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: info@prds.co.in website: w
Applying Demolition strategiesApplying Demolition strategiesApplying Demolition strategiesApplying Demolition strategies,,,, forforforfor constructiveconstructiveconstructiveconstructive
An Information
on
For
Kishore Surampalli,
Prudent Rock Demolition Solutions
Chennai
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hennai-600001
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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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hennai-600001
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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 to
6.5 Ltr 32 mm
36 Ft.
6.5 Ltr 25 mm 42 Ft.
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hennai-600001
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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.
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.

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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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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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wn/roll down/slide down into active
Do not park equipments besides structure/rock on which chemical demolition.

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