required to achieve the recommen-
the concrete. ded extensions for lengths of up to
49.5 m:
C.
B. For length direction - at the non- a) tensioning frogs/belts (available
tensioning end, staple Classic to from distributors) are used for
the form edge, not the face. At the lengthways tensioning for roll
other end, attach the tensioning de- lengths from 3.0 m up to 49.5 m
vice and once the slack is taken up, b) tensioning clamps (available from
induce a minimum extension of 5 distributors) are used for crossways 3 mm/metre
width
mm/metre length. Maintain tension tensioning for roll widths up to
and staple down only after comple- 5.2 m
tion of tensioning in the cross direc- c) For curved formwork or non-ply-
tion. wood faced formwork, guidance on
fixing should be sought from your
D.
C. For cross direction - at the non-ten- local distributor.
sioning end, pull Classic flat and d) Specialist accessories such as
staple down. At the other end, pull staplers, staples and tapes are also
hand tight, attach the tensioning available form distributors.
device and induce a minimum ex-
tension of 3 mm/metre width. Sta-
tie-bolt
ple down and then finish stapling of hole
other face.

29
Zemdrain® MD
Frequently asked questions
1. Damage
Repair of damaged areas. For small
areas use a short length of Zemdrain®
tape. For larger areas place a new
piece of Zemdrain® over the damaged
area and cut through both layers to
form an infill section. Remove the
damaged liner and replace with the
new piece using staples or tape.
2. Tie Bars
Holes for formwork ties should only be
formed after Zemdrain® has been com-
pletely fixed to the formwork. Cut a
clean hole with a blade cutter and for
extra security staple in place.
3. Release Agents
Release agents should not be used
with Zemdrain®. They can block the li-
ner pores or cause uneven swelling
making the liner unfit for use. Care
should be taken to avoid spillage of
diesel, hydraulic oil and other contami-
nants onto the liner.
4. Complicated Shapes
Zemdrain® MD is best for complicated
shapes. The liner has been successfully
used with circular, convex and concave
forms.
30
5. Joints
For Classic, the two pieces of liner are
simply overlapped and stapled down.
For MD, the two pieces are butt jointed
with both stapled down. For good
joints no further action is required. For
poor joints the gap should be filled with
a sealant or covered with Zemdrain®
tape.
6. Spacers
In order to reduce visible imprints on
the concrete, such as those caused by
spacers, the maximum pressure on
Zemdrain® should be less than 20
2.
kg/cm Loading caused by reinforce-
ment should be distributed onto as
many spacers as possible
7. Drainage Path
For Classic, it is essential that the bot-
tom of the liner is open to the atmos-
phere to permit unimpeded drainage.
For MD, there is usually sufficient stora-
ge capacity within the net to accom-
modate all water removed from the
concrete.
8. Steel Faced Formwork
Zemdrain® Classic and MD can be
used with steel faced formwork. Speci-
al fixing techniques may be required
depending upon the dimensions of the
formwork.
It is essential when using Zemdrain®
with steel faced forms to design in the
liner fixing details at the time of manu-
facture of the form.
9. Panel Systems
Zemdrain® MD has been used
successfully with large panel systems
without the need for oversheeting with
additional plywood. Care needs to be
taken to ensure that there are no
gaps between panels before fitting
Zemdrain®. The resulting surface is not
completely flat but is acceptable for
most non-visual applications.
10. Concrete Colour
The colour of the finished concrete is
primarily a function of the type of ce-
ment used. Hence for white cement
the concrete colour remains white. For
GGBS the colour will be light grey, with
other cements giving a darker colour.
The fine aggregate will also have
some influence on the colour, as will
the amount and uniformity of vibration
and curing.
11. Other Questions
If you have any other questions please
call us or visit the Zemdrain® web page
at www.zemdrain.com.
Zemdrain®
Test certificate / References

Zemdrain® has been tested and approved at numerous universities, institutes, laboratories and on construction sites. In
addition to test reports, copies of which are available upon request, there are several independent publications which
document the benefits of using a controlled permeability formwork liner.

Test Certificates:
A. “Zemdrain® CPF“. British Board of Agrément Certificate No 94/3072.
B. “Investigation of the growth of micro-organisms on materials used in the drinking water sector“. Test certificate No
W315D/94. Hygienic Institute, Gelsenkirchen.
C. “Tests of effect on water quality of Zemdrain® CPF liner to BS6920“. Report No M100281,WRc, UK.

References:
1. Wilson, D. “Durability Problems - is formwork the cause?“ Concrete Engineering Summer 2001
2. Monks, W. “The Control of Blemishes in Concrete. Appearance Matters“. BCA. 1987
3. Price, WF. “Controlled Permeability Formwork“. CIRIA Report C511, London, 2000
4. Price, WF. “Curing Concrete“. Current Practice Sheet No. 112. Concrete Magazine, September 1998.
5. Wallbank, EJ. “Performance of concrete in bridges. A survey of 200 highway bridges“. HMSO. 1989
6. Price, WF and Widdows, SJ. “The effects of permeable formwork on the surface properties of concrete“. Magazine of
Concrete Research, 43, No. 155, June 1991
7. Price, WF. “CPF“. Concrete Society Current Practice Sheet No 117. Concrete Magazine, May 1999
8. Dhir, RK et al. “Total design using CPF“. CTU Report 1399, University of Dundee. 1999
9. “Formwork - A guide to good practice 2nd edition“. Concrete Society, 1995
10. Price, WF. “The effect of Zemdrain® CPF on the frost resistance of concrete“. TEL Report 1303/92/6349
11. Reeves, SJ. “The effect of formwork permeability on algae growth on concrete surfaces“ Bath. 1993
12. Monks, B. “Plain formed concrete finishes“. Concrete Society Technical Report No. 52, 1999
13. Price, WF. “The use of Zemdrain CPF for blended cement concretes “. TEL Report 1303/92/6157
14. Coutino, JS. “Effect of CPF on white concrete“. ACI Materials Journal. March-April 2001
15. Price, WF. “High Performance concrete in practice“. Quality Concrete Part II. May 1995
16. Basheer, PAM et al. “Influence of CPF on the durability of concrete“. Concrete 2000, Dundee.
17. Rankin, GIB. “In-situ evaluation of surface properties of concrete cast using Zemdrain®“. Report No TAS9959. 1999
18. McCarthy et al. “Tackling chloride ingress and corrosion: the role of CPF“, Concrete Magazine February 2002
19. “Guide to the construction of reinforced concrete in the Arabian Peninsula“. CIRIA Report CP/62, London 2001
20. Price, WF & Widdows, SJ. “Durability of concrete in hot climates: Benefits from permeable formwork“. Proceedings 3rd
International Rilem Conference. “Concrete in Hot Climates“, Torquay, 1993
21. Basheer, M. et al. “CPF: Influence on carbonation and chloride ingress in concrete“. Proceedings International Conferen-
ce. “Concrete under severe conditions Consec 95“, Sapporo 1995
22. Seyfried, Prof. “Economic feasibility study on the usage of Zemdrain®“. ISAH, Hanover, 1995
23. Beddoe, RE. “Comparison of concrete surfaces formed with the formwork liners Zemdrain® Classic and Zemdrain® MD“.
Technical University of Munich. Report No 3360-03-06. 1996
24. Beddoe, RE. “Concrete surfaces produced with CPF: Durability and effect of liner reuse“. Concrete 2000. Dundee. 1999
25. McCarthy et al. “Specifying concrete for chloride environments using CPF“, Materials and structures, Vol 34, Nov 2001,
pp 566 – 576
26. BRE Special Digest 1. “Concrete in aggressive ground“ BRE 2001
27. BS8500:1:2002 Complementary standard to EN206-1, Part 1, “Method of Specifying and guidance for the specifier“.
BSI 2002
28. “Guide to the construction of reinforced concrete in the Arabian Peninsula“ Concrete Society / CIRIA 2002

This information corresponds to our current state of knowledge in the fields described, and is intended to give you as many
helpful suggestions as possible for your own procedures, which it cannot replace. For each application we recommend that a
trial panel be cast using the intended design mix and formwork to ascertain specific performance. As soon as new experience
or findings arise it will be revised. DuPont and Max Frank undertake no guarantee, liability or other responsibility for test or wor-
king results which are reproduced in connection with this information. This publication gives no grounds for a licence and is
not intended to infringe existing industrial property rights belonging to third parties.
Zemdrain® is DuPont's registered trademark
www.zemdrain.com

31
 17,00

150,00

Max Frank GmbH & Co. KG Sales

Accessories for the reinforced Phone +49/(0) 94 27 / 189-0
17046/2 - E - 09/02

concrete construction Fax +49/(0) 94 27 / 189-220

Mitterweg 1 · D-94339 Leiblfing Technical advisory service
http://www.maxfrank.de Phone +44/(0) 79 68 29 84 39
E-mail: info@frank-online.de Fax +44/(0) 79 68 29 84 46
32