Flexene

Flexene is a composite sheet material for use as a substrate to construct compound surfaces.
History
Flexene was invented in 1999 by Australian Architect Andrew W Killen. Flexene was first produced by bonding layers of polystyrene sheet and a fiberglass mesh. Both outer layers were grooved to allow bending. Mass production started in 2007 using EPS shape moulding machines. Flexene was first made as a substrate to construct compound curved walls lining a themed room in the inventor’s home. Flexene is now used internally and externally on residential and commercial buildings.
Flexene is a registered trade mark for Flexene Systems Pty Ltd. Flexene has been patented in numerous countries with patents pending elsewhere.
Production
Flexene is manufactured in flat sheets 25mm (1") thick. Each sheet is moulded complete with a surface pattern of grooves to allow bending and twisting. A fiberglass mesh fabric is encapsulated in at the centreline of the sheet during the moulding process providing tensile strength and preventing the Flexene from breaking when bent. No glue or other material is used.
Properties
Flexene is a composite material or fibre-reinforced sheet made of fire retardant expanded polystyrene (EPS) and a fiberglass mesh. The sheets are grooved on both sides to allow bending or flexing. The EPS provides a lightweight insulating panel reinforced by the encapsulated fiberglass mesh. Density is 24 kg/m³. Thickness is 25mm (1").
Flexene will easily bend to a 300mm radius. Further bending is achieved with distortion and full 180º folding is possible with “snapping” of the joints. However the sheet will not break due to the fiberglass reinforcement.
Flexene is non-loadbearing and requires a timber or steel frame for support. The Flexene can be screw fixed or stapled to the frame as required.
Flexene is compatible with numerous surface coating systems. Flexene can be coated with gypsum based fillers or coating for internal applications. External applications require cement based or epoxy based filling or coating systems. Coating systems are required to be applied integrally with a fiberglass reinforcing mesh or scrim fabric to improve durability and surface strength.
Specified Assemblies of Frame, Flexene and Finishes have been fire tested and approved for use in a variety of building types and applications. Flexene can be finished in a large range of patterns, textures and colours. Flexene is non-toxic, inert and stable. Flexene reduces energy costs in buildings due to its lightweight and insulating characteristics. Flexene has no CFCs and is HCFC free, and is recyclable.
Use
Flexene is used to build curved, twisted, warped or compound curved shapes or surfaces. Flexene is fixed to a support frame then coated with a protective finishing system.
Compound curves, also known as complex curves or 3D curves, from flat sheet material are difficult surfaces to construct. Flexene is a unique material as it can form a compound curve without stretching. The grooves on the surfaces of Flexene slightly become wider or narrower to accommodate surface expansion or contraction that occurs during bending or twisting. The grooves are filled with a render grout or plaster material locking the sheet into the desired shape. Further surface coats are applied to provide protection and a decorative finish.
Flexene is used inside buildings for curved walls, ceilings and partitions. When coated with durable finishing systems Flexene is used externally for walls, fascias and facades. Flexene is used for theatre, film and television sets as well as for sculptural elements.

Main Menu

See Also

Main Menu