Conbextra EP120 Plus: High-Performance Two-Part Epoxy Grout

Product Overview

Conbextra EP120 Plus is a high-performance, two-part epoxy grout formulation specifically engineered for applications involving heavy dynamic or mobile loads. This advanced grouting solution is particularly well-suited for large volume pours and situations requiring extended working times or low exotherm properties, such as high-ambient-temperature installations.

Key Applications

Conbextra EP120 Plus is recommended for a diverse range of demanding industrial and construction applications, including:

• Reciprocating machinery and testing equipment
• Heavy crane and transporter rails subject to repeated loading
• High-speed turbines operating under heavy dynamic loads
• Centrifuges and drop forges requiring precision grouting
• Chemical plant facilities where spillage exposure is anticipated, including steelworks, refineries, and electroplating works

The product's versatility extends to encapsulation of piletops and waterproofing applications, ensuring continuous bonding to pile surfaces and preventing water seepage through capillaries or reinforcement paths.

Distinctive Advantages

Conbextra EP120 Plus delivers multiple technical and practical benefits:

• Exceptional mechanical strength with high compressive, tensile, and flexural strengths
• Resistance to repetitive dynamic loads ensuring long-term durability under cyclical stress
• Fast and convenient installation facilitating rapid deployment in field conditions
• Broad chemical resistance withstanding a wide range of chemical substances including oil, grease, fats, mild acids, alkalis, and both fresh and sea water
• Virtually no shrinkage, ensuring complete surface contact and optimal load distribution
• Low creep characteristics under sustained loading for dimensional stability
• Excellent flow properties enabling efficient placement in various gap configurations
• Superior quality control through two-part formulation eliminating the need for separate aggregate addition
• Installation at elevated temperatures without compromising performance
• Wide gap thickness accommodation providing design flexibility

Design Specifications

Gap Range and Thickness

Conbextra EP120 Plus is engineered for application in gap widths ranging from 30mm to 120mm. For pours exceeding 120mm thickness, volumes should not surpass 1m³. Additionally, the product can accommodate smaller gap widths down to 10mm, though cure times will be extended. For applications requiring faster curing at narrower gaps, Conbextra EP65 Plus is recommended as an alternative.

Technical Properties

The following performance data was measured at 23°C unless otherwise specified:

Property	Standard	Result
Density	—	1785 kg/m³
Compressive Strength	ASTM C579:2018	95 MPa @ 7 days; 103 MPa @ 28 days
Indirect Tensile Strength	AS1012.2 10-2000	18 MPa @ 28 days
Flexural Strength (Modulus of Rupture)	AS1012.2.11-2000	40 MPa @ 28 days
Modulus of Elasticity	AS 1012.17-1997	14.7 GPa
Thermal Coefficient of Expansion	ASTM C531:2018	2.5 x 10⁻⁵ mm/mm °C
Slant Shear Bond Strength	ASTM C882:2020	22 MPa (bond failure)
Creep (28 days @ 2.8 MPa)	ASTM C1181-2000	8.3 x 10⁻³ cm/cm @ 60°C
Pot Life	—	3 hours @ 23°C
Color (mixed)	—	Charcoal grey
Flow	AS1478.2:2005	650mm (flow trough)
Minimum/Maximum Thickness	—	30mm / 120mm

Chemical Resistance

Conbextra EP120 Plus exhibits robust resistance to:

• Oil, grease, and fats
• Most common chemical substances
• Mild acids and alkalis
• Fresh water and seawater

Note: Consult Fosroc Technical Services when exposure to solvents or concentrated chemicals is anticipated to ensure product suitability.

Component Specifications

Base Component

• Product Code: FC522555-12.2L
• Volume: 12.2 litres
• Shelf Life: 12 months from date of manufacture (when stored in dry conditions in original unopened packaging)

Hardener Component

• Product Code: FC522666-1.8L
• Volume: 1.8 litres
• Shelf Life: 36 months from date of manufacture (when stored in dry conditions in original unopened packaging)

Application Instructions

Surface Preparation

Foundation surfaces must be completely free from oil, grease, free-standing water, and loosely adherent material. Concrete surfaces should be cut back to sound substrate, with mechanical abrasion (needle gun, grit blasting, or grinding) recommended for maximum bond. All dust must be removed and bolt holes/pockets cleaned thoroughly.

Steel surfaces require shot blasting to remove rust, paint, and flaky mill scale completely.

Formwork Requirements

Formwork must be constructed to be leakproof, as Conbextra EP120 Plus is a free-flowing grout. A feeding hopper system is essential to provide adequate hydrostatic head. Forming materials should be coated with release agents (grease, wax, or plastic coating) to enable smooth grout surfaces and formwork reuse.

Mixing Procedure

A forced-action mixer is essential. Mix at slow speed (400-500 rpm) for 3 to 5 minutes using appropriate equipment, such as a heavy-duty 1600W mixer fitted with a 120mm diameter helical mixing paddle. Pour all hardener contents into the base container. To minimize air entrapment, ensure the paddle remains fully immersed in the grout throughout mixing.

Aggregate Addition

Suitable aggregates can be added to reduce material costs:

• Conbextra Grout Aggregate (Product Code: FC502021-20KG)
• Fosroc Anti-slip Grains 02 (Product Code: FC605185-20KG)

Up to 10kg of aggregate per 14-litre kit can be incorporated, with approximate yield increase of 4 litres per 10kg of aggregate. Caution: Air may be entrained during aggregate addition; allow the mixed product to settle and expel air bubbles before placing. Aggregate addition reduces flow characteristics; high-flow performance applications should avoid aggregate incorporation.

Placing

Pour grout steadily from one side only to eliminate air entrapment. Maintain continuous grout flow and ensure sufficient grout availability before commencing. Regulate batch preparation timing to match pouring duration. Pour only from one side to eliminate air or surplus water entrapment.

Cure Time

Conbextra EP120 Plus is a low-exotherm grout with slow curing characteristics. Formwork should remain in place for up to 7 days to allow complete hardening before removal.

Cleaning and Maintenance

All tools and equipment must be cleaned immediately after use with Fosroc Solvent 10. Spillages should be absorbed with sand or sawdust and disposed according to local regulations.

Limitations and Service Conditions

During Application

• Temperature range: Grouting may be carried out without special precautions at ambient temperatures between 10°C and 35°C
• Pot life reduction: At temperatures exceeding 20°C, pot life diminishes
• Low-temperature curing: Below 15°C, strength build-up is slower; at 5°C, curing ceases until material warms

In-Service Performance

Cured Conbextra EP120 Plus exhibits complete resistance to frost and sub-zero temperatures and is suitable for in-service use up to 55°C.

Storage and Shelf Life

• Base component: 12 months shelf life from manufacture (dry storage, original unopened packaging)
• Hardener component: 36 months shelf life from manufacture (dry storage, original unopened packaging)

Pack Configuration

Product	Specification
Conbextra EP120 Plus	14-litre, 2-component pack
Conbextra EP120 Plus Base	FC522555-12.2L
Conbextra EP120 Plus Hardener	FC522666-1.8L

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References

• [1] Fosroc_Conbextra_EP120_Plus_TDS.pdf
• [2] Fosroc_Conbextra_HF_TDS.pdf
• [4] Fosroc_Conbextra_EP300_DP_TDS.pdf