Flexible Concrete Liner System for Africa - TILTEX GCCM

Subgrade preparation - : Remove all sharp rocks, organic matter and vegetation. The surface should present an even profile with no voids - TILTEX conforms to the subgrade shape but must not bridge over hollows. Compact subgrade to a minimum relative Proctor density of 90%, verified by sand cone method. TILTEX may also be installed over existing concrete structures for rehabilitation.

Unrolling and positioning - Unroll TILTEX liner onto the prepared surface with no wrinkles or folds. On slopes, orient panels parallel to the slope direction. Begin at the lowest point of the channel or slope and work upward. Overlap panels in the direction of water flow - upper panel over lower panel, like roof tiles. Use a front-end loader or excavator with a spreader bar assembly for 5.0 m wide rolls. The roll core tube (100 mm internal diameter) accepts a steel spreader pipe for mechanical deployment.

Cutting and fitting - Before hydration TILTEX cuts cleanly with a standard carpet knife or safety knife. Mark cut lines with a felt pen. Panels can be trimmed on site to fit around culvert openings, pipe penetrations, inlet structures, bends and any irregular profile. No power tools or specialist cutting equipment are required.

Watering overlaps - Before laying each successive panel, lift the overlap edge of the upper panel and spray water onto the exposed area of the lower panel in the overlap zone. Lower the upper panel back into position. This pre-wetting ensures the lower panel fully hydrates in the joint area, which would otherwise be shielded from water by the overlying panel.

Joining overlaps - Fix each overlap with screws or steel bars inserted approximately 50 mm from the panel edge at 200 mm centres. Fasteners must be sharp enough to penetrate the cementitious composite cleanly. Alternatively, adhesive sealant or a hot air gun can be used to join panels. For TILTEX Plus, fold back the upper panel to expose the geomembranes. Clean membrane surfaces with acetone. Weld membranes ≥ 0.5 mm thickness using a geomembrane welding machine; join thin films with adhesive tape. Unfold the upper panel over the joint.

Anchoring - At the top of slopes, insert U-bars or equivalent anchors at 500 mm centres along the middle of the anchor trench. Anchor trenches should be 500 mm deep × 600 mm wide, positioned at a safe distance from the slope crest and backfilled with compacted topsoil or concrete after TILTEX edge is placed. Across the panel field, Gripple pins, J-pins or TL-P4 anchors are spaced to design requirements based on slope angle, soil conditions and anticipated loading. Head size of all anchors must be sufficient to prevent pull-through - minimum 15 mm for concrete and wood substrate fixings.

Hydrating -: After fixing and joining all panels, spray TILTEX uniformly with water. Minimum water-to-liner mass ratio is 1:2. Use a sprayer - avoid high-pressure jets. Re-spray one hour after first hydration. Do not move or walk on TILTEX after hydration begins. In hot conditions: hydrate after sunset, cover with polyethylene sheeting immediately, monitor and re-hydrate if top surface dries within the first 24 hours. In cold conditions below 5°C: cover with protective sheeting immediately after hydration. Below −4°C: do not install. Setting begins within 90 minutes; operational within 24 hours; full design strength at 28 days.