we supply Cement & Concrete Technology Cement Additives Cement Additives Product: Cemax Liquid or powder products, which modify and improve the properties of cement. Grinding aids for cement and raw material mills Early strength enhancers Specialty cement

we supply : Cement & Concrete Technology Cement Additives Cement Additives Product: Cemax Liquid or powder products, which modify and improve the properties of cement. Grinding aids for cement and raw material mills Early strength enhancers Specialty cement additives Late strength enhancers Strength enhancers Strength and workability enhancers Air-entrainers for Masonry cement Admixtures Products: Conplast, Cebex, Structuro Liquid or powder products which modify and improve the properties of fresh and hardened concrete or mortar. Plasticisers Pumping aids Superplasticisers Retarders Corrosion inhibitors Specialty admixtures Air-entrainers Accelerators Corrosion Inhibition Corrosion Inhibition Product: Conplast CN Corrosion-inhibiting admixtures used to provide corrosion inhibitor in readymix and precast reinforced concrete. Compatible with other admixtures No adverse effects on workability and strength of concrete Surface Treatments Surface Treatments Products: Concure, Reebol, Preco Concrete curing membranes and other products to enhance the concrete surface. Ease of formwork release Producing exposed aggregate finishes Enhanced curing of freshly placed concrete Grouts & Anchors Grouts & Anchors Products: Conbextra, Cebex, Lokfix Cement and resin-based products to fill voids beneath ( or between) load-bearing units. Resin-anchoring systems to install permanent and removable anchors and fixings. Highly efficient load transfer Excellent chemical resistance High strength high performance Assured bonding of critical fixings Long and distinguished track record Barriers Waterproofing Sealants Gas Membranes Fireproofing Repair & Remediation Concrete Repair Mortars Concrete Repair Mortars Products: Renderoc, Patchroc, Paveroc, Nitomortar, Nitobond Cement and resin-based products for the reinstatement of defective concrete. Structural and non-structural repairs Long and distinguished track record Low, medium and high build solutions Self compacting solutions Rapid cure solutions Design compatibility Crack Injection Resins Crack Injection Resins Products: Nitofil, Nitokit Resin based products for bonding and sealing cracked concrete. Pre-packaged solution for ease of use Suitable for static or open-ended cracks High strength high performance Excellent chemical resistance Physical barrier to water ingress Corrosion Control Products: Galvashield, Ebonex, Norcure Pioneering electrochemical methods for the repair and protection of steel-reinforced concrete offering a unique range of solutions. ? Total repair package - rehabilitation for an entire structure, where required, or for specific areas ? Minimum disruption - silent, self-regulating systems that do not interrupt existing usage ? Long-term solutions - corrosion is controlled to prevent future failure ? Effective - independently tested and proven in use, structural integrity maintained ? Economic - versatile systems, simple to install Grouts Grouts Products: Conbextra, Cebex, Lokfix Cement and resin-based products to fill voids beneath ( or between) load-bearing units. Resin-anchoring systems to install permanent and removable anchors and fixings. Highly efficient load transfer Assured bonding of critical fixings Excellent chemical resistance High strength high performance Long and distinguished track record Conbextra Cebex Lokfix Surface Coatings Flooring Flooring Products: Cemtop, Nitoflor, Polyurea Coatings, toppings, and screeds to provide improved performance to new and existing concrete floors. Enhanced chemical resistance Abrasion and impact resistance Increased durability and strength Clean-environment, trafficable finish Cemtop Nitoflor Polyurea Adhesives Adhesives Products: Nitobond, Nitotile Concrete bonding agents, tile and general-purpose adhesives for use with concrete structures. Improving the bond strength of fresh wet mortars Permanent fixing of ceramic tiles and board materials Nitobond Nitotile Product Information Downloads click here See Case Study on Nitobond: GK, Hyundai Mipo Shipyard, West Rail See Case Study on Nitotile: West Ra Top 107 Seal 2 komponen Semen Pelapiskedap air Fungsi : Sebagaipelapis anti bocoruntuk internal daneksternalpadabeton, mortar, bata, kolamrenang, atapdak, balkon, teras, dinding dll TILEBOND Waterproof Tile Adhesive Tilebond adalah bubuk dasar semen untuk lem keramik yang di formulasi dari polimer special dan pengisi agregat halus pilihan. Polimer dalamTILEBOND menahan air untuk campuran mortar yang liat dan mudah dipasangkan. Polimer dalam TILEBOND meningkatkan reaksi hidrasi yang menambar daya lekat. Untuk melekatkan Keramik, Marmer, Granit, Bata Ringan. KEGUNAAN & KEUNTUNGAN TILEBOND memberikan daya lekat berkekuatan tinggi untuk pemasangan keramik pada permukaan semen. TILEBOND memberikan daya lekat tinggi pada permukaan halus meskipun untuk pemasangan ? tile-on-tile? TILEBOND tahan cuaca dan tahan terhadap lingkungan lembab dan basah ( waterproof) TILEBOND dapat digunakan untuk interior dan juga permukaan exterior dari bangunan. TILEBOND mempunyai kekuatan tinggi dan sifat tidak susut yang juga baik sebagai pengisi nut TILEBOND mortar memiliki kekentalan dan daya lekat tinggi untuk mempermudah pemasangan keramik. TILEBOND mudah dipakai hanya dengan tambahan air. PEMASANGAN Permukaan sudah rata dan tidak bergelombang. Permukaan di basahi atau dilembabkan, tetapi bersih dari debu, kotoran dan lumut. CampurkanTILEBOND dengan air bersih sesuai dosis untuk mendapatkan pasata mortar yang liat. Oleskan pasta TILEBOND dengan ketebalan yang sesuai. Pasang Keramik dan segera atur posisi yang diinginkan, TILEBOND mencapai kekuatan maksimum dalam 24 jam, dan pekerjaan nat dapat di mulai. DOSIS Campurkan 1 kg TILEBOND dengan 300 cc air bersih, 1kg TILEBOND untuk 1 m2 pada ketebalan 1 mm KEMASAN TILEBOND di kemas dalam 25 kg per sak PENYIMPANAN TILEBOND dapat awet disimpan sampai 12 bulan dalam kemasan asli. Mohon di simpan ditempat kering dengan suhu kamar sedang Catatan: TILEBOND tidak beracun TILEBOND tidak dapat terbakar. TILEBOND Roof Tile Adhesive TILE BOND? roof tile adhesive is a single-component polyurethane adhesive for attachment of concrete and clay roof tiles. COMPOSITION TILEBOND is a cement-based powder for tile adhesive formulated from special polymers and selected fine aggregate contents. The polymers is TILEBOND allow good water retention for creamy and easy to apply mortar, The polymers improve the hydration reaction that increase bonding strength of TILEBOND, for ceramic Tiles, Granites, Lightweight Bricks. USES AND BENEFITS. TILEBOND is provide very strong adhesive for all tile installation to cement surfaces. TILEBOND allow strong bonding for smooth surface allow strong bonding for smooth surface even for ? tile-on-tile? application. TILEBOND is weather proof and resistant to humid and wet environment ( waterproof ) . TILEBOND can be used for interior and also exterior surfaces of the building. TILEBOND has high strength and non shrink characteristics which also good for tile grouting. TILEBOND mortar has thickness and bonding strength for easy tilling application. TILEBOND is easy to use with only addition of clean water. APPLICATION Surface must be even and leveled. Surfaces is pre-wet or damp, but must be free from dust, dirt and mould. Mix TILEBOND with clean water according to dosage for creamy and thick mortar. Apply TILEBOND to surface at desired thickness, Fix tiles and adjust for the correct position. TILEBOND is cured after 2, 5 hours. TILEBOND reach maximum strength in 24 hours, then tile grouting can be started COVERAGE Mix 1 kg TILEBOND with 300cc of clean water, 1kg TILEBOND for 1 m2 at 1 mm thickness. PACKAGING TILEBOND is available in 25 kg bags STORAGE TILEBOND can be stored for 12 months in the sealed original packing, Please store in a dry and in a moderate temperature area. NOTES. TILEBOND is not toxic TILEBOND is not flammable. RESIN MORTAR Non ? Slip Heavy Duty Screed. Keterangan Bahan : - Resin Mortar digunakan untuk melindungi permukaan lantai terhadap gesekan dan beban mekanis - Resin Mortar menambah daya tahan lantai terhadap serangan berbagai bahan kimia - Resin Mortar membuat lantai tidak licin ( non-slip) untuk kendaraan dan pejalan kaki - Resin Mortar menambah mutu waterproofing lantai Komposisi Bahan : 1 set Resin Mortar terdiri dari : Resin Mortar : 33 kg Hardener : 3 kg Dosis dan Daya Sebar : 1 set Resin Mortar : 5 s/ d 7 m2 pada ketebalan 2 s/ d 3 mm Pemasangan : 1. Permukaan lantai beton harus kering dan bersih dari kotoran, minyak, lumut dsb Permukaan lantai harus tetap kering mulai dari awal pekerjaan hingga Resin Mortar mongering 2. Pelabuhan BASE COAT ( tersendiri ) Campurkan komponen A ( 1L) dengan komponen B( 1L) , rasio perbandingan 1 : 1 Setelah campuran di aduk rata, di laburkan dengan kuas pada 5 m2 3. Pemasangan MORTAR Campurkan Resin Mortar ( 33kg ) dengan Hardener ( 3L ) hingga rata Sewaktu laburan dasar ( prime coating ) dalam keadaan setengah kering, tuangkan adukan mortar ke atas permukaan lantai dan di ratakan dengan roskam besi ( steel-trowel ) dengan ketebalan s s/ d 3 mm. Roskam besi di basahi thinner supaya pengerjaan permukaan lebih halus dan lebih mudah diratakan. Pemasangan Mortar harus selesai dalam waktu 2 jam. Lantai sebaliknya tidak digunakan untuk 24 jam setelah FORM WORK REEBOL MOULD RELEASE AGENT KEGUNAAN : Mencegah pelekatan beton pada cetakan kayu dan besi KEUNTUNGAN : - Memudahkan pelepasan / pembongkaran cetakan ( Papan Bekisitng ) - Membuat permukaan beton menjadi mulus dan bersih sehingga tidak perlu di lapis finishing. - Apabila dikehendaki, permukaan beton masih bisa di plester maupun di ? cat - Menghemat papan-papan cetakan karena dapat digunakan berulang-ulang - Juga dapat mencegah pelekatan beton pada alat-alat pengerjaan beton ( mixer, ember dll ) Sehingga alat-alat mudah dibersihkan dan lebih awet EFEK DAN SIFAT : - REEBOL akan ber-reaksi dengan bahan alkali dalam semen Portland dan membentuk suatu selaput antara permukaan beton dengan cetakan - Selaput ini yang memisahkan permukaan beton dengan cetakan, sehingga cetakan terhindar dari pelekatan dengan beton, dan permukaan beton menjadi mulus DOSIS : - 1 LITER REEBOL untuk 20 ? 60 m2 ( tergantung pada halusnya papan cetakan) KEMASAN : per gallon 5 liter APLIKASI : - REEBOL dilaburkan pada permukaan cetakan dengan menggunakan kuwas atau alat semprot. - Cetakan dapat dipergunakan setelah laburan REEBOL kering - Laburan REEBOL dapat bertahan dengan baik dalam segala cuaca ( Hujan dan panas ) Contact : Kehan Suply , 0818 07 48 95 48 CURING COMPOUND Concrete Curing Compound KEGUNAAN : - Mencegah penguapan air dari permukaan beton / plesteran yang baru di cor - Terutama sangat berguna pada bidang beton yang luas, seperti lantai pabrik / gudang , landasan pesawat, dermaga pelabuhan , jembatan beton, dll - Pada bidang beton / plesteran yang tegak ( vertical) yang sulit untuk pembasahan dengan air. KEUNTUNGAN : - Mengurangi penyusutan yang terjadi pada permukaan beton - Mencegah retak-retak pada permukaan beton / plesteran yang disebabkan penguapan air. - Membantu tercapainya dengan sempurna proses hidrasi semen sehingga menghasilkan beton/ plesteran yang keras - Menghasilkan permukaan lantai beton yang keras. - Lantai beton dapat segera di gunakan ( beban ringan ) karena tidak perlu di rendam air atau ditutup dengan karung basah DOSIS : 1 liter CURING COMPOUND untuk 4-5 m2 KEMASAN : 1 Gallon = 5 Liter APLIKASI : - Curing Compound dapat di taburkan dengan kuwas atau dapat juga di semprotkan pada permukaan beton, segera setelah lantai cukup keras untuk di lalui orang. - Pada bidang tegak, CURING COMPOUND segera di laburkan setelah cetakan beton dibuka Contact : Kehan Suply , 0818 07 48 95 48 MASTERFLOW 880 Cementitious ultra-high strength non-shrink iron reinforced precision grout DESCRIPTION MASTERFLOW 880 is a non-shrink, iron reinforced precision grout with high early and ultimate strengths. It is formulated to provide extended working time even at high ambient temperatures when mixed and placed at any recommended consistency. MASTERFLOW 880 is normally placed at a flowable consistency to completely fill voids between 10mm and 100mm. RECOMMENDED FOR All precision, non-shrink grouting applications with clearances of 10mm or more, particularly those requiring maximum dynamic load bearing and impact resistance such as: ? Critical equipment baseplates, soleplates & columns. ? Crane rails, ball mills, crushers. ? Rolling, stamping, drawing and finishing mills for the steel and aluminium industries. ? Turbines, generators, pumps and centrifugal compressors. ? Anchor bolts and bars ? ? H? shaped steel columns, steel tube columns. ? Applications requiring high early compressive strengths and high ultimate compressive strengths. FEATURES AND BENEFITS ? Iron reinforced ? contains inert iron aggregate as internal reinforcement to provide improved resistance to heavy impact, vertical and horizontal repetitive loading as well as rotational torque. ? High early strength - ensures rapid commissioning of new equipment and structures. ? High ultimate strength - ensures permanence of the installation under static and repetitive loads. ? Flowable long life grout - easy to grout intricate spaces normally inaccessible by conventional grouting techniques. ? Extended working time - facilitates grouting of large or difficult placements in a single pour, often without the use of a pump. ? Economical - greater volumes of grout can be mixed and handled with less labour. ? Dense, non-shrink grout - hardens free of bleeding, settlement and drying shrinkage, ensuring tight contact with all grouted surfaces. ? Easy to use - requires no special mixing equipment, it can be mixed in a standard concrete mixer or in a pail using a grout stirrer. ? No added chloride. ? Strict quality control - ensures reliable and consistent product performance. ? Compliance with codes - meets the non-shrink requirements of ASTM C1090 and CRD-C 621, Corps of Engineers Specification for Non Shrink Grout; provides complete non shrink performance when tested in accordance with simulated Bedplate Technique; tested to the requirements of AS1478.2 ? Methods of sampling and testing admixtures for concrete, mortar and grout? . PERFORMANCE DATA Strength Development - The strength of the grout is often the determining factor in deciding when loads can be put on structural members or machinery. The strength of the grout is dependent on the amount of mixing water, substrate and ambient temperature, curing and age of the hardened grout. Typical rates of strength development under variable conditions are as follows: 1. Effect of consistency on compressive strength ( MPa) development at 20 C. Consistency Age Flowable Plastic 1 day 3 days 7 days 28 days 40 64 78 90 55 75 84 98 Test Method: AS1478.2 Appendix A 2. Effect of temperature on compressive strength ( MPa) development when placed at a ? flowable? consistency. Temperature Age 10 C 20 C 30 C 1 day 3 days 7 days 28 days 17 45 59 66 40 64 78 90 45 67 79 94 Test Method: AS1478.2 Appendix A Flexural Strength ( MPa) - effect of temperature on strength development when placed at flowable consistency. ( Test Method: JIS R 5201) Temperature Age 10 C 20 C 30 C 1 day 3 days 7 days 28 days 4.0 5.3 5.9 10.0 6.9 10.6 12.4 13.2 7.6 12.0 12.6 13.8 Indirect Tensile Strength ( MPa) - effect of temperature on strength development when placed at ? flowable? consistency. ( Test Method: AS1012.10) Temperature Age 10 C 20 C 30 C 1 day 3 days 7 days 28 days 2.0 3.5 5.1 6.2 3.5 5.0 5.7 6.7 3.9 6.3 7.2 7.4 Volume Change - effect of temperature on volume change when placed at flowable consistency. ( Test Method: ASTM C1090 ( CRD-C621) ) Temperature Age 10 C 20 C 30 C 1 day 3 days 7 days 28 days Positive Positive Positive Positive Positive Positive Positive Positive Positive Positive Positive Positive MASTERFLOW 880 Flow Retention - effect of temperature on flow retention when placed at flowable consistency. Flow Retention ( % ) Age 10 C 20 C 30 C Initial After 30 minutes After 1 hour 100 70 50 100 95 75 100 80 50 Bleeding, Plastic Density and Setting Time - effect of temperature on plastic properties when placed at flowable consistency. ( Test Method: Bleeding AS1012.6; Plastic density AS1012.5; Setting time AS1012.18) Setting Time Temp. Bleedin g ( % ) Plastic Density ( kg/ m3) Initial ( hr: min) Final ( hr: min ) 10 C 20 C 30 C 0 2515 2550 2625 4: 40 4: 10 3: 00 6: 00 5: 00 3: 40 Water Demand Actual water demand will depend on consistency required and temperature ( both ambient and grout) . Do not use too much water, as it will cause grout to bleed or segregate. As a guide, the following table indicates the appropriate quantity of water required to mix a 20kg bag of MASTERFLOW 880 to various consistencies at the temperature shown. Water Demand, Litres per 20kg bag Consistency Temperature Flowable ( 1) Plastic ( 2) 20 C 3.0 2.6 1) AS1478.2 Appendix D, 45-55cm lateral flow in the flow trough. 2) ASTM C230/ C230M, 100-120% flow by flow table after 5 drops in 3 s or AS1478.2 Appendix D, 20-30cm lateral flow in the flow trough. The performance data is typical and based upon controlled laboratory conditions. Actual performance on the job site may vary from these values based on actual site conditions. Field and laboratory tests should be conducted on the basis of the desired placing consistency rather than strictly on indicated water demand. If the project requires strength tests be made on site do not use cylinder moulds. ESTIMATING DATA MASTERFLOW 880 mixed in accordance with BASF Construction Chemicals recommended procedures to the required consistency, will provide the following approximate yields: Approximate Yield, Litres per 20kg bag Temperature Consistency C Flowable Plastic 20 9.2 8.8 APPLICATION For application directions on preparation, forming, mixing, placing and curing MASTERFLOW 880, as well as the precautions to take in hot and cold weather, refer to the ? Application Guide for MASTERFLOW Cementitious Precision Grouts? available from your local BASF Construction Chemicals representative. PACKAGING MASTERFLOW 880 is packaged in 20kg bags. SHELF LIFE MASTERFLOW 880 has a shelf life of approximately 12 months when stored in a cool dry environment. PRECAUTIONS For the full health and safety hazard information and how to safely handle and use this product, please make sure that you obtain a copy of the BASF Construction Chemicals Material Safety Data Sheet ( MSDS) from our office or our website. AMf880/ 17/ 0411 STATEMENT OF RESPONSIBILIT Y The technical information and application advice given in this BASF publication are based on the present state of our best scientific and practical knowledge. As the information herein is of a general nature, no assumption can be made as to a product' s suitability for a particular use or application and no warranty as to its accuracy, reliability or completeness either expressed or implied is given other than those required by law. The user is responsible for checking the suitability of products for their intended use. BASF data sheets are updated on a regular basis and it is the user? s responsibility to obtain the most recent issue. NOTE Field service where provided does not constitute supervisory responsibility. Suggestions made by BASF either orally or in writing may be followed, modified or rejected by the owner, engineer or contractor since they, and not BASF, are responsible for carrying out procedures appropriate to a specific application. BASF Australia Ltd A.B.N. 62008437867 LITE COOL Lightweight. Versatile. Superior Sound Retention. These are characteristics Lite-Deck can offer. Lite-Deck is the solid concrete alternative for conventional floor and deck applications in residential homes, commercial buildings, and safety structures. The results? A quiet, secure concrete structure that is sustainable and energy-efficient ESTOP E t t SQ 25 K / B Fax Mobile Email Page DESCRIPTION QTY UNIT PRICE PRICE Phone Estotop Kg/ Bag Description : Floor Hardener Natural Estorex EPS High Strength, Epoxy Resin Grout Description Estorex EPS is a solvent free epoxy resin grout designed for grouting of gap widths of 10 to 75 mm. It is supplied as a three component system consisting of base, hardener and specially graded aggregate. The components are supplied in the correct mix proportions designed for whole pack mixing on site. Estorex EPS has been tested in accordance to BS 4551, on Compressive Strength; ASTM C307-03, on Tensile Strength Test; ASTM C348-02, on Flexural Strength Test, and complied with the speci cation in this data sheet. Uses Estorex EPS is a free  owing epoxy grout, for use where physical properties and chemical resistance of the hardened grout are of utmost importance. It is suitable for a wide range of heavy duty applications including: ? Excellent durability - high compressive,  exural and tensile strengths ensure a long working life. ? Cost e ective - high early strength gain promotes minimum downtime and early commissioning of plant. ? User friendly - simple, full pack mixing to ensure that the performance characteristics are achieved. ? Versatile - suitable for a wide range of loading situations including repetitive dynamic loads. ? Excellent in service performance - non-shrink capability ensures full surface to surface contact. ? Under plate grouting to substantial structural elements. ? Heavy industrial applications in steelworks, re neries chemical plants and electroplating works. ? Base plate grouting in dynamic load situations such as turbines and other reciprocating machinery. ? Structural in ll where very high strength is required. ? Heavy cranes, or on transporter rails, or rail track support. Advantages ? ASTM C307 - 03 ? ASTM C348 - 02 ? ASTM C531 ? BS4551 Standards Compliance Physical Properties 30 ? 45 120 ? 180 Pot Life, mins 30 C 23 C > 14 > 26 25 C Tensile Strength, N/ mm2 ( ASTM C307-03) 7 Days Flexural Strength, N/ mm2 ( ASTM C348-02) 7 Days 28.1 10-6 Coefficient of thermal Expansion ( ASTM C531) Maximum flow distance ( mm) for a head of 100 mm at 20 C 35 mm gap 70 mm gap 80 90 100 2000 3500 30 C 90 95 101 Compressive Strength, N/ mm2 ( BS 4551) 1 Day 3 Days 7 Days A Member of Group www.estop-group.com Estorex EPS High Strength, Epoxy Resin Grout Technical Support Estop o ers a technical support package to speci ers, end-users and contractors, as well as on-site technical assistance. Storage Estop BJ Transitional Strip has a shelf life of 12 months, if stored in a cool and covered condition. If stored in extreme heat locations the shelf life may be reduced. Precaution Health and safety The use of goggles is recommended but should accidental eye contamination occur, wash thoroughly with plenty of clean water and seek medical treatment immediately. Estop Primer E11 is  ammable. Additional Information Estop manufactures and o ers a wide range of complementary products which includes waterstops, waterproo ng products, grouts, anchors, specialized  ooring products. In addition, a wide range of products formulated for repair and refurbishment of spalled concrete are available. Packing & Size Coverage Estorex EPS 25 kg bag Estop Primer E11 200 mL pack Estorex EPS 1 m2 / 8 mm thick / 8 litre pack Application Instructions Preparation Prepare concrete surface by scrubbing, wire brushing and blow out Under plate grouting The unrestrained surface area of the grout must be kept to a minimum. Generally, the gap between the perimeter formwork and the plate edge should not exceed 75 mm on the pouring side and 25 mm on the opposite side. Formwork on the  ank sides should be kept tight to the plate edge. Air pressure relief holes should be provided to allow venting of any isolated high spots. Formwork The formwork should be constructed to be leak proof as Estorex EPS is a free  ow grout. This can be achieved by using foam rubber strip or mastic sealant beneath the constructed formwork and between joints. For free  ow grout conditions, it is essential to provide a hydrostatic head of grout. To achieve this feeding hopper should be used - please consult your local Estop o ce for more details. Foundation surface This must be free from oil, grease, or any loosely adherent material. If the concrete surface is defective or has laitence, it must be cut back to a sound base. Bolt holes or  xing pockets must be blown clean of any dirt or debris. Base plate If delay is likely before placing steel base plates, it is recommended that the underside and edge are coated with Estop Primer E11 to prevent rust formation and ensure bonding with the Estorex EPS grout. All metal surfaces should be cleaned to a bright  nish in accordance with Swedish Standard SA 2 or equal. Estop Primer E11 can be applied directly onto newly cleaned steel surfaces even if they are damp. Mixing The entire contents of the hardener should be poured into the base container and mixed until homogeneous. Place the mixed base and hardener into a suitable forced action mixer making sure that the entire volume is poured in. Add the aggregate and mix for 2-3 minutes or until uniform colour is achieved. Once mixed, the material must be used within the speci ed pot life. After this time, unused material will have sti ened and should be discarded. Placing Ensure that the grout can be placed within its pot life and the substrate is dry. Continuous grout  ow is essential. Su cient grout must be available prior to starting and the time taken to pour a batch must be regulated to the time taken to prepare the next one. Pouring should be from one side of the void to eliminate air entrapment. The hydrostatic head must be maintained at all times so that a continuous grout front is achieved. Important Note 08-08-05 Estop 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. Whilst Estop endeavors to ensure that any advice, recommendation, speci cation or information in may give is accurate and correct, it shall not, because it has no direct or continuous control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, speci cation, recommendation or information given by it. Sika CarboDur Heavy-Duty CFRP Strengthening System Description Sika CarboDur is a heavy-duty strengthening system for reinforced concrete and timber. It consists of two components: Sikadur-30 adhesive for bonding reinforcement and Sika CarboDur -laminates. Uses The Sika CarboDur system can be used to strengthen reinforced concrete and timber structures due to: n Loading increases. n Damage to structural parts. n Change is structural system. n Design or construction defects. Advantages n Low in weight. n Available in any length. n Low overall thickness. n Easy to transport. n No preparation of Sika CarboDur laminates. n Laminate intersections are simple. n Economical application ? no heavy handling and installation equipment. n Very high tensile or flexural strengths can be achieved. n High modulus of elasticity. n Outstanding fatigue resistance. n Can be coated without preparation. n Alkali resistant. Storage and Shelf Life When not exposed to direct sunlight, Sika CarboDur laminates have unlimited shelf life. Sikadur -30, when stored in the original sealed containers within the temperature range of + 5 C to + 25 C will keep for a minimum of three ( 3) years. Instructions for Use Surface Preparation The concrete or timber surface must be clean and free from grease and oil, dry, and have no loose particles or laitance. This can be prepared by blast cleaning, scabbling or grinding. The concrete age should be 3 to 6 weeks minimum, depending on thickness, curing conditions etc. The surface to be coated must be level, with steps and formwork marks not greater than 0.5mm. After cleaning remove all dust from the surface with an industrial vacuum cleaner. Mixing Sikadur -30 is supplied in factory proportioned units compromising the correct quantities of Part A ( Resin) and Part B ( Hardener) . Thoroughly stir both components separately using s low running drill/ stirrer with a helical paste mixer ( max. speed 600rpm) . Decant all Part B into Part A and mix thoroughly together until a uniform colour is achieved ( typically 3 minutes) . A streaky colouration is indicative of inadequate or incomplete mixing. Apply immediately. Small units may be hand mixed provided an even colour is achieved. Sika CarboDur Page 2 of 4 Application Application If any necessary patching work needs to be done on the surface, this must be done with Sikadur -41, on the day preceding the actual bonding operations. Apply the well mixed Sikadur -30 adhesive carefully to the prepared substrate with a spatula to form a first layer of at least 1 mm. Place the Sika CarboDur laminate on a table and clean it with Sika Colma Cleaner. Apply the Sikadur -30 adhesive across the width of the laminate, ensuring a total coverage. The adhesive should be minimum 1 mm deep at each side, to minimum 2 mm deep at the centre. This is best done using a plastic spatula shaped on site to achieve this profile. Within the open time of the adhesive, depending on temperature, place the Sika CarboDur laminate onto the concrete surface. Using a roller, press the laminate into the epoxy material until the adhesive is squeezed out on both sides of the laminate. Remove surplus epoxy adhesive. Samples should be made up on site to check the adhesive used in respect of curing rate and final strength. Measure the compressive bending and adhesive strength after curing. As a final check, test the laminates for drumminess by tapping lightly. There is no need for mechanical equipment to press strips onto the substrate nor is it necessary to provide clamps or supportive devices to keep overhead strips in place. Once cured the top of the laminates can be painted with a coating material such as Sikagard -62, Sikagard -550 W or Sikagard -680 S, Clear/ Transparent Matt. Cleaning Clean tools immediately with Sika Colma Cleaner. Wash hands and skin thoroughly in warm soapy water. Cured material can only be removed mechanically. Colour Black Base Carbon fibre reinforced with an epoxy matrix Apparent Density 1.6g/ cm3 Temperature Resistance Between 150 C and 500 C Elastic Modulus Sika CarboDur S > 165, 000 MPa Sika CarboDur M > 210, 000 MPa Sika CarboDur H > 300, 000 MPa Tensile Strength* > 2, 800 MPa > 2, 400 MPa > 1, 300 MPa Mean Value of Tensile* Strength at Break 3, 050 MPa 2, 900 MPa 1, 450 MPa Elongation at Break > 1.7% > 1.2% > 0.45% Packaging Supplied in rolls or palletised in pre-cut sections. Availability Type Width mm Thickness mm Cross Sectional Area mm Sika CarboDur S Sika CarboDur S512* 50 1.2 60 Sika CarboDur S812* 80 1.2 96 Sika CarboDur S1012 100 1.2 120 Sika CarboDur S1212 120 1.2 144 Sika CarboDur S614 60 1.4 84 Sika CarboDur S914* 90 1.4 126 Sika CarboDur S1214* 120 1.4 168 Sika CarboDur M Sika CarboDur M914 90 1.4 126 Sika CarboDur M1214* 120 1.4 168 Sika CarboDur H Sika CarboDur H514 50 1.4 70 ( * Readily available, other types available on demand.) Sika CarboDur Page 3 of 4 Sikadur -30 Adhesive for bonding reinforcements - See PDS for Sikadur -30 Design Notes A Sika CarboDur laminate has no plastic deformation reserve. Maximum bending resistance of a strengthened section is reached when laminate failure occurs during steel yield and before concrete failure. Mode of failure is influenced by the laminate cross section. To limit crack widths and deformation the yield point should not be reached in the reinforcing bars under service conditions. Any shear cracks which occur must be prevented from causing displacement on the strengthened surface and shearing of the laminate. Stress and deformation calculations can be made by the normal methods. When assessing the condition of the structure, look at the dimensions, quality of existing construction materials, climatic conditions and agreed conditions of service. Design aspects to be verified in a Sika CarboDur Strengthening system: Bearing safety - non strengthened structure ( total safety factor g H 1.2) - strengthened structure ( mode of failure mentioned above, check on strains) - shearing of laminate must not occur - anchorages Fatigue resistance - check concrete and steel stresses Serviceability - deformation ( with average strains, elastic behaviour of the structure and time-based strain changes in concrete) . - Steel stresses ( no plastic deformation in service conditions) . - Limit crack widths ( by limited the steel stresses to less than the yield point under service conditions) A full Sika Design Manual is available. Contact our Technical Department for details. Important Notes Do not apply Sikadur -30 to surfaces with standing water. Maximum moisture content of the concrete 10% . Always mix a full kit to avoid mix ratio error. Only mix as much material as can be applied within the stated potlife. Do not dilute the product with solvent as this will affect the cure and in service performance. Constant exposure to service temperatures > 50 C may affect the performance of the product. Sika CarboDur can be firerated if required using standard fire rating materials. The temperature at which Sikadur -30 is stored at during the 24 hours before it is mixed will govern its potlife when mixed. Compressive strengths etc. of epoxy resins must be qualified by the testing method eg. Test Standard or size of specimen under test and the rate at which the test piece is loaded under test, as these factors will affect the result markedly. Faster loading rates will generally give higher ultimate loads and vice versa. Also, a specimen at lower temperature will show higher strengths and vice versa. Sikadur -30 Parts A and B are a water pollutant and should not be discharged into drains, waterways or soil. Sika CarboDur Page 4 of 4 Sika Australia Pty Limited www.sika.com.au ABN 12 001 342 329 Tel: 1300 22 33 48 Construction Handling Precautions Avoid contact with the skin, eyes and avoid breathing it? s vapour. Wear protective gloves when mixing or using. If poisoning occurs, contact a doctor or the Poisons Information Centre. If swallowed, do NOT induce vomiting. Give a glass of water. If skin contact occurs, remove contaminated clothing and wash skin thoroughly. If in eyes, hold eyes open, flood with water for at least 15 minutes and see a doctor. Important Notification The information, and, in particular, the recommendations relating to the application and end-use of Sika? s products, are given in good faith based on Sika? s current knowledge and experience of the products when properly stored, handled and applied under normal conditions. In practice, the differences in materials, substrates and actual site conditions are such that no warranty in respect of merchantability or of fitness for a particular purpose, nor any liability arising out of any legal relationship whatsoever, can be inferred either from this information, or from any written recommendations, or from any other advice offered. The proprietary rights of third parties must be observed. All orders are accepted subject of our terms and conditions of sale. Users should always refer to the most recent issue of the Australian version of the Product Data Sheet for the product concerned, copies of which will be supplied on request. PLEASE CONSULT OUR TECHNICAL DEPARTMENT FOR FURTHER INFORMATION. Estop Admix SP2000 High range water reducer Superplasticising admixture Description Estop Admix SP2000 a chloride free high range water reducing superplasticising admixture for high strength concrete. Estop Admix SP2000 is made from selective organic superplasticisers which reacts with cement and inducing high workability concrete with high strength.. Uses To reduce the water demand of a concrete mix without reducing workability, allowing increased early and ultimate strengths without additional cement. To significantly improve the workability of concrete without increasing water demand. To reduce concrete permeability and thereby reduce water penetration and enhance durability. Advantages High range water reducing capabilities allow the high strength concrete without additional excess of cement contents to be produced Higher workability levels are maintained for longer period due to the availability of superplasticisers. Improved cohesion and particle dispersion minimises segregation and bleeding and improves pumpability. Chloride free, safe for use in precast, prestressed and reinforced concrete. Physical Properties Appearance : Dark Brown Liquid Specific gravity : Typically 1.190-1.205 at 20 C Chloride content : Nil to BS 5075 Solids content : 38-42% Instructions for use Compatibility Estop Admix SP2000 is compatible with most normal water reducing and retarding admixtures. However, Estop Technical Dept should be consulted for more informations. Estop Admix SP2000 when used in the same concrete mix, should be added to the mix separately and must not be mixed together with other admixtures. The resultant properties of mixes containing more than one admixture should be assessed by the trial mix attended by Estop Technical Dept. Estop Admix SP2000 is suitable for use with all types of Portland cements, SRC cements and cement replacement materials such as PFA, GGBFS and microsilica. Dosage The optimum dosage of Estop Admix SP2000 to meet specific requirements should always be determined by trials using the materials and conditions that will be experienced in use. This allows the optimisation of admixture dosage and mix design and provides a complete assessment of the mix. The normal recommended dosage is 1.0 litres per 100 kg of cement. Use at other dosages Dosages other than those given on this sheet may be used to meet particular mix requirements provided that adequate supervision is available. Compliance with requirements must be assessed through trial mixes. Contact the Estop Technical Dept for advice in these cases. Dispensing The correct quantity of Estop Admix SP2000 should be measured by means of a recommended dispenser or volumetric conatiner. The admixture should then be added to the concrete mix with the mixing water to obtain the best results. Curing As with all structural concrete, good curing practice should be maintained, particularly in situations where an overdose has occurred. Estop? s Estocure range is suitable for use as curing agent. Health and Safety Estop Admix SP2000 is a water based system and is non-combustible. However, proper PPE such as gloves and safety goggles are recommended during its handling. FOUNDATION PREPARATION The foundation surface must be free of all laitance and unsound material and thoroughly cleaned and cured. Keeping the surface covered will make the later job of cleaning the surface prior to grouting much easier and less costly. The grout foundation should be roughened as specified. The concrete surface may be uniformly roughened before it has set by the use of a nail rake in one direction only. Use of a bull float, darby, broom, or wood float finish, or scratching at random with a garden rake or trowel is NOT recommended. After the concrete hardens, hand held, pistol grip pneumatic hammers with chisel point heads are recommended for roughening to remove laitance and loose material to ensure a good bond. Use of large paving breakers equipped with bush hammers, spade or chisel bits, are NOT recommended. Where grout will extend horizontally out beyond the edge of the plate or object grouted, the foundation must also be prepared below these areas to help assure bond. Before setting structural elements or machinery, all of the areas of the foundation, which will be in contact with the grout, including anchor boltholes, must be thoroughly cleaned. Remove any oil, grease, and curing membrane. One method of cleaning a concrete surface is the use of compressed air and water. Continue cleaning until water runs clear. Foundation surface and bolt holes must be saturated for a minimum time of 4 hours, preferably overnight or 24 hours. This should be concluded immediately prior to grouting. Just before mixing and placing is started, all free ? standing? water must be removed from any anchor bolt holes and foundation surfaces over which grout is to be placed. This most often is accomplished with compressed air and/ or blotting with dry absorbent rags. Any rust, oil or grease on the bedplate being grouted must be removed. Air relief holes must be provided where necessary. Eliminate sources of vibration ( which can cause settlement and bleeding) until grout hardens. 2. FORMING Forms should be watertight and strong enough to withstand the hydraulic pressure of plastic, flowable or fluid grout, without leaking. When flowing the grout into place, all forms should extend vertically at least 25mm above the underside of the bedplate surface to help ensure complete filling of the space to be grouted and prevent overflowing. The side forms should not be tight against the plate, but should be erected 25 to 50mm horizontally away from the plate so that air being displaced is not trapped below the plate. The vertical form on the exit side ( opposite the placing side) should be extended 50 to 100mm away from the plate so that straps or other placing aids can be inserted to assist movement of the grout should that become necessary. Nov 08 Page 3 of 14 HEADER BOX - The form on the placing side should be extended 50 to 100mm horizontally from the plate at the foundation and be slanted upward at an approximate 45 degree angle so that grout can be poured on it with a minimum of turbulence ( and entrapment of air bubbles) while directing it smoothly on its way under the plate. A blackboard ( splash board) form should be built on top of the plate and at the plate edge, opposite the slanted headboard, to prevent spillage of grout and provide containment of the ? head? of grout as it is being placed. For many applications, such as turbines and generators, or other base plates of lengthy dimensions, it is not prudent to build high, pouring ? head? forms for these base plate lengths. In lieu of this, low forms, sufficiently high to contain the grout and at least 25mm above the bottom elevation of the plate to be grouted may be used. However, as a sloped pouring form is desirable, a portable ? head box? which can be moved along the length of the plate as the grouting proceeds may be used. This portable ? head box? serves well in helping to place the grout and saves a lot on forming costs. The box with a sloped pouring surface should rest in part on the form, floor and/ or base plate and this method serves just as well, and often better than a long sloped form, as the thrust of the grout flow is better controlled. Forms should be caulked to prevent leakage. Forming materials, such as wood, which absorb water, should be coated with water resistant oil ( form oil) , a form release agent ( such as Rheofinish FR222) , a good curing compound ( such as Masterkure 100WB) or plastic coating. These coatings prevent loss of water from the grout and act as bond breakers so that smooth grout surfaces result after form removal and the forms are protected for reuse. The points to caulk are the interfaces between the form and rough foundation surface where grout might leak out during its placement or before setting. Material used for caulking between the form and concrete surface may be a stiff consistency of sand-cement mixture or stiff consistency of the grout to be used. Vertical joints in the forms should be caulked if large cracks are evident. The use of duct tape applied on the inside of the form, at corners, is useful for this. After caulking the foundation, the area within the forms to be grouted should be cleaned and flooded with water to see if there are any leaks in the formwork or between the form and foundation. 3. MIXING GROUT Mortar mixers, paddle-type mixers and rotary concrete mixers are most often used for mixing grout. However, concrete mixers are the least efficient of these in terms of speed and thoroughness of mixing. Occasionally, for large volume jobs, which must be placed quickly, transit mix trucks are used. On the other hand, small volumes of grout can be most efficiently mixed using hand held Festo style mixers. Mortar mixers, concrete mixers and ready mix truck mixers will generally not produce lumpfree grout and generally the larger the mixer the less efficient will be the mixing. A few lumps, however, will not harm the grout in place nor the overall placing result, but these may be removed to prevent blocking, or obstructing the grout placement by the use of screens placed in the head form if lumps must be removed. These screens may be made from expanded metal or iron grating with suitable size openings. Nov 08 Page 4 of 14 ? Paddle? type or mortar mixers have horizontal shafts equipped with blades ( or paddles) , which revolve within a stationary drum. These mixers are capable of mixing grout to most any consistency. Revolving drum mixers such as small concrete mixers can be used for grout of flowable or fluid consistency. Introduction of bagged materials on the sides of the drum during successive batches is difficult to remove. If is found helpful to load this type mixer while it is rotating by pouring the dry grout into the mixer from pails rather than from the bag in which it was shipped. Vertical shaft mixers of large capacity are used for grouts of flowable and fluid consistencies, but they are not readily available. Mixers should be located as close as possible to the object being grouted to minimise transporting time, equipment, and labour. If mortar or paddle-type mixers are to be emptied into wheelbarrow, consider elevating these mixers 300 ? 600mm so that they may more easily be discharged into the wheelbarrows. An adequate potable water supply should be located adjacent to the mixer. The size of the batches mixed should be compatible with the volume of the space being filled, and the speed with which the grout can be mixed, discharged, transported and placed. Do not mix more grout at one time than can be placed in ten minutes. However, lower mixed grout temperatures will extend the working time. Also, during short job delays, the grout may be agitated in the mixer to keep it workable. Do not add additional water to maintain the desired consistency. Grout that has been mixed for a long time and has lost workability and reached a consistency that is not placable should be discarded rather than retempered and used. Grout flow and working time can be effectively controlled by the use of temperature controls. See the Hot Weather and Cold Weather Grouting sections of this Application Guide for more details. Consistency of the grout should be checked initially, and periodically thereafter to see that it meets specifications. BASIC PRINCIPLES A. Wet out the mixing container with water. Place the mixing water in the mixer first, then add the dry grout rapidly in a steady stream. Do not let large clumps drop in at one time. B. The best retarder for non-catalysed grouts is a lower ? as mixed? grout temperature. This is usually accomplished through the use of cold or iced mixing water or cool storage of the dry grout material. C. BASF grouts are supplied in a ready to use form requiring only the addition of water. Do not add any other dry materials ( sand, cement etc) . D. Do not use grout from damaged bags. E. Mix with potable water only. F. Do not mix by hand. Nov 08 Page 5 of 14 SMALL SIZE BATCHES Small batches are those in which one or two bags are mixed at one time with a drill-mixer ( eg Festo) and grout stirrer in a 20 to 25-litre pail. Add all the required water to the mixing pail. Slowly and uniformly add the grout into the water over 30 seconds while mixing. Do not ? dump? the grout into the mixer. This may cause lumping, which will be hard to break down. Mix for 1-2 minutes at 300-400rpm ensuring the mixing blade is kept below the surface of the grout to prevent air entrapment. Excessive mixing will entrap air, reducing flow and strength. MEDIUM-SIZE BATCHES A medium-size batch is one prepared in a power driven mixer, using from 1 to 20 bags per batch. The most widely used equipment is the common horizontal-shaft, paddle-type mortar mixer. Other useable mixers are revolving drum concrete mixers and vertical-shaft, paddle mixers. A. Mortar Mixers: add approximately 70% of the required mixing water, then cut into the bags using care to flow each bag slowly into the mix ( rather than dump the entire bag contents as a mass) with the mixer running. Mix for 3 minutes to break up any lumps. Slowly add the remaining water. Mix until grout appears homogeneous, about 4-5 minutes in total. Lumps in the grout as poured are not desirable, but a few small ones, if wet through, can be tolerated. A better procedure is to pour the grout through a 10mm or 13mm screen and waste the lumps. B. Concrete Drum Mixers: To batch the dry grout into the revolving opening of the smaller-sized drum mixers, it is necessary and safer to first empty the bags into steel pails or cans, then pour slowly from the can into the throat of the rotating mixer. Have enough cans to hold an entire batch before starting. The larger concrete drum mixers are normally skip loaded. Here it is a simple matter to empty all of the bags for a batch into the skip and raise it to slide the dry grout into the mixer slowly. C. Vertical Shaft ( Paddle) Mixers: These mixers stir grout in a cylindrical tank with vertical shaft to which pairs of horizontal fins are attached. Batch capacities range from 140 to 300 litres of mixed grout. They are made to prepare very fluid water/ cement or water/ cement/ sand grouts. In normal usage, when sand is employed, it is added after the cement so that the slurry will have enough ? body? to hold the sand in suspension. Because with Masterflow grouts, all dry materials are added at one time, there will be a tendency for the metallic aggregate ( if present) and some of the sand to settle in the dead space between the lowest set of the mixing blades and the bottom of the tank. This space should not be more than 25mm, but usually nearer to 50mm. Have the blades Nov 08 Page 6 of 14 lowered, if possible, or add rubber sweeps that will nearly touch the bottom. If neither of these things can be done, mix a 2 or 3 bag batch, preferably using a drill mixer, to fill this dead space. Waste what will run out without disturbing that which has settled to form a new higher bottom, then go ahead with full batches ? part or all of the mixing water first, then dry grout. Mix for 2 to 3 minutes after the last of the grout or water has been added at a maximum RPM that will not splash the grout excessively. D. High Speed Shear Mixers: High-speed shear mixers should be avoided with all BASF grouts as they tend to adversely affect the cementitious systems of BASF grouts due to their high speed ( 1200 to 1600 RPM) , which quickly heats up the grout. LARGE VOLUME BATCHES When the job requires the pouring of a large volume of grout in a single placement of 0.4 to 4m3 per batch, concrete mixers ( ready-mix trucks; skip loaded, revolving drum mixers; turbine mixers: etc.) will have to be use for preparing the grout. Because large volumes of grout tend to warm up rapidly and thicken, it is essential that the following procedure be rigorously observed. A. Take whatever means necessary to produce a grout temperature under 16 C after mixing. This includes the following: i. Use cold mixing water on ice and cold water as required. ii. Make arrangements for batching the dry grout into the mixer in less than five minutes. If the mixer is a ready-mix truck, all the bags of grout for a given batch must be emptied in advance into a skip or clean, dry concrete bucket set on a platform above the truck or that can be lifted by crane to the throat of the mixer. iii. Put part or all of the mixing water and ice, if used, in the mixer first. Then, with the mixer running at full concrete mixing speed, add the dry grout rapidly, then remaining water, if any, in 3 to 5 minutes. Mix for 3 to 5 minutes and pour. B. Prearrange for rapid and efficient transporting and pouring of the grout so that all of the mix is in place in 10 to 15 minutes after mixing. Either pour directly into head box or have 4 or more wheelbarrows or buggies so that placing is continuous. Alternative Procedure: Where the dry grout cannot be batched rapidly into the water already in the mixer ? as, for example, where there is not headroom for a crane to lift a bucket over the inlet of a ready-mix truck, precede as follows: A. Place all of the dry grout into the drum first, after MAKING SURE THERE IS NO WATER IN THE DRUM. B. With the drum stopped, add all of the iced mixing water in 3 to 5 minutes ? no longer. Pumping the ice water from an adjacent tank through an accurate water meter best does this. Generally, the tank on a ready-mix truck will not hold enough water and Nov 08 Page 7 of 14 the discharge of it is too slow. Also, there will not be time for refills and it is difficult to add ice to it. C. Mix for 3 to 5 minutes at full concrete mixing speed and pour. The mix may contain some lumps, but they will either have to be accepted or strained out by pouring through a 25mm screen. Mixing for a longer period to reduce lumps also reduces handling time ? the longer a large volume of grout is held as a mass in the mixer, the faster it warms up and thickens. SPECIAL APPLICATIONS It is possible to bulk out Masterflow 830 and Masterflow 870 with clean, dry, silt free 10mm pea gravel when sections to be grouted are in excess of 100mm. The pea gravel can be added at 40% weight/ weight ( 8kg/ 20kg) bag of Masterflow 830 or Masterflow 870. Approximate water demand for this mixture is 2.8-3.0 litres/ 20kg bag of grout; however it is advised that the mixture be trialled first to reach the required consistency. This mixture is not to be used for precision grouting applications. Alternatively, Masterflow 830DP can be used for pours up to 500mm thick. 4. PLACING GROUT Grout should be placed as quickly as possible after it has been properly mixed and discharged. Grouts may be poured at a fluid or flowable consistency. The may also be pumped. The method of placement will depend on the size of the object grouted, its shape, available access to accomplish the grouting, clearances, obstacle around which the grout must be placed and environmental temperatures. Placement of grout should be across the shortest dimension of the equipment or base plate involved whenever possible. Make sure that all free water from the surface of the foundation and anchor boltholes has been removed just prior to grouting them. All anchor bolthole grouting should be completed prior to placing the major grouting above, although the foundation may be grouted immediately following the bolthole grouting. Recommended grout thickness for Masterflow 830, Masterflow 870 and Masterflow 880 is 25-50mm, with a minimum of 10mm. Flow distance of more than 3 metres can be expected using flow troughs, at normal thickness. Where grout thickness exceeds 100mm, special procedures may be necessary to restrict temperature rise. However, general practice for placing fluid grout is to have a 50mm vertical clearance between base plate and foundation form flat plates, having few obstructions beneath, with up to 1.2 metre of horizontal placing dimension. Roughly chipped foundations will require additional clearance, and for placements of grout with more than 1.2m horizontal flow, an additional 25mm clearance should be added for each 1.2m travel. These are minimum requirements to which additions should be made allowing for anticipated difficulty of placement. Recommended grout thickness for Masterflow 830DP is 50-500mm. If using a grout of plastic consistency, these clearances should be increased slightly, and may be decreased slightly if a pump is used. It is better to have greater clearance than required than to have too little. Nov 08 Page 8 of 14 When grouts are poured, placing should start at one end ( on the slanted or head box) and continue there until the grout rises above the bottom of the bedplate on the exit side. The pouring point is then moved slowly along the slanted head form on the pouring side as soon as grout continues to come up on the opposite side, to ensure that air is being displaced rather than trapped. Grout should not be placed indiscriminately at separate locations along one side as this prevents tracing the actual movement and progress of the grout and can result in large pockets or voids being trapped between such placing points, nor should grout be poured towards the centre from opposite sides, for the same reason. Before starting the grout placement, steel packing straps 20 ? 25mm wide can be introduced below the plates and worked slowly back and forth to encourage the flow of grout around obstacles and to exit side. DO NOT use chains are for this purpose, as they tend to entrap air bubbles each time the links pass down into the grout. DO NOT vibrate as this may lead to segregation of the grout. Grouting structural or machinery plates that do not have a flat underside, or that are too large to pour, call for a variety of special placing and forming techniques too numerous to cover all applications.. For instance, inverted ? cake pan? plates or those with stiffeners may have to be poured from the top through holes and the corners in each section drilled with small holes to permit displaced air to escape, permitting the grout to rise and make contact with the bottom of a plate during placing. This is occasionally done in 2 or 3 separate placements with delays of from 15 minutes to several days between placements. Extremely large plates, or equipment under which the grout must travel more than 3 ? 4 metres horizontally, may have to be poured through grout holes in the top of the plates to shorten the travel distance, or pumped, using special forming and pipe entry holes in order to fill the space completely. In these cases, one should trace the movement of the grout and move the pumping hose to prevent buckling due to hydraulic pressure. Large plates or cavities requiring a cubic metre or more must be placed quickly and continuously. This volume is often pumped, and a ready mix concrete truck or several large mortar mixes used for bulk mixing, provided they can be brought close to the space being grouted for efficient and continuous discharge. Grout mixes develop considerable heat quickly in a large batch. Usually ice water or shaved ice and chilled ( 0 C) water are employed when truck mixers are used to maintain lower as-mixed temperatures during placing. See section on Hot Weather Grouting. Grouting products generally do not make good floor toppings as they are too rich in cementitious material and are designed for use below base plates. For this reason BASF discourages wide shoulders of grout and recommend that these shoulders have minimal horizontal dimension. Where wide shoulders or topping of large areas of the foundation are anticipated, use a mortar designed for such applications ( eg. Barra Mortar) . 5. HOT WEATHER GROUTING ( above 30 degrees Celsius) High ambient temperatures accelerate stiffening and require grout mixing and placing procedures that can only be accomplished in the short period of time the grout remains workable. The alternative is to extend the length of time the grout is workable and placable through the use of cold materials and cool foundation and base plates. This approach does Nov 08 Page 9 of 14 not affect the non-shrink and strength development characteristics of the grout. This is the only method of extending the working time that may be used with BASF grouts. RECOMMENDATIONS: 1. Store the bags of grout in as cool a place as practicable, but at least in the shade. 2. Give extra attention to saturating the concrete base -- for 24 hours or more. 3. Cool the base plate while saturating the concrete base by covering both with wet burlap or cloth and keeping it wet. Shortly after the grout is poured, its temperature will change to that of the steel base plate and concrete foundation, between which the grout is poured. Keep the temperature of the grout ? as mixed? under 21 C and preferably between 10 C - 13 C. The ? as mixed? temperature is the temperature of the grout immediately after mixing. Rule of Thumb: Try to have the ? as mixed? temperature of the grout at least as much under 21 C as the base plate and foundation are above 21 C. For example: If the base plate and foundation are at 27 C, strive to cool the grouting material and mixing water sufficiently to obtain an ? as mixed? temperature of 15 C and preferably lower. 4. Cool the Mixing Water: To lower the ? as mixed? temperature of the grout, use cold water. If necessary, float ice in drums of water; employing enough drums so that when water is drawn off for mixing, the replacement water has time to cool. Insulating the drums or wrapping them with wet rags will help keep the water cold. Do not add ice directly to the grout mix, and do not use ? dry ice? as a cooling agent. Where large batches of grout are to be mixed or where the packages of grout product are over 32 C, consider substituting shaved ice for some of the mixing water on a weight-forweight basis. Generally, shaved ice can be used in place of 50 to 70% of the mixing water by weight of the mixing water. Do not use more ice than will be completely melted within the proper mixing time of the grout. Unmelted ice poured with the grout will float to the top of the grout and will melt, producing water pockets under the base plate with resulting loss of bearing. Always pour the mixed grout through a 10mm screen to remove unmelted ice, lumps and foreign material. It is good practice to take the temperature of the initial batch to determine if more or less cooling is required. An ? as mixed? temperature of less that 7 C can be damaging to the grout. Therefore, the ice must be carefully controlled in batching and mixing. 5. If the mixer is warm, cool it by charging the mixer with cold or iced water will help reduce heating of the grout. 6. If the grout is being pumped, a warm pump line can heat the grout and cause plugging. Covering the line with cloth or burlap that is kept continually wet will help cool the pump line. Also, consider using reflective insulation around the line and erecting sunshades to shield the line form the hot sun. Nov 08 Page 10 of 14 The pump line can be cooled by filling it with chilled water or chilled cement slurry before batching the grout. However, the chilled priming mix must be completely discharged and discarded before pumping the grout. 7. Use screens to shade the area being grouted. 8. Grout early in the morning or at night when temperatures are cooler WHEN COOLING CANNOT BE ACCOMPLISHED: Two approaches should be considered in order to cope with rapid setting in hot weather. 1. Form the area to be grouted into smaller sections so that each section can be grouted individually. 2. Provide increased mixing capacity so the grout can be poured faster and continuously. Controlling the temperature of the environment and grout as mixed and placed, minimises the need for extra water, provides more working time and results in higher compressive strengths. 6. COLD WEATHER GROUTING ( below 10 degrees Celsius) Cool and cold temperatures affect the properties of grout in the same manner as concrete and mortars. Cold temperatures are more critical in gr