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PRUDENT ROCK DEMOLITION SOLUTIONS
An Information
Expansive Mortar Application
Demolition of RCC and PCC Structures
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An Information
on
Expansive Mortar ApplicationFor
Demolition of RCC and PCC Structures
Kishore Surampalli,
Prudent Rock Demolition Solutions
Chennai
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Expansive Mortar Application
Demolition of RCC and PCC Structures
By
urampalli, B.E, PG.D
Prudent Rock Demolition Solutions
Chennai, Tamilnadu
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PRUDENT ROCK DEMOLITION SOLUTIONS
Non-Explosive Demolition Agents a
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 results. It is also being in
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
demolish rock and concrete structures in dust and noise sensitive areas and
habited areas, gas pipelines, roadways or other areas where
the use of explosive would generate significant safety risk.
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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re the one which can be used to
demolish rock and concrete structures in dust and noise sensitive areas and
pipelines, roadways or other areas where
/marble/sand stone
quarrying industry, and termed as ever best method techno-economically
because of its unique characteristics of application results. It is also being in
s in projects like Metro Rail Station,
lants, and for rock demolition in land
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PRUDENT ROCK DEMOLITION SOLUTIONS
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
‘ECO-CRACK’. Our product has got great performance appreciation from various Mining and Infrastructure
Companies Located in Andhrapradesh,
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
other remaining composites are naturally possessed with base material when extracted from earth crust.
2. Principle of Working:
When a material (dry)
hydration (28-32% w/w of CaO)
volume due to hydro bonding
holes.
Due to exothermic chemical reaction between
heat energy will be liberated which leads to
dry state. During evaporation/dehydration process
termed as Expansion Process
developed from multi points together
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Expansive Mortar: A Non-Explosive Demolition Agent
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 unde
CRACK’. Our product has got great performance appreciation from various Mining and Infrastructure
Companies Located in Andhrapradesh, Tamilnadu, Karnataka, Maharashtra, Assam,
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 %
sium 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
has a natural property of heat generation on Hydration (An Exothermic Chemical
are naturally possessed with base material when extracted from earth crust.
made to fine powdered form measuring certain volume,
w/w of CaO) of powder its physical volume reduces than initially measured
due to hydro bonding. At this min volume state chemical would be applied in drilled
Due to exothermic chemical reaction between Calcium Oxide and water significant int
energy will be liberated which leads to evaporation of H2O from the mixture
dehydration process, it also tries to attain its original volume, which is
termed as Expansion Process in a circumferentially constrained hole. This expansion energy
developed from multi points together implies to create fractures on rock/concrete
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Explosive Demolition Agent
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 Infrastructure
shtra, Assam, Orisaa, Himachal
um Oxide and is prepared from Burnt Lime. Calcium Oxide
Reaction with H2O). All
are naturally possessed with base material when extracted from earth crust.
measuring certain volume, on through
of powder its physical volume reduces than initially measured
At this min volume state chemical would be applied in drilled
and water significant internal
O from the mixture and tries to attain
also tries to attain its original volume, which is
This expansion energy
on rock/concrete.
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We pour the hydrated mix into drilled holes in minimum volume state. After filling the mix,
within 10-15 min evaporation sta
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 will lead to create fractures, and normal
stress will release in upward directi
shown in figure below.
We reiterate that it is not
together due to dehydration.
work stations during concrete demolition with chemical application
expansion process happening
after application.
How to Limit the Crack Propagation
To limit the both penetration and crack propagation, we shall drill the blank
spacing 6-8 inches and 300 mm down to the Drilled Length.
structure.
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We pour the hydrated mix into drilled holes in minimum volume state. After filling the mix,
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.
on stress, Major component is Hoop stress and Minor component is
Normal stress. Hoop stress acting circumferentially will lead to create fractures, and normal
stress will release in upward direction with some chemical spill out at to
We reiterate that it is not a molecular expansion; it is wholly a volumetric expansion all
together due to dehydration. Moreover it is nearly homogeneous medium with concrete.
during concrete demolition with chemical application, we practically noticed that
expansion process happening max of 12 inches in downward direction in a period of 12 hours
How to Limit the Crack Propagation?
o limit the both penetration and crack propagation, we shall drill the blank
mm down to the Drilled Length. It will double ensure the safety of
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We pour the hydrated mix into drilled holes in minimum volume state. After filling the mix,
rts because of internal heat energy developed there by expansion of
. It physically appears as blow shots (1-2 blows per Hole).
on stress, Major component is Hoop stress and Minor component is
Normal stress. Hoop stress acting circumferentially will lead to create fractures, and normal
op face nearby hole as
molecular expansion; it is wholly a volumetric expansion all
homogeneous medium with concrete. At
we practically noticed that
in a period of 12 hours
o limit the both penetration and crack propagation, we shall drill the blank holes with mean
It will double ensure the safety of
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3. Change in Mix ratio & its Implications:
As per practical analysis and purity of calcium oxide it
(w/w) water. When we add less than 30%
flow ability characteristics to full fill the aim of the Job. Improper hydrated mix in a very few minutes
physically appears as blowing
the mixing process.
If we add more water,
may not be sufficient to evaporate the mixed water and remains in wet state with very less
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 needed. 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 chemical reaction with physical c
work piece like either ROCK or CONCRETE
expansion energy to create fractures.
Fracturing Time depends on tensile strength and compressive strength. R
as it is less tensile and concrete takes time as it possesses high compressive strength.
Crack Propagation:
Crack propagation mainly depends on type of material (Tensile / Brittle) and hole position
from nearest free face. Maximum
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
propagates/weakens towards free face. However we consider crack propagates i
region sub tending a max angle of 45 Degrees
6-8 inches mean hole distance and Line
inches for PCC Structures. It is safe for
chipping with breakers with high
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Change in Mix ratio & its Implications:
As per practical analysis and purity of calcium oxide its min volume
water. When we add less than 30% water proper hydration does not happens
flow ability characteristics to full fill the aim of the Job. Improper hydrated mix in a very few minutes
steam and powder solution. Proper eye protection must be w
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.
lways mix 30% w/w to get better results and contact your supplier/manufacturer for any
. Usually it takes 10-15 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.
The whole process is internal chemical reaction with physical change;
ROCK or CONCRETE. There is only Volumetric Change, Which is termed as
expansion energy to create fractures.
Fracturing Time depends on tensile strength and compressive strength. R
as it is less tensile and concrete takes time as it possesses high compressive strength.
Crack propagation mainly depends on type of material (Tensile / Brittle) and hole position
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
case of free structures fracture happens up to drilled depth only and
propagates/weakens towards free face. However we consider crack propagates i
angle of 45 Degrees to Horizontal Plane as shown in Figure.
mean hole distance and Line-Line distance for RCC Structures and
inches for PCC Structures. It is safe for structures to limit the cracks
with high productivity.
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min volume observed at 28-32%
not happens and it will net get
flow ability characteristics to full fill the aim of the Job. Improper hydrated mix in a very few minutes
n. Proper eye protection must be wore during
during the reaction process
may not be sufficient to evaporate the mixed water and remains in wet state with very less volumetric
lways mix 30% w/w to get better results and contact your supplier/manufacturer for any
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.
hange; it does not react with
. There is only Volumetric Change, Which is termed as
Fracturing Time depends on tensile strength and compressive strength. Rock is easy to crack
as it is less tensile and concrete takes time as it possesses high compressive strength.
Crack propagation mainly depends on type of material (Tensile / Brittle) and hole position
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
icant compressive strength, in
case of free structures fracture happens up to drilled depth only and then Crack
propagates/weakens towards free face. However we consider crack propagates in a sector
as shown in Figure. We keep
for RCC Structures and similarly 10-12
cracks and also eases for
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PRUDENT ROCK DEMOLITION SOLUTIONS
Application Procedure and Requirements
Chemical demolition technique involves
a). Drilling Among available drilling techniques pneumatic drilling setup and mechanized hydraulic drilling setup are
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
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.
Among available drilling techniques pneumatic drilling setup and mechanized 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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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
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.
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
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.
Standard Consumption
Sl. No.
Chemical Qty. Water Qty
1 20 Kg 6-6.5 Ltr
2 20 Kg 6-6.5 Ltr
3 20 Kg 6-6.5 Ltr
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e Mortar is a powder that must be mixed thoroughly with clear water in a ratio of 30 %
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.
After 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
required. Do not keep any obstruction on Hole. For further information feel free to discuss with us.
Water Qty. Hole Dia. Consumption
in RFT
6.5 Ltr 40 mm 32 Ft.
Water Qty Subject to6.5 Ltr 32 mm
36 Ft.
6.5 Ltr 25 mm 42 Ft.
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e Mortar is a powder that must be mixed thoroughly with clear water in a ratio of 30 %
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
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
After mix has been prepared it should be poured into the holes. as reaction starts quickly, pour the
do not maintain any delay in any particular
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.
Remarks
Water Qty Subject to change as per site
conditions.
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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 ro
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 be
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
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 ev
new cracks initiate during the process. Usually, For a single hole, 2
towards nearest free surface or nearest hole. When a free surface exists, the crac
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
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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
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.
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
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
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,
Please note during the initial reaction process (i.e., 30
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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
ck/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
After the mortar has poured into holes drilled on rock or concrete, the expansive stress gradually
” is shown in Fig. 1. Cracks initiate from an
inner surface of the hole due to circumferential stress that develops during expansion process while
en after the appearance of cracks, the cracks propagate and also
4 cracks initiate and propagate either
k, 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,
Please note during the initial reaction process (i.e., 30-60mis) there are
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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 chemically highly base in nature with
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 skin as it will react with skin rinse all affected parts
� Always wear nose mask to avoid inhalation into breathing system.
� Wear safety Goggles, Rubber Gloves, Long
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 sit
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hot 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
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
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
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.
Wear safety Goggles, Rubber Gloves, Long sleeve clothing and Helmet while handling, mixing
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.
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hot 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.
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 important to do
thoroughly after use. Ingestion
this product causes severe damage to digestion system of human body. If it comes in contact with eyes do not
e 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.
sleeve clothing and Helmet while handling, mixing
Do not peep into hole till at least one Hour as there is chance of blow shots releasing the evolved
Page 10
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� 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
� Keep away from children.
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, 4th Floor, Linghichetty Street, George Town, Che
5, 9642566077; Email: [email protected] website: w
PRUDENT ROCK DEMOLITION SOLUTIONS
Applying Demolition strategiesApplying Demolition strategiesApplying Demolition strategiesApplying Demolition strategies, , , , forforforfor constructiveconstructiveconstructiveconstructive
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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hennai-600001
www.prds.co.in
PRUDENT ROCK DEMOLITION SOLUTIONS
constructiveconstructiveconstructiveconstructive environment….!environment….!environment….!environment….!
Ensure that portion that to be cracked should not comedown/roll down/slide down into active
Do not park equipments besides structure/rock on which chemical demolition.