~ t!Il't!Il'3IR"lft..,.

• Mumbai Metro Rail Project Line· 4

~
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HMROA _M""',::!!~~~ DOCUMENT REVIEW SHEET (DRS) .L1.~
_-=-==0'- •
lUll
GltAi>~ Hill rnlerna~onal
DEF/NITIONS
DRS No. GC/MML4/CA-12/DRS/0205, Rev. A • Area of Deficiency (1)
Package No: CA-12 1: Design not compiying with functions; 2: Detail incomplete; 3: Detail not submitted;
Reference of LetterlTRN : MMRDAlML4/CA1212019/131 4: Undesirable design feature; 5: Conflicting data; 6: Other (Specify)
Reception date of LetterlTRN : 12-Mar-19 • Assessment Code (2)
Discipline: OMS A. No objection B. No Objection with comments,
Discipline Coordinator: MT C. Returned for correction D. Submit with justification
Discipline TL : TY • Comment Status (3)
P =Pending; H =On Hold; C =Closed
Assessment Code (2) C
SUbject: Submission of Method Statement for Concrete Surface Repair
I ­
1D0cumeni References .,
o;
la- :comment
Ie: ,Slalul (3)
Cl)
I' SI. I r~ <J IT--­
'E '" Closure
No.
Engineer's Comm.enls .,
0
Cl)~

C~ Contractors/Suppliers Answers
3l
Rll~jCode Rev. PagaNo.
PI
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This methology is considered for any repair work for site only, for casting yard repairing contractor
1 General RO VP 6 Noted
required to submit different melholoQY as per castina yard reauirement.
Section :5 Classify the defects with photographic evidence individually and elaborate lhe respective repair
2 RO 4 VP 2 Incorporated
Methodology methodology

Include the following:

Section :5
3 RO 5 The procedure for repairing of Crack, Bugholes, Impression repair,Edge repairs, Rough Surface & VP 3 Incorporated
Methodology
Segregation of concrete (Rough surface due to bleeding) Other Major/Minor Visual Defects.

Section :5 The procedure for repairing of concrete defects to be described in sequential manner and also the
4 RO 5 VP 2 Incorporated
MethodolooY respective repair materials to be used for rectification.
Section :5 Distinguish the defects as per the standard type/class of defect based on width/depth/area etc., and
5 RO 5 VP 2 Incorporated
Methodoloay specify the repair methodoloaY accordinaly
The ITP and Corresponding checklist to be prepared for the following:
a. Problem Identification
6 General RO b. Problem reporting VP 2 Incorporated
c. Classification of repair
d. Post repair monitorina
If any major/minor defects found in structure, contractor should have to informed the Engineer, after
7 General RO VP 3 Noted
decision taken bv the enoineer colractor proceed for further process.
If any major/critical defects found in structure during inspection by the Engineer, should be analysed by
8 General RO approved third party agency and repairing work should allowed only after getling, approval of repairing VP 3 Noted
procedure for that particular activiIY.
Material safety data sheet also required to be atlched with MS.
9 General RO VP 3 Noted
Prooer safelY arranaments and inilial precaulions shall be taken before start of work.

Note: Awice o( No Objection by the Engineer on this submission shall not relieve the Contractor o( any o( its ob/igafions, liabilities or responsibilifies under the contract nor shall create any obligations or liability on the part o( the EmployeriEngineer.

Pogl? J 0/1
 METHOD STATEMENT FOR CONCRETE SURFACE REPAIR
MUMBAI METRO RAIL PROJECT, L1NE-4
(WADALA-GHATKOPAR-MULUND-THANE-KASARVADAVALI

EMPLOYER:
Mumbai Metropolitan Region Development Authority
DB ENGINEERING &CONSULTII\JG
GENERAL 11ILl louis Berger Gmbh, HILL INTERNATIONAL, LOUIS
CONSULTANT HiIIlnlernational
BERGER SAS CONSORTIUM
CONTRACTOR ReLIANce JASTALDI RINFRA ASTALDI JV
CONTRACTOR'S AECOM
CONSULTANT AECOM
MMRDAl04/MMRP/CA-12: Part Design and Construction of elevated viaduct and
6 elevated stations viz.Kapurbawdi, Manpada, Tikuji-Ni-Wadi, DongariPada, Vijay
CONTRACT Garden & Kasarvadavali[Excluding ArchitecturalFinishing & Pre-engineered steel
DETAILS roof structure of Stations] from Chainage 25035.251 m to 31872.088 m of Line- 4
Corridor [Wadala-kasarvadavali] of Mumbai Metro Rail Project of MMRDA.

DOCUMENT TITLE METHOD STATEMENT FOR CONCRETE SURFACE REPAIR

DOCUMENT
MML4-CA12-RIFAST-CIV-MOS-5013 REV NO.01
NUMBER
P-Preliminary, D-Definitive, C-Construction Reference, W-Working
DOC STATUS P Drawing, B-As Built, M-As Manufactured Drawing, E­ Employer's
Drawin
DATE OF FIRST
ISSUE 11.03.2019 No of sheet: 105
Prepared by:
Date: 20.05.2019
Sujit H
Reviewed by:
Date: 20.05.2019
Sujit H
Approved by:
Date: 20.05.2019
Sandeep Naik
Contractors
representative: Date: 20.05.2019
Sandeep Naik
'0
Document history an~/.IW~~

REVISION DATE DESCRIPTION PREPARED BY REVIEW BY APPROVED BY

00 11.03.2019 Initial Submission SH SH SGN

01 20.05.19 Second Submission SH SH SGN

~-
IVIETHOD STATEMENT FOR CONCRETE SURFACE REPAIR
TABLE OF CONTENTS

S No DESCRIPTION Page No
1 PURPOSE 3
2 APPLICABILITY / AREA OF APPLICATION 3
3 REFERENCES 3
4 RESPONSIBILITIES 3
5 ORGANISATION CHART 5
6 MATERIALS 5
7 EQUIPMENT 6
8 REPAIR WORK METHODOLOGY 6 - 18
9 WEATHER LIMITATIONS 18
10 MANDATORY SAFETY REQUIREMENTS 19
11 FORMATS/CHECK LISTS 19
12 ITP 20
13 HIRA 21 - 23
Annexure
ITPs
Check lists
Safety permits

MrvlL4-CA12-RIFAST-CIV-MOS-5013 Page 2
METHOD STATEMENT FOR CONCRETE SURFACE REPAIR
1.0 PURPOSE
The objective of this method statement is to address the repair of the concrete
structural member, if such repair is mandated.

2.0 APPLICABILITY/AREA OF APPLICATION

The work procedure is applicable for the repair of Pile cap, Pier & pier cap, Pre-cast
elements like Pier cap, U-Girders, I-Girders, Cast-in-situ slabs, Parapets, Bearing
pedestals etc for Contract No: MMRDAlL-4/MMRP/CA-12 of MMRDA.

3.0 REFERENCES
~ Technical specifications, Volume-4, Contract No: MMRDAlL-4/ MMRP/CA-12
~ Relevant latest approved GFC drawings
~ IS: 12269, Specification for Ordinary Portland Cement,53 Grade
~ Technical brochures of the product (BASF, Fosroc, Sika and any approved brand)
~ Is:9103, Specifications for concrete admixture
~ IS 456:2000, Plain & Reinforced concrete - Code of practice
~ IS 4926: 1976, RMC concrete
~ IS 4082: 1996,Stacking and storage of construction materials
~ IRC 78,Road and bridges
~ Quality assurance plan
~ Health, Safety and Environment plan

4.0 RESPONSIBILITIES
Following are the responsibilities and reporting structure of personnel involved in the
scope of the procedure

Position Reporting / Responsibilities

• He shall be responsible to control the overall activities in
Project Manager construction.
• Shall report to the PD.

• Shall report to the PM.

• Shall be responsible for overall implementation and control
of construction activities for the setting out, laying of
concrete, preparation of construction records etc.
Deputy Project Manager • Develop construction schedules, construction method
statements & prepare progress & accomplishment reports.
• Shall communicate to Client representative day to day
activities.
• Shall be responsible for overall monitoring and control of
man power, transport facilities etc.

MML4-CA12-RIFAST-CIV-MOS-5013 Page 3
METHOD STATEMENT FOR CONCRETE SURFACE REPAIR
Position Reporting / Responsibilities
• Shall report to Deputy Project Manager
Engineers • Shall be responsible for day-to-day planning of site. Casting
activities and preparation of construction records.

Survey Engineer/Surveyor • Shall report to PM.

• Shall check for the alignment as per the drawing.

• Shall report to Head-Quality & Project Manager.

QA/QC Manager • Shall be responsible for overall implementation, monitoring
and control of QC activities as per approved methodology.

• Shall report to QA/QC Manager.

QC Engineer • Shall be responsible for overall control and inspection of QC
activities as per QAP

Chief SHE Manager • Shall report to Project Manager.

• Shall be responsible for overall control of SHE Activities.

• Shall report to Chief SHE Manager.

• Monitor Safety practices, persuade to minimize non­
compliance.
• Report incidents beyond control and unsafe occurrences to
SHE Officer HSE Manager.
• Responsible for cleaning of board and road from outside.
• To ensure access control from inside/outside of board, also
ensure adequate traffic marshal wherever required.
• Shall be responsible for all safety aspects.

MML4-CA12-RI FAST-CIV-MOS-5013 Page 4

 METHOD STATEMENT FOR CONCRETE SURFACE REPAIR
5.0 ORGANISATION CHART

Project Manager

Head, QA!QC Chief SHE Manager Surveyor DPM for Site

Engineer
QA!QC

Technician
L Safety Officer
Engineer

Supervisior

6.0 MATERIALS

S.No Name Brand/Source Confirms to Remarks

Anti corrosive BASF, Fosroc, Sika and IS:9103 and technical
1
materials any approved brand specifications of product
BASF, Fosroc, Sika and IS:91 03 and technical
2 Bonding agent
any approved brand specifications of product
BASF, Fosroc, Sika and IS:9103 and technical
3 Filler materials
any approved brand specifications of product
High strength low BASF, Fosroc, Sika and IS:91 03 and technical
4
viscous grouts any approved brand specifications of product
BASF, Fosroc, Sika and IS:9103 and technical
5 Epoxy resins
any approved brand specifications of product
BASF, Fosroc, Sika and IS:91 03 and technical
6 Non-shrinkage grouts
any approved brand specifications of product
7 Hessian cloth Locally available --­

BASF, Fosroc, Sika and As per technical

8 Curing compound
any approved brand specifications
BASF, Fosroc, Sika and As per technical
9 De-shuttering agent
any approved brand specifications
METHOD STATEMENT FOR CONCRETE SURFACE REPAIR
7.0 EQUIPMENT

S.I\lo. Description Remarks

1. Hammer As required
2. Chisel As required
3. Air blower As required
4. Trowel, float, carborandam stones As required
5. Grouting pump with accessories As required
6. Grinder As required
7. Power generator of suitable capacity 01
Cube moulds-(Dimension as per product data
8. As required
sheet)

8.0 REPAIR WORK METHODOLOGY

8.1 Detailed procedure for rectification of concrete element:

Utmost care shall be taken in formwork, casting, compacting, curing, handling the
elements to prevent any damage or defect. Damage or defect can affect the elements in
three different ways like aesthetics, structural capacity or durability of the structure. Some
damage / defect may affect combination of above three elements. Purpose of this Repairing
& Finishing Procedure is to improve upon the affected / impaired requirements, so that the
ultimate structure can satisfy all the functional requirements.

After removal of formwork, elements shall be closely inspected to trace any damage /
defects. Following defects / damages are expected in this kind of construction:
A) Air bubbles or pin holes or minor imperfections on concrete surface
B) Surface cracks on concrete surface
C) Spalling of concrete
D) Broken edges
E) Offset in joints
F) Honeycombs in concrete

MML4-CA12-RIFAST-CIV-MOS-5013 Page 6
METHOD STATEMENT FOR CONCRETE SURFACE ,REPAIR
Procedures for treatment of different types of defect / damage are described here under:

A) Air bubbles or Pin holes or minor imperfections on concrete surface:

. J'­ ......
. ":1' ••

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. ' "; .. ,.'~ .
. '

(i) Material: Renderoc FC(Fosroc)

Surface Preparation: Clean the surface and remove any dust, unsound material, plaster,
oil, paint, grease, corrosion deposits or algae. Roughen the surface to remove any laitance
and expose the fine aggregate by light scabbling.

Priming: All prepared areas should be thoroughly soaked with water immediately prior to the
application of Rendroc FC (Fosroc) or any equivalent material. Any residual surface water
should be removed prior to commencement.

Mixing: Small quantities should be taken and mixed thoroughly by hand and usIng a
suitable mixing pan or bucket. Greater quantities should be mixed using a slow speed drill
mixer. Renderoc FC shall be mix continuously for 3 to 5 minutes until fully homogeneous.
The ratio of water to Renderoc FC is 0.25:1 by weight.

Application: Apply the mixed Renderoc FC to the prepared substrate, up to 3 mm thickness

by trowel. It should be applied with the minimum of working and be allowed to partly set
before finally trowelling to a smooth finish. Remove extra material & finish surface with
trowel. If smooth finish is required, a small amount of water may be flicked on to the surface
of the Renderoc FC with a paint brush prior to final trowelling.

Note: If rectification area thickness is 5 mm t015 mm, Renderoc S2 shall be used as per
manufacturer guide lines.

Curing: Curing is not generally required. However, under extreme conditions- high
temperatures and drying winds-it may be prudent to use Nitobond AR as a curing agent.
MML4-CA12-RIFAST-CIV-MOS-5013 Page 7
 IVIETHOD STATEMENT FOR CONCRETE SURFACE REPAIR
(ii) Material: MasterEmaco S 488 (BASF)

Surface Preparation: All loose traces of concrete or mortar, dust, grease oil, etc must be
removed. Damaged or contaminated concrete shall be removed to obtain a keyed aggregate
exposed surface. Non impact/vibrating cleaning methods, e.g. grit or high pressure water
jetting are recommended.

Priming: No special primer is required. To obtain extra strong bonding, the damp substrate
can be primed with a slurry brush coat of MasterEmaco S488(2 parts powder to 1 part
water).

Mixing: Mix MasterEmaco S488 in a forced action pan mixer or with a helical paddle
attached to a low speed (300-600 rpm) mixer for 3 minutes until a lump free, thixotropic
consistency is achieved. Mixing water needed 3.25 to 3.75 litre per 25 kg bag. Allow the
mortar to rest for 2-3 minutes and then mix briefly before applying.

Application: The prepared substrate should be pre-soaked atleast 2 hours before applying
MasreEmaco S488. The surface must be saturated surface dry, but without standing water,
mortar can be hand applied directly to the prepared damp substrate, or wet in wet onto the
primed surface.Spraying the material with the necessary pressure will ensure good adhesion
of the material. Smoothing with a trowel or finishing by float or sponge can be done as soon
as the mortar has begun to stiffen.

Curing: Rectification area should be cured with curing compound or with wet hessian cloth.

(iii) Material: Sika Latex (Sika)

Preparation Surface: Clean the surface and remove any dust, unsound material, plaster,
oil, paint, grease, corrosion deposits or algae. Roughen the surface to remove any laitance
and expose the fine aggregate by light scabbling.

Priming: All prepared areas should be thoroughly soaked with water immediately prior to the
application of material. Any residual surface water should be removed prior to
commencement.

Mixing and application: The inner face of elements, especially at the bottom slab( covered
by inner form) concentration of air bubbles is likely to be more. These spots shall be filled up
by a homogeneous mix of Cement, sand (passing through 1.18 mm sieve), a bonding
agent namely "Sika Latex" of SIKA or equivalent shall be used. Proportion of cement & sand
shall be 1:2 to 1:3. Sika Latex & water will be added at 1:6 ratio by volume. This shall be
added to the mix to form a paste. This paste shall be applied on air bubbles by trowel.

MML4-CA12-RIFAST-CIV-MOS-5013 Page 8
METHOD STATEMENT FOR CONCRETE SURFACE REPAIR
Curing: Rectification area should be cured with curing compound or with wet hessian cloth.
Not to be ponded with water.

B) Surface Cracks:

a) Crack size not detrimental to the structure (Craze cracks):

In spite of taking utmost care during curing, the concrete surface may develop certain cracks
which are generally limited to 5 to 10 mm from concrete surface. This cracks being very fine
in nature, cannot be filled up by any kind of grout material. To prevent ingression of water,
moisture this can be covered by a thin layer of acrylic dispersion material with bridging
properties such as, "Sikagard 550 W Elastic" of SIKA or equivalent product of other
manufacturers.

Any crack noticed shall be investigated and will be repaired after it is confirmed that it is not
a structural crack. In case of structural cracks, separate methodology will be adopted for
repair / rehabilitation after approval from IVIMRDA.

MML4-CA12-RIFAST-CIV-MOS-5013 Page 9
IVlETHOD STATEMENT FOR CONCRETE SURFACE REPAIR

b) Crack size detrimental to the structure:

The width and depth of the crack shall be ascertained by thickness gauge and a thin wire.
After the initial assessment, depending upon the degree of the crack, repair shall be taken
up.

(i) Cracks above a width of 1.5 mm

Surface preparation:
~ Remove all grease, oil, dust, residual curing compound, mould release agent or
other contaminant should be clear from concrete surface.
~ Where the width of crack is more than 1.5mm, the crack will be regularized for its
entire length using a 'concrete crack router' for 3mm wide and 9-1 Omm deep. V­
groove shall be made of 10 mm width and 10 mm depth.
~ After widening of the crack area and V-groove shall be vacuum free from dust and
cleaned again.

Mixing of grout material:

~ Masterlnject 1315' of BASF or 'Nito fill EPLV' of FOCROC or 'Sikadur52' of SIKA or
'Resicrete21, of Chryso equivalent shall be mixed with an electric mixer at low speed
for atleast 3 minutes or as per product data sheets recommended.

Application:
~ After thorough mix of grout material, grouting chemical shall be placed entire the
crack length and grout material shall be fully absorbed in the cracks area. After
setting of grout material, the rectified area shall be matched as required with suitable
material like Sikadur-31 of Sika, Conbextra GP2 of Fosroc, Sikatop 122 HS of Sika or
any equivalent material.
~ If grouting with nozzles required shall be followed as below mentioned Grouting
activity.

MML4-CA12-RIFAST-CIV-MOS-5013 Page 10
METHOD STATEMENT FOR CONCRETE SURFACE REPAIR

Cracks above a width of 0.3 mm

Surface preparation:
>- Remove all grease, oil, dust; residual curing compound, mould release agent or other
contaminant should be clear from concrete surface.
>- Clean the concrete surface 100mm on either side of crack to make the surface free
from dust, algae, curing membrane and any other contaminants.
>- V-groove shall be made of top width 10 mm and depth 10 mm. After widening of the
crack area and V-groove shall be vacuum free from dust and cleaned again.

Fixing of packers:
>- Drill boles of 6-10 mm in diameter at 500 mm center-to-center to a depth of 50 to
1:00mm into the concrete element.
>- These holes shall be drilled in zigzag way on either side of crack to have an angle of
drill not less than 45°. If the length of crack is less than or equal to 300mm, a hole will
be drilled adjacent to its widest location. If the length of the crack is more than
300mm, holes will be drilled at 500mm c/c.
>- After completion of the drilling holes, the holes and the crack will be vacuum cleaned.
>- The packers are installed into the drilled hole and mechanically tightened to make
them remain fixed. The periphery of the packers shall be sealed with epoxy putty of
Mater Brace 2200 of BASF or Sikadur 31 of Sika or any equivalent material.

Filling of cracks or V-groove:

>- The open crack area or V-groove shall be sealed witb epoxy putty of Mater Brace
2200 of BASF or Sikadur 31 of Sika or any equivalent material or a suitable
cementitious mortar as per product data sheet recommended.

MML4-CA12-RIFAST-CIV-MOS-5013 Page 11
METHOD STATEMENT FOR CONCRETE SURFACE REPAIR
~ When mixed to achieve a paste type consistency which can be applied with thin

metal piece. The material shall be carefully pressed into the crack to fill the entire
depth of the crack and troweled at the top making it in line with existing concrete
surface. The epoxy putty shall be allowed to set completely before initiating the
injection process. This would take typically 20 to 30minutes depending' on the
ambient temperature.

Grouting activity:

r Injection
Ports \

Adh

Surface mounted port injection typical flow paths of injected adhesive.

Injection begins at location 1. Injection continues until adhesive flows from location
2. After air and debris is free from the flow at location 2, location 1 injection is
discontinued and injecHon is restarted at locati'on 2. The process is continued until
the fracture is filled. (Port to Port method)

~ The grouting of chemical shall be done using a low pressure (6-10kg/sqcm) air
operated injection equipment.
~ The proporNoning of two component low viscosity epoxy resin like Master Inject 1315
of BASF or Sikadur-52 of Sika or Nitifill EPLV of Fosroc or equivalent shall be done
as per the manufacturer recommendations.
~ The grouting of crack shall be ceased when the chemical is being spilling over from
the top or there is pressure build up on the injecting equipment. This shall be done on
case-to-case basis at site while injection grouting.
~ For horizontal crack, injection should start from any of the ends and to be continued
and completed till the last port is used.
~ For vertical crack, injection should start from the lowest port and continued upwards.

~ For the cracks more than 1.5mm wide, as described above a regularized cut shall be
made and injection grouting will be continued till the chemical started entering in to

MML4-CA12-RIFAST-CIV-MOS-5013 Page 12
METHOD STATEMENT FOR CONCRETE SURFACE REPAIR
the cut. The cut then shall be sealed using MasterBrace 2200 of BASF or 'Renderoc
FC' of FOSROC or 'Top 122HS' of SIKA or 'Armocrete' of Chryso and prepare the
mix in the proportions as mentioned in the product data sheet.
>­ After completion of injection grouting, when a minimum 120-180minutes of time is
elapsed, the nozzle provided shall be removed. Doing so the left over drilled hole will
be filled up using Sika 122 HS of Sika or l\t1asterBrace 2200 of BASF or equivalent
and left undisturbed / protected for 120-180 minutes.
>­ Finally the rectified area surface shall be matched as required
For exact application procedure, doses, handling precautions etc, Product data
sheets shall be referred to.

C) Spalling of Concrete:
Inspite of careful handling of Formwork at the time of demoulding some concrete comes out.
This part of the element requires to be rebuilt in its proper shape & profile. Concrete of same
mix should be used for making up of this area.

Surface preparation:
Before placement of concrete, the parent concrete area should be cleaned thoroughly & all
loosely bonded material shall be removed. Remove the standing water if any.

Priming / Bonding:
Over the damp surface, a coat of Epoxy Resin bonding agent, "Sikadur 32 LP" of SIKA or
"Nitobond EP" of FOSROC or equivalent product of different make shall be applied. For
retaining the green concrete, if required, proper shuttering arrangement is to be done.

Placing of mortar/concrete:
Similar grade or higher grade of concrete shall be placed. After final setting of the concrete I

the formwork shall be removed & the fresh concrete shall be cured properly. Alternatively,
this can be repaired as per the repairing procedure for Broken Edge, described below
provided this is taken up after the concrete attains an age of 6 weeks.

D) Broken Edge:
During demoulding or handling the elements sometimes the edges may get damaged & thus
its aesthetics gets affected.
Surface preparation:
Before placing of repair mortar, the parent concrete area should be cleaned thoroughly & all
loosely bonded material shall be removed. Remove the standing water if any. For rebuilding
the broken edge, the affected area is to be cleaned thoroughly.

MML4-CA12-RIFAST-CIV-MOS-5013 Page 13
METHOD STATEMENT FOR CONCRETE SURFACE REPAIR

Priming I Bonding:
Over the damp surface, a coat of Epoxy Resin bonding agent, "Sikadur 32 LP" of SIKA or
"Nitobond EP" of FOSROC or equivalent product of different make shall be applied. For
retaining the green concrete, if required, proper shuttering arrangement is to be done. In
general, bonding agent or priming may not required for epoxy repair mortars.

Application of mortar:
The 3 - component epoxy resin mortar, namely "Sikadur41" of SIKA or equivalent product of
different make shall be applied by trowel. Before application of this the surface may be
primed by a coat of "Sikadur 31". However, this product can be used only after concrete
attains an age of 6 weeks or more. In case of early requirement, a cohesive mix of Cement,
Sand, a bonding agent namely "Sika Latex" of SIKA or equivalent product of other
manufacturer & water shall be used. Proportion of Cement & Sand will be 1:4 and that of
Cement & Sika Latex will be 5: 1. In case of depth of treatment I repairing is more than 10
mm, stone aggregates of smaller size (passing through 6.3 mm sieve) shall be used along
with sand. Before application of the mix, the area should be thoroughly cleaned. Mix
application shall be done by trowel.

Curing: Curing compound shall be applied or wet hessian cloth shall be maintained as per
product data sheet recommended. For epoxy repair mortars, no need of curing.

E) Offsets in Joints:
Sometimes, in spite of best efforts in matching the mould panels & covering the minor gaps
between the panels, offsets in concrete cannot be eliminated. Though it does not affect
strength or life of the structure, it is a strain to eyes & therefore calls for removal of it. This
can be chipped out by small chisel & the area should be smoothened by carborundum stone
I grinding.

F) Honeycombs in Concrete:
In case of unavoidable leakages causing minor honey combs, all loose material shall be
removed & cleaned thoroughly. Then a coat of Epoxy Resin Bonding Agent such as "Sikadur
32 LP" of SIKA or "Nitobond EP" of FOSROC or equivalent shall be applied on the old
concrete. Then the area shall be rebuilt by using same concrete mix. In case, depth of
treated area is more than 30 mm, nozzle shall be left in fresh concrete for injection of grout if
required. Epoxy Resin based grouts such as "Sikadur 53 UF" of SIKA or other manufacturer
can be used for this purpose.

MML4-CA12-RIFAST-CIV-MOS-5013 Page 14
METHOD STATEMENT FOR CONCRETE SURFACE REPAIR

i) Unsound concrete depth < 30 mm

Surface preparation:

~ The area to be repaired shall be marked on the structure.

~ The edges of all repairs shall be cut by angle grinder or similar to produce a regular
profile with a minimum depth of 20mm. Where rebar are exposed a further chipping
of approximately 10 mm behind rebars shall be done.
~ The predetermined areas shall be broken out till we get sound concrete.
~ Breaking out shall be undertaken using pointed mechanical chisels
~ Exposed steel should be cleaned by wire brush and be washed down with water to
remove any residual dust.

Priming/Bonding :

~ Surface shall be saturated with water prior to rectification. Shuttering shall be

provided as and when required.
~ A coating of MasterEmaco P130 of BASF or Nitozinc primer of Fosroc or Sika rustoff
100 or equivalent shall be applied to exposed reinforcement and allowed to dry.

Mixing of Mortar:

~ Water shall be addition to material as per mentioned in Manufactures specification.

~ Required amount of water shall be added into the mixing drum or pan.
~ Mixing shall be started with MasterEmaco S348 of BASF or Conbextra GP2 of
Fosroc or Sika122 HS or equivalent shall be added continuously.
~ Mixing shall be continued for another 3-4 minutes after all the powder has been
added and mortar is homogeneous and lump free. Extra water within the limit shall

MML4-CA12-RIFAST-CIV-MOS-5013 Page lS
METHOD STATEMENT FOR CONCRETE SURFACE REPAIR
used to get the desired consistency.

Application of Mortar:

~ Procedure is for trowel applied.

~ Where the hand application of repair material is to exceed 30 mm in thickness
overhead, this shall be built in layer, each not exceeding 30 mm. Each underlying
layer should be heavily cross hatched with a trowel and allowed to achieved its initial
set, prior to a subsequently layer being applied in the same manner.
~ The surface of the placed mortar shall be levelled using wooden float. Final finishing
may be done with a wooden, plastic or steel trowel.
~ Minimum cover 30 mm shall be provided to the rebar.

Curing:

~ The appropriate & approved curing compound shall be sprayed on the surface
immediately upon removal of formwork, extending at least 10 cm onto the adjacent
concrete around the periphery of the repair. Or Wet hessian cloth shall be maintained
as per manufacturer recommended.

ii) Unsound concrete depth >30mm

• 't-..
. ....

MML4-CA12-RIFAST-CIV-MOS-5013 Page 16
 METHOD STATEMENT FOR CONCRETE SURFACE REPAIR

1 EVERY 10 YEARS
A.-..JI''J
.
s I I 5
I OPERATING
I EVERY OPERATING
e
2 I < 1 EVERY 10,00 OPERATIONS Vi I 25 20
YEARS
3 I < 10 EVERY 10,00 OPERATIONS
I EVERY MONTH e
OPERATING
r
I EVERY WEEK
4 < 10 EVERY 100 OPERATIONS
OPERATING
5
INCIDENT MOST LIKELY WILL
HAPPEN
1 EVERY DAY
OPERATING
It I 2
Y
Severity
RISK LEVEL
• Potential Hazardous Daily or Routine Task
LOW RISK « 6)
• Regarded as Acceptable with Current Control Measures
(L)
• Use Tool Box Talk
• Hazardous Non routine Tasks
MODERATE RISK (8-12) • High Loss of Potential
(M) • Control Measures are required to reduce the Risk
• Pennit To Work & Operating Procedure
• Potential Disastrous or Catastrophic Operations
SIGNIFICANT RISK (> 15)
• Operations must be altered
(H)
• Significant Safety Control

MML4-CA12-RIFAST-CIV-MOS-5013
METHOD STATEMENT FOR CONCRETE SURFACE REPAIR

Surface preparation:

~ For unsound concrete 30mm to lOOmm, mIcro concrete to be used as per

manufacturer's recommendations.
~ The area to be repaired shall be marked on the structure.
>- The edges of all repairs shall be cut by angle grinder or similar to produce a regular
profile with a minimum depth of 30mm. Where rebar are exposed a further chipping
of approximately 10 mm behind rebars shall be done.
>- The pre determined areas shall be broken out till get sound concrete.
>- Breaking out shall be undertaken using pointed mechanical chisels.

Priming/Bonding:

~ Surface shall be saturated with water prior to rectification. Shuttering shall be

provided as and when required.
~ A coating of MasterEmaco P130 of BASF or Nitozinc primer of Fosroc or Sika rustoff
100 or equivalent shall be applied to exposed reinforcement and allowed to dry.

Mixing of mortar:

~ The mix should be a homogenous, lump free consistency.

~ It should be ensured that the mixing container is clean and dampened down prior
to mixing.
~ A proportion of the specified amount of water (approx. 90%) to achieve the
required flow shall be poured into the mixer. Powder shall be added slowly whilst
the mixing drum is rotating.
~ Mixing shall be carried out for a minimum of 3 minutes during which time the
remaining mix water shall be added, if required, until a uniform free flowing
consistency is achieved.
~ For section larger then 100mm in thickness, the aggregate of 5-12mm size shall be
added as per the Manufacturer's recommendation.
Note: Other approved equivalent product can be used as per manufacturer guideline.

MML4-CA12-RI FAST-CIV-MOS-5013 Page 17

IVIETHOD STATEMENT FOR CONCRETE SURFACE REPAIR
Application:

>­ This should be ensured that all free water is drained from the formwork and the
drain holes are plugged before mixing the repair mortar.
~ The mix shall be applied steadily and continuously.
~ Alternatively, the mix shall be placed at rectification area through opening vent.
~ For large scale repair of extended length, mix shall be placed in layer, i.e. placed from
left to right in one layer and then repeated with the successive batches.
>­ Mix shall be placed continuously, minimizing the amount of time between successive
batches.
~ Mix is self-compacting and dose not repairs external vibration. Tapping the formwork
lightly with a hammer during placement will contribute towards effective
consolidation of the material.

Note: Other approved equivalent product can be used as per manufacturer guideline.

Curing:
>- The appropriate & approved cunng compound shall be sprayed on the concrete
surface immediately upon removal of formwork, extending at least 10 cm onto the
adjacent concrete around the periphery of the repair. Or Wet hessian cloth shall be
maintained as per manufacturer recommended.

Sampling:

>- Cube shall be sampled and tested for each batch of material

>- Cubes shall be filled in the manner similar to application method.

9. WEATHER LIMITATIONS

Season Risk Analysis Preventive Measures

• Rainy • Rain during repairing • Repairing of concrete to be

avoided during rain to avoid
interruption. In case of rain
while work is in progress, the
area shall be
protected/covered.

• Winter/Summer • High / Low • Shall avoid high/low

MNlL4-CA12-RIFAST-CIV-MOS-5013 Page 18
METHOD STATEMENT FOR CONCRETE SURFACE REPAIR
Temperature temperatures as per the
manufacturer's
recommendations of repair
material.

10. MANDATORY SAFETY REQUIREMENTS

• Hand gloves shall be used for all the operations of packing / grouting rectification
methods.
• Nose masks and goggles shall be worn for all operations of rectification methods.
• Measures for health and environment requirements shall be taken as per the
Material Safety Data Sheet.
• All the equipment used for grouting or packing shall be cleaned thoroughly with
water immediately after use.
• Proper area lighting shall be available, if night work is proposed.
• Check the working condition all pressure relieve valves, if compressed air is
used.
• Face shield shall be worn during drilling, grinding and grouting operations.

11. FORMATS I CHECK LISTS

FORMATS - CHECKLISTS FOR CONCRETE REPAIR WORK

S.No Description of check Format Number

1. Concrete repair work check list RAJV/MML4/F 12 RO

2 Formwork inspection RAJV/MML4/F 02 RO

3 Concrete inspection RAJV/MML4/F 03 RO

4 Post concrete inspection RAJV/MML4/F 04 RO

MML4-CA12-RIFAST-CIV-MOS-5013 Page 19
 METHOD STATEMENT FOR CONCRETE SURFACE REPAIR
12. INSPECTION PLAN

Check by
S No Description Check by GC Documentation Format No/ITP Remarks
RAJV
1 Fixing of shutter W W Check list RAJV/MML4/ F02 RO
Check list / RAJV/MML4/ F03 RO
2 Concrete/Repair W W
Pour card RAJV/MML4/ Fi0 RO
3 Compaction of concrete W R - -
4 Slump test W R Record RAJV/MML4/ Fii RO
5 De-shuttering W W - -

Finishing, construction
6 W R Check list RAJV/MML4/ F04 RO
ioint, curing of concrete
RAJV/MML4/ Fi2 RO /
7 Concrete repair work W W/R ITP / Check list MML04-CA­
i2/MMRDAlITP-i5

N1N1L4-CA12-RIFAST-CIV-MOS-5013 Page 20
 IIImLsTALDI
Contract details: MMRDAl04JMMRP/CA-12: Part Design and Construction of elevated viaduct and 6 elevated stations viz.
Kapurbawadi, Manpada, Tikuji Ni Wadi, Dongari Pada, Vijay Garden & Kasarvadavali of Line - 4 Corridor
Kasarvadavali] of Mumbai Metro Rail Project of MMRDA".
[Wadala -
[Excluding ;=' .HI
M"~
elM. IlIIl
Hill l'ltmllionai
g)
Architectural Finishing & Pre-engineered steel roof structure of Stations]

PROJECT PACKAGE CA-12 , LINE -04 , Rev:OO,

INSPECTION AND TEST PLAN - CONCRETE REPAIR WORK MML04-CA-12fMMRDAJITP-23
MUMBAI METRO RAIL PROJECT Date: 26.02.2019

I
INSPECTION BY

SINo
I
MATERIAL DESCRIPTION
REFERENCE DOCUMENTS I ACCEPTANCE
FREQUENCY
VERIFYING
TESTING
EVALUATION
.
~

c c .. U ~ Remarks
STANDARDS CRITERIA DOCUMENTS '0, o E' a ~
SOURCE c .. I'll u
w u.s:::
.. u ~ '~ t')
,
2 CJ)E w
en
1 PRIOR TO WORK COMMENCEMENT

Nolice of no objection certificate from Before commencement of worK or Notice of no objection certificate
1.1 Design and Dala development Contract specifications RINFRA·AST JV N/A H R R
MMRDA I GC I Approved slatus wilh design alteration from MMRDA f GC

Method statement !Work Adequacy to meet scope,

GFC drawings and technical Notice of no objection certificate
1.2 methodologyJITP/ChecklisVWorking Performance and Technical Prior to commencement of works RINFRA·AST JV R P H R
specifications from MMRDA I GC
drawings specification requirement

Notice of no objection certificate from RINFRA-AST JV lab f

1.3 Testing facilities Contract Specifications Prior to commencement of works Approved letter INFI NfA H R R
MMRDA I GC f Approved status Extemallab

Contract Specifications / or any Notice of no objection certificate from Prior 10 commencement of works I Notice of no objection /
1.4 Source of materials/Repair material RINFRA·AST JV N/A H H R
additional approved vendor MMRDA I GC I Approved status Change of source Acceptance from MMRDA / GC

Once for each grade and type of

Notice of no objection /
1.5 Concrete mix design Technical specifications Approved concrete mix design concrete and orior to production RINFRA-AST JV R H P R
Acceptance from MMRDA / GC
commencement

Approved method statement / Contract Prior arrangements to be made

1.6 Plant and equipment Prior to commencement of work Visual inspection RINFRA-AST JV R P H R
specifications berfore start of production

Approval from MMRDAlGC for

Calibration of batching plant / Notice
Approval of batching plant I RMC RMC plants / Trial run of the
1.7 IS:4925 of no objection certificate from Prior to commencement of work RINFRA·AST JV R R P/H R
plant RINFRA-AST JV plant with
MMRDA/GC
clearance certificate
Once prior to start and subsequent Site laboratory plan I Extemal
Calibration certificates for Measuring RINFRA-AST JV I
1.8 Contract specifications To be made available periodical calibration as per laboratory calibration / R P H R
equipment / Load test certificate Exlemallab
calibration plan Manufacturer laboratory

2.0 MATERIAL RECEIPT, STORAGE, HANDLING AND DELIVERY

2.1 Repair material

MTC I Product data sheeV

Invoice / MTC from manufacturer to
2.1.1 Receiving inspection Technical specifications For each lot Delivery challan /Inspection RINFRA·AST JV R H P R
be available
reoort

2.1.2 Sampling and testing Review of MTC MTC I Test report RINFRA·AST JV R R H W/R

Segregated with tag and stackage

Prior to commencement of works
2.1.3 Storage and segregation Technical specifications above ground with clear space from Visual RINFRA·AST JV P H R R
and regular
ground
 GIlr.il~ Hilllnl,maliooal
Contract details: MMRDAl04/MMRP/CA-12: Part Design and Construction of elevated viaduct and 6 elevated stations viz.

_ASTALDI
Kapurbawadi, Manpada, Tikuji Ni Wadi, Dongari Pada, Vijay Garden & Kasarvadavali of Line - 4 Corridor
Kasarvadavali] of Mumbal Metro Rail Project of MMRDA".
Architectural Finishing & Pre-engineered steel roof structure of Stations]
[Wadala -
[Excluding ;~ ~
M.~
11111
lDm
PROJECT PACKAGE CA-12 , LINE -04, Rev:OO,
INSPECTION AND TEST PLAN - CONCRETE REPAIR WORK MML04.cA-121M MRDAlITP-23
MUMBAI METRO RAIL PROJECT Dale: 26.02.2019
-

INSPECTION BY
~
TESTING
REFERENCE DOCUMENTS I ACCEPTANCE VERIFYING ''c:""
..
~
SINo MATERIAL DESCRIPTION FREQUENCY EVALUATION c: Remarks
STANDARDS CRITERIA DOCUMENTS o '"~
"' o 1!
'0, l) '"
SOURCE l)
c:
w u.z:::
'" u
UlE
~ 'wg; (9

J!l
Cii

3.0 REPAIR WORK

Co-ordinates and levels shall be

GFC drawings and technical
within specification tolerances as
3.1 Setting out of works specifications for the works, Method Each element Survey check list for structure Manufacturer lab P R R W/R
specified in technical specifications I
statement for works
GFC drawings

3.2 Form work

Should be clean and clear from dust

3.2.1 Form wor1< surface cleaning and other deleterious material 10 the P R R W/R
Approved method statement concrete
The de-shutler release agent should
3.2.2 Application of de-shettering agent have no detrimental etrect on the Each element Form worK check list RINFRA·AST JV P R R W/R
finished surface of the wall
Approved method statement I
3.2.3 Dimension & Alignment of form work Technical specifications P R R W/R
Construction drawings

3.3 Concretingl Repairing material application

Item 3.1 to 3.2 is properly

Approved method statement I
3.3.1 Final inspection prior to concrete implemented, recorded and Each element Pre-concrete check list P R P H/W
Construction drawings
acceoted
Thoroughly mixing of the ingrediants
3.3.2 Mixing time .... to be ensured
Each batch R R P R

Pre-numbered and to be issued

3.3.3 Delivery docket Issued with each transit mixer sequenllially. Must record time of Each transit load Concrete pour card R R R R
batchinn como!etion
PCE based admixture-150 mm (min) Each batch of concrete. Agitator
3.3.4 Workability testing Technical specifications (Non confirming first slump can be deliveries to be checked at the R R P W/R
retested from the same sam Ie Doinl of discharae at site RINFRA-AST JV
Item 3.1 to 3.2 is properly
Approved method statemenV Product
3.3.5 Repairing material mix & application implemented recorded and
I Each element Repair check list R R HIP RJW
data sheets
.ooenled

3.4 Sampling of hardened concrete

lAS per IS:456,clause 16 and table 11.

Concrete cube moulds
3.4.1 Technical specifications Should achieve minimum Each element Test report R R P W/R
(150x150x150 mm)
charar-.tI:·ridil'. . nnlh

Cube moulds for repair material (as Approved method slatemenV Product As per relevant codes I Producl data
3.4.2 Each element Test report! MTC R R P W/R
per material guide lines) data sheets sheets/MTC
 ~TALDI
Contract details: MMRDAl04/MMRP/CA·12: Part Design and Construction of elevated viaduct and 6 elevated stations viz.
Kapurbawadi, Manpada, Tikuji Ni Wadi, Dongari Pada, Vijay Garden & Kasarvadavali of Line - 4 Corridor
Kasarvadavali) of Mumbai Metro Rail Project of MMRDA".
[Wad ala •
[Excluding ~~
.#'ft"II
M.~
i lM 85glr nul
HiIIlnlematiollll [QBJ
Architectural Finishing & Pre-engineered steel roof structure of Stations)

PROJECT PACKAGE CA·12 , LINE -04, Rev:OO.

INSPECTION AND TEST PLAN - CONCRETE REPAIR WORK MML04-CA·121MMRDAlITP-23
Date: 26.02.2019
MUMBAI METRO RAIL PROJECT

INSPECTION BY
I "­
I TESTING Q>
REFERENCE DOCUMENTS I ACCEPTANCE VERIFYING Q> c: Q> U "­
SINo MATERIAL DESCRIPTION FREQUENCY EVALUATION c: Q> Remarks
STANDARDS CRITERIA DOCUMENTS ';;, 02' a~ u
SOURCE c: :::iC"O'.
W
u.<:
Q> U ~ .~ Cl
2 <Jl.E w
Cii

3.5 Post pour inspection

3.5.1 Checking as built level of structure Approved method statement I Drawing GFC drawings R R P W/R
Post concrete inspection RINFRA·AST JV
Curing, surface defects, posHion of Adequate curing upto required period
3.5.2 Approved method statement J Drawing Each element R R P W/R
inserts if any shall be maintained and ensured
Contract specifications I Approved
All corrective actions initiated by'H'
4.0 Corrective actions method statement I Construction
are properly implemented
Each element All check lists referred to above RINFRA-AST JV R R P R
drawinns
All properties conforming to
5.0 Release specifications
Each element RINFRA·AST JV N/A R H R

PREPARAED BY : I REVIEWED BY : APPROVED BY : MMRDAlGC

NAME: SUJIT H NAME: SUJIT H NAME: SANDEEP G NAIK

QA/QC In-Charge QA/QC In-Charge PROJECT MANAGER

DATE: DATE: DATE:

Legend: H= Hold, R = Review, W= Witness, P = Perform, S= Submit, RJW= Random Witness, , RINFRAAST JV. MMRDA

I
Critical Category is Hold Point This activity requires inspection I verification and acceptance by MMRDA/GC Responsible for the stage before further processing is permitted.

This activity requires inspection I verification, and acceptance by the MMRDA I GC responsible for this stage before any further processing is permitted.
Major Category is Witt ness Point
RINFRAAST JV Sub-Contractor shall not process activity beyond a witness point without written approval by MMRDAlGC. The related quality records shall be submitted to MMRDAlGC for their review.
 METHOD STATEMENT FOR CONCRETE SURFACE REPAIR

METHODOLOGY
1. Identify hazards.

EVERY 10 YEARS 2. List hazard event.

.
.... ...., ...,
~
• 1

OPERATING
S I I 5
I 3. Calculate risk factor with initial risk rating
1 EVERY OPERATING
e
2 I < 1 EVERY 10,00 OPERATIONS _ I 25 20 Le. probability x severity.
YEARS V

3 I < 10 EVERY W,OO OPERATIONS

1 EVERY MONTH e ~ Low Risk 4. Details controls.
OPERATING 5. Calculate residual risk factor with final risk
r
I EVERY WEEK
4 < 10 EVERY 100 OPERATIONS rating.
OPERATING

5
INCIDENT MOST LIKELY WILL I EVERYDAY t I 2 6. Enter risk priority.
HAPPEN OPERATING 7. Evaluate acceptability of risk.
-I Y
Severity
RISK LEVEL
• Potential Hazardous Daily or Routine Task
LOW RISK « 6)
• Regarded as Acceptable with Cun'ent Control Measures
(L)
• Use Tool Box Talk
• Hazardous Non routine Tasks
MODERATE RISK (8-12) • High Loss of Potential
(M) • Control Measures are required to reduce the Risk
• Permit To Work & Operating Procedure
• Potential Disastrous or Catastrophic Operations
SIGNIFICANT RISK (> 15)
• Operations must be altered
(H)
• Significant Safety Control

MML4-CA12-RIFAST-CIV-MOS-501~
 METHOD STATEMENT FOR CONCRETE SURFACE REPAIR

Initial Risk
Rating Risk Final Risk
Potential Consequence Person Control measuresl Residua Risk
SNo 1.0 Activity Probability x Factor Rating
hazard s at Risk Mitigation actions I Risk Accep
Severity Lx S=R Probability
Factor table
LxS x Severity

Fall and Sub­ No loose material at height. Safe

falling procedure for handling of
contract
objects. Person injury scaffold material. Mandatory
or 3 4 12 I 4 4 Low
Slip & Trip Workers PPEs for all workmen engaged
I Public for height work. Experience
workmen allow for height work.
Incomplete Experienced certified personnel
platform. for scaffold erection work. Safe
Failure of
Unsafe techniques for erection, safe
scaffold, Sick I
scaffolding I " 4 4 16
access, complete platform.
1 4 4 Low
person injury
III healthy Ensure authorized person at site.
person Medically fit for height work
Ground soil Ensure good soil compaction for
condition, Failure of scaffold post positioning. All ..,
1
Scaffold
missing scaffolding " 4 4 16
components to be ensured. Area
2 .) 6 Low
Erecti ng and
components must be compacted.
Dismantling
Ensure safe techniques for
Iifting shifting of material during
Erecting the
erection of scaffold at height.
material to Person injury
Proper Anchoring of Guide
height, Failure damage nearby " 3 4 12
Ropel Life line. TPI of lifting
1 3 3 Low
of guide ropel structure
machine tools & Tackles.
life line
Authorized workmen allow to
work.
Ensure Designed PPEs with all
Failure of
workers at site. Ensure Double
PPEs, Full
lane yard full body harness with
body harness Person injury " 3 4 12
anchorage on scaffold. Tagging
I 4 4 Low
with double
system for scaffold work.
lane yard
Medical fit workmen engaged

MML4-CA12-RIFAST-CIV-MOS-5013
 METHOD STATEMENT FOR CONCRETE SURFACE REPAIR

Improper
lifting, Complete platform for fall
Incomplete protection. Ensure that no
working Person injury slippery condition at platform.
platform, damage nearby I " 4 4 16 Work under competent 2 3 6 Low
shortcuts, structure Supervision. Do not allow
haphazard shortcuts and half hearted work
lifting for scaffold erection.
practices.
Loose material
at working No loose material at height on
platform, working platform. Good
height phobia,
Person injury " 3 4 12 Illumination. Medical checkup 1 4 3 Low
Poor of all workers to avoid any
illumination. sickness of height phobia.
No loose material to be kept I
Incomplete left at height. Safe procedure for
Sub­
platform. handling of scaffold material.
Failure of contract
Unsafe Do not throw any material tool
scaffolding I or 3 4 12 1 4 4 Low
scaffold, Sick from height. Mandatory PPEs
person I nJ ury Workers
lun- healthy for all workmen engaged for
I Public
person height work. Experience
workmen allow for height work.
2 Height work Experienced certified personnel
for scaffold erection work. Safe
Lifting the
techniques for erection, safe
material to
Person injury access, complete platform.
height w/o
Safety, Failure
damage nearby " 4 4 16 Ensure authorized person at site. 2 4 8 Low
structure Medically fit for height work.
of guide ropel
Follow work permit system.
life line
Work permit syst, mandatory
PPES for height work.

MML4-CA12-RIFAST-CIV-MOS-5013
METHOD STATEMENT FOR CONCRETE SURFACE REPAIR

Ensure safe techniques for

Failure of lifting shifting of material during
PPEs, erection of scaffold at height.
incorrect type Proper Anchoring of Guide
body harness
Person injury " 3 4 12 Rope/ Life line with safety 1 3 3 Low
without double harness, full body harness with
lane yard double lane yard. Medically fit
workmen. Height work permit
system, Inspection of PPE's
Ensure checking of PPEs with
Improper all workers at site. Ensure
lifting, Sub- Double lane yard full body
Horseplay contract harness with scaffold hook with
Serious injury
shortcuts, or 4 4 16 all workers working at height. 2 4 8 Low
to person
haphazard Workers All workers /staff using Body
lifting / Public harness must be trained in
practices. correct usage of Body harness.
Follow the safe system of work.
Work under competent
Supervision. Do not allow
shortcuts and half hearted work
for scaffold erection. No
improvised (Jugaad) lifitng
Fall of person equipments / tools / Tackles to
Height phobia,
from height / be encouraged at site, during
Poor
Serious injury " 4 4 16
night shift maintain illumination
2 4 8 Low
illumination.
to person. at site. Medical checkup of all
workers to avoid any sickness
related to height phobia. Follow
the work permit system strictly.
All workmen undergo 96 hours
training then allow for work.

MML4-CA12-RIFAST-CIV-MOS-5013
 METHOD STATEMENT FOR CONCRETE SURFACE REPAIR

Safe welding work techniques.

Ensure Safe work condition.
Separate storage of combustible
material and flammable
Sub­
Person injury / material. Arrangement for pre
contract
Fire, Heat, protection and Prevention.
property or 4 4 16 1 3 3 Low
Shock Lighting alTangement. First aid
damage Workers
facilities. Trolly for gas
/ Public
cylinders, All safety gadgets
Welding work
3 and gas shall be ensured with Gas
cutting set. Safe routing of
cutting set
hoses.
Safe Storage of hazardous waste
Soil material. Ensure Safe electrical
/I
Contamination Land pollution 3 3 9 Setup. Provision of electrical 1 3 3 Low
, Electrocution safety gadgets, standardized
accessories.
Designed PPEs for welder and
Smoke, Fumes /I
Air pollution 4 4 16 blacksmith. Proper Ventilation 2 4 8 Low
and Dust
at work location.
Use PVC / plastic hand gloves to
Sub­
Handling Contact with avoid direct contact with cement
contract
cement and body part and construction chemicals. Use
4 Masonry work or 3 4 12 1 4 4 Low
construction cement & safety goggles. Only authorized
Workers
chemicals chemical workmen allow to work.
/ Public
Designed PPEs for Mason.
Only authorized operator allow
Cut to body, for the work. Green card system
Sub­
Wrong is in use. Before start work
contract
Grinding Operation, Person injury / checks the grinding machine
5 or 4 5 20 1 5 5 Low
work Unauthorized eye injury properly. Machine having body
Workers
Operation, earthing properly. Safety
/ Public
Electrocution, goggles, Mandatory PPE's must
used by operator.

MML4-CA12-RIFAST-CIV-MOS-501 3 1
 METHOD STATEMENT FOR CONCRETE SURFACE REPAIR

During mobilization follow safe

Sub­ lifting process. Used mandatory
Falling object / contract PPE's
Mobilization Person injury /
Crush / struck or 3 4 12 During lifting do stand below 1 4 4 Low
of electrical electric shock
/ hitting / , Workers lifted load. Only authorized
equipment /
/ Public workmen allow for work.
Stabilization
6 follow safe system of work.
ofDG Sets
and electrical All electric equipments, EDB
Toppling/ having roper platform, double
panel. Person injury /
Tilting of
electric shock " 3 4 12 earthing arrangements. Only 1 4 4 Low
equipments. allow authorized workmen for
work.
Welding machine must have
double earthing. All parts of
machine properly guarded. Only
Sub­
allow authorized operator allow
Unprotected contract
Person injury / for the work. Good
welding or 3 4 12 1 4 4 Low
electric shock housekeeping maintain at
machine Workers
machine area. Inspection of
/ Public
Gas cutting welding machine and proper
7 and welding colour coding. Daily operator
work checklist is being followed.
Cable management must be
proper. Avoid cables lying on
Person injury /
ground. Proper joint of cables.
Cables lying electric
on access shock/slip, trip, " 3 4 12 Only authorized person allow 1 4 4 Low
for electrical work. No
fall.
overlapping of welding and
electric cables.

MML4-CA12-RIFAST-CIV-MOS-5013
METHOD STATEMENT FOR CONCRETE SURFACE REPAIR

All electrical connection is

routed through RCCB, Double
Connectors earthing is provided. Hot work
Person injury / /I permit is taken before starting
not used & 4 4 16 1 4 4 Low
electric shock work. No overlapping of
protected
welding and electric
cables.Green card system is in
use.
All electrical connection is
routed through RCCB, Double
earthing is provided. Replace
Damaged the damage switches with new
Switch and Person injury / one. Cables joint must be proper.
Knob, open electric shock " 4 4 16
Authorized person allow to 1 4 4 Low
terminal work. Appropriate PPES are
provided during handling
electrical equipments, EDB and
cables.
Follow the hot work permit
system strictly. Appropriate
Property PPES are provided. Only allow
/I
Fire hazard damage/ 4 4 16 authorized operator for work. 2 4 8 Low
person inj ury Maintain housekeeping at work
place. Remove flammable
material from work area.
Gas cutting set inspected daily
before starting work, flash back
Property
arresters use for torch and
Back fire / damage / /I
4 4 16 cylinder to avoid back fire. 2 3 6 Low
Fire person inj ury/
Follow the work permit system.
Fire
Area housekeeping maintain at
workplace.

MML4-CA12-RIFAST-CIV-MOS-5013
 METHOD STATEMENT FOR CONCRETE SURFACE REPAIR

Prepared By
Name Rajesh Shende
Designation Sr. Manage!: - SHE
Signature

MML4-CA12-RIFAST-CIV-MOS-5013
 :1

ifiii ReLIANce £
Hill International -ASTALD
-
Mumbai Metro Line 4 Contract Package CA12

FORMAT: RAJV / MML4 / F -02-RO

Client: Mumbai Metropolitan Region Development Authority (MMRDA)

Contractor: RINFRA-ASTALDI Joint Venture (RAJV)
FORMWORK INSPECTION CHECKLIST
Structure: Date of Inspection:
Location: Drawing No

s. No. Description Yes No Remarks

1 Formwork design & drawing approved

2 Safe access provided

3 Adequate work space provided for workers / equipment

4 Formwork level/alignment and dimensions are checked

5 Adequate supports are provided to formwork

6 Cleaning offormwork done

7 All formwork joints to be sealed & made leak proof

8 Formwork release oil approved

9 Formwork released oil applied properly

10 Check rigidity of formwork supports

11 Tie rod provided as per form work design

12 Survey co-ordinates checked for formwork

If comments any:

RAJV Representative GC Representative

Date: Date:
 ;1

I1ll ReLIANce i AS ALD

Hill International --
Mumbai Metro Line 4 Contract Package CA12

FORMAT: RAJV / MI\J1L4 / F -03-RO

Client: Mumbai Metropolitan Region Development Authority (MMRDA)

Contractor: RINFRA-ASTALDI Joint Venture (RAJV)

PRE CONCRETE INSPECTION CHECKLIST

Structure: Date of Inspection:
Location: Drawing No

s. No. Description Yes No Remarks

1 Grade of concrete as per drawing

2 Mix design approved

I

3 Source of concrete approved for batching plant

4 Sufficient qty of concrete ingredients are available

Method of concreting
5
Boom placer / Static pump / Chute/ Crane bucket

Compaction arrangement (in sufficient numbers)

6
Immersion/External vibrators available as required

7 Theoretical concrete qty ........... cum

8 Sufficient lighting arrangement made

9 Slump cone/Cube moulds/Thermo meter available

10 Stand by arrangements for concrete

11 Any inserts provided as required

If comments any:

RAJV Representative GC Representative

Date: Date:
 ;1

iiif ReLIANce
Hill International

Mumbai Metro Line 4 Contract Package CA12

FORMAT: RAJV I MML4 I F -04-RO

Client: Mumbai Metropolitan Region Development Authority (MMRDA)

Contractor: RINFRA-ASTALDI Joint Venture (RAJV)

POST CONCRETE INSPECTION CHECKLIST

Structure: Date of Inspection:
Location: Drawing No

s. No. I Description Yes No Remarks

1 Surface finish OK

2 Alignment ,Ievels, dimensions are OK

I

Curing Method
3 (i)Water curing (or)
(ii)Curing compound

4 Curing is proper as per required

5 Any surface defects found

6 Any rectification required

7 Rectification done as per approved methodology

I
8 All inserts are in position (if required).

9 Structure id & Date of casting marked

If comments any:

RAJV Representative GC Representative

Date: Date:
 ;1

Il ReLIANce , ASTALD
Hill International I

Mumbai Metro Line 4, Contract Package CA-12

FORMAT: RAJV / MML4/ F -12-RO
Client: Mumbai Metropolitan Region Development Authority (MMRDA)
Contractor: RIt\lFRA-ASTALDI Joint Venture (RAJV)
CONCRETE REPAIR WORK CHECKLIST
Structure: Date of Inspection:
Location: Drawing No

S.No Description Yes No Remarks

1 Approved repair work methodology available

Type of rapair work:
a) Air bubbles / pin holes / minor imperfections
b) Surface cracks on concrete surface
2 c) Spalling of concrete
d) Broken edges
e) Offset in joints
I f) Honey comb
3 Surface preparation done as per approved MS

4 All laitance/loose/contaminated material removed

5 Priming / Bonding agent applied as per MS

6 Corrosion treatment done if steel bars are exposed

7 Approved repair material is available

8 Form work provided as per required (if needy)

Mixing of material done as per approved
9
methodoloQY / Matertal product data sheet
10 Application of material done as per MS

11 Fixing of packers maintained as per MS

12 Grouting done as per methodology

-

I 13 Packers removed and nozzle holies filled as per MS

14 Surface finishing done as per required

If comments any:

RAJV Representative GC Representative

Date: Date:
 ;1

ifill ReLIANce j ASTALD

HiIIlntemational I

RAJV Representative GC Representative

Date: Date:
 ····ReiliANce
I _ 4....'
• . ~ ~
.1 Lifting Permit

Project Name:
Location: Date:
Sub-Contractor: Permit No.
Doc No: MML4-CA12-RIFAST-HMS-PER-5002 Rev.:02

Description Of Work: I Description Of Crane:

Permit Validity Period:

CHECK POINTS
No abnormal physical damage to crane Shackles, lifting hook and safety latch are visibly
in good working condition
All safety limit switches and mechanisms Audible alarm / warning horns are In good
provided are completely connected working conditions (include testing of limit
switch alarms)
Capacity chart is provided and in full view of Outrigger of crane are fully extended and place
the operator. on the firm footing
Windscreen of crane operator's cabin is clean Operator is experienced and competent
and free from dirt / obstruction I

Wire ropes, slings are visibly free from Lifting capacity of slings and D-shackles checked
fraying or kinking
Automatic Safe Load Indicator (ASLI) Crane and all lifting tools certified by competent
provided and working properly. person and colour coded.
Pre-lift study conducted and checklist IS Fire extinguisher is available in crane cabin. I

attached.

STAGE-l:- APPLICATION BY JOB SUPERVISOR

I have checked and confirmed that the above safety requirements have been complied with:­
Name:­ Designation: _
Company: -­ _
Date: Time: Signature: -­

STAGE-2:- APPROVAL BY LIFTING ENGINEER/SUPERVISOR

Actual site condition sketch has been prepared and attached. Based on that I am fully satisfied that all safety
measures have been implemented and enforced.
Name: Designation: _
Date: Time: Signature: _

STAGE-3:- INSPECTION BY HSE PERSONAL

I have inspected the above-stated location and confirmed that the recommended safety measures are in place
and the said lifting plan is safe for work at the point of inspection.
Name: Designation:
------------
Date: Time: Signature: _
 Lifting Permit

Project Name:
, Location: Date:
Sub-Contractor: Permit No.
Doc No: MML4-CA12-RIFAST-HMS-PER-5002 Rev.:02

STAGE - 4:- INSPECTION BY EMPLOYER (Optional at the Discretion of MMRDA)

I have inspected the above-stated location and confirmed that the recommended safety measures are in place
and the said lifting plan is safe for work at the point of inspection.
Name: Designation:. _
Date: Time: Signature: _

STAGE-5: CANCELLATION

I declare the all lifting work under my control has now been stopped and all tools and other equipment's
have been removed.
Name:- - - - - - - - - - - - - - Designation: _
Date: - - - - - - - - Time:- - - - - - Signature: -----­

STAGE - 6: PERMIT CLOSURE

We have inspected the above-stated location and confirmed that the recommended safety measures required
to close this permit have been done.
Name:______________ Designation: _
Date:- - - - - - - - Time:- - - - Signature:" . _ - - - - - - - - - - - ­

Name: Designation: _
Date: Time: Signature: _

IMPORTANT NOTE:

>- Validity of this permit shall be only for the period mentioned in "Permit Validity
Period".
>- Any authority of Rinfra higher than lifting Engineer/Supervisor or any authority of
MMRDA can cancel this lifting permit by recording reasons below and taking
acknowledgement of the lifting Engineer/Supervisor
 • IA\

Hot Work Permit ASTALDI

Project Name:
Location: Date:
Doc No: MML4-CA12-RIFAST-HMS-GNS-5008 Rev.:02

Precise location of hot work: PERMIT VALIDITY (Max. 12 hrs)

From To
Hot work activity: Date
Time
Safe System: A suitable and sufficient safe system of work must be available for this activity. Essential checkpoints are as below:
S.
Condition Yes/No NA Comments
No
1 Risk Assessment available

2 Tool box talk performed, attendance recorded

Area cordoned off and precautionary sign board displayed
3
prominently
4 Proper means of escape / exit available

5 Gas cutting set is equipped with flash back arrestor

6 Gas cylinders kept upright in trolley's

7 Only lSI marked regulators are in use I

8 Fire extinguishers available in location of work
For working at height, the area below the work area is cordoned
9
off.
10 Provision made to contain molten metal/spatters dropping

11 Welding machine is earthed

12 No combustible material are stored below / adjacent structures

Sufficient lights are available when working during night (Min. 200
13
lux)
14 All persons expected to working at height have full body harness.

15 Carry bag is available for hand tools I

16 II Persons are trained / experienced to perform hot work activity I

17 Is all electrical connection are in good condition.

Legend' Yes - ",/", No - "x", NA - Not Applicable
PERMIT TO WORK - INSPECTION & DECLARATION [SECTION IN-CHARGE / SUPERVISOR]
COMPLANCE BY SECTION IN CHARGE / SUPERVISOR: As the In-Charge / Supervisor, I am familiar with the scope of work and safe
systems to be implemented and shall ensure it during execution of work. A briefing has been delivered to the workforce on this
I safe system of work.
Name and designation of Section In-Charge / Supervisor I
Sign and date of Section In-Charge / Supervisor I
PERMIT TO WORK AUTHORIZATION [ACTIVITY IN-CHARGE]
Name and designation of Activity In charge I
Sign and date of Activity In charge I
VERIFICATION OF COMPLIANCE TO PERMIT CONDITIONS BY SHE MANAGER / ENGINEER
Observed that the permit conditions are complied. I All permit conditions are not complied and advised to
(tick the box) go ahead after compliance. ((tick the box)) I
Name
I
I Sign I Date & Time
II
VERIFICATION OF CONDITIONS TO CLOSE PERMIT BY SHE MANAGER / ENGINEER & ACTIVITY IN-CHARGE

Observation:

SHE Manager Sign I Date &

I Time
Activity In Sign I Date &
Charge Time
 I.U'! ::',[:.JW...A ..

Project Name:
~ r" Height Work Permit
=-.t&)
~ASTALDI

Location: Date:

Sub-Contractor: Permit No.

Doc No: MML4-CA12-RIFAST-HMS-PER-5003 Rev.:02

Precise location of Height work: PERMIT VALIDITY (Max. 12 hrs)

From To
Height work activity: Date
Time
Safe System: A suitable and sufficient safe system of work must be available for this activity. Essential checkpoints are as below:
,
S.N I Condition ! Yes/No NA Comments
1. Risk Assessment available I

2. Tool box talk performed, attendance recorded I

Area cordoned off and precautionary sign board displayed

3.
prominently for traffic I

4. Proper means of escape I exit available

5. Scaffold erected as ber desiqn and secured properly.
Scaffold is having guard rails, toe board and proper planks
6.
without Qaps.
Scaffolds are tagged. Red - Scaffold not to be used. Green­
7. II
Scaffold inspected and Qood for use I

All persons expected to working at height have full body

8. I
harness.
On top of the platform, there is no provision of hooking
9.
lanyard'. Is lifeline provided?
Fall arresters are available and provided to access difficult
10.
location
11. Persons are trained I experienced to perform work at heiQht
12. II Carry baq is available for hand tools
I Sufficient lights are available when working during night (Min.
13.
200 lux)
Persons are either not incapacitated or does not have
14.
symptoms of blood pressure.
Scaffold not being used to keep material or the material kept
15.
is within permissible desiqn load.
Persons are trained / experienced to perform Scaffolding work
16.
activity
17. Drinkinq water is available.
legend: Yes - "./", No - "X", NA - Not Applicable
PERMIT TO WORK - INSPECTION & DEClARATION [SECTION IN-CHARGE / SUPERVISOR]
COMPlANCE BY SECTION IN CHARGE / SUPERVISOR: As the In-Charge / Supervisor, I am familiar with the scope of work and safe
systems to be implemented and shall ensure it during execution of work. A briefing has been delivered to the workforce on this
safe system of work.
Name and designation of Section In-Charge / Supervisor I
Sign and date of Section In-Charge / Supervisor I
PERMIT TO WORK AUTHORIZATION [ACTIVITY IN-CHARGE]
Name and designation of Activity In charge I
Sign and date of Activity In charge I
VERIFICATION OF COMPLIANCE TO PERMIT CONDITIONS BY SHE MANAGER / ENGINEER
Observed that the permit conditions are complied. All permit conditions are not complied and advised to
(tick the box) go ahead after compliance. I
(tick the box)
Name I I Sign I Date & Time I
VERIFICATION OF CONDITIONS TO CLOSE PERMIT BY SHE MANAGER / ENGINEER & ACTIVITY IN-CHARGE

Observation:

SHE Manager Sign Date &

Time
Activity In Charge Sign Date &
Time
 Shuttering and de shuttering
Work

Project Name:
Sub Contractor: Permit No.:
Location: Date:
Doc No: MML4-CA12-RIFAST-HMS-PER-5005 Rev.:02

Precise location of work: PERMIT VALIDITY (Max. 12 hrs)

From To
Shuttering / De-Shuttering work activity: Date
Time
Safe System: A suitable and sufficient safe system of work must be available for this activity.
Essential checkpoi,nts are as below:
S.
Check Points Yes/No NA Comments
No
1. Risk Assessment available
2. Tool box talk performed, attendance recorded
Is there any temporary fencing / edge protection
3. fixed at perimeter area to prevent objects / persons
falling from height while de-shuttering / shuttering?
Are all slab openings are covered and openings more
4.
than 20 x 20cm barricaded / closed?
Is safety net fixed at one floor lower from the
5.
working floor / 6m?
Temporary barricade and caution signs provided
6.
until fixing the edge protections.
Is proper access and egress been provided for safe
7.
access?
Is suitable anchorage point available to hook the
8.
harness?
Is any work being going on underneath of proposed
9.
work?
10. Is the work area found anti slippery?
Legend: Yes - "./", No - "x.", NA - Not Applicable
Safety Measures (to be followed by shuttering / de-shuttering engineer / supervisor
• All activities carried out under proper supervision.
• Tired & unfit workers should not be permitted to work.
• Proper illumination should be provided at all workplaces
• All safety norms should be strictly followed.
• Work should be immediately stopped due to / unfavorable wind, rain / thunder.
• Electrically operated hand tools such as drilling / nailing / cutting shall be used with due care
only be highly competent / skilled workers.
• Use of appropriate personnel protective equipment should be ensured.
• Perimeter area should be cordoned off / fixed of edge protection to prevent fall of person.
• All workers must be wear harness and it must be hooked in anchorage point while working at
perimeter / near to openings.
• Underneath area should be barricaded, caution sign shall be placed and watcher appointed
 Shuttering and de shuttering
Work
ASTALDI
Project Name:
Sub Contractor: Permit No.:
Location: Date:
Doc No: MML4-CA12-RIFAST-HMS-PER-5005 Rev.:02

during this operation.

- All props in the slab edge should be secured (braced / tied) for prevent from falling
I-All de-shuttered materials should free of nails and stack away from edges.
- Loss materials (hammer, hand held tools) should be tied with nyl'on string to prevent falling
from height.
PERMIT TO WORK -INSPECTION & DECLARATION [SECTION IN-CHARGE I SUPERVISOR]
COMPLANCE BY SECTION IN CHARGE I SUPERVISOR:
Condition of Permit issuing:
The above work is authorized to proceed subject to the above inspections and conditions being
taken and maintained for the entire course of the work Always one first aider should be standby
to provide first aid. The work area and adjoining areas must be inspected by the permit acceptor
from start of work until 30 minutes after completion of work (including break / rest period)

As the In-Charge / Supervisor, I am familiar with the scope of work and safe systems to be
implemented and shall ensure it during execution of work. A briefing has been delivered to the
workforce on this safe system of work.
Name and designation of Section In-Charge I
Supervisor
Sign and date of Section In-Charge I Supervisor
PERMIT TO WORK AUTHORIZATION [ACTIVITY IN-CHARGE]
Name and designation of Activity In
charge
Sign and date of Activity In charge
VERI,FICATION OF COMPLIANCE TO PERMIT CONDITIONS BY SHE MANAGER I ENGINEER
Observed that the permit conditions All permit conditions are not complied
are complied. (tick the box) and advised to go ahead after
compliance.
(tick the box)
Name I I Sign I Date & Time I
VERIFICATION OF CONDITIONS TO CLOSE PERMIT BY SHE MANAGER I ENGINEER & ACTIVITY IN-CHARGE
Observation:

SHE Sign Date &

Manager Time
Activity Sign Date &
In Time
Charge I
 CHRYSO® RESICRETE 21
Solvent Free Injectable Epoxy Grouting Compound

Description Method of Application

Surface Preparation
RESICRETE 21 is a two components (Component A -Resin, and
Component B -Hardener) solvent free low viscosity free flowing, The area to be treated should be properly cleaned to remove dust,
fast curing epoxy resin system. laitance, grease, fungus etc. Injection nipples are fixed in a square
grid maxim.um 500 to 800 mm c/c depending on the cracks and
Indicative Characteristics nature of concrete. If required for effective treatment, the grid
may be reduced. Before the injection starts all cracks and crevices
Mix Ratio by wt. Part A:B 2:1 are to be sealed with RESICRETE - 21 mortar (Resin- 2part,
Color of mixed products Light to Dark Amber Hardener -0.5 part and fine silica sand 12 to 14 part) or any other
Pot life at 27°C, minutes 45 suitable quick setting mortar. This mortar can also be used for
Relative Density of mixed 1.09 surface sealing for other porous areas.
material, 30°C
Viscosity, poise, at 30°C, 5 Mixing
ASTM 02393
Compressive Strength, 50 Mix the entire component - B (Hardener) with Component - A
N/mm 2 , 24 hours, ASTM (Resin). Mix for 2-3 minutes to uniform colour without any streak
0695 using a drill and paddle (speed approx. 250 - 400 R.P.M.) mixer so
Compressive Strength, 75 as to avoid any entrapped air. Mix only sufficient materials for
N/mm 2, 7 days, ASTM 0 immediate requirements. Leave the mixed material to stand for 2­
695 3 minutes to enable entrapped air, if any, to escape from the mix
Bond Strength, 2/14 days 8.1/12 and then use as quickly as possible.
(moist cure), N/mm 2
ASTM C882
Tensile Strength, N/mm 2 , 38 Application
7days, 30°C, ASTM 0638
In case of application by injection method, the grout mixture
Shrinkage, ASTM 0 883 Passes test
should be pumped by a positive displacement plunger type pump.
24 Hours Water 0.08
Inject at slow and even pressure through the injecting nipples till
absorption, % (w/w),
refusal: or when the grout oozes out from the nipple immediately
ASTM 0570
adjacent to or above the one being injected. The mixed material
Elongation at Break, %, 1.1
can also be applied by simple pouring the material through the
ASTM 0638 I
pockets or repairable cracks or both the surfaces to be joined. The
excess material must be removed with a sharp scraper or concrete
Domains of Application
finishing tools to a smooth and flat finish. In case of application (as
concrete sealer) by brush or roller, the mixed mixture should be
As an injection resin with good adhesion to dry
painted (by a brush or roller) for minimum two coats. The second
concrete, mortar, stone, steel and wood. coat of painting will be done after proper air curing of first coat.
To fill and seal voids and cracks in structures such as Preferably it should be done after 8 hours of application of first
bridges and other civil engineering buildings, industrial coat.
and residential buildings, e.g. columns, beams,
foundations, walls, floors and water retaining
structures.
Grouting of machine base plate, bridge bearing bases,
anchoring of bolts, etc.

The information contained In this technical dillil sheet is given to the best of our knowledge and Ihc results from elrtenslvc testing In order to remaIn .n objective itS ponible.
However, il cannot, in arr{ case be considered as it warranty involving our liabnity in case of misuse or any different use of our products from the "Application" paragraph of this
technical data sheet. Some application tests should be carried out before using the product to ensure that the methods of use and conditIons of appUcation of the product are
sat!sfaClory. Our technical assIstance Is at the disposal of the users.
Consult the latest update of the technical data sheet on our website _.chryso.com
I; III1YS II
CHRY50 India Private Limited I Registered & Corporate Office: Plot No. 0 -30/7, TTC Industrial Area, M.1.0.C. Turbhe, Nav;
Mumbai - 400705. Maharashtra, INDIA. Tel: +912Z 27685991/Z
 ISO ,):DOI RE~GISTEREO

m~.
'W~~ .
CHRYSO® RESICRETE 21 . '1['1"("
I~",I.•. ;"
I~ ,,~iJU!i
Solvent Free Injectable Epoxy Grouting Compound

Advantages Precautions

Designed for pressure injection grout into concrete for Store the material in shaded cool place and keep it

carrying structural repairs and small pocket grout, away from fire and any heated body. Clean all tools

grouting of bearing base plates, etc. with MEK or any standard solvent before

The cured resin possesses high mechanical strength, polymerization starts.

excellent adhesion, practically no shrinkage and Mix only sufficient materials for immediate

chemical resistance. requirements, Leave the mixed material to stand for 2­

Fine cracks, joints and small voids can be successfully 3 minutes to enable entrapped air, if any, to escape

sealed with RESICRETE - 21. from the mix and then use as quickly as possible.

Although RESICRETE - 21 has a very high strength, the Should not be mixed multiple packs at a time. This may

cured material is not brittle and remains a slight result drastic reduction of pot life and material may gel

flexible in nature. quickly before injection process.

Shelf Life & Storage Safety

12 months from the date of manufacturing when stored in un­ Wear hand gloves, safety shoes and safety goggles
opened, original sealed and dry condition at a temperature while using and handling the product.
range from +5°C to 40°C.
In case eyes or mouth are affected wash with plenty of
Packing clean water and seek medical treatment immediately,

3kg, Pack- A (Resin): 2kg, Pack-B (Hardener):1kg Before use, refer to the Material Safety Data Sheet.
The MSDS is available on www.chryso.com

The information contained in this technical data sheet is given to the best of our knowledge and the results from extensive testing In order 10 remain 35 objective as possible.
However, It cannot, In any case be considered as a warranty involving our Uabmty In case of misuse or any different use of our producls from Ihe "Application" paragraph of this
technical data sheet. Some appllcatlon tests should be carried out before using the product 10 ensure thaI the methods of use and condllion~ of application of the product are
~atisfactory. Our technical assistance Is at the disposal of the users.
Consult the latest update of the technical data sheet on our website www.chryso.com

CHRYSO India Private limited I Registered & Corporate Office: Plot No. 0 -30/7, TIC Industrial Area, M.I.D.C. Turbhe, Navi
I: HIIY~ II
Mumbai - 400705. Maharashtra, INDIA. Tel: +9122 2768S991/2
 EmceColor-flex
Acrylic Polymer modified Elastic Elastomeric Breathable, Anti-Carbonation,
Crack Bridging, and UV Resistant Protective Coating for Concrete
Product Properties
Crack Bridging coating for strained facades and concrete surfaces on the basis of modified pure acrylic dispersion.
Resistant to carbonation
Seamless membrane with breathing capacity
Water repellent
Weathering and ultra violet (UV) resistant.
Solvent free, safe and non-corrosive
Good cleanability
Application by roller or spraying.

Areas of Application
Concrete protection system against aggressive pollutants.
Carbonation resistant coating for protection of new concrete, repaired concrete, old facades, etc
Protective coating for concrete subjected to adverse climatic conditions like in cooling towers, chimneys, bridges.etc.
Protective coating for strained concrete facades due to hair cracks, crazing and shrinkage cracks.

Application Notes

General' application.The EmceColor-flex system is suitable for the

protection and repair of cracked facades exhibiting so called
EmceColor-f1ex system is specially designed for protection of hair-line cracks and fine shrinkage cracks (within the region of
concrete. It is an elastic membrane forming material based on acrylic about 0.2 mm crack-width).
polymers and selected mineral fillers. EmceColor-f1ex is water based
and therefore retains the breathing capacity of concrete. Fine cracks of this kind are often detectable only in the
presence of moisture so dampen surface before examining dry
The product has low water vapour diffusion and high resistance to facades. Such hairline cracks and fine shrinkage cracks are
diffusion of carbon dioxide. The coating acts as protection against generally to be found on the surfaces only. By additional
carbonation of concrete. The most important characteristic of application of EmceColor-f1ex coats, the crack bridging ability
EmceColor-f1ex is that it has crack bridging properties, which can be of the system can be increased as a function of the thickness of
taken advantage of in case of repair and protection to cracked the coats involved.
facades, exhibiting hairline and shrinkage cracks.
Flaky old paintwork must be completely removed. Smoothen the
Surface Preparation base with mortar or Nafuquick readymade mortar. Unpainted
surfaces should be primed with Primex 250, consumption 75­
2
A primer coat of Primex 250 is required for adhesion and sealing of 100 g/m . Subsequent coats of EmceColor-flex can be applied
the surface. EmceColor-flex is supplied in white colour. Some by roller, brush or spraying in two coats at a consumption of 400
2
shades can be made available for large surface areas. Pigments and to 450 gms/m for a thickness of 200 to 225 microns.
color stains can be added to obtain different decorative shades. Two
coats are normally recommended under usual conditions. More coats This product is fully compatible with solvent free PCC system
offer higher degree of protection and better crack bridging properties. for the Protection, Repairs and Maintenance of Concrete
Structures. Please request details.
Surface preparation should be conducted as per painting rules.
Surfaces shol!Jld be free from oils and fats for better bonding. The EmceColor-f1ex can be diluted In a ratio of 1:2 pbw with water
surface to be coated must comply with the principles ot building and resultant solution can be used to provide white solar
construction and should fulfil structural requirements. The surface refiecting coat for bituminous-based roofing system. This
should be firm, clean, and free from fats, oil, grease, dust or any other coating also lowers the effective heat in top level living areas
contamination. and provides indirect insulation. EmceColor-flex is supplied as
a ready-to-use paste. Mechanical Mixing should be done at site
EmceColor-f1excan be used on cracked or crack susceptible to avoid settlement of heavier minerals in EmceColor-flex, for
surfaces as preventive protection or repair, on rough or smooth best coating results.
plaster, brickwork and concrete surfaces. The nature of the base and
particularly the kind of cracks involved must be analysed before

MC-Bauchemie (India) Private Limited, 411, Arenja Corner, Sector-17, Vashi, Navi Mumbai 400703, India
Tel: 022-27892856, 27880803 Fax: 022-27893870 e-mail: mcbindia@yahoo.co.in
 Further Instructions/Precautions

1. Depth of Carbonation for protected & unprotected concrete 2. Crack bridging characteristic

Technical Data for EmceColor-F/ex

Characteristic Unit Value Comments
-Coiisumptioii---------------------------GmsiITi'-- 400:450--------- For2cio-t022S-ITiicroii-thickness,-fji-two coaiS---'-'-'-'
Carbon dioxide Diffusion Resistance 1.78x10'
R Value m 589
--Crack bridging-cap-acilY .------- m m - - - - - 2 1 0 · - - - - - - - -m--------­

Dynamic crack bridging after Weathering mm 0.4

-Water vapourdTffuSio-ncoefficient-------""j(----1780--------..-..- ........----------..- -...- - - - - - - - - -....- ..- ......-­
'-Wate-r-VapourbiffusionSo mO:S8- .........................--------- - - - - - - - - ­

Permeability under pressure 0 (as per IS 3085)

--caPi!iaryAbsorption-'-'---"-'-- Kg/m'tiiy,--o1""---- ---.-- - ..---.- -- - ----.---- .. .. .. __ .. .._ _ _mm _
-Adh~;~~-----------------------------rw;;;;;;2------2-.0-------------------------------------------------------.

-AdhesTOn-after-exposUreto-temperature-~~~;------~~;-----------------------------------------------

_g_h?Qge_§<_s?lil1i;<:~cl(<:>9_______mm_____ .m________ ...____

Resistance to humidity, heat
temperature change, salinated fog I No lamination, cracks or bubbles
_cl~(~o_stiQg~?lt_?~cl""~?m~~iQg .... _- _._--_. __ . .
Under xenon are lights. Contrast Level < 5
Ultraviolet Rays Hrs 350
Colourfastness fulfilled
UV resistance after 300 hrs f\!.~cha~~_E'!_i~r~~i~~!~p.~E'!_~r:..~~c.:r:. _
-Aciti-esionstrength after UV exposur-e----N7ITirri'"---1~o----

Product Characteristics for EmceColor-Flex

Type of Product Acrylic Based Anti-Carbonation, Breathable, Crack Bridging coating for Concrete
coioi-··------·------·Vlii-iite-OSe-lj-nrversaicOiourslaTilStoobtafii-othE;rcolours ..-------------------­
-co;;-siste-iicy-----------------------smootti--pas(y-Ilqukj----------------------------------------­
.. _.. -_.. _-_ - _ __
_._ _.. _---------.. _ __ _---. -.~.- ...-._ -._.. _ _-- .. _._._---- _ _---_ .. ­
~_.----------_._--.-._------_._._

Cleaning Agent Water, when material still fresh

"-oe"iiv-ery'-- ··-----·-·····-¥---·-·-····~---Emcecolo·r:fiex:4oT(gy-rimex- .
~f50:3o"f<g-&5-kg·----·--·_--_···_··· . ·. -·---·-_··.-.. _.-_.. _.--.-.-.­
"-Storage ···-·..···------- .. ----fncooi-anddry-con-ciitions··in··tighlIyclosedcontai·ners--·---- .... - - - -...- ....------.-...- -....

Disposal Empty packs completely and dispose carefully to protect our environment
--stiEiTiife·----------gmonths from cialeoTManUtacture-----·----·-----------------------------­

Note: The information on this data sheet is based on our experiences and correct to the best of our knowledge. It is, however, not binding. It has to be
adjusted to the individual structure, application purpose and especially to local conditions. Our data refers to the accepted engineering rules, which have
to be observed during application. This provided we are liable for the correctness of this data within the scope of our terms and conditions of sale­
delivery-and-service. Recommendations of OUf employees, YJhich may differ from the data contained in our information sheets, are only binding if given
in written form. The accepted engineering rules must be observed at all times. E. & O.E

Older editions are invalid and may not be used anymore. If a technically revised new edj'tion is issued, this edition becomes invalid.

Edition: September 2012

MC-Bauchemie (India) Private Limited, 411, Arenja Corner, Sector-17, Vashi, Navi Mumbai 400703, India
Tel: 022-27892856, 27880803 Fax: 022-27893870 e-mail: mcbindia@yahoo.co.in
 BASF
The Chemical Company

MasterBrace® 2200 (Formerly known as Concresive 2200)

High strength epoxy bedding and repair mortar

"

• Bond strength >2, MPa (concrete

failure)
MasterBrace 2200 is a solvent free, high
performance, non-slumping epoxy mortar and Setting time 12 hours @ 25°C
adhesive. MasterBrace 2200 can be used as a Meets the requirements of ASTM C881 Type 1 Grade
bedding mortar, thixotropic adhesive and non-sag

.
3 Class B & C I
concrete repair mortar.
,. Chemical Resistance
MasterBrace 2200 resists most common organic
• Bedding of bridge beams or steel bridge and inorganic acids in diluted form, also resistant
bearings to alkalis, water, oils, grease, etc. Chemical
• Repairing surface defects in concrete in resistance depends on the chemicals involved,
horizontal, vertical and overhead applications their concentration, temperature and degree of
• Fining of injection ports for Masterlnject resins exposure. Good housekeeping practices such as
• Bonding of dowels, bolts and anchors into immediate clean-up of all spillages will greatly
concrete extend the service life.
• Rapid structural repair of concrete Part A Part B Mixed
•
. .:
Re air of concrete p-osts inrs_it_u ..,.
Supply Form
Colour
Paste
Grey
Liquid
Amber
Paste
Grey
• Adheres to concrete surfaces - Allows rapid
repair of concrete Mix Ratio 100:75 pbw
• Solvent free - Low vac and non-shrink Density (Mixed) 1.85 kg/L
• Pre-proportioned packaging - No job site Application Temperature 15°C - 35°C
errors
• Easy application - No primer necessary
• High abrasion, impact and chemical
Surface preparation
resistance - Can be used as contact surface in
aggressi,ve environments Remove all grease, oil, dust, residual curing
• Cures hard at low temperatures - Wide compound, mould release agent or other
application range contaminant that could impair adhesion, Laitance
•• o· • should preferably be removed by i1ight sweep
blasting or hydro-jetting. Mechanical wire brushing
may be appropriate for small areas.
Mixed resin and hardener only
Spalled concrete should be cut back to sound
Compressive Strength (BS 40 MPa @ 1 day concrete and made good with MasterBrace 2200
6319 part 2) @ 25°C mortar, Conventional concrete curing compounds
65 MPa @ 7 days
should be removed before application.
Flexural strength (ASTM C 20 MPa @ 7 days
580 part 7) @ 25°C Mixing
Tensile Strength (BS 6319 10 MPa @ 7 days Proportion part kits accurately mixing only what
Part 7) @ 25°C can be used in less than 30 minutes. Thoroughly
stir Part A, add Part B and blend thoroughly using
Pot life 50 minutes @ 25°C a slow speed mixer fitted with a suitable paddle.
30 minutes @ 40°C .Application
Recoat time 8 hours @ 25°C The MasterBrace2200 may be placed using a
6 hours @ 40°C trowel or spatula and applied evenly across the
whole surface. Subsequent coats should be placed
within 30-45 minutes and the MasterBrace' 2200

MASTER®
»BUILDERS
" UTI I C'
 BASF
The Chemical Company

MasterBrace® 2200 (Formerly known as Concresive 2200)

should still be tacky. The use of a trowel dipped in
solvent is recommended of a very smooth final
surface is required. MasterBrace 2200 can be stored in tightly closed
original containers for 12 months at moderate
temperature.
-=.."..-...,...,,--......,-.......,~~""""I"!~~~
Cure time will vary depending, on the ambient
temperature, quantity mixed and placed.
MasterBrace 2200 will have fully cured after 7 For the full health and safety hazard information
days at 23°C. and how to safely handle and use this product,
please make sure that you obtain a copy of the
•• BASF Material Safety Data Sheet (MSDS) from
A 6 kg kit of MasterBrace 2200 will yield 3.24 our office or our website.
Iitres.

MasterBrace 2200 comes in a 6 kg kit

MasterBrace 2200/01/0313

The technical information and application advice given in this BASF Construction Chemicals publication are based
STATEMENT OF on the present state of our best scientific and practical knowledge. As the information herein is of a general nature,
RESPONSIBILITY 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
(Disclaimer) user is responsible for checking the suitability of products for their intended use.
® = registered trademark of BASF group in many countries
Field service where provided does not constitute supervisory responsibility. Suggestions made by BASF
NOTE Construction Chemicals either orally or in writing may be followed, modified or rejected by the owner, engineer or
contractor since they, and not BASF Construction Chemicals, are responsible for carrying out procedures
appropriate to a specific application.
BASF India Limited
Construction Chemicals Division
Plot No.37, Chandivali Farm Road, Chandivali, Andheri(East)
Mumbai - 400072 India
Tel: +91 2228580200, Fax: +91 2228478381
e-mail: construction-india@basf.com www.master-builders-solutions.basf.in
 BASF
The Chemica'il Company

MasterEm aco ® P 130 (formerly known as Concresive ZRi)

Two component epoxy based zinc rich primer for steel

I
• no oil, grease or dust is present. Surfaces should
be dry.
MasterEmaco P 130 is a two component, solvent Mixing:
borne zinc rich epoxy primer, providing active Stir each component of MasterEmaco P 130.
galvanic protection to steel. It is a thick grey liquid Add Hardener to Base and mix using a drilling
of paint-like consistency, recommended for use machine fitted with a mixer.
where chloride Induced attack on steel is Ilkel .
I • Application:
~ .... ­ .~.

Apply MasterEmaco P 130 immediately after

• As a protective coating to steel reinforcing
bars in concrete.
completion of preparation to prevent any
contamination. Do not leave blasted or prepared
As a touch-up primer for damaged galvanised
steel uncoated.
metal.
• As a primer for steel substrates prior to
suitable top coating.
Brush the MasterEmaco P 130 onto the prepared

. :
Protects steel - provides active protection
substrate, ensuring uniform and full coverage,
particularly on the back face of reinforcement. In
case of doubt on achieving continuous film in one
coat apply second coat immediately after the
against steel corrosion. drying of the first coat. Please consult BASF
c Excellent adhesion - bonds to steel to representative for adv,ising the numbers of coats
create a protective anti-corrosion barrier. necessary. Repair mortars can be applied as
Fast installation - Short overcoating time. soon as the MasterEmaco P 130 is dry.

MasterEmaco P 130 is not designed as a

Aspect : Thick grey finished coating. Although protection to the steel
suspension will be provided for some time, overcoating
Mixed density : 2.4 ± 0.1 kg/litre should be carried out as soon as possible,
Volume Solids, % : 57 ± 3 particularly in aggressive environments.
Mixing Ratio, by volume : 4(B) : 1(H)
Pot Life : 120 Minutes at Equipment care
25°C Tools should lbe cleaned with CLEANING
Tack free time : 25 Minutes at SOLVENT NO.2 immediately after use.
25°C •• •
: 10 Minutes at Each 1 litre pack can cover 8 - 10m /coat on
40°C smooth substrates. On rebar approximate
Recoat time : 6-8 Hours at 25°C coverage shall be as under:
: 2-4 Hours at 40°C
Total zinc content in dry film : >84% by weight Diameter of rebar Coverage
DFT. per coat : > 50 microns (in mm) Running
Application temperature : minimum 10°C meter/litre/coat
: maximum 40°C 8 210 - 265
12 140 - 175
STANDARDS 16 105 - 135
MasterEmaco P 130 is formulated to meet the 25 85 ­ 115
sco e of BS 4652, T e 2 32 55 ­ 65
•
Surface preparation PACKAGING - .
The steel surfaces should be grit blasted or wire
brushed to remove all traces of corrosion. Ensure MasterEmaco P 130 is a two component system,
supplied in 1 litre combined unit.

MASTER®
»BUILDERS
S)L JTJlJtl
 ASF
The Chemical Company

MasterEmaco® P 130 (formerly known as Concresive ZRi)

•
Store under cover, out of direct sunlight and For the full health and safety hazard information
protect from extremes of temperature. In tropical and how to safely handle and use this product,
climates the product must be stored in an air­ please make sure that you obtain a copy of the
conditioned environment. BASF Material Safety Data Sheet (MSDS) from
our office or our website.
Shelf life is six months when stored as above.

MasterEmacoP130/01/0313
The technical information and application advice given in this BASF Construction Chemicals publication are based
STATEMENT OF on the present state of our best scientific and practical knowledge. As the information herein is of a general
RESPONSIBILITY nature, no assumption can be made as to a product's suitability for a particular use or application and no warranty
(Disclaimer) 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.
® = registered trademark of BASF group in many countries
Field service where provided does not constitute supervisory responsibility. Suggestions made by BASF
NOTE Construction Chemicals either orally or in writing may be followed, modified or rejected by the owner, engineer or
contractor since they, and not BASF Construction Chemicals, are responsible for carrying out procedures
appropriate to a specific application.

BASF India Limited

Construction Chemicals Division
Plot No.37, Chandivali Farm Road, Chandivali, Andheri(East)
Mumbai - 400072 India
Tel: +91 2228580200, Fax: +91 2228478381
e-mail: construction-india@basf.com www.master-builders-solutions.basf.in
 BASF
The Chemical Company

MasterEmaco® 5 348 (formerly known as Emaco S48C T)

Dual shrinkage compensated, trowelable fibre reinforced thixotropic repair mortar

• Mixing water per 25kg bag Approx.3.75 - 4.25 litres

MasterEmaco S 348 trowelable mortar is a dual Application Temperature
shrinkage compensated, thixotropic high strength substrate +5 to +40°C
formulation for structural concrete repairs.
MasterEmaco S 348 is suitable for placing in
thicknesses of 12mm to 50 mm both vertically and
overhead.
material

. .. .
Surface preparation
+5 to +30°C

MasterEmaco S 348 provides a durable, strong

All' loose traces of concrete or mortar, dust,
structural repair fully compatible with host
grease oil, etc. must be removed. Damaged or
concrete.
contaminated concrete shall be removed to obtain
a keyed aggregate exposed surface. Non-impacU
MasterEmaco S 348 is the ideal material for vibrating cleaning methods, e.g. grit or high
vertical or horizontal structural repairs where the pressure water blasting are recommended. Cut
thickness of repair is more than 10-12 mm and the edges of the repair vertically to a minimum
use of hand or machine applied structural repair depth of 5 mm. Clean all exposed reinforcement
systems is required. Typical applications are: to a minimum grade of
SA 2 according to ISO 8501-1 / ISO 2944-4.
• Extensive repairs to beams, columns and other
Ensure back of rebar is also clean.
structural elements
Where reinforcing bars are corroded, cut back the

.
• Repair of structural members subjected to
repetitive loading concrete to at least 20mm behind the reinforcing
bars. Grit blast to remove corrosion products from
:
around reinforcing bars and coat with
• Dual shrinkage compensated - volume stable MasterEmaco P 130 to protect from corrosion.
in wet and hardened state reducing cracking Replace the affected part of rebar if the diameter
tendency after grit blasting is found reduced by more than
• One component, factory made only addition 20% of the original diameter on the advice of the
of water - uniform predictable performance structural engineer responsible for the works.
even in remote situations Mixing
• No bonding agent required - simple Only full bags are mixed. Damaged or opened
installation bags should not be used. Mix MasterEmaco S
• Impermeable to aggressive elements - long 348 in a forced action pan mixer, or with a helical
life repairs paddle attached to a low speed (300-600rpm)
• Sprayable - able to repair complex profiles mixer for 3 minutes until a lump free, thixotropic
easily with minimal rebound consistency is achieved. Only use clean water.
• Fast and easy placing - reduced time for Mixing water needed: 3.75 to 4.25 litres per 25kg
repairs bag. Allow the mortar to rest for 2 - 3 minutes and
then remix briefly before applying. If more than
P.ROPERTIES:
, . " ,
30°C use chilled water as the mixing water.
Appearance Grey powder Priming Concrete
Water powder ratio 0.16
No special primer is required. To obtain extra
strong bonding, the damp substrate can be primed
Compressive strength 15 MPa 1 Day with a slurry brush coat of MasterEmaco S 348 (2
(ASTM C1 09 7cm cube) parts powder to 1 part water).
25 MPa 3 Days
35 MPa 7 Days Mortar application
45 MPa 28 Days The minimum temperatures must be maintained
3
during application and for at least 24 hours
Density Approx. 2250kg/m thereafter for optimum curing of the product. The

MASTER®
»BUILDERS
c:; 'L' lv',.
 -BASF
The Chemical Company

MasterEmaco® S 348 (formerly known as Emaco S48CT)

prepared substrate should be pre-soaked, datasheets.

preferably for 24 hours, but at least 2 hours before
applying MasterEmaco S 348. The surface must
be saturated surface dry, but without standing MasterEmaco S 348 should be cured with
water. MasterEmaco S 348 can be spray- or MasterKu re 181 or clear polythene sheeting over
hand-applied. Apply mixed product directly to the wet hessian.
prepared damp substrate, or wet on wet onto the i .'
~"E.STIPJ1AnNGDAT~,
'JI'-' ,~." ,., 'I', .
.r-" '~l~.1:~ .~,; 1',1" .. ' . •
primed surface. Spraying the material with the
Each bag of MasterEmaco S 348 when mixed
necessary pressure will ensure good adhesion of
the material. with 4.0L of water yields 12.8L.
A thin scrape coat or contact layer before building
up to the required thickness, wet on wet, will MasterEmaco S 348 is available in 25kg bags.
improve adhesion especially in case of hand
application. Apply to the desired layer thickness of
12 to max 50 mm and level using a screeding bar, MasterEmaco S 348 has a shelf life of 6 months.
trowel or wooden board. Can be applied in thicker Store out of direct sunlight, clear of the ground on
layers in smaller patches or where additional pallets protected from rainfall.
reinforcement is present. Smoothing with a trowel PRECAUTIONS
or finishing by float or sponge can be done as For the full health and safety hazard information
soon as the mortar has begun to stiffen. and how to safely handle and use this product,
Protective coatings please make sure that you obtain a copy of the
Subsequent coatings of MasterProtect anti BASF Material Safety Data Sheet (MSDS) from
carbonation barriers or silane impregnations our office or our website.
should be applied as recommend on the individual

MasterEmacoS 34810110313
The technical information and application advice given in this BASF Construction Chemicals publication are based
STATEMENT OF on the present state of our best scientific and practical knowledge. As the information herein is of a general
RESPONSIBILITY 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.
(Disclaimer) The user is responsible for checking the sUitability of products for their intended use.
® = registered trademark of BASF group in many countries
Field service where provided does not constitute supervisory responsibility. Suggestions made by BASF
NOTE Construction Chemicals either orally or in writing may be followed. modified or rejected by the owner, engineer or
contractor since they. and not BASF Construction Chemicals, are responsible for carrying out procedures
appropriate to a specific application.

BASF India Limited

Construction Chemicals Division
Plot No.37, Chandivali Farm Road, Chandivali, Andheri(East)
Mumbai - 400072 India
Tel: +91 2228580200, Fax: +91 22 28478381
e-mail: construction-india@basf.com www.master-builders-solutions.basf.in
 BASF
The Chemical Company

MasterEmaco® 5 488 (formerly known as Emaco S88e T)

Dual shrinkage compensated, trowelable fibre reinforced thixotropic repair mortar

Substrate +5 to +40°C

MasterEmaco S 488 trowelable mortar is a dual material +5 to +30°C

shrinkage compensated, thixotropic high strength Mixing water per 25kg bag Approx. 3.25 - 3.75
formulation for structural concrete repairs. litres
MasterEmaco S 488 is suitable for placing in Compressive strength 20 MPa 1 Day
thicknesses of 12mm to 50 mm both vertically and' (ASTM C1 09 7cm cube)
50 MPa 3 Days
overhead.
60 MPa 7 Days
MasterEmaco S 488 provides a durable, strong
structural repair fully compatible with host 70 MPa 28 Days
concrete. Flexural Strength >9 MPa @ 28 days
l'J I I (ASTM C348)
MasterEmaco S488 is the ideal material for Tensile Strength >4 MPa @ 28 days
vertical or horizontal structural repairs where the (ASTM C496)
thickness of repair is more than 12mm and use of
Resistivity approx. 125000cm
hand or machine applied structural repair systems
is required. Typical applications are: Water penetration <5mm
• Extensive repairs to beams, columns and other Coefficient of Oxygen 2.58 x 10'8

•
structural elements.
Repair of structural members subjected to
repetitive loading.
Repairs to piers, navigation locks, dams
diffusion

, .. .
Surface preparation
seawalls and other marine structures All loose traces of concrete or mortar, dust, grease
• Repairs to bridges, tunnels, garages, silos etc oil, etc. must be removed. Damaged or
,I : contaminated concrete shall be removed to obtain
a keyed aggregate exposed surface. Non-impact!
• Dual shrinkage compensated - Volume stable vibrating cleaning methods, e.g. grit or high
in wet and hardened state reducing cracking pressure water blasting are recommended. Cut the
tendency edges of the repair vertically to a minimum depth
• One component, factory made only addition of 5 mm. Clean all exposed reinforcement to a
of water - Uniform predictable performance minimum grade of Sa 2 according to ISO 8501-1 /
even in remote situations . ISO 2944-4. Ensure back of reinforcing bar is also
• No bonding agent required Simple clean.
installation
Where reinforcing bars are corroded, cut back the
• Impermeable to aggressive elements - Long concrete to at least 20mm behind the reinforcing
life repairs bars. Grit blast around the reinforcing bars to
• Sprayable - Able to repair complex profiles remove corrosion products and coat with
easily with minimal rebound MasterEmaco P 130 to give corrosion protection..
• Fast and easy placing - Reduced time for

.. ­
Replace the affected part of rebar if the diameter
repairs after grit blasting is found reduced by more than
.- 20% of the original diameter on the advice of the
structural engineer responsible for the works.
Appearance Grey powder Mixing
Water powder ratio 0.14 Only full bags are mixed. Damaged or opened
bags should not be used. Mix MasterEmaco S
Density Approx. 2300 kg/m3 488 in a forced action pan mixer, or with a helical
Application temperature paddle attached to a low speed (300-600rpm)
mixer for 3 minutes until a lump free, thixotropic

MASTE ®
»BUI DERS
TI f
 BASF
The Chemical Company

MasterEmaco® 5 488 (formerly known as EmacoS88CT)

consistency is achieved. Only use clean water. thicker layers in smaller patches or where
Mixing water needed: 3.25 to 3.75 Iitres per 25kg additional reinforcement is present. Smoothing
bag. Allow the mortar to rest for 2 - 3 minutes and with a trowel or finishing by float or sponge can be
then remix briefly before applying. If the done as soon as the mortar has begun to stiffen.
temperature is more than 30°C then use chilled Protective coatings .
water for the mixing water.
Subsequent coatings of MasterProtect anti­
Priming Concrete carbonation barriers, or silane impregnations
No special primer is required. To obtain extra should be applied as recommend on the individual
strong bonding, the damp substrate can be primed datasheets.
with a slurry brush coat of MasterEmaco S 488 (2
parts powder to 1 part water).
MasterEmaco S 488 should be cured with
Mortar application
MasterKure 181 or clear polythene sheeting over
The minimum temperatures must be maintained wet hessian.
during application and for at least 24 hours
thereafter for optimum curing of the product. ESTIMATING DATA
The prepared substrate should be pre-soaked, Each bag of MasterEmaco S 488 when mixed
preferably for 24 hours, but at least 2 hours before with 3.5L of water yields 12.4L.
applying MasterEmaco S 488 The surface must
be saturated surface dry, but without standing
MasterEmaco S 488 is available in 25kg bags.
water. MasterEmaco S 488 can be spray or hand
applied. Apply mixed product directly to the
prepared damp substrate, or wet in wet onto the MasterEmaco S 488 has a shelf life of 6 months.
primed surface. Spraying the material with the Store out of direct sunlight, clear of the ground on
necessary pressure will ensure good adhesion of pallets protected from rainfall.
the material.
A thin scrape coat or contact layer before building ,
------------..
",0. ..~ ~

up to the required thickness, wet on wet, will For the full health and safety hazard information
improve adhesion especially in case of hand and how to safely handle and use this product,
application. Apply to the desired layer thickness of please make sure that you obtain a copy of the
12 mm to max 50 mm and level using a screeding BASF Material Safety Data Sheet (MSDS) from
bar, trowel or wooden board. Can be applied in our office or our website.

MasterEmacoS488/01/0313

The technical information and application advice given in this BASF Construction Chemicals publication are based
STATEMENT OF on the present state of our best scientific and practical knowledge. As the information herein is of a general
RESPONSIBILITY 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.
(Disclaimer) The user is responsible for checking the suitability of products for their intended use.
® =registered trademark of BASF group in many countries
Field service where provided does not constitute supervisory responsibility. Suggestions made by BASF
NOTE Construction Chemicals either orally or in writing may be followed, modified or rejected by the owner, engineer or
contractor since they, and not BASF Construction Chemicals, are responsible for carrying out procedures
appropriate to a specific application.

BASF India Limited

Construction Chemicals Division
Plot No.37, Chandivali Farm Road, Chandivali, Andheri(East)
Mumbai - 400072 India
Tel: +91 2228580200, Fax: +91 22 28478381
e-mail: construction-india@basf.com www.master-builders-solutions.basf.in
 BASF
The Chemical Company

MasterFlo w® 718 (formerly known as Masterflow 918)

Non-shrink, cementitious grout for use in general civil engineering works

t
• ':l::.r•• -
MasterFlow 718 is a ready to use, non-shrink, Flowable
natural aggregate cementitious grout for use in
general civil engineering works. MasterFlow 718 Compressive strength
2
provides extended working life and high early and 1 day 20 N/mm
2
ultimate strengths. 3 days 35 N/mm
2
• • I 7 days 55 N/mm
2
28 days 65 N/mm
MasterFlow 718 is recommended for:
• stanchion baseplates and columns; Flexural strength (ASTM C
78) 28 days 9 MPa
prefabricated concrete panels and beams;
bridge bearing plates; Supply form Powder
• anchor bolts and bars; Colour Cement grey
underpinning; Water addition 16 %
patch repair works. Density (wet) 2.1 Kg/L
t :
Modulus of Elasticity 28 days >30 GPa
• High strength - provides good early and ultimate Pull out Bond strength 7 >17 MPa
strengths which ensure quick return to service days
and long term durability Bond Strength to concrete >2 MPa
• Non shrink - Hardens free of bleeding, 28 Days
settlement and drying shrinkage when placed at
Dynamic load resistance Condition of sample:
f10wable consistency
undamaged
• Flowable consistency - Ensures ccmplete filling
of even intricate voids often without the need for Compressive strength:
pumping and strapping Slightly higher
• Ample working' time - remains placeable - up to Specimen subjected to alternating loads of 5 and 25
1 hour - even at high ambient temperatures MPa at 300 cycles per minute and for 2000000 cycles
•

•
Dense, impermeable grout - Provides a good
watertight seal
Economical - Greater volumes of grout can be
_....
and then tested for compressive strength

'
........ _-_
.l~
......

MasterFlow 718 can be mixed to a f10wable or

--1
mixed and handled with less labour.
• Easy to use - requires no special miXing trowelable consistency. The quantity of water
equipment, it can be mixed in a pail using a grout required to produce a f10wable grout from a 25 kg
stirrer. bag is approximately 4.0 Iitres.
• No added chloride - Does not add to chloride Water addition may be affected by temperature
load on structure conditions on site. Trials are recommended to
determine the correct water requirement.
• Provides complete non shrink performance­
When tested in accordance with simulated MasterFlow 718 should be mixed using a suitable
Bedplate Technique. mixer. For f10wable conSistency, use a hand drill
and paddle for small works up to two bags at a
• Versatile- Can be placed from f10wable to
time and specialise grout mixers for larger volume.
trowelable consistency
Drum type mixers may not provide sufficient mixing
efficiency to derive the optimum performance from
the grout.
The correct volume of water should be added to
the mixer followed by the powder. Mixing should
continue until the grout has a smooth, lump free
appearance. This will normally be between 3 - 5
minutes after miXing has started.

MASTE ®
»BUILDE 5
:v ill .0:lS
 BASF
The Chemical Company

MasterF I0 w® 718 (Formerly known as Masterflow 918)

For best results, MasterFlow 718 should be used II '

within 30 minutes once mixed.
A 25 kg bag of MasterFlow 718 when mixed to a
The substrate should be properly prepared and f10wable consistency (Add 4.0 litres water) will
should be free from contamination, laitance and yield 13.2 litres grout.
loose material. Thoroughly saturate the substance
with water at least 2 - 3 hours prior to pouring the
grout. All free water ponding should be blown out MasterFlow 718 is packaged in 25 kg moisture
of the void just before pouring the grout. resistant bags.
As for all cementitious materials, curing is essential _r--------------,
to prevent rapid drying out of the grout and
shrinkage caused by the water loss. Curing should MasterFlow 718 has a shelf life of approximately 6
be effected by accepted methods such as curing months when stored in a cool dry place in
compounds, polythene sheet, wet hessian or water unopened sacks.
ponding.
If a shaped shoulder is required, it should be
•
For detailed Health, Safety and Environmental
formed before the grout has reached its final set. Recommendations, please consult and follow all
Carefully remove the formwork once the instructions on the product Material Safety Data
MasterFlow 718 is self-supporting and cut the Sheet (MSDS) from our office or our website.
shape of the shoulder with a trowel. Preferably the
shoulder should be cut to a 45° angle to minimise
stresses.

Clean tools and equipment with water before

MasterFlow 718 has hardened, otherwise
mechanical cleaning will be required.

MasterFlow 718/01/0313
The technical information and application advice given in this BASF Construction Chemicals publication are based
STATEMENT OF on the present state of our best scientific and practical knowledge. As the information herein is of a general
RESPONSIBILITY nature, no assumption can be made as to a product's suitability for a particular use or application and no warranty
(Disclaimer) 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.
Field service where provided does not constitute supervisory responsibility. Suggestions made by BASF
NOTE Construction Chemicals either orally or in writing may be followed, modified or rejected by the owner, engineer or
contractor since they, and not BASF Construction Chemicals, are responsible for carrying out procedures
appropriate to a specific application.

BASF India Limited

Construction Chemicals Division
Plot No.37, Chandivali Farm Road, Chandivali, Andheri(East)
Mumbai - 400072 India
Tel: +91 2228580200, Fax: +91 2228478381
e-mail: construction-india@basf.com www.basf-cc.co.in
 BASF'
We create chemi'stry

Masterlnject@ 1315
Low viscosity epoxy resin with long potlife for crack injection

Part A Part 8 Mixed

Masterlnject 1315 is a low viscosity epoxy resin Supply Form Liquid Liquid Liquid
based crack injection resin system long mixed Colour Clear Amber Pale
potlife designed for sealing cracks in concrete and Yellow
restoring its structural integrity.
Mix Ratio 77:23 pbw
•• Density (Mixed) 1.05kg/L
• Stabilised cracks in structural members
• Sealing of cracks from 0.1 mm to 10mm Application Temperature 15°C - 35°C
• Unfilled voids behind tiles or stone facades
• Bonding of steel plates to concrete

.
• Rapid structural repair of concrete Surface preparation
• Grouting dowels Remove all grease, oil, dust, residual curing
: compound, mould release agent or other
contaminant that could impair adhesion of the
• Solvent free -Low vac and non-shrink
injection ports. The injection ports should be applied
• Pre-proportioned packaging - No job site
over 6-10mm diameter holes drilled' at least 50­
errors
75mm into the concrete element. For deeper
• Low viscosity - Easy to inject into fine cracks
penetration deeper holes should be considered.
• High bond strength to concrete -Can restore Use MasterEmaco ADH 2200 to adhere the
the structural integrity of the concrete injection ports over the holes ensuring that the
• Cures hard at ,low temperatures -Wide adhesive does not block the drilled holes. Allow the
application range MasterEmaco ADH 2200 to cure before injecting.
• High heat deflection temperature - Suitable The ports should follow the crack at intervals of
for high ambient temperature environments 500mm or a maximum of 1m centres. Inject from the
• Can be applied for Wet and Damp Substrates lowest point or furthest point towards the centre
checking for resin coming out of the next hole along.
For detailed instructions on crack injection ask you
BASF representative for the "Masterlnject guide to
Mixed resin and hardener only crack injection".
Viscosity (25°C) <500 cps
Mixing
Proportion part kits accurately mixing only what can
Compressive Strength 65 MPa @ 1 day
(ASTM C579)
be used in Jess than 30 minutes. Thoroughly stir
70 MPa @ 7 days Part A, add Part B and blend thoroughly using a
Flexural strength (ASTM C 45 MPa @ 1 day slow speed mixer fitted with a suitable paddle.
6319 part 3)
55 MPa @ 7 Days
Tensile 18 MPa Cure time will vary depending on the ambient
strength(ASTMD638) temperature, quantity mixed and placed.
7days Masterlnject 1315 will have fully cured after 7 days
Pot life

Slant shear bond strength

50 minutes @ 25°C
30 minutes @ 40°C
>18 MPa (Concrete
at 23°C.

.' .
Usage will depend on the injection pressure and the
(ASTM C 882 @ 7 days) failure) size of the cracks and is impossible to estimate.
Bond strength >2.5 MPa (concrete
failure) Masterlnject 1315 comes in 1 litre and 4 litre kit
Tack free time 6.5 hours @ 25°C sizes
Meets the requirements of ASTM C881 Type 1 & 4
Grade 1 Class B & C
ASTER®
»BUILDERS
. :>L iTI
 BASF
We create chemistry

Masterlnject® 1315
make sure that you obtain a copy of the BASF
Material Safety Data Sheet (MSDS) from our office
Masterlnject 1315 can be stored in tightly closed or our website.
original containers for 12 months at moderate
temperature. Masterlnject 1315/0210718

•
For the full health and safety hazard information and
how to safely handle and use this product, please

The technical information and application advice given in this BASF Construction Chemicals publication are based on the present
STATEMENT OF 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
RESPONSIBILITY
expressed or implied is given otherthan those required by law. The user is responsible for checking the suitability of products for their
(Disclaimer)
intended use.
® = registered trademark of BASF group in many countries

NOTE Field service where provided does not constitute supervisory responsibility. Suggestions made by BASF Construction Chemicals
either orally or in writing may be followed, modified or rejected by the owner, engineer or contractor since they, and not BASF
Construction Chemicals, are responsible for carrying out procedures appropriate to a specific application.

BASF India Limited

Construction Chemicals Division
Plot.No.12,TTC Area
Thane Belapur Road,Turbhe
Navi Mumbai - 400705,lndia
Tel: +91 2267127600, Fax: +91 2267917358
E-mail: construction-india@basf.com. www.master-builders-solutions.basf.in
 Conbextra EP10 constructive solutions

High strength, epoxy resin grout

Uses Properties
Pot life 50 min.@2rC
Provides a free flowing grout, for use where physical properties
Density approx. 1050 kg/m 3
and chemical resistance of the hardened grout are of utmost
Tensile strength 20 N/mm 2 @ 7 days
importance. It is suitable for a wide range of heavy duty ap­
Flexural strength 40 N/mm 2 @ 7 days
plications including:
Compressive strength 45 N/mm 2 @ 1 day
• Underplate grouting to substantial structural elements. 60 N/mm 2 @ 3 days
80 N/mm 2 @ 7 days
• Base plate grouting in dynamic load situations such as Instructions for use
turbines and other reciprocating machinery.
Preparation
• Heavy industrial applications in steelworks, refineries chemi­
Underplate grouting
cal plants and electroplating works.
The unrestrained surface area of the grout must be kept to a
• Structural infill where very high strength is required.
minimum. Generally, the gap between the perimeter formwork
• Rail track applications, to support heavy cranes, or on and the plate edge should not exceed 75 mm on the pouring
transporter rails. side and 25 mm on the opposite side. Formwork on the flank

Advantages sides should be kept tight to the plate edge. Air pressure relief
holes should be provided to allow venting of any isolated high
• Excellent durability - high compressive, flexural and tensile spots.
strengths ensure a long working life.
Formwork
• Cost effective - high early strength gain promotes minimum
The formwork should be constructed to be leak proof as Con­
downtime and early commissioning of plant.
bextra EP1 0 is a free flow grout. This can be achieved by using
• User friendly - simple, full pack mixing to ensure that the foam rubber strip or mastic sealant beneath the constructed
performance characteristics are achieved. formwork and between joints.

• Versatile - suitable for a wide range of loading situations For free flow grout conditions, it is essential to provide a hydro­
including repetitive dynamic loads. static head of grout. To achieve this a feeding hopper shou1ld be
used - please consult your local Fosroc office for more details.
• Excellent in service performance - non-shrink capability
ensures full surface to surface contact. Foundation surface

Description This must be free from oil, grease, or any loosely adherent

Conbextra EP10 is a solvent free epoxy resin grout designed material. If the concrete surface is defective or has laitence, it

for grouting of gap widths of 0.25 to 10mm. It is an all liquid must be cut back to a sound base. Bolt holes or fixing pockets

system consisting of base and hardener. The components are must be blown clean of any dirt or debris.

supplied in the correct mix proportions designed for whole pack Base plate
mixing on site.
If delay is likely before placing steel base plates, it is recom­
Specification mended that the underside and edges are coated with Nitoprime

Where shown on the contract documents, the epoxy grout shall 25* to prevent rust formation and ensure bonding with the
Conbextra EP1 0 grout. All metal surfaces should be cleaned to
be Conbextra EP10 supplied by Fosroc. It shall provide good
general chemical resistance, and a 7 day compressive strength a bright finish ,in accordance with Swedish Standard SA 2Y. or
of at least 80 N/mm 2 . equal. Nitoprime 25 can be applied directly onto newly cleaned
steel surfaces even if they are damp.

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 Conbextra EP10

Mixing Estimating

The entire contents of the hardener can should be poured into Supply
the base container and mixed for 2-3 minutes or until uniform col­ Conbextra EP1 0 1 litre pack
our is achieved. Once mixed, the material must be used within Nitoprime 25 1 and 4 litre packs
the specified pot life (see under Properties). After this time, Nitoflor Sol 5 & 10 litre tins
unused material will have stiffened and should be discarded. Coverage
Note: Immediately prior to placement, all surfaces must be dry. Nitoprime 25 5.0 to 6.5 m 2/litre

Placing Storage

Ensure that the grout can be placed within its pot life. Continu­ When stored in warehouse conditions below 35°C, Conbextra
ous grout flow is essential. Sufficient grout must be available EP10 will have a shelf life of 12 months.
prior to starting and the time taken to pour a batch must be
Precautions
regulated to the time taken to prepare the next one. Pouring
should be from one side of the void to eliminate air entrapment. Health and safety
The hydrostatic head must be maintained at all times so that a
Some people are sensitive to epoxy resin so gloves and a
continuous grout front is achieved.
barrier cream. Work or similar should be used when handling
Cleaning these products. If contact with the resin occurs, it must be
removed before it hardens with a resin removing cream. Fol­
All tools and equipment should be cleaned immediately after
low by washing with soap and water. Do not use solvent.
use with Nitoflor Sol*.
The use of goggles is recommended but should accidental
Hot weather working eye contamination occur, wash thoroughly with plenty of clean
water and seek medical treatment immediately.
Whilst the performance of Conbextra EP1 0 at elevated tempera­
tures is assured, application under such conditions can some­ Fire
times be difficult. It is therefore suggested that, for temperatures Nitoprime 25 and Nitoflor Sol are flammabl'e.
above 35°C, the following guidelines are used:
Flash points
(i) Store unmixed materials in a cool (preferably temperature Nitoprime 25 39°C
controlled) environment, avoiding exposure to direct sun­ Nitoflor Sol 33°C
light.
Additional Information
(ii) Keep mixing and placing equipment cool, arranging shade
protection if necessary. It is especially important to keep Fosroc manufactures a wide range of complementary products
cool those surfaces of the equipment which will come into which include:
direct contact with the material itself.
• waterproofing membranes & waterstops
(iii) Try to eliminate application in the middle of the day, and
• joint sealants & filler boards
certainly avoid application in direct sunlight.
• cementitious & epoxy grouts
(iv) Ensure that there are sufficient operatives available to
complete application within the material's pot life. • specialised flooring materials

Lim itations

Grouts should not be placed in any unrestrained situation,

i.e. base plate plinths, etc. Failure to comply may lead to
crack development in the grout.

constructive solutions page 2 of3

Conbextra EP10

Fosroc additionally offers a comprehensive package of prod­

ucts specifically designed for the repair and refurbishment of
damaged concrete. Fosroc's 'Systematic Approach' to concrete
repair features the following:

• hand-placed repair mortars

• spray grade repair mortars

• fluid micro-concretes

• chemically resistant epoxy mortars

• anti-carbonation/anti-chloride protective coatings

• chemical and abrasion resistant coatings

For further information on any of the above, please consult your

local Fosroc office - as below.

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
"Sapthagiri Palace", No.38,
II & III Floor, 12th Cross, ++91 80-42521900 ++91 80-23551510 enquiryindia@fosroc.com
CBI Road, Ganganagar North,
8angalore 560 024

Regional Offices

Chennai Mumbai Naida Kalkata

No. 26(01d no.33), 1st Floor, 1401/1402, 14th Floor, 0-166 Sector 10 304, Jodhpur Park
1st Street Postal Colony, A-Wing'The Great Eastern Summit' Dist. Gautam Budha Nagar, Kolkata 700 068
West Mambalam, Sector-15, CBD, Belapur Noida, Ph:033-65343188
Chennai 600 033. Navi Mumbai 400 614 UP 201 301 Fax: 033-2499-0280
Ph: 044-24899949-94 Ph: 022-43406800-04 Ph:0120-4270620-21
Fax: 044-24896641 Fax: 022-27562423 Fax: 0120-4270622

www.fosroc.com

page 3 of3 INDIA/2014/0314/A

 Conbextra GP2 constructive solutions

Free flow, high strength, non-shrink,

cementitious precision grout

Uses Properties
Compressive strength: (BS 1881 - Part 116: 1983)
Conbextra GP2 is used for precision grouting where it is essential
Compressive strength (N/mm')
to withstand static and dynamic loads. Typical applications would
Age (days) Consistency
be the grouting of base plates of turbines, compressors, boiler
Flowable (W/P 0.18) Pourable (W/P 0.165)
feed pumps etc., It can also be used for anchoring a wide range
1 24 27
of fixings. These include masts, anchor bolts and fence posts.
3 45 54
7 55 66
Advantages 28 65 78
• Gaseous expansion system compensates for shrinkage Compressive strength with addition of aggregates
and settlement in the plastic state Age Compressive strength (N/mm') W/P 0.18
(days) % of aggregates ( IS 516 - 1959)
• No metallic iron content to cause staining 50% 75% 100%
• Pre-packed material overcomes onsite batching variations 1 28 30 32
3 50 52 55
• Develops high early strength without the use of chlorides 7 60 63 68
• High ultimate strength ensure the durability of the hardened 28 70 75 78
grout Flexural strength ( BS 4551, 1998)

• Free flow ensures high level of contact with load bearing Age Flexural strength (N/mm')
area (days) W/P 0.18

1 2.5
Description 3 7.0
7 9.0
Conbextra GP2 is supplied as a ready to use dry powder. The
28 10.0
addition of a controlled amount of clean water produces a free
flowing, non-shrink grout for gap thicknesses up to 100mm. Tensile strength 3.5N/mm' @ 28 days
(W/P-0.18)
Conbextra GP2 is a blend of Portland cement, graded fillers
and chemical additives which impart controlled expansion in the Pullout bond strength 17 N/mm' @ 7 days
plastic state whilst minimising water demand. The low water (W/P-0.18) 20 N/mm' @ 28 days
demand ensures high early strength. The graded fillers are
Time for expansion Start : 20 minutes
designed to assist uniform mixing and produce a consistent
(after mixing) Finish: 120 minutes
grout.
Freshwet density Approximately 2220kg/m 3
Technical support depending on actual
consistency used
An experienced technical advisory team is available to give
technical service on request. Young's modulus 28 kN/mm 2
(ASTM 0469 - 94)

Dynamic load resistance Specimens of Conbextra GP2

remained undamaged even
after subjecting them to
alternate loads of 5N/mm 2 &
25N/mm 2 at the rate of 500
cycles / minute for two million
cycles.

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o page 1 of 4
 Conbextra GP2

Coefficient of thermal expansion 11 x 10 -6/oC The compressive strength of the grout must exceed 50 N/mm 2
Unrestrained expansion 2 - 4 % in the plastic at 7 days and 60 N/mm 2 at 28 days.
state enables to
The flexural strength of grout must exceed 9N/mm 2 @ 28 days.
overcome shrinkage.
The freshwetdensity ofthe mixed grout must exceed 2150 kg/m 3 .
Pressure to restrain 0.004 N/mm 2 approx.
Flow characteristics: The maximum distance of flow is The storage, handling and placement of the grout must be in
governed by the gap width and the head of the grout. Typical strict accordance with the manufacturer's instructions.
data for flow design assuming grout is poured immediately Application instructions
after mixing is given in the table below:
Preparation
Grout Max. flow distance in mm
Foundation surface
consistency Gap width 50mm 100mm 250mm
(mm) head head head The substrate surface must be free from oil, grease or any
loosely adherent material. If the concrete surface is defective
Flowable 30 350 1000 1500
or has laitence, it must be cut back to a sound base. Bolt holes
40 500 1500 2000
and fixing pockets must be blown clean of a':!y dirt or debris.
50 900 2000 3000+
Pre-soaking
Note: This table is based on the following factors temperature
- 30°C; Water saturated substrate; Minimum unrestricted flow Several hours prior to placing, the concrete substrates should
width is 300mm. be saturated with fresh water.

Immediately before grouting takes place any free water should

Specification Clauses
be removed with particular care being taken to blowout all bolt
Performance specification holes and pockets.

All grouting shown on the drawing must be carried out with a Base plate
pre packed cement based product which is chloride free.
It is essential that this is clean and free from oil, grease or scale.
It shall be mixed with clean water to the required consistency. Air pressure relief holes should be provided to allow venting
The grout must not bleed or segregate. of any isolated high spots.

A positive volumetric expansion shall occur while the grout is Levelling shims
plastic by means of gaseous system.
If these are to be removed after the grout has hardened, they
Typical detail of stanchion base plate should be treated with a thin layer of grease.

Formwork
~~6U:'...0t'4:y C.O::;,H ~l ~::Jf,l DIJO~.Nu
tor flr-~J o:ldJ e:trnon' r"f 1Mi"::'
~t.-:~p'l.·.: I-:?r",. pr;,;}.~ I.t) gr'(luhi)~) The formwork should be constructed to be leakproof. This
can be achieved by using foam rubber strip or mastic sealant
Pr f::5l<Jri
~Jrou~
beneath the constructed formwork and between joints.
~"'~:Of\13
"t3';Jol
In some cases it is practical to use a sacrificial semi-dry sand
and cement formwork. The formwork should include outlets
for pre-soaking.

<":hnmtt';:At t4f1oct"l,<}{ I

c( p.fc.-oloton- 't]fClt.lt
.., (1t1"5.tt::t"g~)

constructive solutions page 20f4

 Conbextra GP2

Unrestrained surface area

This must be kept to a minimum. Generally the gap width Any bolt pockets must be grouted prior to grouting between the
between the perimeter formwork and the plate edge should substrate and the base plate.
not exceed 150mm on the pouring side and 50mm on the op­
posite side. It is advisable, where practical, to have no gap Continuous grout flow is essential. Sufficient grout must be
at the flank sides. prepared before starting. The time taken to pour a batch must
be regulated to the time to prepare the next one.
Mixing and placing
Typical hopper system
Mixing
Removable hopper: For large pours the grout may be hand
For best results a mechanically powered grout mixer should placed or pumped into a removable hopper (trough)
be used. When quantities up to 50kg are used, a heavy duty
slow speed drill (400-500 rpm) fitted with a paddle is suitable..
Larger quantities will require a heavy duty mixer.
20mm thick plywood
and formers
To enable the grouting operation to be carried out continu­
ously, it is essential that sufficient mixing capacity and labour
50 x 75 mm timber
are available. The use of a grout holding tank with provision bolted to substrate

to gently agitate the grout may be required.

Consistency of grout mix

The quantity of clean water required to be added to a 25kg bag

to achieve the desired consistency is given below:

Pourable 4.125 litres

Flowable 4.5 Iitres 50 -100 mm

The selected water content should be accurately measured

into the mixer. The total content of the Conbextra GP2 bag Pouring should be from one side of the void to eliminate any air
should be slowly added and continuous mixing should take or presoaked water becoming trapped under the base plate. It
place for 5 minutes. This will ensure that the grout has a is advisable to pour the grout across the shortest distance of
smooth even consistency. travel. The grout head must be maintained at all times so that
Placing a continuous grout front is achieved.

At 30 DC place the grout within 20 minutes of mixing to gain Where large volumes have to be placed Conbextra GP2 may
full benefit of the expansion process. be pumped. A heavy duty diaphragm pump is recommended
for this purpose. Screw feed and piston pumps may also be
Conbextra GP2 can be placed in thicknesses up to 1OOmm in suitable.
a single pour when used as an underplate grout.
Curing
For thicker sections it is necessary to fill out Conbextra GP2
with well graded silt free aggregate to minimise heat build up. On completion of the grouting operation, exposed areas should
Typically a 10mm aggregate is suitable. 50 - 100% aggregate be thoroughly cured. This should be done by the use of Con­
by weight of Conbextra GP2 can be added. cure WB curing membrane, continuous application of water
and/or wet hessian.

constructive solutions page 3 of4

 Conbextra GP2

Limitations Storage
Low temperature working Shelf life

When the air or contact surface temperatures are 1QOC or below Conbextra GP2 has a shelf life of6 months if kept in a dry store
on a falling thermometer, warm water ( 30 - 40°C) is recom­ in sealed bags. If stored in high temperature and high humidity
mended to accelerate strength development. locations, the shelf life may be reduced.
Precautions
For ambient temperature below 10°C the formwork should be Health and Safety instructions
kept in place for at least 36 hours.
Conbextra GP2 is alkaline and should not come into contact
Normal precautions for winter working with cementitious materi­ with skin and eyes. Inhalation of dust during mixing should
als should then be adopted. be avoided.
High temperature working
Gloves, goggles and dust mask should be worn.
At ambient temperatures above 40° C, cool water ( below 20°C)
should be used for mixing the grout prior to placement. If contact with skin occurs, it shall be washed with water.
Splashes to eyes should be washed immediately with plenty
Estimating of clean water and medical advice sought.
Packaging
Fire
Conbextra GP2 is supplied in 25 kg moisture resistant bags.
Conbextra GP2 is non flammable.
Yield
Additional information
Allowance should be made for wastage when estimating quanti­
For further details about the use and selection of grouts refer
ties required. The approximate yield per 25 kg bag for different
to the Fosroc Information module entitled 'Precision grouting
consistency is :
in the Construction industry'.
Consistency Pourable Flowable

Yield ( litres) 12.5 13.3

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
"Sapthagiri Palace", No.38,
II & III Floor, 12th Cross, ++91 80-42521900 ++91 80-23551510 enquiryindia@fosroc.com
CBI Road, Ganganagar North,
Bangalore 560 024

Regional Offices

Chennai Mumbai Naida Kalkata

No. 26(01d no.33), 1st Floor, 1401/1402, 14th Floor, 0-166 Sector 10 304, Jodhpur Park
1st Street Postal Colony, A-Wing'The Great Eastem Summit' Dis\. Gautam Budha Nagar, Kolkata 700 068
West Mambalam, . Sector-15, CBD, Belapur Noida, Ph:033-65343188
Chennai 600 033. Navi Mumbai 400 614 UP 201 301 Fax: 033-2499-0280
Ph: 044-24899949-94 Ph: 022-43406800-04 Ph:0120-4270620-21
Fax: 044-24896641 Fax: 022-27562423 Fax: 0120-4270622

www.fosroc.com

page 4 of4 INOIAl201410306lA

Nitobond AR constructive solutions
---------'---.--------------------------------r----,
Acrylic emulsion cement modifier and water
based concrete bonding agent

Uses Specification clauses

Recommended primer for Fosroc cementitious repair system, As a bonding agent

For improving and bonding floor toppings, renders and mortars;
The bonding agent shall be Nitobond AR an acrylic based
repair of worn, damaged or spalled concrete; polymer modified
emulsified solution containing a minimum of 43% solids and
floor screeds.
compatible with cementitious materials, The bonding agent
Advantages shall provide adequate bond strength when directly applied on
concrete and also mixed with neat cement
Simply brush onto concrete as a primer. Single component,
gauged as required, As a mortar modifier

• High adhesion -Provides excellent bond to concrete, The mortar modifier shall be Nitobond AR, an acrylic emulsi­
masonry, stone work plaster and block board. fied cement modifier which provides good bond with concrete
/ masonry and improves the flexural strength, tensile strength
• Increased strength- Improves tensile and flexural properties
properties of the mortar when added in the specified quanti­
of mortar. Allows thin section applications,
ties, It shall be compatible with all common hydraulic cements,
• Versatile - Compatible with all common hydraulic
App1lication instructions
cements
Surface Preparation
• Economical- Economical to use
The object of the surface preparation is to achieve a clean
Description
sound surface with a good mechanical key, All substrates
Nitobond AR is a modified acrylic emulsion specially designed should be cleaned and free of dust, plaster, oil, paint, grease,
for use as a bonding aid and gauging liquid for cementitious corrosion deposits, and any other deleterious substances, Lait­
systems. It is resistant to hydrolysis and can therefore be used ence should be removed by mechanical means, Oil or greasy
for external applications, deposits should be removed by suitable means. All surfaces so
treated should be ,thoroughly washed with clean water. Smooth
Nitobond AR is the recommended primer for the Fosroc ce­
substrates must be mechanically roughened e,g, by scabbling,
mentitious repair system,
needle gun or griU sand blasting to provide a mechanical key.
Technical support
Concrete repairs: Remove all surface dust and debris. Any
Fosroc offers a technical support service to specifiers, end us­ reinforcing steel in the repair area should be exposed around
ers and contractors, as well as on-site technical assistance in its full circumference and cleaned to remove all loose scale
locations all over the country. and corrosion deposits and then primed with Nitozinc Primer.

Properties Priming

Specific gravity : 1.025 to 1.04 g/cc Immediately before priming, the concrete substrate should
be thoroughly dampened with water and any excess being
Mechanical properties
brushed off, Scrub Nitobond AR into the substrate. Avoid
Typical improvements in mechanical properties of a 3 : 1 ce­ pudding of the emulsion. The repair mortar/topping should be
ment mortar /sand using Nitobond AR. applied whilst the primer is still tacky. The bond coat becomes
tacky in about 2 minutes and best results are achieved if the
Mechanical properties Curing Control Nitobond AR
mortar is applied within the next 5-10 min
conditions
In case of Nitobond AR slurry coat (1 volume of Ntiobond AR +
Adhesion to concrete Dry 5.0 20.0
1,5 volume of water + 1,5 volume of cement), best results are
Slant shear strength
achieved, if mortar is applied within 5 minutes of application
N/mm 2 ( BS 6319)
of bond coat

page 1 of 3
 Nitobond AR

Typical Mix designs to modify mortars: Equipment cleaning

OPC 50 kg Immediately after use, wash all tools with clean water.

Zone 2 sand 150 kg Estimating

NitobondAR 8 - 10 litres Packaging

Water Add sufficient water to Nitobond AR is supplied in 1, 5 and 20 litre plastic containers.
give required consistency
Coverage
Note: Trials are recommended to optimise mix designs. 1:4
Approximately 6 - 8m 2/ litre depending on substrate
cement sand mortars can also be used with same dosage of
Nitobond AR. Storage
General recomme'ndations Shelf life

For repairs 12 months at 30°C. NitobondAR should be protected from frost.

Prepare surfaces thoroughly as previously recommended Cut Precautions

back edges to avoid feather edging. Prime all surfaces including
Health & Safety instructions
edges, using Nitobond AR.
Nitobond AR is non toxic. However it should never be ingested
All, applications shall be wet on wet. For best results Nitobond
and if it comes in contact with eyes, wash immediately with
AR should be allowed to become tacky. If the bonding agent is
plenty of water and seek medical treatment.
allowed to dry for more than 15 minutes at 30° C initial 'grab' to
the repair mortar will be reduced. Therefore, the use of tempo­ Nitobond AR is slightly alkaline. Skin contact should be
rary shuttering is recommended. Water content of the mortar avoided. Gloves and protective clothing should be worn dur­
should be kept to the minimum necessary. ing application.

For consistent results, the use of clean, dry sand is recom­ Fire
mended. Where the use of wet sand is unavoidable, the quantity
Nitobond AR is non flammable.
of water to be added must be reduced.
Flash point: 48°C
Cure mortars using Nitobond AR to prevent rapid drying out.
Additional information
Protect uncured mortar from frost and rain. Do not retemper
mortar after initial set. Nitobond AR forms a part of the Fosroc concrete repair system.

Minimum application temperature for Nitobond AR is 10°C, but Fosroc manufactures a wide range of products specifically
the mortar should not be applied if the temperature is expected designed for repair and refurbishment of damaged reinforced
to fall. concrete. This includes hand-placed and spray grade repair
mortars, fluid micro concretes, chemical resistant epoxy mortars
For permanently immersed conditions consult Local Fosroc
and a comprehensive package of protective coatings. In addi­
office.
tion, a wide range of complementary products is available. This
Limitations includes joint sealants, water proofing membranes, grouting,
anchoring and specialised flooring materials.
As a bonding agent

Nitobond AR may exhibit less overlay time at higher tempera­

ture. In such cases as overlay mortar shall not be applied when
Nitobond AR is totally dry.

Nitobond AR when used as bonding agent cannot act as a

barrier coat against ingress of chloride ions from the substrate.

constructive solutions page 20f3

 Nitobond AR

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
"Sapthagiri Palace", No.38,
II & III Floor, 12th Cross, ++91 80-42521900 ++91 80-23551510 enquiryindia@fosroc.com
CBI Road, Ganganagar North,
Bangalore 560 024

Regional Offices

Chennai Mumbai Noida Kolkata

No. 26(01d no.33), 1st Floor, MBC Park, 12th floor, Office No.12B, Unit No. 601, Highway Tower-II 304, Jodhpur Park
1st Street Postal Colony, 'D' Block, Near G Corp/Hyper City A-13/2, 6th Floor, Sector- 62 Kolkata 700 068
West Mambalam, Kasarwadawali, Ghodbunder Road, Gautam Buddha Nagar, Ph:+91 33-65343188
Chennai 600 033. Thane (West) 400 615 Noida 201 309, Uttar Pradesh Fax: 033-2499-0280
Ph: +91 44 24899949-94 Ph: +91 2262296800 Ph: +91120 6121900
Fax: 044-24896641 Fax: 022 62296809

www.fosroc.com

page 30f3 INOIAl201710903lA

 Nitobond EP constructive solutions

Epoxy resin concrete bonding agent

Uses Properties

For bonding fresh wet cementitious materials to existing Specific gravity : 1.15 to 1.2 glee
cementitious surfaces. For use on horizontal surfaces or on
At 20 aC At 30 aC
vertical surfaces where mortar or concrete can be supported
by formwork. The long 'open' life makes it suitable for use Pot life 5 - 6 hrs 2 - 3 hrs
with formwork or where additional steel reinforcement has to
Full cure 7 days 5 days
be fitted. The product is ideal for roads, bridges, pavements,
loading bays and factories, building segment and for bonded Overlay time 10 hrs 6 hrs
or granolithic floor toppings. Nitobond EP is equally suited to
Compressive strength
internal and external applications.
BS 6319 Pt 2 @ 7 days 50 N/mm 2
Nitobond EP may also be used as part of a repair system where Flexural strength
a bonding agent is required or where the substrate is likely to
BS 6319 Pt 3 @ 7 days 35 N/mm 2
remain permanently damp or wet.
Tensile strength
Advantages
BS 6319 Pt 7 @ 7 days 20 N/mm 2
Nitobond EP can be applied by brush.
Shear strength
• More overlay time: Enables to place the concrete for longer BS 6319 Pt 4 @ 7 days 10 N/mm 2
period of time, without risk of delamination
Note:The typical physical properties given above are derived
• High bond strength: Bond strength is more than the
tensile strength of good quality concrete from testing in a controlled laboratory environment. Results
derived from testing field-applied samples may vary, dependent
• Barrier coat: Acts as a 'barrier coat' to the migration of
actual site conditions.
chloride ions from host concrete.
Specification clauses
• Can be applied on to dry or damp substrates
The bonding agent shall be Nitobond EP an epoxy based two
Description
component resin system prepacked in distinct colours to give
Nitobond EP is based on solvent free epoxy resins containing> visual evidence for proper mixing. The bonding agent should
pigments and fine fillers. It is supplied as a two part material remain in tacky state after application for a minimum period of
in preweighed quantities for ready onsite mixing and use. Col­ 5-6 hrs at 20°C & 2-3 hrs at 30°C 6. The product shall achieve
oured components - white base and green hardener - provide 50 N/mm 2 compressive strength, 20 N/mm 2 tensile strength,
visual evidence that adequate mixing is achieved. 35 Nfmm 2 flexural strength and 10 Nfmm 2 shear strength. The
Technical support adhesive bond to the concrete substrate shall exceed the tensile
strength of the host concrete.
The company provides a technical advisory service supported
by a team of specialists in the field. Application instructions

Preparation
Design Criteria
All surfaces to be treated must be firm, dust free and clean.
Nitobond EP is designed with an overlay time of 5-6 hrs at
All laintence should be removed by etching with Reebaklens
20 aC, 2-3 hours at 30 ac making it more suitable for use where
and wire-brushing. In some cases, the existing concrete must
additional steel reinforcement and formwork has to be fitted or
be chipped to a sound substrate. Where surfaces are con­
where temperature is high. The minimum application tempera­
taminated with oil or grease, this should be removed by using
ture for Nitobond EP is 10 aC. Consult the local Fosroc office
a strong industrial detergent or organic degreaser. Surface
for further information.
should be washed thoroughly with water and dried before the
application of Nitobond EP.

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page 1 of 3
 Nitobond EP

Mixing Cleaning

Care should be taken to ensure that Nitobond EP is thoroughly Nitobond EP should be removed from tools, equipment and mix­
mixed, The 'hardener' and 'base' components should be stirred ers with Nitoflor Sol immediately after use. Hardened material
separately before mixing to disperse any settlement. can only be removed mechanically,

The entire contents of the hardener can should be poured into Storage
the base container and the two materials thoroughly mixed
until a uniform colour is obtained, To facilitate application at Shelf life
temperatures below 10 DC the separate components should
12 months if stored under normal warehouse conditions below
be warmed in hot water to a maximum of 25 DC before mixing,
35 DC, in unopened containers,
Coating
Precautions
Where Nitobond EP is to be used as part of a repair system to Health and Safety
form a substrate/repair barrier, care should be taken to achieve
an unbroken coating, One coat should be applied and allow to Contact with skin and eyes should be avoided. Gloves should
gel. A second coat should be applied and used as the bonding be used when handling these products, If contact wiith the
coat. In some situations (e,g, sprayed concrete repairs) it may resin occurs, wash immediately with a strong detergent or a
be advantageous to scatter dust free sharp sand over this coat resin removing cream. Eye contamination must be immediately
and leave to harden, washed with plenty of water and medical treatment sought.

As soon as the Nitobond EP has been applied, any required Fire

steel reinforcement and/or formwork should be erected and

Nitobond EP is inflammable. No naked flame should be allowed
fixed securely in place.
near the site. Do not smoke during use,

Limitations Additional information

Nitobond EP should not be applied when the temperature is Fosroc manufactures a wide range of products specifi­
below 10DC. If any doubts arise concerning temperature or cally designed for the repair and refurbishment of damaged
substrate conditions, consult the local Fosroc office. reinforced concrete. This includes repair mortars, fluid
Estimating micro-concretes, chemical resistant epoxy mortars and a com­
prehensive package of protective coatings, In addition, a wide
Packaging range of complementary products are available. This includes
joint sealants, waterproofing membranes, grouts and anchors
Nitobond EP - 0.5,1 & 4 Litre packs
and specialised flooring materials.
Nitoflor Sol - 5 & 20 Litres
Separate datahsheets are available on these products.
Coverage

Nitobond EP - Approximately 2.6 m 2/litre.

Actual coverage will depend upon the texture and porosity of

the substrate being covered.

constructive solutions page 2 of3

 Nitobond 'EP

~ 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
Fos,roc Chemical1s 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
"Sapthagiri Palace", No.38,
II & III Floor, 12th Cross, ++91 80-42521900 ++91 80-23551510 enquiryindia@fosroc.com
CBI Road, Ganganagar North,
Bangalore 560 024

Regional Offices

Chennai Mumbai Noida Kolkata

No. 26(01d no.33), 1st Floor, MBC Park, 12th floor, Office No.12B, Unit No. 601, Highway Tower-II 304, Jodhpur Park
1st Street Postal Colony, '0' Block, Near G Corp/Hyper City A-13/2, 6th Floor, Sector- 62 Kolkata 700 068
West Mambalam, Kasarwadawali, Ghodbunder Road, Gautam Buddha Nagar, Ph:+91 33-65343188
Chennai 600 033. Thane (West) 400 615 Naida 201 309, Uttar Pradesh Fax: 033-2499-0280
Ph: +91 44 24899949-94 Ph: +91 22 6229 6800 Ph: +911206121900
Fax: 044-24896641 Fax: 022 62296809

www.fosroc.com

page 3 of3 INDIAl2018/0913/B

 Nitofill EPLV constructive solutions

Low viscous epoxy injection resin grout

Uses Exotherm

All epoxy products will develop a temperature rise on mixing.

Nitofill EPLV is used for injecting into cracks, honeycombs and
Its extent will be a function of the volume to surface ratio,
cavities in concrete structures. It can also be used for grouting
the ambient temperature as well as the mass and thermal
base plates with very narrow gaps ( <1 Omm).
conductivity of the surrounding materials. Fosroc shall be
Advantages contacted for specific data.

• Low viscosity - Can be injected into fine cavities and narrow Specification clauses
gaps. Performance specification

• High mechanical strength - Performs even under heavy All epoxy injection must be carried out with a two component
loads and stresses. low viscous epoxy resin system. The epoxy resin shall have
sufficiently low viscosity ( 150-300 cps) to ensure easy injection
• Exce(,lent adhesive strength - Good bonding with substrate
into cracks and voids. The epoxy injection grout shall develop
• Two part system - Easy to mix and handle a compressive strength exceeding 60 N/mm 2 @ 7days, tensile
strength exceeding 15 N/mm 2 and flexural strength exceeding
• Non shrink - Complete filling of voids and cracks
50N/mm 2 . The mixed epoxy shall have a pot life exceeding 30
• Chemical resistant -Can be used in aggressive environments. minutes @ 30°C.
Description Supplier specification
Nitofill EPLV is a two part system comprising of liquid base and A'II epoxy injection must be carried out using Nitofill EPLV
hardener. It is designed for injecting into narrow gaps, cracks manufactured by Fosroc and used in accordance with the
and voids ranging from 0.25mm to 9mm. manufacturer's datasheet.
Technical support
The storage, handling and placement of the grout must be in
Fosrocoffers a comprehensive range of high performance, high strict accordance with the manufacturer's instructions.
quality concrete repair and construction products. In addition,
Application instructions
Fosroc offers technical support service to specifiers, end- users
Surface preparation
and contractors, as well as on-site technical assistance in
locations all over the country. The area to be injected shall be cleaned to remove all loose
Properties material, laitence, grease and other deposits.
Drilling injection holes
The following results are typical forthe hardened grout at 30°C.
Injection holes of 8 -10mm dia shall be drilled at fixed interva,ls
Density (kg/m 3 ) 1100
along the crack length or in a grid pattern incase of grouting of
Compressive strength (N/mm 2 ) 10 3D 7D voids in concrete.
BS 6319 Part 2 45 60 70

Tensile strength (N/mm 2 )

The holes shall be cleaned to remove all dust and loose material
BS 6319 Part 7 (7 days) 18
by blowing compressed air.
Flexural strength (N/mm 2 )
Fixing Nipples
BS 6319 Part 4 (7 days) 55
Suitable injection nipples of GI/PVC shall be fixed in these
Pot life 60 minutes @ 20°C
holes using an epoxy sealing putty. The cracks shall also be
30 minutes @ 30°C
sealed with this product.
Chemical resistance
Injection of resin
Nitofill EPLV is resistant to oil, grease, fats, most chemicals, The two components of Nitofill EPLV injection grout shall be
mild acids and alkalis, fresh and sea water. Fosroc shall be individually stirred and then mixed and injected into the nipples
contacted when exposure to solvent or concentrated chemicals through a suitable injection pump exerting a uniform pressure.
is anticipated. Injection shall be carried out till it flows from the adjacent nipple
and then stopped. The same operation shall be carried out for
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the next nipple.

page 1 of2
 Nitofill EPLV

Precautions

After all the holes are completed, the nipples are removed next Health and Safety instructions
Nitofill EPLV contains resins which may cause sensitisation
day and the holes shall be sealed with a high strength mortar.
when comes in contact with skin. Contact with skin and
eyes and inhalation of vapour shall be avoided. Use of
Note: For grouting under base plates with very narrow gaps,
suitable protective clothing, gloves and eye/face protection
either injection grouting or normal grouting by pouring, can be
is recommended. Barrier creams provide additional skin
resorted to. For details, Fosroc shall be contacted.
protection. Should accidental skin contact occur, it shall be
Cleaning removed immediately with a resin removing cream, followed
by soap and water. Solvent should not be used. Incase of
All tools and equipment should be cleaned immediately after
contact with eyes, immediate rinsing with plenty of clean water
use with Nitoflor Sol. Spillages should be absorbed with sand is suggested and medical attention shall besought immediately
or sawdust and disposed in accordance with local regulations. - Vomiting should not be induced.

Estimating Fire

Packaging Nitoflor Sol is flammable. In the event of fire, use of fire

extinguishers like Carbon dioxide or foam is suggested.
Nitofill EPLV: 1 Litre pack
Flash point:
Storage
Additional information
Shelf life
The Fosroc range of associated products includes high strength
12 months in unopened container under normal warehouse cementitious epoxy grout, polyester resin based mortar for
condition. rapid presetting of steel shims to level or for direct bedding
of small base plates. Resin Anchoring systems for same day
anchoring of bolts in drilled holes in concrete or rock. Also
available a range of products for use in construction; viz.,
admixtures, curing compounds, mould release agents, flooring
systems and repair mortars. Separate datasheets are available
on these products.
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
"Saplhagiri Palace", No.38,
II & III Floor, 12th Cross, ++91 80-42521900 ++91 80-23551510 enquiryindia@fosroc.com
CBI Road, Ganganagar North,
Bangalore 560 024

Regional Offices

Chennai Mumbai Noida Kolkata

No. 26(01d no.33), 1st Floor, 1401/1402, 14th Floor, 0-166 Sector 10 304, Jodhpur Park
1st Street Postal Colony, A-Wing'The Great Eastern Summit' Dis!. Gautam Budha Nagar, Kolkata 700 068
West Mambalam, Sector-15, CBD, Belapur Noida, Ph:033-65343188
Chennai 600 033. Navi Mumbai 400 614 UP 201301 Fax: 033-2499-0280
Ph: 044-24899949-94 Ph: 022-43406800-04 Ph:0120-4270620-21
Fax: 044-24896641 Fax: 022-27562423 Fax: 0120-4270622

www.fosroc.com

page 20f2 INDIA/2014/0421/A

 Nitomortar 5 constructive solutions

High strength, abrasion - resistance epoxy

reinstatement mortar

Uses Properties

Nitomortar S is used for the fast and permanent reinstatement The following results were obtained at a temperature of 30°C
of concrete, particularly where high strength, abrasion - resist­ unless otherwise specified.
ance and resistance to chemicals is required. The product
Test method Typical result
is designed for horizontal use but can be applied vertically,
although generally in thinner sections. It is ideally suited for Compressive strength
acid tanks, sea walls, industrial floors and for use as a bedding (BS 6319, Pt 2) 60N/mm 2 @ 7 days
mortar. Nitomortar S can be used for emergency repairs where
Flexural strength
fast strength gain is important. When properly compacted, the
(BS 6319, Pt 3) 20N/mm 2 @ 7 days
mortar is highly impermeable.
Tensile strength
In certain instances, Nitomortar S can be used on metal sub­
(ASTM C 307) 1ON/mm 2 @ 7 days
strates. Contact the local Fosroc office for advice in this respect.

Advantages Pot life 20 mins @ 35°C

• High ultimate strength - Suitable for structural use Initial hardness 24 hours

• Early development of strength Minimises disruption Full cure 7 days

• Abrasion resistance - Suitable for heavy traffic areas Fresh wet density Approximately 2000kg/m 3
(fully compacted)
• Highly resistant - To a wide range of chemicals
Chemical resistance The low permeability of
• Will cure under damp conditions - Cured product is highly Nitomortar S retards chemical
impermeable to water attack in aggressive
• Typically twice as strong as good quality concrete environments.

• Pre-weighed components ensure consistency Performance of Nitomortar S blocks continually immersed at

20°C.
Description
Citric acid 10% Resistant
Nitomortar S is based on a high quality solvent-free epoxy resin
Tartaric acid 10% Resistant
system. The special silica aggregates provide high strength
and excellent abrasion resistance. Nitomortar S is a three ­ Hydrochloric acid 18% Resistant
component material supplied in pre-weighed quantities ready Sodium Hydroxide 50% Resistant
for on-site mixing and use.
Diesel fuel I Petrol 100% Resistant
Technical support
Sulphuric acid 10% Resistant
Fosroc offers a comprehensive range of high performance, high Sugar solutions Saturated Resistant
quality concrete repair and construction products. In addition,
Lactic acid 10% Resistant
Fosroc offers a technical support package to specifiers, end­
users and contractors, as well as on-site technical assistance Hydrocarbons 100% Resistant
in locations all over the country. Phosphoric acid 50% Resistant

Design criteria Nitric acid 10% Resistant

Acetic acid 5% Resistant

Nitomortar S can be applied in sections upto 50mm thickness
in horizontal locations and 12mm in vertical locations in a sin­
gle application and without the use of formwork. The material
should not be applied at less than 5mm thickness. Greater
thicknesses than those specified above can be achieved by
the application of subsequent layers. Larger areas should be
applied in a 'checker board' fashion. Local Fosroc office shall
UJ be contacted for further information.
~
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E
.2
~ p~e1~4
 Nitomortar 5

Specification clauses Substrate priming

High strength epoxy repair mortar The substrate should be primed using Nitoprime 25. The primer
should be mixed in the proportions supplied, adding the entire
The high strength repair mortar shall be Nitomortar S, a three
contents of the 'hardener' tin to the 'base'tin. The two com­
component epoxy resin with a density not greater than 2000
ponents should be thoroughly mixed together, for 3 minutes.
kg/m 3 . The cured mortar shall ach ieve a compressive strength
of 60 N/mm 2 , a flexural strength of 20 N/mm 2 and a tensile The mixed primer should be scrubbed well into the prepared
strength of 10 N/mm 2 when tested at 7 days. substrate, taking care that all imperfections in the surface are
properly coated and avoiding 'puddling' in depressions. If the
Application instructions
primer is absorbed within 30 minutes, a second coat should
Preparation be applied before continuing. Nitomortar S can be applied as
soon as the primer has started to gel but still has surface 'tack'.
Clean the surface and remove any dust, unsound material,
This is normally between 30 minutes and 4 hours dependent
plaster, oil, paint, grease, corrosion deposits or algae. Rough­
on the ambient and substrate temperatures. If the primer cures
en the surface and remove any laitance by light scabbling or
hard, a second application must be made before application of
grit blasting. Saw cut or cut back the extremities of the repair
Nitomortar S. The usable life of the mixed primer is approxi­
locations to a depth of at least 5mm to avoid featheredging
mately 60 minutes at 20°C or 30 minutes at 35°C.
and to provide a square edge. Break out the complete repair
area to a minimum depth of 5mm upto the sawn edge. Mixing

Oil and grease deposits should be removed by steam clean­ Care should be taken to ensure that Nitomortar S is thoroughly
ing, detergent scrubbing or the use of a proprietary degreaser. mixed to produce a fully homogenous, trowellable mortar.
The effectiveness of decontamination should then be assessed
The 'hardener' and 'base' components should be stirred
by a pull-off test.
thoroughly in order to disperse any settlement before mixing
Expose fully any corroded steel in the repair area and re­ them together. The entire contents of the 'hardener' container
move all loose scale and corrosion deposits. Steel should should then be emptied into the 'base' container and thoroughly
be cleaned to a bright condition paying particular attention to mixed for 3 minutes, then emptied into a forced action mixer of
the back of exposed steel bars. Grit blasting is recommended adequate capacity. Add the aggregate slowly with the mixer
for this purpose. running and continue for 2 to 3 minutes until all the components
are thoroughly blended. Under no circumstances should part
Reinforcing steel priming
packs be used.
The cleaned steel should be coated within 3 hours. Apply one
Application
full coat of Nitozinc Primer and allow to dry before continuing.
If any doubt exists about having achieved an unbroken coating, Apply the mixed Nitomortar S to the prepared substrate by wood
a second application should be made and, again. allowed to float, pressing firmly into place to ensure positive adhesion and
dry before continuing. full compaction. Thoroughly compact the mortar around any
exposed reinforcement. In restricted locations, or where ex­
posed reinforcing steel is present, application by gloved hands
is an acceptable alternative but, in all cases, the product must
be finished to a tight surface with a steel trowel. Nitomortar
S mortar can be applied in sections upto 50mm thickness in
horizontal locations or upto 12mm thickness in vertical loca­
tions in a single application and without the use of formwork.

constructive solutions page 2 of 4

Nitomortar 5

Cleaning

Nitozinc Primer, Nitoprime 25 and Nitomortar S should be re­

Thicker vertical sections may sometimes be possible depend­
moved from tools and equipment with Nitoflor Sol immediately
ent on the profile of the substrate and the volume of exposed
after use.
reinforcing steel but should generally be built up in layers, when
larger areas are being rendered, a checkerboard application Estimating
technique is recommended.
Packaging & Coverage
Note: The minimum applied thickness of Nitomortar S is
Packaging Coverage
5mm.
Nitomortar S 10 litre pack 2m 2
Buildup
@ 5 mm thickness
If sagging occurs during application, the Nitomortar S should
Nitoprime 25 1& 4 litre packs 5.5-6.5m 2/1itre
be completely removed and reapplied at a reduced thickness
on to the correctly rep rimed substrate. Nitoflor Sol 5 & 20 litre tins

Finishing Note: The coverage figures given above are theoretical due
to wastage factors and the variety and nature of possible sub­
Nitomortar S is finished by the use of a wood float and closed
strates, practical coverage figures will be reduced.
with a steel trowel. The completed surface should not be
overworked Storage

Over coating with protective / decorative finishes Shelf life

Nitomortar S is extremely durable and resistant to a wide range All products have a shelf life of 12 months at 30°C if kept in a
of acids, alkalis and industrial chemicals and will provide excel­ dry store in the original, unopened bags or packs.
lent protection to the concrete and embedded steel reinforce­
Storage conditions
ment within the repaired locations. The surrounding parts of
the structure may benefit from the application of a protective Store in dry conditions in the original. unopened bags or packs.
coating, thus bringing them up to the same protective standard If stored at high temperatures, the shelf life may be reduced
as the repair itself. Fosroc recommend the use of the Nitocote to 4 to 6 months.
range of epoxy resin, chemical resistant, protective coatings. Precautions
For surrounding areas not subjected to chemical attack or Health and Safety instructions
physical wear, Fosroc recommend the use of the Dekguard
range of anti-carbonation, anti-chloride protective coatings. Nitozinc Primer, Nitoprime 25, Nitomortar Sand Nitoflor Sol
These products provide a decorative and uniform appear­ should not come in contact with skin or eyes, or be swal­
ance as well as protecting areas of the structure which might lowed. Adequate ventilation shall be provided and inhalation
otherwise be at risk from the environment. of vapours shall be avoided. Some people are sensitive to
resins, hardeners and solvents. Suitable protective clothing,
Nitocote epoxy resin protective coatings should be applied
gloves and eye protection shall be worn. If working in confined
within 24 hours. Dekguard products should not be applied
areas, suitable respiratory protective equipment must be used.
until the Nitomortar S is at least 3 days old. For further advice,
The use of barrier creams provide additional skin protection.
consult the local Fosroc office.

constructive solutions page 3 of4

 Nitomortar 5

Additional information

In case of contact with skin, it shall be removed immediately Fosroc have produced several educational training videos which

with resin removing cream followed by washing with soap and provide more detail about the mechanisms which cause cor­
water. Solvent should not be used. In case of contact with rosion within reinforced concrete structures and the solutions
which are available to arrest or retard these destructive mecha­
eyes,it shall be rinsed immediately with plenty of clean water
and medical advice shall be sought. If swallowed, medical nisms. Further information is available from the publication

attention shalll be sought immediately - Vomiting should not 'Concrete Repair And Protection - The Systematic Approach'.
be used. For further information about products, training videos or pub­
Fire lications, contact the local Fosroc office.

Nitomortar S mortar is nonflammable.

Nitozinc Primer, Nitoprime 25, Nitoflor Sol are flammable. It

shall be kept away from sources of ignition. Smoking is prohib­
ited during handling / application of the product. In the event
of fire, use of fire extinguishers like carbon-dioxide or foam, is
suggested. Use of water jet is not suggested.

Flash points

Nitozinc Primer

Nitoprime 25

Nitoflor Sol

lDE! 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
·Sapthagiri Palace", No.38,
II & III Floor, 12th Cross, ++91 80-42521900 ++91 80-23551510 enquiryindia@fosroc.com
CBI Road, Ganganagar North, Ban­
galore 560 024

Regional Offices

Chennai Mumbai Naida Kalkata

No. 26(old no.33), 1st Floor, 1401/1402, 14th Floor, 0-166 Sector 10 304, Jodhpur Park
1st Street Postal Colony, A-Wing'The Great Eastern Summit' Dist. Gautam Budha Nagar, Kolkata 700 068
West Mambalam, Sector-15, CBD, Belapur Noida, Ph:033-65343188
Chennai 600 033. Navi Mumbai 400614 UP 201 301 Fax: 033-2499-0280
Ph: 044-24899949-94 Ph: 022-43406800-04 Ph:0120-4270620-21
Fax: 044-24896641 Fax: 022-27562423 Fax: 0120-4270622

www.fosroc.com

page 4 of 4 INDIA/2014/0415/A
 Nitoprime® 25 constructive solutions
---------_._--------------­
Epoxy resin based primer for concrete surfaces

Uses Old concrete floors

Nitoprime 25 is suitable for priming concrete surfaces prior Again, mechanical cleaning methods are strongly
to the application of any of the Nitoflor SL2000/4000, TS / TF recommended on old concrete floors, particularly where heavy
range of resin based floor toppings, Nitocote range of contamination by oil and grease has occurred or existing
protective coatings or Nitomortar range of epoxy repair coatings are present. These may well have been absorbed
mortars. several millimeters deep into the concrete. To ensure good
adhesion all contamination should be removed and the
Advantages surface thoroughly cleaned of all dust and loose debris. A
• Can be applied even on damp surfaces thorough detergent wash is also recommended followed by
.' Improves the adhesion of epoxy floor toppings and mortars thorough cleaning with clean water and mopping it off to a dry
with the substrate. state.

Mixing
Description
Add the entire contents of the hardener tin to the base and
Nitoprime 25 is a two component epoxy based primer with
mix thoroughly for 3 mins. until homogeneous, using a slow
good penetrating properties for concrete surfaces.
speed drill (400 - 500 rpm) fitted with a suitable mixing paddle.

Technical support Application

Fosroc provides a countrywide technical advisory service Once mixed the primer should be applied immediately in a
supported by a team of specialists in the field. thin continuous film to the clean prepared surface. Work the
primer into the surface using a stiff brush or roller. Excess
Properties application and puddling should be avoided, On porous
surfaces Nitoprime 25 will be absorbed very quickly leaving
characteristic light coloured dry patches. it is recommended
Pot life 90 mins 30 mins that a second priming coat be applied to these dry areas.
This not only helps to ensure good adhesion but also prevents
air release from the porous substrate which may cause
Application instructions bubbles in the final epoxy topping later.

Surface preparation
For Nitoflor SL2000 / 4000 applications, leave the NHoprime
Thorough surface preparation is vital. For best results Fosroc 25 to dry overnight. For Nitoflor TF, Nitomortar and Nitocote,
recommends mechanical preparation techniques. (For aUow the solvent in the Nitoprime 25 to evaporate and become
example, mechanical scarifying, grit-blasting, sand blasting). tacky. the relevant data sheets may please be referred to, to
For flooring and tanking works, care must be taken to ensure ensure this.
that the substrate does not suffer from rising dampness. If
such conditions exist, consult Fosroc. Limitations

New concrete floors Temperature limitations

Should be at least 28 days old or have a moisturecontent of Recommended application range is 10°C - 40°C. Fosroc
less than 5% before proceeding with epoxy application. shall be consulted where application or service is outside the
Laitance and deposits on new concrete floors are best range of 5°C to 40°C.
removed by light grit blasting, mechanical scabbling or
grinding. On smaller areas thorough etching using Estimating
Reebaklens may be considered. After etching the floor, it
Packaging and coverage
should be thoroughly washed with clean water and then
allowed to dry. Nitoprime 25 is available in 1 and 4 litre packs.

Coverage
Approximate coverage rate 5.5 - 6.5 m2 /ltr
 Renderoc® 52

Apply the mixed Renderoc S2 to the prepared substrate by Overcoating with protective decorative finishes
gloved hand or trowel. Thoroughly compact the mortar on to
the primed substrate and around the exposed reinforcement. Renderoc S2 is extremely durable and will provide excellent
Renderoc S2 can be applied from a minimum of 5mm to 15mm protection to the embedded steel reinforcement within the'
thickness in smaller pockets or with the use of form work. If repaired locations. The surrounding parts of the structure will
form work is used it should have properly sealed faces to ensure generally benefit from the application of a barrier/decorative
that no water is absorbed from the repair material. In horizontal coating to limit the advance of chlorides and carbon dioxide,
locations, Renderoc S2 can be applied up to 100mm thickness. thus bringing them up to the same protective standard as the
repair itself. Fosroc recommends the use of Dekguard range
If sagging occurs during application to vertical surfaces, the
of protective, anticarbonation coatings. These products be
Renderoc S2 should be completely removed and reapplied at
applied over the repaired area after removal of the curing
a reduced thickness on the correctly reprimed substrate.
membranes.
Renderoc S2 should not be applied as a render on large areas.
Cleaning
Note: The minimum applied thickness of Renderoc S2 is
5mm. Nitobond AR, Concure WB should be removed from tools,
Finishing equipment and mixers with clean water immediately after
use. Cured material can only be removed mechanically.
Renderoc S2 is finished by striking off with a straight edge and
Equipment used with Nitozinc primer and Nitobond EP should
closing with a wooden or plastic noats, or damp sponges may
be cleaned with Nitonor Sol.
be used to achieve the desired surface texture. The completed
surface should not be over worked. Limitations
Low temperature working
Renderoc S2 should not be used when the temperature is
In cold conditions down to 5°C, the use of warm water ( upto below 5°C and falling. The product should not be exposed to
30°C) is advisable to accelerate strength development. moving water during application. Exposure to heavy rainfall
Normal precautions for winter working with cementitious may result in the surface scour. The material should not be
materials should then be adopted. The material should not be applied on large continuous areas in single application as a
applied when the substrate and / or air temperature is 5°C and render. If any doubts arise concerning temperature or
rising, the application may proceed. substrate conditions, consult the local Fosroc office.

High temperature working Estimating

At ambient temperatures above 35°C, the material should be Packaging

stored in the shade and cool water used for mixing.

Curing Renderoc S2 Part A 25 kg Powder

Part B 1/4 kg polymer
Renderoc S2 is a cement based mortar. In common with all Nitozinc Primer 1 & 5 Iitres
cementitious materials, Renderoc S2 must be cured surface Nitobond AR 1,5 & 20 Iitres
of the finished Renderoc S2 in a continuous film, is Nitobond EP 1 & 4 L packs
recommended. Large areas should be cured as trowelling Nitoflor Sol 5 & 20 litres Cans
progresses ( 0.5m at a time) without waiting for completion of Concure WB 20 litres Cans
the entire area. In fast drying conditions, supplementary curing Coverage and Yield
with polythene sheeting taped down at the edges must be
used. In cold conditions, the finished repair must be protected Renderoc S2 Approximately 13.5 litres/
from freezing. 25 kg bag ( 1.30m2 at
10mm thickness )
Renderoc® 52

Nitozinc Primer 5 - 7 m 2 / litre contact with skin, rinse with plenty of clean water, then cleanse
Nitobond AR 6-8m 2 /litre with soap and water. Incase of contact with eyes, rinse
Nitobond EP 2.5 m 2 / litre immediately with plenty of clean water and seek medical
Concure WB 4 to 6 m 2 / litre advice. If swallowed seek medical attention immediately.
Do not induce vomiting.
Note: The actual yield per bag of Renderoc S2 will depend
on the consistency used. The coverage figures for liquid Nitozinc Primer, Nitobond products and Nitoflor Sol should
products are theoretical. Due to wastage factors and the not come in contact with the skin and eyes, or be swallowed.
variety and nature of possible substrates, practical coverage Ensure adequate ventilation and avoid inhalation of vapours.
figures may be reduced. Some people are sensitive to resin, hardeners and solvents.
Wear suitable protective clothing, gloves and eye protection.
Storage If working in confined areas, suitable respiratory protective
equipment must be used. The use of barrier cream provide
Shelf life additional skin protection. In case of contact with skin, rinse
with plenty of clean water, then cleanse with soap and water.
Renderoc S2 has a shelf life of 6 months if kept in a dry store
In case of skin contact with Nitozinc Primer and Nitobond EP,
in the original, unopened bags or packs. If stored at high remove immediately with resin removing cream followed by
temperature and/or high humidity conditions shelf life may washing with soap and water. Do not use solvent. In case of
be reduced to 4 - 6 months. Nitobond AR should be protected contact with eyes, rinse immediately with plenty of clean water
from frost. Nitozinc Primer has a shelf life of 6 months in and seek medical advice. If swallowed, seek medical
unopened condition. attention immediately. Do not induce vomiting.
Precautions Fire

Health and Safety Renderoc S2, Nitobond AR and Nitobond EP are non
flammable. Nitozinc Primer and Nitoflor Sol are flammable.
Renderoc S2 contain cement powder which when mixed or
Flash points
become damp, release alkalis which can be harmful to the
skin. During use, avoid inhalation of dust and contact with
Nitozinc Primer 16°C
skin and eyes. Wear suitable protective clothing, gloves, eye
protection and respiratory protective equipments. The use of Nitoflor Sol 33°C
barrier cream provides additional skin protection. Incase of

® Denotes the trademark of Fosroc International Limited

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 directly or indirectly arising from the
use of its products whether or not in accordance with any advice, specification, recommendation
Fosroc Chemicals (India) Pvt. Ltd. or information given by it.

Head Office telephone fax e·mail

111/3, Hafeeza Chamber 11 Floor,
++91 80-22240018/120 ++91 80-22233474 india@fosroc.com
K H Road, PBNo. 2744, Bangalore 560027
www.fosroc.com
Regional Offices
Bangalore Mumbai Delhi Kolkata
Shankar House, IV Floor 208/209, Persepolis First ftoor,1/2 East Patel Nagar 30/B Jodhpur Park
1 & 18, RMV Ex1ension Sector 17, Vashi Opp: Vivek Cinema, Main Patel Rd Ground Floor
Bangalore 560 080 Navi Mumbai 400 703 New Delhi 110008 Kolkata 700 068
Ph:080-2361 3161/2361 2004 Ph:022-27896412/14 Ph:011-25884903/4 Ph: 033 2472 5482
Fax: 080-2361 7454 Fax: 022 - 2789 6413 Fax: 011- 25884422 Fax: 033-2472 9921
email: Bangalore@fosroc.com email:Mumbai@fosroc.com email:Delhi@fosroc.com email:Kolkata@fosroc.com

eAhmedabad: (079) 26762799 eAnkleshwar :(02646) 220704/224687 e Bhubaneshwar: (0674) 2521176 e Chennai (044) 24899949/24853383
eChandigarh : (0172) 2639360 e Cochin : (0484) 2356668 eCoimbatore: (0422) 2472966 eGoa : (0832) 2542465 eGuwahati (0361) 2548793
eHyderabad: (040) 27662324/27662425 e Hubli (0836) 3402597 elndore: (0731) 504339/5061477 e Jaipur: (0141) 2235349 e Lucknow:(0522)
22239044 e Nagercoil (04652) 2224849 e Mangalore: (0824) 22272234 e Visakhapatnam: (0891) 2564850 INDIN2004/0401/E
 Fosroc Renderoc Fe constructive solutions

Single component polymer modified cementitious

pinhole filler

Uses Specification

Renderoc FC is designed for application to minor imperfec­ The filler for minor surface imperfections (up to 3 mm depth)
tions in concrete and masonry surfaces. It is suitable for shall be Renderoc FC - a single component, polymer mod­
application in the range of feather edge to 3 mm, and can be ified, cementitious mortar. The material shall be capable of
used in the following situations: use without the need for an independent primer or curing
system.
• Filling pinholes prior to overcoating

• General reprofiling over large areas, up to 3 mm depth Standards compliance

• Fairing coat, in association with other Renderoc mortars Renderoc FC has been approved by the British Board of
Agrement, under Certificate No. 98/3461.
Advantages
Design criteria
• Cost effective - no independent primer necessary
Renderoc FC is designed for vertical and overhead use in
• Time saving - curing not necessary
filling voids up to a depth of 3 mm. It can also be used to
• High performance - excellent bond to the substrate render over large areas, from a feather-edge up to 3 mm
thickness.
Description
Anti-dusting properties may be imparted upon the mix by
Renderoc FC is supplied as a ready to use blend of dry the addition of Nitobond SBR*t to the gauging water. This
powders which requires only the site addition of clean water will also enhance other performance properties; but should
to produce a highly consistent cementitious mortar. not be viewed as mandatory for every application. However,
where subsequent coatings are to be applied, it is impor­
Renderoc FC exhibits excellent thermal compatibility with
tant to produce a dust-free surface upon which to apply the
concrete, and is fully compatible with other Renderoc*t
coating.
mortars.

Left:
Typical Application of Ren­
deroc FC

U
LL
U
o
lii
"0
c:
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<>:
 Fosroc Renderoc Fe

Properties Mixing - large volumes

The following results were obtained at a liquid:powder ratio of For larger volumes, place 5 to 5.33 litres of cool, potable
0.25:1 by weight. water into the mixer and, with the machine in operation, add
one full 20 kg bag of Renderoc FC and mix continuously for 3
to 5 minutes until fully homogeneous.
Test method Typical result
@20°C Water addition may vary slightly according to both the ambi­
Coefficient of thermal ent temperature and the desired consistency of the mix, but it
expansion : 7 to 12 x 10-srC should not exceed 5.33 Iitres
Working life Approx. (854555) : 60 mins
For additional anti-dusting, or enhanced performance proper­
Setting time (854550 P3) : 4 hours
ties, add 0.9 Iitres of Nitobond SBR to the gauging water until
Fresh wet density (854555) : 1920 kg/m 3
the desired consistency is achieved.
Note: Working life and setting time will vary dependent on
ambient and substrate temperatures. Note: In all cases Renderoc FC powder must be added to
the water.
Instructions for use
Application
Preparation
Apply the mixed Renderoc FC to the prepared substrate, up
Clean the surface and remove any dust, unsound material, to 3 mm thickness, by steel trowel. It should be applied with
plaster, oil, paint, grease, corrosion deposits or algae. Rough­ the minimum of working and be allowed to partly set before
en the surface to remove any laitence and expose the fine finally trowelling to a smooth finish.
aggregate by light scabbling or grit-blasting.
If a very smooth finish is required, a small amount of water
Oil and grease deposits should be removed by steam clean­ may be flicked on to the surface of the Renderoc FC with a
ing, detergent scrubbing or the use of a proprietary degreaser. paint brush prior to final trowelling.
The effectiveness of decontamination should then be as­
Do not proceed with the application when rainfall is imminent
sessed by a pull-off test.
unless in a sheltered or protected situation.
Renderoc repair mortars require no additional preparation
Finishing
prior to the application of Renderoc FC.
Renderoc FC is finished by striking off with a straight edge
The cleaned areas should be blown clean with oil-free
and closing with a steel or plastic float. Note that water can be
compressed air before continuing. All prepared areas should
drawn to the surface if 'overworking' with the float occurs, and
be thoroughly soaked with clean water immediately prior to
an unsightly finish may result.
the application of Renderoc FC. Any residual surface water
should be removed prior to commencement. Damp sponges or plastic floats may be used to achieve a
desired surface texture, but care should again be taken not to
Mixing - small quantities
overwork the surface.
Care should be taken to ensure that Renderoc FC is thor­
Curing
oughly mixed. Small quantities (up to 5 kg) can be mixed
using a suitable mixing drum or bucket. Greater quantities Curing is not generally required. However, under extreme
should be mixed using a forced-action mixer. Mixing in a suita­ conditions - high temperatures and drying winds - it may be
bly sized drum using an approved spiral paddle attached to prudent to use Nitobond AR*t as a curing agent.
an approved slow speed (400/500 rpm) heavy-duty drill is an
Nitobond AR does not require mechanical removal prior to
acceptable alternative.
overcoating.
If mixing small quantities by hand, Renderoc FC should be
Cleaning
volume-batched. Add 3 volumes of the Renderoc FC powder
(loose-filled to excess and struck off level with the top of the Renderoc FC should be removed from tools, equipment and
measuring container) to one volume of potable water. This mixers with clean water immediately after use. Cured material
should be mixed vigorously until fully homogeneous. can only be removed by mechanical means.

; - Page 2 of 4
Fosroc Renderoc Fe

Limitations Estimating

• If applying decorative or protective coating, it is Supply

recomended to use Renderoc BF or Renderoc BF2 in Renderoc FC 20 kg bags
stead of Renderoc FC. Alternativley, use Nitobond SBR Nitobond SBR 25 and 200 litre drums
with Renderoc FC to impart improved anti-dusting Nitobond AR 1 and 5 litre packs
properties as described above
Coverage and yield
• Renderoc FC should not be used when the temperature Renderoc FC 4 m2 at 3 mm thick
is below 5°C and falling. (approx. 12 litres/bag)
Nitobond AR 6 to 8 m2 per litre
• Do not proceed with the application when rainfall is
imminent unless in a sheltered or protected situation. Note :Actual coverage of Renderoc FC will be wholly de­
pendent upon the general substrate condition. It is
• The product should not be exposed to moving water
recommended, therefore, that site trials over a typical
during application or prior to initial set.
area are carried out to determine actual usage.
• If any doubts arise concerning temperature or substrate
conditions, consult the local Fosroc office. Storage

High temperature working Shelf life

It is suggested that, for temperatures above 35°C, the follow­ All products have a shelf life of 12 months if kept in a dry
ing guidelines are adopted as good working practice: store in the original, unopened bags or packs @ 25°C.

(i) Store unmixed materials in a cool (preferably Storage conditions

temperature controlled) environment, avoiding
Store in dry conditions in the original, unopened bags or
exposure to direct sunlight.
packs. If stored at high temperatures and/or high humidity
(ii) Keep equipment cool, arranging shade protection if conditions the shelf life may be considerably reduced to 4 to
necessary. It is especially important to keep cool those 6 months.
surfaces of the equipment which will come into direct
contact with the material itself. Precautions
(iii) Try to avoid application during the hottest times of
Health and safety
the day, and in direct sunlight.
(iv) Make sufficient material, plant and labour available to Renderoc FC contains cement powders which, when mixed
ensure that application is a continuous process. or become damp, release alkalis which can be harmful to the
skin. Nitobond AR and Nitobond SBR are slightly alkaline.
Technical support During use, avoid inhalation of dust and contact with skin and
Fosroc offers a comprehensive technical support service to eyes. Wear suitable protective clothing, gloves, eye protec­
specifiers, end users and contractors. It is also able to offer tion and respiratory protective equipment.
on-site technical assistance, an AutoCAD facility and dedicat­ The use of barrier creams can provide additional skin protec­
ed specification assistance in locations all over the world. tion. In case of contact with skin, rinse with plenty of clean
water, then cleanse with soap and water. 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.

For further information, refer to the appropriate Product Mate­

rial Safety Data Sheet.

Fire

Renderoc FC, Nitobond AR and Nitobond SBR are all

non-flammable products.

Renderoc Fe - Page 3 of 4
 Fosroc Renderoc Fe

Additional Information

Fosroc manufactures a wide range of complementary prod­

ucts which include:

• waterproofing membranes & waterstops

• joint sealants & filler boards

• cementitious & epoxy grouts

• specialised flooring materials

Fosroc additionally offers a comprehensive package of prod­

ucts specifically designed for the repair and refurbishment
of damaged concrete. Fosroc's 'Systematic Approach' to
concrete repair features the following:

• hand-placed repair mortars

• spray grade repair mortars

• fluid micro-concretes

• chemically resistant epoxy mortars

• anti-carbonation/anti-chloride protective coatings

• chemical and abrasion resistant coatings

For further information on any of the above, please consult

your local Fosroc office - as below.

* Denotes the trademark of Fosroc International Limited

See separate 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 Service. All Fosroc datasheets are updated on a regular basis. It is the user's responsibility to obtain the latest version.

Head Office
telephone: (+9714) 2039699 fax: (+9714) 2859649 email: agf@fosroc.com
AI Gurg Fosroc LLC
Regional offices
Post Box 657, Dubai Abu Ohabi,JlJ Gutg Fosroc telephone; 673 1779 fax: 673 1449 email: abudhabi@fosroc.com
Bahrain, YBA Kanoo telephone: 17738200 fax: 17732828 email: bahrain@fosroc.com
United Arab Emirates Kuwait. Boodai telephone: 4817618 fax: 4832124 email: kuwait@fosroc.com
";l'.
Oman. N Amana telephone: 24815080 fal(: 24817554 email: oman@fosroc.com
Qatar, Tadmur telephone: 4432365 fal(: 4419517 email: qalar@fosroc.com
www.fosroc.com

UAE/0263/14/J
Renderoc® RG Spl constructive solutions

General purpose, non-shrink, cementitious

micro-concrete Properties

Uses The following results were obtained at a water:Powder ratio

of 0.15 @ 30 DC.
Renderoc RG Spl is used for repairs to damaged reinforced'
concrete elements, particularly where access is restricted and
where vibration of the placed material is difficult or impossible.
Test Typical result at 30 DC
It is suitable for various structural strengthening measures
Compressive strength (N/mm 2 )
such as encasement build-ups, jacketing, piletop encapsula­
tion resin system, etc. 1 Day 30
7 Days 60
28 Days 75
Advantages
Flexural strength 8N/mm 2 @ 28 days
• Gaseous expansion system compensates for shrinkage
Young's Modulus 25 kN/mm 2
and settlement in the plastic state.
Expansion Characteristics Unrestrained expansion
• Can be pumped or poured into restricted locations.
of 1 to 4%. Pressure to
• Fluidity to allow for placement without vibration. restrain Plastic expan­
sion ­ Approx. 0.004NI
• Pre-bagged to overcome site-batched variations.
mm 2
• Rapid strength gain to facilitate early reinstatement.
Coefficient of thermal 10 -12 x 10-6I DC.
• High ultimate strengths and low permeability of cured repair. expansion

• Contains no chloride admixture. Thermal conductivity

• Ensures piletop integrity as part of a waterproofing system Fresh wet density 2300 - 2400 kg/m 3

Specification clauses
Description
Performance specification
Renderoc RG Spl is supplied as a ready to use blend of dry
powders which requires only the site addition of clean water to The fluid micro-concrete repair material shall be Renderoc
produce a free-flowing non-shrink repair micro concrete. The RG Spl, a single component, cement based, micro-concrete
material is based on Portland cements, graded aggregates to which only the site-addition of clean water ( and approved
and fillers, and additives which impart controlled expansion graded coarse aggregates where specified) shall be permitted.
characteristics in the plastic state, while minimising water de­ The micro-concrete shall contain no metallic aggregates, or
mand. The low water requirement ensures high early strength chlorides and shall be shrinkage compensated in the plastic
and long-term durability. state. The micro concrete in the flowable consistency should
achieve a compressive strength of not less than 30N/mm 2 after
For larger repairs, the mixed Renderoc RG Spl may be modi­ 24 hours at 30 DC. Most importantly, the cured microconcrete
fied by the addition of 5mm to 12mm clean, graded, saturated
shall have a coefficient of thermal expansion similar to that of
surface dry aggregates at site. For exceptionally large repairs, the host concrete.
the local Fosroc office shall be consulted.

Technical support Application instructions

Preparation
Fosroc offers a technical support package to specifiers, end
users and contractors as well as technical on-site assistance The unrestrained surface area of the repair must be kept to a
in locations all over the country. minimum. The formwork should include drainage outlets for
Design criteria pre-soaking and, ,if beneath a soffit, provision for airventing.
Provision must also be made for suitable access points to pour
Renderoc RG Spl can be applied in sections upto 1OOmm deep.
or pump the mixed micro-concrete in place.
For larger sections, the addition of approved aggregates may
be required. This will depend on the specific configuration of
the repair location. Fosroc office shall be contacted for further
information.
page 1 of 3
Renderoc® RG Spl

Defective concrete surfaces must be cut back to a sound base. Placing

Smooth surfaces should be mechanically roughened. Corroded
The mixed material should be placed immediately. if placed by
reinforcing steel should be exposed around its full circumfer­
pump, standard concrete pumping practice should be followed.
ence and cleaned to remove all loose scale and corrosion
The pump and pipeline must be primed with cement slurry.
deposits. It is important to clean the steel to a bright condition.
Pumping should be commenced immediately after priming.
Grit-blasting is recommended.
If poured in the form work, avoid air entrapment by pouring
One coat of Nitozinc Primer should be applied on the reinforc­ from one side only.
ing steel. If any discontinuity in the applied film is noticed, one
Low temperature working
more coat has to be applied.
In cold conditions down to 15°C, the use of warm water (upto
Several hours prior to placing, the concrete substrates should
30°C) is advisable to accelerate strength development. Normal
be saturated with clean water. Immediately prior to placing, any
precautions for working with cementitious materials in winter
free water should be removed.
should be adopted.
Note: For repair sections generally deeper than 100m m it may
High temperature working
be necessary to mix the Renderoc RG Spl with properly graded
5mm to 12mm silt-free aggregate to minimise temperature rise. At ambient temperature above 35°C the material should be
The quantity of aggregate required may vary depending on the stored in the shade and cold water used for mixing.
nature and configuration of the repair location. However it can
Curing
added between 50-100% by weight of microconcrete.
As Renderoc RG Spl is a cement-based repair material, it
Mixing
should be cured immediately after stripping the formwork in
Care should be taken to ensure that Renderoc RG Spl is accordance with good concrete practice. the use of Nitobond
thoroughly mixed in a forced-action mixer of adequate capacity. AR or any of Fosroc's Concure range of curing compounds,
Alternatively, mix in a suitably sized drum with a high torque sprayed on the surface of the Renderoc RG Spl. in a
(400/500 rpm) rotary drill fitted with a mixing paddle. It is continuation film, is recommended soon after tripping the form
essential that machine mixing capacity and labour availability work. In harsh drying conditions, supplementary curing such a
is adequate to enable the placing operation to be carried out wed hessian orlor polythene sheeting must be used.
continuously. The quantity water required will generally be
Estimating
between 3.50 Iitres and 3.75 litres per 25 kg bag of Renderoc
RG Spl. The optimum water content should be determined Packaging
and accurately measured into the mixer. However it should Renderoc RG Spl is supplied in 25 kg bags.
not exceed 3.75 litres/25 kg in any case. With the mixer
Yield
running, slowly empty Renderoc RG Spl bag into the mixer. Mix
continuously for 5 minutes, ensuring a smooth even consistency Approximately 12.0 litres per 25 kg bag. Actual yield per bag
of the mix. Where the addition of graded coarse aggregate has will depend on the consistency of Renderoc RG Spl and
been specified it should be added after the water and Renderoc quantity of coarse aggregate added.
RG Spl are properly mixed. Mixing should then continue for a
Storage
further 1 minute to ensure proper dispersion.
Shelf life
Form Work
Renderoc RG Spl has a shelf life of 6 months if kept in a dry
Slurry tight form work that will not deform or leak when store in the original, unopened bags. If stored at high tem­
subjected to hydraulic pressure imposed by the micro concrete peratures andlor high humidity conditions the shelf life may
will be fabricated and erected where the material is gravity fed, be reduced.
provision in the formwork will be made for a suitable feedhopper
at the highest point. Where necessary, provision will be made
for airvents to prevent air entrapment. Form work will be coated
with Reebol mould releasing agent prior to fixing.

constructive solutions page 2 of 3

 Renderoc® RG Spl

Precautions Additional Information

Health & Safety instructions Fosroc manufactures a wide range of products specifically de­
signed for the repair and refurbishment of damaged reinforced
Renderoc RG Spl contains cement powders which, during
normal use, have no harmful effect on dry skin. However, concrete. These include hand placed and trowellable repair mor­
when Renderoc RG Spl is mixed, or becomes damp, alkali is tars, fluid micro concretes, chemical resistant epoxy mortars and
released which can be harmful to the skin. During use, avoid a comprehensive package of protective coatings. In addition,
inhalation of dust and contact with skin and eyes. Suitable a wide range of complimentary products are available. These
gloves, eye protection and dust masks shall be worn. The use include admixtures, joint sealants, waterproofing membranes,
of barrier creams is recommended. Incase of contact with skin, grouting, anchoring, and specialised flooring materials.
it shall be washed with clean water. Incase of contact with eyes,
it shall be rinsed immediately with plenty of clean water and Separate datasheets are available on these products.
medical advice shall be sought. If swallowed, medical attention
shall be sought immediately - Vomitting should not be induced.
Renderoc RG Spl 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
"Sapthagiri Palace", No.38,
II & III Floor, 12th Cross, ++91 80-42521900 ++91 80-23551510 enquiryindia@fosroc.com
CBI Road, Ganganagar North,
Bangalore 560 024

Regional Offices

Chennai Mumbai Noida Kolkata

No. 26(old no.33), 1st Floor, 1401/1402, 14th Floor, 0-166 Sector 10 304, Jodhpur Park
1st Street Postal Colony, A-Wing'The Great Eastern Summit' Dist. Gautam Budha Nagar, Kolkata 700 068
West Mambalam, Sector-15, CBD, Belapur Noida, Ph:033-65343188
Chennai 600 033. Navi Mumbai 400 614 UP 201 301 Fax: 033-2499-0280
Ph: 044-24899949-94 Ph: 022-43406800-04 Ph:0120-4270620-21
Fax: 044-24896641 Fax: 022-27562423 Fax: 0120-4270622

www.fosroc.com

page 3 of3 INDIAl20171040SlA

 -BASF
The Chemical Company

MasterBrace® 2200 (Formerly known as Concresive 2200)

High strength epoxy bedding and repair mortar

• Bond strength >2. MPa (concrete

failure)
MasterBrace 2200 is a solvent free, high
performance, non-slumping epoxy mortar and Setting time 12 hours @ 25°C
adhesive. MasterBrace 2200 can be used as a Meets the requirements of ASTM C881 Type 1 Grade
bedding mortar, thixotropic adhesive and non-sag 3 Class B & C
concrete repair mortar.
Chemical Resistance
• D
MasterBrace 2200 resists most common organic
• Bedding of bridge beams or steel bridge and inorganic acids in diluted form, also resistant
bearings to alkalis, water, oils, grease, etc. Chemical
• Repairing surface defects in concrete in resistance depends on the chemicals involved,
horizontal, vertical and overhead applications their concentration, temperature and degree of
• Fining of injection ports for Masterlnject resins exposure. Good housekeeping practices such as
• Bonding of dowels, bolts and anchors into immediate clean-up of all spillages will greatly
concrete extend the service life.

.
• Rapid structural repair of concrete Part A Part B Mixed
• Re air of c~ncrete [2osts in situ
Supply Form Paste Liquid Paste
:
Colour Grey Amber Grey
• Adheres to concrete surfaces - Allows rapid
repair of concrete Mix Ratio 100:75 pbw
• Solvent free - Low vac and non-shrink Density (Mixed) 1.85 kg/L
• Pre-proportioned packaging - No job site Application Temperature 15°C - 35·C
errors
•
•
Easy application - No primer necessary
High abrasion, impact and chemical
•
Surface preparation
resistance - Can be used as contact surface in
aggressive environments Remove all grease, oil, dust, residual curing
• Cures hard at low temperatures - Wide compound, mould release agent or other
application range contaminant that could impair adhesion. Laitance
should preferably be removed by light sweep
blasting or hydro-jetting. Mechanical wire brushing
may be appropriate for small areas.
Mixed resin and hardener only
Spalled concrete should be cut back to sound
Compressive Strength (BS 40 MPa @ 1 day concrete and made good with MasterBrace 2200
6319 part 2) @ 25°C
65 MPa @ 7 days mortar. Conventional concrete curing compounds
should be removed before application.
Flexural strength (ASTM C 20 MPa @ 7 days
580 part 7) @ 25°C Mixing
Tensile Strength (BS 6319 10 MPa @ 7 days Proportion part kits accurately miXing only what
Part 7) @ 25°C can be used in less than 30 minutes. Thoroughly
stir Part A, add Part B and blend thoroughly using
Pot life 50 minutes @ 25°C
a slow speed mixer fitted with a suitable paddle.
30 minutes @ 40·C . Application
Recoat time 8 hours @ 25°C The MasterBrace2200 may be placed using a
6 hours @ 40°C trowel or spatula and applied evenly across the
whole surface. Subsequent coats should be placed
within 30-45 minutes and the MasterBrace 2200

MASTER®
»B ILDERS
.,I JTIO '
 -BASF
The Chemical Company

MasterBrace® 2200 (Formerly known as Concresive 2200)

should still be tacky. The use of a trowel dipped in
solvent is recommended of a very smooth final
surface is required. MasterBrace 2200 can be stored in tightly closed
original containers for 12 months at moderate
temperature.
Cure time will vary depending on the ambient
temperature, quantity mixed and placed.
For the full health and safety hazard information

.
MasterBrace 2200 will have fully cured after 7
days at 23°C. and how to safely handle and use this product,
:;r.:;;:~------- please make sure that you obtain a copy of the
'
BASF Material Safety Data Sheet (MSDS) from
A 6 kg kit of MasterBrace 2200 will yield 3.24 our office or our website.
litres.

MasterBrace 2200 comes in a 6 kg kit

MasterBrace 2200/01/0313

The technical information and application advice given in this BASF Construction Chemicals publication are based
STATEMENT OF on the present state of our best scientific and practical knowledge. As the information herein is of a general nature,
RESPONSIBILITY 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
(Disclaimer) user is responsible for checking the suitability of products for their intended use.
® =registered trademark of BASF group in many countries
Field service where provided does not constitute supervisory responsibility. Suggestions made by BASF
NOTE Construction Chemicals either orally or in writing may be followed, modified or rejected by the owner, engineer or
contractor since they, and not BASF Construction Chemicals, are responsible for carrying out procedures
appropriate to a specific application.
BASF India Limited
Construction Chemicals Division
Plot No.37, Chandivali Farm Road, Chandivali, Andheri(East)
Mumbai - 400072 India
Tel: +91 2228580200, Fax: +91 2228478381
e-mail: construction-india@basf.com www.master-builders-solutions.basf.in
 BASF
The Chemical Company

MasterEmaco ® P 130 (formerly known as Concresive ZRi)

Two component epoxy based zinc rich primer for steel

• • no oil, grease or dust is present. Surfaces should

be dry.
MasterEmaco P 130 is a two component, solvent Mixing:
borne zinc rich epoxy primer, providing active Stir each component of MasterEmaco P 130.
galvanic protection to steel. It is a thick grey liquid Add Hardener to Base and mix using a drilling
of paint-like consistency, recommended for use machine fitted with a mixer.
where chloride induced attack on steel is likely.
• • c Application:
Apply MasterEmaco P 130 immediately after
As a protective coating to steel reinforcing
completion of preparation to prevent any
bars in concrete.
contamination. Do not leave blasted or prepared
As a touch-up primer for damaged galvanised
steel uncoated.
metal.
• As a primer for steel substrates prior to
Brush the MasterEmaco P 130 onto the prepared
suitable top coating.
substrate, ensuring uniform and full coverage,
particularly on the back face of reinforcement. lin
case of doubt on achieving continuous film in one
• Protects steel - provides active protection coat apply second coat immediately after the
against steel' corrosion. drying of the first coat. Please consult BASF
• Excellent adhesion - bonds to steel to representative for advising the numbers of coats
create a protective anti-corrosion barrier. necessary. Repair mortars can be applied as
Fast installation - Short overcoating time. soon as the MasterEmaco P 130 is dry.

MasterEmaco P 130 is not designed as a

Aspect : Thick grey finished coating. Although protection to the steel
suspension will be provided for some time, overcoating
Mixed density : 2.4 ± 0.1 kg/litre should be carried out as soon as possible,
Volume Solids, % : 57 ± 3 particularly in aggressive environments.
Mixing Ratio, by volume : 4(B) : 1(H)
Pot Life : 120 Minutes at Equipment care
25°C Tools should be cleaned with CLEANING
Tack free time : 25 Minutes at SOLVENT NO.2 immediately after use.
25°C
: 10 Minutes at Each 1 litre pack can cover 8 - 10m /coat on
40°C smooth substrates. On rebar approximate
Recoat time : 6-8 Hours at 25°C coverage shall be as under:
: 2-4 Hours at 40°C
Total zinc content in dry film : >84% by weight Diameter of rebar Coverage I
OFT. per coat : > 50 microns (in mm) Running
Application temperature : minimum 10°C meter/litre/coat
: maximum 40°C 8 210 - 265
12 140 - 175
STANDARDS .
16 105 -135

, .. .
MasterEmaco P 130 is formulated to meet the
sco e of BS 4652, T e 2

Surface preparation
25
32

PACKAGING :
85 ­ 115
55 ­ 65

The steel surfaces should be grit blasted or wire

brushed to remove all traces of corrosion. Ensure MasterEmaco P 130 is a two component system,
supplied in 1 litre combined unit.

MASTER®
»BUILDERS
SOL i r Iii! S
 BASF
The Chemical Company

MasterEmaco® P 130 (formerly known as Concresive ZRi)

Store under cover, out of direct sunlight and For the full health and safety hazard information
protect from extremes of temperature. In tropical and how to safely handle and use this product,
climates the product must be stored in an air­ please make sure that you obtain a copy of the
conditioned environment. BASF Material Safety Data Sheet (MSDS) from
our office or our website.
Shelf life is six months when stored as above.

MasterEmacoP130/01/0313
The technical information and application advice given in this BASF Construction Chemicals publication are based
STATEMENT OF on the present state of our best scientific and practical knowledge. As the information herein is of a general
RESPONSIBILITY nature, no assumption can be made as to a product's suitability for a particular use or application and no warranty
(Disclaimer) 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.
® = registered trademark of BASF group in many countries
Field service where provided does not constitute supervisory responsibility. Suggestions made by BASF
NOTE Construction Chemicals either orally or in writing may be followed, modified or rejected by the owner, engineer or
contractor since they, and not BASF Construction Chemicals, are responsible for carrying out procedures
appropriate to a specific application.

BASF India Limited

Construction Chemicals Division
Plot No.37, Chandivali Farm Road, Chandivali, Andheri(East)
Mumbai - 400072 India
Tel: +91 2228580200, Fax: +91 22 28478381
e-mail: construction-india@basf.com www.master-builders-solutions.basf.in
 BASF
The Chemical Company

MasterEmaco® 5 348 (formerly known as Emaco S48C T)

Dual shrinkage compensated, trowelable fibre reinforced thixotropic repair mortar

. . ....•
MasterEmaco S 348 trowelable mortar is a dual
Mixing water per 25kg bag
Application Temperature
Approx.3.75 - 4.25 litres

shrinkage compensated, thixotropic high strength substrate +5 to +40°C

formulation for structural concrete repairs.
MasterEmaco S 348 is suitable for placing in
thicknesses of 12mm to 50 mm both vertically and
overhead.
material

. .. .
Surface preparation
+5 to +30°C

MasterEmaco S 348 provides a durable, strong

All loose traces of concrete or mortar, dust,
structural repair fully compatible with host
grease oil, etc. must be removed. Damaged or
concrete.
contaminated concrete shall be removed to obtain
•• a keyed aggregate exposed surface. Non-impact!
MasterEmaco S 348 is the ideal material for vibrating cleaning methods, e.g. grit or high
vertical or horizontal structural repairs where the pressure water blasting are recommended. Cut
thickness of repair is more than 10-12 mm and the edges of the repair vertically to a minimum
use of hand or machine applied structural repair depth of 5 mm. Clean all exposed reinforcement
systems is required. Typical applications are: to a minimum grade of
SA 2 according to ISO 8501-1 I ISO 2944-4.
• Extensive repairs to beams, columns and other
structural elements Ensure back of rebar is also clean.
• Repair of structural members subjected to Where reinforcing bars are corroded, cut back the
repetitive loading concrete to at least 20mm behind the reinforcing
bars. Grit blast to remove corrosion products from
around reinforcing bars and coat with
• Dual shrinkage compensated - volume stable MasterEmaco P 130 to protect from corrosion.
in wet and hardened state reducing cracking Replace the affected part of rebar if the diameter
tendency after grit blasting is found reduced by more than
• One component, factory made only addition 20% of the original diameter on the advice of the
of water - uniform predictable performance structural engineer responsible for the works.
even in remote situations Mixing
• No bonding agent required - simple Only full bags are mixed. Damaged or opened
installation bags should not be used. Mix MasterEmaco S
• Impermeable to aggressive elements - long 348 in a forced action pan mixer, or with a helical
life repairs paddle attached to a low speed (300-600rpm)
• Sprayable - able to repair complex profiles mixer for 3 minutes until a ,lump free, thixotropic
easily with minimal rebound consistency is achieved. Only use clean water.
• Fast and easy placing - reduced time for

..
Mixing water needed: 3.75 to 4.25 Iitres per 25kg
repairs Ibag. Allow the mortar to rest for 2 - 3 minutes and
.. . . then remix briefly before applying. If more than
30°C use chilled water as the mixing water.
Appearance Grey powder Priming Concrete
Water powder ratio 0.16 No special primer is required. To obtain extra
strong bonding, the damp substrate can be primed
Compressive strength 15 MPa 1 Day with a slurry brush coat of MasterEmaco S 348 (2
(ASTM C109 7cm cube) parts powder to 1 part water).
25 MPa 3 Days
35 MPa 7 Days Mortar application
45 MPa 28 Days The minimum temperatures must be maintained
3
during application and for at least 24 hours
Density Approx. 2250kg/m thereafter for optimum curing of the product. The

MASTER®
»BUILDE S
I· I
 BASF
The Chemical Company

MasterlEmaco® 5 348 (formerly known as Emaco S48CT)

prepared substrate should be pre-soaked, datasheets.

preferably for 24 hours, but at least 2 hours before
applying MasterEmaco S 348. The surface must
be saturated surface dry, but without standing MasterEmaco S 348 should be cured with
water. MasterEmaco S 348 can be spray- or MasterKure 181 or clear polythene sheeting over
hand-applied. Apply mixed product directly to the wet hessian.
prepared damp substrate, or wet on wet onto the
primed surface. Spraying the material with the
Each bag of MasterEmaco S 348 when mixed
necessary pressure will ensure good adhesion of
with 4.0L of water yields 12.8L.
the material.
PACKAGING .
A thin scrape coat or contact layer before building
up to the required thickness, wet on wet, will MasterEmaco S 348 is available in 25kg bags.
improve adhesion especially in case of hand
SHELF LIFE
application. Apply to the desired layer thickness of
12 to max 50 mm and level using a screeding bar, MasterEmaco S 348 has a shelf life of 6 months.
trowel or wooden board. Can be applied in thicker Store out of direct sunlight, clear of the ground on
layers in smaller patches or where additional pallets protected from rainfall.
reinforcement is present. Smoothing with a trowel PRECAUTIONS
or finishing by float or sponge can be done as For the full health and safety hazard information
soon as the mortar has begun to stiffen. and how to safely handle and use this product,
Protective coatings please make sure that you obtain a copy of the
Subsequent coatings of MasterProtect anti BASF Material Safety Data Sheet (MSDS) from
carbonation barriers or silane impregnations our office or our website.
should be applied as recommend on the individual

MasterEmacoS 348/01/0313

The technical information and application advice given in this BASF Construction Chemicals publication are based
STATEMENT OF on the present state of our best scientific and practical knowledge. As the information herein is of a general
RESPONSIBILITY 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.
(Disclaimer) The user is responsible for checking the suitability of products for their intended use.
® =registered trademark of BASF group in many countries
Field service where prOVided does not constitute supervisory responsibility. Suggestions made by BASF
NOTE Construction Chemicals either orally or in writing may be followed, modified or rejected by the owner, engineer or
contractor since they, and not BASF Construction Chemicals, are responsible for carrying out procedures
appropriate to a specific application.

BASF India Limited

Construction Chemicals Division
Plot No.37, Chandivali Farm Road, Chandivali, Andheri(East)
Mumbai - 400072 India I ~-
I~~·"..t ..
Tel: +91 2228580200, Fax: +91 2228478381
e-mail: construction-india@basf.com www.master-builders-solutions.basf.in ..
 BASF
The Chemical Company

MasterEmaco® S 488 (formerly known as Emaco S88e T)

Dual shrinkage compensated, trowelable fibre reinforced thixotropic repair mortar

• • Substrate
material
+5 to +40°C
+5 to +30°C
MasterEmaco S 488 trowelable mortar is a dual
shrinkage compensated, thixotropic high strength Mixing water per 25kg bag Approx. 3.25 - 3.75
formulation for structural concrete repairs. Iitres
MasterEmaco S 488 is suitable for placing in Compressive strength 20 MPa 1 Day
thicknesses of 12mm to 50 mm both vertically and (ASTM C109 7cm cube)
50 MPa 3 Days
overhead.
60 MPa 7 Days
MasterEmaco S 488 provides a durable,· strong
structural repair fully compatible with host 70 MPa 28 Days
concrete. Flexural Strength >9 MPa @ 28 days
•• (ASTM C348)
MasterEmaco S488 is the ideal material for Tensile Strength >4 MPa @ 28 days
vertical or horizontal structural repairs where the (ASTM C496)
thickness of repair is more than 12mm and use of
Resistivity approx. 125000an
hand or machine applied structural repair systems
is required. Typical applications are: Water penetration <5mm
• Extensive repairs to beams, columns and other Coefficient of Oxygen 2.58 x 10.8
structural elements. diffusion
• Repair of structural members subjected to
repetitive loading.
• Repairs to piers, navigation locks, dams Surface preparation
seawalls and other marine structures All loose traces of concrete or mortar, dust, grease
•

•
~ .:
Repairs to bridges, tunnels, garages, silos etc

Dual shrinkage compensated - Volume stable

oil, etc. must be removed. Damaged or
contaminated concrete shall be removed to obtain
a keyed aggregate exposed surface. Non-impacU
vibrating cleaning methods, e.g. grit or high
in wet and hardened state reducing cracking pressure water blasting are recommended. Cut the
tendency edges of the repair vertically to a minimum depth
• One component, factory made only addition of 5 mm. Clean all exposed reinforcement to a
of water - Uniform predictable performance minimum grade of Sa 2 according to ISO 8501-1 /
even in remote situations ISO 2944-4. Ensure back of reinforcing bar is also
• No bonding agent required Simple clean.
installation
Where reinforcing bars are corroded, cut back the
• Impermeable to aggressive elements - Long concrete to at least 20mm behind the reinforcing
life repairs bars. Grit blast around the reinforcing bars to
• Sprayable - Able to repair complex profiles remove corrosion products and coat with
easily with minimal rebound MasterEmaco P 130 to give corrosion protection ..
• Fast and easy placing - Reduced time for

..
Replace the affected part of rebar if the diameter
repairs after grit blasting is found reduced by more than
. .. . 20% of the original diameter on the advice of the
structural engineer responsible for the works.
Appearance Grey powder Mixing
Water powder ratio 0.14 Only full bags are mixed. Damaged or opened
bags should not be used. Mix MasterEmaco S
Density Approx. 2300 kg/m3 488 in a forced action pan mixer, or with a helical
Application temperature paddle attached to a low speed (300-600rpm)
mixer for 3 minutes until a lump free, thixotropic

MASTER®
»BUILDERS
ITI
 BASF
The Chemical Company

MasterEmaco ® S 488 (formerly known as Emaco S88C T)

consistency is achieved. Only use clean water. thicker layers in smaller patches or where
Mixing water needed: 3.25 to 3.75 Iitres per 25kg additional reinforcement is present. Smoothing
bag. Allow the mortar to rest for 2 - 3 minutes and with a trowel or finishing by float or sponge can be
then remix briefly before applying. If the done as soon as the mortar has begun to stiffen.
temperature is more than 30°C then use chilled Protective coatings
water for the mixing water.
Subsequent coatings of MasterProtect anti­
Priming Concrete carbonation barriers or silane impregnations
No special primer is required. To obtain extra should be applied as recommend on the individual
strong bonding, the damp substrate can be primed datasheets.
with a slurry brush coat of MasterEmaco S 488 (2
parts powder to 1 part water).
MasterEmaco S 488 should be cured with
Mortar application
MasterKure 181 or clear polythene sheeting over
The minimum temperatures must be maintained wet hessian.
during application and for at least 24 hours
thereafter for optimum curing of the product.
The prepared substrate should be pre-soaked, Each bag of MasterEmaco S 488 when mixed
preferably for 24 hours, but at least 2 hours before with 3.5L of water yields 12.4L.
applying MasterEmaco S 488 The surface must
be saturated surface dry, but without standing
MasterEmaco S 488 is available in 25kg bags.
water. MasterEmaco S 488 can be spray or hand
applied. Apply mixed product directly to the
prepared damp substrate, or wet in wet onto the MasterEmaco S 488 has a shelf life of 6 months.
primed surface. Spraying the material with the Store out of direct sunlight, clear of the ground on
necessary pressure will ensure good adhesion of pallets protected from rainfall.
the material. ,-----_.­
A thin scrape coat or contact layer before building •
up to the required thickness, wet on wet, will For the full health and safety hazard ,information
improve adhesion especially in case of hand and how to safely handl'e and use this product,
application. Apply to the desired layer thickness of please make sure that you obtain a copy of the
12 mm to max 50 mm and level usin9' a screeding BASF Material Safety Data Sheet (MSDS) from
bar, trowel or wooden board. Can be applied in our office or our website.

MasterEmacoS488/01/0313

The technical information and application advice given in this BASF Construction Chemicals publication are based
STATEMENT OF on the present state of our best scientific and practical knowledge. As the information herein is of a general
RESPONSIBILITY 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.
(Disclaimer) The user is responsible for checking the suitability of products for their intended use.
® = registered trademark of BASF group in many countries
Field service where provided does not constitute supervisory responsibility. Suggestions made by BASF
NOTE Construction Chemicals either orally or in writing may be followed, modified or rejected by the owner, engineer or
contractor since they, and not BASF Construction Chemicals, are responsible for carrying out procedures
appropriate to a specific application.

BASF India Limited

Construction Chemicals Division
Plot No.37, Chandivali Farm Road, Chandivali, Andheri(East)
Mumbai - 400072 India
Tel: +91 2228580200, Fax: +91 22 28478381
e-mail: construction-india@basf.com www.master-builders-solutions.basf.in
 -BASF
The Chemical Company

MasterFlow® 718 (formerly known as Masterflow918)

Non-shrink, cementitious grout for use in general civil engineering works

• :J~j • • -
MasterFlow 718 is a ready to use, non-shrink, Flowable
natural aggregate cementitious grout for use in
general civil engineering works. MasterFlow 718 Compressive strength
2
provides extended working life and' high early and 1 day 20 N/mm
2
ultimate strengths. 3 days 35 N/mm

•• •• 7 days
28 days
55 N/mm
65 N/mm
2

2
MasterFlow 718 is recommended for: I

stanchion baseplates and columns; Flexural strength (ASTM C

78) 28 days 9 MPa
prefabricated concrete panels and beams;
bridge bearing plates; Supply form Powder
anchor bolts and bars; Colour Cement grey
underpinning; Water addition 16 %
patch repair works. Density (wet) 2.1 Kg/L
~ .: Modulus of Elasticity 28 days >30 GPa
• High strength - provides good early and ultimate I Pull out Bond strength 7 >17 MPa
strengths which ensure quick return to service days
and long term durability Bond Strength to concrete >2 MPa
• Non shrink - Hardens free of bleeding, 28 Days
settlement and drying shrinkage when placed at
flowable consistency Dynamic load resistance Condition of sample:
undamaged
• Flowable consistency - Ensures complete filling
of even intricate voids often without the need for Compressive strength:
pumping and strapping I Slightly higher
• Ample working time - remains placeable - up to Specimen subjected to alternating loads of 5 and 25
1 hour - even at high ambient temperatures MPa at 300 cycles per minute and for 2000000 cycles
• Dense, impermeable grout - Provides a good and then tested for compressive strength
watertight seal
• Economical - Greater volumes of grout can be l ~.: .1~1:
1
mixed and handled with less labour. MasterFlow 718 can be mixed to a flowable or
• Easy to use - requires no special mixing trowelable consistency. The quantity of water
equipment, it can be mixed in a pail using a grout required to produce a flowable grout from a 25 kg
stirrer. bag is approximately 4.0 litres.
• No added chloride - Does not add to chloride Water addition may be affected by temperature
load on structure conditions on site. Trials are recommended to
determine the correct water requirement.
• Provides complete non shrink performance­
When tested in accordance with simulated MasterFlow 718 should be mixed using a suitable
Bedplate Technique. mixer. For flowable consistency, use a hand drill
and paddle for small works up to two bags at a
• Versatile- Can be placed from flowable to
time and specialise grout mixers for larger volume.
trowelable consistency
Drum type mixers may not provide sufficient mixing
efficiency to derive the optimum performance from
the grout.
The correct volume of water should be added to
the mixer followed by the powder. Mixing should
continue until the grout has a smooth, lump free
appearance. This will normally be between 3 - 5
minutes after mixing has started.

MASTER0
»SUILDERS
. 'J 'l·
 -BASF
The Chemical Company

MasterF I0 w® 718 (Formerly known as Masterflow 918)

For best results, MasterFlow 718 should be used

within 30 minutes once mixed.
A 25 kg bag of MasterFlow 71'8 when mixed to a
The substrate should be properly prepared and f10wable consistency (Add 4.0 litres water) will
should be free from contamination, laitance and yield 13.2 litres grout.
loose material. Thoroughly saturate the substance
with water at least 2 - 3 hours prior to pouring the
..
grout. All free water ponding should be blown out MasterFlow 718 is packaged in 25 kg moisture
of the void just before pouring the grout. resistant bags.
As for all cementitious materials, curing is essential
to prevent rapid drying out of the grout and
shrinkage caused by the water loss. Curing should MasterFlow 718 has a shelf life of approximately 6
be effected by accepted methods such as curing months when stored in a cool dry place in
compounds, polythene sheet, wet hessian or water unopened sacks.
ponding. •
If a shaped shoulder is required, it should be For detailed Health, Safety and Environmental
formed before the grout has reached its final set. Recommendations, please consult and follow all
Carefully remove the formwork once the instructions on the product Material Safety Data
MasterFlow 718 is self-supporting and cut the Sheet (MSDS) from our office or our website.
shape of the shoulder with a trowel. Preferably the
shoulder should be cut to a 45° angle to minimise
stresses.

Clean tools and equipment with water before

MasterFlow 718 has hardened, otherwise
mechanical cleaning will be required.

MasterFlow 718/01/0313
The technical information and application advice given in this BASF Construction Chemicals publication are based
STATEMENT OF on the present state of our best scientific and practical knowledge. As the information herein is of a general
RESPONSIBILITY nature, no assumption can be made as to a product's suitability for a particular use or application and no warranty
(Disclaimer) 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.
Field service where provided does not constitute supervisory responsibility. Suggestions made by BASF
NOTE Construction Chemicals either orally or in writing may be followed, modified or rejected by the owner, engineer or
contractor since they, and not BASF Construction Chemicals, are responsible for carrying out procedures
appropriate to a specific application.

BASF India Limited

Construction Chemicals Division
Plot No.37, Chandivali Farm Road, Chandivali, Andheri(East)
Mumbai - 400072 India
Tel: +91 2228580200, Fax: +91 2228478381
e-mail: construction-india@basf.com www.basf-cc.co.in
 BASF
We create chemistry

Masterlnject@ 1315
Low viscosity epoxy resin with long potlife for crack injection

• Part A Part 8 Mixed

Masterlnject 1315 is a low viscosity epoxy resin Supply Form Liquid Liquid Liquid
based crack injection resin system long mixed Colour Clear Amber Pale
potlife designed for sealing cracks in concrete and Yellow
restoring its structural integrity.
1l!Z_------~-_, Mix Ratio 77:23 pbw
Density (Mixed) 1.05kg/L
• Stabilised cracks in structural members
• Sealing of cracks from 0.1 mm to 10mm Application Temperature 15°C - 35°C
• Unfilled voids behind tiles or stone facades
• Bonding of steel plates to concrete
• Rapid structural repair of concrete Surface preparation
•

•
Grouting dowels

-
.
:
Solvent free -Low vac and non-shrink
Remove all grease, oil, dust, residual curing
compound, mould release agent or other
contaminant that could impair adhesion of the
injection ports. The injection ports should be applied
• Pre-proportioned packaging - No job site
over 6-10mm diameter holes drilled at least 50­
errors
75mm into the concrete element. For deeper
• Low viscosity - Easy to inject into fine cracks
penetration deeper holes should be considered.
• High bond strength to concrete -Can restore Use MasterEmaco ADH 2200 to adhere the
the structura'i integrity of the concrete injection ports over the holes ensuring that the
• Cures hard at low temperatures -Wide adhesive does not block the drilled holes. Allow the
application range MasterEmaco ADH 2200 to cure before injecting .
• High heat deflection temperature - Suitable The ports should foillow the crack at intervals of
for high ambient temperature environments 500mm or a maximum of 1m centres. Inject from the
• Can be applied for Wet and Damp Substrates lowest point or furthest point towards the centre
checking for resin coming out of the next hole along.
PROPERTIES For detailed instructions on crack injection ask you
BASF representative for the "Masterlnject guide to
I Mixed resin and hardener only crack injection".
Viscosity (25°C) <500 cps
Mixing
Proportion part kits accurately mixing only what can
Compressive Strength 65 MPa @ 1 day
(ASTM C579)
be used in less than 30 minutes. Thoroughly stir
70 MPa @ 7 days Part A, add Part B and blend thoroughly using a
Flexural strength (ASTM C 45 MPa @ 1 day slow speed mixer fitted with a suitable paddle.
6319 part 3)
55 MPa @ 7 Days
Tensile 18 MPa Cure time will vary depending on the ambient
strength(ASTMD638) temperature, quantity mixed and placed.
7days Masterlnject 1315 will have fully cured after 7 days
Pot life 50 minutes @ 25°C
at 23°C.

30 minutes @ 40°C
Slant shear bond strength >18 MPa (Concrete
Usage will depend on the injection pressure and the
(ASTM C 882 @ 7 days) failure) size of the cracks and is impossible to estimate.
Bond strength >2.5 MPa (concrete
.,
failure) Masterlnject 1315 comes in 1 litre and 4 litre kit
Tack free time 6.5 hours @ 25°C sizes
Meets the requirements of ASTM C881 Type 1 & 4
Grade 1 Class B & C
MASTER®
»BUILDERS
<:' i ,TIC) ,_
 BASF
We create chemistry

Masterlnject® 1315
make sure that you obtain a copy of the BASF
Material Safety Data Sheet (MSDS) from our office
Masterlnject 1315 can be stored in tightly closed or our website.
original containers for 12 months at moderate
temperature. Masterlnject 1315/02/0718

For the full health and safety hazard information and

how to safely handle and use this product, please

The technical infonnation and application advice given in this BASF Conslruclion Chemicals publication are based on the presenl
STATEMENT OF state of our best scientific and practical knowledge. As the information herein is of a generat 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
RESPONSIBILITY
expressed or implied is given other than those required by law. The user is responsible for checking the suitability of products for their
(Disclaimer)
intended use.
® = registered trademark of BASF group in many countries

NOTE Field service where provided does not constitute supervisory responsibility. Suggestions made by BASF Construction Chemicals
either orally or in writing may be followed, modified or rejected by the owner. engineer or contractor since they, and not BASF
Construction Chemicals, are responsible for carrying out procedures appropriate to a specific application.

BASF India Limited

Construction Chemicals Division
Plot.No.12,TTC Area
Thane Belapur Road,Turbhe
Navi Mumbai - 400705,lndia
Tel: +91 2267127600, Fax: +912267917358
E-mail: construction-india@basf.com, www.master-builders-solutions.basf.in