Division 04 · rockfrac.com
RockFrac® Non-Explosive Demolition Agent (11,200+ PSI)
Restored from preparation.txt, mixing.txt, loading.txt, cautions.txt & quicktips.txt
Standard Operating Procedure: Drilling, Mixing, Loading & Safety
1. Borehole Drilling & Geometry Preparation
- •Select hole diameter strictly between 30 mm and 40 mm for standard applications (35 mm to 65 mm depending on rock hardness and structural conditions). Undersized holes (<30 mm) inhibit expansive pressure development, while oversized holes (>50-65 mm) dramatically elevate blowout risks.
- •Ensure at least one free face exists prior to drilling. Expanding rock needs a free relief boundary to split toward.
- •Drill borehole spacing approximately 10 times the hole diameter in an offset staggered pattern, ranging from 15 to 30 cm in reinforced concrete to 40 to 60 cm in mass rocks.
- •Drill hole depth to 80% to 90% of object thickness for isolated concrete or boulders (at least 70% deep through boulders), 105% to 110% of stone thickness for quarrying and benching, and approximately 10% deeper than the final required grade.
- •Thoroughly clean all pre-drilled boreholes using high-pressure compressed air to eliminate dust, sludge, drilling slurry, and standing water. Boreholes must be 100% clean and free of water to ensure complete depth loading.
- •Measure borehole temperature. Do not load holes if rock or concrete internal temperature exceeds 21 deg C (70 deg F) to avoid rapid steam flash and blowouts.
2. Water-to-Powder Mixing Protocol
- •Use clean, ice-cold water. Always keep dry RockFrac bags stored in a cool, dry place out of direct sunlight prior to use.
- •Measure the exact water ratio: 30% water by weight of the powder. Pour 1.45 to 1.7 liters (1.5 US quarts / 48 oz / 3 to 3.5 pints) of cold water into a clean plastic mixing bucket.
- •If using universal RockFrac NEDA, dissolve the predetermined quantity of reaction inhibitor into the water prior to introducing powder.
- •Gradually pour one 5 kg (11 lb) bag of RockFrac powder into the water.
- •Stir rapidly using a mechanical mixer or wooden rod until a smooth, fluid, lump-free slurry is obtained.
- •Synchronize mixing operations with adequate labor so the batch can be placed immediately within its working window.
3. Slurry Pouring, Tamping & Stemming
- •Pour mixed mortar into boreholes directly from the bucket or pouring vessel within 10 minutes following completion of mixing.
- •Complete the entire mixing and placement sequence for a batch within 20 minutes maximum.
- •For vertical downward holes, pour slurry directly to fill 100% of the drilled depth. For exceptionally deep boreholes, tamp the mortar section by section to avoid air pockets.
- •For horizontal and inclined/slant holes, insert a slightly smaller diameter plastic feeding pipe to the bottom of the borehole. Slowly inject the mortar into the pipe while gradually withdrawing the pipe simultaneously, then immediately seal the borehole entrance firmly using a wooden cap or iron wedge.
- •Do not place restrictive caps or tamping plugs on open vertical holes. Allow the slurry to remain open to atmosphere; crack initiation will occur naturally.
4. Cautions, Blowout Prevention & PPE
- •Always wear safety goggles, heavy rubber gloves, protective clothing, and an anti-dust mask during unpacking, mixing, and pouring.
- •Never look directly down into loaded boreholes at any time. Keep faces and bodies away from the borehole collar.
- •If mixed mortar begins to get warm, generate vapor, or bubble inside the mixing bucket before loading, do not pour it into holes. Discard the batch immediately with plenty of cold water, as loading hot mortar will cause violent borehole blowouts.
- •Cover all loaded boreholes with heavy tarps or canvas immediately after pouring to protect personnel from potential blowout squirts.
- •Enforce an exclusion perimeter: all personnel must stay clear of loaded holes for a minimum of 3 hours following completion of loading.
- •In case of contact with skin or eyes, do not rub. Immediately flush affected eyes or skin with massive amounts of cold clean water for at least 10 minutes and consult a physician promptly.
5. Storage & Shelf-Life Management
- •Store in a clean, covered, dry storage facility completely isolated from atmospheric moisture and water exposure.
- •Maintain storage at constant, cool temperatures away from direct sunlight and heat sources.
- •Handle cartons and inner plastic bags carefully to prevent tearing or puncturing the airtight seals.
- •RockFrac maintains a shelf life of 2 years from production date when preserved unopened in its original moisture-proof packaging.