Conbextra ® AT constructive solutions Conbextra ® AT Non-shrink, free flow, extra high strength grout Uses Conbextra AT is used for heavy duty support beneath load bearing units especially where high static and dynamic forces occur. Also as an efficient medium for transferring all operational loads to the foundation. And for effective grouting of base plates and bolt pockets of Turbo Generators, Diesel Generating sets, Crane and Transporter Rails even with high wheel loadings, Heavy Reciprocating Equipments, Compressors, Pump sets, Pulverising mills, Metal Shearing and Processing Machines, Steel Rolling Mill Beds, Cement, Textile, Granite and Paper Plant machinery. Advantages Nonshrink : Will continue to occupy the filled space without shrinkage. Ensures high level of contact with load bearing areas. Also helps complete filling without voids. No need for external aids like rodding, poking, chaining etc. Increased strength: Can be used under heavy duty machines and equipment with high operational and static loads Prepacked and factory controlled: Consistency and reliability ensured. Site batching and blending variations eliminated. Iron free : No chance of deterioration by uncontrolled rust expansion, corrosion and staining of grout. Chloride free : Does not cause corrosion of machine parts, anchor bolts etc., in contact with grout Description Conbextra AT is supplied as a ready-to-use dry powder, requiring only the addition of water to produce a free flowing non-shrink grout. The material is a blend of specially processed cement, pregraded fillers and additives which impart : High early and final strengths due to very low water requirement Controlled expansion to retain the original volume filled even after setting Free flow characteristics without any segregation and bleeding Conbextra AT, on setting, will have a microcellular structure with high frost, fire and oil resistance. Technical Support Fosroc offers a comprehensive range of high performance, high quality concrete repair and construction products. In addition, Fosroc offers technical support service to specifiers, end-users and contractors, as well as onsite technical assistance in locations all over the country. Properties Compressive strength ( N/mm 2 ) 1 day 3days 7days 28days Flowable 40 60 70 80 (W/P 0.16) Note : Cubes cast are kept under restraint before testing, to simulate site conditions. Size of the cubes used 70.6mm x 70.6mm x 70.6mm tested at 27 0 C. Tensile strength : At 28 days tensile strength achieved is typically 3.5 N/mm 2 . Young's modulus : 28 kN/mm 2 Expansion characteristics : Controlled expansion occurs in the unset material to ensure that the grout, when cured, will continue to occupy its original volume within the confines of the voids in which it was placed (2% max.). Unrestrained expansion : Upto 4% Time for expansion : Expansion starts 20 minutes after mixing and will be completed 150 minutes later. Pressure to restrain plastic expansion: Appro. 0.004N/mm 2 Coefficient of Thermal expansion : 11 x 10 -6 per 0 C Thermal conductivity : 1 0 W/m 0 C Fresh wet density : At flowable consistency 2200kg/m 3 W/P ratio : Recommended water powder ratio for flowable consistency is 0.16. Total quantity of water required for 25 kg bag is 4 litres. Flow characteristics : The maximum distance of flow is governed by the gap width and the head of the grout. Typical data for flow design, assuming grout is poured immediately after mixing, is given in the table below : Max. flow distance in mm Grout Gap 50mm 100mm 250mm Consistency Width head head head (mm) Flowable 30 200 1000 2000 40 500 1500 2500 50 1000 2000 3000 (Formerly Conbextra Spl.)
Transcript
Con
bext
ra® A
T
constructive solutionsConbextra® AT
Non-shrink, free flow, extra high strength grout
Uses
Conbextra AT is used for heavy duty support beneath loadbearing units especially where high static and dynamic forcesoccur. Also as an efficient medium for transferring alloperational loads to the foundation. And for effective groutingof base plates and bolt pockets of Turbo Generators, DieselGenerating sets, Crane and Transporter Rails even with highwheel loadings, Heavy Reciprocating Equipments,Compressors, Pump sets, Pulverising mills, Metal Shearingand Processing Machines, Steel Rolling Mill Beds, Cement,Textile, Granite and Paper Plant machinery.
Advantages
Nonshrink : Will continue to occupy the filled space withoutshrinkage. Ensures high level of contact with load bearingareas. Also helps complete filling without voids. No needfor external aids like rodding, poking, chaining etc.
Increased strength: Can be used under heavy dutymachines and equipment with high operational and staticloads
Prepacked and factory controlled: Consistency andreliability ensured. Site batching and blending variationseliminated.
Iron free : No chance of deterioration by uncontrolled rustexpansion, corrosion and staining of grout.
Chloride free : Does not cause corrosion of machineparts, anchor bolts etc., in contact with grout
Description
Conbextra AT is supplied as a ready-to-use dry powder,requiring only the addition of water to produce a free flowingnon-shrink grout. The material is a blend of speciallyprocessed cement, pregraded fillers and additives whichimpart :
High early and final strengths due to very low waterrequirement
Controlled expansion to retain the original volume filledeven after setting
Free flow characteristics without any segregation andbleeding
Conbextra AT, on setting, will have a microcellular structurewith high frost, fire and oil resistance.
Technical Support
Fosroc offers a comprehensive range of high performance,high quality concrete repair and construction products. In
addition, Fosroc offers technical support service to specifiers,end-users and contractors, as well as onsite technicalassistance in locations all over the country.
Properties
Compressive strength ( N/mm2)
1 day 3days 7days 28days
Flowable 40 60 70 80(W/P 0.16)
Note : Cubes cast are kept under restraint before testing, tosimulate site conditions. Size of the cubes used 70.6mm x70.6mm x 70.6mm tested at 270C.
Tensile strength : At 28 days tensile strength achieved istypically 3.5 N/mm2 .
Young's modulus : 28 kN/mm2
Expansion characteristics : Controlled expansion occursin the unset material to ensure that the grout, when cured, willcontinue to occupy its original volume within the confines ofthe voids in which it was placed (2% max.).
Unrestrained expansion : Upto 4%
Time for expansion : Expansion starts 20 minutes aftermixing and will be completed 150 minutes later.
Pressure to restrain plastic expansion: Appro. 0.004N/mm2
Coefficient of Thermal expansion : 11 x 10 -6 per 0C
Thermal conductivity : 10 W/m0C
Fresh wet density : At flowable consistency 2200kg/m3
W/P ratio : Recommended water powder ratio for flowableconsistency is 0.16. Total quantity of water required for 25 kgbag is 4 litres.
Flow characteristics : The maximum distance of flow isgoverned by the gap width and the head of the grout. Typicaldata for flow design, assuming grout is poured immediatelyafter mixing, is given in the table below :
Max. flow distance in mm
Grout Gap 50mm 100mm 250mmConsistency Width head head head (mm)
Important note :Fosroc products are guaranteed against defective materials and manufacture and are sold subjectto its standard terms and conditions of sale, copies of which may be obtained on request. WhilstFosroc endeavours to ensure that any advice, recommendation specification or information it maygive is accurate and correct, it cannot, because it has no direct or continuous control over whereor how its products are applied, accept any liability either directly or indirectly arising from theuse of its products whether or not in accordance with any advice, specification, recommendationor information given by it.
N.B : This table is based on the following factors.Temperature : 270C; Water saturated substrate; Minimumunrestricted flow width : 300mm.
Application guidelines
A few DOs and DON'Ts
DO's
Measure water precisely
Mix mechanically
Use mixed grout within 30 minutes
Clean concrete and steel surfaces thoroughly beforegrouting
Build a strong, carefully designed leakproof shuttering
Start curing when grout reaches 'touch-hard' state - within4 - 6 hrs.
Cure properly for at least 7 days.
DON'Ts
Mix cement, sand, fibres, admixtures, etc., withConbextra AT
Mix water more than specified
Pour grout from two sides while grouting base plates.
Pour grout from a height
Use vibrators in grout
Use damaged bags of Conbextra AT
Detailed application procedure will be supplied by Fosrocon request.
Estimating
Packaging
Conbextra AT is supplied in 25 kg bags.
Yield
One bag of Conbextra AT will yield 12.5 litres at flowableconsistency
Shelf life
6 months when stored under cold dry conditions in unopenedbags.
Precautions
Health & Safety instructions
Conbextra AT is nontoxic, but alkaline in nature. Glovesshould be worn while handling this product. Splashes ofgrout on the skin or eyes should be washed off with cleanrunning water. In the event of prolonged irritation, seekmedical advice.
Additional information
The Fosroc range of associated products includesAdmixtures, Floorings, Protective coatings, Repair andProtection systems, sealants and waterproofing compoundsAdhesives & Mining. Separate datasheets are available onthese products.
Con
bext
ra® B
PG
constructive solutionsConbextra® BPG
High strength, pourable, non-shrink, cementitious boltpocket grout
Uses
Conbextra BPG grout is used for general purpose grouting ofbolt pockets of equipments where it is essential for the boltto withstand static and dynamic loads. Typical applicationswould be the grouting of bolt pockets of turbines,compressors, boiler pumps etc. It can also be used foranchoring a wide range of fixings. These include masts,anchor bolts and fence posts.
Advantages
Gaseous expansion system compensates for shrinkageand settlement in the plastic state
No metallic iron content to cause staining
Pre-packed material overcomes onsite batching variations
Develops high early strength without the use of chlorides
High strength ensures the performance of grout evenunder severe operating conditions.
Good bonding with substrate
High pull out bond strength
Description
Conbextra BPG grout is supplied as a ready to use drymixture. The addition of a controlled amount of clean waterproduces a pourable, non-shrink grout for bolt pockets up to1000mm depth. (Bolt pocket size 150 x 150).
Conbextra BPG grout is a blend of Portland cement, gradedfillers, graded coarse aggregates and chemical additiveswhich impart controlled expansion in the plastic state whilstminimising water demand. The low water demand ensureshigh early strength. The graded filler is designed to assistuniform mixing and produce a consistent grout. The gradedcoarse aggregates minimise the heat of hydration andcracking and produce a dense hard grout.
Technical support
An experienced technical advisory team is available to givetechnical service on request.
Properties
Compressive strength (N/mm2) @ W/P 0.17(BS 1881 - Part 116:1983)
1 day 293 days 507 days 6028 days 70
Flexural strength(N/mm2)@ 28 days ( BS 4551, 1998) 11.0
Tensile strength (N/mm2)@ 28 days (W/P - 0.17) 3.5
Pullout bond strength (N/mm2)@ 28 days (W/P - 0.17) 20
Time for expansion Start: 20 - 25 minutes(after mixing ) Finish : 120 -140 minutes
Fresh wet density Approximately 2350- 2450kg/m3 depending on actualconsistency used.
Young's modulus 28 kN/mm2
(ASTM C464-94)
Coefficient of thermalexpansion 11x10-6/0C
Unrestrained expansion 1- 3% in the plastic stateenables to over comeshrinkage.
Pressure to restrain 0.004 N/mm2 approx.plastic expansion
Specification Clauses
Performance specification
All bolt pocket grouting shown on the drawing must be carriedout with a pre packed cement based product which is chloridefree.
It shall be mixed with clean water to the required consistency.The grout must not bleed or segregate.
A positive volumetric expansion shall occur while the grout isplastic by means of gaseous system.
Conbextra® BPG
The compressive strength of the grout must exceed 55 N/mm2 at 7 days and 65 N/mm2 at 28 days.
The flexural strength of grout must exceed 10 N/mm2 @ 28days. The fresh wet density of the mixed grout must exceed2300 kg/m3.
The storage, handling and placement of the grout must be instrict accordance with the manufacturer's instructions.
Application instructions
Preparation
Bolt pockets
The inside of the pockets shall be cleaned free from debrisetc., using oil free compressed air. If the walls of the pocketare smooth, they shall be roughened by using a wire brush.
If any oil or grease deposits are observed on the walls of thepocket they shall be cleaned thoroughly. The bolts shall becleaned to remove any rust on its surface using wire brush oremery paper.
Pre-soaking
Several hours prior to grouting, the bolt pockets should beflooded with fresh water.
Immediately before grouting takes place any free water shouldbe removed with particular care being taken to blow out allbolt holes and pockets.
Mixing and placing
For best results a mechanically powered grout mixer shouldbe used. When quantities up to 50kg are used, a heavy dutyslow speed drill ( 300 - 500 rpm) fitted with a suitable paddleshall be used. Larger quantities will require a high shearvane mixer. Normal concrete mixers can also be used.
To enable the grouting operation to be carried out continuously,it is essential that sufficient mixing capacity and labour areavailable. The use of a grout holding tank with provision togently agitate the grout may be required.
Consistency of grout mix
The quantity of clean water required to be added to a 25kgbag to achieve the desired consistency is 4.25 litres(pourable).
The selected water content should be accurately measuredinto the mixer. The total content of the Conbextra BPG groutbag should be slowly added and continuous mixing shouldtake place for 5 minutes. This will ensure that the grout hasan even consistency without any bleed or segregation.
Placing
At 300C the mixed Conbextra BPG shall be placed within20 - 25 minutes of mixing to gain full benefit of the expansionprocess.
Conbextra BPG can be placed in depths up to 1000mm in asingle pour incase of a 150 x 150mm pocket.
For larger depths grouting in stages (2 or 3) isrecommended.
While grouting bolt pockets which are difficult to access, afunnel and hosepipe of 50mm internal dia shall be used.
Continuous pouring of grout is essential. Sufficient groutmust be prepared before starting. The time taken to pour abatch must be regulated to the time to prepare the next one.
It is necessary to fill the pockets up to a height of 25mmbelow the top surface. This is to provide a mechanical keyto the base plate grout.
Curing
On completion of the grouting operation, exposed areasshould be thoroughly cured. This should be done by theuse of Concure curing membrane, continuous applicationof water and/or wet hessian.
Conbextra® BPG
Limitations
Low temperature working
When the air or contact surface temperatures are 100C or belowon a falling thermometer, warm water ( 30 - 400C) isrecommended to accelerate strength development.
Normal precautions for winter working with cementitiousmaterials should be adopted.
High temperature working
At ambient temperatures above 400 C, cool water ( below 200C)should be used for mixing the grout prior to placement.
Estimating
Packaging
Conbextra BPG grout is supplied in 25 kg moisture resistantbags.
Yield
Allowance should be made for wastage when estimatingquantities required. The approximate yield per 25 kg bag fordifferent consistency is :
Consistency Pourable
Yield ( litres) 11.9
Storage
Shelf life
Conbextra BPG grout has a shelf life of 6 months if kept in a drystore in sealed bags. If stored in high temperature and highhumidity locations, the shelf life may be reduced.
Precautions
Health and Safety instructions
Conbextra BPG grout is alkaline and should not come intocontact with skin and eyes. Inhalation of dust during mixingshould be avoided.
Gloves, goggles and dust mask should be worn.
If contact with skin occurs, it should be washed with water.Splashes to eyes should be washed immediately with plentyof clean water and medical advice sought.
Fire
Conbextra BPG grout is non flammable.
Additional information
For further details about the use and selection of grouts referto the Fosroc Information module entitled 'Precision groutingin the Construction industry'.
Conbextra® BPG
INDIA/0341/C
Important note :Fosroc products are guaranteed against defective materials and manufacture and are sold subjectto its standard terms and conditions of sale, copies of which may be obtained on request. WhilstFosroc endeavours to ensure that any advice, recommendation specification or information it maygive is accurate and correct, it cannot, because it has no direct or continuous control over whereor how its products are applied, accept any liability either directly or indirectly arising from theuse of its products whether or not in accordance with any advice, specification, recommendationor information given by it.
For fixing of fully grouted steel rock bolts or wooden dowelsfor strata control in tunnelling and mining to minimise fall ofroof and as support system.
Advantages
Reliability - Laboratory controlled prepacked materialseliminate all problems of controlling grout mixingunderground and thus minimise risk in achieving a fullcolumn grouted bolt or dowel.
Encapsulated - Grout pumping totally eliminated. Allowscost saving in labour and equipment.
Chloride free - Early strength development without theuse of chlorides. Safe in use with embedded steel.
Thixotropic - Minimises grout loss from overhead holesor under conditions of running water.
Choice - Fast, Medium and slow set capsules availableto meet strength development requirements in eachsituation.
Description
Conbextra Capsule is supplied as a ready to use dry powderencapsulated in a perforated skin, available in three grades- Fast, Medium and slow set. When required for use thecapsule is submerged in water to allow sufficient water to beabsorbed through the perforations to form a non-shrink,thixotropic cementitious grout.
Additives in the grout impart controlled expansioncharacteristics, stabilise the grout and control the wateruptake to ensure an optimum water powder ratio for highearly strengths. The overall cohesiveness of the grout allowsit to be used in wet conditions or even in moving water withoutexcessive grout washout.
Technical support
The company provides a technical advisory servicessupported by a team of specialists in the field.
Properties
Effect of temperature : The hardened grout is nonflammableand will provide satisfactory anchorage up to 2000C
Toxicity : Product is non-toxic.
Setting time :
Initial Final
Fast set 9-12 min. 11-15 min.
Medium set 40-45 min. 50-60 min.
Slowset 6-7 hours 7 - 8 hours
Application instructions
Drill hole to specified depth using rotary / percussive drillingmachine; check hole is clean and free of obstruction.
Remove the required number of Conbextra Capsules fromtheir packing and place in a trough of water. ConbextraCapsules should be soaked for 3 minutes to allow correctwater uptake. The capsules may be soaked in water for amaximum of 4 minutes (Fast & medium set) or 10 minutes(Slow set) without any adverse effects.
When the Conbextra Capsule is thoroughly wetted out, removefrom the water and insert into the drilled hole. With the aid ofa stemming rod or similar, push the capsule to the end of thehole and tamp.
Insert subsequent Conbextra Capsules in a manner until therequired number are inserted.
Insert the rock bolt or dowel into the hole and push it in as faras possible. If necessary, the rock bolt/dowel should then bepushed to the bottom of the hole with the aid of an air auger(150 - 400 rpm) or leg drill.
Estimating
Packaging
Conbextra Capsules are supplied in double lined polythenesacks and corrugated cardboard boxes each containing 50nos.
Conbextra® Capsule
INDIA/0309/D
Important note :Fosroc products are guaranteed against defective materials and manufacture and are sold subjectto its standard terms and conditions of sale, copies of which may be obtained on request. WhilstFosroc endeavours to ensure that any advice, recommendation specification or information it maygive is accurate and correct, it cannot, because it has no direct or continuous control over whereor how its products are applied, accept any liability either directly or indirectly arising from theuse of its products whether or not in accordance with any advice, specification, recommendationor information given by it.
Other lengths and/or diameter as per individual customer'srequirements can be made depending on quantities.
Storage
In dry place. Unused Conbextra Capsules should always bekept under double lined polythene cover to avoid exposure toatmosphere.
Shelf life
Six months from date of manufacture when stored undernormal ware house conditions in original packagings. Shelflife will be reduced when exposed to humid conditions.
Precautions
Health and Safety
The capsule grout is based on hydraulic cements which arealkaline. Splashes on skin should be washed off. Splashesin eyes should be washed out immediately and medical adviceshould be taken.
Additional information
Fosroc supplies a range of associated products for theconstruction and anchoring industries. Details are availableon request.
Con
bext
ra® E
P10
constructive solutionsConbextra® EP10
High strength, epoxy resin grout
Uses
Provides a free flowing grout, for use where physicalproperties and chemical resistance of the hardened groutare of utmost importance. It is suitable for a wide range ofheavy duty applications including :
Underplate grouting to substantial structural elements.
Base plate grouting in dynamic load situations such asturbines and other reciprocating machinery.
Heavy industrial applications in steelworks, refinerieschemical plants and electroplating works.
Structural infill where very high strength is required.
Rail track applications, to support heavy cranes, or ontransporter rails.
Advantages
Excellent durability - high compressive, flexural andtensile strengths ensure a long working life.
Cost effective - high early strength gain promotesminimum downtime and early commissioning of plant.
User friendly - simple, full pack mixing to ensure that theperformance characteristics are achieved.
Versatile - suitable for a wide range of loading situationsincluding repetitive dynamic loads.
Excellent in service performance - non-shrink capabilityensures full surface to surface contact.
Description
Conbextra EP10 is a solvent free epoxy resin grout designedfor grouting of gap widths of 0.25 to 10mm. It is an all liquidsystem consisting of base and hardener. The componentsare supplied in the correct mix proportions designed forwhole pack mixing on site.
Specification
Where shown on the contract documents, the epoxy groutshall be Conbextra EP10 supplied by Fosroc. It shall providegood general chemical resistance, and a 7 day compressivestrength of at least 93 N/mm2.
The unrestrained surface area of the grout must be kept to aminimum. Generally, the gap between the perimeter formworkand the plate edge should not exceed 75 mm on the pouringside and 25 mm on the opposite side. Formwork on the flanksides should be kept tight to the plate edge. Air pressurerelief holes should be provided to allow venting of any isolatedhigh spots.
Formwork
The formwork should be constructed to be leak proof asConbextra EP10 is a free flow grout. This can be achieved byusing foam rubber strip or mastic sealant beneath theconstructed formwork and between joints.
For free flow grout conditions, it is essential to provide ahydrostatic head of grout. To achieve this a feeding hoppershould be used - please consult your local Fosroc office formore details.
Foundation surface
This must be free from oil, grease, or any loosely adherentmaterial. If the concrete surface is defective or has laitence,it must be cut back to a sound base. Bolt holes or fixingpockets must be blown clean of any dirt or debris.
Base plate
If delay is likely before placing steel base plates, it isrecommended that the underside and edges are coated withNitoprime 25* to prevent rust formation and ensure bondingwith the Conbextra EP10 grout. All metal surfaces should becleaned to a bright finish in accordance with SwedishStandard SA 2½ or equal. Nitoprime 25 can be applied directlyonto newly cleaned steel surfaces even if they are damp.
Conbextra® EP10
Mixing
The entire contents of the hardener can should be pouredinto the base container and mixed for 2-3 minutes or untiluniform colour is achieved. Once mixed, the material mustbe used within the specified pot life (see under Properties).After this time, unused material will have stiffened and shouldbe discarded.
Note: Immediately prior to placement, all surfaces must bedry.
Placing
Ensure that the grout can be placed within its pot life.Continuous grout flow is essential. Sufficient grout must beavailable prior to starting and the time taken to pour a batchmust be regulated to the time taken to prepare the next one.Pouring should be from one side of the void to eliminate airentrapment. The hydrostatic head must be maintained at alltimes so that a continuous grout front is achieved.
Cleaning
All tools and equipment should be cleaned immediately afteruse with Nitoflor Sol*.
Hot weather working
Whilst the performance of Conbextra EP10 at elevatedtemperatures is assured, application under such conditionscan sometimes be difficult. It is therefore suggested that, fortemperatures above 35ºC, the following guidelines are used:
(i) Store unmixed materials in a cool (preferably temperaturecontrolled) environment, avoiding exposure to directsunlight.
(ii) Keep mixing and placing equipment cool, arrangingshade protection if necessary. It is especially importantto keep cool those surfaces of the equipment which willcome into direct contact with the material itself.
(iii) Try to eliminate application in the middle of the day, andcertainly avoid application in direct sunlight.
(iv) Ensure that there are sufficient operatives available tocomplete application within the material’s pot life.
Limitations
- Grouts should not be placed in any unrestrained situation,i.e. base plate plinths, etc. Failure to comply may lead tocrack development in the grout.
Estimating
SupplyConbextra EP10 : 1 litre packNitoprime 25 : 1 and 4 litre packsNitoflor Sol : 5 & 10 litre tins
CoverageNitoprime 25 : 5.0 to 6.5 m2/litre
Storage
When stored in warehouse conditions below 35ºC,Conbextra EP10 will have a shelf life of 12 months.
Precautions
Health and safety
Some people are sensitive to epoxy resin so gloves and abarrier cream. Work or similar should be used when handlingthese products. If contact with the resin occurs, it must beremoved before it hardens with a resin removing cream.Follow by washing with soap and water. Do not use solvent.The use of goggles is recommended but should accidentaleye contamination occur, wash thoroughly with plenty of cleanwater and seek medical treatment immediately.
Fire
Nitoprime 25 and Nitoflor Sol are flammable.
Flash pointsNitoprime 25 : 39°CNitoflor Sol : 33°C
Conbextra® EP10
Additional Information
Fosroc manufactures a wide range of complementaryproducts which include :
waterproofing membranes & waterstops
joint sealants & filler boards
cementitious & epoxy grouts
specialised flooring materials
Fosroc additionally offers a comprehensive package ofproducts specifically designed for the repair andrefurbishment of damaged concrete. Fosroc’s ‘SystematicApproach’ to concrete repair features the following :
For further information on any of the above, please consultyour local Fosroc office - as below.
INDIA/0322/C
Conbextra® EP10
Important note :Fosroc products are guaranteed against defective materials and manufacture and are sold subjectto its standard terms and conditions of sale, copies of which may be obtained on request. WhilstFosroc endeavours to ensure that any advice, recommendation specification or information it maygive is accurate and correct, it cannot, because it has no direct or continuous control over whereor how its products are applied, accept any liability either directly or indirectly arising from theuse of its products whether or not in accordance with any advice, specification, recommendationor information given by it.
Provides a free flowing grout, for use where physicalproperties and chemical resistance of the hardened groutare of utmost importance. It is suitable for a wide range ofheavy duty applications including :
Underplate grouting to substantial structural elements.
Base plate grouting in dynamic load situations such asturbines and other reciprocating machinery.
Heavy industrial applications in steelworks, refinerieschemical plants and electroplating works.
Structural infill where very high strength is required.
Rail track applications, to support heavy cranes, or ontransporter rails.
AdvantagesExcellent durability - high compressive, flexural and tensilestrengths ensure a long working life.
Cost effective - high early strength gain promotes minimumdowntime and early commissioning of plant.
User friendly - simple, full pack mixing to ensure that theperformance characteristics are achieved.
Versatile - suitable for a wide range of loading situationsincluding repetitive dynamic loads.
Excellent in service performance - non-shrink capabilityensures full surface to surface contact.
Description
Conbextra EP75 is a solvent free epoxy resin grout designedfor grouting of gap widths of 10 to 75 mm. It is supplied as athree component system consisting of base, hardener andspecially graded aggregate. The components are suppliedin the correct mix proportions designed for whole pack mixingon site.
Specification
Where shown on the contract documents, the epoxy groutshall be Conbextra EP75 supplied by Fosroc. It shall providegood general chemical resistance, 7 day compressivestrength of at least 100 N/mm2 and a compressive creep of2.85N/mm² in accordance with ASTM C1181
Properties
Pot life : 2 hours @ 23°CTensile strength : 14 N/mm2 at 7 daysFlexural strength : 26 N/mm2 at 7 daysCompressive strength : 90 N/mm2 at 1 day
95 N/mm2 at 3 days100 N/mm2 at 7 days
Maximum flow distance for a head of 100 mm at 20°C :35 mm gap - 2000 mm70 mm gap - 3500 mm
Coefficient of thermal expansionASTM C531 : 28.1 x 10-6
The unrestrained surface area of the grout must be kept to aminimum. Generally, the gap between the perimeter formworkand the plate edge should not exceed 75 mm on the pouringside and 25 mm on the opposite side. Formwork on the flanksides should be kept tight to the plate edge. Air pressurerelief holes should be provided to allow venting of any isolatedhigh spots.
Formwork
The formwork should be constructed to be leak proof asConbextra EP75 is a free flow grout. This can be achieved byusing foam rubber strip or mastic sealant beneath theconstructed formwork and between joints.
For free flow grout conditions, it is essential to provide ahydrostatic head of grout. To achieve this a feeding hoppershould be used - please consult your local Fosroc office formore details.
Foundation surface
This must be free from oil, grease, or any loosely adherentmaterial. If the concrete surface is defective or has laitence,it must be cut back to a sound base. Bolt holes or fixingpockets must be blown clean of any dirt or debris.
Conbextra® EP75
Base plate
If delay is likely before placing steel base plates, it isrecommended that the underside and edge are coated withNitoprime 25* to prevent rust formation and ensure bondingwith the Conbextra EP75 grout. All metal surfaces should becleaned to a bright finish in accordance with SwedishStandard SA 2½ or equal. Nitoprime 25 can be applied directlyonto newly cleaned steel surfaces even if they are damp.
Mixing
The entire contents of the hardener can should be pouredinto the base container and mixed until homogeneous. Placethe mixed base and hardener into a suitable forced actionmixer making sure that the entire volume is poured in. Addthe aggregate and mix for 2-3 minutes or until uniform colouris achieved. Once mixed, the material must be used withinthe specified pot life (see under Properties). After this time,unused material will have stiffened and should be discarded.
Note: Immediately prior to placement, all surfaces must be dry.
Placing
Ensure that the grout can be placed within its pot life.Continuous grout flow is essential. Sufficient grout must beavailable prior to starting and the time taken to pour a batchmust be regulated to the time taken to prepare the next one.Pouring should be from one side of the void to eliminate airentrapment. The hydrostatic head must be maintained at alltimes so that a continuous grout front is achieved.
Cleaning
All tools and equipment should be cleaned immediately afteruse with Nitoflor Sol*.
Hot weather working
Whilst the performance of Conbextra EP75 at elevatedtemperatures is assured, application under such conditionscan sometimes be difficult. It is therefore suggested that, fortemperatures above 35°C, the following guidelines are used:
i Store unmixed materials in a cool (preferably temperaturecontrolled) environment, avoiding exposure to directsunlight.
ii Keep mixing and placing equipment cool, arrangingshade protection if necessary. It is especially important tokeep cool those surfaces of the equipment which will comeinto direct contact with the material itself.
iii Try to eliminate application in the middle of the day, andcertainly avoid application in direct sunlight.
iv Ensure that there are sufficient operatives available tocomplete application within the material’s pot life.
Limitations
- Grouts should not be placed in any unrestrained situation,i.e. base plate plinths, etc. Failure to comply may lead tocrack development in the grout.
Estimating
SupplyConbextra EP75 : 14 litre packsNitoprime 25 : 1 and 4 litre packsNitoflor Sol : 5 & 20 litre tins
CoverageNitoprime 25 : 5.5 - 6.5 m2/litre
Storage
When stored in warehouse conditions below 35°C, ConbextraEP75 will have a shelf life of 12 months.
Conbextra® EP75
Precautions
Health and safety
Some people are sensitive to epoxy resin so gloves and a barriercream or similar should be used when handling these products.If contact with the resin occurs, it must be removed before ithardens with a resin removing cream. Follow by washing withsoap and water. Do not use solvent. The use of goggles isrecommended but should accidental eye contamination occur,wash thoroughly with plenty of clean water and seek medicaltreatment immediately.
Fire
Nitoprime 25 and Nitoflor Sol are flammable.
Flash pointsNitoprime 25 : 39°CNitoflor Sol : 33°C
Conbextra® EP75
INDIA/0355/A
Important note :Fosroc products are guaranteed against defective materials and manufacture and are sold subjectto its standard terms and conditions of sale, copies of which may be obtained on request. WhilstFosroc endeavours to ensure that any advice, recommendation specification or information it maygive is accurate and correct, it cannot, because it has no direct or continuous control over whereor how its products are applied, accept any liability either directly or indirectly arising from theuse of its products whether or not in accordance with any advice, specification, recommendationor information given by it.
An epoxy free flow grout for use in situations where heavydynamic or mobile loads are encountered. The gap betweena base plate and substrate will need to be filled in suchapplications as reciprocating machinery, testing equipment,heavy crane and transporter rails, high speed turbines andcentrifuges and drop forges.
Specially suitable for a wide gap range above 10mm - 120mm.It can also be used when high ambient temperatures areencountered.
Also for use in conditions where chemical spillage may beencountered. Typical situations could be met in steel works,refineries, electroplating works and chemical plants.
Advantages
Low temperature rise during cure ( <95 0 F)
Low creep characteristics under sustained loading
Resistant to repetitive dynamic loads
Non-shrink and hence ensures complete surface contactand bond
High compressive, tensile and flexural strengths
Fast, convenient installation with early strength gain
Impervious to oil and chemical attack
Strong bond to metal and concrete
Suitable for narrow and large gaps
Description
Conbextra EP120LE is a low exotherm material which isparticularly suitably where long working time is needed andalso for narrow & large gaps.
Technical support
Fosroc offers a technical support package to specifiers andcontractors as well as technical advice from staff withunrivalled experience in the industry.
Properties
The following results are typical for the hardened grout at300C
Density ( kg/m3) 2475
Compressive strength ( N/mm2) 7 days 120
Tensile strength ( N/mm2) 7 days 17
Flexural strength ( N/mm2) 7 days 33
Chemical resistance
Conbextra EP120LE is resistant to oil, grease, fats, mostchemicals, mild acids and alkalis, fresh and sea water.Consult Fosroc when exposure to solvent or concentratedchemicals is anticipated.
Pot life
Ambient temperature affects the time for which bulk materialwill remain fluid.
Typical values in minutes are :
200C 300C 400C
Conbextra EP120LE 120 90 50
Conbextra EP120LE will develop a temperature rise on mixing.Its extent will be a function of the volume to surface ratio, theambient temperature as well as the mass and thermalconductivity of the surrounding materials. Contact Fosroc forspecific data.
Application instructions
Preparation
Foundation surface
All contact surface must be free from oil, grease, free standingwater or any loosely adherent material. Concrete surfacesshould be cut back to a sound base.
All dust must be removed and bolt holes or fixing pocketsblown clean of any dirt or debris.
Conbextra® EP120LE
Steel surfaces
All steel surfaces should be shot blasted free of rust andflaky mill scale. Cleaned surfaces may be protected by theapplication of Nitoprime 28.
Formwork
The formwork should be constructed to be leakproof asConbextra EP120LE is a free flowing grout. Loss of groutonce the material is placed, but not hardened, will result inincomplete filling of the gap.
For free flow grout conditions it is essential to provide ahydrostatic head of grout. To achieve this a feeding hoppersystem should be used.
Mixing
Pour all the contents of the hardener pack into the basecontainer. Mix using a slow speed power mixer untilhomogenous.
Pour all the resultant liquid into a container with a capacity of15 - 25 litres. Add all the filler provided. Mix using a slowspeed power mixer for 2 minutes or until a uniform colour isachieved in the grout.
Placing
The mixed grout should be poured steadily from one sideonly to eliminate the entrapment of air.
Continuous grout flow is essential. Sufficient grout must beavailable prior to starting.
Time taken to pour a batch should be regulated to the timetaken to prepare the next batch.
Flow characteristics
The maximum distance of flow is governed by the gapthickness, the head of grout applied and ambienttemperature. Conbextra EP120LE is a free flow grout andthe minimum gap thickness required is 5mm.
Cleaning
All tools and equipment should be cleaned immediately afteruse with Nitoflor Sol. Spillages should be absorbed withsand or sawdust and disposed in accordance with localregulations.
Limitations
Temperature
During application
For Conbextra EP120LE, at temperatures below 20 deg.Cthe cure rate may be slow, but will go to completion providedthe temperature remains above 50C.
In service
The cured grout, which is completely resistant to frost andsub-zero temperatures, is suitable for use upto 600C.
Conbextra® EP120LE
Estimating
Packaging
Conbextra EP120LE is supplied in 16kg packs containingbase, hardener and filler.
Yield
6.4 litres.
Shelf life
Conbextra EP120LE has a shelf life of 12 months if kept indry conditions at 300C.
Precautions
Health and Safety instructions
Conbextra EP120LE contains resins which may causesensitisation by skin contact. Avoid contact
with skin and eyes and inhalation of vapour. Wear suitableprotective clothing, gloves and eye/face protection. Barriercreams provide additional skin protection. Should accidentalskin contact occur, remove immediately with a resin removingcream,. followed by soap and water. Do not use solvent.Incase of contact with eyes, rinse immediately with plenty ofclean water and seek medical attention immediately - do notinduce vomiting.
Keep away from sources of ignition - no smoking. Wearsuitable protective clothing, gloves and eye/face protection.Use only in well ventilated area.
Fire
Nitoflor Sol is flammable. In the event of fire extinguish withCarbon dioxide or foam.
Nitoflor Sol : Flammable liquid
Flash Point : 330C
Additional information
The Fosroc range of associated products includes highstrength cementitious, epoxy grout, polyester resin basedmortar for rapid presetting of steel shims to level or for directbedding of small base plates; Resin Anchoring systems forsame day anchoring of bolts in drilled holes in concrete orrock. Also available a range of products for use inconstruction; viz., admixtures, curing compounds, releaseagents, flooring systems and repair mortars.
Separate datasheets are available on these products.
Conbextra® EP120LE
Important note :Fosroc products are guaranteed against defective materials and manufacture and are sold subjectto its standard terms and conditions of sale, copies of which may be obtained on request. WhilstFosroc endeavours to ensure that any advice, recommendation specification or information it maygive is accurate and correct, it cannot, because it has no direct or continuous control over whereor how its products are applied, accept any liability either directly or indirectly arising from theuse of its products whether or not in accordance with any advice, specification, recommendationor information given by it.
Suitable for use where heavy, dynamic or mobile loads areencountered. Particularly well suited to applications wherelong working time and/or low exotherm properties are required
Grouting under reciprocating or rotating equipment
Heavy crane/transporter rails
High speed turbines and centrifuges
Grouting over long distances or in thick sections
All applications under conditions of high ambienttemperature
Advantages
Low creep characteristics under sustained loading.
Resistant to repetitive dynamic loads.
Non-shrink and hence ensures complete surface contactand bond.
High compressive, tensile and flexural strengths.
Withstands a wide range of chemicals.
Description
Conbextra EP300 is a low exotherm material which isparticularly suitable where long working time is needed; forlarge gaps (up to 300 mm) or for grouting at high ambienttemperatures (up to 55°C).
Conbextra EP300 is a three component system consistingof base resin, liquid hardener and specially graded inert fillers.
Technical support
Fosroc offers a comprehensive range of high performance,high quality construction products all backed by BS 5750certification. Fosroc offers a technical support package tospecifiers and contractors as well as technical advice fromstaff with unrivalled experience in the industry.
7 days - 11 12.5Flexural strength (N/mm2)BS 6319 Part 3: 1983:
7 days - 30 30Density : 1950 kg/m³Pot life : 50 min at 40°C
90 min at 30°C240 min at 20°C
Chemical resistance: Oil, grease, fats, most chemicals,mild acids and alkalis, fresh andsea water.
Note: Consult the local Fosroc Office when exposure tosolvents or concentrated chemicals is anticipated.
Specification
Supplier specification
All epoxy resin grouting where shown on the contractdocuments, shall be carried out using Conbextra EP300manufactured by Fosroc and used in accordance with themanufacturer's current data sheet.
Performance specification
All epoxy resin grouting where shown on the contractdocuments must be carried out with a factory packed product.The hardened grout must have strengths exceeding:
Compressive strength : 80 N/mm2 at 7 daysTensile strength : 10 N/mm2 at 7 daysFlexural strength : 27 N/mm2 at 7 days
The storage, handling and placement of the grout must be instrict accordance with the manufacturer's instructions.
Low exotherm, epoxy resin free flow grout
Conbextra® EP300
Application instructions
Preparation
Underplate grouting
The unrestrained surface area of the grout must be kept to aminimum. Generally, the gap between the perimeter formworkand the plate edge should not exceed 75 mm on the pouringside and 25 mm on the opposite side. Formwork on the flanksides should be kept tight to the plate edge. Air pressurerelief holes should be provided to allow venting of any isolatedhigh spots.
Formwork
The formwork should be constructed to be leak proof asConbextra EP300 is a free flow grout. This can be achievedby using foam rubber strip or mastic sealant beneath theconstructed formwork and between joints. Loss of grout oncethe material is placed, but not hardened, will result inincomplete filling of the gap.
For free flow grout conditions, it is essential to provide ahydrostatic head of grout. To achieve this a feeding hoppershould be used - please consult your local Fosroc office formore details.
Typical on-plate shutter system
Removable hopper: for larger pours the grout may be handplaced or pumped into a removable hopper (trough)
Foundation surface
This must be free from oil, grease, or any loosely adherentmaterial. If the concrete surface is defective or has laitence,it must be cut back to a sound base. Bolt holes or fixingpockets must be blown clean of any dirt or debris.
Base plate
If delay is likely before placing steel base plates, it isrecommended that the underside and edges are coated withNitoprime 25* to prevent rust formation and ensure bondingwith the Conbextra EP10 grout. All metal surfaces should becleaned to a bright finish in accordance with SwedishStandard SA 2½ or equal. Nitoprime 25 can be applied directlyonto newly cleaned steel surfaces even if they are damp.
Mixing
Pour all the contents of the hardener pack into the basecontainer. Mix using a slow speed power mixer untilhomogeneous.
Pour all the resultant liquid into a container with a capacity of20 - 25 litres. Add all the filler provided and mix using a slowspeed power mixer for two minutes or until a uniform colouris achieved in the grout.
Placing
The mixed grout should be poured steadily from one sideonly to eliminate the entrapment of air.
Continuous grout flow is essential.
Sufficient grout must be available prior to starting.
The time taken to pour a batch should be regulated to thetime taken to prepare the next batch.
Flow characteristics
The maximum distance of flow is governed by the gapthickness, the head of grout applied and the ambienttemperature.
Cleaning
All tools and equipment should be cleaned immediately afteruse with Nitoflor Sol*. Spillages should be absorbed withsand or sawdust and disposed in accordance with localregulations.
Conbextra® EP300
Low temperature working
Whilst the performance of Conbextra EP300 at lowtemperatures is assured, application under such conditionscan sometimes be difficult. It is therefore suggested that, fortemperatures below 25ºC, the following guidelines areadopted:
(i) Store unmixed materials in a warm(preferablytemperature controlled) environment.
(ii) Keep mixing and placing equipment warm, arrangingprotection if necessary. It is especially important to keepwarm those surfaces of the equipment which will comeinto direct contact with the material itself.
(iii) Try to eliminate application in the coldest time of the day,and certainly avoid application at night.
(iv) Minimum temperature of the mixed material to be 25ºC,and loading shall only be allowed 72 hours after pouring.
Limitations
- Grouts should not be placed in any unrestrained situation,i.e. base plate plinths, etc. Failure to comply may lead tocrack development in the grout.
- At temperatures below 25°C the cure rate may be slow, butwill go to completion provided the temperature remainsabove 5°C.
- The cured grout, which is resistant to frost and sub-zerotemperatures, is most suited for ambient temperatures inthe range of 25° to 55°C.
All Conbextra EP300 has a shelf life of 12 months if kept in dryconditions at 20°C. If stored at high temperatures the shelf lifewill be reduced.
Precautions
Health and safety
Conbextra EP300 contains resins which may causesensitisation by skin contact. Avoid contact with skin and eyesand inhalation of vapour. Wear suitable protective clothing,gloves and eye/face protection. Barrier creams provideadditional skin protection. Should accidental skin contact occur,remove immediately with a resin removing cream, followed bysoap and water. Do not use solvent. In case of contact witheyes, rinse immediately with plenty of clean water and seekmedical advice. If swallowed seek medical attentionimmediately - do not induce vomiting.
Fire
Nitoflor Sol is flammable. Keep away from sources of Ignition.No smoking. In the event of fire extinguish with CO2 or foam.Do not use a water jet.
Flash pointsNitoflor Sol : 33°C
For additional information see relevant Material Safety DataSheet.
Conbextra® EP300
INDIA/0356/B
Important note :Fosroc products are guaranteed against defective materials and manufacture and are sold subjectto its standard terms and conditions of sale, copies of which may be obtained on request. WhilstFosroc endeavours to ensure that any advice, recommendation specification or information it maygive is accurate and correct, it cannot, because it has no direct or continuous control over whereor how its products are applied, accept any liability either directly or indirectly arising from theuse of its products whether or not in accordance with any advice, specification, recommendationor information given by it.
Fosroc manufactures a wide range of complementaryproducts which include :
waterproofing membranes & waterstops
joint sealants & filler boards
cementitious & epoxy grouts
specialised flooring materials
Fosroc additionally offers a comprehensive package ofproducts specifically designed for the repair andrefurbishment of damaged concrete. Fosroc’s ‘SystematicApproach’ to concrete repair features the following :
For further information on any of the above, please consultyour local Fosroc office - as below.
Con
bext
ra ®
EU
W
constructive solutionsConbextra® EUW
Water insensitive epoxy material
Uses
For use in grouting gaps ranging from 0.25mm to 10mm asan epoxy injection material.
As an underwater epoxy fillerised grout in conjunction withquartz filler.
As an underwater epoxy repair mortar in conjunction withquartz filler.
Advantages
Water insensitive. Can be applied under water.
Low creep characteristics
High compressive, tensile and flexural strengths
Fast, convenient pumping with early strength gain
Withstands a wide range of chemicals
Description
Conbextra EUW is a two part , low viscous epoxy resin systemconsisting of a water insensitive base and hardener.
Technical support
Fosroc offers technical support service to specifiers, end-users and contractors, as well as on-site technical assistancein locations all over the country.
Properties
The following results are typical for the mixed grout
Flexural strength (N/mm2)@ 7 days (BS6319 Part 3) 42
Bond strength @ 7 days 28( ASTM C882 )
Chemical resistance
Conbextra EUW is resistant to oil, grease, fats, mostchemicals, mild acids and alkalis, fresh and sea water.
Exotherm
All epoxy systems will develop a temperature rise on mixing.Its extent will be a function of the volume to surface ratio, theambient temperature as well as the mass and thermalconductivity of the surrounding materials. Contact Fosroc forspecific data on each product.
Application instructions
Prepare the surface and seal the cracks with a sealingcompound which can also be used for bonding injectionnipples. Depending on the crack width and depth the distancebetween nipples should be 200 to 500 mm.
Mixing and placing
Pour all the contents of the hardener pack into the basecontainer. Mix using a slow speed power mixer for 60 seconds.Use a suitable grout pump for injecting the material intocracks. After 24 hours remove the nipples and seal the holesor voids with suitable sealing the compound and allow to cure.
For filling cracks of more than 10mm :
Conbextra EUW has to be mixed with clean graded quartzsand upto 1:3.5 parts by weight depending on the consistencyrequired. Mixing can be done with a paddle fitted to a drillingmachine.
For using as an under water epoxy mortar :
Conbextra EUW has to be thoroughly mixed with clean gradedquartz upto 1:7 parts by weight using a heavy duty mixer.
Cleaning
All tools and equipment should be cleaned immediately afteruse with Nitoflor Sol. Spillages should be absorbed with sandor sawdust and disposed in accordance with local HSEregulations.
Estimating
Packaging
Conbextra EUW : 1.5 litre packs
Storage
All Conbextra EUW products has a shelf life of 12 months inunopened container under normal warehouse conditions.
Conbextra® EUW
INDIA/0332/D
Important note :Fosroc products are guaranteed against defective materials and manufacture and are sold subjectto its standard terms and conditions of sale, copies of which may be obtained on request. WhilstFosroc endeavours to ensure that any advice, recommendation specification or information it maygive is accurate and correct, it cannot, because it has no direct or continuous control over whereor how its products are applied, accept any liability either directly or indirectly arising from theuse of its products whether or not in accordance with any advice, specification, recommendationor information given by it.
Conbextra EUW contains resins which may causesensitisation by skin contact. Contact with skin and eyes andinhalation of vapour shall be avoided. Suitable protectiveclothing, gloves and eye/face protection shall be worn. Barriercreams provide additional skin protection. Should accidentalskin contact occur, it shall be removed immediately with aresin removing cream, followed by washing with soap andwater. Solvent should not be used. In case of contact with eyes,it shall be rinsed immediately with plenty of clean water andimmediate medical attention shall be sought.
Fire
Nitoflor Sol is flammable. In the event of fire extinguish withCO2 or foam. DO NOT use waterjet.
Flash point : 330C
Should be kept away from sources of ignition . Smoking isprohibited during handling / application of the product. Suitableprotective clothing, gloves and eye/face protection should beworn. Use in well ventilated areas is suggested.
Additional information
The Fosroc range of associated products include high strengthcementitious, epoxy grout, polyester resin based mortar forrapid presetting of steel shims to level or for direct beddingof small base plates; Resin Anchoring systems for same dayanchoring of bolts in drilled holes in concrete or rock. Alsoavailable a range of products for use in construction; viz.,admixtures, curing compounds, release agents, flooringsystems and repair mortars.
Separate datasheets are available on these products.
Con
bext
ra® G
P2
constructive solutionsConbextra® GP2
Free flow, high strength, non-shrink, cementitiousprecision grout
Uses
Conbextra GP2 is used for precision grouting where it isessential to withstand static and dynamic loads. Typicalapplications would be the grouting of base plates of turbines,compressors, boiler feed pumps etc., It can also be used foranchoring a wide range of fixings. These include masts,anchor bolts and fence posts.
Advantages
Gaseous expansion system compensates for shrinkageand settlement in the plastic state
No metallic iron content to cause staining
Pre-packed material overcomes onsite batching variations
Develops high early strength without the use of chlorides
High ultimate strength ensure the durability of the hardenedgrout
Free flow ensures high level of contact with load bearingarea
Description
Conbextra GP2 is supplied as a ready to use dry powder. Theaddition of a controlled amount of clean water produces a freeflowing, non-shrink grout for gap thicknesses up to 100mm.
Conbextra GP2 is a blend of Portland cement, graded fillersand chemical additives which impart controlled expansion inthe plastic state whilst minimising water demand. The lowwater demand ensures high early strength. The graded fillersare designed to assist uniform mixing and produce a consistentgrout.
Technical support
An experienced technical advisory team is available to givetechnical service on request.
Properties
Compressive strength : (BS 1881 - Part 116: 1983)
Compressive strength (Nmm2)
Age (days) Consistency
Flowable (W/P 0.18) Pourable (W/P 0.165)
1 24 273 45 547 55 6628 65 78
Compressive strength with addition of aggregates
Age Compressive strength (N/mm2) W/P 0.18(days) % of aggregates ( IS 516 - 1959)
50% 75% 100%
1 28 30 323 50 52 557 60 63 6828 70 75 78
Flexural strength ( BS 4551, 1998)
Age Flexural strength (N/mm2)(days) W/P 0.18
1 2.53 7.07 9.028 10.0
Tensile strength 3.5N/mm2 @ 28 days(W/P - 0.18)
Pullout bond strength 17 N/mm2 @ 7 days(W/P - 0.18) 20 N/mm2 @ 28 days
Time for expansion Start : 20 minutes(after mixing ) Finish : 120 minutes
Freshwet density Approximately 2220kg/m3
depending on actual consistency used
Young's modulus 28 kN/mm2
(ASTM D469 - 94)
Dynamic load resistance Specimens of Conbextra GP2remained undamaged evenafter subjecting them toalternate loads of 5N/mm2 &25N/mm2 at the rate of 500cycles / minute for two millioncycles.
Conbextra® GP2
Coefficient of thermal expansion 11 x 10 -6/ 0 C
Unrestrained expansion 2 - 4 % in the plasticstate enables toovercome shrinkage.
Pressure to restrain : 0.004 N/mm2 approx.plastic expansion
Flow characteristics : The maximum distance of flow isgoverned by the gap width and the head of the grout.Typical data for flow design assuming grout is pouredimmediately after mixing is given in the table below :
Grout Max. flow distance in mmconsistency Gap width 50mm 100mm 250mm (mm) head head head
Note : This table is based on the following factors temperature- 300C ; Water saturated substrate; Minimum unrestricted flowwidth is 300mm.
Specification Clauses
Performance specification
All grouting shown on the drawing must be carried out with apre packed cement based product which is chloride free.
It shall be mixed with clean water to the required consistency.The grout must not bleed or segregate.
A positive volumetric expansion shall occur while the grout isplastic by means of gaseous system.
Typical detail of stanchion base plate
The compressive strength of the grout must exceed 50 N/mm2
at 7 days and 60 N/mm2 at 28 days.
The flexural strength of grout must exceed 9N/mm2 @ 28 days.The fresh wet density of the mixed grout must exceed 2150 kg/m3.
The storage, handling and placement of the grout must be instrict accordance with the manufacturer's instructions.
Application instructions
Preparation
Foundation surface
The substrate surface must be free from oil, grease or anyloosely adherent material. If the concrete surface is defectiveor has laitence, it must be cut back to a sound base. Bolt holesand fixing pockets must be blown clean of any dirt or debris.
Pre-soaking
Several hours prior to placing, the concrete substrates shouldbe saturated with fresh water.
Immediately before grouting takes place any free water shouldbe removed with particular care being taken to blow out allbolt holes and pockets.
Base plate
It is essential that this is clean and free from oil, grease orscale. Air pressure relief holes should be provided to
allow venting of any isolated high spots.
Levelling shims
If these are to be removed after the grout has hardened, theyshould be treated with a thin layer of grease.
Formwork
The formwork should be constructed to be leakproof. Thiscan be achieved by using foam rubber strip or mastic sealantbeneath the constructed formwork and between joints.
In some cases it is practical to use a sacrificial semi-drysand and cement formwork. The formwork should includeoutlets for pre-soaking.
Conbextra® GP2
Unrestrained surface area
This must be kept to a minimum. Generally the gap widthbetween the perimeter formwork and the plate edge shouldnot exceed 150mm on the pouring side and 50mm on theopposite side. It is advisable, where practical, to have no gapat the flank sides.
Mixing and placing
Mixing
For best results a mechanically powered grout mixer shouldbe used. When quantities up to 50kg are used, a heavy dutyslow speed drill (400-500 rpm) fitted with a paddle is suitable..Larger quantities will require a heavy duty mixer.
To enable the grouting operation to be carried out continuously,it is essential that sufficient mixing capacity and labour areavailable. The use of a grout holding tank with provision togently agitate the grout may be required.
Consistency of grout mix
The quantity of clean water required to be added to a 25kgbag to achieve the desired consistency is given below :
Pourable : 4.125 litres
Flowable : 4.500 litres
The selected water content should be accurately measuredinto the mixer. The total content of the Conbextra GP2 bagshould be slowly added and continuous mixing should takeplace for 5 minutes. This will ensure that the grout has asmooth even consistency.
Placing
At 300C place the grout within 20 minutes of mixing to gainfull benefit of the expansion process.
Conbextra GP2 can be placed in thicknesses up to 100mmin a single pour when used as an underplate grout.
For thicker sections it is necessary to fill out Conbextra GP2with well graded silt free aggregate to minimise heat buildup. Typically a 10mm aggregate is suitable. 50 - 100%aggregate weight of Conbextra GP2 can be added.
Any bolt pockets must be grouted prior to grouting betweenthe substrate and the base plate.
Continuous grout flow is essential. Sufficient grout must beprepared before starting. The time taken to pour a
batch must be regulated to the time to prepare the next one.
Typical hopper system
Removable hopper : For large pours the grout may be handplaced or pumped into a removable hopper ( trough)
Pouring should be from one side of the void to eliminate anyair or presoaked water becoming trapped under the baseplate. It is advisable to pour the grout across the shortestdistance of travel. The grout head must be maintained at alltimes so that a continuous grout front is achieved.
Where large volumes have to be placed Conbextra GP2 maybe pumped. A heavy duty diaphragm pump is
recommended for this purpose. Screw feed and piston pumpsmay also be suitable.
Curing
On completion of the grouting operation, exposed areasshould be thoroughly cured. This should be done by the useof Concure WB curing membrane, continuous application ofwater and/or wet hessian.
Conbextra® GP2
INDIA/0302/D
Important note :Fosroc products are guaranteed against defective materials and manufacture and are sold subjectto its standard terms and conditions of sale, copies of which may be obtained on request. WhilstFosroc endeavours to ensure that any advice, recommendation specification or information it maygive is accurate and correct, it cannot, because it has no direct or continuous control over whereor how its products are applied, accept any liability either directly or indirectly arising from theuse of its products whether or not in accordance with any advice, specification, recommendationor information given by it.
When the air or contact surface temperatures are 100C orbelow on a falling thermometer, warm water ( 30 - 400C) isrecommended to accelerate strength development.
For ambient temperature below 100C the formwork shouldbe kept in place for at least 36 hours.
Normal precautions for winter working with cementitiousmaterials should then be adopted.
High temperature working
At ambient temperatures above 400 C, cool water ( below200C) should be used for mixing the grout prior to placement.
Estimating
Packaging
Conbextra GP2 is supplied in 25 kg moisture resistant bags.
Yield
Allowance should be made for wastage when estimatingquantities required. The approximate yield per 25 kg bag fordifferent consistency is :
Consistency Pourable Flowable
Yield ( litres) 12.5 13.3
Storage
Shelf life
Conbextra GP2 has a shelf life of 6 months if kept in a drystore in sealed bags. If stored in high temperature and highhumidity locations, the shelf life may be reduced.
Precautions
Health and Safety instructions
Conbextra GP2 is alkaline and should not come into contactwith skin and eyes. Inhalation of dust during mixing shouldbe avoided.
Gloves, goggles and dust mask should be worn.
If contact with skin occurs, it shall be washed with water.Splashes to eyes should be washed immediately with plentyof clean water and medical advice sought.
Fire
Conbextra GP2 is non flammable.
Additional information
For further details about the use and selection of grouts referto the Fosroc Information module entitled 'Precision groutingin the Construction industry'.
Con
bext
ra® G
PI
constructive solutions
Non-shrink, free flow, general purpose cementitiousgrout
Uses
Conbextra GPI is used for effective support beneath loadbearing units especially where static and operational loadsapply. Also as an efficient medium for transferring alloperational loads to the foundation.
For free flow grouting of machine base plates, crane andtransporter rails, standing equipment bed plates, stanchionbases, steel rolling mill beds, pump sets etc.
Advantages
Non-shrink - Will continue to occupy the filled spacewithout shrinkage. Continues to provide support to thebearing areas and dampens vibration.
Free flow - Ensures high level of contact with load bearingarea. Also helps complete filling without voids. No needfor external aids like rodding, poking, chaining etc.
Pre-packed and factory controlled - Consistency andreliability ensured. Site batching and blending variationseliminated.
Iron free - No chance of deterioration by uncontrolled rustexpansion, corrosion and staining of grout.
Chloride free - Does not cause corrosion of machine parts,anchor bolts etc., in contact with grout.
Description
Conbextra GPI is supplied as a ready to use dry powder,requiring only the addition of water to produce a free-flowing,non-shrink grout. The material is blend of specially processedcement, pregraded fillers and additives which impart :
Good early and final strengths due to very low waterrequirement
Controlled expansion to retain the original volume filledeven after setting
Free flow characteristics without any segregation andbleeding.
Conbextra GPI, on setting will have a micro-cellular structurewith high frost, fire and oil resistance.
Technical support
An experienced technical advisory team is available to givetechnical service on request.
Age Compressive strength (N/mm2 )(days) ( W/P 0.19)
Aggregate by weight 50% 75% 100%
1 12 14 16
3 29 32 34
7 38 40 44
28 48 50 53
Note : Cubes cast were kept under resistant before testingto simulate site condition. Size of the cubes used 70.6mmx 70.6mm x 70.6mm tested at 300C.
Young's modulus : 24 kN/mm2
Expansion characteristics : Controlled expansion occursin the unset material to ensure that the grout, when cured,will continue to occupy its original volume within the confinesof the voids in which it has placed.
Unrestrained expansion : 1 to 4%
Time of expansion : Starts 20 minutes Finish 150 minutes
Pressure to restrain : Approx. 0.004 N/mm2
plastic expansion
Note : It is necessary to restrain free flow grout edges over50mm wide. Otherwise unrestrained expansion may leadto some cracks.
Conbextra® GPI
Conbextra® GPI
Coefficient of thermal expansion : 11x10-6 per 0C
Thermal conductivity : 1.04 W/m0 C
Fresh wet density : At flowable consistency 2170 kg/m3
Water powder ratio :
Consistency W/P Water required per 25 kg bag
Flowable 0.19 4.75 litres
Flow characteristics : The maximum distance of flow isgoverned by the gap width and the head of the grout. Typicaldata for flow design, assuming grout is poured immediatelyafter mixing, is given in the table below.
Max flow distance in mm
Grout Gap width 50mm 100mm 250mmConsistency (mm) head head head
Flowable 30 500 1000 2000 50 1000 2000 3000+
N.B : This table is based on the following factors: Temperature- 250C : Water saturated substrate; Minimum unrestrictedflow width : 300mm.
Specification Clauses
Performance specification : All grouting ( specify detailsand areas of application) must be carried out with aprepackaged cement based product which shall be mixedwith water on site at water powder ratio of 0.19. The groutmust not bleed or segregate, must be iron free and chloridefree. Expansion of 1 - 4% shall occur while the grout is plastic.The compressive strength of the grout must exceed 30 N/mm2 at 7 days and 40 N/mm2 at 28 days. The grout must bestored, handled and placed strictly in accordance with themanufacturer's instructions.
Supplier specification : All grouting ( specify details andareas of application) must be carried out using ConbextraGPI grout manufactured by Fosroc applied strictly inaccordance with the manufacturer's application manual forConbextra grouts.
Application instructions
Preparation
Foundation surface
The substrate surface must be free from oil, grease or anyloosely adherent material. If the concrete surface is defectiveor has laitence, it must be cut back to a sound base. Boltholes and fixing pockets must be blown clean of any dirt ordebris.
Pre-soaking
Several hours prior to placing, the concrete substrates shouldbe saturated with clean water.
Immediately before grouting takes place any free water shouldbe removed with particular care being taken to blow out all boltholes and pockets.
Base plate
It is essential that this is clean and free from oil, grease orscale. Air pressure relief holes should be provided to allowventing of any isolated high spots.
Levelling shims
If these are to be removed after the grout has hardened, theyshould be treated with a thin layer of grease.
Formwork
The formwork should be constructed to be leakproof. Thiscan be achieved by using foam rubber strip or mastic sealantbeneath the constructed formwork and between joints.
In some cases it is practical to use a sacrificial semi-drysand and cement formwork. The formwork should includeoutlets for pre-soaking.
Conbextra® GPI
Unrestrained surface area
This must be kept to a minimum. Generally the gap widthbetween the perimeter formwork and the plate edge shouldnot exceed 150mm on the pouring side and 50mm on theopposite side. It is advisable, where practical, to have no gapat the flank sides.
Mixing and placing
Mixing
For best results a mechanically powered grout mixer shouldbe used. When quantities up to 50kg are used, a slow speeddrill fitted with a high shear mixer is suitable. Larger quantitieswill require a high shear vane mixer. Do not use a colloidalimpeller mixer.
To enable the grouting operation to be carried out continuously,it is essential that sufficient mixing capacity and labour areavailable. The use of a grout holding tank with provision togently agitate the grout may be required.
Consistency of grout mix
The quantity of clean water required to be added to a 25kgbag to achieve the desired consistency is given below:
Flowable : 4.75 litres
The selected water content should be accurately measuredinto the mixer. The total content of the Conbextra GPI grout bagshould be slowly added and continuous mixing should takeplace for 5 minutes. This will ensure that the grout has asmooth even consistency.
Placing
At 30 0C place the grout within 20 minutes of mixing to gainfull benefit of the expansion process.
Conbextra GPI can be placed in thicknesses up to 100mm ina single pour when used as an underplate grout.
For thicker sections it is necessary to fill out Conbextra GPIgrout with well graded silt free aggregate to minimise heatbuild up. Typically a 10mm aggregate is suitable. 50 - 100%aggregate weight of Conbextra GPI can be added.
Any bolt pockets must be grouted prior to grouting betweenthe substrate and the base plate.
Continuous grout flow is essential. Sufficient grout must beprepared before starting. The time taken to pour a batch mustbe regulated to the time to prepare the next one.
Typical hopper system
Removable hopper : For large pours the grout may be handplaced or pumped into a removable hopper ( trough). Pouringshould be from one side of the void to eliminate any air orpresoaked water becoming trapped under the base plate. Itis advisable to pour the grout across the shortest distance oftravel. The grout head must be maintained at all times so thata continuous grout front is achieved.
Where large volumes have to be placed Conbextra GPI groutmay be pumped. A heavy duty diaphragm pump isrecommended for this purpose. Screw feed and pistonpumps may also be suitable.
Curing
On completion of the grouting operation, exposed areasshould be thoroughly cured. This should be done by the useof Concure curing membrane, continuous application ofwater and/or wet hessian.
Cleaning
Conbextra GPI grout should be removed from tools andequipment with clean water immediately after use. Curedmaterial can be removed mechanically, or with Reebaklens.
Estimating
Packaging
Conbextra GPI grout ins supplied in 25 kg single lined HDPEbags.
Yield
One bag of Conbextra GPI will yield 13.7 litres at flowableconsistency.
Conbextra® GPI
INDIA/0301/E
Important note :Fosroc products are guaranteed against defective materials and manufacture and are sold subjectto its standard terms and conditions of sale, copies of which may be obtained on request. WhilstFosroc endeavours to ensure that any advice, recommendation specification or information it maygive is accurate and correct, it cannot, because it has no direct or continuous control over whereor how its products are applied, accept any liability either directly or indirectly arising from theuse of its products whether or not in accordance with any advice, specification, recommendationor information given by it.
6 months if stored in a dry and well enclosed place.
Precautions
Health and safety instructions
Conbextra GPI is non toxic, but alkaline in nature. Glovesshould be worn while handling this product. Splashes ofgrout on the skin or eyes should be washed off with cleanrunning water. In the event of prolonged irritation, medicalattention shall be sought immediately.
Additional information
For further details about the use and selection of grout referto the Fosroc Information module entitled 'Precision groutingin the Construction industry'.
Con
bext
ra® H
ES
constructive solutionsConbextra® HES
Free flow, high strength, rapid setting, cementitious grout
Uses
Conbextra HES is used for special grouting where it isessential to have fast setting and high early strength. It canalso be used for grouting/fixing glass or metallic railings inconcrete.
Advantages
Non-shrink
Quick setting
No metallic ion content to cause staining
Pre-packed material overcomes onsite batchingvariations
Develops high early strength without the use of chlorides
High ultimate strength and low permeability ensure thedurability of the hardened grout
Free flow ensures high level of contact with load bearingarea
Description
Conbextra HES is supplied as a ready to use dry powder.The addition of a controlled amount of clean water producesa free flowing, non-shrink grout for gap thicknesses up to50mm.
Conbextra HES is a blend of Portland cement, graded fillersand chemical additives which impart non shrink propertywhilst minimising water demand. The formulation ensureshigh early strength. The graded filler is designed to assistuniform mixing and produce a consistent grout.
Technical support
An experienced technical advisory team is available to givetechnical service on request.
1 hr 143 hr 296 hr 3424 hr 413 days 407 days 5128 days 59
Age Flexural strength Tensile(days) ( BS 4551) strength (N/mm2) (N/mm2)
1 4.05 1.23 4.20 1.87 4.60 3.028 5.00 4.0
Pullout bond strength 17N/mm2 @ 7 days(W/P 0.21) 20N/mm2 @ 28 days
Freshwet density 1.98 - 2.01 g/cc
Application instructions
Surface Preparation
Foundation surface
The substrate surface must be free from oil, grease or anyloosely adherent material. If the concrete surface is defectiveor has laitence, it must be cut back to a sound base. Boltholes and fixing pockets must be blown clean of any dirt ordebris.
Pre-soaking
Several hours prior to placing, the concrete substrates shouldbe saturated with fresh water.
Conbextra® HES
Immediately before grouting takes place any free water shouldbe removed with particular care being taken to blow out all boltholes and pockets.
Formwork
The formwork should be constructed to be leakproof. Thiscan be achieved by using foam rubber strip or mastic sealantbeneath the constructed formwork and between joints.
In some cases it is practical to use a sacrificial semi-dry sandand cement formwork. The formwork should include outletsfor pre-soaking.
Unrestrained surface area
This must be kept to a minimum. Generally the gap widthbetween the perimeter formwork and the plate edge shouldnot exceed 150mm on the pouring side and 50mm on theopposite side. It is advisable, where practical, to have no gapat the flank sides.
Mixing and placing
Mixing
For best results a mechanically powered grout mixer shouldbe used. When quantities up to 30kg are used, a slow speeddrill fitted with a high shear mixer is suitable.
To enable the grouting operation to be carried out continuously,it is essential that sufficient mixing capacity and labour areavailable. The use of a grout holding tank with provision togently agitate the grout may be required.
Note : When required to grout at high ambient temperatures,Fosroc recommends usage of cold water maintained at 50C.
Consistency of grout mix
The quantity of clean water required to be added to a 15kg bagto achieve the desired consistency is given below
The selected water content should be accurately measuredinto the mixer. The total content of the Conbextra HES bagshould be slowly added and continuous mixing should takeplace for 5 minutes. This will ensure that the grout has asmooth even consistency.
Placing
At 300C place the grout within 10 minutes of mixing.
Conbextra HES can be placed in thicknesses up to 50mm ina single pour.
For thicker sections it is necessary to fill out Conbextra HESwith well graded silt free aggregate to minimise heat build up.Typically a 5 - 10mm aggregate is suitable. 50 - 100%aggregate weight of Conbextra HES can be added dependingon the thickness to be applied.
Continuous grout flow is essential. Sufficient grout must beprepared before starting. The time taken to pour a batch mustbe regulated to the time to prepare the next one.
The uniformly mixed grout should be placed using a suitablegrout pump for faster application.
Curing
On completion of the grouting operation, the grout should beleft for air drying. However membrane curing agent or polythenesheet may be used to give an early surface protection fromprecipitation. But never cure the grout with water.
Cleaning
Conbextra HES should be removed from tools and equipmentwith clean water immediately after use. Cured material canbe removed mechanically, or with Reebaklens.
Conbextra® HES
Limitations
Low temperature working
When the air or contact surface temperatures are 100C or belowon a falling thermometer, the strength development may beslow.
Normal precautions for winter working with cementitiousmaterials should then be adopted.
High temperature working
At ambient temperatures above 350 C, cool water ( below 200C)should be used for mixing the grout prior to placement.Otherwise the pot life of the mixed material will be reduced.
Estimating
Packaging
Conbextra HES is supplied in 15 kg moisture resistant bags.
Yield
Allowance should be made for wastage when estimatingquantities required. The approximate yield per 15 kg bag is 9litres ( for pourable consistency).
Storage
Shelf life
Conbextra HES has a shelf life of 6 months if kept in a drystore in sealed bags. If stored in high temperature and highhumidity locations, the shelf life may be reduced.
Precautions
Health and Safety
Conbextra HES is alkaline and should not come into contactwith skin and eyes. Avoid inhalation of dust during mixing.
Gloves, goggles and dust mask should be worn.
If contact with skin occurs, wash with water. Splashes to eyesshould be washed immediately with plenty of clean water andmedical advice sought.
Conbextra® HES
INDIA/0320/D
Important note :Fosroc products are guaranteed against defective materials and manufacture and are sold subjectto its standard terms and conditions of sale, copies of which may be obtained on request. WhilstFosroc endeavours to ensure that any advice, recommendation specification or information it maygive is accurate and correct, it cannot, because it has no direct or continuous control over whereor how its products are applied, accept any liability either directly or indirectly arising from theuse of its products whether or not in accordance with any advice, specification, recommendationor information given by it.
Conbextra HF is used for free flow precision grouting in awide range of applications. These critical uses include heavyduty support beneath machine base plates, bridge bearingsand crane rails.
Advantages
Unique non-metallic dual expansion systemcompensates for shrinkages in both the plastic andhardened states.
Excellent initial flow and flow retention
High early strength facilitates rapid installation and earlyoperation of plant
Hydrogen free gaseous expansion
Chloride free
Suitable for pumping or pouring over a large range ofapplication consistencies and temperatures
Standards compliance
Conbextra HF conforms fully to U S Corps of Engineersspecification for non-shrink grout CRD-C621-89 and ASTMC1107-91 (Type C ).
Description
Conbextra HF is supplied as a ready to use dry powder. Theaddition of a controlled amount of clean water produces afree-flowing precision grout for gap thickness up to 125mm.In addition the low water requirement ensures high earlystrength and long term durability.
Conbextra HF is a blend of portland cements, graded fillersand chemical additives which impart controlled expansion inboth the plastic and hardened states. The filler gradingminimises segregation and bleeding over a wide range ofapplication consistencies.
Technical support
Fosroc offers a comprehensive range of high quality, highperformance construction products. In addition, Fosroc offerstechnical support and on-site service to specifiers, end-usersand contractors.
Properties
The following results were obtained at a water powder ratioof 0.19 and a temperature of 30o C.
Test Typical result
Compressive strengthBS 1881:part 116 1983 : 20N/mm2 @ 1 day
Setting timeBS4550 part 3 1978 : Initial set 5.5 hours Final set 7.5 hours
Time for expansion
Plastic state Start 15 minutesFinish Initial set
Hardended state Start Initial setFinish Up to 28 days
Fresh wet density Approximately 2200 kg/m3
depending on actualconsistency used.
Young's modulus ASTM C-469-83 25N/mm2
Expansion characteristics : An expansion of up to 2.5%when measured according to ASTM C827 overcomes plasticsettlement in the unset material. Longer term expansion in thehardened state is designed to comply with the requirements of ASTMC1107-91 to compensate for drying shrinkage.
Specification Clauses
Performance specification
All precision grouting (specify details and areas of application)must be carried out with a prepacked cement based productwhich is non-metallic and chloride free.
It shall be mixed with clean water to the required consistencyand not exhibit bleed or segregation.
Conbextra® HF
A volumetric expansion of up to 2% shall occur while thegrout is in a plastic state by means of a gaseous hydrogenfree system. The grout must also be compensated forshrinkage in the hardened state.
The compressive strength of the grout must exceed 40 N/mm2 at 7 days and 55N/mm2 at 28 days.
The grout shall fully conform to the requirements of US ArmyCorps of Engineers Specification for non-shrink grout CRD-C621-89 or ASTM C 1107-91.
The storage, handling and placement of the grout must be instrict accordance with the manufacturer's instructions.
Supplier specification
All precision grouting ( specify details and areas of application)must be carried out using Conbextra HF grout manufacturedby Fosroc and used in accordance with the manufacturer'sdatasheet.
Application instructions
Preparation
Foundation surface
The substrate surface must be free from oil, grease or anyloosely adherent material. If the concrete surface is defectiveor has laitence, it must be cut back to a sound base. Boltholes and fixing pockets must be blown clean of any dirt ordebris.
Pre-soaking
Several hours prior to placing, the area of cleaned foundationshould be flooded with fresh water. Immediately beforegrouting takes place, any free water should be removed.Particular care should be taken to blow out all bolt holes andpockets.
Base plate
It is essential that this is clean and free from oil, grease orscale. Air pressure relief holes should be provided to allowventing of any isolated high spots.
Levelling shims
If these are to be removed after the grout has hardened, theyshould be treated with a thin layer of grease.
Formwork
The formwork should be constructed to be leakproof asConbextra HF is a free flowing grout. This can be achievedby using foam rubber strip or mastic sealant beneath theconstructed formwork and between joints.
In some cases it is practical to use a sacrificial semi-drysand and cement formwork. The formwork should includeoutlets for pre-soaking.
The unrestrained surface area of the grout must be kept to aminimum. Generally the gap width between the perimeterformwork and the plate edge should not exceed 150mm onthe pouring side and 50mm on the opposite side. Thereshould be no gap at the flank sides.
Mixing
For best results a mechanically powered grout mixer shouldbe used. When quantities up to 50kg are used, a slow speeddrill fitted with a high shear mixer is suitable. Larger quantitieswill require a high shear vane mixer. Do not use a colloidalimpeller mixer.
It is essential that machine mixing capacity and labouravailability is adequate to enable the grouting operation to becarried out continuously. This may require the use of a holdingtank with provision for gentle agitation to maintain fluidity.
The selected water content should be accurately measuredinto the mixer. Slowly add the total contents of the ConbextraHF bag, mix continuously for 5 minutes, ensuring a smooth,even consistency is obtained.
Consistency of the mixed grout
To achieve the consistencies which are defined in CRD-C621,1989, the amount of clean water that is added to a 25kg bagat 300C is :
Flowable 4.5 litresFluid 4.8 litresMaximum flow distance at 300C
Conbextra® HF
Max. flow distance in mm
Grout consistency Gap depth 100mm 250mm mm head head
Pla ce the grout within 15 minutes of mixing to gain the fullbenefit of the expansion process.
Conbextra HF grout can be placed in thickness up to 125mmin a single pour.
Any bolt pockets must be grouted prior to grouting betweenthe substrate and the base plate.
Continuous grout flow is essential.
Removable hopper : For large pours the grout may be handplaced or pumped into a removable hopper ( trough).
Sufficient grout must be available prior to starting and thetime taken to pour a batch must be regulated to the timetaken to prepare the next one.
The mixed grout should be poured only from one side of thevoid to eliminate the entrapment of air or surplus presoakingwater. This is best achieved by pouring the grout across theshortest distance of travel. The grout head must bemaintained at all times so that a continuous grout flow isachieved.Where large volumes hve to be placed ConbextraHF grout may be pumped. A heavy duty diaphragm pump isrecommended for this purpose. Screw feed and pistonpumps may also be suitable.
Figure 2 - Typical hopper system
Holding-down boltsNon-removable : Re-bar bolt (with / without extended thread lengthand sleeve)Removable: Loksleeve bolt with stud - fully sleevedRemovable: Loksleeve bolt with hexagon head, bolt, fully sleeved.ShutteringTimber: All timber to be 50 x 75. Bolted to the substrate or fixed tobaseplate where appropriate.Plywood: All plywood to be 20mm thick.Levelling devicesSteel shims, elastic stools, double nuts. See note on alternativelevelling devices in this datasheet.For pouring head and pouring distances see tables in this datasheet
Conbextra® HF
INDIA/0304/B
Important note :Fosroc products are guaranteed against defective materials and manufacture and are sold subjectto its standard terms and conditions of sale, copies of which may be obtained on request. WhilstFosroc endeavours to ensure that any advice, recommendation specification or information it maygive is accurate and correct, it cannot, because it has no direct or continuous control over whereor how its products are applied, accept any liability either directly or indirectly arising from theuse of its products whether or not in accordance with any advice, specification, recommendationor information given by it.
On completion of the grouting operation, exposed areasshould be thoroughly cured. This should be done by the useof Concure curing membrane, continuous application of waterand/or wet hessian.
Cleaning
Conbextra HF should be removed from tools and equipmentwith clean water immediately after use. Cured material canbe removed mechanically, or with Reebaklen
Limitations
Low temperature working
When the air or contact surface temperatures are 100C orbelow on a falling thermometer warm water ( 30 - 400C) isrecommended to accelerate strength development.
For ambient temperatures below 100C the grout consistencyshould be flowable and the formwork should be maintainedin place for at least 36 hours.
Normal precautions for winter working with cementitiousmaterials should then be adopted.
High temperature working
At ambient temperatures above 350C the mixed grout shouldbe stored in the shade. Cool water ( below 200C) should beused for mixing the grout.
Estimating
Packaging
Conbextra HF is supplied in 25 kg moisture resistant bags.
Yield
Allowance should be made for wastage when estimatingquantities required. The approximate yield per 25 kg bag fordifferent consistencies is
Consistency Flowable Fluid
Yield (litres) 13.25 13.5
Storage
Shelf life
Conbextra HF grout has a shelf life of 6 months if kept in a drystore in sealed bags. If stored in high temperature and highhumidity locations the shelf life may be reduced.
Precautions
Health and Safety
Conbextra HF is alkaline and should not come into contactwith skin and eyes. Inhalation of dust during mixing shouldbe avoided. Gloves, goggles and dust mask should be worn.
If contact with skin occurs, it shall be washed with water.Splashes to eyes should be washed immediately with plentyof clean water and medical advice sought.
Con
bext
ra® H
R
constructive solutionsConbextra® HR
Heat resistant, high strength, nonshrink, free flow,cementitious Grout
Uses
Conbextra HR is used for grouting of equipment like blastfurnace, chimneys, etc., and also for concrete floorrefurbishments, where high temperature and thermalgradients are envisaged.
Advantages
Expansion system compensates for shrinkage in theplastic state
No iron content to cause staining
Prepacked material overcomes onsite batchingvariations
Develops high strength
Free flow ensures high level of contact with the loadbearing area
Thermal resistance property ensures effective functioningeven at high temperatures upto 5000C and thermal gradients
Description
Conbextra HR is supplied as a ready to use dry powder. Theaddition of a controlled amount of clean water produces afree flowing, non shrink grout for applications in hightemperature zones.
Conbextra HR is a blend of Portland cement, graded fillersand chemical additives which impart controlled expansion,while minimising water demand. The product is designedto provide resistance to high temperatures upto 5000C withoutlosing its performance characteristics.
Technical Support
An experienced technical advisory team is available to givetechnical service on request.
Properties
Compressive strength (IS : 4031 Part 6) (W/P=0.14)
* Normally 25 - 30% decrease in mechanical properties willbe noticed after exposure to 5000C.
Specification Clauses
Performance specification
All grouting must be carried out with a pre packed cementbased product which is chloride free.
It shall be mixed with clean water to the required consistency.The grout must not bleed or segregate.
A positive volumetric expansion shall occur while the grout isplastic by means of gaseous system.
The ultimate compressive strength of the grout must exceed50 N/mm2 at 28 days after 15 cycles of exposure to 5000C.
The storage handling and placement of the grout must be instrict accordance with the manufacturer's instructions.
The grout shall be capable of resisting high temperaturesupto 5000C and thermal gradients.
Conbextra® HR
Application instructions
Preparation
Foundation surface
The substrate surface must be free from oil, grease or anyloosely adherent materials. If the concrete surface is defectiveor has laitance, it must be cut back to a sound base. Boltholes and fixing pockets must be blown clean of any dirt ordebri. Immediately before grouting takes place any free watershould be removed with particular care being taken to blowout all bolt holes and pockets.
Base plate
It is essential that this is clean and free from oil, grease, rust orscale. Air pressure relief holes should be provided to allowventing of any isolated high spots.
Levelling shims
If these are to be removed after the grout has hardened, theyshould be treated with a thin layer of grease.
Form work
The formwork should be constructed to be leakproof. This canbe achieved by using foam rubber strip or mastic sealantbeneath the constructed formwork and between joints.
In some cases, it is practical to use a sacrificial semi-dry sandand cement formwork. The formwork should include outletsfor pre-soaking.
Unrestricted surface area
This must be kept to a minimum. Generally the gap widthbetween the perimeter formwork and the plate edge shouldnot exceed 150 mm on the pouring side and 50 mm on theopposite side. It is advisable, where practical, to have no gapat the flank sides.
Mixing and placing
Mixing
For best results a mechanically powered grout mixer shouldbe used. When quantities upto 50 kg are used, a slowspeed drill fitted with a high shear mixer is suitable. Largerquantities will require a high shear vane mixer. Do not usea colloidal impeller mixer.
Consistency of grout mix
The quantity of clean water required to be added to a 25 kgbag to achieve the desired consistency is 3.5 - 4.0 litres.
The selected water content should be accurately measuredinto the mixer. The total content of the Conbextra HR bagshould be slowly added and consistency.To enable thegrouting operation to be carried out continuously, it isessential that sufficient mixing capacity and labour areavailable. The use of a grout holding tank with provision togently agitate the grout may be required.
Placing
At 300C place the grout within 20 minutes of mixing to gainfull benefit of the expansion process.
Conbextra HR can be placed in thicknesses of upto 100mmin a single pour when used as an underplate grout.
For grouting sections, exceeding 100mm thick ConbextraHR shall be added with special coarse aggregate. Pleasecontact local Fosroc office.
Any bolt pockets must be grouted prior to grouting betweenthe substrate and the base plate.
Continuous grout flow is essential. Sufficient grout mustbe prepared before starting. The time taken to pour a batchmust be regulated to the time to prepare the next one.
Curing
On completion of the grouting operation, exposed areasshould be thoroughly cured. This should be done by theuse of Concure curing membrane, continuous applicationof water and/or wet hessian.
Conbextra® HR
Cleaning
Conbextra HR should be removed from tools and equipmentwith clean water immediately after use. Cured material can beremoved mechanically, or with Reebaklens.
Limitations
Low temperature working
When the air or contact surface temperatures are 100C or belowon a falling thermometer, warm water (30-400C) isrecommended to accelerate strength development. For ambienttemperature below 100C the formwork should be kept in placefor at least 36 hours.
Normal precautions for winter working with cementitiousmaterials should then be adopted.
High temperature working
At ambient temperatures above 400C, cool water (below 200C)should be used for mixing the grout prior to placement.
Estimating
Packaging
Conbextra HR is supplied in 25 Kg moisture resistant bags.
Yield
Allowance should be made for wastage when estimatingquantities required. The yield per bag depends on the quantityof water added. The approximate yield per 25 Kg bag @ W/p =0.14 is 12 Ltrs.
Storage
Shelf life
Conbextra HR has a shelf life of 6 months if kept in a dry storein sealed bags. If stored in high temperature and high humidity,the shelf life may be reduced.
Precautions
Health and Safety instructions
Conbextra HR is alkaline and should not come into contactwith skin and eyes. Avoid inhalation of dust during mixing.
Gloves, goggles and dust mask should be worn.If contactwith skin occurs, wash with water. Splashes on eyes shouldbe washed immediately with plenty of clean water and medicaladvice sought
Fire
Conbextra HR is non-flammable.
Additional information
Fosroc manufactures a wide range of products includesadmixtures, grouts & anchors, specialised flooring materials,joint sealants, waterproofing membranes, and adhesives.
Separate data sheets are available on these products.
Conbextra® HR
INDIA/0310/D
Important note :Fosroc products are guaranteed against defective materials and manufacture and are sold subjectto its standard terms and conditions of sale, copies of which may be obtained on request. WhilstFosroc endeavours to ensure that any advice, recommendation specification or information it maygive is accurate and correct, it cannot, because it has no direct or continuous control over whereor how its products are applied, accept any liability either directly or indirectly arising from theuse of its products whether or not in accordance with any advice, specification, recommendationor information given by it.
For heavy duty support beneath load bearing units especiallywhere high static and dynamic forces occur. Also as anefficient medium for transferring all operational loads to thefoundation. For effective grouting of base plates and boltpockets of Turbo Generators, Diesel Generating Sets, Craneand Transporter Rails even with high wheel loadings, HeavyReciprocating equipments, compressors, pump sets,pulverising mills, metal shearing and processing machines,steel rolling mill beds, cement, textile, granite and paper plantmachinery.
Advantages
Non shrink - Will continue to occupy the filled spacedwithout shrinkage.
High strength - Can be used under heavy duty machinesand equipment with high operational and static loads.
Free flow - Ensures high level of contact with load bearingareas. Also helps complete filling without voids. No needfor external aids like rodding, poking, chaining etc.
Prepacked and factory controlled : Consistency andreliability ensured. Site batching and blending variationseliminated.
Chloride free : Does not cause corrosion of machineparts, anchor bolts etc., in contact with grout.
Hydrogen free : Non metallic expansion system.
Description
Conbextra UHS is supplied as a ready-to-use dry powder,requiring only the addition of water to produce a free flowingnon-shrink grout. The material is a blend of speciallyprocessed cement, pre-graded fillers and additives whichimpart.
High early and final strengths due to very low waterrequirement.
Controlled expansion to retain the original volume filledeven after setting.
Free flow characteristics without any segregation andbleeding.
Conbextra UHS, on setting, will have a micro-cellularstructure with high frost, fire and oil resistance.
Properties
Compressive strength ( N/mm2) As per IS 4031 Part 6.
1 day 3days 7 days 28 days
Flowable 35 60 70 90(W/P 0.14)
Note : Cubes cast are kept under restraint before testing, tosimulate site condition. Size of the cubes used 70.6mm x70.6mm x 70.6mm tested at 300C.
Tensile strength : At 28 days tensile strength achieved istypically 45kg/cm2.
Flexural strength: 120 kg/cm2 ( BS 4551, 1980 )
Young's modulus : 28 kN/mm2
Expansion characteristics : Controlled expansion occurs inthe unset material to ensure that the grout, when cured, willcontinue to occupy its original volume within the confines ofthe voids in which it was placed.
Unrestrained expansion : 1- 4 %
Time for expansion : Expansion starts 20 mins. after mixingand will be complete 150 mins. later.
Pressure to restrain plastic expansion :Appr. 0.004 N/mm2.
Note : It is necessary to restrain free grout edges over 50mmwide. Otherwise unrestrained expansion may lead to somecracks.
Fresh wet density : At flowable consistency 2250-2350 kg /m3
W/P ratio : Recommended water powder ratio for flowableconsistency is 0.14. Total quantity of water required for 25 kgbag is 3.5 litres.
Flow characteristics : The maximum distance of flow isgoverned by the gap width and the head of the grout.
Typical data for flow design, assuming grout is pouredimmediately after mixing, is given in the table below :
Max. flow distance in mmGrout Gap widthconsistency (mm) 50mm 100mm 250mm
Important note :Fosroc products are guaranteed against defective materials and manufacture and are sold subjectto its standard terms and conditions of sale, copies of which may be obtained on request. WhilstFosroc endeavours to ensure that any advice, recommendation specification or information it maygive is accurate and correct, it cannot, because it has no direct or continuous control over whereor how its products are applied, accept any liability either directly or indirectly arising from theuse of its products whether or not in accordance with any advice, specification, recommendationor information given by it.
Pour grout from two sides while grouting base plates
Pour grout from a height
Use vibrators in grout
Use damaged bags of Conbextra UHS
Detailed application procedure will be supplied separatelyprior to usage.
Estimating
Packaging
Conbextra UHS is supplied in double lined HDPE bags in 25kg weight.
Yield
One bag of Conbextra UHS will yield 12 litres at flowableconsistency.
Shelf life
6 months when stored under cool dry conditions.
Precautions
Health & Safety
Conbextra UHS is non-toxic, but alkaline in nature. Glovesshould be worn while handling this product. Splashes ongrout on the skin or eyes should be washed off with cleanrunning water. In the event of prolonged irritation, seekmedical advice.
Additional information
In addition, Fosroc manufactures a range of products whichincludes admixtures, curing compounds, flooring products,repair and protection systems, sealants and waterproofingproducts.
Separate datasheets are available on these products.
Con
bext
ra® U
W
constructive solutionsConbextra® UW
Antiwashout, Non-shrink, High strength cementitiousunderwater grout
Uses
As free flow or pumped material for underwater groutingwithout significant 'wash-out' of the cement phase.
Advantages
Shrinkage compensation : Gaseous expansion systemcompensates for shrinkage and settlement in the plasticstate, associated with conventional cement repairmaterials.
Anti wash out : No risk of significant wash-out of cementphase when placed under water. Displaces watereffectively.
Low porosity : Better steel protector than concrete.
High bond strength : No primer required.
High early strength : Facilitates rapid installation andearly operation of plant.
Durability : High early and ultimate strength combined withexceptional resistance to attack by freeze/thaw cycling.
Reliability : Factory controlled, prepacked components.Only the addition of water is required on site.
Chloride free : Composition allows high early strengthdevelopment without the use of chlorides.
Standards Compliance
Conbextra UW is tested using the appropriate sections of thefollowing specifications : BS 1881, BS 4550 & BS455.
Description
Conbextra UW is supplied as a ready to use dry powderrequiring only the addition of water to produce a free flowing,non shrink, grout material which exhibits exceptionalresistance to 'washing out' of the cement phase when placedin stationary or moving water. The material is a mixture ofspecially processed cement, with carefully graded fineaggregate. Additives impart controlled expansion, waterreduction and non washout characteristics. The aggregategrading is designed to aid uniform mixing, minimisesegregation and bleeding whilst assisting the flowcharacteristics.
Technical Support
The company provides a technical advisory service supportedby a team of specialists in the field.
Properties
Compressive strength : To simulate site conditions,compressive strength test cubes were cast under water andunder restraint. ( at 270C)
Compressive 1 day 3 days 7 days 28 daysstrength N/mm2 15 30 44 53
Adhesion to submerged concrete : To simulate siteconditions, direct tensile specimens were prepared underwater and under restraint. The specimens were curedsubmerged for 14 days at 300C at time of test. The tensilestrength of the substrate concrete was 3.1 N/mm2.
Density of hardened material : 2100 kg/m3.
Setting time : Dependent on temperature. Typical values (at300C) are as follows :
Initial Final
Setting time 4 hrs 5 hrs
Temperature limitation : Should not be applied below 50C.
Expansion characteristics : Controlled expansion occurs inthe unset material to ensure that the material when cured,will continue to occupy its original volume within the confinesof the void in which it was placed.
Specification clauses
Performance specification
All underwater grouting (specify details and areas ofapplication) must be carried out with a prepackaged cementbased product, which shall be mixed with water on site at aWater Powder ratio of 0.22. The grout must not bleed orsegregate, must be iron-free and chloride free. Expansion of1 - 4% shall occur while the grout is plastic by means of agaseous system. The grout shall contain special admixturesto minimise washout in underwater applications. Thecompressive strength of the grout must exceed 30 N/mm2 at7 days and 50N/mm2 at 28 days.
Conbextra® UW
The grout must be stored, handled and placed strictly inaccordance with the manufacturer's instructions.
Supplier specification
All underwater grouting (specify details and areas ofapplication) must be carried out using Conbextra UWmanufactured by Fosroc Chemicals (I) Pvt. Ltd, applied strictlyin accordance with the manufacturer's technical data sheet.
Application instructions
Preparation
Substrate must be clean and sound. All loose material mustbe removed. Substrates which are permanently immersedshould be sand blasted or cleaned with a high pressurewater jet. Non-immersed or intermittently immersedsubstrates can also be prepared using these techniques.Depending on the circumstances, scabbling or bushhammering may be appropriate.
Inview of the fluid nature of Conbextra UW, all shuttering mustbe leakproof. This can be achieved using foam rubber sealingstrips at the edges.
Mixing
The quantity of water required to achieve a fluid consistencymust be accurately measured for each mix. Each 25 kg bagrequires 5.5 litres of water.
A mechanically powered mixer must be used. Ensure thatthe machine capacity and the number of operatives isadequate to enable grouting to be carried out as a continuousoperation.
Place the specified amount of water in the mixer. Slowly addthe contents of Conbextra UW pack, mixing continuously.When all contents are added, mix continuously for a minimumof 5 minutes making sure that a smooth, even mix is obtained.(Fluidity increases with increased mixing). Pass the mixedmaterial through a 5mm sieve to remove any lumps prior toplacing.
Important : The need to observe the accurate gauging ofwater addition and the stated mixing time should be stressedto all operatives and, wherever possible, included inspecifications.
Placing
Place the mixed material within 20 minutes of mixing to gainfull benefit of the expansion process. Continuous materialflow is required and the material should be poured or pumpedthrough a flexible tube, minimum diameter 50mm, to thelowest point in the form. At the start of the operation, thematerial flow should be restricted in order to avoid any waterentrapment. The bottom of the tube may be raised asnecessary to reduce any back pressure but should not beraised above the level of the material.
Application thickness
Conbextra UW may be placed in thicknesses upto 80mm inone pour when placed above water. When placed underwater, the heat sink effect in this environment permitsthicknesses upto 150mm to be placed. For thicker sectionsupto 200mm above water and 400mm under water, it isnecessary to fill out Conbextra UW using a clean, roundedand well graded aggregate in the size range 2mm upto 10mm.The quantity of aggregate added should not exceed 1 partaggregate to 1 part Conbextra UW by weight. For such mixesa concrete mixer must be used. Unrestrained surface areashould be kept to a minimum.
Curing
Curing will not be required in intermittently or totallysubmerged situations. However, when cast above water, allexposed surfaces should be thoroughly cured.
Cleaning
Because of its water resisting properties, equipment usedfor Conbextra UW will be harder to wash than with acementitious grout. Use of hot water greatly reduces thetime required for cleaning. Do not use hot water for mixingwith Conbextra UW.
Conbextra® UW
Estimating
Packaging and coverage
Pack YieldConbextra UW 25 kg 14.5 litres
Storage
Shelf life
6 months shelf life if kept in a dry store in sealed bags.
Precautions
Health & Safety
Conbextra UW is alkaline in nature. Gloves should be worn.Splashes of grout to the skin or eyes should be washed offwith clean water. In the event of prolonged irritation, seekmedical advice.
Fire
Conbextra UW is non-flammable
Conbextra® UW
INDIA/326/B
Important note :Fosroc products are guaranteed against defective materials and manufacture and are sold subjectto its standard terms and conditions of sale, copies of which may be obtained on request. WhilstFosroc endeavours to ensure that any advice, recommendation specification or information it maygive is accurate and correct, it cannot, because it has no direct or continuous control over whereor how its products are applied, accept any liability either directly or indirectly arising from theuse of its products whether or not in accordance with any advice, specification, recommendationor information given by it.
