Renderoc Plug constructive solutions

Rapid setting cement-based, water-stopping

mortar

Uses Properties

For the rapid temporary patching and plugging of concrete Initial set time: Approximately one minute at
o
segments, concrete and brick tunnel linings, sewage 20 C. Set times will be
systems, below ground access chambers, pipes, basements, extended when mixed at
foundations and mines. lower temperatures
Compressive strength
2 o
(BS 6319 Part 2:1983): 25 N/mm at 28 days at 20 C
Advantages
Heat generation High heat output (exotherm)
characteristics: leads to undesirably high
 Emergency water-stopping capability. shrinkage and consequent
thermal cracking. The curves
 Single component - only the addition of clean water is overleaf show the low heat
required. output of Renderoc Plug
which minimises the risk of
 Excellent bond to the substrate. shrinkage and thermal
cracking.
 Low exotherm minimises 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. o
Early age compressive strength at 20 C
Renderoc Plug provides an initial set time of approximately
Heat output of Renderoc Plug (exotherm) leads to
one minute.
undesirably high shrinkage and consequent thermal
cracking. The curves overleaf show the low heat output of
Technical support Renderoc Plug which minimeses the risk of shrinkage and
thermal cracking.
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
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.
Application instructions
Preparation
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.
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.
Mixing
Renderoc Plug should be added to clean water in the
following proportions:
One part clean water:3 parts Renderoc Plug (measured by
volume).
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.
Note the minimum applied thickness of Renderoc Plug
should be 15 mm.
Low temperature working
o
In cold conditions down to 1 C, the use of warm water (up to
o
20 C) is advisable to accelerate strength development.
Normal precautions for winter working with cementitious
materials should be adopted. The material should not be
o
applied when the substrate and/or air temperature is 1 C and
o o
falling. At 1 C static temperature or at 1 C and rising, the
application may proceed.
High temperature working
constructive solutions
o
At ambient temperatures above 35 C, the material should
o
be stored in the shade and cooler water (down to 20 C)
used for mixing.
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.
Limitations
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.
Estimating
Supply
Renderoc Plug: 10 kg bags
Yield
Renderoc Plug: 5 litres per 10 kg bag
UN packaging regulations
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.
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.
Storage
Shelf life
All products have a shelf life of 9 months if kept in a dry
store in the original, unopened bags or packs.
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

Telephone: +966 2 637 5345 Fax: +966 2 637 5891 email: fosam@fosroc.com
Head Office
Post Box 11081 Regional Offices
Jeddah Sales Office Tel: (02) 608 0999 Fax: (02) 638 0693 Yanbu Tel: (04) 322 4280 Fax: (04) 391 2980
Jeddah – 21453
Jeddah Showroom Tel: (02) 665 0187 Fax: (02) 667 4844 Makkah Tel: (02) 542 0869 Fax: (02) 542 0869
Saudi Arabia Riyadh Tel: (01) 482 9303 Fax: (01) 482 7562 Medinah Tel: (04) 855 0091 Fax: (04) 855 0047
Dammam Tel: (03) 814 1282 Fax: (03) 814 1581 Jubail Tel: (03) 362 3904 Fax: (03) 362 3875

www.fosroc.com Khamis Mushayt Tel: (07) 250 0469 Fax: (07) 250 0469 CSD Tel: (02) 608 0999 Fax: (02) 638 0693

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