Rock Anchoring Jobwork / Services

A Field Study in Collaboration with COEP and Viraj Engineers To determine the safe pull-out capacities and bonding performance of steel rebars anchored in rock strata using ICFS CM585 Pure Epoxy, under realistic site conditions in India. With growing demand for high-rise construction, deeper foundations often reach rock strata where hydrostatic uplift pressures become significant. Traditional anchoring methods are slow, costly, and poorly suited for wet, uneven surfaces. There's been a lack of documented performance data under Indian conditions. • Sites: Two live construction sites in Pune with different rock types intact bold and bold rock.
• Testing Oversight: Dr. Inshwar Sonar (Assistant Professor, COEP), with certified calibrated equipment.
• Data Captured: Pull-out strength, elongation, failure modes.
• Bond Stress: Decreased with bar diameter (e.g., 16mm: 7.2 T/mm, 32mm: 5.71 T/mm)
• Max Stress: 32mm bars showed highest bond strength (3.38 MPa) due to greater surface area
• Rock Influence: Intact basalt out performed fragmented rock by 15-20%
• Failure Modes: Predominantly failures found of rock breakage and no bar fractures
• Anchor Orientation: Vertical and horizontal anchors showed comparable performance with proper installation technique
• Account for rock type, bar diameter, moisture levels and orientation
• Use site-specific pull-out values to design anchor embedment depths
• ICFS CM585PE is suitable for demanding conditions like uneven, water-exposed rock surfaces
For structural rock anchoring using pure epoxy injectable mortars, this first of its kind field study validates the application in Indian geology. ICFS CM585PE provides a reliable, tested alternative to conventional systems, ensuring both speed and safety in modern foundation engineering.
CM585 is a 2 component high strength pure epoxy chemical anchoring resin system. It is designed for deep embedment and large diameter holes due to its zero shrinkage and longer working times. For diamond drilled holes, with rebar, and in areas of high chemical exposure eg. Seasalt and swimming pools.

Specific Benefits :

• Long working times
• High loads possible
• High chemical resistance
• Use with potable water
• Fixing studs in wood
• 24 Month shelf life
• Corrosion resistance

• Diamond drilled holes
• Zero shrinkage
• European approved
• Fire approved
• Studs and Rebar
• A+ Rating VOC content
• ICFS Anchor design software

• Cracked Noncracked concrete
• Hammer drilled holes
• Small edge distance and spacing
• Variable embedment
• Depth Static quasi load

• ETA Option 1 ETAG 001 for cracked concrete with studs and rebar TR029
• ETA Option 1 ETAG 001 for rebar TR023 : Approved for Seismic Loads C2
• F120 Fire Test report
• ICC-ES Approval ESR 3853
• BS6920 for use with potable water WRAS Approval 1309522
• ETA approved in flooded holes, wet and dry concrete
• Tested according to LEED 2009 EQ c4.1, SCAQMD rule 1168 (2005)

• How to fix iron rods in stone foundation?
• How to drill and fix rebar into hard rock?
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• How to anchor a building foundation to stone?
• Fixing foundation bolts in stone mountain?
• Chemicals to join a steel rod and a black rock?

Overcoming Hard Geological Constraints: Standard mechanical anchor bolts or cement grouting fail to grip or crack heavily compacted natural stone like basalt. Chemical rock anchoring turns natural rock into a structurally sound base. Resisting Hydrostatic Uplift and Tension: In high-rise buildings or deep foundations, groundwater exerts massive upward pressure. Rock anchoring transfers these massive tensile forces deep into competent rock strata to keep the structure safely tied down. Heavy-Duty Structural Reinforcement without Stress: Unlike mechanical expansion anchors that wedge tightly and risk fracturing natural stone, chemical anchoring relies on an adhesive bond. This creates zero expansion stress, allowing for near-edge fixes and heavy seismic or structural load transmission.

• A Collaborative Indian Field Study on Bond Stress and Load Capacities under Live Site Conditions:

1. Introduction & Geological Challenge
In modern high-rise civil construction and deep-foundation engineering across India, anchoring into dense rock formations presents significant challenges. Basalt rock formations require anchor systems capable of managing massive hydrostatic uplift pressures and structural tension. To establish empirical evidence for design engineers, ICFS conducted a comprehensive field study in collaboration with the College of Engineering Pune (COEP) and Viraj Engineers across live construction sites in Pune, Maharashtra.

2. Field Testing Methodology
The live field investigation rigorously tested post-installed reinforcement bars using ICFS CM585PE-PRO Pure Epoxy Injection Mortar. To establish explicit baseline limits, performance was monitored across a matrix of installation variables:
• Rebar Diameters: 16 mm, 20 mm, 24 mm, and 32 mm.
• Embedment Depths: 800 mm, 900 mm, and 1,000 mm.
• Installation Orientations: Verifying performance behavior in both vertical and horizontal drill paths.
• Substrate Conditions: Comparative evaluating between intact basalt formations and highly fragmented/fractured rock strata.

3. Key Findings & Performance Metrics
• Bond Stress Dynamics: Field results demonstrated that peak bond stress holds an inverse relationship with structural rebar diameter. For instance, 16 mm rebar achieved a bond     stress profile of 7.2 T/mm², whereas large-diameter 32 mm bars leveled at 5.71 T/mm².
• Substrate Continuity Impact: Intact basalt rock formations yielded significantly higher ultimate load capacities compared to fractured strata.
• Failure Modes: Controlled pull-out testing utilizing certified, calibrated tension machinery confirmed that the failure mechanisms were predominantly limited to bond slippage or   localized rock mass breakout. Notably, zero rebar tensile fractures occurred, proving that the chemical bond boundary securely outmatched structural yield expectations.