Conbextra EP300 DP: Low Exotherm Three Part Epoxy Resin Grout

Product Overview

Conbextra EP300 DP is a low exotherm, three-component epoxy resin grout manufactured by Fosroc. This specialized grouting material is engineered as a free-flowing system designed specifically for large volume pours and applications subjected to heavy dynamic or mobile loads. The product combines a base resin, a hardener, and a filler material to create a cohesive grouting system suitable for demanding construction and industrial environments.

Product Composition

The product is supplied in 11.4 litre packs containing three distinct components:

• Base Component: 2.7L (Product Code: FC500547)
• Hardener Component: 860ML (Product Code: FC500545)
• Filler Component: 20KG (Product Code: FC500546)

Key Features and Advantages

Conbextra EP300 DP offers multiple performance benefits:

• High compressive, tensile and flexural strengths for reliable load-bearing capacity
• Resistant to repetitive dynamic loads, making it ideal for machinery and equipment applications
• Low exotherm properties that minimize heat generation during curing, reducing thermal stress and cracking risk in large pours
• Excellent flow properties enabling proper distribution and filling of voids
• Fast, convenient installation with minimal on-site preparation requirements
• Virtually no shrinkage, ensuring complete surface contact and bond maintenance
• Low creep characteristics under sustained loading conditions
• Capable of installation at high temperatures for versatile application conditions
• Wide range of gap thickness capability from 10mm up to 300mm
• Chemical resistance to oil, grease, fats, most chemicals, mild acids and alkalis, fresh and sea water

Primary Applications

Conbextra EP300 DP is particularly well-suited for:

• Reciprocating machinery grouting
• Testing equipment installations
• Heavy crane and transporter rails foundations
• High-speed turbines and centrifuges
• Drop forges and industrial equipment
• Piletop encapsulation and water tightness applications
• Chemical plant environments including steelworks, refineries, and electroplating works where chemical spillage may occur

Design Criteria

The product is engineered for grouting gaps ranging from 10mm to 300mm in thickness. For pours exceeding 300mm, single pour volumes should not exceed 1.5 m³ depending on pour geometry. For smaller gap widths below 50mm requiring faster cure, Conbextra EP65 Plus is recommended as an alternative.

Technical Specifications

Mechanical Properties

Working Properties

Flow Characteristics

The maximum distance of flow is governed by gap thickness, head of grout applied, and ambient temperature. At 23°C with a 100mm gap thickness and 100mm hydrostatic head, the maximum flow distance is 2000mm.

Temperature Resistance

When cured, Conbextra EP300 DP is completely resistant to frost and sub-zero temperatures and can withstand service temperatures up to 55°C.

Mixing Instructions

Procedure:

1. Pour all contents of the hardener pack into the base container
2. Mix using a slow speed heavy-duty mixer (such as a 140mm x 600mm helical mixing paddle fitted to a 1600W mixer)
3. Once base and hardener are mixed, slowly add the filler component
4. Continue mixing for a further 2 minutes until the filler is wetted out and uniform colour is achieved
5. Ensure the paddle remains fully immersed; do not pull the paddle up and down during mixing
6. Verify no unmixed material remains in the drum before placing

For large pours, a purpose-made diaphragm pump can be used.

Shelf Life and Storage

• Base and Hardener Components: 5 years shelf life when stored properly
• Filler Component: 18 months shelf life when kept in original, unopened bags

Surface Preparation Requirements

• All contact surfaces must be free from oil, grease, free standing water, and loosely adherent material
• Concrete surfaces should be cut back to sound base
• All dust must be removed and bolt holes blown clean of dirt and debris
• Steel surfaces should be shot blasted free of rust, paint, and flaky mill scale
• Formwork must be leakproof (as the product is free-flowing)

Dimensional Stability

A critical factor influencing effective bearing area (EBA) is the degree of air entrapment within the product. Air can be introduced during mixing or, with the separate filler component, can be released as the filler wets out over time. Proper mixing technique and adequate mixing time are essential to minimize air entrainment.

Filler Classification

The Conbextra EP300 DP Filler component is classified as not hazardous for RCS (Respirable Crystalline Silica) in accordance with the Australian Inventory of Industrial Chemicals and contains <0.1% RCS.

Important Safety Information

A Safety Data Sheet (SDS) is available from the Fosroc website and must be read carefully prior to use. Application or performance data may change over time. In emergencies, contact the Poisons Information Centre (phone 13 11 26 within Australia) or a doctor.

References

• [1] Fosroc_Conbextra_EP300_DP_TDS.pdf
• [2] Fosroc_Conbextra_EP65_Plus_TDS.pdf
• [6] Fosroc_Conbextra_Grout_Aggregate_TDS.pdf