Fosroc Presentation -L&T,Dhuvaran
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Transcript of 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
constructive solutions
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 solutions
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
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• 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
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• 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
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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
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
constructive solutionsGood Grouting Practices
• 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
constructive solutionsGood Grouting Practices
• 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
constructive solutionsGood Grouting Practices
• 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
constructive solutionsTrouble Shooting
• 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
constructive solutionsTrouble Shooting
• 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
constructive solutionsTrouble Shooting
• 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
constructive solutionsTrouble Shooting
• 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
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• 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
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• 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
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Correct proportionsCorrect Proportions
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Checking flow using BS coneChecking Flow using BS Cone
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Measuring of grout flowMeasuring Grout Flow
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Proper RestraintProper Restrain
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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
constructive solutions
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
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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