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Summary
Al Gurg Fosroc LLC was founded as a joint venture in 1975 between HE Easa Saleh Al Gurg and
Fosroc International. Al Gurg Fosroc was the first construction chemicals company to establish a
manufacturing base in the region, and has grown to serve the markets of the U. A. E., Kuwait,
Bahrain, Qatar, Oman and other Fosroc companies worldwide.
Fosroc is a world leader in the delivery of tailored Constructive Solutions for virtually any type of
construction project, combining high quality products, expert technical support, customer service and
innovation.
Fosroc’s worldwide presence includes group companies in 15 countries with exports to over 70
countries.
Fosroc has over 76 years’ experience in supply of speciality chemicals and have gained the
acknowledgement as “market leaders” in quality production and supply of the most comprehensive
range of high performance construction chemicals serving the construction industries in building and
civil structures above and below ground.
Fosroc Support
Our experienced staff will assist you with high level support in:
CAD Details
Project Specifications
Site Support
Seminars & Training
www.fosroc.com
Contact
Al Gurg Fosroc LLC
P O Box 657, Dubai, UAE.
215 Community, Street No. 13, Nad Al Hamar Road
Al Ramool Industrial Area, Rashidiya.
tel : 04 203 9699, fax : 04 285 9649, email : agf@fosroc.com
Certificates/License
ISO 9001:2008
ISO 14001:2004
OHSAS 18001:2007
Scope of Certification
Note: Contact Al Gurg Fosroc office to obtain the latest copy of the above
certificates/license
Technical Datasheet
Fosroc
Conbextra Sureflow 100 constructive solutions
Dual Expansion system shrinkage- additives which impart controlled expansion in both
compensated, high flowable, high strength, plastic and hardened state whilst minimising water
cementitious precision grout. demand. Special additives obtain adjustable flow
with good flow retention. The low water demand
Uses ensures high early strength and high ultimate
strength. The specially graded filler ensures rapid
Conbextra Sureflow 100 is used for flowing uniform mixing and produces a consistent grout
precision grouting, where high compressive with no bleeding or segregation.
strengths and flow retention are required.
Technical Support
Machine base plates
Bridge Bearings Fosroc offers a comprehensive technical support
Stanchions & Columns service to specifiers, end users and contractors. It
Precast erection is also able to offer on-site technical assistance, an
Anchor bars AutoCAD facility and dedicated specification
Concrete voids/repairs assistance in locations all over the world.
Crane rails
Advantages Properties
DUAL EXPANSION system compensates for The following properties were obtained in Fosroc’s
shrinkage and settlement in both plastic and testing facilities at a temperature of 25°C.
hardened states, increasing the effective
bearing area Consistency Plastic Pourable Flowable
Water: 13% 15% 16%
Good flow and flow retention Powder Ratio
Water 3.25 3.75 4.0
High early strengths addition/25kg
Compressive Strength (N/mm²) ASTM C 109
Adjustable consistency 1 day 40 30 25
7 days 70 60 55
High resistance to bleed and segregation 28 days 85 70 65
Flow Characteristics ASTM cone (mm) ± 10%
Hydrogen-free gaseous expansion system 0 Mins 190 250 280
30 Mins 160 230 260
No Chlorides
Flexural Strength BS EN 196:1 (W/P: 16%)
7 Days 8 Mpa
Standards Compliance 28 Days 10 Mpa
Conbextra meets and exceeds the requirements of
ASTM C 1107 Type C. Expansion: Plastic State ASTM C827
Start: 15 minutes
Description Finish: Initial Set
Total Expansion: 0.25-2%
Conbextra Sureflow 100 is a new generation of
cementitious grout with excellent workability, dual Expansion: Hardened State ASTM C1107
shrinkage compensation and good flow retention. Start: Initial set
Conbextra Sureflow 100 cementitious grout is Finish: 28 days
supplied as a ready to use dry powder. The Total Expansion: 0~0.3%
addition of a controlled amount of clean water
3
produces a flowing non-shrink grout for gap Fresh Wet Density: 2200~2300 kg/m
thicknesses between 10 to 100 mm.
E- Modulus(ASTM C469): ≥ 25 GPa (28 days)
Conbextra Sureflow 100 has a unique blend of
Portland cement, graded fillers and chemical
Fosroc
Conbextra Sureflow 100
constructive solutions
Specification
Levelling Shims
Supplier specification
If these are to be removed after the grout has
Where mentioned on the contract documents, all
hardened, they should be treated with a thin layer
precision grouting (specify details and areas of
of grease.
application) must be carried out using Conbextra
Sureflow 100 manufactured by Fosroc and used in
Levelling Screws
accordance with the manufacturer’s data sheet.
Levelling screws should have a waxed sleeve
enclosure if subsequent re-levelling will be
Performance specification
required.
All precision grouting (specify details and areas of
application) must be carried out with a pre-
Formwork
packaged cement based product, which is non-
The formwork should be constructed to be leak-
metallic and chloride-free.
proof as Conbextra Sureflow 100 is a free flowing
It shall be mixed with clean water to the required
grout. This can be achieved by using foam rubber
consistency and not exhibit bleed or segregation.
strip or mastic sealant beneath the constructed
A volumetric expansion of up to 2% shall occur
formwork and between joints.
while the grout is in a plastic state by means of a
gaseous, hydrogen-free system. The grout must
In some cases it is practical to use a sacrificial
also be compensated for shrinkage in the
semi-dry sand and cement formwork. The
hardened state.
formwork should include outlets for the pre-soaking
water.
The compressive strength of the grout must
exceed 55 N/mm² at 7 days and 65 N/mm² at 28
Unrestrained surface area
days when tested at water powder ratio of 0.15.
This must be kept to a minimum. Generally the gap
The storage, handling and placement of the grout
width between the perimeter formwork and the
must be in strict accordance with the
plate edge should not exceed 75 mm on the
manufacturer’s instructions.
pouring side and 25 mm on the opposite side.
There should be no gap at the flank sides.
Instructions for Use
Preparation
Concrete surface
The substrate surface must be free from oil,
grease or any loosely adherent material. If the
concrete surface is defective or has laitance, it
must be cut back to a sound base. Bolt holes and
fixing pockets must be blown clean of any dirt or
debris.
Pre-soaking
For a minimum of 2 hours prior to grouting, the
area of cleaned substrate should be flooded with
fresh water. Immediately before grouting takes
Figure 1: Alignment of formwork with sleeved
place, any free water should be removed.
levelling screws
Particular care should be taken to blow out all bolt
holes and pockets.
Mixing
For best results a mechanically powered grout
Base plate
mixer should be used. For quantities up to 50 kg a
It is essential that this is clean and free from oil,
slow speed drill fitted with a Fosroc Mixing Paddle
grease or scale. Air pressure relief holes should be
(MR3) should be used. Larger quantities will
provided to allow venting of any isolated high
require a high shear vane mixer. Do not use a
spots.
colloidal impeller mixer.
Fosroc
Conbextra Sureflow 100
constructive solutions
It is essential that machine mixing capacity and diaphragm pump is recommended for this purpose.
labour availability is adequate to enable the Screw feed and piston pumps may also be
grouting operation to be carried out continuously. suitable.
This may require the use of a holding tank with
provision for gentle agitation to maintain fluidity. Curing
On completion of the grouting operation, exposed
Consistency of mixed grout areas should be thoroughly cured. This should be
To achieve the consistencies the amount of clean done by the use of Concure curing membrane, or
water that is added to a 25 kg bag is: continuous application of water and/or wet
hessian.
Plastic: 3.25~3.5L
Pourable: 3.75~4.0L
Flowable: 4.00~4.25L Cleaning
Conbextra Sureflow 100 should be removed from
The selected water content should be accurately tools and equipment with clean water immediately
measured into the mixer. Slowly add the total after use. Cured material can be removed
contents of the Conbextra Sureflow 100 bag, mix mechanically, or with Fosroc Acid Etch*†.
continuously for 3 minutes, ensuring a smooth,
even consistency is obtained. Sampling procedure
Cementitious grouts cannot be tested as concrete.
Placing Special sampling procedures are required. Refer to
At 25°C, place the grout within 15 minutes of your local Fosroc office for further details.
mixing to gain the full benefit of the expansion
process. High temperature working
It is suggested that, for temperatures above 35°C,
Conbextra Sureflow 100 can be placed in a the following guidelines are adopted as good
minimum thickness of 10mm up to a maximum working practice:
thickness of 100mm in a single pour when used as (i) Store unmixed material in a cool (preferably
an underplate grout. For thicker sections it is temperature controlled) environment, avoiding
necessary to fill out Conbextra SureFlow 100 with exposure to direct sunlight.
well graded 5~10mm, silt free aggregate to (ii) Keep equipment cool, arranging shade
minimise exotherm. If bulking with aggregate is protection if necessary. It is especially important to
used the ratio shall not exceed 1:1. Contact Fosroc keep cool those surfaces of the equipment which
for details of pre-bagged supply. The properties of will come into direct contact with the material itself.
a bulked grout will differ from those published in (iii) Try to eliminate application during the hottest
this data sheet. Consider the use of Conbextra TS times of the day and in direct sunlight.
for thick section grouting where precise material (iv) Make sufficient material, plant and labour
properties are required. available to ensure that application is a continuous
process.
Any bolt pockets must be grouted prior to grouting (v) Water (below 20°C) should be used for mixing
between the substrate and the base plate. the grout prior to placement
Estimating
Supply
Conbextra Sureflow 100: 25kg Bags
Yield
Plastic: ~12.5L /25kg
Pourable: ~13L /25kg
Flowable: ~13.2L /25kg
Storage
Conbextra Sureflow 100 has a shelf life of 12
months if kept in a dry store in sealed bags. If
stored in high temperature and high humidity
locations the shelf life will be reduced.
Precautions
Health and safety
Conbextra Sureflow 100 is alkaline and should not
come into contact with skin and eyes. Avoid
inhalation of dust during mixing. Gloves, goggles
and dust mask should be worn.
If contact with skin occurs, wash with water.
Splashes to eyes should be washed immediately
with plenty of clean water and medical advice
sought.
Fire
Conbextra Sureflow 100 is non-flammable.
Important note
Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the
Supply of Goods and Services, copies of which may be obtained on request. Whilst Fosroc endeavours to ensure that any advice,
recommendation, specification of information it may give is accurate and correct, it cannot, because it has no direct or continuous control
over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or
not in accordance with any advice, specification, recommendation or information given by it.
Al Gurg Fosroc
LLC telephone: fax: email:
1.2. Relevant identified uses of the substance or mixture and uses advised against
Identified uses Cementitious overlay
Health hazards Skin Irrit. 2 - H315 Eye Dam. 1 - H318 Skin Sens. 1 - H317 STOT SE 3 - H335
Human health Dust or splashes from the mixture may cause permanent eye damage. Dust may irritate the
respiratory system. Symptoms following overexposure may include the following: Coughing.
Dust has an irritating effect on moist skin. Prolonged contact with moist or wet product may
cause burns. Frequent inhalation of dust over a long period of time increases the risk of
developing lung diseases.
Environmental The product will harden into a solid mass in contact with water and moisture. The resultant
material is not biodegradable.
Pictogram
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3.2. Mixtures
Classification
Skin Irrit. 2 - H315
Eye Dam. 1 - H318
Skin Sens. 1 - H317
STOT SE 3 - H335
FORMALDEHYDE <1%
CAS number: 50-00-0 EC number: 200-001-8
The Full Text for all R-Phrases and Hazard Statements are Displayed in Section 16.
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Inhalation Move affected person to fresh air at once. Dust in throat and nasal passages should clear
spontaneously. Get medical attention if irritation persists or later develops, or if discomfort,
coughing or other symptoms persist.
Ingestion Do not induce vomiting. Rinse mouth thoroughly with water. Give plenty of water to drink. Give
milk instead of water if readily available. Never give anything by mouth to an unconscious
person. Get medical attention immediately.
Skin contact Wash immediately with copious quantities of water. Remove contaminated clothing
immediately. Obtain medical advice if skin orders develop.
Eye contact Do not rub eye. Remove any contact lenses and open eyelids wide apart. Remove any
contact lenses and open eyelids wide apart. Rinse immediately with plenty of water. Continue
to rinse for 30 minutes. Get medical attention. Show this Safety Data Sheet to the medical
personnel.
4.2. Most important symptoms and effects, both acute and delayed
General information The severity of the symptoms described will vary dependent on the concentration and the
length of exposure.
Inhalation Frequent inhalation of dust over a long period of time increases the risk of developing lung
diseases.
Ingestion Ingestion of large doses may result in irritation to the gastrointestinal tract.
Skin contact May have an irritating effect on moist skin after prolonged contact, or may cause dermatitis
after repeated contact.
Prolonged skin contact with wet preparation may cause serious burns without pain being felt,
including through clothing.
Eye contact Eye contact may cause serious and potentially irreversible injuries.
4.3. Indication of any immediate medical attention and special treatment needed
Notes for the doctor No specific recommendations.
Special protective equipment Use protective equipment appropriate for surrounding materials.
for firefighters
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Protective equipment
Appropriate engineering Atmospheric levels of dust must be maintained within the Occupational Exposure Limit.
controls Where mechanical methods are inadequate or impractical, appropriate personal protective
equipment must be used.
Personal protection Personal protection equipment should be chosen according to the CEN standards and in
discussion with the supplier of the personal protective equipment. This product may present a
chromate (VI) allergy risk. It contains a chromate reducing agent, but users should wear
appropriate personal protective equipment.
Eye/face protection The following protection should be worn: Chemical splash goggles. (conform EN 166)
Hand protection Use impervious, abrasion and alkali resistant gloves. Barrier cream applied before work may
make it easier to clean the skin after exposure, but does not prevent absorption through the
skin.
Other skin and body Use barrier creams to prevent skin contact. Wear appropriate clothing to prevent repeated or
protection prolonged skin contact.
Respiratory protection Wear a respirator fitted with the following cartridge: Particulate filter, type P2.
Colour Grey.
Odour Odourless.
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Oxidising properties The mixture itself has not been tested but none of the ingredient substances meet the criteria
for classification as oxidising.
10.1. Reactivity
Reactivity When mixed with water, hardens to form a stable mass that is not reactive in normal
conditions.
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Inhalation Irritating to respiratory system. Inflammation of the nasal mucous membrane by exposure to
cement dust.
Skin contact This product is strongly irritating. Prolonged contact may cause burns. May cause
sensitisation by skin contact.
Eye contact Irritating and may injure eye tissue if not removed promptly.
Acute and chronic health Repeated and/or prolonged contact may lead to dermatitis
hazards
Species Rabbit
FORMALDEHYDE
Species Rat
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Species Rat
12.1. Toxicity
Acute toxicity - fish Not determined.
The product is not expected to be hazardous to the environment. The addition of cements to
water will, however, cause the pH to rise and may therefore be toxic to aquatic life in some
circumstances.
FORMALDEHYDE
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Disposal methods Dispose of waste to licensed waste disposal site in accordance with the requirements of the
local Waste Disposal Authority. Note that fully cured material is not considered as hazardous
waste.
General The product is not covered by international regulations on the transport of dangerous goods
(IMDG, IATA, ADR/RID).
14.1. UN number
Not relevant.
UN No. (IMDG)
UN No. (ICAO)
ADR/RID class
ADR/RID label
IMDG class
ICAO class/division
Transport labels
EmS
14.7. Transport in bulk according to Annex II of MARPOL73/78 and the IBC Code
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15.1. Safety, health and environmental regulations/legislation specific for the substance or mixture
National regulations The Control of Substances Hazardous to Health Regulations 2002 (SI 2002 No. 2677) (as
amended).
The Chemicals (Hazard Information and Packaging for Supply) Regulations 2009 (SI 2009
No. 716).
Revision comments NOTE: Lines within the margin indicate significant changes from the previous revision.
Revision 1
The information on this data sheet represents our current data and is reliable provided that the product is used under the
prescribed conditions and in accordance with the application specified on the packaging and/or in the technical guidance
literature. Any other use of the product which involves using the product in combination with any other product or any other
process is the responsibility of the user.
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Method Statement
Method statement constructive solutions
A: General Comments
S:1
High temperature working
It is suggested that, for temperatures above 35°C, the following guidelines are adopted as good
working practice:
(i) Store unmixed materials in a cool (preferably temperature controlled) environment, avoiding
exposure to direct sunlight.
(ii) Keep equipment cool, arranging shade protection if necessary. It is especially important to
keep cool those surfaces of the equipment, which will come into direct contact with the
material itself.
(iii) Try to avoid application during the hottest times of the day.
(iv) Make sufficient material, plant and labour available to ensure that application is a continuous
process.
(v) Use water (below 20 ºC) for mixing the grout prior to placement.
Equipment
Al Gurg Fosroc
LLC
Post Box 657, Dubai telephone: fax: email:
United Arab Emirates (+9714) 2039699 (+9714) 2859649 agf@fosroc.com
www.fosroc.com Registered Office: 215 Community, Street No. 13, Nad Al Hamar Road, Al Ramool Industrial Estate, Rashidiya, Dubai
constructive solutions
Fosroc operates a policy to encourage the use, where possible, of approved or licensed applicators.
This ensures that works are completed satisfactorily so that the long term performance of the
materials is assured. For contractors who wish to apply the materials themselves Fosroc is also able
to offer technical assistance and training, either on-site or at its Training Centre in Dubai.
B: Application Method
1.1 The substrate surface must be free from oil, grease or any loosely adherent material.
1.2 Remove laitance, defective surfaces must be cut back to a sound base.
1.3 Blow clean all bolt holes or fixing pockets of any dirt or debris.
2.1 The underside of the base plate should be clean and free from oil, grease, rust, scale or other
loosely adherent material.
2.2 It may be necessary to provide air pressure relief holes to allow venting of any isolated high
spots.
2.3 If levelling shims are to be removed once the grout has hardened, then they should be pre-
treated with a thin layer of grease.
3.1 Before fixing any formwork, ensure that the area to be grouted is clean.
3.2 The formwork itself must be constructed to be leak proof, to prevent any possible grout loss.
This can be achieved by using foam rubber strip or mastic sealant beneath the formwork, and
at any joints in the formwork. It shall, however, also be provided with drain holes and plugs.
3.3 The formwork should also be constructed in such a way as to keep the final, unrestrained
surface area of the grout to a minimum, to avoid problems with cracking at a later stage.
MS/0634/16/A Page 2
constructive solutions
3.4 It should be fixed in such a way as to allow easy stripping, without causing damage or
distress to the grout - particularly if this is to be done whilst the grout is still ‘green’.
3.5 All dirt and debris to be removed from the grout area before the last piece of formwork is
fixed, to facilitate pre-soaking (see below).
- set up so that grout will be poured the shortest distance across the base plate
- erect a minimum of 150 mm higher than the underside of the base plate
MS/0634/16/A Page 3
constructive solutions
5.0 Pre-soaking
5.1 All concrete surfaces within the formwork area should be saturated with clean, fresh water for
several hours prior to grouting.
5.2 Immediately before grouting takes place, any free water should be removed. Particular care
should be taken to blow out all bolt holes and pockets.
6.0 Mixing
6.1 For best results a mechanically powered grout mixer should be used - do not use a colloidal
impeller mixer.
6.2 For small quantities of grout a slow speed drill (400/500 rpm) fitted with a high shear paddle
is acceptable, but mixing should be restricted to one bag at a time in a container of minimum
capacity 25 liters.
6.3 Measure out clean water into the mixer, as per below mentioned quantities:
3.75 ~ 4.0 liters for Pourable consistency of the mix / 25kg bag
6.4 Slowly add the full bag of Conbextra Sureflow 100 to the water and mix continuously for 3
minutes, until a smooth, free flowing consistency is obtained.
6.5 Alternatively, to improve material flow, the selected water content should be accurately
measured. Put 70~80% of the pre-measured water into the mixer, gradually add the whole
Conbextra Sureflow 100 bag materials into the mixer while continuously mixing. Add the
remaining water until the desired consistency is achieved, Mix for 3~4 minutes. This will
ensure that the grout has a smooth, homogeneous consistency.
6.6 Under no circumstances should part bags be used, or additional water employed. Either of
these two actions will change the water: powder ratio, adversely affecting material
performance and automatically invalidating Fosroc’s standard product guarantee.
6.7 Conbextra Sureflow 100 can be placed in a minimum thickness of 10mm up to a maximum
thickness of 100mm in a single pour when used as an underplate grout. For thicker sections
it is necessary to fill out Conbextra SureFlow 100 with well graded 5~10mm, silt free
aggregate to minimise exotherm. If bulking with aggregate is used the ratio shall not exceed
1:1. Contact Fosroc for details of pre-bagged supply. The properties of a bulked grout will
differ from those published in this data sheet.
MS/0634/16/A Page 4
constructive solutions
7.0 Placing
7.1 It is essential that the machine mixing capacity, material supply and labour availability is
adequate to enable the grouting operation to be carried out continuously. This may require
the use of a holding tank, with provision for gentle agitation to maintain fluidity.
7.2 Immediately prior to placement, the mixed grout should be briefly agitated to release any
surface tension. Place the grout within 15 minutes of mixing to gain the full benefit of the
expansion process.
7.3 Any bolt pockets must be grouted prior to grouting between the substrate and the base plate.
7.4 Continuous grout flow during the grouting operation is essential. Sufficient grout must be
available prior to starting, and time taken to pour a batch must be regulated to the time taken
to prepare the next one.
7.5 The mixed grout should be poured only from one side of the void to eliminate the entrapment
of air, or surplus pre-soaking water. The grout head must be maintained at all times so that a
continuous grout front is achieved.
7.6 Do not attempt to vibrate or agitate the grout to encourage flow or settlement. Vibrations may
lead to bleeding or segregation of the material.
7.7 When the grout reaches the open side of the formwork, and rises above the underside of the
base plate, pouring should continue slowly down the length of the base plate until completed.
7.8 In the event of formwork leakage, plug immediately using Fosroc Renderoc Plug.
8.0 Finishing
8.1 Wherever possible unrestrained “shoulders” are to be avoided. These have a tendency to
crack and/or debond, due to their unrestrained nature.
9.0 Curing
9.1 On completion of the grouting operation, all exposed areas of grout should be thoroughly
cured. For best results use Concure curing membrane, continuous application of water
and/or wet hessian.
MS/0634/16/A Page 5
constructive solutions
This method statement is offered by Fosroc as a ‘standard proposal’ for ‘Conbextra Sureflow 100’. It
remains the responsibility of the Engineer to determine the correct method for any given grouting
operation.
Where alternative methods are to be used, these must be submitted to Fosroc for approval, in
writing, prior to commencement of any work. Fosroc will not accept responsibility or liability for
variations to the above method statement under any other condition.
MS/0634/16/A Page 6
Test Certificates
Al Gurg Fosroc LLC
P O Box 657, Dubai U.A.E.
Tel : 04 2039699, Fax : 04 2859649
Email: agf@fosroc.com
www.fosroc.com