Grouts and Anchoring

Solutions

constructive solutions

www.bergerfosroc.com
Our Profile
Index
Berger Fosroc Limited, Bangladesh is a new joint venture entity formed between Berger Paints
Bangladesh Limited and Fosroc International Limited on 31st January 2018. ■■ Introduction to Conbextra Grouts 4
Berger is one of the renowned names in the paint industry and the country’s major specialty ■■ Why Grout? 5
paint business with products and ingredients dating back more than 250 years. Over the ■■ Product Range 6
decades, Berger has evolved to become the leading paint solutions provider in Bangladesh and
■■ Grouting Solutions for Hydro Carbon,
has diversified into every sphere of the industry- from Decorative Paints to Industrial, Marine
and Powder Coatings. Steel and Heavy Engineering Sector 8
Fosroc International is the flagship company of the JMH Group which over the years has ■■ Grouting Solutions for Power Sector 10
emerged as a leading supplier of construction products and solutions across the world. ■■ Grouting Solutions for Transport Sector 12
Fosroc world-wide backed by its rich history of over 75 plus years of international presence
■■ Grouting Solutions for Precast Housing
has operating companies spread across Europe, Middle East, India and Asia besides other
emerging geographies, with over 20 manufacturing locations and distribution network in over ■■ Polyester Anchors 16
100 countries worldwide. ■■ Project References 17
Berger Fosroc Limited in Bangladesh will provide complete solutions to all sectors of the ■■ Application Guidelines 18
construction industry, specializing in solutions for the construction of buildings, industrial
facilities, power plants and to all types of transportation and civil infrastructure.
This new entity will be supported by the parent companies Group Research & Development
facilities located in various International locations with state of the art laboratories and a team
of dedicated Scientists pioneering product development and innovation.
Berger Fosroc’s wide range of constructive solutions portfolio includes
ƒƒ Cement Grinding Aids such as Cemax, Auracem
ƒƒ Admixture products such as Conplast, Structuro, Auramix, Auracast
ƒƒ Waterproofing products such as Supercast, Nitoproof, Proofex
ƒƒ Precision Grouts & Anchors such as Conbextra, Cebex,Lokfix
ƒƒ Joint Sealants such as Thioflex, Nitoseal
ƒƒ Flooring products such as Nitoflor, Cemtop, Adhesives
ƒƒ Concrete Repair & Protection such as Renderoc, Nitomortar, Nitocote, Dekguard.

Product Range

Admixtures and Grouts and Anchors Industrial Flooring Concrete Repair Joint Sealants and Waterproofing Cement Additives
Surface Treatments Structural Strengthening Adhesives
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Introduction to Grout
Fosroc has been servicing grout requirement of Indian
industry for more than three decades. Conbextra range
of cementitious and Epoxy grouts are considered to be
the most dependable grouting solutions by engineers,
erectors and machine manufacturers.

The journey started way back in mid-eighties when Indian

power sector accepted the locally produced Conbextra
GP2 and stopped importing cement grouts from
European sources. Since then almost all the critical
equipments like turbine, generator and other equipments
in thermal power sector are grouted with Conbextra GP2.
Consequentially the product is also accepted in other
sectors like steel, petrochemical, cement and general
engineering.

Conbextra range offers comprehensive solutions to

grouting requirements of wide sectors like thermal power,
wind energy, refineries, steel plants, transportation and
precast. The range offers both cement and epoxy grouts.

Conbextra range of grouts offer high performance

standards in terms of high early and ultimate strength,
flow properties, high EBA (Effective Bearing Area) and
also dynamic load resistance.

The product range outperforms industry laid norms and

standards.

The product range has been certified by institutions of

repute like Indian Institute of Technology, Chennai and
strongly recommended by equipment manufacturers like
BHEL in Power industry, Loche in Cement industry and Why Grout?
also consultants.
The typical machine installation sequence in industrial sufficient mechanical properties to effectively transfer
TEST REPORT
scenario calls for filling the gap between the steel base the load of machine – static load and also vibrations –
plate / frame and concrete foundation. The gap arises dynamic load to concrete foundation during service life of
STRUCTURAL ENGINEERING DIVISION
during alignment of steel frame as the frame cannot rest equipment.
directly over the concrete foundation due to its uneven
As traditional concrete or mortars do not have sufficient
PROJECT : REPORT ON FREE EXPANSION TEST OF
CONBEXTRA GP3
surface texture. The base frame therefore is placed over
CLIENT : M/s FOSROC INDIA PVT LTD,
BANGALORE shim plates leaving gap between frame and concrete flow properties and also shrink during hardening
CONSULTANT : Prof. DEVDAS MENON foundation. process, they are not suitable and therefore necessitates
ASSISTED BY : V.PRIYESH
requirement of high precision engineering grouts like
The gap filling of foundation frame is a precision job Berger Fosroc Conbextra range with specific technical
STRUCTURAL ENGINEERING DIVISION
DEPARTMENT OF CIVIL ENGINEERING
INDIAN INSTITUTE OF TECHNOLOGY, MADRAS
and requires specially designed material with technical parameters like non-shrink, high flow, high early and
parameters in plastic and hardened state. The materials ultimate strength dynamic load resistance etc. These
CHENNAI – 600 036

DATE: 05-07-2013
should fill the gap effectively achieving sufficient contact grouts can be either cementitious complying with ASTM C
with steel plate without any cavities and also have 1107 or epoxy grouts ASTM C 1181.

Grouting Solutions for Various Sectors

Industry Power Transport Precast Anchors

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Product Range
STANDARDS ULTIMATE ULTIMATE
PACK SIZE STANDARDS
PRODUCT NAME P PRODUCT DESCRIPTION W/P RATIO COMPLAINCE COMPRESSIVE COMPRESSIVE PACK SIZE
STRENGTH PRODUCT NAME P PRODUCT DESCRIPTION W/P RATIO COMPLAINCE
STRENGTH

CEMENT GROUTS
CEMENT GROUT ADDITIVES
Non Shrink , High Flow Cementitious grout ASTM C 1107
0.15 45 N/ mm2 25 Kgs
1 Conbextra GP1 with static Load Resistance Type A
As per Site As per Site Mix
22 Cebex 100 Non Shrink cement grout Additive 225 gms
Mix Design Design
Non Shrink , High Flow , High Strength
ASTM C 1107
2 Conbextra GP2 Cementitious grout with static & Dynamic load 0.18 65 N/mm 2
25 Kgs
Type A Non Shrink cement grout additive with As per Site As per Site Mix
resistance 23 Cebex 200 225 gms
Hydrogen free expansion system Mix Design Design
Non Shrink , High Flow , High Strength ASTM C 1107
3 Conbextra STD 0.12- 0.13 65 N / mm2 25 Kgs
cementitious grout Type A
EPOXY GROUTS
Non Shrink , High flow cementitious grout ASTM C 1107
4 Conbextra TS 0.14 65 N/mm2 25 Kgs
suitable for grouting Height up to 500 mm Type A
24 Conbextra EP10 Low viscosity epoxy injection system ASTM C 1881 80 N/mm2 1 Ltr
ASTM C 1107 High Flow , High Strength - High Exotherm
5 Conbextra HF Non shrink , Ultra High flow cementitious grout 0.19 56 N /mm2 25 Kgs
Type C 25 Conbextra EP75 Epoxy grout suitable for grouting heights upto ASTM C 1881 100 N /mm2 14 Ltrs
75 mm
Non shrink , High Flow cmentitious grout with ASTM C 1107
6 Conbextra AT 0.16 80 N/mm2 25 Kgs High Flow , High Strength - Low Exotherm
high Early & Ultimate strength Type A
26 Conbextra EP300 Epoxy grout suitable for grouting heights upto ASTM C 1881 82 N/mm2 14 Ltrs
75 mm
Free fl ow, high strength, rapid setting, ASTM C 1107
7 Conbextra HES 0.21 55 N/mm2 25 Kgs
cementitious grout Type A
27 Conbextra EBG ( M ) Epoxy Bridge Bearing Grout ASTM C 1881 60 N/mm2 3 Ltrs

HIGH PERFORMANCE CEMENT GROUTS

Non shrink , High Flow , High Early & Ultimate ASTM C 1107
14 Conbextra UHS 90 0.12 90 N/ mm2 25 Kgs
strength cement grout Type C

Non shrink , High Flow , High Early & Ultimate ASTM C 1107
15 Conbextra BB92O 0.11 90 N / mm2 25 Kgs
strength cement grout Type A
Non shrink , High Flow , High Early & Ultimate
ASTM C 1107
16 Conbextra BB92 IN strength cement grout with Dynamic load 0.11 90 N / mm2 25 Kgs
Type C
resistance
Non shrink , High Flow , High Early & Ultimate
ASTM C 1107
17 Conbextra BB72 IN strength cement grout with Dynamic Load 0.16 75 N / mm2 25 Kgs
Type C
resistance
ASTM C 1107
18 Conbextra HR Heat resistant cementitious grout 0.14 90 N/mm2 25 Kgs
Type A

ASTM C 1107
19 Conbextra UW Anti washout Underwater cementitious grout 0.22 53 N/mm2 25 Kgs
Type A

CABLE DUCT GROUTS

Conbextra Cable Ultra High Flow, High Strength PT Cable duct

20 0.28 - 0.30 EN 447 / 445 70 N/mm2 25 Kgs
Grout HS grout

Conbextra Cable
21 Ultra High Flow PT Cable duct grout 0.33 - 0.35 EN 447 / 445 30 N/mm2 25 Kgs
Grout

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Grouting Solutions for Hydro Carbon,
Steel and Heavy Engineering Sector
Berger Fosroc has a wide range of precision grouts ensuring the smooth running of plant and factory facilities from steel plants,
petrochemical, cement plants, sugar etc. We understand the strains placed upon machinery and the importance of minimising
downtime, and have the solutions to achieve these aims.

Column Cement grout machine Epoxy grout machine Lokfix Anchors

foundation foundation foundation

APPLICATIONS REFINERY STEEL PLANTS CEMENT PLANTS GENERAL INDUSTRIES

Sinter Plant,
Steel Column Steel Column Blast Furnace, Steel Column Mill Foundation/ Equipment Grout
Compressor Other Static Load
GROUTS PRODUCT DESCRIPTION Foundation / Foundation / Coke Oven and Foundation / Compressors, With Static and
Foundation Equipments Applications
Pipe racks Pipe racks Other Equipment Pipe racks Pumps Dynamic Load
Foundations
1 Conbextra GP1 Non shrink cementitious grout with static load resistance    
Plastic shrinkage compensated cementitious grout for static and Dynamic
2 Conbextra GP 2    
load resistance
3 Conbextra Std Free flow, high strength, non-shrink, cementitious precision grout   
Dual shrinkage compensated cementitious grout with static and Dynamic
4 Conbextra GP3    
load resistance
5 Conbextra HR Heat Resistant cementitious grout 
6 Conbextra EP75 / 300 Free flow, High Strength epoxy grout 

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Grouting Solutions for Power Sector
Power generation has been the key to economic and social development of any country. Berger Fosroc has been servicing this
sector since last three decades. Conbextra range of grouts are widely accepted in thermal, hydel and wind power.

Lokfix anchoring systems are used in solar power sector.

Column Cement grout machine Epoxy grout machine Lokfix Anchors

foundation foundation foundation

APPLICATIONS THERMAL POWER WIND POWER HYDEL POWER SOLAR POWER NUCLEAR POWER
Steel BFP / ID Fan / Sluice Gates, Steel Solar Power Steel
On shore Precast Joints Hydroturbine
Column Turbine ESP / Pumps and Column Foundations Panel Column Equipment
GROUTS PRODUCT DESCRIPTION Wind Mill for Concrete and Auxiliary
Foundation / Assembly other Auxiliary and Other Static Load Foundation Foundation / Grouts
Foundation Towers Equipment
Pipe racks Equipments Applications Bolt anchoring Pipe racks
1 Conbextra GP1 Non-shrinkt cementitious grout with static load resistance   
2 Conbextra GP 2 Plastic shrinkage compensated cementitious grout for static and dynamic load resistance 
3 Conbextra GP3 Dual shrinkage compensated cementitious grout with static and dynamic load resistance   
4 Conbextra BB92O Sulphate resistant, high early and ultimate strength, plastic shrinkage compensated wind mill grout 
5 Conbextra BB92 High early and ultimate strength, plastic shrinkage compensated wind mill grout 
6 Conbextra BB72 Plastic shrinkage compensated cementitious grout for static load resistance 
ANCHORS

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Grouting Solutions for Transport Sector
Transportation sector in India has shown exponential growth in last couple of years. There are three major grouting applications
in this sector – ballast less track (rail fixing plates), bridge bearings, bearings in elevated viaducts, cable duct grouting of
post-tensioned cables – cable stay bridges. Berger Fosroc offers customised product solutions for these applications:

Cementitious bearing grout Epoxy bearing grout Cable duct grouting Rail plate grouting

APPLICATIONS BRIDGES METRO

Rail , Road ,Cable stay Elevated Vaiducts Ballastless Metro Track
Stressing Cable Injection Grouting of Stressing Cable
GROUTS PRODUCT DESCRIPTION Bearings Rail Plate Grouting Bearings
Grouts Shear Connectors Grouts
1 Conbextra GP1 Non-shrink cementitious grout with static load resistance
2 Conbextra GP 2 Plastic shrinkage compensated cementitious grout for static and dynamic load resistance  
3 Conbextra GP3 Dual shrinkage compensated cementitious grout with static and dynamic load resistance  
4 Conbextra EBGM Epoxy Grout  
5 Conbextra Cable Grout  
6 Conbextra Cable Grout HS  
7 Conbextra EP75 / 300 Free flow, high strength epoxy grout 
8 Conbextra EP10 Low viscosity epoxy injection grout 
GROUTING ADDITIVES
7 Cebex 100  
8 Cebex 200  

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Grouting Solution for Precast Construction
Precast construction technique for mass housing is becoming increasingly popular and widely used these days.

Precast construction technique has large grouting applications between junctions of various precast elements. There are also grouting
applications in dowel bar ducts.

Precast Wall

Sleeve

1 Conbextra GP1 Non-shrink, high flow cementitious grout Dowel Rebars

2 Conbextra Std Free flow, high strength, non-shrink, cementitious precision grout
3 Lokfix Polyester anchors Conbextra Cement Grout

Precast Slab

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Lokfix Polyester Anchors Project References
Polyester resin grouts for high strength corrosion resistant anchoring of bolts and bars into concrete, rock, masonry or brickwork. Selecting the correct grout requires more than looking at compressive strength. That is why Berger Fosroc
The system offers high speed of installation and early application of load. provides a wide array of grouting products and complimentary ancillaries. We design our materials to exhibit
‘best-in-class’ properties, always looking at the critical issues such as material stability, flowability and ease of
The typical applications are in the area of installation of dowel bars, safety fences like staircase grills, ground anchor for towers,
solar power panel anchoring, cranes etc. application, compressive, flexural and tensile strengths. Perhaps most critically, Berger Fosroc design the grouts to
stand the test of time. Here is a selection of some of our projects from around the world:

King Fahad Causeway Saudi Arabia

The 25 km King Fahad Causeway, linking Bahrain to Saudi Arabia, is used by

over 19 million passengers a year. Reducing maintenance cycles is a key aim of all
designers, this critical piece of infrastructure is no different. This enormous structure
has been supported by Berger Fosroc’s Conbextra HF since its construction began
in 1981.

The product was pumped under pressure between the segmental rings of the precast
piles that support the bridge as they were lifted into place. The grout was selected
for its flowability at high temperatures, stability under pumping pressure and dual
shrinkage compensation. The speed of its set allowed rapid erection of the piles.
Conbextra HF has weathered the elements and exposure, proving Berger Fosroc is
the supplier of choice for critical and durable applications.

Paradip Oil Refinery India

Construction at the massive Paradip refinery for the Indian Oil Corporation presented
a challenge to the Fosroc team. The processing units for crude oil required varying
depths in application and base plate sizes were very large. To add to the difficulty,
ambient temperatures during application frequently rose above 40ºC. Of course, the
grouts also had to exhibit resistance to a number of very aggressive chemicals and
excellent flexural strength and creep resistance.

The team worked to produce special product formulations to meet the application
procedures ensuring high contact, high strength and crack-free grouting beneath
the machines. Our ability to produce bespoke solutions and a variety of products
including Conbextra EP75, Conbextra EP300, Conbextra GP and Conbextra BB92
to meet application needs meant Berger Fosroc were the only company selected to
supply the refineries’ grouting.

Emirates Airline Cable Car UK

A novel piling technique was used to cast the supporting columns in the brisk tidal
zone of London’s River Thames. The use of Conbextra UW enabled a very high
quality of concrete to be cast even under water. Once the piles were in place the
1 Lokfix S Difference between hole dia and bar dia less than 25 mm. Suitable for vertically down holes initial skirt of the tower was set onto them almost immediately, meaning the early age
Lokfix P is used in overhead or horizontal holes. The thixotropic nature of Lokfix polyester resin compressive strength of Conbextra UW was another critical requirement.
2 Lokfix P
grout P reduces flow of grout out of the hole
Initially the proposed construction method and programme meant that the cable car
would not be operational until the end of the summer. Berger Fosroc’s Conbextra
Application Instructions UW was an integral part of the success of the new innovative piling technique
adopted due to its very high strength and anti-wash out characteristics. This
innovative approach took 6 weeks off the completion time of the project; ensuring
that it finished well ahead of schedule and was in place to assist in the logistics of
staging the London 2012 Olympic Games.

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Application Guidelines for Conbextra Grouts
The following procedure is designed to provide guidance to achieving the best grout pour results using
Conbextra Cementitious Grouts. Consult your local Berger Fosroc team for specific site guidance.

1. Planning 2. Preparation and Setting 5. Saturation 6. Mixing

Correct planning is essential. Calculate the correct material Remove laitance, damage or contaminants from the slab Fill the formwork with clean water and allow it to stand for a Use a slow speed drill (appx 500rpm) with Mixer Paddle
consumption factoring water addition and including material conducting repairs if necessary. Ensure all corrosion deposits minimum of 2 hours. Check formwork for leaks and plug MR3, for large quantities a shear vane mixer may be used.
wastage. Ensure that the correct head/flow/distance has been have been removed from the baseplate. Identify any high spots where necessary. After saturation, drain water and remove Slowly add powder to a pre-measured amount of water,
calculated. Ensure the correct equipment is available including in the baseplate and drill through to prevent air entrapment. When any standing water in low spots using sponges or vacuum. ensure consistency of water/powder ratio. Do not allow
strapping or rods as well as sufficient mixing teams to undertake setting the plate, using a threaded bolt to level is often the best Begin the grouting process immediately after completion of material to stand for more than 15 minutes. Material mixing
a continuous pour. Plan the correct amount of time that will be technique, providing maximum adjustability before, during and the saturation process. Do not saturate concrete when using process should ensure that a constant pour is achieved with
needed for the work. Ensure the correct working temperatures after the pour. Levelling shims may also be used, but must be Conbextra epoxy resin grouts! no time gaps.
are achieved. removed after the pour.

3. Fixing 4. Formwork 7. Pouring 8. Finishing

Make sure the bolts and bolt holes are clean and dry with Using timber, fix the shuttering around the baseplate. Gaps at the Using the header box pour the grout continuously through the Exposed edges of the material should be cured using
sufficient mechanical key. Apply Lokfix or Lokfix DUR resin pouring end should not exceed 150 mm and at the free end no area, keeping gaps between pours to an absolute minimum and Concure WB. The edges of the pour should not project above
anchors into the hole. Immediately place the holding bolts into more than 50 mm. All shuttering should be watertight and supported maintaining head of pressure. Check that material flows correctly the bottom level of the baseplate, especially if movement
the resin, applying in a twisting motion until the required depth sufficiently to be able to withstand the pressures of the grouting beneath the plate, and any air vents are plugged as they become is anticipated. 45º chamfers may be achieved by formwork,
is reached and some resin protrudes slightly above the line of process. The shuttering should be designed to allow water release full. Pour only from one side to avoid entrapping air. Do not cutting the grout, or by using a Renderoc mortar. Observe
the floor. Ensure the bolts are straight and centred and allow the or removal. The grout box shall provide sufficient head of pressure vibrate or agitate Conbextra grout when it is in its plastic state. material strength gain information prior to loading.
material to set. in relation to the viscosity of the grout and the length of the pour. For large area pours consider using a grout pump.
A smooth wood should be used and, where necessary, carefully
applied Reebol mould release oil may be used.

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 Leaders in constructive solutions
FCA/BSW/15/08/2019

Important note :
Berger Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its
standard terms and conditions of sale, copies of which may be obtained on request. Whilst Berger Fosroc endeavours
to ensure that any advice, recommendation specification or 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 or information given by it.

Berger Fosroc Limited

Corporate Address:
‘Berger House’, House # 08, Road # 02, Sector # 03, Uttara Model Town, Dhaka 1230, Bangladesh.
telephone( Hunting) : +880248953665, fax : +880248951350,
e-mail : enquiry.bangladesh@bergerfosroc.com, website : www.bergerfosroc.com