Waterproofing, Antitermite and Clay Modification Products

 
     Polytech International (India) - An ISO 9001-2000 Company 

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Polycrete^®  is available in packing of 200 ml, 1 Liters, 5 Liters and 20 Liters.

Polycrete^®   is a complete cement admixture. It is totally chloride free, superb plasticizing, water reducing, high early and final strength providing, excellent waterproofing, strong reinforcement cement concrete bonding and corrosion resistant agent.

•   Provides high workability  of cement concrete, retards the initial setting time (till the compaction is done) for perfect working.

•  Makes concrete and mortar remarkably cohesive and improves bonding strength. For the same reason, it requires less curing.

•   Provides high strength (up to twice the design strength has been obtained in independent testing) at suitable dosages and makes up to 15% savings in quantity of cement used possible.  

•  Improves coverage of plaster with classic finish. Provides excellent waterproofing properties.

•  Makes early removal of shuttering in R.C.C. roof slabs possible. With M-20 grade of concrete, shuttering may be removed in slabs in just 4 days for spans up to 3 meters and  8 days in longer spans.

•  Converts the high heat cement like 43 and 53 grades to low heat cement, deactivating the high heat producing hydrolysis process, enabling them to be used under tropical conditions also.

•  Provides excellent resistance to sewage water, sea water, acid rains and  salty atmosphere of costal regions.

•  Provides a corrosion resistant coating over reinforcement and makes strong bond between the cement concrete and reinforcement making the R.C.C. structures remarkably strong, highly tensile and extremely durable.

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USES AND DOSAGES

1.                 For laying totally waterproof slabs:

•   Use 0.5% solution of Polycrete for preparation of concrete for laying slabs. This means using 200 ml of Polycrete per bag of cement dissolved in necessary water.

•  Use cement slurry treatment over the freshly laid and compacted roof surface. Use 1% solution of Polycrete i.e. 100 ml  in 10 liters of water for preparation of cement slurry. Cement slurry treatment, if not done on the same day, should necessarily be done on the second day of roof slab casting.

2.                 For preparing white cement or  wall finishing emulsions:

•  Use 1% solution i.e. 100 ml. of Polycrete in 10 liters of water for preparation of emulsions for wall finishing. Three days of curing with water results in fine, glossy and  waterproof finish.

3.                  For Injection / Pressure grouting:

•  Use 1% solution i.e. 100 ml. of Polycrete in 10 liters of water for preparation of cement slurry for injection or pressure grouting. Very high bonding strength is achieved.

4.                 For making of waterproof basements:

•  Where water is coming from all sides at the site of basement, make a drain 1 feet to 1½ feet deep on all the four sides with a sump 3' x 4' x 4' to drain and pump out the water continuously to keep the surface of the basement dry. If the surface of the basement is dry, flag stone may be laid. If it is marshy, spread hard murram 3" thick duly compacted and then flag stone may be laid. Use 1:6 or 1:8 cement-sand mortar with Polycrete  400 ml per bag of cement. Joints between the flag stones should be filled with 1:3 cement-sand mortar using 400 ml Polycrete per bag of cement.

•  For floors, beams, columns and vertical walls cement concrete mix  of 1:1½:3 with M-20 grade mix using 400ml Polycrete per bag of cement should be used.  The floor thickness should be 5" to 6" and wall thickness 6" to 8". The outer surface of the R.C.C. walls should be plastered using 1:4 cement-sand mortar with 400 ml Polycrete per bag of cement. The plaster should be finished with cement slurry.

• While casting concrete floor and walls, water should be continuously pumped out for at least 10 hours so that during the initial and final setting water level remains low. Like wise, while plastering it is necessary to keep the water level low. If the floor and walls are not cast in one day, then cement slurry treatment using 1% Polycrete solution should be done at the joints of floor and walls.

• On the floor and inner surface of walls, plaster should be done with 1:4 cement-sand mortar using 400 ml Polycrete per bag of cement.

4.                 Industrial Uses:

•   Prestressed concrete elements used in electric poles, railway sleepers, fencing poles, hume pipes where steam curing is adopted, half the design strength is achieved within 4 hours. there are no cracks, no warping, no breakage, and therefore, no rejection.

            Thus use of Polycrete results into high savings in inputs, enhances productivity and improves profitability of the unit.

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THE CHEMISTRY OF POLYCRETE^®

The Chemistry of Cement:

The main strength giving constituents of Portland Cement are Tri Calcium Silicate (3CaO. SiO₂) and Di Calcium Silicate (2 CaO. SiO₂). Tri Calcium Silicate (TCS) contributes towards early strength; on the other hand Di Calcium Silicate (DCS) contributes towards later strength.

For setting and strengthening of cement following processes are responsible :

(a)               Hydrolysis           

(b)               Hydration              I. Gel formation                      II. Hardening

(a)               Hydrolysis :  When water is added to cement, hydrolysis of Calcium Silicate take place. Calcium Silicate decompose into Calcium Silicates of lower basicity and release Calcium Oxide which forms Calcium Hydroxide with water.

(i)     Hydrolysis of Tri Calcium Silicate -

                                           Hydrolysis

3CaO. SiO₂ +  H₂O              à               2CaO. SiO₂ +  Ca (OH)₂     

                                      (When water is less) 

                                           Hydrolysis

2(3CaO. SiO₂) +  3H₂O       à               3CaO. 2SiO₂ + 3Ca (OH)₂  

                                      (When water is more)

 (ii)     Hydrolysis of Di Calcium Silicate -

                                           Hydrolysis

2CaO. SiO₂ +  H₂O              à               CaO. SiO₂ +  Ca (OH)₂       

(b)              Hydration : These silicates take up water molecules to form hydrated silicate molecules in the process of non-reversible gel formation which then change into metastable gel with simultaneous production of crystalline products during the setting process of cement paste. Hardening of the set cement paste is due to development of much stronger and irreversible intertwined crystalline structure.

In normal course of cement setting and hardening, cement actually loses strength as the calcium silicates of higher basically decompose to lower basicity during the process of hydrolysis and on hydration these lower basic calcium silicates form hydrated calcium silicate crystals of lower molecular weights and therefore acquire less strength during hardening process.

Features of Polycrete^® :

• In dilute solution, Polycrete, as soon as comes in contact with Portland Cement, stops the process of hydrolysis and does not allow the cement to lose its strength. Gel activator activates the gel formation and with the help of high grade plasticizer it forms a very cohesive and plastic mass of Portland Cement in which the initial setting time is retarded for perfect working.

• During activated gel formation the whole mass accumulates high percentage of water and hydration process is activated to acquire very high degree of hydration, that's why hardening of the hydrated mass continues, even after stopping the water curing, for at-least 72 hours, till all the accumulated moisture is transformed and hardening process is complete to achieve final strength.

• Polycrete solution reacts with the reinforcement to produce a protective coating and creates a strong bond between the reinforcement and cement concrete mass thereby facilitating a high tensile strength in the R.C.C. structures.

• Polycrete contains high class stabilizers to make the cement concrete and mortar highly resistant to atmospheric acidity as well as salinity and thereby makes them much more durable.

• In tropical regions like India because of very high temperature fluctuations, low heat cement is used for construction works in which Tri-Calcium Silicate  must be kept as low as possible, at about 30%. In higher grades of cement e.g. 43 grade and 53 grade the Tri Calcium Silicate content is kept at 43% and 53% to achieve high early strength. Heat of hydrolysis and hydration in these cements are very high and therefore these cements need very high degree of water curing or otherwise cracks are resulted in the structures. Polycrete overcomes this problem by stopping the process of hydrolysis and converting the high heat evolving process to low heat process.

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 CERTIFICATIONS

Polycrete has been extensively tested independently. A summary of some results:

•  Chief Engineer, Military Engineer Services, Jabalpur Zone :

Tests for Compressive Strength on 1:3 Cement Sand Concrete cubes  made with 0.5% Polycrete yielded following results:

7-day strength                                    -    234.66 kg/sq.cm.

7-day strength (without curing)         -    211.62 kg/sq.cm.

28-day strength                                  -    336.72 kd/sq.cm.

These results have been conveyed vide their letter no. 200032/Cor/NBM/390/E2 Plg dated 02 Nov. 1998.

The Chief Engineers of Jabalpur Zone and Lucknow Zone have approved the use of this product for :

• RCC for roof work and sunken slabs of WC/Bath/Kitchen etc.

• External Plaster.

• White wash/ colour wash/ dry distemper and snowcem.

• Bharat Ratna Bhim Rao Ambedkar Institute of Telephone Training, Jabalpur:

Tests for Compressive Strength on 1: 2 : 4 Plain Cement Concrete cubes  made with 0.5% Polycrete yielded following results:

7-day strength (with curing)

Sample 1        -    257.77 kg/sq.cm.

Sample 2        -    311.11 kg/sq.cm.

Sample 3        -    271.11 kg/sq.cm.

These results have been conveyed by Engineering Consultancy Services of Government Polytechnic, Jabalpur vide their letter no. 95/CE/97-98 dated 24/06/1997.

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