ACTFLEX FLEXIPLUG Repair mortar
High-performance flexible joint and crack repair mortar
Fast-setting elastomeric mortar for joints, coves and penetrations. Membranes go over it after 2 hours.
ACTFLEX FLEXIPLUG coverage, coats and cure times
Two-component elastomeric mortar for sealing joints, cracks, corner junctions and service penetrations. It bonds to damp, saturated-surface-dry concrete and forms the coves in ACTFLEX 988 CWP and 989 CWP.
- Mix ratio
- 1 : 1Part A : Part B by weight · TDS p2
- Pot life
- 10–15 mintypicalat 20°C, working time 6–8 min at 30°C · TDS p2
- Final set
- 50–60 mintypicalat 20°C, initial set 25–30 min · TDS p2
- Membrane over
- 2 hoursFORSPEC membranes over the finished detail · TDS p2
- Foot traffic
- 8 hourstypicalpedestrian access · TDS p2
- Wheel traffic
- 24 hourstypicalvehicle and forklift traffic · TDS p2
- Movement
- Up to 15%typicaljoint movement capability · TDS p2
- Apply at
- +10 to +30°Cambient and substrate · TDS p2
- Kits
- 2, 5, 10 kgPart A and Part B 1 : 1, grey · TDS p3
From the FORSPEC data sheet, TDS-FLEXIPLUG · Revision 2 · 12 August 2026. Times are at 25°C and 50% relative humidity unless the data sheet says otherwise. Typical = FORSPEC’s own typical value, not a laboratory-certified one.
ACTFLEX FLEXIPLUG on site
More FORSPEC jobs
Where ACTFLEX FLEXIPLUG is used
Use it for
- Corner coves, fillets and rebates in FORSPEC membrane systems
- Crack reglets over 2.0 mm within FORSPEC membrane systems
- Fast sealing of construction joints in wet or submerged areas
- Urgent repairs in pools, tanks, pipelines and reservoirs
- Precast, facade panel and tunnel segment joints
- Joints around penetrations, pipe entries, sleeves and drains
Know before you start
- Not below +10°C or above +30°C, or in sun or wind that flash-dries it
- Not for joints wider than 50 mm or moving more than 15%
- Never dilute or extend with water, cement, sand or aggregate, or re-temper
- No rain or water for the first 24 hours, and 72 hours before immersion
How to apply ACTFLEX FLEXIPLUG
- 01
Prepare
Sound, cured substrate free of dust, laitance, oil, paint and curing compounds. Saw and square joints, 5 mm to 50 mm wide. Fit closed-cell backing rod 25% oversize.
- 02
Dampen
Pre-wet the concrete to saturated surface dry: damp, with no standing water. Stop any flowing water with ACTFLEX HYDROPLUG first.
- 03
Mix
Add Part A to a clean container, slowly add Part B and mix 2–3 minutes at 400–600 rpm. Rest 1 minute and re-mix briefly. Mix only what you can place in 10–15 minutes at 20°C.
- 04
Place
Trowel, putty knife or gun it in, compacting firmly against the joint walls and backing rod. Tool immediately with a trowel lubricated with soapy water.
- 05
Coves
Cut a 15 × 15 mm rebate, or a 35 × 35 mm diagonal fillet in high-movement areas. Apply a thin bonding layer, compact into the angle and tool dense.
- 06
Cover
Membrane after 2 hours, foot traffic at 8 hours, wheels at 24 hours and permanent immersion at 72 hours.
A short guide from the data sheet. Read the full ACTFLEX FLEXIPLUG TDS before you start.
ACTFLEX FLEXIPLUG questions
How soon can I coat over FLEXIPLUG?
FORSPEC membranes can go over the finished detail after 2 hours. Initial set is 25–30 minutes and final set is 50–60 minutes at 20°C.
Can I use it on a damp slab?
Yes. It bonds to damp, saturated-surface-dry concrete. There must be no standing or ponded water, and any active flow must be stopped with ACTFLEX HYDROPLUG first.
What depth do I fill a joint to?
Joints 15 mm wide or more: depth is 50% of the width. Joints under 15 mm: depth equals the width. Minimum joint width is 5 mm and maximum is 50 mm.
How much do I need?
Consumption in kg per metre is 0.00128 × joint width (mm) × joint depth (mm). A 10 kg kit fills about 17 m of a 30 × 15 mm joint, or about 12–13 m of a 35 × 35 mm diagonal cove.
What sizes does it come in?
Two-component kits of 10 kg, 5 kg and 2 kg, mixed 1 : 1 by weight, in grey.
When can it go under water?
After at least 72 hours cure at 25°C and 50% RH. No rain or water exposure at all in the first 24 hours.
Used with ACTFLEX FLEXIPLUG
ACTFLEX FLEXIPLUG TDS and SDS
Always work from the current data sheet. Every FORSPEC TDS and SDS →
Specify it. Or buy it.
Send the drawings or photos and FORSPEC comes back with the system, the details and the quantities. Or find a FORSPEC stockist for ACTFLEX FLEXIPLUG.