PRUDENT ROCK DEMOLITION SOLUTIONS
INFORMATION ON EXPANSIVE MORTAR APPLICATION
Applicable for demolition of Boulders, Open Surface and Sub Surface Rock Excavation, Concrete Structures, Decorative Stone Mining Industry like Granite, Marble, Sandstone, Kota Stone etc.,
By Kishore Surampalli Updated on 01/05/2014
PRUDENT ROCK DEMOLITION SOLUTIONS Applying Demolition s trategies……. for constructive environment!
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, natural gas lines, pipelines, roadways or other areas where the use of explosive would generate significant safety risk.
In India these are extensively being used in natural stone quarrying industry, and termed as ever best method techno-economically because of its unique characteristics of application results. It is also being in use for applications like demolition of rock/concrete structures inside tunnels, heavy process plants, and for rock demolition in land development, boulder demolitions in road constructions, etc.
2 …………………………………………………………………………………………………………………………………………………………………………………… Regd. Address: # 259/125, 4 th Floor, Linghichetty Street, George Town, Chennai-600001 Mobile No: +91-9952051475, 9642566077; Email: [email protected] website: www.prds.co.in
PRUDENT ROCK DEMOLITION SOLUTIONS Applying Demolition s trategies……. for constructive environment!
COMPANY PROFILE:
PRUDENT ROCK DEMOLITION SOLUTIONS was established in the year 2013 from the root of “Productive Mining Solutions” and is head quartered in Chennai. Prudent Rock Demolition
Solutions is leading and fastest growing product and service oriented organization in Non-Explosive
Chemical Demolition Technology in India. We are a prominent Exporter, Importer and Service provider. “We won our first work order in prestigious CHENNAI METRO RAIL PROJECT as a sub contractor under Transtonnelstroy-Afcons JV for the demolition of Cement Concrete structures applying chemical demolition technology across 9 metro stations”. We are actively involved in Importing/Trading of non explosive demolition chemicals being used in mining and infrastructure industry and demolition work contracts. Our more prestigious clientele include the eminent vendors of India as well as leading infrastructure development companies in India and abroad.
We aspire to serve clients in rock mining and quarrying Industry through prudent solutions for critical works like Foundation pit excavations, demolition of cement concrete structures like equipment foundations and heavy pipe line supporting structures in Oil/Gas/Energy industry, bridges and piles etc. We provide expertise solutions for basement development in real estate business where rock excavation is necessarily to be done prohibiting explosive usage. We are well known for
In-Situ and sub surface rock excavations using non explosive demolition chemicals. We equipped with well qualified and experienced Human Resources to deliver qualitative and innovative solutions to our esteemed clients .
3 …………………………………………………………………………………………………………………………………………………………………………………… Regd. Address: # 259/125, 4 th Floor, Linghichetty Street, George Town, Chennai-600001 Mobile No: +91-9952051475, 9642566077; Email: [email protected] website: www.prds.co.in
PRUDENT ROCK DEMOLITION SOLUTIONS Applying Demolition s trategies……. for constructive environment!
Expansive Mortar: A Non-Explosive Demolition Agent
We at Prudent Rock Demolition Solutions have actively engaged in developing Non-Explosive Demolition Technology in Infrastructure and Mining Industry across in India. We with registered offices in Chennai (Tamilnadu), Chimakurthy (Andhrapradesh) and committed dealers in Jodhpur (Rajasthan) & Guwahati(Assam) supplying Expansive Mortar throughout the India under the brand name of ‘Productive SCA’, ‘STONE CRACK’, ‘SINO- CRACK’
Our product has got great performance appreciation from various Mining and Infrastructure Companies Located in Andhrapradesh, Maharashtra, Assam, and Rajasthan etc.
Why Non-Explosive Demolition Technique?
As the requirements for demolition of rock and concrete structures in infrastructure industry growing rapidly and the use of explosives and explosive agents are becoming more restricted as far as safety and environmental pollution problems, “Expansive Mortar” is looking as an attractive and productive replacement for explosive users.
Non Explosive Rock Demolition Agents are commercial products that are an alternative to explosives and gas pressure blasting products in demolition, mining, and quarrying. To use non-explosive demolition agents in demolition or quarrying, holes are to be drilled on the base rock according to drilling pattern supplied.. A thoroughly mixed non-explosive demolition agent and water is poured into the drill holes. Over the next few hours the slurry expands, cracking the rock in a pattern somewhat like the cracking that would occur from conventional explosives.
Non-explosive demolition agents offer many advantages including that they are silent and do not produce vibration the way a conventional explosive would. In many countries these are available without restriction unlike explosives which are highly regulated. These agents are much safer than explosives, but it is important to follow directions closely in order to avoid steam blow outs during the first few hours after these materials are placed.
In natural stone quarrying industry non explosive demolition chemical application termed as ever best method techno-economically because of its unique characteristics of application results.
• Accurate sizing/dimensioning of blocks. • No vibration hence No internal cracks & reduction in scrap. • Cheapest method compared with other techniques like Wire-Saw Cutting. • No supervision required once applied. • Less skill and less man power. • Multi task execution hence more productivity etc.
4 …………………………………………………………………………………………………………………………………………………………………………………… Regd. Address: # 259/125, 4 th Floor, Linghichetty Street, George Town, Chennai-600001 Mobile No: +91-9952051475, 9642566077; Email: [email protected] website: www.prds.co.in
PRUDENT ROCK DEMOLITION SOLUTIONS Applying Demolition s trategies……. for constructive environment!
Now a day in real estate development in urban and sub-urban cities non explosive demolition application become an essential activity due to safety risks in inhabitant areas, And this technology also being used in demolition of concrete structures like Turbine-Generator Foundations in Power Plants, Big size equipment foundations, Gas Pipe Lines Anchor blocks, Pile structures of Bridges, various concrete foundations etc.
Why Non-Explosive Technique?
As the requirements for demolishing rock or reinforced concrete in construction/infrastructure/Real-estate industry growing rapidly and the use of explosives and explosive agents are becoming more restricted as far as safety and environmental pollution problems, “Expansive Mortar” is looking as an attractive and productive replacement for explosive users.
Principle of Working
The principles applied in using “Expansive Mortar” are very much similar to those ones followed in traditional blasting techniques. As like for explosives, holes must be drilled to contain ‘Expansive Mortar’ which must thoroughly be mixed with a measured quantity of water and poured into the holes. Few minutes after filling, a reaction of hydration is taking place generating heat and crystallizing and expanding while hardening. If hydration takes place under confinement, significant expansive pressure will result. Cracks will develop along the line of holes. A person who can deeply understand hydration reaction, Starvation and Expansion process become an expert in this product application. No need for detonator, ignition and professional operators.
5 …………………………………………………………………………………………………………………………………………………………………………………… Regd. Address: # 259/125, 4 th Floor, Linghichetty Street, George Town, Chennai-600001 Mobile No: +91-9952051475, 9642566077; Email: [email protected] website: www.prds.co.in
PRUDENT ROCK DEMOLITION SOLUTIONS Applying Demolition s trategies……. for constructive environment!
Application Procedure and Requirements
Chemical demolition technique involves a). Drilling b). Mixing c). Filling. a). Drilling
Among available drilling techniques pneumatic drilling setup and mechanized hydraulic drilling setup are in practice for productive results.
Drilling Design Specifications:
Sl Mean Hole Distance Range Hole Dia Applicable for No For Rock For Concrete Structures Sub-surface Rock/Concrete 1 25-32 mm 6-8 Inch Or 15-20 CM 6-8 Inch Or 15-20 CM demolition(If no free face) Surface Rock/Concrete 2 25-32 mm 8-10 Inch Or 20-25 CM 6-8 Inch Or 15-20 CM demolition Above surface 3 30-45 mm 10-12 Inch Or 25-30 CM 8-10 Inch Or 20-25 CM Rock/Concrete demolition Free boulder/concrete 4 30-45 mm 12-14 Inch Or 30-35 CM 10-12 Inch Or 25-30 CM blocks with multi free faces 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 1.65 Lit/5Kg ) to decide the correct proportion for better results. Gradually add the powder to water 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 are requested to follow the instructions mentioned on the bag.
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 reaction resulting throw out of chemical. No Capping required. Do not keep any obstruction on Hole. For further information feel free to discuss with us.
6 …………………………………………………………………………………………………………………………………………………………………………………… Regd. Address: # 259/125, 4 th Floor, Linghichetty Street, George Town, Chennai-600001 Mobile No: +91-9952051475, 9642566077; Email: [email protected] website: www.prds.co.in
PRUDENT ROCK DEMOLITION SOLUTIONS Applying Demolition s trategies……. for constructive environment!
Standard Consumption:
Total Consumption Sl. No. Chemical Qty Water Qty Hole Dia. Remarks in RFT
1 20 Kg 6.5 Ltr 40 mm 32 Ft appx. Water Qty Subject to 2 20 Kg 6.5 Ltr 32 mm 36 Ft appx change as per site conditions 3 20 Kg 6.5 Ltr 25 mm 42 Ft appx
Free Surface
It is one of the significant factors that play an important role in cracking process. As expansive 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 please email us photograph for the suitable Hole Drilling pattern to demolish the big boulder/rock rooted inside the earth. We have dedicated geologists and rock engineers to serve you the best. 7 …………………………………………………………………………………………………………………………………………………………………………………… Regd. Address: # 259/125, 4 th Floor, Linghichetty Street, George Town, Chennai-600001 Mobile No: +91-9952051475, 9642566077; Email: [email protected] website: www.prds.co.in
PRUDENT ROCK DEMOLITION SOLUTIONS Applying Demolition s trategies……. for constructive environment!
Cracking Mechanism
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 “Productive SCA” is shown in Fig. 1. Cracks initiate from an 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, 2-4 cracks initiate and propagate either 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 crack also arises from the bottom of the hole, running toward the free surface. Please note during the initial reaction process (i.e., 30-60mis) there are chances for blow-shot releasing gases evolved in the hydration reaction. So, during that period we insists workers to stay away at least 10 mts from Job place. Peeping onto the hole strictly prohibited.
8 …………………………………………………………………………………………………………………………………………………………………………………… Regd. Address: # 259/125, 4 th Floor, Linghichetty Street, George Town, Chennai-600001 Mobile No: +91-9952051475, 9642566077; Email: [email protected] website: www.prds.co.in
PRUDENT ROCK DEMOLITION SOLUTIONS Applying Demolition s trategies……. for constructive environment!
Fig. 1 Fracture mechanism of Expansive Mortar Application
9 …………………………………………………………………………………………………………………………………………………………………………………… Regd. Address: # 259/125, 4 th Floor, Linghichetty Street, George Town, Chennai-600001 Mobile No: +91-9952051475, 9642566077; Email: [email protected] website: www.prds.co.in
PRUDENT ROCK DEMOLITION SOLUTIONS Applying Demolition s trategies……. for constructive environment!
Safety Precautions
Even though it is safe demolition technique, as the product is chemically highly base in nature with pH-13 ++ it is necessary to take proper care while handling and applying. Being safe is prime important to do a safe demolition. Always wear hand gloves while handling and wash hands thoroughly after use. Ingestion this product causes severe damage to digestion system of human body. If it comes in contact with eyes do not rub your eyes and rinse with clear water several times and contact an eye doctor at the earliest to avoid major damage to eye. Also avoid contact with skin as it will react with skin rinse all affected parts thoroughly. 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 and be a safe applicant.
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 work place after got cracked.
Do not park equipments besides structure/rock on which chemical demolition work in progress.
Keep the material away from children.
10 …………………………………………………………………………………………………………………………………………………………………………………… Regd. Address: # 259/125, 4 th Floor, Linghichetty Street, George Town, Chennai-600001 Mobile No: +91-9952051475, 9642566077; Email: [email protected] website: www.prds.co.in
PRUDENT ROCK DEMOLITION SOLUTIONS Applying Demolition s trategies……. for constructive environment!
Packing & Storage
Expansive Mortar is available in powdered form and will be packed in 5kgs Moist-proof bags. One strong export type carton will be packed with 4 Nos of 5kg bags. 50-60 Cartons per Pallet/crate. Although it is packed in anti-moisture covers long storage may cause deterioration of its working ingredients (Maximum storage period 1 year). Therefore, store in a dry place and use it as soon as possible. While storing, do not place the boxes directly on the floor, put them on wooden pallets and keep in a dry warehouse (wood Insulation from ground and wall faces will avoid ingress of moisture). Material stored in this manner, can be effectively used for about 1 year. The bag should be unpacked before use only. Do not use previously opened packs as it already absorbed moisture from atmosphere and lost properties. While storing a portion of powder remained after use, evacuate the air from the bag, and then seal it with suitable means so that air does not ingress into the bag and use as soon as possible. However, as it already exposed to moisture there is a risk of losing its effectiveness once the bag has been opened. If you receive broken bags they may not work due to chance of moisture absorption. Please report to suppliers immediately about the same.
For Productive Results & Trouble shooting
Select the right temperature grade according to job site temperature. Ensure drilled holes free from foreign particles & water, before filling; clean with compressed air. Prepare mix following said procedure Use cold water and apply the mix within 5-10 Min. For better results mix 2 Bags or 10 Kilograms at once. Fill the drill holes starting from free end. In order to obtain best results, it's advisable to carry out experiment at first with different water mix ratios (Per 5 Kg Packet 1.5, to 1.8 Lit max) Large diameter holes positioned closer together accelerate Cracking Time (Max Dia. 52mm) The workers need to take synchronized operation, especially while dealing with hard stone. Taking synchronized steps when mixing, stirring and filling will lead to maximum expansive stress with all holes expand at the same time If your job site temperature is more than the selected material grade please add 100ml water additionally. Never use glass or metal containers for mixing. While mixing if it begins to steam in container, add little water to dilute and process properly. Do not dilute more which may take much time to crack.
Thank you very much for your attention on Environment ! 11 …………………………………………………………………………………………………………………………………………………………………………………… Regd. Address: # 259/125, 4 th Floor, Linghichetty Street, George Town, Chennai-600001 Mobile No: +91-9952051475, 9642566077; Email: [email protected] website: www.prds.co.in