Experts from the industry speak about few construction chemicals and how smartly they are applied

  In India the infrastructure development has been among the focused priorities with large scale investments planned in both public works as well as private development projects. Large scale highways constructions and other public infrastructure projects have been initiated by the state and central governments. At the same time, private investments in projects, in the form of BOT, PPP basis is increasing.

We take a look at few construction chemicals and how smartly they are applied in executing such projects:
1. MaterEase“
We have always been a key driving force behind developments in technology for concrete plasticisers and super plasticisers. With MasterEase, our researchers have now succeeded in creating a new product that combines the advantages of the most efficient super plasticiser technologies. The resulting concrete has an excellent plasticising capacity, superb rheological properties, and long workability coupled with good early strength. With this technology, plastic viscosity can be reduced by up to 30 per cent, which results in a substantial reduction of pumping pressure required to pump the concrete on the construction site,” explains Nilotpol Kar, Business Director – Construction Chemicals, BASF South Asia.

MasterEase concrete is easy to place, finish, and pump, and at the same time it has become easier to select the raw materials for concrete production. Previously critical sands, as well as demanding supplementary cementitious materials, can now be used in concrete with more ease and efficiency. This all saves time and money in every single construction project. The choice of raw materials for concrete producers is now wider—and often more cost-effective. The improved rheological properties of the concrete make the installation more straightforward and faster.

Application: Concrete producers and users benefit in many ways from this new technology – MaterEase. It is flexible and can be adapted to challenging situations such as temperature variations. Moreover, the high level of rheology and workability retention minimises the risk of jobsite addition of water.

“Whenever the rheology of concrete is of importance, MasterEase can play fully to its strengths. That is to say, whenever concrete is finished manually, for excellent surface quality as with exposed concrete, for example, or in the prefabrication of demanding components. This is also the case whenever the pumpability of concrete is critical to success,” says Kar.

The new technology is particularly suitable for concrete mixes which are optimised for advanced engineering properties and sustainability – the Smart Dynamic Concrete or the Green Sense Concrete concept from Master Builders Solutions. High strength concrete with low water or cement rations, as well as mixes with higher levels of secondary cementitious materials, reduce the CO2 footprint and are easier to produce and place. This helps engineers and investors to improve sustainability ratings of their projects.

Kar adds, “Starting in Europe and the Middle East and with the recent launch in India, this technology will be globally available as MasterEase.” 3000 series for ready mix and site mix concrete applications.”

2. ShaliSeal CTE
Bitumen is black due to presence of asphaltene. It fails to provide coloured surfaces which are required to serve specific purpose. STP Ltd has developed coloured asphalt – ShaliSeal CTE.

ShaliSeal CTE has long lasting colour options, increased road safety, higher contrast, greater illumination inside tunnels, reduced lighting in tunnels, greater creativity for landscape, differentiates in pavement functions, attractiveness of sport venues and it is durable and easy to  maintain.

Application: ShaliSeal CTE repairs of cracks in rigid and flexible pavement by three component cold applied polymerised elastomeric processed tar based crack filler.

3. KEM Proof Ultimate
Concrete may be exposed to many environmental conditions and hence requires protection. Among the less aggressive of the environmental conditions is atmospheric carbonation. Carbonation occurs because carbon dioxide diffuses into the concrete and dissolves in the pore water. This produces carbonic acid which reacts with lime to form calcium carbonate.

Coatings may be applied to concrete to arrest the carbonation process. “KEM Proof Ultimate is a high quality acrylic emulsion based coating launched by Chembond during the recently concluded Acetech exhibition held in month of Janaury’16 at Ahmedabad along with improved version of their existing product KEM Proof 87,” says a spokesperson from Chembond Chemicals Ltd.

KEM Proof Ultimate is elastomeric in nature and has good resistance to weather and sunlight. It is single component system containing inert pigments and fillers suitable for application by brush, roller or spray. It prevents chloride ion ingress and exceeds all the requirements of a coating that resists carbonation and provides a smooth, durable and water repellent coating for concrete and masonry surfaces.

Application: KEM Proof Ultimate is designed to bind and to protect concrete structures against carbon dioxide, air or water born chlorides. It is used as elastomeric water repellent coating for asphalt, timber, fibre cements and zinc sheets. It may be applied to many types of substrates particularly those commonly requiring elastomeric anti-carbonation and water repellent coating like concrete bridges, highways, structures in marine environments, car parking structures, commercial and industrial buildings, flat and slopping roofs. It also acts as heat insulator and protects from damage and reduces heat conductivity.

KEM Proof Ultimate acts as a comprehensive barrier against carbon dioxide, water, sulphates and chloride ions. It maintains its appearance and elastomeric performance with high recovery even after long term UV weathering. Easily applied by roller, brush or airless spray, it is capable of bridging cracks and withstands substrate cracking up to 2 mm and cyclic movement upto 1 mm. It acts as a barrier against salts and atmospheric gases. It masks imperfections in substrate. Water vapour can escape from the structure and it also helps in reducing room and surface temperature, thus helping to keep room cool.

4. KEM Proof 87 – improved version
KEM Proof 87 is an elastomeric coating based on selected acrylic co-polymers. When applied, it cures to form a durable, protective, waterproof membrane. It is applied by brush or roller. It is a single-component emulsion containing inert pigments and has brushable consistency.Application: Used for coating roofs, it protects concrete structure against carbonation and chloride ingress. Its application includes concrete, cement boards, wood, bricks, tiles. It can also be used in damp and sunken areas such as under terrazzo or tiles floors, shower pans, kitchen, laundry and bathroom floors.

A spokesperson from Chembond Chemicals informs, “The improved version of KEM Proof 87 has good resistance to UV and atmospheric gases and salts ensures excellent durability. It has good tensile strength and elongation ensures crack bridging and movement accommodation. It is also highly resistant to water.”

5. Fibfloor Car Deck System Fibfloor car deck system is a water based technology, multi layer, multi polymer coating system comprising of an epoxy primer, epoxy car deck system to form seamless, anti skid coatings in attractive colours. It is mainly for car parks, making the parking and pedestrian areas easily identifiable and creating a welcome environment.

This technology’s features include abrasion resistant, hard wearing, skid resistant, seamless, flexible, dust proof, adhesion, improves aesthetics, light and bright, reduces noise levels, fire resistant, resistant to common fuels, fast curing schedule, car park internal decks, ramps and turning areas, multi storey car parks, crack bridging abilities.

Fibfloor car deck system comprises of:
• Primer: Solvent free, two components, medium viscosity, epoxy based pre-conditioning primer, which stabilises concrete. Substrate and isolates subsequent epoxy coating from the alkalinity of concrete which assists in degradation of urethane.
• Membrane: Solvent dust free epoxy flooring, has crack bridging abilities.
 Broad casting: Washed and dried quartz silica sand.
 Top coat: Aromatic or aliphatic polyurethane coating, which has wear resistance.
• Line marker: Aromatic polyurethane coating.
Application: The application areas include car park decks, drive aisle, ramps, walkways and pedestrian, internal and exposed decks.

“Economy is the top requirement, at times direct epoxy on RCC will be economical if drainage is not a criteria,” says Puneet Kakroo, Business Head, Fibrex Construction Chemicals Pvt Ltd.

6. ShaliSeal RSTC
In India the condition of most of the roads is pitiful, especially during the monsoon. The reason is; water entering the roads is the main cause of damage. The life of the roads can be increased by providing proper side drains and water resistant top layer. Over the years STP Ltd has developed ShaliSeal RSTC, which is a coal tar based sealer and almost unaffected by water. This product has been tried in small patched and has given incredible results.

“Bitumen has been used as a paving material since 18th century. It detoriates under sun’s ultraviolet rays, gets dissolved by petrochemicals, attacked by chemicals, deicing salts etc. Presently bitumen based fog sealer are used in India. We all know bitumen get detoriated by water. Time has come we need to use a water resistant sealer in roads, the answer is ShaliSeal RSTC from STP Ltd, this is an incredible product set to revolutionise the Indian roads,” says Hasan Rizvi, Vice President, STP Ltd.
Application: ShaliSeal RSTC acts as a top coat road slurry for enhancing road life by preventing water ingress. This is a refined coal tar based emulsion, designed to protect asphalt pavement. It resists ultra violet radiation, fuel impregnation and reduces aging of asphalt.

7. Fibelastic (PU) Spray Applied Waterproofing
Fibelastic (PU) Spray Applies Waterproofing is one of the component hybrid liquid applied elastomeric membranes which can be sprayed or hand applied, made up of special PU aliphatic polymer systems to form a tough impervious membrane. Typical application includes the waterproofing of structures like roof decks, basements cut and cover stations typically everywhere which needs water tightness.

The product requires no ‘pre-striping’ of existing cracks, monolithic, wear resistance, UV and weather resistant, attractive appearance, low dirt retention, easy to clean and maintain, allows diffusion of water since breathable, complies to various international codes, easy installation and dependable detailing due to spray or nap roller or brush, no welds laps or seams, slip resistant.

Application: Fibelastic Spray comes in single colours and can be used from 1mm to 3 mm thickness. It is ready to use and has to be sprayed by wet system equipment from graco or laurius or roller or brush. “The success of any system is heavily dependent upon the substrate preparation so proper cleaning of substrate is a must. The concrete should be at least 7 days cured and free from loose laitance and other contaminants which if remains can potentially decrease the performance of the product system. The curing starts immediately after spray and normally can be recoated after 8-10 hours at 30 C. The applied system needs protection by putting a drainage board when done on vertical and horizontal surfaces,” explains Kakroo.

8. SuperThermoLay APP membrane
Bridges are one of the major life lines in connecting people. They need to be protected from one of their major silent enemy, which is water. STP Ltd has been associated with bridge deck waterproofing using SuperThermoLay APP membrane.

Application: “SuperThermoLay APP membrane prevents the ingress of water into the bridge concrete, thus preventing harmful ingredients from damaging the concrete. This system has been done successfully on number of bridges in India. The process consist of application of Shalitex Primer followed by torching of SuperThermoLay APP membrane 3 or 4 mm thick followed by overlay of bituminous wearing course,” informs Rizvi.

Whenever the rheology of concrete is of importance, MasterEase can play fully to its strengths.
Nilotpol Kar, Business Director – Construction Chemicals, BASF South Asia.

The success of any system is heavily dependent upon the substrate preparation so proper cleaning of substrate is a must.
Puneet Kakroo, Business Head, Fibrex Construction Chemicals Pvt Ltd.

SuperThermoLay APP membrane prevents the ingress of water into the bridge concrete, thus preventing harmful ingredients from damaging the concrete.
Hasan Rizvi, Vice President, STP Ltd./strong>

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