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Hi-Flex 50: A Technical Overview
Hi-Flex 50 is a high-performance, MS Polymer-based hybrid sealant designed for critical construction, marine, and waterproofing applications. With primerless adhesion to most substrates, it delivers exceptional performance on aluminium, concrete, powder-coated metals, and timber. It resists UV, weather, and humidity exposure, cures without bubbling, and accommodates ±25% joint movement. Its neutral cure, non-slump thixotropic formula allows easy tooling, while compatibility with Everflex membranes makes it ideal for integrated systems. Whether used as a bond breaker, adhesive, or façade joint sealant, Hi-Flex 50 offers Australian trades a reliable, low-VOC solution with long-term durability.
±25%
Joint Movement Capability (ASTM C719)
Core Features & Specifications
- Single-component MS Polymer with neutral cure and low VOC (1.5%)
- Primerless adhesion to metal, timber, fibre cement, and powder-coated surfaces
- High movement tolerance of ±25% — ideal for joints with thermal variation
- Excellent UV, humidity, and mould resistance — suitable for coastal and humid zones
- Service temperature range from -40°C to 100°C — built for Australian climate zones
- Tooling time of 10 minutes, cures at 3mm per 24 hrs at 25°C & 50% RH
- Paintable with acrylic, rubber, or oil-based paints (check flexibility)
- Compatible with Adheseal Everflex WPM, Aqua-Ban, WPUV, and SMP systems
The Hi-Flex 50 Advantage
- No bubbling in humid environments — eliminates rework and callbacks
- Works as adhesive, sealant, and bond breaker — reduce inventory and simplify site logistics
- Non-staining and non-corrosive — safe on metals, including galvanised steel
- Long shelf life (12 months) and easy-to-use 600ml sausage packaging
- Meets Green Star VOC requirements — safer for sensitive and indoor environments
Best Practices: Do's & Don'ts
Do
- Prime porous substrates like concrete with Everflex Supaprime
- Use open-cell backer rods to maintain optimal joint depth
- Apply between 5°C and 40°C — ideal for most job site conditions
- Use bond breaker tape where backer rod isn't feasible
- Tool before skin forms (within approx. 10 minutes)
Don't
- Don’t use in submerged or swimming pool applications
- Don’t apply in completely sealed environments without humidity access
- Don’t expose uncured sealant to alcohol-based cleaners or solvents
- Don’t use on bitumen, EPDM rubber, or substrates that leach plasticisers
- Don’t exceed joint depth guidelines without using backer rod
Applications in Practice: Trade Scenarios
For Builders (On-Site Applicator): Façade & Expansion Joints
The Engineering Challenge
Dynamic movement in expansion joints across façades can lead to failure if incorrect sealants are used. Traditional silicones lack durability on painted surfaces and require priming, slowing installation time.
The System-Based Solution with Hi-Flex 50
Apply a 12x12mm joint using open-cell backer rod and tool Hi-Flex 50 into place. No primer needed on powder-coated steel, saving time. The sealant flexes with ±25% movement, withstanding expansion/contraction cycles.
Best Practice Note
Use bond breaker tape on flat joints to avoid 3-point adhesion. Mask edges for a clean finish and tool before skin forms for a watertight result.
For Waterproofers (Specifier): Fillet Seals Under Membranes
The Engineering Challenge
Membrane failures often originate from improperly formed bond breakers or fillets at wall-floor junctions. Standard silicones can be incompatible or not sufficiently flexible.
The System-Based Solution with Hi-Flex 50
Apply a 10x10mm triangular bead of Hi-Flex 50 at internal junctions before membrane application. The product is fully compatible with Everflex WPUV and Aqua-Ban systems, ensuring long-term flexibility and bond integrity.
Best Practice Note
Allow minimum 24 hours cure before membrane overlay in cold/humid zones. Always check compatibility for paint or coating adhesion.
For Aluminium Fabricators (Business Owner): Seam Sealing & Panel Bonding
The Engineering Challenge
Powder-coated aluminium panels often suffer from poor sealant adhesion and cracking at seam lines. Many products require primers and complex prep, increasing labour costs.
The System-Based Solution with Hi-Flex 50
Hi-Flex 50 bonds directly to aluminium and powder coat with minimal prep. Apply using a 6x6mm bead between lap joints and tool flush. It remains elastic and non-staining, preserving finish aesthetics.
Best Practice Note
Light abrasion and a wipe-down with Adheseal 50A surface prep improves bond strength for powder coat and aluminium — no primer required in most cases.
Performance Benchmark: Hi-Flex 50 vs. Standard Alternatives
| Metric | Hi-Flex 50 | Standard Alternative | Advantage |
|---|---|---|---|
| Movement Capability | ±25% Superior Flexibility | ±12.5% | Withstands larger thermal expansion in joints |
| UV Resistance | Excellent No degradation | Moderate | No chalking, cracking or fading |
| Adhesion to Powder Coat | Primerless Time-saving | Primer required | Faster installation, less material |
| VOC Content | 1.5% Green Star Compliant | >5% | Safer for indoor and enclosed spaces |
Frequently Asked Questions
Can Hi-Flex 50 be used as a bond breaker under waterproofing membranes?
Yes, Hi-Flex 50 is fully compatible with Adheseal Everflex WPUV, SMP, and Aqua-Ban membranes. It is ideal for forming bond breaker fillet joints before applying waterproofing systems, ensuring flexibility and long-term durability at internal junctions.
What surfaces can Hi-Flex 50 be applied to without primer?
Hi-Flex 50 achieves primerless adhesion to most non-porous substrates including aluminium, powder-coated steel, PVC, glazed tiles, and waterproof membranes. For porous substrates like concrete or brick, use Everflex Supaprime for enhanced performance in critical joints.
Is Hi-Flex 50 suitable for external applications exposed to UV and weather?
Absolutely. Hi-Flex 50 is engineered for high UV and weather resistance. It remains stable under harsh Australian conditions including heat, coastal humidity, and UV exposure, making it ideal for façades, aluminium joints, and external precast panels.
How do I tool and apply Hi-Flex 50 correctly?
Apply Hi-Flex 50 using a sausage gun, ensuring even bead placement. Tool within 10 minutes using a moistened spatula for a smooth finish. Always use backer rod or bond breaker tape to control joint depth and prevent three-point adhesion.
What are the curing times for Hi-Flex 50?
Hi-Flex 50 skins in approximately 30 minutes and cures at a rate of 3mm per 24 hours under standard conditions (25°C, 50% RH). For thicker joints or cold environments, allow additional curing time before applying coatings or membranes.
Can Hi-Flex 50 be painted over?
Yes, Hi-Flex 50 is paintable with most acrylic, rubber, and oil-based coatings. Always conduct a test patch first, as rigid coatings may crack if applied over high-flex joints.
Applications & Benefits
| Application / Use Case | Key Benefit | Primary Trades |
|---|---|---|
| Expansion Joint Sealing (Façades & Panels) | ±25% flexibility and non-slump formula handle movement without failure | Builders, Commercial Contractors |
| Bond Breaker for Waterproofing Systems | Compatible with Everflex WPUV, SMP, and Aqua-Ban membranes | Waterproofers, Tilers |
| Aluminium Cladding & Seam Sealing | Adheres to powder-coated and anodised aluminium without primer | Aluminium Fabricators, Facade Installers |
| Fillet Joint Formation at Wall/Floor Junctions | Non-bubbling and paintable seal for detailing under membranes | Waterproofers, Remedial Specialists |
| Interior Acoustic & Ceiling Panel Sealing | Low-VOC and non-toxic formula meets Green Star criteria | Fitout Contractors, Drywall Installers |
| Marine & Automotive Bonding | High adhesion and chemical resistance for fibreglass and composite use | Boat Builders, Vehicle Manufacturers |
Applying Hi-Flex 50: Enhanced Protocols & Best Practices
-
1. Surface Preparation
Ensure substrates are clean, dry, and free from oil, dust, or curing agents. For porous surfaces like concrete, allow a minimum 28-day cure and wipe using a two-cloth method with Xylene. For metal or powder-coated surfaces, lightly abrade and wipe with Adheseal 50A.
Porous Substrates
Prime using Everflex Supaprime and allow 30–120 minutes drying time before applying sealant.
Non-Porous Substrates
No primer usually required. Use Adheseal 50A surface prep for metals and waterproof membranes.
Timing: Ensure all substrates are prepped immediately before application to reduce dust recontamination.Pro Tip: Avoid excessive primer pooling in joints — a thin even coat is ideal. -
2. Joint Design & Masking
Design joints with a 2:1 width-to-depth ratio. Use open-cell backer rod to control sealant depth and avoid three-sided adhesion by using bond breaker tape. Mask joint edges for clean lines if needed.
Internal Joints
Min. 5mm width/depth, backer rod recommended above 10mm.
External Façade Joints
Min. 12mm wide. Ensure UV exposure is considered in dimensioning.
Timing: Backer rod and masking should be installed just prior to sealant application to prevent moisture ingress.Pro Tip: Use bond breaker tape in tight or shallow joints where backer rod won't fit. -
3. Sealant Application
Cut nozzle at 45° angle for joint sealing or 90° for adhesive use. Insert 600ml sausage into a sealant gun and apply a continuous bead, pushing the sealant forward to avoid air entrapment.
As a Sealant
Use a 45° nozzle and fill joint fully. Tool within 10 minutes using a moistened spatula for a smooth finish.
As an Adhesive
Use a triangular bead, approximately twice as high as it is wide. Press surfaces together to compress bead to ≥2mm.
Timing: Tool immediately before skin forms (approx. 10 mins). Apply between 5°C and 40°C.Pro Tip: Use Adheseal citrus wipes for quick cleanup before cure. Remove masking tape before skin forms. -
4. Curing, Painting & Maintenance
Allow Hi-Flex 50 to cure at a rate of approximately 3mm per 24 hours (25°C, 50% RH). Paintable with acrylic and oil-based paints. Ensure the sealant is fully cured before painting.
Painting
Test flexibility of coating. Rigid coatings may crack under joint movement.
Clean-up
Use Xylene for tools while wet. Cured sealant must be removed mechanically.
Timing: Allow ≥24 hours before overlaying membranes or coatings in cold or humid environments.Pro Tip: Avoid contact with alcohol-based cleaners during cure — this may inhibit proper curing or cause discolouration.
Limitations & Safety
Product Limitations
Not suitable for permanent water immersion or internal swimming pool joints.
Use Adheseal S100 for submerged or stone-safe applications.
Avoid use in totally enclosed or sealed joints without atmospheric humidity access — curing requires air moisture.
Not recommended for direct use on bitumen, EPDM rubber, or plasticised substrates that may leach solvents or oils.
May discolour copper and brass. Perform compatibility tests before use on reactive metals or high-value finishes.
Consider Hi-Power MS609 for mirror-safe or decorative metal applications.
Avoid alcohol-based cleaners or solvents during curing — this may interfere with proper sealant performance.
Safety & Handling Requirements
Personal Protective Equipment
Wear nitrile or chemical-resistant gloves, safety glasses with side shields, and protective clothing to avoid prolonged skin contact during application.
Ventilation Requirements
Use in well-ventilated areas. Avoid use in enclosed spaces without mechanical or natural ventilation to allow moisture curing.
Fire & Handling Precautions
Non-flammable. Keep away from sources of ignition and strong oxidising agents. Do not smoke during use. Avoid contact with incompatible materials during storage.
Emergency First Aid
Eyes:
Flush immediately with running water for at least 15 minutes. Seek medical advice.
Skin:
Wash thoroughly with soap and water. Remove contaminated clothing and wash before reuse.
Inhaled:
Move to fresh air. Seek medical attention if symptoms persist.
Swallowed:
Do not induce vomiting. Rinse mouth. Seek urgent medical attention. Never give anything by mouth to an unconscious person.
Seek medical attention immediately in all cases of serious exposure.
Hi-Flex 50 Application Guide
Concrete & Masonry
Surface Preparation
Ensure surfaces are clean, dry, and free from laitance, oil, or curing compounds. Allow new concrete to cure for at least 28 days. Use a two-wipe method for cleaning using Xylene.
Primer Requirements
Primer required for high-stress or external applications
Prime with Everflex Supaprime when used in expansion joints or water-exposed zones.
Everflex SupaprimePowder-Coated Aluminium
Surface Preparation
Wipe using Adheseal 50A surface prep after light abrasion with a fine scouring pad. Avoid contamination from silicone oils or polish residues.
Primer Requirements
No primer typically required
For vertical façades or cladding joints, use 50A surface prep to enhance bond consistency.
Adheseal 50A Surface PrepFibre Cement Board
Surface Preparation
Wipe with a dry cloth to remove dust and fibres. Ensure board is structurally fixed and dry. Do not apply sealant to wet or saturated sheets.
Primer Requirements
Primer recommended for exposed vertical joints
Apply Everflex Supaprime in areas subject to water ingress or UV exposure.
Everflex SupaprimePainted Timber or Plasterboard
Surface Preparation
Ensure painted surfaces are clean and sound. Sand glossy finishes to dullness. Avoid dusty or flaking edges.
Primer Requirements
No primer typically required
Ensure good mechanical key and always test adhesion if unsure. Avoid highly flexible acrylic paints where joint movement is expected.
Waterproof Membranes
Surface Preparation
Clean membrane surface with a lint-free cloth. Ensure fully cured before sealant application. Avoid applying onto wet or soft membrane films.
Primer Requirements
No primer typically required
Hi-Flex 50 is directly compatible with Everflex Aqua-Ban, SMP, and WPUV membranes for bond breaker or detailing joints.
None Required (Membrane Compatible)
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