Conbextra EP160 constructive solutions

Epoxy Resin Grout

Uses Description

Conbextra EP160 a grout for use in situations where Conbextra EP160 is a solvent free epoxy resin based
heavy static or dynamic loads are encountered. The gap product is designed for assisted grouting of gaps from
between a base plate and substrate will need to be filled in approximately 30 mm to 200 mm.
such applications as reciprocating machinery, testing
equipment, heavy crane and transporter rails, high speed Conbextra EP160 is a three component systems
turbines, centrifuges and drop forges. consisting of base resin, liquid hardener and specially
graded inert fillers. The components of the product is
Also for use in conditions where chemical spillage may be supplied in the correct mix proportions designed for whole
encountered. Typical situations could be met in pack mixing on site and no other materials should be
steelworks, refineries, electroplating works and chemical added.
plants. To achieve more flow reduce filler and considering
maximum thickness 150 mm.
Conbextra EP160 is especially suitable where extended
working time and large volume applications, deep gaps or Technical Support
high ambient temperatures.
Fosroc offers a comprehensive range of high
Advantages performance, high quality construction products. Fosroc
offers a technical support package to specifiers and
 Low creep characteristics under sustained loading. contractors as well as technical advice from staff with
unrivalled experience in the industry.
 Resistant to repetitive dynamic loads.
Properties
 Non-shrink and hence ensures complete surface
contact and bond.
The following results are typical for the hardened grout at
o
 High compressive, tensile and flexural strengths. 25 C.

 Fast, convenient installation with early strength gain. Test Method Typical Results
3
Density (kg/m ) 2230
 Withstands a wide range of chemicals. Compressive strength 35oC
(N/mm2) ASTM C579
1 day 82
3 day 96
7 day 105
28 day 110
Tensile strength (N/mm2)
(ASTM C307), 7 day 14
2
Flexural strength (N/mm )
(ASTM C580), 7 day 28
Modulus of elasticity
2
(KN/mm ) ASTM C580, 7 day 10
Linear shrinkage (%)
(ASTM C531), 7 day 0.019
Linear coefficient of thermal
expansion 10-6 (mm/mmoC)
(ASTM C531) 42
Linear shrinkage of cured
material (ASTM D2566) 0.0002
Gel time at 38oC (minutes)
(ASTM D2471) 100
Peak exothermic temperature at
o
32 C (ASTM D2471) 38
Water absorption (%)
(ASTM C413) 0.14

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Conbextra EP160
Specification clauses

Supplier specification

All epoxy resin grouting where shown on the drawings,

must be carried out using the suitable grade of Conbextra
EP160 product manufactured by Fosroc and used in
accordance with the manufacturer’s data sheet.

Performance Specification

All epoxy resin grouting where shown on the drawings

must be carried out with a factory packed product. The
hardened grout must have:
2
Compressive strength which exceeds 90 N/mm at 7 days,
2
tensile strength which exceeds 14 N/mm at 7 days, and
2
Flexural strength which exceeds 28 N/mm at 7 day.

The storage, handling and placement of the grout must be

in strict accordance with the manufacturer’s instructions.

Application Instructions

Preparation

Foundation surface

All contact surfaces must be free from oil, grease, free

Chemical Resistance standing water or any loosely adherent material. Concrete
surfaces should be cut back to a sound base. All dust
Conbextra EP160 product is resistant to oil, grease, fats, must be removed and bolt holes or fixing pockets blown
most chemicals, mild acids and alkalis, fresh and sea clean of any dirt or debris.
water. Consult Fosroc’s Technical Department when
exposure to solvents or concentrated chemicals is Steel surfaces
anticipated.
All steel surfaces should be shot blasted free of rust and
Pot Life flaky mill scale. Cleaned surfaces may be protected by
the application of Nitoprime 28.
Ambient temperature affects the time for which bulk
material will remain fluid. Typical values in minutes are Formwork
enclosed below:
The formwork should be constructed to be leak proof; loss
24oC 35oC of grout once the material is placed, but not hardened, will
Conbextra EP160: 170 130 result in incomplete filling of the gap.

For applications outside the above temperature ranges For free flow grout conditions it is essential to provide a
please contact your local Fosroc office. hydrostatic head of grout. To achieve this, a feeding
hopper system should be used.
Exotherm
For deep section placing in inaccessible, extended widths
chains may be used to encourage lateral movement and
All epoxy systems will develop an increase in temperature
complete filling of the gap, thus eliminating air pockets.
on mixing. Its extent will be a function of the volume to
For further information please contact Fosroc for specific
surface ratio, the ambient temperature as well as the
advice.
mass and thermal conductivity of the surrounding
materials. Contact Fosroc for specific data on each
product.

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Conbextra EP160
Typical on-plate shutter system absorbed with sand or sawdust and disposed in
accordance with local regulations.
Removable hopper: For larger pours the grout may be
hand placed or pumped into a removable hopper (trough). Hot weather working

Whilst the performance of Conbextra EP160 at elevated

temperatures is assured, application under such
conditions can sometimes be difficult. It is therefore
o
suggested that, for temperatures above 35 C, the
following guidelines are used:

(i) Store unmixed materials in a cool (preferably

temperature controlled) environment, avoiding
exposure to direct sunlight.

(ii) Keep mixing and placing equipment cool, arranging

shade protection if necessary. It is especially
important to keep cool those surfaces of the
equipment which will come into direct contact with
the material itself.

(iii) Try to eliminate application in the middle of the day,

and certainly avoid application in direct sunlight.

(iv) Ensure that there are sufficient operatives available

to complete application within the material’s pot life.
Mixing Limitations
Pour all the contents of the hardener pack into the base Grouts should not be placed in any unrestrained situation,
container. Mix using a slow speed power mixer until i.e. base plate plinths, etc. Failure to comply may lead to
homogeneous. crack development in the grout.
Pour all the resultant liquid into a container with a capacity Temperature
of 15-25 litres. Add the filler provided for the product to
achieve the required consistency. Mix using a slow speed Duration application
power mixer for two minutes or until a uniform colour is Conbextra EP160 grouting may be carried out without
achieved in the grouts. o
special precautions at ambient temperatures from 5 C to
o
25 C.
Placing o
Conbextra EP160 at temperatures below 20 C the cure
The mixed grout should be poured steadily from one side rate may be slow, but will go to completion provided the
o
only to eliminate the entrapment of air. temperature remains above 5 C.
Careful planning of shuttering should be made to reduce
Continuous grout flow is essential. exposed surfaces of epoxy grout and shoulders to an
absolute minimum. Exposure to cyclic temperature
Sufficient grout must be available prior to starting. changes is likely to cause cracking and peeling in
unrestrained grout. Please contact Fosroc for further
The time taken to pour a batch should be regulated to the details.
time taken to prepare the next batch.
Estimating
Flow Characteristics
Supply Size
The maximum distance of flow is governed by the gap Conbextra EP160: 92 Kgs
thickness, the head of grout applied and the ambient
temperature and the quantity of filler added. * Bulk packaging is available

Cleaning

All tools and equipment should be cleaned immediately

after use with Fosroc Solvent 102. Spillages should be

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Conbextra EP160
Storage

Conbextra EP160 product has a shelf life of 12 months if

o
kept in dry conditions at 25 C.

Precautions

Fire

Fosroc Solvent 102 is flammable. In the event of fire

extinguish with CO 2 or foam.

Health and Safety

Conbextra EP160: Contains reins which may cause

sensitisation by skin contact. Avoid contact with skin and
eyes and inhalation of vapour. Wear suitable protective
clothing, gloves and eye/face protection. Barrier creams
provide additional skin protection. Should accidental skin
contact occur, remove immediately with a resin removing
cream, followed by soap and water. Do not use solvent. In
case of contact with eyes, rinse immediately with plenty of
clean water and seek medical advice. If swallowed seek
medical attention immediately. Do not induce vomiting.
o
Fosroc Solvent 102 Flammable liquid. Flash point 33 C.

Keep away from sources of ignition - non smoking. Wear

suitable protective clothing, gloves and eye/face protection.
Use only in well ventilated area.

For additional information see relevant Material Safety Data

Sheet.

Important note:
Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions
for the Supply of Goods and Services, copies of which may be obtained on request. Whilst Fosroc endeavours to ensure that
any advice, recommendation, specification of 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 directly or indirectly arising from the
use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.

Fosam Company Limited

Head Office Telephone: +966 2 637 5345 Fax: +966 2 637 5891 email: [email protected]
Post Box 11081 Regional Offices
Jeddah Sales Office Tel: (02) 6080999 Fax: (02) 635 3330 Yanbu Tel: (04) 322 4280 Fax: (04) 391 2980
Jeddah – 21453
Jeddah Showroom Tel: (02) 665 0787 Fax: (02) 667 4884 Makkah Tel: (02) 542 0869 Fax: (02) 542 0869
Saudi Arabia Riyadh Tel: (01) 482 9303 Fax: (01) 482 7562 Medinah Tel: (04) 845 1767 Fax: (04) 846 3195
Dammam Tel: (03) 814 1282 Fax: (03) 814 1581 Jubail Tel: (03) 362 3904 Fax: (03) 362 3875

www.fosroc.com Khamis Mushayt Tel: (07) 250 0469 Fax: (07) 250 0469
Registered Office: Industrial Area, Phase 4, Road No. 414, Street No. 407
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FO SA/Conbextra EP160/01/13