Indospark Construction Services

Chemical Mortar CM400PE

 
Chemical Mortar
 
As a pure epoxy resin, CM400PE offers excellent adhesion to both steel and concrete and has highest load values of all our systems, it is primarily designed for heavy duty bonding of rebar, starter bars and dowels, anchor studs, bolts, threaded bars and sockets. Description
  • Overview
  • Description
  • Product Range
  • Installation
  • Loadchart
  • Accesories

What is styrene?

Styrene is mainly a synthetic material which is produced in industrial quantities from benzene and ethylene and classified as a toxin, an irritant and a potential caricinogen. To some extent oily colourless liquid form, it easily evaporates and has a sweet smell although this odour often changes once mixed with other components. It can dissolve in some liquids but is not easily dissolved in water. It it also produced naturally at low levels from some fruits and vegetables.


Where is it used? 

Styrene is heavily used, mostly in what is termed a linked form as a monomer to produce plastic based products such as polystyrene,ABS, SBR rubber, unsaturated polyesters. Which in turn are then used in industry to produce items such as vehicle parts, food containers and general plastic products. In our industry it used a great deal in polyester and vinylester based resin systems, adhesives and some sealant type products in its unlinked liquid form. 

What happens when styrene enters the environment?

For the most part, inert products such as plastic part and packaging etc. bring in styrene into the environment through the manufacture and disposal processes with proof of styrene contamination being found in air, water and ground soils. However, in unlinked liquid form it penetrates the environment quickly and in larger quantities through evaporation and is also further broken down by bacteria found in water and soils allowing further rapid entry. It is not expected to enter the food chain by grazing animals.

How does it affect humans?

Surprisingly, for a frequently used industrial product, little is known about the effects of styrene on us, what we do know to date is that although exposure may not lead to any symptoms at all, breathing high levels of styrene for short periods can lead to possible respiratory problems and nervous system effects such as depression, tiredness, nausea, muscle weakness, ENT irritation. There is presently no test data on the consequences of breathing low levels for a long time, nor are any records available on the consequences of ingestion or absorption although animal studies revealed a range of symptoms such as damage to the brain, kidneys, liver and lung along with some reproductive effects.
The international Agency for Research on Cancer and the Environmental Protection Agency has also now determined that styrene could be a possible carcinogen to humans in airborne form and a number of studies of workers have revealed that breathing styrene may cause leukemia. There is no present evidence to support any cancer or health risks for final finished products containing styrene where skin contact or ingestion has occurred.

To summarize.

Clearly, styrene is a toxic, dangerous product in its raw form. It finds its way into the market in either solid form e.g. plastic parts, packing etc. or in liquid form. It is not damaging to humans in its inert solid form although it is damaging to the environment if not disposed of appropriately. It is harmful to humans in liquid form both as a finished product and during manufacture. 

So where do we fit in?

In the chemical anchor market styrene has always been used in resin systems by most manufactures as it is both a readily available product and is the cheapest method of formulation. Clearly, styrenated chemical anchor products are high risk as they are always in liquid or certainly semi solid format when supplied. They are harmful to both humans and the environment during the installation phase when operators may breath in fumes and semi solid or liquid resins are placed in direct contact with ground and construcion elements (drilled holes etc.), it should be noted however that they are regarded as non hazardous in a cured state. Discarding of used cartridges also has an impact environmentally through soil entry of the broken down materials.
 It would have been entirely irresponsible to keep manufacturing and supplying a potentially dangerous product to customers when there are substitutes available and therefore we took the decision some time ago to eliminate all styrene from our cartridged resin products, this has been accomplished by reformulating our resin blends using other components and manufacturing processes to produce an anchor range which is now not harmful to the operators or the environment whilst still maintaining the properties of a high performance chemical anchor i.e. high strength, fast cure, pumpable etc.
 You will now find our polyester, epoxy acrylate and vinylester products totally styrene free, we have also made our pure epoxy product as safe as possible by formulating it in a low odour format and as inert as possible in order to pass WRAS approval for use in drinking water, pure epoxy based systems by nature, are not styrene based but do contain some harmful chemical, unfortunately if these were totally removed the product would then cease to function as an epoxy anchoring system. It is perfectly safe product when used properly.
 Our chemical capsules do still currently contain styrene as this is a requirement for product performance and not simply due to the manufacturing process and we are presently limiting the amounts used where possible whilst maintaining high performace function.We are committed to removing styrene from our total product range and therefore we hope to have alternative formulations available in the near future.

How do I recognize a styrenated product?

A chemical anchor or resin based product containing liquid styrene will always have a very strong petroleum type odour whereas styrene free products have practically no smell, the product will also carry a flammable symbol on the label and of course styrene will be listed in the manufactures MSDS. Styrene free products are usually classed as an irritant only.

What’s in it for us?

Nothing ! Clearly it is more expensive to manufacture styrene free resins, however we compensate the increased costs by the logistical savings on storage, handling and transport of a now non inert and non flammable product no longer needing special transport certification or strorage facilities etc. therefore there is no cost increase to our customers over standard styrene product. Also we normally take our environmental and customer responsibilities seriously and we are tremendously proud that we doing the best we can in real terms rather than just talking about it.
Description :

The Chemical Mortar CM345VESF is a high performance rapid curing styrene free low odor two component chemical injection anchoring system based on a high reactivity unsaturated vinylester resin in methacrylate monomers. The side-by-side cartridge format comprises of a resin and hardening agent in separate internal compartments which are mixed to the correct proportions in the delivery nozzle when triggered using the required manual dispenser.

Base materials :

Recommended for use in reinforced non-reinforced concrete, rock and stone. It also provides a higher grade bond than standard epoxy acrylate resin in solid masonry, hollow brick-work and pre-cast units (requires suitable sleeve) with minimal shrinkage.

Advantages :

Non programmable
Non hazardous environmentally friendly low odor.
Extreme heat and high chemical resistance
High load values in concrete and masonry for medium to heavy duty applications.
Imparts no expansion stresses on the base material.
Suitable for close to edge and reduced anchor center fixing.
Usable in damp and wet environments and submerged drill holes.
Rapid cure.
Vibration resistant.
Corrosion resistant.


Suitable For :

Usage is diverse and wide ranging in both static and dynamic load applications.

Static loads :

Structural connections transferring high loads into columns, beams, concrete pads and sections. Holding down bolts for steel columns. Masonry tie backs for steel structures. Bonding of irregular shapes and architectural features such as ballustrading. Due to low shrinkage the resin can also be used for rebar applications.

Dynamic loads :

Holding down machinery, fans and motors.
Anchoring racking systems.
Fixing of services, ducting and industrial pipe work bracketry.
Installation

Installation - concrete and solid masonry

 Drill hole to correct diameter and depth, diamond cored drill holes should be roughened prior to injection.
 Clean drill hole thoroughly using remove all dust using a blow out pump or airline.
 Remove screw cap and attach mixer nozzle onto cartridge and insert in manual dispenser.
 Discard the first 100mm of resin or until a uniform color has been achieved.
 Inject from the base of the drill hole withdrawing as the hole fills until 1/3 to 1/2 full (dependant on application).
 Insert clean fixing with a rotating motion until resin can be seen at the mouth of the hole, remove any excess immediately.
 Leave undisturbed until cured and then attach fixture and torque to required setting.


Installation - hollow masonry

 Drill hole to correct diameter and depth, diamond cored drill holes should be roughened prior to injection.
 Clean drill hole thoroughly using wire brush and remove all dust using a blow out pump or airline.
 Remove screw cap and attach mixer nozzle onto cartridge and insert in manual dispenser.
 Discard the first 100mm of resin or until a uniform color has been achieved.
 Insert nylon or metal sleeve as appropriate.
 Inject from the base of the drill hole withdrawing as the hole fills until the sleeve is completely full.
 Insert fixing carefully with a rotating motion.
 Leave undisturbed until cured and then attach fixture.





Dispenser DM 300

Steel body and mechanism

Description :

 
The professional dispenser DM300 for use with chemical mortar cartridges CM300PESF & CM300EASF.

 
Dispenser DM300 Variant 300ml 10:1 ratio cartridge

  Material steel body and mechanism



Dispenser DM 380


 
Steel body and mechanism

 


 
Description :

 
The professional dispenser DM380 for use with chemical mortar cartridges CM380EASF & CM380VESF.

 
Dispenser DM380 Variant 380ml co-axial 10:1 ratio cartridge

  Material steel body and mechanism



Dispenser DM 400

 
Steel body and mechanism

 


 
Description  
The professional dispenser DM400 for use with chemical mortar cartidge CM400PE.

Dispenser DM400 Variant 400ml side by side 1:1 ratio cartidge

  Material steel body and mechanism

Mixer nozzle MN

 
plastic  


Description :

 
Spare mixer nozzles for use with chemical mortar cartridges CM 300PESF, CM300EASF, CM380EASF, CM380VESF & CM400PE.

Mixer nozzle MN Variant co-axial

  Material plastic



Accessories for drill hole cleaning

 
Blow-out pump BP

 
plastic

 


Description :

 
The hand operated blow out pump BP is for drill hole cleaning prior to anchor installation.

 
Mixer nozzle MN Variant hand operated

  Material ABS



Cleaning brush CB

 
plastic

 


Description :

 
Wire brush CB is for thorough cleaning and hole preparation.

Cleaning brush CB Variant hand operated

  Material steel body and head

 
 
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INDO-SPARK CONSTRUCTION
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Mandir,  Kolhapur - 416 003 ,
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Contact to Mr. Sandeep Ingale-DIR.
Please visit at:
www.indospark.in/id/sandeepingale