Conbextra EP40 constructive solutions

High Strength free flow epoxy resin grout

Uses
Suitable for use in situations where heavy dynamic or mobile
loads are encountered. The gap between a base plate and
substrate will need to be filled in such applications as
reciprocating machinery, testing equipment, heavy crane and
transporter rails, high speed turbines, centrifuges and drop
forges.
Also for use in conditions where chemical spillage may be
encountered. Typical situations could be met in steelworks,
refineries, electroplating works and chemical plants.
Exotherm
Conbextra EP40 epoxy systems will develop an increase in
temperature on mixing. Its extent will be a function of the
volume to surface ratio, the ambient temperature as well as
the mass and thermal conductivity of the surrounding
materials. Contact Fosroc for specific data on the product.
Typical on-plate shutter system
Removable hopper: For larger pours the grout may be
hand placed or pumped into a removable hopper (trough).

Advantages
 Suitable to fill gaps from 10 mm to 40 mm.

 Low creep characteristics under sustained loading.

 Resistant to repetitive dynamic loads.

 Non-shrink and hence ensures complete surface

contact and bond.

 High compressive, tensile and flexural strengths.

 Withstands a wide range of chemicals.

 Low exotherm epoxy grout .

Technical Support
Fosroc offers a comprehensive range of high performance,
high quality construction products. Fosroc offers a technical
support package to specifiers and contractors as well as
technical advice from staff with unrivalled experience in the
industry.
Description
Conbextra EP40 range of epoxy resin based products is
designed for free-flow grouting of gaps from approximately 10
- 40 mm.
Conbextra EP40 three component systems consisting of
base resin, liquid hardener and specially graded inert fillers
are supplied in the correct mix proportions designed for
whole pack mixing on site and no other materials should be
added.
Chemical Resistance
Conbextra EP40 product is resistant to oil, grease, fats, most
chemicals, mild acids and alkalis, fresh and sea water.
Consult Fosroc’s Technical Department when exposure to
solvents or concentrated chemicals is anticipated.
Specification clauses
Supplier Specification
All epoxy resin grouting where shown on the drawings,
must be carried out using Conbextra EP40 product
manufactured by Fosroc and used in accordance with the
manufacturer’s data sheet.
Limitations
Grouts should not be placed in any unrestrained situation,
i.e. base plate plinths, etc. Failure to comply may lead to
crack development in the grout.
o
Conbextra EP40, at temperatures below 20 C the cure rate
may be slow, but will go to completion provided the
o
temperature remains above 5 C.
Careful planning of shuttering should be made to reduce
exposed surfaces of epoxy grout and shoulders to an
absolute minimum. Exposure to cyclic temperature
changes is likely to cause cracking and peeling in
unrestrained grout. Please contact Fosroc for further
details.

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Conbextra EP40
Properties For deep section placing in inaccessible, extended widths
chains may be used to encourage lateral movement and
Typical Results complete filling of the gap, thus eliminating air pockets. For
Test Method
Density (kg/m ):
3 further information please contact Fosroc for specific
1950
o advice.
Compressive strength @ 40 C
2
(N/mm ) ASTM C579:
Mixing
3 days 91
7 days 97 Pour all the contents of the hardener pack into the base
28 days 103 container. Mix using a slow speed power mixer until
2
Tensile strength (N/mm ) homogeneous.
ASTM C307, 7 days: 17
2
Flexural strength (N/mm ) Pour all the mixed liquid into a container then add all the
ASTM C580, 7 days: 34 filler gradually. Mix using a slow speed power mixer for two
Modulus of elasticity minutes or until a uniform colour is achieved in the grout.
2
(KN/mm ) ASTM C580, 7 days: 14.5
Linear shrinkage (%) Placing
ASTM C531, 7 days: 0.094 The mixed grout should be poured steadily from one side
Linear coefficient of thermal only to eliminate the entrapment of air.
-6 o
expansion 10 (mm/mm C)
ASTM C531: 43 Continuous grout flow is essential.
Linear shrinkage of cured material
ASTM D2566: 0.0002 Sufficient grout must be available prior to starting.
o
Pot life at 40 C ASTM D2471 (min): 75
Peak exothermic temperature The time taken to pour a batch should be regulated to the
o
at 40 C (ASTM D2471): 40 time taken to prepare the next batch.
Water absorption (%)
ASTM C413: 0.20 Flow Characteristics
The maximum distance of flow is governed by the gap
Application Instructions thickness, the head of grout applied and the ambient
temperature. The following table gives typical data for flow
Preparation design.
Foundation surface
o Gap thickness Hydrostatic Maximum
All contact surfaces must be free from oil, grease, free C
(mm) head (mm) flow (mm)
standing water or any loosely adherent material. Concrete 35 10 100 900
surfaces should be cut back to a sound base. All dust 35 40 100 1600
must be removed and bolt-holes or fixing pockets blown
clean of any dirt or debris.
Cleaning
Steel surfaces
All tools and equipment should be cleaned immediately
All steel surfaces should be shot blasted free of rust and flaky after use with Fosroc Solvent 102. Spillages should be
mill scale SA 2½. Cleaned surfaces may be protected by the absorbed with sand or sawdust and disposed in
application of Nitoprime 28. accordance with local regulations.

Formwork
Estimating
The formwork should be constructed to be leakproof as
Conbextra EP40 product is free flowing grouts. Loss of grout Supply Yield
once the material is placed, but not hardened, will result in Conbextra EP40: 16 kg 8 litres
incomplete filling of the gap. 92 kg 46 litres

For free flow grout conditions it is essential to provide a Bulk packaging is available.
hydrostatic head of grout. To achieve this a feeding hopper
system should be used. Storage

Conbextra EP40 product has a shelf life of 12 months if kept

o
in dry conditions at 25 C.

constructive solutions Page 2

Conbextra EP40
Precautions Additional Information

Health and Safety Fosroc manufactures a wide range of products specifically

Conbextra EP40 Contains resins which may cause
sensitisation by skin contact. Avoid contact with skin and
eyes and inhalation of vapour. Wear suitable protective
clothing, gloves and eye/face protection. Barrier creams
provide additional skin protection. Should accidental skin
contact occur, remove immediately with a resin removing
cream, followed by soap and water. Do not use solvent. In
case of contact with eyes, rinse immediately with plenty of
clean water and seek medical advice. If swallowed seek
medical attention immediately. Do not induce vomiting.
o
Fosroc Solvent 102 Flammable liquid. Flash point 33 C.
Keep away from sources of ignition - non smoking. Wear
suitable protective clothing, gloves and eye/face protection.
Use only in well ventilated area.
designed for the repair and refurbishment of damaged
reinforced concrete. This includes hand-placed and spray
grade mortars, fluid micro-concretes, chemical resistant
epoxy mortars and a comprehensive package of protective
coatings. In addition, a wide range of complementary
products is available. This includes joint sealants,
waterproofing membranes, grouting, anchoring and
specialised flooring materials.
Fosroc has produced several educational training videos
with provide more details about the mechanisms which
cause corrosion within reinforced concrete structures and
the solutions which are available to arrest or retard these
destructive mechanisms. Further information is available
from the publication: ‘Concrete repair and Protection - The
Systematic Approach’, available in seven language formats.

For additional information see relevant Material Safety Data For further information about products, training videos or
Sheet. publications, contact the local Fosroc office.

Fire

Fosroc Solvent 102 is flammable. In the event of fire

extinguish with CO 2 or foam.

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 of information given by it.

Fosam Company Limited

Head Office Telephone: +966 2 637 5345 Fax: +966 2 637 5891 email: fosam@fosroc.com
Post Box 11081 Regional Offices
Jeddah – 21453 Jeddah Sales Office Tel: (02) 608 0999 Fax: (02) 638 0693 Yanbu Tel: (04) 322 4280 Fax: (04) 391 2980
Jeddah Showroom Tel: (02) 665 0187 Fax: (02) 667 4844 Makkah Tel: (02) 542 0869 Fax: (02) 542 0869
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Dammam Tel: (03) 814 1282 Fax: (03) 814 1581 Jubail Tel: (03) 362 3904 Fax: (03) 362 3875
www.fosroc.com Khamis Mushayt Tel: (07) 250 0469 Fax: (07) 250 0469 CSD Tel: (02) 608 0999 Fax: (02) 638 0693

Registered Office: Industrial Area, Phase 4, Road No. 414, Street No. 407
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