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What's CRACK AGENT / Expansive Mortar?

CRACK AGENT (Expansive Mortar) is a kind of powder with amazing 18,000 PSI expansive strength when mixed with common water. Poured into holes, CRACK AGENT breaks reinforced concrete & rock safely and quietly, while providing SILENT cracking. Since CRACK AGENT provides controlled demolition according to drilling patterns, it is very easy to break reinforcedconcrete and all kinds of stone into desired sizes and shapes, without noise, vibration or dust.

In demolition, concrete cutting & excavating industry, CRACK AGENT helps you to break reinforced concrete and rock into chunks, so you may easily cut off rebar, haul it away with a crane or truck without damage remaining part.

 

In mining and quarrying industry, CRACK AGENT helps to achieve perfect slabs and blocks from limestone, onyx, marble, granite or any other type of stone you are working with. Compares to blasting, CRACK AGENT avoids waste of valuable stone, high insurance, costly storage and labor. CRACK AGENT can also be applied along with traditional methods like primer cord, hydraulic breaker, diamond blade saw and jackhammer to help cut cost, work time and increase safety, Plus silent operation, CRACK AGENT is perfect for residential, school and airport area. CRACK AGENT helps your work to become more efficient and cost effective.

Depending on different working temperature, there are four types of crack agent for your choice.

 

How to use

Drilling

1. Drill holes using an air hammer drill and appropriate drill bit specific to the rock type.

2. Holes should be drilled no further than 30-60cm (1ft-2ft) apart. Note: In reinforced concrete recommended no more than 20cm (8") apart.

3. Recommended hole diameter 38mm - 50mm (1 ½" - 2.0"). Depth would be 70-90% of the way depending on the type of rock/material to be removed.

Mixing

1. For regular safety reasons and mixing small amounts by hand, it is recommended to use rubber gloves.

2. In a bucket, combine 1.5 Liters of water to one 5kgs bag of CRACK AGENT. Or pour water and CRACK AGENT as a rate of 1:3 units by weight.

3. Mix well, using a drill and paddle is recommended. If mixing with a stick or other method, make sure powder is completely dissolved into the water. Mix to a slurry.

Filling

1. Clean holes before filling using air hose remove excess dust from drilling.

2. CRACK AGENT slurry should be poured into holes within 10-15 min. after mixing. Do not fill to the top, only fill the holes about 15mm ( ½" to 1") from the top.

3. Mix well and pour into holes while agitating the hole to make sure no air gaps are in the hole. Example: Using a piece of rod or stick to poke holes.

4. For Horizontal holes, a grouting pump would be most reliable to poor.

Cracking

The cracks appear in 40-60 min. after filling, depending on the weather,rocks, and concrete type. The cracks become wider within time (maximun 48 hours expanding time).

 

Consumption

 

Benefits

1. Amazing Expansive Capability

Amazing 18,000 PSI expansive strength when mixed with common water.

2. Easy to use

No training required before use. Just mix with water and then fill into holes. Once mixed with clean water, CRACK AGENT can be poured into holes pre-drilled in the material you are working with It can be poured into the same holes that dangerous explosives are usually placed in.

3. Non-Explosive & Environmentally Friendly

An alternative to blasting, diamond blade saw, hydraulic breaker and jackhammer, which is safer, more efficient, works without noise, vibration, dust by providing silent expansive cracking.

4. Works Efficiently and Cost Effectively

No Special License, training or equipment needed.

Package

1. First step: 5kg in plastic bag
2. Second step: 4 plastic bags in 1 carton
3. Third step: 50-60 cartons on every wooden or plastic pallet.

 

Tips

• Well designed hole drilling pattern will minimize consumption of CRACK AGENT by cutting into desired sizes.

• To insure success, CRACK AGENT needs FREE SPACE to expand to.

• For better results, it is important to note both air and material temperature. Material temperature is the temperature inside of the rock or concrete which can be different from the air temperature.

• In summer, the best time to use CRACK AGENT is in the evening when material temperature is cool.

• In summer, cover holes from direct sunlight to avoid blow-out. Example: using a tarp or damp hay to provide shade.

• If CRACK AGENT completely dries into powder and did NOT crack, pour additional water onto CRACK AGENT filled holes.

• When using CRACK AGENT on highly absorbent materials like concrete, the holes should be dampened before the mortar is poured, making sure however, that there is no presence of water.

• Fresh mortar should be poured into holes within 5 minutes after mixing.

• The workers need to take synchronized operation, especially to hard stone. The quantity of holes each worker responsible to fill has to be moderate. Taking synchronized steps when mixing, stirring and filling will lead to maximum expansive stress with all holes expand at the same time.

• When mixing, if CRACK AGENT begins to steam in container, add some water to dilute and process properly.

 

Safety Precautions

'Make sure that everyone working with CRACK AGENT understands the possibility of blowouts, and has read the technical instructions thoroughly.

'CRACK AGENT is a highly alkaline product, pH reaches 13 after contact with water and can cause severe irritation to mucous membranes, especially eyes. Skin and eye contacts with CRACK AGENT must be rinsed off with large amounts of cold water immediately without rubbing. Consult a doctor quickly.

'Wear safety goggles and rubber gloves during CRACK AGENT handling, mixing and filling. Dust-proof mask is recommended in poorly ventilated areas such as tunnels or mines.

'Plug the holes immediately after filling and cover the holes with straw mat. Keep your face away from the holes filled by mortar. Stay away from filled holes at least 3 hours after filling to avoid blow-out shot. Keep people away from job site after filling .

'Warm or bubbling mortar is forbidden to fill into holes. Once filled holes start to smoke or steam, that is the sign they may be about to blow out. Clear the area of people immediately.

'Keep people away from jobsite after filling holes. In case of people have to remain in the area, cover filled holes with a tarpaulin.

'Take care of fall of cracked block from the cracking object.

 

Environmental Friendly Dust Free Rock Cracking Powder

WHAT IS EXPANSIVE MORTAR?

EXPANSIVE MORTAR Non-Explosive Demolition Agent is a non-toxic and cementations powder, which consisting of calcined oxides of calcium, silicon and aluminum, EXPANSIVE MORTAR becomes a highly powered amazing expansive pressure of T / m2 when mixed with water. Marble, granite, limestone, plain concrete, reinforced concrete, boulders, and ledge are fractured overnight without noise, vibration, or fly rock. Especially, used as environment constraints or when explosive is not permitted for use.

 

HOW DOES EXPANSIVE MORTAR WORKS?

It develop rise of highly expansive capabilities at the consistent volume exceeding 122 Mpa ( T/ M2) more than enough to break up any materials to be cut or demolished. The tensile strength for most rock is less than 5-25 Mpa (500- T/m2 50-250 kg /cm 2), Reinforced concrete breaks at 3-5 Mp (30-50 kg /cm2, 300- 500 T/ M2). 

 

WHAT IS EXPANSIVE MORTAR USED FOR?

1.Quarrying marble and granite, limestone, sand stone; cracking nature ground

2.Breaking rock into pieces; deposition of falling rocks

3.Demolishing concrete structure, Chipping defective concrete piles, etc

4.In the field as a new method of demolition, EXPANSIVE MORTAR can effectively be use in the construction and civil engineering fields as follows:

Bridges Dams

Ledge Boulders

Machinery Bases Concrete Piers

Slabs 6" thick and more Marble and Granite 

 

WHAT ARE EXPANSIVE MORTAR ADVANTAGES AND BENEFITS?

 

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1.   No licenses or permit required

2.   2 year shelf life

3.   One product available for all temperature

4.   Use in safe, no noise, vibration, or fly rock,

5.   Easy to use, no need of train.

6.   MSDS available 

 

TYPES AND PACKING OF EXPANSIVE MORTAR

There are three types of Expansive mortar for traditional type, depending on usable temperature,

Type of EXPANSIVE MORTAR  Usable temperature 

 

SCA-1 25°C-40°C ( 77°F-104°F)

SCA-2 10°C-25°C ( 50°F-77°F)

SCA-3 -5°C-10°C ( 23°F-50°F) 

 

Universal type: one product for all temperature

Packing: powder by inner plastic bag, 5kg / bag, 20 kg / carton, one ton / wood pallet

Form:  powder and cartridge available 

EXPANSIVE MORTAR Technical manual.pdf , covers cracking design (hole depth, hole pattern,), drilling, mixing, filling instructions, estimating consumption quantity, cracking time, cracking gap.

STORAGE
1.Although SPLITSTAR® expansive mortar is packed in anti-moisture plastic bags, long storage may cause deterioration of its working ingredients. Therefore, store in a dry place and use it as soon as possible.

2.When storing, do not place the bags of SPLITSTAR® expansive mortar directly on floor, put them on a pallet and keep in a dry warehouse etc. SPLITSTAR® expansive mortar is stored in this manner, can be effectively used for about 1 year.

3.SPLITSTAR® expansive mortar should be unpacked before use.

4.When storing the portion of SPLITSTAR® expansive mortar remaining after use, push the air out of the bag, then seal with gum tape and use as soon as possible. However, as it may get exposed to moisture there is a risk of SPLITSTAR® expansive mortar losing its effectiveness once the bag has been opened.

5.If you receive broken bags of SPLITSTAR® expansive mortar, they may not work due to chance of moisture absorption.

STANDARD QUANTITY

 Pre-drilled hole design table

Materials & purpose

                                                    Hole design

Diameter'mm'

Hole spacing

Depth

 Soft stone quarrying

28-38

200-300mm

105% of Height

 Hard stone quarrying

30-40

200-300mm

105% of Height

 Stone cutting

28-38

200-400mm

90% of Height

 Plain concerte demolition

30-40

300-500mm

80% of Height

 Reinforced concrete demolition

35-40

150-300mm

90% of Height

 

Reference consumption of

Hole diameter'mm'

30  32  34  36  38  40  42  44  46  48  50

Consumption 'kg/m3'

1.2   1.3   1.5   1.7  1.9  2.1  2.5  2.8  3.0  3.2

Hole depth 'm'

1

HOW TO USE THE SPLITSTAR® EXPANSIVE MORTAR

a. Mixing:  SPLITSTAR® expansive mortar is a powder that must be thoroughly mixed with clear water before used in a ratio of 30% of the overall weight (1.5 liters of each 5 kg packages). Gradually add the powder to water stirring all the time to obtain a smooth lump free mortar.

b. Filling:  Pour the mortar into the prepared holes within 5 to 10 minutes only .Stope horizontal holes to allow an easy pouring of SPLITSTAR® expansive mortar (should some of the mortar leak out of hole. Stop it with a piece or soft sponge) or fill the holes with thick mortar of SPLITSTAR® expansive mortar,

c. Drilling : The distance between holes varies depending on the size of the hole (from 32 mm diam. to 42 mm diam.) and the type of materials to be demolished or cut. For rock or non-reinforced concrete should be 30 to 60 cm. And reinforced concrete should be 20 to 30 cm.

Selection of Proper Type of SPLITSTAR® expansive mortar
To avoid blown-out shots the proper type of SPLITSTAR® expansive mortar should be selected in accordance with the temperature of the object to be demolished. NOTE :When the season is shifting, ex. winter to spring, or when tunnel or underground demolition work is carried out, carefully select the proper type of SPLITSTAR® expansive mortar in accordance with the temperature of the object to be demolished, not outdoor temperature, because the temperature of the object is often great[y different from the outdoor temperature. If the temperature of the object is higher than the outdoor temperature and the type of SPLITSTAR selected in accordance with the outdoor temperature is used, blown-out shots will certainly occur.

Temperature Estimation
As shown in following picture, place a thermometer in the bottom of the hole and leave it in place for 2-3 minutes. Then quickly pull out the thermometer and take a reading.
NOTE :Avoid taking temperature right after drilling since the temperature of the hole is higher because of friction heat.

Drilling
Drill holes designed for demolition with a drilling machine.
(1) Drilling machine : Jack Hammer, Leg Hammer etc.
(2) Drilling Direction : It is preferable to drill holes vertically, but in case of a wall or pillar of reinforced concrete where vertical drilling is hard, an inclined hole may be drilled. For horizontal holes, the same idea of spacing as with vertical holes can be applied. Try to drill horizontal holes with some slope.
(3) Drilling machine : Use of Spiral Sheath Pipes
In the case of a temporary concrete structure (to be demolished), place spiral sheath pipes as holes before placing concrete. When the structure needs to be cracked, fill the holes with SPLITSTAR® expansive mortar after removing the spiral sheath pipes.

There is no change in breaking effect by the use of spiral sheath pipes. However, spiral sheath pipes of 36-50mm (1 3/8"-2") diameter should be used.
NOTE : Never use vinyl chloride pipes etc. instead of spiral sheath pipe. Leg Hammer Spiral Sheath Pipe

SAFETY PRECAUTIONS
1. Wear safety goggles, rubber gloves, long sleeve cloth and helmet during SPLITSTAR® expansive mortar handling, mixing and filling.
2. Do not get your face close to or stand near filled holes for at least 3 hours after filling completion stop the hurt to eyes in case of blow out shots.
3. Wear a dust-proof mask when using SPLITSTAR® expansive mortar in poorly ventilated areas such as tunnels or mines.
4. Keep people away from job-site after filling mortar.
5. Skin contact with SPLITSTAR® expansive mortar must be rinsed off with large amounts of cold water immediately.  
6. Should you get spray from SPLITSTAR® expansive mortar in your eyes, do not rub but wash the eyes immediately with plenty of cold water and consult doctor.

For more Expansive Mortar Cracking Powderinformation, please contact us. We will provide professional answers.