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

Product Overview

Conbextra EP120 Plus is a high-performance two-part epoxy grout specifically engineered for dynamic and repetitive load applications requiring large volume pours. Manufactured by Fosroc, this advanced grouting system combines superior mechanical properties with exceptional installation convenience, making it ideal for demanding industrial and structural applications.

Key Product Characteristics

Composition and Formulation

Conbextra EP120 Plus is formulated as a two-component epoxy grout system that does not require additional aggregate to be added during preparation. This distinctive feature eliminates the need for separate mixing procedures and provides superior quality control during the mixing process compared to single-part alternatives. The product is supplied as a convenient 14-litre two-component pack, with components pre-measured for optimal performance.

The system comprises:

• Base Component (FC522555-12.2L): 12.2 litres with a shelf life of 12 months
• Hardener Component (FC522666-1.8L): 1.8 litres with a shelf life of 36 months

Design Specifications

Conbextra EP120 Plus is designed to accommodate a versatile range of gap thicknesses:

• Minimum thickness: 30mm
• Maximum thickness: 120mm
• Extended pours: Gaps greater than 120mm are possible, provided the total volume of a single pour does not exceed 1m³
• Smaller gaps: Down to 10mm can be grouted, though cure time will be extended

Mechanical Properties and Performance

Compressive Strength

Conbextra EP120 Plus exhibits exceptional compressive strength characteristics when tested at 23°C:

• 7 days: 95 MPa
• 28 days: 103 MPa

Additional Strength Properties

The grout delivers comprehensive mechanical performance across multiple parameters:

Property	Test Method	Result
Density	-	1785 kg/m³
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 × 10⁻⁵ mm/mm °C
Slant Shear Bond Strength	ASTM C882:2020	22 MPa (bond failure)
Creep (28 days @ 2.8MPa @ 60°C)	ASTM C1181-2000	8.3 × 10⁻³ cm/cm
Flow (flow trough)	AS1478.2_2005	650mm
Pot Life	-	3 hours @ 23°C
Color (mixed)	-	Charcoal grey

Key Advantages

Conbextra EP120 Plus offers multiple performance and practical benefits:

• High compressive, tensile, and flexural strengths enabling reliable load distribution
• Resistant to repetitive dynamic loads from machinery, turbines, and similar equipment
• Fast, convenient installation with minimal on-site preparation requirements
• Withstands a wide range of chemicals including oils, greases, fats, and mild acids/alkalis
• Virtually no shrinkage, ensuring complete surface contact and structural bond
• Low creep characteristics under sustained loading conditions
• Excellent flow properties enabling optimal placement and coverage
• Two-part material system providing better quality control during mixing
• Can be installed at elevated temperatures with controlled curing characteristics
• Wide range of gap thicknesses accommodating diverse structural requirements
• Low exotherm properties enabling use for large pours and high ambient temperature applications

Primary Applications

Conbextra EP120 Plus is specifically designed for applications involving:

• Reciprocating machinery requiring uniform load distribution
• Testing equipment subjected to dynamic loads
• Heavy crane and transporter rails carrying substantial moving loads
• High-speed turbines requiring precise alignment and load transfer
• Centrifuges and drop forges experiencing repetitive impact forces
• Chemical plant environments where exposure to spillages is anticipated
• Steel works, refineries, and electroplating facilities requiring chemical resistance

Chemical Resistance

Conbextra EP120 Plus demonstrates excellent resistance to:

• Oil and grease
• Fats and fatty substances
• Most common chemicals
• Mild acids and alkalis
• Fresh and sea water

For applications involving solvents or concentrated chemicals, technical consultation with Fosroc is recommended.

Installation Characteristics

Mixing Requirements

• Mixer type: Forced-action mixer (essential)
• Mixing speed: 400-500 RPM (slow speed)
• Mixing duration: 3 to 5 minutes
• Equipment: Heavy-duty 1600W mixer fitted with 120mm diameter helical mixing paddle
• Immersion requirement: Paddle must remain fully immersed during mixing to minimize air entrapment

Placing and Curing

• Method: Pour steadily from one side only to eliminate air entrapment
• Flow continuity: Continuous grout flow is essential
• Formwork: Must be constructed leakproof due to free-flowing nature
• Hydrostatic head: Feeding hopper system required
• Cure time: Formwork should remain in place for up to 7 days to allow full hardening
• Release agents: Formwork should be coated with grease, wax, or plastic coating

Temperature Considerations

During application:

• Optimal ambient temperature range: 10°C to 35°C
• Above 20°C: Pot life will be reduced
• Below 15°C: Slower strength build-up occurs
• At 5°C: Cure stops until temperature increases

In service:

• Maximum service temperature: 55°C
• Completely resistant to frost and sub-zero temperatures

Aggregate Addition Option

Conbextra EP120 Plus can be modified with suitable aggregates to reduce material costs:

• Compatible aggregates: Conbextra Grout Aggregate (FC502021-20KG) or Fosroc Antislip Grains 02 (FC605185-20KG)
• Addition rate: Up to 10kg per 14-litre kit
• Yield increase: Approximately 4 litres per 10kg of aggregate
• Caution: Aggregate addition may entrap air; allow mixed product to settle and expel bubbles before placing

Storage and Shelf Life

Component	Storage Conditions	Shelf Life
Base Component	Dry store, original unopened packaging	12 months from manufacture
Hardener Component	Dry store, original unopened packaging	36 months from manufacture

Cleaning and Maintenance

All tools and equipment should be cleaned immediately after use with Fosroc Solvent 10 before the epoxy hardens. Spillages should be absorbed with sand or sawdust and disposed of in accordance with local regulations.

Safety and Documentation

A Safety Data Sheet (SDS) is available from the Fosroc website and must be read prior to use. In emergency situations, contact any Poisons Information Centre (phone 13 11 26 within Australia) or consult a medical doctor.

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References

• [1] Fosroc_Conbextra_EP120_Plus_TDS.pdf