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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hennai-600001

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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 are the one which can be used to

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 r

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

e use of explosive would generate significant safety risk.

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

quarrying industry, and termed as ever best method techno

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

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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Explosive Demolition Agents are 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

esults. It is also being in

ures 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

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

Infrastructure Companies Located in Andhrapradesh,

Himachal 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.

with base material when extracted from earth crust.

2. Principle of Working:

When a material (dry)

hydration of powder its physical volume reduces than initially measured volume

bonding.

Calcium Oxide has natural property of heat liberation during hydration reaction. Because

this internal heat energy developed in the

state. During evaporation/dehydration process

termed as Expansion Process. This expansion energy implies to creat

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Expansive Mortar: A Non-Explosive Demolition Agent

We at Prudent Rock 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 under the brand name of

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

Infrastructure Companies Located in Andhrapradesh, Tamilnadu, Karnataka, Mahara

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 %

Magnesium 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

a natural property of heat generation on Hydration. All other remaining composites

with base material when extracted from earth crust.

made to fine powdered form measuring certain volume,

hydration of powder its physical volume reduces than initially measured volume

Calcium Oxide has natural property of heat liberation during hydration reaction. Because

energy developed in the mixture, a part of water will evaporate

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

This expansion energy implies to create fractures.

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Explosive Demolition Agent

We at Prudent Rock 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

Maharashtra, Assam, Orisaa,

um Oxide and is prepared from Burnt Lime. Calcium Oxide

sites are naturally possessed

measuring certain volume, on through

hydration of powder its physical volume reduces than initially measured volume due to hydro

Calcium Oxide has natural property of heat liberation during hydration reaction. Because of

a part of water will evaporate and tries to attain dry

also tries to attain its original volume, which is

e fractures.

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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 starts because of internal heat energy developed

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

in upward direction with some chemical spill out nearby hole.

We reiterate that it is not

together due to dehydration.

stations during concrete demolition with chemical application,

expansion process happening 4

application. However, to lim

blank holes with mean spacing 6

double ensure the safety of structure.

3. Change in Mix ratio & its Implications:

As per practical analysis and purity of calcium oxide it

water. When we add less than 30%

completely evaporate the mixed water. It physically appears as b

solution. Proper eye protection must be worn during the mixing process.

If we add more water,

may not be sufficient to evaporate the mixed water and remains in wet

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 need. 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 chem

work piece like either ROCK or CONCRETE or any other material. There is only Volumetric

Change, Which is termed as expansion energy to create fractures.

Fracturing Time depends on tensile strengt

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

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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.


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

in upward direction with some chemical spill out nearby hole.

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

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

during concrete demolition with chemical application, we practically noticed that

expansion process happening 4-6 inches in downward direction in a period of 12 hours after

. However, to limit the both penetration and crack propagation, we shall drill the

with mean spacing 6-8 inches and 150 mm down to the Drilled Length

double ensure the safety of structure.

Change in Mix ratio & its Implications:

As per practical analysis and purity of calcium oxide it possesses min volume at 30%

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

completely evaporate the mixed water. It physically appears as blowing in steam and powder

solution. Proper eye protection must be worn during the mixing process.

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.


changes if need. Usually it takes 10-15 min for reaction initiation, so the mi

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 or any other material. There is only Volumetric

Change, Which is termed as expansion energy to create fractures.

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


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15 min evaporation starts because of internal heat energy developed there by expansion of

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


will lead to create fractures, and normal stress will release

molecular expansion; it is wholly a volumetric expansion all

is homogeneous medium with concrete. At work

we practically noticed that

in a period of 12 hours after

it the both penetration and crack propagation, we shall drill the

150 mm down to the Drilled Length. It will

min volume at 30% (w/w)

not happens and generated heat can

g in steam and powder

during the reaction process

state with very less volumetric


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.

ical reaction with physical change; it does not react with

ROCK or CONCRETE or any other material. There is only Volumetric

h and compressive strength. Rock is easy to crack


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Mobile No: +91-9952051475,


Crack Propagation:

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

from nearest free face. Maximum Crack Propagation is up to 1

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 Crack propagates/weakens

towards free face. However we consider crack propagates in a sector region sub tending an

angle of 45 Degrees to Horizontal Plane

distance and Line-Line distance

Structures. It is safe for structures to limit the

with high productivity.

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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



to Horizontal Plane as shown in Figure. We keep 6

Line distance for RCC Structures and similarly 10

structures to limit the cracks and also eases for chipping w

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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

being a porous medium with significant compressive strength, in



We keep 6-8 inches mean hole

10-12 inches for PCC

and also eases for chipping with breakers

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Mobile No: +91-9952051475,


Application Procedure and Requirements

Chemical demolition technique involves

a). Drilling

Among available drilling techniques pneumatic drilling setup and mechanized

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 in

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.

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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Mobile No: +91-9952051475,


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 1.6

results. Gradually add the powder to wat

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 do not maintain any delay in any particular

hole Otherwise it may lead to non-homogeneous

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 6.5 Ltr

2 20 Kg 6.5 Ltr

3 20 Kg 6.5 Ltr

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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.

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

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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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

er 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

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

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

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.

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 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.

Cracking Mechanism

After the mortar has poured into holes drilled on rock or

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 “

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

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

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


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

h 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.

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 width

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



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

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


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

h for the suitable Hole Drilling pattern to demolish the big boulder/rock rooted inside the

concrete, the expansive stress gradually

. Cracks initiate from an



4 cracks initiate and propagate either

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Mobile No: +91-9952051475,


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

pushed apart mainly by the shear stress, and a secondary

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

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

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

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

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

and pouring Expansive Mortar

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

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

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


Fig. 1 Fracture mechanism of Expansive Mortar Application

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

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

safe demolition. Always wear hand gloves while handling and wash hands thoroughly after use. Ingestion

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.

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crack also arises from the bottom of the hole,

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

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


chemically highly base in nature with

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

thoroughly after use. Ingestion

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

contact an eye doctor at the earliest to avoid major

skin as it will react with skin rinse all affected parts thoroughly.

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

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Mobile No: +91-9952051475,


� 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.

� Ensure that portion that to be cracked should not comedo

work place after got cracked.

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

� Keep away from children.

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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.

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

wn/roll down/slide down into active

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

expansive mortar application on rcc & pcc structures

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