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Learn more about using expanding grout for your next rock breaking project!

 

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About our Expanding Grout

Expanding grout (also known as expansive mortar or rock-breaking grout), is a non-explosive demolition agent used in the rock breaking industry. It is designed to fracture and break up rocks and concrete without the need for traditional blasting methods.

Expanding grout typically consists of a powdered mixture composed of cementitious materials, such as calcium oxide or calcium hydroxide, along with a small amount of water. When mixed together and poured into pre-drilled holes in the rock or concrete, the grout undergoes a controlled expansion process.

The expansion is a result of a chemical reaction that occurs when water is added to the grout mixture. This reaction generates a large amount of heat and causes the mixture to expand, exerting significant pressure on the surrounding rock or concrete. Over time, this pressure leads to the cracking and breaking of the material.

One of the primary advantages of expanding grout over traditional blasting methods is its non-explosive nature. This makes it safer to use in areas where blasting may not be permitted, such as in urban or environmentally sensitive locations. It eliminates the risks associated with flying debris, shockwaves, and the release of harmful gases that are typically associated with explosives.

Expanding Grout FAQ

What projects work best for Rock-X?

Rock - X is built for smaller commercial or residential demolition project where you need to demolish concrete structures, bedrock and bolders. We engineered this grout to require less man hours, and to require less drill holes.

What projects work best for Rock-XX?

Rock - XX is built for commercial demolition project where you need to demolish large concrete structures, bedrock and massive bolders. We engineered this grout to require less man hours, and to require less drill holes.

What are the typical errors individuals tend to commit when it comes to bedrock, boulder, and concrete breaking with expanding grout?
  • Neglecting Comprehensive Reading: A common oversight is failing to thoroughly read and digest the User Guide, instructions, and FAQs provided.

  • Inappropriate Grout Selection: Another prevalent mistake is selecting the wrong type of grout for the job at hand.

  • Ignoring Expansion Requirements: Overlooking the necessity of providing adequate expansion space for the concrete or rock to fracture and disintegrate when using grout.

  • Incorrect Hole Dimensions: Using holes with the wrong diameter or spacing them too far apart can lead to ineffective results.

  • Shallow Material Depth: Insufficient material depth can hinder the breaking process.

  • Impatience: Rushing the process by not allowing the grout a full 24-48 hours to achieve maximum expansion and facilitate wider cracking.

Why is meticulous planning of your drilling pattern absolutely essential?

The answer is straightforward: a thoughtfully crafted hole-drilling pattern brings about a range of significant advantages:

• Enhanced Grout Efficiency: A well-designed pattern maximizes the efficiency of your grout, ensuring it achieves the desired results.

• Cost Savings: By optimizing the pattern, you'll minimize grout consumption, leading to financial savings.

• Precision and Control: A carefully planned pattern enables precise and controlled breaking, minimizing the potential for unexpected outcomes.

• First-Time Success: With a strategic drill pattern, you increase the likelihood of completing the job correctly on the initial attempt.

• Structural Safeguard: Thoughtful planning helps protect any nearby sensitive structures from unintended damage.

Why is it crucial to guarantee ample open space around the bedrock, boulder, or concrete slated for cracking?

To achieve optimal results with grout, it's imperative to provide the material with an unobstructed surface or adequate room for expansion and subsequent fragmentation. Attempting to break rock or concrete that is completely enclosed on all sides inhibits the expansive pressure generated by the grout from effectively causing the material to crack and fracture.

How should I drill the holes?

Spacing, depth, and drill pattern should be adjusted based on:

Project objectives

Material density

• Presence of reinforcing

• Desired size of broken material

• Desired cracking time

• If you need to protect an adjoining structure

Why are empty relief holes essential in bedrock, boulder, and concrete breaking?

Drilling holes and intentionally leaving them unfilled can serve a multitude of strategic purposes, including:

• Facilitating Controlled Expansion: Unfilled holes provide vital expansion space for the material to fracture when it's enclosed or confined.

• Precision Cracking: These empty holes enable precise control over the cracking process, ensuring it follows the desired path.

• Grout Conservation: By strategically leaving some holes unfilled, you can reduce the overall amount of grout required for the operation.

• Accelerated Breaking: Empty holes can expedite the breaking process, helping you achieve your goals more quickly.

• Structural Protection: When necessary, unfilled holes allow for controlled breaking to protect specific parts of a structure.

• Fracture Guidance: These empty holes can direct the fracturing in a way that aligns with your project's requirements.

• Corner Creation: In applications such as forming openings or stone quarrying, unfilled holes play a pivotal role in shaping corners as needed.

What is the impact of drilling more holes, closer together?

More holes spaced closer together results in:

Faster break times

Smaller and more manageable pieces

Adds labour cost (drilling & filling more holes)

May increase quantity of grout used

Reduces the cost of rubble removal

How big or small can I drill my holes?

For best results with ROCK-X, we highly recommend 1” diameter holes - do not exceed 2.5”.

For best results with ROCK-XX, we highly recommend 2.5” diameter holes - do not exceed 5”. Using smaller diameter holes will require holes to be spaced closer together and may NOT be successful in some materials.

Will grout work for ALL shallow applications?

No. For grout to be effective, we strongly recommend materials to be cracked be a MINIMUM of 3” in depth.

When is the best time to pour grout?

The best time to pour grout is early in the morning. An effective strategy is to drill holes the day prior, so you can pour first thing early the next morning. In cold conditions, add a tarp and a heater overnight.

What can cause expansive demolition grouts to blowout?
  • Using the wrong grout type
  • Pouring grout mixture into warm/hot holes
  • Using warm water. In hot conditions, use cold or ice water
  • Hole diameter is too large and too deep
  • Adding grout and water to leftover mixture remaining from previously mixed batch
  • Not measuring water or using too little water
  • Too much time passing between beginning to mix and pouring into holes

testimonials

Here’s What Our Partners are Saying

After researching other grouts, we were so happy to find Rock Buster’s ROCK XX. The owner and the crew were friendly and helped us understand everything about the product, and how it saved us a ton of money on efficiencies on our large rock demo projects.

ROCK XX

We used ROCK X to help demo the thick slab foundation of our old house! Fair prices – best I’ve seen for expanding grout. We will definitely recommend Rock Busters to all our fellow contractors!

ROCK X

rockbusters does excellent work! the bedrock we needed demoed is perfectly gone!