Expansive Mortar Application on RCC & PCC Structures

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Regd. Address: # 259/125, 4t

Mobile No: +91-9952051475,

PRUDENT ROCK DEMOLITION SOLUTIONS

An Information

Expansive Mortar Application

Demolition of RCC and PCC Structures

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, 4th Floor, Linghichetty Street, George Town, Che

5, 9642566077; Email: [email protected] website: w


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An Information

on

Expansive Mortar ApplicationFor


Kishore Surampalli,

Prudent Rock Demolition Solutions

Chennai

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Expansive Mortar Application


By

urampalli, B.E, PG.D

Prudent Rock Demolition Solutions

Chennai, Tamilnadu

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Mobile No: +91-9952051475,


Non-Explosive Demolition Agents a

demolish rock and concrete structures in dust and noise sensitive areas and

places close to inhabited areas, gas

the use of explosive would generate significant safety risk.

In India these are extensively being used in

quarrying industry, and termed as ever best method techno

because of its unique characteristics of application results. It is also being in

use for demolition of concrete struct

Power Plant Developments, Process P

development, boulder demolitions in road constructions, etc.

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Introduction

Explosive Demolition Agents are the one which can be used to


habited areas, gas pipelines, roadways or other areas where

the use of explosive would generate significant safety risk.

these are extensively being used in granite/marble/sand stone

quarrying industry, and termed as ever best method techno


concrete structures in projects like Metro Rail Station,

Power Plant Developments, Process Plants, and for rock demolition in land

development, boulder demolitions in road constructions, etc.

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re the one which can be used to


pipelines, roadways or other areas where

/marble/sand stone

quarrying industry, and termed as ever best method techno-economically


s in projects like Metro Rail Station,

lants, and for rock demolition in land

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Mobile No: +91-9952051475,


Expansive Mortar: A Non

We at Prudent Rock Demolition Solutions have actively engaged in developing Non

Chemical Demolition Technology in Infrastructure and Mining Industry across India. We with registe

office in Chennai, Tamilnadu, supplying Expansive Mortar throughout the

‘ECO-CRACK’. Our product has got great performance appreciation from various Mining and Infrastructure

Companies Located in Andhrapradesh,

Pradesh and Rajasthan etc.

Technical Information:

NON-HAZARDOUS CHEMICAL COMPOUNDS (% by weight)

SL.No. Inorganic Compounds

1 Silicon Dioxide (SiO2)

2 Aluminum Trioxide (Al2O3)

3 Ferric Oxide (Fe2O3)

4 Calcium Oxide (CaO)

5 Magnesium Oxide (MgO)

6 Sulfur Trioxide (SO3)

1. Base Material:

The base product in the compound is Calci

has a natural property of heat generation on Hydration

other remaining composites are naturally possessed with base material when extracted from earth crust.

2. Principle of Working:

When a material (dry)

hydration (28-32% w/w of CaO)

volume due to hydro bonding

holes.

Due to exothermic chemical reaction between

heat energy will be liberated which leads to

dry state. During evaporation/dehydration process

termed as Expansion Process

developed from multi points together

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Expansive Mortar: A Non-Explosive Demolition Agent

Demolition Solutions have actively engaged in developing Non

Technology in Infrastructure and Mining Industry across India. We with registe

supplying Expansive Mortar throughout the India unde

CRACK’. Our product has got great performance appreciation from various Mining and Infrastructure

Companies Located in Andhrapradesh, Tamilnadu, Karnataka, Maharashtra, Assam,

HAZARDOUS CHEMICAL COMPOUNDS (% by weight)

Inorganic Compounds % of Composition

Silicon Dioxide (SiO2) 1.5 - 8 %

xide (Al2O3) 0.4 - 5 %

Ferric Oxide (Fe2O3) 0.2 - 2 %

Calcium Oxide (CaO) 81 - 95 %

sium Oxide (MgO) 0 – 1.1 %

Sulfur Trioxide (SO3) 0.6 - 4 %

The base product in the compound is Calcium Oxide and is prepared from Burnt Lime. Calcium Oxide

has a natural property of heat generation on Hydration (An Exothermic Chemical

are naturally possessed with base material when extracted from earth crust.

made to fine powdered form measuring certain volume,

w/w of CaO) of powder its physical volume reduces than initially measured

due to hydro bonding. At this min volume state chemical would be applied in drilled

Due to exothermic chemical reaction between Calcium Oxide and water significant int

energy will be liberated which leads to evaporation of H2O from the mixture

dehydration process, it also tries to attain its original volume, which is

termed as Expansion Process in a circumferentially constrained hole. This expansion energy

developed from multi points together implies to create fractures on rock/concrete

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Explosive Demolition Agent

Demolition Solutions have actively engaged in developing Non-Explosive

Technology in Infrastructure and Mining Industry across India. We with registered

India under the brand name of

CRACK’. Our product has got great performance appreciation from various Mining and Infrastructure

shtra, Assam, Orisaa, Himachal

um Oxide and is prepared from Burnt Lime. Calcium Oxide

Reaction with H2O). All

are naturally possessed with base material when extracted from earth crust.

measuring certain volume, on through

of powder its physical volume reduces than initially measured

At this min volume state chemical would be applied in drilled

and water significant internal

O from the mixture and tries to attain

also tries to attain its original volume, which is

This expansion energy

on rock/concrete.

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Mobile No: +91-9952051475,


We pour the hydrated mix into drilled holes in minimum volume state. After filling the mix,

within 10-15 min evaporation sta

chemical happens in a constrained hole

That expansion stress is more enough to create fractures in the structure.

In the expansion stress, Major component is Hoop stress and Minor component is

Normal stress. Hoop stress acting circumferentially will lead to create fractures, and normal

stress will release in upward directi

shown in figure below.

We reiterate that it is not

together due to dehydration.

work stations during concrete demolition with chemical application

expansion process happening

after application.

How to Limit the Crack Propagation

To limit the both penetration and crack propagation, we shall drill the blank

spacing 6-8 inches and 300 mm down to the Drilled Length.

structure.

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15 min evaporation starts because of internal heat energy developed

chemical happens in a constrained hole. It physically appears as blow shots (1

more enough to create fractures in the structure.

on stress, Major component is Hoop stress and Minor component is


stress will release in upward direction with some chemical spill out at to

We reiterate that it is not a molecular expansion; it is wholly a volumetric expansion all

together due to dehydration. Moreover it is nearly homogeneous medium with concrete.

during concrete demolition with chemical application, we practically noticed that

expansion process happening max of 12 inches in downward direction in a period of 12 hours

How to Limit the Crack Propagation?

o limit the both penetration and crack propagation, we shall drill the blank

mm down to the Drilled Length. It will double ensure the safety of

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rts because of internal heat energy developed there by expansion of

. It physically appears as blow shots (1-2 blows per Hole).

on stress, Major component is Hoop stress and Minor component is


op face nearby hole as

molecular expansion; it is wholly a volumetric expansion all

homogeneous medium with concrete. At

we practically noticed that

in a period of 12 hours

o limit the both penetration and crack propagation, we shall drill the blank holes with mean

It will double ensure the safety of

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Mobile No: +91-9952051475,


3. Change in Mix ratio & its Implications:

As per practical analysis and purity of calcium oxide it

(w/w) water. When we add less than 30%

flow ability characteristics to full fill the aim of the Job. Improper hydrated mix in a very few minutes

physically appears as blowing

the mixing process.

If we add more water,

may not be sufficient to evaporate the mixed water and remains in wet state with very less

change or sometimes no change there by no expansion.

So, always mix 30% w/w to get better results and contact your supplier/manufacturer for any

changes if needed. Usually it takes 10

drilled holes within 10-15 min. else it will create blow in container itself changing wet to dry state.

No Packing required for this product after filling. During dehydration it becomes self packing.

The whole process is internal chemical reaction with physical c

work piece like either ROCK or CONCRETE

expansion energy to create fractures.

Fracturing Time depends on tensile strength and compressive strength. R

as it is less tensile and concrete takes time as it possesses high compressive strength.

Crack Propagation:

Crack propagation mainly depends on type of material (Tensile / Brittle) and hole position

from nearest free face. Maximum

case of in-situ rock crack will form 80% of total drill depth only bottom 20% will not give result due

to high shear stress limit.

Concrete Structures,

case of free structures fracture happens up to drilled depth only and

propagates/weakens towards free face. However we consider crack propagates i

region sub tending a max angle of 45 Degrees

6-8 inches mean hole distance and Line

inches for PCC Structures. It is safe for

chipping with breakers with high

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Change in Mix ratio & its Implications:

As per practical analysis and purity of calcium oxide its min volume

water. When we add less than 30% water proper hydration does not happens


steam and powder solution. Proper eye protection must be w

If we add more water, the amount of heat energy that liberates during the reaction process

may not be sufficient to evaporate the mixed water and remains in wet state with very less

or sometimes no change there by no expansion.

lways mix 30% w/w to get better results and contact your supplier/manufacturer for any

. Usually it takes 10-15 min for reaction initiation, so the mix must be poured in

15 min. else it will create blow in container itself changing wet to dry state.

equired for this product after filling. During dehydration it becomes self packing.

The whole process is internal chemical reaction with physical change;

ROCK or CONCRETE. There is only Volumetric Change, Which is termed as

expansion energy to create fractures.

Fracturing Time depends on tensile strength and compressive strength. R



from nearest free face. Maximum Crack Propagation is up to 1.5 ft in case of free boulders

situ rock crack will form 80% of total drill depth only bottom 20% will not give result due

being a porous medium with significant compressive strength, in

case of free structures fracture happens up to drilled depth only and

propagates/weakens towards free face. However we consider crack propagates i

angle of 45 Degrees to Horizontal Plane as shown in Figure.

mean hole distance and Line-Line distance for RCC Structures and

inches for PCC Structures. It is safe for structures to limit the cracks

with high productivity.

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min volume observed at 28-32%

not happens and it will net get


n. Proper eye protection must be wore during

during the reaction process

may not be sufficient to evaporate the mixed water and remains in wet state with very less volumetric

lways mix 30% w/w to get better results and contact your supplier/manufacturer for any

15 min for reaction initiation, so the mix must be poured in

15 min. else it will create blow in container itself changing wet to dry state.

equired for this product after filling. During dehydration it becomes self packing.

hange; it does not react with

. There is only Volumetric Change, Which is termed as

Fracturing Time depends on tensile strength and compressive strength. Rock is easy to crack



ft in case of free boulders, while in

situ rock crack will form 80% of total drill depth only bottom 20% will not give result due

icant compressive strength, in

case of free structures fracture happens up to drilled depth only and then Crack

propagates/weakens towards free face. However we consider crack propagates in a sector

as shown in Figure. We keep

for RCC Structures and similarly 10-12

cracks and also eases for

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Application Procedure and Requirements

Chemical demolition technique involves

a). Drilling Among available drilling techniques pneumatic drilling setup and mechanized hydraulic drilling setup are

practice for productive results.

Drilling Design Specifications:

Sl

No

Hole

Dia.

MM

Mean Hole Distance Range

For Rock

1 30-45 6-8 Inch Or 15-20 CM

2 30-45 8-10 Inch Or 20-25 CM

3 30-45 10-12 Inch Or 25-30 CM

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Application Procedure and Requirements

Chemical demolition technique involves a). Drilling b). Mixing c). Filling.

Among available drilling techniques pneumatic drilling setup and mechanized hydraulic drilling setup are

Drilling Design Specifications:

Mean Hole Distance Range Applicable for

For Concrete Structures

20 CM 6-8 Inch Or 15-20 CM

Sub-surface Rock/

Concrete

Demolition (If no free face)

25 CM 6-8 Inch Or 15-20 CM

Surface Rock/

Structures

30 CM 8-10 Inch Or 20-25 CM Above

Rock/Concrete demolition

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c). Filling.

Among available drilling techniques pneumatic drilling setup and mechanized hydraulic drilling setup are in

Applicable for

surface Rock/RCC

Concrete Structures

Demolition (If no free face)

Surface Rock/ PCC Concrete

Structures demolition

Above the surface

Rock/Concrete demolition

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b). Mixing:

Expansive Mortar is a powder that must be mixed thoroughly with clear water in a ratio of 30 %

(w/w) say 1.5-to-1.7 Lit for 5 Kg bag. We insist users to carry out a test in practical with various proportions

from 1.5 to 1.7 Lit per 5 kgs (Most using proportion is

results. Gradually add the powder to water and stir all the time to obtain a smooth and

Excessive water may delay the cracking process and less water may lead to starvation during

are requested to follow the instructions mentioned on the bag.

c). Filling:

After mix has been prepared it should be poured into the holes. as reaction starts quickly, pour the

Expansive Mortar within 5-10 min after mixing. During filling

hole Otherwise it may lead to non-homogeneous reaction resulting throw out of chemical. No Capping

required. Do not keep any obstruction on Hole. For further information feel free to discuss with us.

Standard Consumption

Sl. No.

Chemical Qty. Water Qty

1 20 Kg 6-6.5 Ltr

2 20 Kg 6-6.5 Ltr

3 20 Kg 6-6.5 Ltr

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e Mortar is a powder that must be mixed thoroughly with clear water in a ratio of 30 %

1.7 Lit for 5 Kg bag. We insist users to carry out a test in practical with various proportions

Most using proportion is 1.6 Lit/5Kg) to decide the correct proportion for

results. Gradually add the powder to water and stir all the time to obtain a smooth and

Excessive water may delay the cracking process and less water may lead to starvation during

are requested to follow the instructions mentioned on the bag.


after mixing. During filling do not maintain any delay in any particular

homogeneous reaction resulting throw out of chemical. No Capping


Water Qty. Hole Dia. Consumption

in RFT

6.5 Ltr 40 mm 32 Ft.

Water Qty Subject to6.5 Ltr 32 mm

36 Ft.

6.5 Ltr 25 mm 42 Ft.

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e Mortar is a powder that must be mixed thoroughly with clear water in a ratio of 30 %

1.7 Lit for 5 Kg bag. We insist users to carry out a test in practical with various proportions

) to decide the correct proportion for better

results. Gradually add the powder to water and stir all the time to obtain a smooth and LUMP-FREE mortar.

Excessive water may delay the cracking process and less water may lead to starvation during reaction. Users


do not maintain any delay in any particular

homogeneous reaction resulting throw out of chemical. No Capping


Remarks

Water Qty Subject to change as per site

conditions.

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Mobile No: +91-9952051475,


Free Surface

It is one of the significant factors that play an important role in cracking process. As expansive

pressure acts towards free surface, it is necessary to ensure free surface at least at one edge (Other than Top

face and Front Face) for a bottom free ro

email us photograph for the suitable Hole Drilling pattern to demolish the big boulder/rock rooted

earth. We have dedicated geologists and rock engineers to serve you the be

Cracking Mechanism

After the mortar has poured into holes drilled on rock or concrete, the expansive stress gradually

increases with time, the material to be cracked undergoes a process of:

� Crack initiation

� Crack propagation

� The increase of crack

The mechanism by the expansive stress of “

inner surface of the hole due to circumferential stress that develops during expansion process while

hardening. The expansive stress continues ev

new cracks initiate during the process. Usually, For a single hole, 2

towards nearest free surface or nearest hole. When a free surface exists, the crac

pushed apart mainly by the shear stress, and a secondary crack also arises from the bottom of the hole,

running toward the free surface. Please note during the initial reaction process (i.e., 30

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face and Front Face) for a bottom free rock/boulder. If the rock/boulder is routed into the earth surface

email us photograph for the suitable Hole Drilling pattern to demolish the big boulder/rock rooted

earth. We have dedicated geologists and rock engineers to serve you the best.


increases with time, the material to be cracked undergoes a process of:

Crack initiation

Crack propagation

The increase of crack width

The mechanism by the expansive stress of “Expansive Mortar” is shown in Fig. 1. Cracks initiate from an


hardening. The expansive stress continues even after the appearance of cracks, the cracks propagate and also

new cracks initiate during the process. Usually, For a single hole, 2-4 cracks initiate and propagate

towards nearest free surface or nearest hole. When a free surface exists, the crack, as shown in Fig. 2, is


Please note during the initial reaction process (i.e., 30

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ck/boulder. If the rock/boulder is routed into the earth surface please

email us photograph for the suitable Hole Drilling pattern to demolish the big boulder/rock rooted inside the


” is shown in Fig. 1. Cracks initiate from an


en after the appearance of cracks, the cracks propagate and also

4 cracks initiate and propagate either

k, as shown in Fig. 2, is


Please note during the initial reaction process (i.e., 30-60mis) there are

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Mobile No: +91-9952051475,


chances for blow-shot releasing gases evolved in the hydration reaction. So, during that period we

workers to stay away at least 10 mts from Job place. Peeping onto the hole strictly prohibited.

Fig. 1 Fracture mechanism of Expansive Mortar Application

Safety Precautions

Even though it is safe demolition technique, as the product is chemically highly base in nature with

pH-13++ it is necessary to take proper care while handling and applying. Being safe is prime

a safe demolition. Always wear hand gloves while handling and wash hands

this product causes severe damage to digestion system of human body. If it comes in contact with eyes do

rub your eyes and rinse with clear water several times and

damage to eye. Also avoid contact with skin as it will react with skin rinse all affected parts

� Always wear nose mask to avoid inhalation into breathing system.

� Wear safety Goggles, Rubber Gloves, Long

and pouring Expansive Mortar and be a safe applicant.

� Do not peep into hole till at least one Hour as there is chance of blow shots releasing the evolved

gases. So please maintain some distance from job sit

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hot releasing gases evolved in the hydration reaction. So, during that period we


Fig. 1 Fracture mechanism of Expansive Mortar Application


13++ it is necessary to take proper care while handling and applying. Being safe is prime

hand gloves while handling and wash hands thoroughly after use. Ingestion

this product causes severe damage to digestion system of human body. If it comes in contact with eyes do

rub your eyes and rinse with clear water several times and contact an eye doctor at the earliest to avoid

damage to eye. Also avoid contact with skin as it will react with skin rinse all affected parts

Always wear nose mask to avoid inhalation into breathing system.

Wear safety Goggles, Rubber Gloves, Long sleeve clothing and Helmet while handling, mixing

pouring Expansive Mortar and be a safe applicant.

Do not peep into hole till at least one Hour as there is chance of blow shots releasing the evolved

gases. So please maintain some distance from job site for at least 1 hour.

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hot releasing gases evolved in the hydration reaction. So, during that period we insists



13++ it is necessary to take proper care while handling and applying. Being safe is prime important to do

thoroughly after use. Ingestion

this product causes severe damage to digestion system of human body. If it comes in contact with eyes do not

e doctor at the earliest to avoid major

damage to eye. Also avoid contact with skin as it will react with skin rinse all affected parts thoroughly.

sleeve clothing and Helmet while handling, mixing

Do not peep into hole till at least one Hour as there is chance of blow shots releasing the evolved

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Mobile No: +91-9952051475,


� Ensure that portion that to be cracked should not comedown/roll down/slide down into active

work place after got cracked.

� Do not park equipments besides structure/rock on which chemical demolition

� Keep away from children.

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Ensure that portion that to be cracked should not comedown/roll down/slide down into active

place after got cracked.

Do not park equipments besides structure/rock on which chemical demolition

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Ensure that portion that to be cracked should not comedown/roll down/slide down into active

Do not park equipments besides structure/rock on which chemical demolition.

Documents

Expansive Mortar Application on RCC & PCC Structures