Renderoc Plug

constructive solutions

Rapid setting cement-based, waterstopping mortar

Uses

Properties

For the rapid temporary patching and plugging of concrete

segments, concrete and brick tunnel linings, sewage
systems, below ground access chambers, pipes,
basements, foundations and mines.

Initial set time:

Compressive strength
(BS 6319 Part 2:1983):
Heat
generation
characteristics:

Advantages
Emergency water-stopping capability.
Single component - only the addition of clean water is
required.
Excellent bond to the substrate.
Low exotherm minimises thermal cracking.

Approximately one minute at

20oC.
Set times will be
extended when mixed at
lower temperatures
25 N/mm2 at 28 days at 20oC
High heat output (exotherm)
leads to undesirably high
shrinkage and consequent
thermal cracking. The curves
overleaf show the low heat
output of Renderoc Plug
which minimises the risk of
shrinkage
and
thermal
cracking.

Pre-bagged formulation to overcome variations in site

batching.
Contains no chloride admixture.
Description
Renderoc Plug is supplied as a ready to use blend of dry
powders which requires only the site addition of clean
water to produce a highly consistent, rapid setting mortar
which is easy to apply in many difficult conditions. The
material is based on a blend of cement, graded
aggregates, special fillers and chemical additives which
control the rate of set and minimise the risk of thermal
cracking.
Renderoc Plug provides
approximately one minute.

an

initial

set

time

Early age compressive strength at 20oC

of

Heat output of Renderoc Plug (exotherm) leads to

undesirably high shrinkage and consequent thermal
cracking. The curves overleaf show the low heat output of
Renderoc Plug which minimeses the risk of shrinkage and
thermal cracking.

Technical support
Fosroc offers a comprehensive range of high
performance, high quality construction products.
In
addition, Fosroc offers a technical support service to
specifiers, end-users and contractors, as well as on-site
technical assistance in locations all over the world.
Design Criteria
Renderoc Plug can be applied to horizontal, vertical or
overhead surfaces at a wide range of thicknesses.
Generally, the volume of mixed material used in a single
application is restricted to that which can be applied by
trowel or gloved hand. Thicker section can be built up in
layers. If any doubt arises about the nature of the
substrate consult the local Fosroc office for further
information.

Heat output of Renderoc Plug

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Renderoc Plug
Specification clauses

High temperature working

o
At ambient temperatures above 35 C, the material should
be stored in the shade and cooler water (down to 20oC)
used for mixing.

Water stopping mortar

The water stopping mortar shall be Renderoc Plug, a
single component cement-based blend of powders to
which only the site-addition of clean water shall be
permitted.
It must be chloride-free and must be
formulated to prevent high exotherm and minimise thermal
cracking.

Cleaning
Renderoc Plug product should be removed from tools,
equipment and mixers with clean water prior to the initial
set. Cured material can only be removed mechanically.

Application instructions

Limitations

Preparation

Renderoc Plug should not be used when the temperature

o
is below 1 C and falling. If any doubts arise concerning
application or substrate conditions, consult the local
Fosroc office.

Areas to be patched should be cut back to a depth of 15

mm and given a good mechanical key. Feather-edges
must not be allowed. Surface should be brushed clean to
remove loose material, dust and laitance. Grease, slime
or mould growth should be removed by steam cleaning or
high-pressure water jetting. A proprietary degreasing
agent should be used for removal of light oil or grease
contamination.

Estimating
Supply
Renderoc Plug:

10 kg bags

To seal leaks, crack openings must be chased out to

approximately 20 mm square. The chase should always
be undercut to avoid leaving a v-section. All loose
material and debris should be removed.

Yield

Mixing

UN packaging regulations

Renderoc Plug should be added to clean water in the

following proportions:

To comply with current regulations, all product of a

hazardous nature that are involved in a sea crossing as
part of the delivery requirements must be packed in United
Nations Approved receptacles.

Renderoc Plug:

One part clean water:3 parts Renderoc Plug (measured by

volume).

5 litres per 10 kg bag

When a known sea crossing is involved, whether local to

the United Kingdom or for export worldwide, Fosroc will
supply in the correct UN packaging. Where Fosroc are
only requested to deliver within the United Kingdom
mainland, but the purchaser intends to ship on, it is
incumbent on the purchaser to specify that UN packaging
is required at the time of placing the order. Otherwise,
once delivery is received, the responsibility is that of the
purchaser. The use of UN packaging may affect the
selling price of products. Refer to the local Fosroc office
or representative.

Mix to a stiff consistency in a suitable mixing drum or

bucket, using a trowel or gloved hand. Due to the rapid set
characteristics of the product, only prepare a quantity of
mortar which can be placed within the prescribed set time.
Application
Trowel apply or hand-knead the mixed mortar in place,
ensuring maximum contact with the substrate before the
material sets. If being used to plug running water,
Renderoc Plug should be used and held in place until the
initial set is reached.

Storage

Note the minimum applied thickness of Renderoc Plug

should be 15 mm.

Shelf life

Low temperature working

All products have a shelf life of 9 months if kept in a dry

store in the original, unopened bags or packs.

o
In cold conditions down to 1 C, the use of warm water (up
o
to 20 C) is advisable to accelerate strength development.
Normal precautions for winter working with cementitious
materials should be adopted. The material should not be
applied when the substrate and/or air temperature is 1oC
o
o
and falling. At 1 C static temperature or at 1 C and rising,
the application may proceed.

constructive solutions

Storage conditions
Store in dry conditions in the original, unopened bags or
packs. If stored at high temperatures and/or high humidity
conditions the shelf life may be reduced to 4 to 6 months.

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Renderoc Plug
Precautions
Health and safety
Renderoc Plug contains cement powders which, when
mixed or become damp, release alkalis which can be
harmful to the skin. During use, avoid inhalation of dust and
contact with skin and eyes.
Wear suitable protective clothing, gloves, eye protection and
respiratory protective equipment. The use of barrier creams
provide additional skin protection. In case of contact with
skin, rinse with plenty of clean water, then cleanse with
soap and water. In case of contact with eyes, rinse
immediately with plenty of clean water and seek medical
advice. If swallowed, seek medical attention immediately
do not induce vomiting.
Fire
Renderoc Plug is non-flammable. For further information,
refer to the Product Material Safety Data sheet.
Additional information
Fosroc manufactures a wide range of products specifically
designed for the repair and refurbishment of damaged
reinforced concrete. These include hand-placed and spray
grade repair mortars, fluid micro-concrete, chemical
resistant epoxy mortars and a comprehensive package of
protective coatings.
In addition, a wide range of
complementary products in available. This includes joint
sealants, waterproofing membranes, water stops, grouting,
anchoring and specialised flooring materials.
Fosroc have also produced several educational training
videos which provide more details about the mechanisms
which cause corrosion within reinforced concrete structures
and the solutions which are available to arrest or retard
these destructive mechanisms.
Further information is
available from the publications. Concrete Repair and
Protection. The Systematic Approach, available in seven
language formats.
For further information about products, training videos or
publications, contact the local Fosroc office.

Important note:
Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions
for the Supply of Goods and Services, copies of which may be obtained on request. Whilst Fosroc endeavours to ensure that
any advice, recommendation, specification of information it may give is accurate and correct, it cannot, because it has no direct
or continuous control over where or how its products are applied, accept any liability either directly or indirectly arising from the
use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.

Fosam Company Limited

Head Office
Post Box 11081
Jeddah 21453
Saudi Arabia

www.fosroc.com

Telephone: +966 2 637 5345

Fax: +966 2 637 5891

email: fosam@fosroc.com

Regional Offices
Jeddah Sales Office
Jeddah Showroom
Riyadh
Dammam
Khamis Mushayt

Tel: (02) 6080999

Tel: (02) 665 0787
Tel: (01) 482 9303
Tel: (03) 814 1282
Tel: (07) 250 0469

Fax: (02) 635 3330

Fax: (02) 667 4884
Fax: (01) 482 7562
Fax: (03) 814 1581
Fax: (07) 250 0469

Yanbu Tel: (04) 322 4280

Makkah Tel: (02) 542 0869
Medinah Tel: (04) 845 1767
Jubail Tel: (03) 362 3904

Fax: (04) 391 2980

Fax: (02) 542 0869
Fax: (04) 846 3195
Fax: (03) 362 3875

Registered Office: Industrial Area, Phase 4, Road No. 414, Street No. 407

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FO SA/Plug/05/A