Conbextra GP2 constructive solutions

Free flow, high strength, non-shrink,

cementitious precision grout
Technical support
Uses
An experienced technical advisory team is available to give
Conbextra GP2 is used for precision grouting where it is essential
technical service on request.
to withstand static and dynamic loads. Typical applications would
be the grouting of base plates of turbines, compressors, boiler
Properties
feed pumps etc., It can also be used for anchoring a wide range
Compressive strength
of fixings. These include masts, anchor bolts and fence posts.
Compressive strength (N/mm2)
Advantages Age (days) Consistency
Flowable (W/P 0.18) Pourable (W/P 0.165)
Gaseous expansion system compensates for shrinkage
1 24 26
and settlement in the plastic state
3 45 51
No metallic iron content to cause staining 7 55 57
28 65 68
Pre-packed material overcomes onsite batching variations
Compressive strength with addition of aggregates
Develops high early strength without the use of chlorides Age Compressive strength (N/mm2) W/P 0.18
(days) % of aggregates ( IS 516 - 1959)
High ultimate strength ensure the durability of the hardened
50% 75% 100%
grout
1 28 30 32
Free flow ensures high level of contact with load bearing 3 50 52 55
area 7 60 63 68
28 70 75 78
Standard Compliance
Flexural strength ( BS 4551, 1998)
Conbextra GP2 conforms to ASTM C1107 (Standard
Age Flexural strength (N/mm2)
Specification for Packaged Dry, Hydraulic-Cement Grout
(days) W/P 0.18
(Non-shrink).
1 2.5
Description
3 7.0
Conbextra GP2 is supplied as a ready to use dry powder. The 7 9.0
addition of a controlled amount of clean water produces a free 28 10.0
flowing, non-shrink grout for gap thicknesses up to 100mm.
Tensile strength 3.5N/mm2 @ 28 days
Conbextra GP2 is a blend of Portland cement, graded fillers (W/P - 0.18)
and chemical additives which impart controlled expansion in the
Pullout bond strength 17 N/mm2 @ 7 days
plastic state whilst minimising water demand. The low water
(W/P - 0.18) 20 N/mm2 @ 28 days
demand ensures high early strength. The graded fillers are
designed to assist uniform mixing and produce a consistent Time for expansion Start : 20 minutes
grout. (after mixing ) Finish : 120 minutes

Freshwet density Approximately 2220kg/m3

depending on actual
consistency used

Young’s modulus 28 kN/mm2

(ASTM D469 - 94)

Dynamic load resistance Specimens of Conbextra GP2

remained undamaged even
after subjecting them to
alternate loads of 5N/mm2 &
25N/mm2 at the rate of 500
Conbextra GP2

cycles / minute for two million

cycles.

page 1 of 4
Conbextra GP2

Coefficient of thermal expansion 11 x 10 -6/ 0 C Typical detail of stanchion base plate

Unrestrained expansion 2 - 4 % in the plastic
The compressive strength of the grout must exceed 50 N/mm2
state enables to
at 7 days and 60 N/mm2 at 28 days.
overcome shrinkage.
Pressure to restrain 0.004 N/mm2 approx. The flexural strength of grout must exceed 9N/mm2 @ 28 days.
Flow characteristics : The maximum distance of flow is The fresh wet density of the mixed grout must exceed 2150 kg/m3.
governed by the gap width and the head of the grout. Typical
The storage, handling and placement of the grout must be in
data for flow design assuming grout is poured immediately
strict accordance with the manufacturer’s instructions.
after mixing is given in the table below :
Application instructions
Grout Max. flow distance in mm
consistency Gap width 50mm 100mm 250mm Preparation
(mm) head head head
Foundation surface
Flowable 30 350 1000 1500
The substrate surface must be free from oil, grease or any
40 500 1500 2000
loosely adherent material. If the concrete surface is defective
50 900 2000 3000+
or has laitence, it must be cut back to a sound base. Bolt holes
Note : This table is based on the following factors temperature and fixing pockets must be blown clean of any dirt or debris.
- 300C ; Water saturated substrate; Minimum unrestricted flow
Pre-soaking
width is 300mm.
Several hours prior to placing, the concrete substrates should
Note: The typical physical properties given above are derived
be saturated with fresh water.
from testing in a controlled laboratory environment. Results
derived from testing field-applied samples may vary, dependent Immediately before grouting takes place any free water should
on actual site conditions. be removed with particular care being taken to blow out all bolt
holes and pockets.
Specification Clauses
Base plate
Performance specification
It is essential that this is clean and free from oil, grease or scale.
All grouting shown on the drawing must be carried out with a
Air pressure relief holes should be provided to allow venting
pre packed cement based product which is chloride free.
of any isolated high spots.

Levelling shims

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

should be treated with a thin layer of grease.

Formwork

The formwork should be constructed to be leakproof. This

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

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

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

Unrestrained surface area

It shall be mixed with clean water to the required consistency.
The grout must not bleed or segregate. This must be kept to a minimum. Generally the gap width
between the perimeter formwork and the plate edge should
A positive volumetric expansion shall occur while the grout is
not exceed 150mm on the pouring side and 50mm on the op-
plastic by means of gaseous system.
posite side. It is advisable, where practical, to have no gap at
the flank sides.

constructive solutions page 2 of 4

Conbextra GP2

Mixing and placing Typical hopper system

Mixing Removable hopper : For large pours the grout may be hand
placed or pumped into a removable hopper ( trough)
For best results a mechanically powered grout mixer should
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.

To enable the grouting operation to be carried out continu-

ously, it is essential that sufficient mixing capacity and labour
are available. The use of a grout holding tank with provision
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 litres Pouring should be from one side of the void to eliminate any air
or presoaked water becoming trapped under the base plate. It
The selected water content should be accurately measured
is advisable to pour the grout across the shortest distance of
into the mixer. The total content of the Conbextra GP2 bag
travel. The grout head must be maintained at all times so that
should be slowly added and continuous mixing should take
a continuous grout front is achieved.
place for 5 minutes. This will ensure that the grout has a
smooth even consistency. Where large volumes have to be placed Conbextra GP2 may
Placing be pumped. A heavy duty diaphragm pump is recommended
for this purpose. Screw feed and piston pumps may also be
At 300C place the grout within 20 minutes of mixing to gain
suitable.
full benefit of the expansion process.
Curing
Conbextra GP2 can be placed in thicknesses up to 100mm in
a single pour when used as an underplate grout. On completion of the grouting operation, exposed areas should
be thoroughly cured. This should be done by the use of Con-
For thicker sections it is necessary to fill out Conbextra GP2
cure WB curing membrane, continuous application of water
with well graded silt free aggregate to minimise heat build up.
and/or wet hessian.
Typically a 10mm aggregate is suitable. 50 - 100% aggregate
by weight of Conbextra GP2 can be added. Limitations

Any bolt pockets must be grouted prior to grouting between Low temperature working
the substrate and the base plate.
When the air or contact surface temperatures are 100C or below
Continuous grout flow is essential. Sufficient grout must be on a falling thermometer, warm water ( 30 - 400C) is recom-
prepared before starting. The time taken to pour a batch must mended to accelerate strength development.
be regulated to the time to prepare the next one.
For ambient temperature below 100C the formwork should be
kept in place for at least 36 hours.

Normal precautions for winter working with cementitious materi-

als should then be adopted.

constructive solutions page 3 of 4

Conbextra GP2

High temperature working Precautions

At ambient temperatures above 400 C, cool water ( below 200C) Health and Safety instructions
should be used for mixing the grout prior to placement.
Conbextra GP2 is alkaline and should not come into contact
Estimating with skin and eyes. Inhalation of dust during mixing should
be avoided.
Packaging
Gloves, goggles and dust mask should be worn.
Conbextra GP2 is supplied in 25 kg moisture resistant bags.
If contact with skin occurs, it shall be washed with water.
Yield Splashes to eyes should be washed immediately with plenty
of clean water and medical advice sought.
Allowance should be made for wastage when estimating quanti-
ties required. The approximate yield per 25 kg bag for different Fire
consistency is :
Conbextra GP2 is non flammable.
Consistency Pourable Flowable
Additional information
Yield ( litres) 12.5 13.3

For further details about the use and selection of grouts refer
Storage
to the Fosroc Information module entitled ‘Precision grouting
in the Construction industry’.
Shelf life

Conbextra GP2 has a shelf life of 6 months if kept in a dry store

in sealed bags. If stored in high temperature and high humidity
locations, the shelf life may be reduced.

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

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Chennai Mumbai Noida Kolkata

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