Conbextra GP2 constructive solutions

Free flow, high strength, non-shrink, Compressive strength with addition of aggregates
cementitious precision grout
Compressive strength(N/mm2)
Age (days) (W/P - 0.18)
Uses % of aggregates(IS516-1959)
Conbextra GP2 is used for precision grouting where it is essential 50 75 100
to withstand static and dynamic loads. Typical applications 1 28 30 32
would be grouting of base plates of turbines, compressors, 3 50 52 55`
boiler feed pumps, bridge bearing pedastal applications & other 7 60 63 68
critical applications. It can be used for anchoring a wide range 28 70 75 78
of fixing i.e masts, anchor bolts and fence posts..
Flexural Strength (BS 4551,1998)
Advantages Age (days) Flexural strength (N/mm2)
Gaseous expansion system compensates for shrinkage 1 2.5
and settlement in the plastic state 3 7.0
No metallic iron content to cause staining 7 9.0
Pre-packed material overcomes onsite batching variations 28 10.0
Develops high early strength without the use of chlorides Tensile strength 3.5 N/mm2 @ 28 days
(BS 4551,1998)
High ultimate strength ensure the durability of the hardened (W/P - 0.18)
grout Pullout bond strength 17N/mm2 @ 7 days
Free flow ensures high level of contact with load bearing (W/P - 0.18) 20N/mm2 @ 28 days
area Time for expansion Start : 20 minutes
(after mixing) Finish : 120 minutes
Resistant to oil Freshwet density Approx. 2220kg/m3 depending on
actual consistency used
Standard Compliance
Young’s modulus 28kN/mm2
Conbextra GP2 conforms to ASTM C1107 (Standard (ASTM D469-94)
Specification for Packaged Dry, Hydraulic-Cement Grout Dynamic load Speciments of Conbextra GP2
resistance remained undamaged even after
(Non-shrink). subjecting them to alternate loads
of 5N/mm2 & 25N/mm2 at the rate
Description of 500 cycles/minute for two mil-
lion cycles.
Conbextra GP2 is supplied as a ready to use dry powder. The
Coefficient of thermal 11 x 10-6/oC
addition of a controlled amount of clean water produces a free expansion
flowing, non-shrink grout for gap thicknesses up to 100mm.
Unrestrained 0-4% in the plastic state enables
expansion(as per to overcome shrinkage
Conbextra GP2 is a blend of Portland cement, graded fillers ASTM C940-16)
and chemical additives which impart controlled expansion in the
Unrestrained 2-4% in the plastic state enables
plastic state whilst minimising water demand. The low water expansion as per to overcome shrinkage
demand ensures high early strength. The graded fillers are Fosroc method (ASTM
C827 modified)
designed to assist uniform mixing and produce a consistent
Pressure to restrain 0.004 N/mm2 approx.
grout.

Technical support Flow Characteristics: The max. distance of flow is gov-

erned by the gap width and the head of the grout. Typical
An experienced technical advisory team is available to give data for flow design assuming grout is poured immediately
technical service on request. after mixing is given in the table below:
Max. flow distance in mm
Properties Grout Gap width 50mm 100mm 250mm
Compressive strength (N/mm2) consistency (mm) head head head
Consistency 30 350 1000 1500
Flowable
Age (days) Flowable Pourable 40 500 1500 2000
(W/P - 0.18) (W/P -0.165) 50 900 2000 3000+
1 24 26
Conbextra GP2

Note 1: This table is based on the following factors:

3 45 51
1. Temperature : 30oC
7 55 57 2. Water saturated substrate.
28 65 68 3. Minimum unrestricted flow width is 300mm.
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Conbextra GP2
Note 2: The typical physical properties given above are derived
Several hours prior to placing, the concrete substrates should
from testing in a controlled laboratory environment. Results
derived from testing field-applied samples may vary,dependent be saturated with fresh water.
on actual site conditions. Immediately before grouting takes place any free water should
Specification Clauses be removed with particular care being taken to blow out all bolt
holes and pockets.
Performance specification
Base plate
All grouting shown on the drawing must be carried out with a
pre packed cementious based product with negligible chloride It is essential that this is clean and free from oil, grease or scale.
content. Air pressure relief holes should be provided to allow venting
of any isolated high spots.

Levelling shims

If these are to be removed after the grout has hardened, they

should be treated with a thin layer of grease.

Formwork

The formwork should be constructed to be leakproof. This

can be achieved by using foam rubber strip or mastic sealant
beneath the constructed formwork and between joints.

In some cases it is practical to use a sacrificial semi-dry sand

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

Unrestrained surface area

This must be kept to a minimum. Generally the gap width

between the perimeter formwork and the plate edge should
Fig.1: Typical detail of stanchion base plate not exceed 150mm on the pouring side and 50mm on the op-
It shall be mixed with clean water to the required consistency. posite side. It is advisable, where practical, to have no gap at
The grout must not bleed or segregate. the flank sides.

A positive volumetric expansion shall occur while the grout is Mixing and placing
plastic by means of gaseous system. Mixing
The compressive strength of the grout must exceed 50 N/mm 2
For best results a mechanically powered grout mixer should
at 7 days and 60 N/mm2 at 28 days.
be used. When quantities up to 50kg are used, a heavy duty
The flexural strength of grout must exceed 9N/mm2 @ 28 days. slow speed drill (400-500 rpm) fitted with a paddle is suitable..
The fresh wet density of the mixed grout must exceed 2150 kg/m3. Larger quantities will require a heavy duty mixer.

The storage, handling and placement of the grout must be in To enable the grouting operation to be carried out continu-
strict accordance with the manufacturer’s instructions. ously, it is essential that sufficient mixing capacity and labour
are available. The use of a grout holding tank with provision
Application instructions
to gently agitate the grout may be required.
Preparation

Foundation surface Consistency of grout mix

The substrate surface must be free from oil, grease or any
The quantity of clean water required to be added to a 25kg bag
loosely adherent material. If the concrete surface is defective
to achieve the desired consistency is given below :
or has laitence, it must be cut back to a sound base. Bolt holes
and fixing pockets must be blown clean of any dirt or debris. Pourable : 4.125 litres

Pre-soaking Flowable : 4.5 litres

The selected water content should be accurately measured into

the mixer. The total content of the Conbextra GP2 bag should

constructive solutions page 2 of 4

Conbextra GP2
be slowly added and continuous mixing should take place for Pouring should be from one side of the void to eliminate any air
5 minutes. This will ensure that the grout has a smooth even or presoaked water becoming trapped under the base plate. It
consistency. is advisable to pour the grout across the shortest distance of
Placing travel. The grout head must be maintained at all times so that
a continuous grout front is achieved.
At 300C place the grout within 20 minutes of mixing to gain
full benefit of the expansion process. Where large volumes have to be placed Conbextra GP2 may
be pumped. A heavy duty diaphragm pump is recommended
Conbextra GP2 can be placed in thicknesses up to 100mm in
for this purpose. Screw feed and piston pumps may also be
a single pour when used as an underplate grout. suitable.
For thicker sections it is necessary to fill out Conbextra GP2 Curing
with well graded silt free aggregate to minimise heat build up.
Typically a 10mm aggregate is suitable. 50 - 100% aggregate On completion of the grouting operation, exposed areas should
by weight of Conbextra GP2 can be added. be thoroughly cured. This should be done by the use of Con-
cure WB curing membrane, continuous application of water
Any bolt pockets must be grouted prior to grouting between
and/or wet hessian.
the substrate and the base plate.
Limitations
Continuous grout flow is essential. Sufficient grout must be
prepared before starting. The time taken to pour a batch must Low temperature working
be regulated to the time to prepare the next one.
When the air or contact surface temperatures are 100C or below
Removable hopper : For large pours the grout may be hand on a falling thermometer, warm water ( 30 - 400C) is recom-
placed or pumped into a removable hopper ( trough). mended to accelerate strength development.

For ambient temperature below 100C the formwork should be

kept in place for at least 36 hours.

Normal precautions for winter working with cementitious materi-

als should then be adopted.

High temperature working

At ambient temperatures above 400 C, cool water ( below 200C)

should be used for mixing the grout prior to placement.

Estimating

Packaging

Conbextra GP2 is supplied in 25 kg & 30 kg moisture

resistant bags.

Yield

Allowance should be made for wastage when estimating quanti-

ties required. The approximate yield per 25 kg & 30 kg bag for
different consistency is :

Packing Consistency Pourable Flowable

25kg Yield ( litres) 12.5 13.3

30kg Yield (litres) 15 15.96

Fig.2 Typical Hopper detail

constructive solutions page 3 of 4

Conbextra GP2
Storage Additional information

Shelf life Fosroc manufactures a wide range of products specifically de-

signed for the repair and refurbishment of damaged reinforced
Conbextra GP2 has a shelf life of 6 months if kept in a dry store
concrete. This includes repair mortars, fluid microconcretes,
in sealed bags. If stored in high temperature and high humidity
chemical resistant epoxy mortars in addition to comprehen-
locations, the shelf life may be reduced.
sive package of protective coatings. In addition, a wide range
of complementary products are available. This includes joint
Precautions sealants, waterproofing membranes, grouts and anchors and
specialised flooring materials.
Health and Safety instructions
*Separate data sheets are available on these products.
Conbextra GP2 is alkaline and should not come into contact
with skin and eyes. Inhalation of dust during mixing should
be avoided.

Gloves, goggles and dust mask should be worn.

If contact with skin occurs, it shall be washed with water.

Splashes to eyes should be washed immediately with plenty
of clean water and medical advice sought.

Fire

Conbextra GP2 is non flammable.

Important note :
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. Whilst Fosroc endeavours to ensure that any advice, recommendation, specification
or information it may give is accurate and correct, it cannot, because it has no direct or
continuous control over where or how its products are applied, accept any liability either
Fosroc Chemicals directly or indirectly arising from the use of its products whether or not in accordance with
any advice, specification, recommendation or information given by it.
(India) Pvt. Ltd.
Head Office telephone fax e-mail
Embassy Point, No. 150,
2nd Floor, Infantry Road, +91 80-42521900 +91 80-22281510 [email protected]
Bangalore 560 001,
Karnataka

Regional Offices

Chennai Mumbai Noida Kolkata

Hills Centre,Old No 5, MBC Park, 12th floor, Office No.12B, Unit No. 601, Highway Tower-II 304, Jodhpur Park
New No 9, 3rd Cross Street, ‘D’ Block, Near G Corp/Hyper City A-13/2, 6th Floor, Sector– 62 Kolkata 700 068
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