fosroc presentation -l&t,dhuvaran

constructive solutions

Fosroc Chemicals India Pvt.Ltd.Partnering in Constructive Solutions

Welcome delegates of Larsen & Toubro, Dhuvaran Project Date: 13/03/2013

BHAIRAV PRAJAPATI-Specification Engineer + 91 99740 [email protected]

constructive solutionsAgenda

Introduction to Fosroc

Grouts & Anchors

Waterproofing & Sealants

Q&A


Introduction to

Fosroc

constructive solutionsFosroc 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 company’s most well known solutions are found in iconic structures around the globe

constructive solutionsLocation of Production facilities

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

Philippines

Indonesia

Malaysia

China

S. Korea

India

UAE

SaudiArabia

Jordan

Spain

UK Denmark

Pakistan

Australia

Nigeria

Brazil

Trinidad

Romania

constructive solutionsTechnology and Knowledge

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 customer’s problem

constructive solutionsProduct Range

Admixtures Coatings Concrete Repair Corrosion Control

Flooring Grinding aids Grouts & Anchors Joint Sealants

Surface treatments Waterproofing

constructive solutionsPrecision Grout - Definition

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.

constructive solutionsTypes of Precision Grouts

• Cementitious

• Epoxy based grouts

• Polyurethane grouts

• Epoxy cementitious grouts

constructive solutionsBasic Ingredients in Grouts

Cement

Graded Filler

Plasticiser

Expansive Agents

Thermosetting epoxy resin system

Amide Resin Catalyst

Blended Aggregate or Silica or Quartz

Cementitious Grouts Epoxy Grouts

constructive solutionsChoice of Precision Grouts

Depends on

• 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

constructive solutionsEssential properties of grouts

• High compressive strength

• High Flowability

• Creep resistance

• Shrinkage compensation

• Dimensional stability

• Resistance to Dynamic/Static loading

constructive solutionsEffective Bearing Area (EBA)

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.

constructive solutionsComparison of ultimate strengths

Conbextra Conbextra Conbextra Conbextra Conbextra Conbextra Conbextra GPI HF HES GP2 EP 10 EP 75 EP 300


• 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

Advantages of Cementitious Grout materials


• 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

Characteristics of Epoxy Grout materials


• 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

Advantages of using Fosroc pre-bagged grout materials

constructive solutionsProduct Selector - Cementitious

constructive solutionsGood Grouting Practices

• 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


• 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


• 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


• 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 6–8 hours at low temperatures and within 2–3 hours at high temperatures.

• Shuttering shall be removed only after 24 hours

• Curing shall be continued for a minimum of 7 days

constructive solutionsImportant tools & accessories

• Measuring Can to measure the qty of water precisely

• Sponge to remove excess water

• Sufficient length and diameter Hose pipe for deep pockets grouting

• Powerful torch light to examine dark areas.

constructive solutionsImportant tools & accessories

• 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

constructive solutionsTrouble Shooting

• 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

Delay in setting time


• Incorrect mixing – Part mix , insufficient agitation

• 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

Grout does not flow


• Excessive exotherm – thickness higher than recommended

• 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.

Cracks appearing in Grout


• 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

Grout surface bubbles and laitance


• 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

Grout is weak

constructive solutionsDo’s & Don'ts

Do’s Don’ts

Store the grout in a well ventilated space protected from moisture

Mix more water than specified for cementitious grouts

Check everything for damages and expiry date before using

Mix any other ingredient like sand, cement 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 mixed grout within 30 minutes depending on temperature and humidity

Use vibrators

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


• 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

• Grout should be restrained by plates

• Demould exactly after 24 hours

Grout testing guidelines


• Edges should be taken care during demoulding.

• 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.

Grout testing guidelines


Correct proportionsCorrect Proportions


Checking flow using BS coneChecking Flow using BS Cone


Measuring of grout flowMeasuring Grout Flow


Proper RestraintProper Restrain


Cubes casting at LabCube Casting at Lab

constructive solutionsPre – Dispatch Quality Checks – At Factory

• 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


Anchoring of Shear connectors

constructive solutionsAdvantages of Polyester Resin Grouts

Easy mixing

Very fast reacting and setting times

Rapid strength gain

Temperature tolerant

Irreversible chemical reaction

Water tolerant

Corrosion resistant

constructive solutionsLokfix range

Vertical Appln

25-50mm

Lokfix L

Vertical Appln

<25mm

Lokfix S

Horz/Over head Appln

<25mm

Lokfix P

constructive solutionsLokfix S

100 mm minimum bonded length

200 400 600 800

10

20

30Rebar bolt in drilled hole using percussive drill

Bonded length

Fai

lure

load

(T

)

M20 Concrete & 25mm deformed bar

constructive solutionsLokfix used for anchoring foundations to rock strata


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


Lokfix used for anchoring dowel bars for sunshade at Chellammal College


Lokfix used anchoring staircase handrails

fosroc presentation -l&t,dhuvaran

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