constructive solutions

Fosroc Chemicals India Pvt.Ltd.

Partnering in Constructive Solutions
Welcome delegates of Date: 13/03/2013

Larsen & Toubro, Dhuvaran Project

BHAIRAV PRAJAPATI-Specification Engineer + 91 99740 36845
bhairav.prajapati@fosroc.com

Agenda
Introduction to Fosroc Grouts & Anchors Waterproofing & Sealants Q&A

constructive solutions

constructive solutions

Introduction to

Fosroc

Fosroc Overview
For over 50 years, Fosroc has become an international leader in providing Constructive Solutions for a variety of projects Fosroc delivers to a broad range of sectors including, industrial, commercial, residential, marine and infrastructure Some of the companys most well known solutions are found in iconic structures around the globe

constructive solutions

Location of Production facilities

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Fosroc has 15 owned and 6 licensee production facilities around the world, with dedicated sales and technical support teams

UK

Denmark Romania

Spain

Pakistan Jordan UAE Saudi Arabia India China Philippines Malaysia Indonesia S. Korea

Trinidad

Nigeria

Brazil Australia

Technology and Knowledge

constructive solutions

Fosroc solutions and technology are driven by the needs of our customers Our focus is on our customer's application and construction solution We have an extensive portfolio of reliable and quality products, well known throughout the construction industry worldwide Our technical strength lies in knowing what chemical technology works best with specific applications to solve the customers problem

Product Range
Admixtures Coatings Concrete Repair

constructive solutions

Corrosion Control

Flooring

Grinding aids

Grouts & Anchors Joint Sealants

Waterproofing

Surface treatments

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Precision Grout - Definition

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A fluid material which is designed to be introduced into a cavity for the purpose of filling it and which will subsequently hardened to give specific physical properties.

Types of Precision Grouts

Cementitious

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Epoxy based grouts

Polyurethane grouts Epoxy cementitious grouts

Basic Ingredients in Grouts

Cementitious Grouts
Cement

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Epoxy Grouts
Thermosetting epoxy resin system
Amide Resin Catalyst

Graded Filler

Plasticiser

Blended Aggregate or Silica or Quartz

Expansive Agents

Choice of Precision Grouts

Depends on

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The strength criteria

Size of installation Depth and volume of grouting Gap Width Flow criteria base plate size How critical is EBA ? Type of loading conditions

Cyclic & Frequency of loading

Static / Dynamic loading Accessibility of installation Chemical resistance

Essential properties of grouts

High compressive strength High Flowability

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Creep resistance
Dimensional stability

Shrinkage compensation
Resistance to Dynamic/Static loading

Effective Bearing Area (EBA)

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EBA is a term used to describe the contact of grout with the surface of the plate, which is expressed in percentage and is usually effected by segregation, bleeding and shrinkage.

Comparison of ultimate strengths

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20

00

100
100

80

60

56 45

55

65

80

40

20

0
Conbextra Conbextra Conbextra Conbextra Conbextra Conbextra Conbextra Conbextra Conbextra Conbextra GPI HF HES GP2 EP 10 GPI HF HES GP2 EP10 Conbextra Conbextra Conbextra Conbextra EP 75 EP 300 EP75 EP300

Advantages of Cementitious Grout materials

constructive solutions

Compatibility in terms of modulus of elasticity and thermal expansion Economical compared to epoxy grouts Ease of mixing and application. Only a measured water addition required. No metallic iron content to cause staining

Characteristics of Epoxy Grout materials

constructive solutions

High Physical Strengths Faster Curing and Higher Strength gain than Cement Grouts Shrinkage Nil Approximately 2 to 3 times stronger than concrete Resistance to Chemical Attack Higher vibration damping efficiency 10 times greater than cement grout 30 times greater than steel Other dynamic load transference to the foundation for proper absorption & dissipation

Advantages of using Fosroc pre-bagged grout materials

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Precise strength, flow and shrinkage characteristics Reproducible consistent performance from factory controlled product Pre bagged. Convenient to use. Overcomes on-site batching variations Ability to eliminate segregation and bleed Reduced risk of failure

Product Selector - Cementitious

Product Type
Cement Based

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Specific Function
General purpose High Strength precision Grout Rapid setting

Specific requirements
Withstand static load Withstand static and dynamic loads High early strength

Application Type
Pourable

Product
Conbextra GPI

Pack size
25 kg

Coverage /Yield
13.7 litres

Cement based

Flowable/Pourable

Conbextra GP2

25 kg

13.3 litres

Cement Based

Pourable

Conbextra HES

15 kg

9 litres

Cement Based

Precison grout

High flow High strength/antiwashout/thickness upto 150mm under water Heat resistant,high strength

Flowable

Conbextra HF

25kg

13.25 litres

Cement Based

Under water grout

Pourable/pumpable

Conbextra UW

25kg

14.5litres

Cement Based

Grouting blast furnance/chimneys

Pourable

Conbextra HR

25kg

12 litres

Good Grouting Practices

constructive solutions

Ensure good quality shuttering materials are used Ensure through sealing of gaps in shuttering Pre wetting the substrate receiving the grout is a must Confirm the water tightness by conducting the water tests Check the shelf life and quantity of materials

Good Grouting Practices

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Ensure proper measuring aid for water is available at mixer machine Divide the lengthier base plate applications into sections

Cordon off the open areas around the grouting location to prevent early surfacial drying of grout.
Ensure that shoulder width is not beyond 50mm for sides other than the pouring end Ensure sufficient head is maintained at the pouring end before grouting

Good Grouting Practices

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Use washed and pre weighed aggregates in sites Ensure the planned area is done in one shot and from one side

Ensure the provision of air vent hole to release entrapped air

Use ice water as mixing water in grouts when atmospheric temperatures are around 35 degree centigrade

Good Grouting Practices

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Mechanical mixing for cementitious grouts is a must Use grout in pourable consistency (thixotropic consistency) for bolt pockets. In flowable consistency for base plates. Curing the surface starts after initial hardness is attained Generally after 68 hours at low temperatures and within 23 hours at high temperatures. Shuttering shall be removed only after 24 hours Curing shall be continued for a minimum of 7 days

Important tools & accessories

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Measuring Can to measure the qty of water precisely Sponge to remove excess water Sufficient length and diameter Hose pipe for pockets grouting Powerful torch light to examine dark areas. deep

Important tools & accessories

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Heavy Steel balls for pounding the lumps in mass mixer machines Air Blower, Masonry tools like pan,trowel etc.

Wheel Barrows and buckets to carry grout

Quick setting cement plugging agent for arresting unanticipated leaks

Trouble Shooting
Delay in setting time

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Ambient, in situ, storage, water- Low temperature in each will delay setting time. Mixing- Unlikely but poor mixing can contribute

Heat Sink: Foundation or base plate at a cooler temperature

Trouble Shooting
Grout does not flow Incorrect mixing Part mix , insufficient agitation

constructive solutions

Temperature High temperature causing premature setting Time after mixing Pouring of the grout is too long after mixing

Unwetted substrate Substrate draws water out of the grout

Incorrect Gap to head ratio The head in the hopper is too small to push the grout through the gap

Trouble Shooting
Cracks appearing in Grout

constructive solutions

Excessive exotherm recommended

thickness

higher

than

Early loading Insufficient time allowed to reach required strength Poor Curing Surface drying due to poor curing Insufficient Restraint The shrinkage compensation to work must have a restrained volume Excessive water - Segregation & Shrinkage Latent heat of base plate.

Trouble Shooting
Grout surface bubbles and laitance

constructive solutions

Wrong Mixer Some mixers can induce excessive air which will rise to the surface Non continuous pour

Air becomes trapped between successive pours

Excessive water (bleed) Bleed water on surface which will appear as laitance Over wetted surface Water mixes in with the grout leading to bleed

Trouble Shooting
Grout is weak

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Cube size Test method and cube size will differ strengths as quoted in the data sheet Temperature effects cure rate and thus strengths

Time Strengths should always be related to a time

Mixing Incomplete mixing may result in reduced strengths Incorrect data Strengths may be compared with data which is not applicable

Dos & Don'ts

Dos Store the grout in a well ventilated space protected from moisture Donts

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Mix more water than specified for cementitious grouts

Check everything for damages and expiry Mix any other ingredient like sand, cement date before using etc. to the grout

Mix mechanically

Have exposed edges larger than necessary. 50mm on all sides and 100-150 mm on pouring side is ideal
Use vibrators

Use mixed grout within 30 minutes depending on temperature and humidity

Ensure shuttering is strong and leak proof Pour grout from two different sides Start curing as soon as grout reaches touch hard state incase of cementitious grouts Cure grout atleast for a period of 7 days in case of cementitious grouts

Grout testing guidelines

Full bag of grout should be mixed . ISI moulds applied with mould release agent shall be used Use 70.6mm cubes for checking compressive strength Rate of loading shall be 35 N/ sq.mm/min. Spatula must be used for poking the grout in moulds

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Grout should be restrained by plates

Demould exactly after 24 hours

Grout testing guidelines

Edges should be taken care during demoulding.

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For 3, 7, 28 days cubes should be dried after removing from curing tanks Calibrated testing machines should be used for correct results Failure pattern of the cubes shall be checked

Compressive strength shall be taken as average of 3 cubes.

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Correct proportions Correct Proportions

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Checking flowFlow usingusing BS cone Checking BS Cone

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Measuring of grout flow

Measuring Grout Flow

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Proper Restraint

Proper Restrain

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Cubes casting at Lab

Cube Casting at Lab

Pre Dispatch Quality Checks At Factory

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Computerised Manufacturing Process Automated batching through PLC system Sample immediately checked for flow Material is unloaded and packed thru Automated filling machines (Quantity assured) Setting time,Expansion and Strength tests are carried out Minimum 3 days Compressive Strength checked before dispatch As per ISO 9001 our equipments are calibrated periodically

constructive solutions

Anchoring of Shear connectors

Advantages of Polyester Resin Grouts

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Easy mixing Very fast reacting and setting times Rapid strength gain Temperature tolerant Irreversible chemical reaction Water tolerant Corrosion resistant

Lokfix range

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Lokfix L
Lokfix S Lokfix P

Vertical Appln
Vertical Appln
Horz/Over head Appln

25-50 mm <25 mm <25 mm

Lokfix S
30

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20

Rebar bolt in drilled hole using percussive drill

10

200

400

600

800

100 mm minimum bonded length

Bonded length
M20 Concrete & 25mm deformed bar

Lokfix used for anchoring foundations to rock strata

constructive solutions

Lokfix used to anchor foundations 24 m underground at JVSL, Bellary

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Lokfix used for anchoring dowel bars for sunshade at Chellammal College

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Lokfix used anchoring staircase handrails

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