CRACKSREPAIRINGMETHODOLOGYOFPAVEMENT

QUALITY CONCRETE
 Contents

Description PageNos.

1. STAPLEPINSTITCHING 2-7

2. STITCHING AND SEALING CRACKS 8-10

3. Shear Cracks and Temperature cracks 11-13

(Width3mm-5mm&3mm-8mm)

4. REPLACEMENTOFSLABWITHFULLDEPTHREPAIRS 13-16
 METHODOLOGY FOR REPAIR OF PQC PANELS

SCOPE: Methodology for repair of cracked PQC panels.

1. STAPLE PIN STITCHING

Manpower Requirement:-

 Site In charge. -01

 Site Supervisor.. -01
 Skilled and Experienced Mason .–01
 Trained Cutter Operator -01
 Skilled team of workers for repairing. . –02

Safety Arrangements:-

Care shall be taken to ensure suitable mitigation measures against noise and dust, pollution
and damage to the environs whether temporary or permanent and shall be taken as
incidental to work.
Adequate precautions shall be taken for safety of personnel, road users and existing
services, which, during execution, shall be considered as incidentals to work.
Persons working should wear safety helmets, Safety Goggle and rubber gloves.

Tools Requirement:-

 Groove Cutting Machine.

 Diamond Segmented Blades as consumables
 Drilling Machine capable of drilling the required sizes.
 Drill bits of various diameter and lengths as consumables.
 Electric Power Supply(DG)
 Epoxy in two components as consumable.
 Vessel of suitable capacity for mixing epoxy.
 Stirrer for mixing epoxy.
 Air Blower.
 Water as consumable for cutting.
Crack Repair Product:

1. FOSROC Lokfix P

A complete pack of resin and catalysed filler should be mixed in one operation. Mixing may be
carried out manually or mechanically. When a smooth, even consistency is achieved the grout
is ready for use and should be placed well within the gel time of the grout. Packs have been
designed to produce practical and economic volumes of grout. DO NOT attempt to mix partial
pack components.

2. FOSROCConbextraEP10M

ConbextraEP10(M) is a two part epoxy resin system for grouting gaps ranging from 0.25mm to
9mm.Itisanallliquidsystemconsistingofabaseandhardener.

3. FOSROCNitobondEP

Nitobond EP is based on solvent free epoxy resins containing pigments and fine fillers. It is
supplied as a two part material in preweighed quantities for ready onsite mixing and uses colored
components - white base and green hardener - provide visual evidence that adequate mixing is
achieved.

4. FOSROCConbextraGP2

FOSROC Conbextra GP2 Free Flow, high Strength, non-Shrink, Cementitous precision grout.
Conbextra GP is used for precision grouting where it is essential to withstand static and dynamic
loads.Typical applications would be the grouting of base plates of turbines, compressors, boiler
feed pumps etc. It can also use for anchoring a wide range of fixing.
Repair procedure of Crack:

1) Thickness of the Pavement:300 mm.

2) Clean the crack surface to V groove to a minimum depth of about 50mm.
3) Mark line sperpendicular to the crack at a pitch distance of 300mm for a length of 200 mm
distributing equally on either side of the crack.
4) By using a diamond segmented blades and Groove Cutting machine, grooves of 20mm wide
shall be done along the marked lines.
5) The depth of the groove shall be 30mm.
6) Two vertical holes of 16mm D shall be drilled at a distance of 200 mm within the groove
equidistance from the crack line.
7) The depth of the drilled hole shall be230mm.
8) Water shall be used as coolant while grooving and drilling.
9) The grooves and holes shall be cleaned thoroughly with the help of suitable tool sand water
jets.
10)The groove sand holes are thoroughly dried to remove any water traces with the help of the
blowers.
11)It may be advisable to leave it to dry by sunlight for one day.
12)Each groove shall be inserted with a rod of 12mm D
13)The rod shall be 580mm long with a bent portion of 190mm on either side. The centre
distance between both the bent portions shall be 200mm.
14)ConbextraEP10(M)epoxy is mixed thoroughly in a suitable container and poured into the
grooves about15mm above the bottom surface of the groove.
15)The bent rod is inserted into the groove such that the bent portions enter into the holes on
either side of the crack.
16)Before inserting the rod,the Lokfix P epoxy is poured in drilled hole. Now insert the rod into
hole.
17)Allow the epoxy to set for 5hours.
18)A thin Film of Nitobond EP should apply using brush.
19)Then rest of the groove shall then be filled with cement based grout material like Rendroc RG
or GP-2 the surface of the panel.
20)The epoxy is also poured along the crack.
21)After final setting time of the epoxy covered with gunny bag and water curing should be
done.
22) Curing period of this repair will be7days.
Making Staple Groves across crack
Arrangement of Reinforcement

Site Photo of Staple Stitching

 2. STITCHING AND SEALING CRACKS

Manpower Requirement:-

 Site In charge. -01

 Site Supervisor.. -01
 Skilled and Experienced Mason. -01
 Trained Cutter Operator -01
 Skilled team of workers for repairing.. -02

Safety Arrangements:-

Care shall be taken to ensure suitable mitigation measures against noise and dust,pollution
and damage to the environs whether temporary or permanent and shall be taken as
incidental to work.

Adequate precautions shall be taken for safety of personnel, road users and existing
services, which, during execution, shall be considered as incidentals to work.

Persons working should wear safety helmets, Safety Goggle and rubber gloves.

METHODOLOGY:

 Clean the crack surface to V groove to a minimum depth of 20-mm.Blow off all loose
materials.

 Drill in and Epoxy 12-mm dia HYSD bar across the crack at an angle of 36º.Ensure after
completing the entire drilling work, the holes are cleaned thoroughly with the help of suitable
tool sand the water collected is removed.

 Locate and mark centers of the holes on either side of the crack at a pitch distance 400-mm
with an offset 200-mm on the other side.

 Theperpendiculardistanceofthecenteroftheholefromthecrackshallbe100-mm.

 Thereinforcementbarshouldbeminimum25-mmbelowthetoplevel.

 Drillingshallbedoneusing14-mmdrilltoaccommodate12-mmdiabar.

 LokfixPismixedthoroughlyinsuitablecontainerandpouredintoalltheholesuptohalf
 depthandrodinserted.TopuptheEpoxywhererequired.

 AlsopourtheNitobondEPalongthecrack. Toppingshouldcontinuetilllevelsare
maintained for 15 minutes.

 AllowtheEpoxytosetforfivehoursandcuringshouldbedonefor7 days.

Crack Repair Product:

1. LokfixP:-
A complete pack of resin and catalysed filler should be mixed in one operation. Mixing may be
carried out manually or mechanically. When a smooth, even consistency is achieved the grout
is ready for use and should be placed well within the gel time of the grout. Packs have been
designed to produce practical and economic volumes of grout. DO NOT attempt to mix partial
pack components.

2. NitobondEP:-
Nitobond EP is based on solvent free epoxy resins containing pigments and fine fillers. It is
supplied as a two part material in preweighed quantities forready onsite mixing and use.Coloured
components - white base and green hardener - provide visual evidence that adequate mixing is
achieved.

DrillingHoleat45degreestoHorizontalplane
CrackAsAppearsinPavement

SitePhoto
 ForShearCracksandTemperaturecracks

ManpowerRequirement:-

 SiteIncharge. -01
 SiteSupervisor.. -01
 SkilledandExperiencedMason .–01
 TrainedCutterOperator -01
 Skilledteamofworkersforrepairing. . –02

SafetyArrangements:-

Care shall be taken to ensure suitable mitigation measures against noise and dust,pollution
and damage to the environs whether temporary or permanent and shall be taken as
incidental to work.

Adequate precautions shall be taken for safety of personnel, road users and existing
services, which, during execution, shall be considered as incidentals to work.

Personsworkingshouldwearsafetyhelmets,SafetyGoggleandrubbergloves.

 Identify the Depth of Crack up-to 3/4th of thickness of the pavement and less than 3mm in
width opt Injection Grout of Epoxy Material/Cement Grout Material.

 PourtheNitobondEPbyusingInjectionslowlytillthecrackgetsclosedbyepoxymaterial.

 ApplytheCement+NitobondEPpastoverthecrackandsealforwatertight.Takethecore
after7daystoaccesstheeffectiverepairofCrack.

ForCracks3mm-5mm

 CleanthecracksurfacetoVgroovetoaminimumdepthof5-mmandwidthof25mm. Blow off all

loose materials. If required may be wash with water the whole area of V groove

 ThreepartsEpoxyNitobondEPismixedthoroughlyinsuitablecontainerandpouredinto
alltheholesupto full depth.Topup the Epoxy where required.
 Also pour the Epoxy along the crack.Topping should continue till levels are maintained for
15 minutes.

 AllowtheEpoxytosetforthreehours.

 Guard the repair surface for at least three hours till the mix set. Then traffic can be allowed
after three hours

ForCracks3-8mm&HoneycombusingGroutingofEpoxy

 ForcrackswhicharenotinlinearorDiagonalGroutingispreferred.

 FixtheSurfaceNozzlesusingepoxymortar.Leftforsettingfor2-3hours.

 After 3 hrs pump the Epoxy material Nitobond EP using automatic/Manual Grout pump in
liquid form.

 Remove/CutofftheSurfaceNozzlesafterrepairandAllowtrafficafter12Hours.

Crackrepair material(A+B+C) 3different typeofNozzlesforgrout

EpoxyInjection ByGroutingPump
 4.CUTTINGOUTANDREPLACEMENTOFSLABWITHFULLDEPTHREPAIRS

ManpowerRequirement:-

 SiteIncharge. -01
 SiteSupervisor.. -01
 SkilledandExperiencedMason .–01
 TrainedCutterOperator -01
 Skilledteamofworkersforrepairing. . –02

SafetyArrangements:-

 Care shall be taken to ensure suitable mitigation measures against noise and dust,
pollution and damage to the environs whether temporary or permanent and shall be
taken as incidental to work.

 Adequate precautions shall be taken for safety of personnel, road users and existing
services, which, during execution, shall be considered as incidentals to work.

 Personsworkingshouldwearsafetyhelmets,SafetyGoggleandrubbergloves.

METHODOLOGY:

FULLDEPTHCUTTING

Replacementofaportionofaslabcomprisesthefollowingtasks:

 Identifytheportionofthepavement,whichisdamaged.

 A job mix design shall be tested in the laboratory with a target slump of 20 - 40 mm. To
decreasethewater-cementratioawater-reducingadmixturemayberequiredforGrade 43 or
Grade 53 cement design).

 Theportiontobereplacediscutoutandremoved.Theperimeteroftheareatobe
repairedshallbecutwithaconcretesawtothespecifieddepth.Transverseperimeter
cutsarefirstmadearoundtheboundaryoftherepairdowntoaboutaquarter(1/4)to
athird(1/3)oftheslabthickness.Separatefulldepthcutsarethenmadeforremovalof
theslabTheconcretebetweenthetwocutsprovidesabuffertopreventundercut
spallingandallowschippingforexposingthesteeldowel/tiebarreinforcement.Always
 cuttowardtheshouldersothatanyshearforcedevelopedfromthecompressionofthe
slabsgetconcentratedandrelievedinthepavedshoulderportion.

 Holesaredrilledfordowelbarsortiebarsintheedgewallsoftheremainingslab
portion.Ratherthansinglehand-helddrills,itisbettertoprovideenoughspacefor usingdowel-
drillingrigswithwheelstoproperlycontrolalignmentandwandering.

 Both standard pneumatic or hydraulic percussion drills are acceptable. They drill a hole
in about 30 seconds. Electric pneumatic rotary drills take three to four times longer. The
hole shall be 2 mm bigger than bar diameter for epoxy anchor material or 6 mm bigger
than the bar diameter for cement based anchor material.

 Thedowelholeiscleanedcarefullybymeansofanozzleandcompressedair.Priorto
thisoperationensurethatthecompressorisnotblowingoilandmoisturecontaminated air by
blowing into a piece of dry cloth.

 The epoxy anchoring material is fed to the back ofthe hole before inserting the dowel/ tie
bars.Thisensuresthattheanchoringmaterialwillflowforwardalongtheentire
dowel/tieembedmentlengthduringinsertionanddecreasesthelikelihoodofleaving voids
between the dowel and concrete.
 Reinforcement is fixed in top of the repair when the length to width ratio of the patch
exceeds1.5soastocontrolanycrackingonaccountoftheshapefactor.The
reinforcementshallbeplacedabout75mmbelowthetopsurface.

 Concreteispouredinthepitfromreadymixorbatchtrucks,orsitemixedforsmall jobs in small

mixers. Evenly distribute and compact the mix by penetration ofa vertical vibrator. Special
care is important to compact concrete in the corners, along the patch perimeter and around
the dowel bars.

 Strike off and finish the concrete surface with a vibrating screed or manual screed
depending upon the size of work. Hand fmishing should be minimum as it will leave
undulations in the surface.

 A wire brush/tyned texture is applied to get surface texture to match the existing
pavement.

 Suitablecuringconditionsareprovidedimmediatelybymeansofaliquidmembrane curing
compound.

 Laboratory tests shall be performed in advance to determine the appropriate mix

proportionsandestablishthetimerequiredtoachievetheminimumcompressive
 strengthrequiredtoopentotraffic.Theminimumcompressivestrengthofrepairs
beforeopeningtotrafficshouldnotbelessthan32MPa.

 Themethodsforplacementandcuringtheconcreteshalltakeintoconsiderationthe weather,
seasonal and other environmental.
Lokfix® constructivesolutions

Polyesterresingrouts
Lokfix P is used in overhead or horizontal holes where
Uses bar / hole relationship conforms to Lokfix polyester
Lokfixareusedforhighstrengthcorrosionresistantanchor resin grout S.
ing ofboltsandbarsfrom10- ThethixotropicnatureofLokfixpolyesterresingroutPreduc
51mmdiameterintoconcrete,rock, masonry or es flow of grout out of the hole.
brickwork where high speed of installation and early
application of load is required.

Permanent installation of reinforcement starter bars,

foundation bolts, base plates, balustrading, barriers
and safety fences, railwaytracks,tie-
backanchors,reinforcementdowellingabut- ments,
ground anchors for towers, cranes, dock sills.

Advantages

 Rapidstrengthgain

 Vibrationresistant

 Corrosion resistant

 Non expansive

 Can be placed under water

Standardsandspecifications

Materials tested in accordance

with

BS4551

BS5080

BS2782

Description

Thethreeversions of Lokfix polyester resingrout are all

pre-
measured,twopart,filledpolysterresingrouts.Afterharde
n- ing the groutproduces anchorages
ofconsistentreproducible values.

Theversionsare:

LokfixL(Largeaggregate

LokfixS(Smallaggregate

LokfixP(Pumpablegrade)

LokfixLisusedwhereholediameterexceedsbardiameter
by 25 to50mm.

Lokfix Sisusedwherethedifferencebetweenthehole
diameter
andbar diameteris<25mm.
 Length of resin bond to bar

Holepreparationandformati
Properties
on Type and dimension of
Specificgravity

Lokfix ‘S’: 1.9 g/cc bar 2.9

Lokfix‘P’:

Technicalsupport Thefollowingformulamaybeusedtodeterminetheminim
um
Fosrocoffersacomprehensiverangeofhighperformance, depthofinstallationforType1rebarbolts,toensuretheshe
high qualityconcreterepairand ar stress within the concrete is kept within the limits
constructionproducts.Inaddition, set out inBS 8110.
Fosrocofferstechnicalsupportservicetospecifiers,end-
users andcontractors,aswellason- Minimum hole 0.6Y.d21πdd2 1
2
= 0.15Yd 1
=
sitetechnicalassistanceinloca- tions all over the Depth (mm) Sπd2 4 Sd2

country. whereYischaracteristicyieldstrengthofsteel
Design criteria (545 N/mm2)

Theversionof Lokfix grouttobeusedwilldependupon Sispermitted

ambient
shearstressinconcrete(N/mm2) d1is bar
temperatureand anchorconditions.

The high strength of the cured resin permits strong diameter (mm)
anchorstobecreated.Theultimatebondstrengthdevelo d2is holediameter(mm)
peddepends upon:
Thisformulaisusedtypicallyas showninTable 1.
Strength of host material
Lokfi

page1of4
x
Lokfix®

Table1

Minimum hole depth

 Strengthofhostmaterial
Characteristicconcrete  Lengthof resinbondtobar
strength (N/mm2): 20 25 30 40
 Holepreparation andformation
Permitted concrete shear
 Typeanddimensionofbar
stressusingTypeOneBar
(N/mm2): 1.8 2.0 2.2 2.5 Fig.1Typicalloadsattained
Bar Yield Hole
diamete (tonne ) diameter Minimumhole depth
r s (mm)
(mm)
10 4.4 18 255 228 210 182
12 6.3 20 330 295 270 236
16 11.2 24 485 440 400 350
20 17.5 28 650 590 531 468
25 27.3 33 860 775 704 620
32 44.7 40 1165 1050 951 838
40 69.9 48 1515 1365 124 1090
0

Properties

Geltime Geltime Minimum time Concrete:20N/mm2unreinforced

Temp(0C) (min) requiredbefore
Bar :25mmdiaDeformedrebar toIS:1786
loading( hours)
32mmdiahole:Air-flushedrotarypercussivedrilled
20 80 7
30 40 3 Note:Thegraphillustratestypicalfailureloads.
40 15 1
Minimumsafetyfactorsof 1.5innoncriticalandof
2incritical cases should be considered for design
Compressivestrength:Aftertheminimumtimerequiredbe purposes.Wherever relevant, the local code of
fore loading the grout typically attains a compressive practice or standard must also be considered in
strength in excess of 20N/mm2and an ultimate relation to anchorage length.
compressive strength of 70N/mm2in 7 days ( 50mm x
Holepreparationandformation
50mm x 50mm) when tested as per BS 6319 Part 2 :
1983. OptimumperformanceofLokfixrequiresroughsided,dust
free
Chemical resistance :The cured resin is resistant to
holes.Usesofrotarypercussivedrillswithairorwaterflushi
freshand salt water, petrol, oils, grease and most
ng is recommended.
acids, alkalis and solvents.
Diamonddrilledholesshouldbeunder-
Applicationinstructions
reamedunlessneces- sary safety factors are
Selection ofgroutversion
incorporated.
TheversionofLokfixchosenwilldependonanchorcondition
Castholesshouldpreferablybeinversedovetailconfigurat
s
ion.
(seedescription)
Ifparallelsidesholesarecasttheyshouldberoughtoprovid
Parametersofanchor design e adequate keying.
Thehighstrengthofthecuredresinpermitsstronganchorst Barpreparation
o be created.Ultimate strength is determined by :
Allbarsshouldpreferablybedegreasedandallflakyrust
removed.
Lokfix®

constructive solutions page2of4

Lokfix®

Mixing

Acompletepackofresinandcatalysedfillershouldbemixed
*Consumption mentioned in above table are based on
in oneoperation.
theo- retical calculations and may vary due to
Mixingmaybecarriedoutmechanically.When asmooth,
evenconsistency is achievedthegroutis ready for use wastage & variationin dimensions
and should be placed well within the geltime ofthe
If theanchor is inveryoldconcrete, masonryor
grout ( See properties).
brickwork the wastage factor should be increased.
Packshavebeendesignedtoproducepracticalandecono
mic volumes of grout. No of bolts/200 mm deep hole which can be fixed
using a 2.5 litre pack of Lokfix
Donotattemptto mix partialpack components.

Installation Holediameter Bolt sizemm

mm 10 12 16 20 25 32 40
LokfixpolyesterresingroutS&L
18 50
Using the calculated volume of grout based on Table
20 40 50
1, the grout shouldbepoured steadily intothe
25 47 25 31 50
preparedholes.The
anchorbaristhenpressedintotheholetotherequireddept 32 15 17 21 31
h. Slight agitation of the bar will assist in achieving a 38 12 12 16 27
complete bond.Thebar 45 8 9 12 27
shouldthenbeleftundisturbedintherequired position 50 6 8 9 13
until the resin is set. 62 4 4 5 5
LokfixpolyesterresingroutP
Estimating
The grout should be injected to the rear of the hole to
Packaging
avoid air
entrapment.ThethixotropicnatureofLokfixPwillprevent 0.5and2.5LPacks
LokfixS/P :
significant flow of resin out of the hole.
18L LokfixL :
Cleaning NitoflorSol : 5litres and20litres.
Anymixingdrums,pumps,etc.shouldbecleanedwithinth
e
potlifeofofthegrout.NitoflorSolisavailableforthispurpos
e.
Table1
Storage
Quantityestimatingguide The product should be stored away from high
temperature.6
TableindicatesvolumeofLokfixpolyesterresingroutgrou
t in monthsshelflifewhenstoredbelow250Cinoriginalunopen
cm3/100mmbond ed containers.

Precautions
Holediameter Boltdiametermm
mm 10 12 16 20 25 32 40 Fireresistanceandcreep
18 25
At operating temperatures above 400C, the creep of
20 32 25
Lokfix
25 47 50 40 25
polyesterresingroutresinunderloadmaybecomesignific
32 80 70 60 40
ant.
38 100 100 75 45
Resinanchorsshouldnotbeusedwherestructuralloadbea
45 150 130 100 45
r-
50 180 150 90
ingperformancehastobemaintainedinanchorssubjected
62 280 225
to fire conditions.

Thesefiguresallowfora25%wastagefactor. Healthandsafetyinstructions
Lokfix®
Confined areas must be well ventilated and no naked contact with the polyester
flames allowed.Contact with the skin should be resin.Insuchcasesifcontactwiththeresinoccurs,theskin
avoided as certain sensitive skins may be affected by

constructivesolutions
page3of4
Lokfix®

shouldbe washed immediatelywith soap and water-

notsol- vent.Gloves and barrier creams should be
used when han-
dlingtheseproducts.Eyecontaminationmustbeimmedia
tely washed with plenty of water and medical
treatment sought.

Fire

Lokfixpolyesterresingroutresinisflammable.Confinedar
eas must be wellventilatedandnonaked
flamesallowed.Donot smoke during use.

Flash point

LokfixS,L,P 290C

NitoflorSol 330C
Additionalinformation

The Fosroc range of associated products includes high

strength cementitious grouts, epoxy grouts.Also
available a range of
productsforuseinconstruction;viz.,admixtures,curingco
m- pounds, release agents, flooring systems and
repair mortars.

Separatedatasheets areavailable on theseproducts.

Importantnote:
Fosroc products are guaranteed against defective materials and manufacture and
are sold subject to its standard terms and conditions of sale, copies of which may be
obtained on
request.WhilstFosrocendeavourstoensurethatanyadvice,recommendationspecificati
on or information it may give is accurate and correct, it cannot, because it has no
FosrocChemicals direct or continuous control overwhereor howitsproductsareapplied,
(India) Pvt. Ltd. acceptanyliabilityeither
HeadOffice directlyorindirectlyarisingfromtheuseofitsproductswhetherornotinaccordancewith
“SapthagiriPalace”,No.3 any advice,specification,recommendationorinformationgiven by it.
8, II & III Floor, 12th
Cross, telephone fax e-mail
CBIRoad,GanganagarNorth, ++9180-42521900 ++9180-23551510 [email protected]
Bangalore 560 024

RegionalOffices

Chennai Mumbai Noida Kolkata

No. 26(old no.33), 1st Floor, 1401/1402, 14th Floor, D-166 Sector 10 304, Jodhpur Park
1st Street Postal Colony, A-Wing’The Great Eastern Summit’ Dist. Gautam Budha Nagar, Kolkata 700 068
West Mambalam, Sector-15, CBD, Belapur Noida, Ph:033-65343188
Chennai 600 033. Navi Mumbai 400 614 UP 201 301 Fax:033-2499-
0280
Ph:044-24899949-94 Ph:022-43406800-04 Ph:0120-4270620-21
Lokfix®
Fax:044-24896641 Fax:022-27562423 Fax:0120-4270622

www.fosroc.com

page4of4 INDIA/2017/0319/A
 ConbextraEP10(M) constructivesolutions

Moistureinsensitiveepoxyresininjection material ConbextraEP10(M) 60 30

Uses

ConbextraEP10(M)isatwopartepoxyresinsystemforgro
ut-
inggapsrangingfrom0.25mmto9mm.Itisanallliquidsyst
em consisting of a base and hardener.

Advantages

 Moisture insensitive

 Lowcreep characteristics

 Highcompressive,tensile and flexuralstrengths

 Fast,convenientpumpingwithearlystrengthgain

 Withstandsawiderangeofchemicals

Technicalsupport

Fosroc offers a comprehensive range of high

performance, high
qualityconcreterepairandconstructionproducts.Inadditi
on,
Fosrocofferstechnicalsupportservicetospecifiers,end-
users andcontractors,aswellason-
sitetechnicalassistanceinloca- tions all over the
country.

Properties

The following results are typical for the hardener

grout at 30 deg.C.

Testmethod Typical result

Density(Kg/m3) 1060

Compressivestrength(N/mm2) ASTM
D695 60

Tensilestrength(N/
mm2) ASTM C307 - 94 20

Flexuralstrength(N/mm2)
BS6319 Part 4 45

Chemical resistance

Conbextra EP10(M) is resistant to oil, grease, fats, most

chemi- cals, mild acids and alkalis, fresh and sea
water.

Potlife

Ambienttemperatureaffectsthetimeforwhichbulkmater
ial
willremainfluid.

Typicalvaluesin minutesare:
traEP10(M

200C 300C
Con injecting the material into cracks.After 24hours
removethe nipples andseal theholes or voids with
more sealing the compound and allow to cure.

Forfillingcracksofmorethan10mmandusing
asanepoxymortar
Exotherm
ConbextraEP10(M)hastobemixedwithcleangradedquar
All epoxy systems will develop a temperature rise on
tz sand from1:3 to 1:6parts by weight depending on
mixing. Its extent will be a function of the volume to
the con- sistency required.Mixing can be done with a
surface ratio, the
paddle fitted toa drilling machine.
ambienttemperatureaswellasthemassandthermalcon
duc- Typicalpropertesareasfollows:
tivityofthesurroundingmaterials.ContactFosrocforspe
Compressivestrength(N/mm2)
cific data on each product.
@7days : 50
Applicationinstructions
Tensilestrength(N/mm2) : 3-4
Prepare the surface and seal the cracks with a
Flexuralstrength( N/mm2) : 10
sealing com- pound which can also be used for
bonding injection nipples. Cleaning
Dependingonthecrackwidthanddepththedistancebetw All tools and equipment should be cleaned
een nipples should be200 to 500 mm. immediately after
Mixingandplacing usewithNitoflorSol.Spillagesshouldbeabsorbedwithsan
d
Pour all the contents of the hardener pack into the
orsawdustanddisposedinaccordancewithlocalregulatio
base con- tainer.Mix using a slow speed power mixer
ns.
for 60 seconds. Use a suitable pressure pump for

page1of2
ConbextraEP10(M)

Limitations
Temperature
Duringapplication immediately with a resin removing cream, followed
by soap
Grouting may be carried out without special
andwater.Donotusesolvent.Incaseofcontactwitheyes,
precautions at ambient temperatures from 50to 350C.
rinseimmediatelywithplentyofcleanwaterandseekmed
Inservice ical attention immediately - do not induce vomiting.

Thecuredmaterial issuitableforusefrom00C. Fire

Estimating NitoflorSolisflammable.Intheevenoffireextinguishwith
Packaging CO2orfoam.

ConbextraEP10(M) :1.5litre packs Flashpoint :330C

Storage Keepawayfromsourcesofignition-
All nosmoking.Wearsuit-
ConbextraEP10(M)productshasashelflifeof12months ableprotectiveclothing,glovesandeye/faceprotection.
in unopened container under normal warehouse Use only in well ventillated area.
conditions. Additionalinformation
Precautions
The Fosroc range of associated products include high
HealthandSafety strength cementitious, epoxy grout, polyester resin
ConbextraEP10(M):Containsresinswhichmaycausesen based mortar for rapidpresettingof steel shimsto
si- level or for direct bedding
tisationbyskincontact.Avoidcontactwithskinandeyesan ofsmallbaseplates;ResinAnchoringsystemsforsameda
d y anchoring of bolts in drilled holes in concrete or
inhalationofvapour.Wearsuitableprotectiveclothing,gl rock.Also
oves and eye/face protection.Barrier creams provide availablearangeofproductsforuseinconstruction;viz.,a
additional d- mixtures, curing compounds, release agents, flooring
skinprotection.Shouldaccidentalskincontactoccur,rem systems and repair mortars.
ove Separatedatasheets areavailable on theseproducts.

Importantnote:
Fosroc products are guaranteed against defective materials and manufacture and
are sold subject to its standard terms and conditions of sale, copies of which may be
obtained on
request.WhilstFosrocendeavourstoensurethatanyadvice,recommendationspecificati
on or information it may give is accurate and correct, it cannot, because it has no
FosrocChemicals direct or continuous control overwhereor howitsproductsareapplied,
(India) Pvt. Ltd. acceptanyliabilityeither
HeadOffice directlyorindirectlyarisingfromtheuseofitsproductswhetherornotinaccordancewith
“SapthagiriPalace”,No.3 any advice,specification,recommendationorinformationgiven by it.
8, II & III Floor, 12th
Cross, telephone fax e-mail
CBIRoad,GanganagarNorth, ++9180-42521900 ++9180-23551510 [email protected]
Bangalore 560 024

RegionalOffices

Chennai Mumbai Noida Kolkata

No. 26(old no.33), 1st Floor, 1401/1402, 14th Floor, D-166 Sector 10 304, Jodhpur Park
1st Street Postal Colony, A-Wing’The Great Eastern Summit’ Dist. Gautam Budha Nagar, Kolkata 700 068
West Mambalam, Sector-15, CBD, Belapur Noida, Ph:033-65343188
Chennai 600 033. Navi Mumbai 400 614 UP 201 301 Fax:033-2499-
0280
Ph:044-24899949-94 Ph:022-43406800-04 Ph:0120-4270620-21
Fax:044-24896641 Fax:022-27562423 Fax:0120-4270622

www.fosroc.com
page2of2
INDIA/2014/0315/A
NitobondEP constructivesolutions

Epoxyresinconcretebondingagent

Uses
Properties
For bonding fresh wet cementitious materials to
Specificgravity: 1.15to1.2g/cc
existing cementitious surfaces. For use on horizontal
surfaces or on vertical surfaces where mortar or At200C At300C
concrete can be supported by formwork. The long Pot life 5-6hrs 2-3hrs
‘open’ life makes it suitable for usewith formwork or
where additional steel reinforcement has to be fitted. Fullcure 7days 5days
The product is ideal for roads, bridges, pavements, Overlaytime 10hrs 6hrs
loading bays and factories, building segment and for
bonded or granolithic floor toppings. Nitobond EP is Compressivestrength
equally suited to internal and external applications. BS 6319 Pt 2 @7days 50 N/mm2

Flexuralstrengt
Nitobond EPmay also be used as part of a repair system
h BS 6319 Pt 3 @7days 35 N/mm2
where abondingagentisrequiredor
wherethesubstrateislikelyto remain permanently Tensilestrength
damp or wet. BS 6319 Pt 7 @7days 20N/mm2
Advantages Shearstrength
NitobondEPcanbeappliedbybrush. BS 6319 Pt 4 @7days 10 N/mm2

 Moreoverlaytime:Enablestoplacetheconcreteforlon Note:The typical physical properties given above are

ger period of time, without risk of delamination derived from testing in a controlled laboratory
 Highbondstrength:Bondstrengthismorethan environment. Results derived from testing field-applied
the tensile strength of good quality samples may vary, dependent actual site conditions.
concrete Specificationclauses
 Barrier coat : Acts as a ‘barrier coat’ to the
Thebondingagent shallbeNitobondEPan epoxy
migration ofchloride ions from host concrete.
basedtwo component resin system prepacked in
 Canbeappliedontodryor damp substrates distinct colours to give visual evidence for proper
Description mixing.Thebonding agent should
remainintackystateafterapplicationforaminimumperio
NitobondEPisbasedonsolventfreeepoxyresinscontainin
dof 5-6hrsat20oC&2-
g pigments and fine fillers.It is supplied as a two part o
3hrsat30 C6.Theproductshallachieve 50 N/mm2
material 2
compressive strength, 20 N/mm tensile strength,
inpreweighedquantitiesforreadyonsitemixinganduse.C
35N/mm2flexuralstrengthand10N/mm2shearstrength.T
ol- ouredcomponents- whitebaseandgreenhardener-
he adhesive bond to the concretesubstrate shallexceed
provide visual evidence that adequate mixing is
the tensile strength of the host concrete.
achieved.
Applicationinstructions
Technicalsupport
Preparation
Thecompanyprovidesatechnicaladvisoryservicesuppor
ted All surfaces to be treated must be firm, dust free and
byateamof specialistsinthefield. clean. All laintence should be removed by etching
Design Criteria with Reebaklens andwire-
brushing.Insomecases,theexistingconcretemust be
Nitobond EP is designed with an overlay time of 5-6 chipped to a sound substrate.Where surfaces are con-
hrs at 200C,2- taminatedwithoil orgrease, this shouldberemovedby
3hoursat300Cmakingitmoresuitableforusewhere using a strong industrial detergent or organic
additionalsteelreinforcementandformworkhastobefitte degreaser. Surface shouldbe washed thoroughlywith
dor waterand dried before the application of Nitobond EP.
wheretemperatureishigh.Theminimumapplicationtem
pera- ture for Nitobond EP is 100C. Consult the local
Fosroc office for further information.
 NitobondEP

page1of3
NitobondEP

Mixing
Cleaning
CareshouldbetakentoensurethatNitobondEPisthoroughl
Nitobond EPshould be removed from tools,equipment
y
and mix-
mixed.The‘hardener’and‘base’componentsshouldbestir
erswithNitoflorSolimmediatelyafteruse.Hardenedmate
red separately before mixing to disperse any
settlement. rial can only be removed mechanically.

Storage
Theentirecontentsof the hardener
canshouldbepouredinto the basecontainer and the two Shelflife
materials thoroughly mixed until a uniform colour is
12monthsifstoredundernormalwarehouseconditionsbe
obtained.To facilitate application at temperatures
low 350C, in unopened containers.
below 100C the separate components
shouldbewarmedinhot water toamaximumof 25 Precautions
0
Cbefore mixing.
HealthandSafety
Coating
Contactwithskinandeyesshouldbeavoided.Glovesshoul
WhereNitobondEPis tobeusedas partof arepair d be used when handling these products. If contact
systemto wiith the resin occurs, wash immediately with a strong
formasubstrate/repairbarrier,careshouldbetakentoachi detergent or a
eve anunbrokencoating. Onecoat resinremovingcream.Eyecontaminationmustbeimmedia
shouldbeappliedandallowto gel.Asecondcoat shouldbe tely washed with plenty of water and medical
appliedandusedasthebonding coat. In somesituations treatment sought.
(e.g. sprayedconcrete repairs) it may
Fire
beadvantageoustoscatterdustfreesharpsandoverthisco
at and leave to harden. NitobondEPis inflammable.No naked flame should be
allowed
As soon as the Nitobond EP has been applied, any nearthesite.Donotsmokeduringuse.
required steel reinforcement and/or formwork should
Additionalinformation
be erectedand fixed securely in place.
Fosrocmanufacturesawiderangeofproductsspecifi-
Limitations
cally designed for the repair and refurbishment of
Nitobond EP should not be applied when the damaged reinforced concrete. This includesrepair
temperature is below 100C. If any doubts arise mortars,fluid micro-
concerning temperature or substrate conditions, concretes,chemicalresistantepoxymortarsandacom-
consult the local Fosroc office. prehensivepackageofprotectivecoatings.Inaddition,aw
ide
Estimating
rangeofcomplementaryproductsareavailable.Thisinclu
Packaging des joint sealants,waterproofingmembranes,grouts
andanchors and specialised flooring materials.
NitobondEP- 0.5,1&4Litre packs

Separate datahsheetsareavailableon theseproducts.

Nitoflor Sol -5&20Litres

Coverage

NitobondEP-Approximately2.6m2/litre.

Actual coverage will depend upon the texture and

porosity of the substrate being covered.
NitobondEP

constructive solutions page2of3

NitobondEP

Importantnote:
Fosroc products are guaranteed against defective materials and manufacture and
are sold subject to its standard terms and conditions of sale, copies of which may be
obtained on
request.WhilstFosrocendeavourstoensurethatanyadvice,recommendationspecificati
on or information it may give is accurate and correct, it cannot, because it has no
FosrocChemicals direct or continuous control overwhereor howitsproductsareapplied,
(India) Pvt. Ltd. acceptanyliabilityeither
HeadOffice directlyorindirectlyarisingfromtheuseofitsproductswhetherornotinaccordancewith
“SapthagiriPalace”,No.3 any advice,specification,recommendationorinformationgiven by it.
8, II & III Floor, 12th
Cross, telephone fax e-mail
CBIRoad,GanganagarNorth, ++9180-42521900 ++9180-23551510 [email protected]
Bangalore 560 024

RegionalOffices

Chennai Mumbai Noida Kolkata

No. 26(old no.33), 1st Floor, MBC Park, 12th floor,Office No.12B, Unit No. 601, Highway Tower-II304, Jodhpur
Park 1st Street Postal Colony, ‘D’ Block, Near G Corp/Hyper City A-13/2, 6th Floor, Sector– 62 Kolkata 700 068
West Mambalam, Kasarwadawali, Ghodbunder Road, Gautam Buddha Nagar, Ph:+9133-
65343188 Chennai 600 033. Thane (West) 400 615 Noida 201 309, Uttar PradeshFax: 033-2499-
0280
Ph:+914424899949-94 Ph:+912262296800 Ph:+911206121900
Fax:044-24896641 Fax:02262296809

www.fosroc.com page3of3
NitobondEP

INDIA/2018/0913/B
ConbextraGP2 constructivesolutions

Freeflow,highstrength,non-shrink,
cementitiousprecisiongrout

Uses
Properties
ConbextraGP2isusedforprecisiongroutingwhereitisessenti Compressivestrength:(BS 1881-Part116:1983)
al Compressivestrength(N/mm2)
towithstandstaticanddynamicloads.Typicalapplicationsw Age(days) Consistency
ould Flowable(W/P0.18) Pourable(W/P0.165)

bethegroutingofbaseplatesofturbines,compressors,boil 1 24 27
3 45 54
er feedpumpsetc.,It canalso beused for
7 55 66
anchoringawiderange
28 65 78
offixings.Theseincludemasts,anchorboltsandfencepost
s. Compressivestrengthwithadditionof aggregates
Age

Advantages
50% 2)W/P0.18
Compressivestrength(N/mm 75%
(days) 100%% of
 Gaseousexpansionsystemcompensatesforshrinkag aggregates
1 28
( IS 516 - 1959) 30 32
e and settlement in the plastic state 3 50 52 55
7 60 63 68
 Nometallic ironcontenttocausestaining
28 70 75 78
 Pre-
packedmaterialovercomesonsitebatchingvariations

 Developshighearlystrengthwithouttheuseof Flexuralstrength(BS4551,1998)
chlorides
Age Flexuralstrength(N/mm2)
 Highultimatestrengthensurethedurabilityofthehard (days) W/P0.18
ened grout
1 2.5
 Freeflowensureshighlevelofcontactwithloadbearing 3 7.0
area 7 9.0
28 10.0
Description
Tensile strength
ConbextraGP2issuppliedasareadytousedrypowder.The
additionofacontrolledamountofcleanwaterproducesafr 3.5N/mm2@28days (W/P - 0.18)
ee flowing, non-shrink grout for gap thicknesses up to
100mm. Pulloutbond strength 17N/mm2@7days
(W/P-0.18) 20N/mm2@28days
Conbextra GP2 is a blend of Portland cement, graded
fillers and chemical additives which impart controlled Time for expansion Start :20 minutes

expansion in the plastic state whilst minimising water (after mixing ) Finish:120minutes

demand.The low water demand ensures high early Freshwet density

strength.The graded fillers are designedto assist
uniform mixing and produce a consistent grout. Approximately2220kg/
m3depending on
Technicalsupport actual consistency
An experienced technical advisory team is available used
to give technical service on request. Young’s modulus

28kN/mm2 (ASTM D469 - 94)

DynamicloadresistanceSpecimens of ConbextraGP2
remained undamaged even
after subjecting them to
alternate loads of 5N/mm2&
25N/mm2 at the rate of 500
cycles/minutefortwomillion
ConbextraGP cycles.

page1of4
2
ConbextraGP2

Coefficient of thermal expansion11 x 10 -6/0 C

Thecompressivestrengthofthegroutmustexceed50N/
Unrestrained expansion 2-4%intheplastic
mm2 at 7 days and 60 N/mm2at 28 days.
stateenables to
overcome shrinkage. Theflexuralstrengthofgroutmustexceed9N/
Pressure to restrain mm2@28days.
0.004 N/mm2approx. Thefreshwetdensityofthemixedgroutmustexceed2150kg/
Flow characteristics :The maximum distance of flow is m3.
governed by the gap width and the head ofthe
The storage, handling and placement of the grout must
grout.Typical data for flow design assuming grout is
be in strict accordance with the manufacturer’s
poured immediately after mixing is given in the table
instructions.
below :
Applicationinstructions Preparation
Grout Max.flow distancein mm
Foundationsurface
consistency Gapwidth 50mm100mm 250mm
(mm) head head head The substrate surfacemust be free from oil, grease or
any
Flowable 30 350 1000 1500
looselyadherentmaterial.Iftheconcretesurfaceisdefecti
40 500 1500 2000
ve
50 900 2000 3000+
orhaslaitence,itmustbecutbacktoasoundbase.Bolthole
Note:Thistableisbasedonthefollowingfactorstemperatur s andfixingpocketsmust beblowncleanofanydirt
e ordebris.
-
300C;Watersaturatedsubstrate;Minimumunrestrictedflo Pre-soaking
w
Severalhours prior
widthis 300mm.
toplacing,theconcretesubstratesshould be saturated
with fresh water.
SpecificationClauses
Performancespecification Immediatelybeforegroutingtakesplaceanyfreewatersh
ould
All grouting shown on the drawing must be carried out beremovedwithparticularcarebeingtakentoblowoutallb
with a pre packed cement based product which is olt holes and pockets.
chloride free.
Baseplate
It shallbe mixed with clean waterto the
It isessential that thisiscleanandfreefrom oil, greaseor
requiredconsistency. The grout must not bleed or
scale. Air pressure relief holes should be provided
segregate.
toallow venting of any isolated high spots.
Apositive volumetric expansion shall occur while the
Levellingshims
grout is plastic by means of gaseous system.
If these are to beremoved after thegrout
Typicaldetailofstanchionbaseplate
hashardened, they should be treated with a thin layer
of grease.

Formwork

The formwork should be constructed to be

leakproof.This canbe achieved by using foam rubber
stripor mastic sealant beneath the constructed
formwork and between joints.

In somecases it is practical touse asacrificial semi-dry

sand and cement formwork.The formwork should
include outlets for pre-soaking.
ConbextraGP2

constructivesolutions page2of4
ConbextraGP2

Unrestrainedsurfacearea

This must be kept to a minimum.Generally the gap

width between the perimeter formwork and the plate Anyboltpocketsmustbegroutedpriortogroutingbetween
edge should the substrate and the base plate.
notexceed150mmonthepouringsideand50mmontheo
Continuous grout flow is essential.Sufficient grout
p- posite side.It is advisable, where practical, to have
must be
no gapat the flank sides.
preparedbeforestarting.Thetimetakentopourabatchmu
Mixingand placing st be regulated to the time to prepare the next one.

Mixing Typicalhoppersystem

For best results a mechanically powered grout mixer Removablehopper :For largepoursthegrout maybehand
should beused.Whenquantities placed or pumped into a removable hopper ( trough)
upto50kgareused,aheavyduty slowspeeddrill(400-
500rpm)fittedwithapaddleissuitable.. Larger
quantities will require a heavy duty mixer.

To enable the grouting operation to be carried out

continu-
ously,itisessentialthatsufficientmixingcapacityandlab
our are available.The use of a grout holding tankwith
provision to gently agitate the grout may be
required.
Consistencyofgroutmix

Thequantityofcleanwaterrequiredtobeaddedtoa25kgba
g to achieve the desired consistency is given below :

Pourable :4.125litres

Flowable :4.5 litres

Pouringshouldbefromonesideofthevoidtoeliminateanya
The selected water content should be accurately ir
measured into the mixer.The total content of the orpresoakedwaterbecomingtrappedunderthebaseplate
Conbextra GP2bag should be slowly added and .It is advisable to pour the grout across the shortest
continuous mixing should take place for 5 distance of
minutes.This will ensure that the grout has a smooth travel.Thegroutheadmustbemaintainedatalltimessotha
even consistency. t a continuous grout front is achieved.
Placing
Where large volumes have to be placed Conbextra
0
At30 Cplacethegroutwithin20minutesofmixingtogain GP2 may be pumped.Aheavy duty diaphragm pump is
fullbenefitof theexpansion process. recommended for this purpose.Screw feed and piston
pumps may also be suitable.
ConbextraGP2canbeplacedinthicknessesupto100mmi
Curing
n a single pour when used as an underplate grout.
Oncompletionofthegrouting
For thicker sections it is necessary to fill out
operation,exposedareasshould bethoroughly
Conbextra GP2
cured.This shouldbedoneby theuseof Con- cure WB
withwellgradedsiltfreeaggregatetominimiseheatbuild
curing membrane, continuous application of water
up. Typicallya10mmaggregateissuitable.50-
and/or wet hessian.
100%aggregate by weight of Conbextra GP2 can be
added.
ConbextraGP2

constructivesolutions
page3of4
ConbextraGP2

Limitations
Storage
Low temperatureworking
Shelflife
0
When the airorcontact surface temperatures are 10 C or
ConbextraGP2hasashelflifeof6monthsifkeptinadrystor
below on a falling thermometer, warm water ( 30 -
e
400C) is recom- mended to accelerate strength insealedbags.Ifstoredinhightemperatureandhighhumid
development. ity locations, the shelf life may be reduced.
Precautions
Forambienttemperaturebelow 100C the formwork
HealthandSafetyinstructions
should be kept in place for at least 36 hours.
Conbextra GP2 is alkaline and should not come into
Normal precautions for winter working with cementitious
contact with skin and eyes.Inhalation of dust during
materi- als should then be adopted.
mixing shouldbe avoided.
Hightemperatureworking
Gloves,gogglesanddustmaskshouldbeworn.
Atambienttemperaturesabove400C,coolwater(below20
0
C) should be used for mixing the grout prior to If contact with skin occurs, it shall be washed with
placement. water. Splashes to eyes should be washed
immediately with plenty of clean water and medical
Estimating
advice sought.
Packaging
Fire
ConbextraGP2is suppliedin25kgmoistureresistant
bags. ConbextraGP2isnonflammable.
Yield
Additionalinformation
Allowance should be made for wastage when For further details about the use and selection of
estimatingquanti- grouts refer to the Fosroc Information module entitled
tiesrequired.Theapproximateyieldper25kgbagfordiffer ‘Precision grouting in the Construction industry’.
ent consistency is :

Consistency Pourable Flowable

Yield(litres) 12.5 13.3

Importantnote:
Fosroc products are guaranteed against defective materials and manufacture and
are sold subject to its standard terms and conditions of sale, copies of which may be
obtained on
request.WhilstFosrocendeavourstoensurethatanyadvice,recommendationspecificati
on or information it may give is accurate and correct, it cannot, because it has no
FosrocChemicals direct or continuous control overwhereor howitsproductsareapplied,
(India) Pvt. Ltd. acceptanyliabilityeither
HeadOffice directlyorindirectlyarisingfromtheuseofitsproductswhetherornotinaccordancewith
“SapthagiriPalace”,No.3 any advice,specification,recommendationorinformationgiven by it.
8, II & III Floor, 12th
Cross, telephone fax e-mail
CBIRoad,GanganagarNorth, ++9180-42521900 ++9180-23551510 [email protected]
Bangalore 560 024

RegionalOffices

Chennai Mumbai Noida Kolkata

No. 26(old no.33), 1st Floor, 1401/1402, 14th Floor, D-166 Sector 10 304, Jodhpur Park
1st Street Postal Colony, A-Wing’The Great Eastern Summit’ Dist. Gautam Budha Nagar, Kolkata 700 068
West Mambalam, Sector-15, CBD, Belapur Noida, Ph:033-65343188
Chennai 600 033. Navi Mumbai 400 614 UP 201 301 Fax:033-2499-
0280
Ph:044-24899949-94 Ph:022-43406800-04 Ph:0120-4270620-21
ConbextraGP2
Fax:044-24896641 Fax:022-27562423 Fax:0120-4270622

www.fosroc.com
page4of4
INDIA/2014/0306/A