Category: Concrete Repair

ROCKMAX AG GEL

ACRYLATE GEL RESIN

ACRYLATE GEL RESIN
CURTAIN GROUTING, WATER BARRIER, SOIL STABILIZATION


INTRODUCTION

Rockmax AC GEL is a low viscosity, environmentally friendly, acrylate injection system. It is able to spread to fine soil and fill voids between interface areas of the concrete and substrate. This injection system provides excellent waterproofing capabilities for use in the creation of grout curtains behind existing concrete walls or abutments. It can create solid, homogeneous membranes beneath concrete floors as well as stabilizing soil and filling voids at the building foundation and interface areas. Their hydrophilic properties provide a lasting and durable barrier against moisture and water pressure intrusion. It non-toxic chemical that can use with portable water tank and underground.

AREA OF USES

Rockmax AC GEL can be used to create water barrier, soil stabilization and curtain grouting underground including with tunnels, subways, sewages, water tanks, retaining walls, dams, canals, shafts, basements, construction joints, expansion joints, crack filling, leakage of concrete structures and brick or block gap filling. Protect moisture movement from underground.

ADVANTAGES

  • Design specially for underground curtain grouting for water barrier or waterproofing purpose.
  • Excellent permeability during application state, it is very easy to permeate in to very find soil and voids.
  • Swell upon contact with water to create water barrier.
  • Highly elastic and flexible gel type. Can be use on movement from concrete structures or movement of soil undergrounds.
  • Control workability. It can adjust the curing time of material depend on job site conditions.
  • Non-toxic, Can be use to all kind of underground structures and portable water tank.
  • Non-flammable or explosive.
  • Long life, Its maintain waterproofing capabilities in long period of time and more than any others injection materials
  • Increase strength of soil underneath create the support of structure.

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    APPLICATION AND INSTALLATION

    PREPARATION

    It is necessary to analyze the nature and state of the building and to examine the foundation soil before making new sealing surface (curtains) in building components in direct contact with the foundation soil or within the existing structure. Such an analysis provides the necessary information on the feasibility of the planned injection measures and the materials consumption rate to be expected. The results of this analysis are decisive for positioning the drill holes to be made for the building project. Standard paterns: gel injection into the foundation soil in the form of a vertical curtain and horizontal floor.

    MIXING

  • For reasons of storage stability, component A is supplied in two separate container. Mix component A with accelerator which are provided according to the required mixing ratio.
  • Component B is ready to mix.
  • Component A (A + accelerator) and component B should be mixed in identical vessels.
  • After mixing the components, apply the material swiftly by means of 2- component injection pump at a mixing ratio of 1 : 1 (parts by volume).

    • APPLICATION – Curtain injection

    Install injection packers in the drill hole. Inject the AG gel from bottom to top (beginning at the lowest point). Proceed with the injection process until the emergence of material of the gel formation in the adjacent drill hole. The reference value for the gel’s consumption is approx. 5 to 60 kg/m2 depend on soil condition. Strongly cohesive, very dense soil will provide a low consumption rate while sandy soil or even large rocks behind the structure increase consumption rate.

    FINAL WORK

    The packer can be removed immediately after the gel formation. Mechanical packers cleaned by means of rinsing pump (water) can generally be used again. After dismounting the packers, remove all gel from the drill holes and fill with concrete repair mortar (Rockmax TOP) or quick setting cement mortar for brick work (Rockmax Waterplug).

    PACKAGING

    Part A: 20kg, accelerator: 150gram
    Part B: 20kg

    STORAGE

    Storage in shade and dry condition free from frost, water, moisture and high temperature. Rockmax AC GEL must be store in air tight container. Must protect from atmospheric moisture. Must be store in area where temperature around 10ºC – 25ºC degree.

    ROCKMAX PU600

    HARD PU GEL

    TWO COMPONENTS HIGH STRENGTH POLYURETHANE RESIN SOIL STABILIZATION & REINFORCEMENT WEAK GROUND


    INTRODUCTION

    Rockmax PU600 is a solvent free, two components polyurethane injection resin. Cured material results high compressive strength, bonding and tensile strength. Its very tough and solid. It is recommended to use specially for soil stabilization, reinforcing behind concrete structure, protect water infiltration to concrete structure, sealing cracks, filling cavities and gravel nests.

    AREA OF USES

    water barriers and curtain injections. Range of application include:

  • Soil stabilization.
  • Improve weak underground substrate.
  • Increase strength of soil underground.
  • Lifting ground concrete slab.
  • Water barrier for concrete structures attached to the ground or soil.
  • Crack sealing on concrete structures.
  • Sealing on construction joint leakage.

    • ADVANTAGES

  • Permanent seal which provide longer life time than conventional concrete.
  • Very high strength.
  • Low viscosity that can penetrate into very small voids.
  • Good bonding to concrete and brick/block.
  • High chemical resistance to almost underground chemicals.
  • Hard and tough material.
  • Can do both wet & dry crack.
  • It is non-permeable material.
  • Adjustable reaction.
  • Total 100% solid & non-shrinkage.
  • Non-toxic once cured hard material. Can use with potable water (cured material).
  • Non-corrosive with steel or concrete.

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    APPLICATION AND INSTALLATION

    PREPARATION

    The soil structural or concrete structure analysis must be carried out prior to process the injection. The extent of the examination and application method depends on the conditions on site. The nature and state of the soil structure must be determined.

    In case of high water pressure, it must be stop water by inject Rockmax PU100 or Rockmax PU200 prior to start inject Rockmax PU600. Remove the loose materials from the surface of the cracks. Drill the injection holes and Install the metal packer along the cracks line. Tight it by wrench and ready to injection.

    MIXING

    Mix part A and part B by low speed mixer (400- 500rpm) for 2 minutes until homogeneous. Place the material into the bucket and ready to inject.

    APPLICATION (1-coponent injection)

    The works must be carried out by experienced and trained contractors. Use single component pump for inject the resin though the cracks. Pour the mixed resin in to the bucket ready to injection. Inject from bottom to top. Re-inject again to ensure the area is fulfilling by material.

    APPLICATION (2-coponent injection)

    Place the material each part on each component of injection machine. Adjust the rate of each bucket as per design reaction time. Ensure the volume flow is sufficient so that part A and part B are mixed homogenously in the mixing device.

    CURTAIN INJECTION

    Curtain injection for below grade structures it is recommended to drill through the structure in pattern that is determined by the physical of the soil. Standard pattern hold are approximate 40 to 50cm spacing.

    FINAL WORK

    The packer can be removed immediately after the gel formation. Mechanical packers cleaned by means of rinsing pump can generally be used again. After dismounting the packers, remove all gel from the drill holes and fill with concrete repair mortar (Rockmax TOP) or quick setting cement mortar for brick work (Rockmax Waterplug).

    PACKAGING

    Part A: 19 kg.
    Part B: 21 kg.

    STORAGE

    Storage in shade and dry condition free from frost, water, moisture and high temperature. Rockmax PU600 must be store in air tight container. Must be protected from atmospheric moisture. Must be store in area where temperature around +10ºC to +30ºC degree. All open container should be

    ROCKMAX EB547

    2 COMPONENT EPOXY PATCHING MORTAR


    INTRODUCTION

    Rockmax EB547 is a solvent free, 2 component epoxy patching mortar. The material is consists of resin, hardener and selected fine aggregates. Its use as repair mortar, fill voids & gaps and bonding substrates.

    AREA OF USES

    Rockmax EB547 is suitable for use in many application areas include with repair surface of pre-stressed concrete elements, repair precast concrete elements, repair cast in place concretes, fill voids and gaps, repair verticals and overheads, bonding concretes, increase thickness of concrete st ructure, repair mortar for concrete structures.

    ADVANTAGES

  • Excellent bonding strength.
  • Good abrasion and impact resistance.
  • Good compressive strength.
  • Good mechanical properties.
  • Solvent free.
  • Easy to apply.
  • Can apply on damp surface.

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    APPLICATION AND INSTALLATION

    PREPARATION

    Concrete substrate must be clean and free from oil, grease, dust, particles, mould oil, curing compound. Remove all loose material and laitance by mechanical means. New concrete must be at least 21 days old. When working with high temperature, please consult Rockmax for recommendation.

    PRIMING

    No primer required. However to increase bonding strength between substrate and repair mortar, Rockmax EB545, epoxy bonding agent shall be use. Apply repair mortar while the primer still tacky. Do not wait until the primer dry. Reapply primer when it dry.

    MIXING

    Mix part A and part B at 2-3 minute by low speed electric drill. Mix until the mortar homogeneous and uniform color. Do not mix by hand trowel.

    APPLICATION

    Apply mortar by steel trowel. Multi layer could be applied. Make sure good surface finished after application. Protect the mortar from rain and water.

    PACKAGING

    3kg set; part A: 2 kg part B:1 kg

    STORAGE

    Storage in shade and dry condition Avoid from frost, water, moisture and high temperature.

    ROCKMAX EB545

    2 COMPONENT EPOXY BONDING AGENT


    INTRODUCTION

    Rockmax EB545 is a solvent free, 2 component epoxy bonding agent. The cured material provides high bonding strength between old substrate and new topping material. It is also used in area where critical bonding strength is required.

    AREA OF USES

    Rockmax EB545 can used to bond between cement mortar to old concrete substrate, between steel plate and concrete, between repair mortar and dama ged concrete substrate or any other
    applications please consult
    Rockmax for advice.

    ADVANTAGES

  • Good adhesion.
  • Can use both internal & external.
  • Easy to apply.
  • Good smooth & fine surface.
  • Can over paint.

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    APPLICATION AND INSTALLATION

    PREPARATION

    Concrete substrate must be clean and free from oil, grease, dust, particles, mould oil, curing compound. Remove all loose material and laitance by mechanical means. New concrete must be at least 21 days old. When working with high temperature, please consult Rockmax for recommendation.

    MIXING

    Mix part A and part B at 2-3 minute by low speed electric drill. Mix until the material homogeneous and uniform color. Do not mix by hand trowel.

    APPLICATION

    Apply the material direct to substrate by brush. Pour or patch new material such as topping mortar, repair mortar, screed while Rockmax EB545 still wet and tacky. If the bonding agent is dry. It is recommended to apply new layer of bonding agent.

    PACKAGING

    4kg set;
    part A: 4 kg
    part B:2 kg

    STORAGE

    Storage in shade and dry condition Avoid from frost, water, moisture and high temperature.

    ROCKMAX EB543

    2 COMPONENT EPOXY ADHESIVE


    INTRODUCTION

    Rockmax EB543 is a solvent free, thixotropic two components epoxy adhesive and repair mortar. It can used to bond many kinds of materials such as concrete, steel, iron, mortar or wood. It is supplied in pre-weight 2 pack system with ready to use on construction site. The mixed material is high consistency (paste) suitable and easy to use for anchoring reinforcing steel bar with concrete.

    AREA OF USES

    Rockmax EB545 can used to for patching repair mortar, bonding steel plates, setting anchor bolts or dowel bars, seal crack or void on concrete surfaces.

    ADVANTAGES

  • High early strength.
  • Excellent bonding strength.
  • Can use on dry or damp surface.
  • Durability.
  • Non Sag.
  • Shrinkage free.

    • APPLICATION AND INSTALLATION

    PREPARATION

    Bonding/Repairing :
    Concrete substrate must be clean and free from oil, grease, dust, particles, mould oil, curing compound. Remove all loose material and laitance by mechanical means. New concrete must be at least 21 days old. When working with high temperature, please consult Rockmax for recommendation.

    Anchoring Reinforcing Steel Bar :
    Drill the hole by drilling machine according to specific depth and diameter. Blow the dust from the bottom of the hole. Clean the hole with wire brush and remove the dust again.

    MIXING

    Mix part A and part B at 2-3 minute by low speed electric drill. Mix until the material homogeneous and uniform color. Do not mix by hand trowel.

    APPLICATION

    Bonding/Repairing :
    Apply the material by steel trowel to the prepare substrate. The maximum thickness per layer is 10mm (vertical) and 35mm (horizontal).

    Anchoring Reinforcing Steel Bar :
    Apply the mixed to the reinforcing steel with fully cover the bar by steel trowel and pour mixed material in to the prepare holes approximate 10-20% of volume of holes. Put the reinforcing steel in to the hole and compress it firmly till the depth of the hole. Ensure all material is full the hole and steel bar.

    PACKAGING

    2kg set.

    STORAGE

    Storage in shade and dry condition Avoid from frost, water, moisture and high temperature.

    ROCKMAX PU200

    One Component Elastic & Flexible Polyurethane


    INTRODUCTION

    Rockmax PU200 is a one component hydrophobic elastic & flexible polyurethane injection resin. The material reacts when contact with water and creates expansion and high flexible & elastic solid type of foam to stop and displace coming pressure water leakage. Unlike the conventional polyurethane foam injection, the cured material provides good flexible and elongation designed for the movement joints or any settlements of the structures. The material is crack sealing permanently.

    AREA OF USES

    Rockmax PU200 can be used to stop water pressure leakage
    permanently in concrete and
    masonry. It designed especially for movement joints, cracks and settleme nt or displacement in the buildings/structures where
    conventional hydrophobic
    polyurethane injection (closed cell type) can not use.

    ADVANTAGES

  • Permanent sealing crack.
  • Excellent elasticity and flexibility.
  • Good bonding to concrete.
  • Good expansion.
  • Good tear and puncture resistance.
  • High resistance to water pressure.
  • Only material that can use for stop water pressure leakage in movement joints.
  • No use of catalyst make it easy application.
  • One step system.

    • APPLICATION AND INSTALLATION

    PREPARATION

    Crack line or leak area must be structurally sound, clean and free from oil, dust, cement paste, existing sealants and other contaminants. Remove all loose materials by wire brush or mechanical means.

    APPLICATION

    This below application or installation method is for guide line only. The detail installation method must be provided upon request and depend on project details.

    Drill injection holes by electrical drill at approximate half depth of thickness of concrete with 45 degree angle. The distance between hole is 150mm to 500mm depend on width of crack. Install packer (recommended ½ inch) in to injection hole. Use wrench to tight the packer. Packer size depend on crack width and depth of concrete structures. Please consult Rockmax for more information.

    Stir the material by hand using electric mixer for 30-45 second. Use electr ical single component pump to inject the material. Inject the material from bottom to top with carefully monitor the material and pressure. After finished re inject again from top to bottom to ensure all cracks are full fill with materials.

    PACKAGING

    20kg pail.

    STORAGE

    Storage in shade and dry condition free from frost, water, moisture and high temperature. Rockmax PU200 must be store in air tight container. Must protect from atmospheric moisture. Must be store in area where temperature around 10ºC – 30ºC degree.

    ROCKMAX PU100

    POLYURETHAN INJECTION TO STOP WATER LEAKAGE



    INTRODUCTION

    Rockmax PU100 is a hydrophobic water activated injection foam grout and soil stabilization based on polyurethane. It is designed to stop water leakage by pressure injection through cracks, honeycombs, voids and/or damaged concretes. The material will react immediately when contact with water and create expansion to stop water leakage. The reaction time can be adjusted by percentage of accelerator. The cured material is semi-flexible and constant volume.

    AREA OF USES

  • Crack leakage.
  • Repair construction joints.
  • Repair expansion joints.
  • Tunnel leakage.
  • Basement leakage.
  • Dam, reservoir, pipe, subway, tanks.
  • Diaphragm and retaining wall.

    • ADVANTAGES

  • Expansion more than 20 times.
  • Non toxic.
  • Can use in portable watertank.
  • Low viscosity.
  • Deep penetration.
  • Excellent bonding.
  • Easy to use.
  • Can adjust reaction time.

    • APPLICATION AND INSTALLATION

    PREPARATION

    Investigate the temperature and humidity of the site environment for determine the pot life of the mixed. Do not over mix the material more than the amount will be pumped. In case of high temperature and high humidity, the percentage of accelerator must be less than low temperature. In completely dry cracks, it is necessary to pre injection of water prior to start application.

    APPLICATION

    The mixture can be used conjunction with single line injection pumps together with metal injection packers. Holes are drilled on alternating sides along the course of the crack at an interval of approximate 20-25cm. Insert packer to the drilled ho les and start injection from bottom to top. Inspect the material injected after full cured (approximate 24 hours).

    PACKAGING

    22kg set.
    part A: 20kg ; part B: 2kg (1kg x 2set).

    STORAGE

    Storage in shade and dry condition free from frost, water, moisture and high temperature. Rockmax PU100 must be store in air tight container. Must be Protect from atmospheric moisture. Must be store in area where temperature around 10ºC – 30ºC degree.

    ROCKMAX TOP200

    ONE PART SKIM RENDER POWDER


    INTRODUCTION

    Rockmax TOP200 is a ready to use one part skim smooth surface rendering powder form. It can be applied both internal and external surfaces. Rockmax TOP200 provides a thin fairing surface over hairline crack, pinholes, air pocket, seams and minor defected surfaces.

    AREA OF USES

  • Cast in place concrete surfaces.
  • Pre cast concrete surfaces.
  • Over rendering mortar surfaces.
  • All cementitious substrates.

    • ADVANTAGES

  • Good adhesion.
  • Can use both internal & external.
  • Easy to apply.
  • Good smooth & fine surface.
  • Can over paint.

    • APPLICATION AND INSTALLATION

    PREPARATION

    Concrete substrate must be clean and free from oil, grease, dust, particles, mould oil, curing compound. Soak water until concrete saturated.

    MIXING

    Mixer must use low speed drill mixer (500 rpm) with and including good quality steel paddle. Make sure all tools and equipments are in good conditions and clean. Measure 7.4 – 8.0litre of clean water for 20kg bag of Rockmax TOP200. Add material slowly into water while mixing. Mix continuous for approximate 3 minute until homogeneous. The mixing ratio could be adjusted according to user and environment conditions.

    APPLICATION

    Apply mortar by steel trowel. Multi layer could be applied.

    CURING

    Wait to dry for 7 days prior to paints.

    PACKAGING

    20kg bag.

    ROCKMAX TOP (OH)

    One Part Lightweight Cement Repair Mortar


    INTRODUCTION

    Rockmax TOP (OH) is one part lightweight polymer modified fiber reinforced cementitious repair mortar. The material is suitable to use with vertical and overhead repair areas. Its provide high strength concrete with and include high bonding strength to the existing substrate.

    AREA OF USES

    Rockmax TOP (OH) is designed for repair damaged concrete for both vertical and overhead applications.

    ADVANTAGES

  • High strength materials.
  • Excellent bonding.
  • Design for overhead application.
  • Non shrinkage.
  • Non-sag.
  • Easy to use similar to mortar.

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    APPLICATION AND INSTALLATION

    PREPARATION

    Concrete substrate must be clean and free from oil, grease, dust, particles, mould oil, curing compound. Concrete substrate must be at least 28 days old and include compressive strength of 25Mpa. Shape concrete by grinder machine to receive thicken layer (approximate 10mm thick). All edge must be shape until receive smooth and sound concrete substrate. Soak water until concrete saturated. Bonding agent should be applied to increase bonding strength.

    MIXING

    Mixer must use low speed drill mixer (500 rpm) with and including good quality steel paddle. Make sure all tools and equipments are in good conditions and clean. Measure 5.25litre for 25kg bag of Rockmax TOP (OH) . Add material slowly into water while mixing. Mix continuous for approximate 3 minute until homogeneous. Adjust water if the mortar is not workability.

    APPLICATION

    For overhead application, Use steel trowel patch repair mortar to prepared substrate. Working wet on wet with bonding agent (epoxy bonding agent is required). Apply only 10-15mm per layer. Build up next layer if required. Finishing by steel trowel on top of surface. Do not mix with Portland cement.

    PACKAGING

    25kg bag.

    STORAGE

    Storage in shade and dry condition Avoid from frost, water, moisture and high temperature.

    ROCKMAX TOP

    ONE PART CONCRETE REPAIR MORTAR


    INTRODUCTION

    Rockmax TOP is one part polymer modified fiber reinforced cementitious repair mortar. It contains selected grade of fillers to become smooth surface. The product provide high strength and good bonding to existing substrate. It can use for both precast concrete and cast in situ concrete.

    AREA OF USES

  • Repair horizontal and vertical concrete.
  • Repair pre-cast concrete work.
  • Fill void in concrete structure.
  • Strengthening concrete structure.
  • Increase depth of concrete girder.
  • Modify and adjust concrete member.

    • ADVANTAGES

  • Good adhesion.
  • High strength.
  • Ready to use.
  • Non shrinkage.
  • Non corrosive.
  • Good abrasion resistance.

    • APPLICATION AND INSTALLATION

    PREPARATION

    Concrete substrate must be clean and free from oil, grease, dust, particles, mould oil, curing compound. Concrete substrate must be at least 28 days old and include compressive strength of 25Mpa. Shape concrete by grinder machine to receive thicken layer (approximate 10mm thick). All edge must be shape until receive smooth and sound concrete substrate. Soak water until concrete saturated. Bonding agent should be applied to increase bonding strength.

    MIXING

    Mixer must use low speed drill mixer (500 rpm) with and including good quality steel paddle. Make sure all tools and equipments are in good conditions and clean. Measure 3.5litre for 25kg bag of Rockmax TOP. Add material slowly into water while mixing. Mix continuous for approximate 3 minute until homogeneous. Adjust water if the mortar is not workability.

    APPLICATION

    Use steel trowel patch repair mortar to prepared substrate. Working wet on wet with bonding agent. Apply only 20-25mm per layer. Compress the repair mortar with rubber hammer. Build up next layer if required. Finishing by steel trowel on top of surface. For vertical area, epoxy bonding or latex bonding must be applied. The thickness for vertical area is not more than 10mm per layer. Do not mix with Portland cement.

    CURING

    Curing by spray water or wrap with plastic sheet for prevent drying up of mortar.

    PACKAGING

    25kg bag.

    STORAGE

    Storage in shade and dry condition Avoid from frost, water, moisture and high temperature.