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Nippon Electric Glass America Inc., 2604 W. Marshall Drive, Suite 102,
Grand Prairie, TX 75051. Tel: 972 602 1740, Web: www.negamerica.com
les
A) Aggregate to cement ratio should not exceed 2.5: 1
B) Acrylic curing compound addition is recommended at a minimum dosage of
3% polymer solids per weight of cement. This will reduce the loss of water
through evaporation and will enhance the bond to the back-up mix. Do not
allow too much time between facing and back-up application as the acrylic
may film form and create a bond break.
C) High or Low Range water reducers that meet ASTM C494 should be added to
maintain a low water/cement ratio and achieve higher density, lower
permeability, and a more durable surface.
D) Water addition should not exceed that required to achieve a 28 day
compressive strength = or> 4000 psi and an absorption = or < 10% by weight.

A) Cement shall meet ASTM C150. Type I/II, low alkali cements are
recommended.
B) Acrylic curing compound minimum addition shall be 5% polymer solids per
weight of cement.
C) High or Low Range water reducers meeting ASTM C494.
D) Water/Cement ratio should not exceed .35.
E) Glass Fiber shall meet PCl requirements per MNL-130 Appendix D. The
glass shall contain a minimum zirconium oxide content of 16%. Unprotected
"E" glass designed for use in plastics, shall not be used. The minimum fiber
content shall be 4% by total weight.
F) Sand shall meet compositional requirements of ASTM C144. To minimize
clogging of the concentric gun nozzle, all of the particles shall pass a U.S. No.
20 sieve.

Batch Mix Formulation:

Cement 94lbs
Sand 94lbs
Polyplex curing compound 10 lbs
Water 25.71bs
High or Low Range water reducers as required
Total weight 223.7lbs
 Polyplex Curing Compound
1. Weight of Cement x 5% ... 94 x .05 = 4.7 lbs
2. Polyplex contains 47% polymer solids, 53% water, so
The weight of PolypI ex required = 4.7 = 10 lbs
.47
Mix Water
1. (Weight of cement x .33) - (water content in the Polyplex)
= (94 x .33) - (.53 x 10) = 25.7 lbs.

Glass Fiber Content

1. Weight of glass divided by the total mix weight, including
the weight of glass fiber.
Glass content = (wt. of mix w/o fiber) x (glass % required)
100 - % of glass required

= 223.7 x .05 = 11.8 lbs

100-.05

Typical Composite Mix Formulation

Cement 94lbs
Sand 94lbs
Polyplex curing compound 10lbs
Water 25.7lbs
Glass Fiber 11.8 lbs
High or Low Range Water Reducer as required

Typical Composite Mix Formulation

Cement 941bs
Sand 80lbs
Polyplex curing compound 10lbs
Water 27.61bs
Glass Fiber 6.5 Ibs (3 % by weight)
High or Low Range Water Reducer as required
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NEGA, Inc. • P.O. Box 515 • 1828 Carpenter Road

les
Hutchins, Texas 75141 • Tel: 972/225-6342 • Fax: 972/225-2536

In an effort to identify the optimum mix and fiber

The Subject of BONDING PADS comes up
length for the premix type of product
regularly, in particular, what they are called, the
John Jones of Molloy and Associates developed a
mix design, how they arc produced and how they
test program to explore the benefits of various
are applied. lengths and concentrations of NEG AR Glass.
Note that thc strengths of spray up bonding pads
The bonding pad was first produced by spraying
was also evaluated.
GFRC about 5/8 of an inch thick on a flat board
about four feet by four feel. The material was
Inve5ti1:atiQn Qf effect Qn. anchQr pull Qff
rolled out between spray applications the same as
stren~ths Qf varyin1: 1:1355fiber CQntent and
when producing a panel. Then the pads were cut
lent:th Qf fiber in the bondin1: pads.
from the board in strips of four inches wide by
about scven inches long, thcn applicd ovcr the
anchor foot using roHets and making sure the heel
of the anchor was not covered. Mix design was
The flex anchors used were 3/8" Dia with 7'~ leg
the same as the panel matrix.
and 5" fool.
This method had several notable advantages. First
The backing material and bonding pad material
the shape was consistent, the quality of the pad
used in each test sample were the same
consistent, and the appearance consistent. Waste
formulation. .
material was kept to a minimum. From a critical
point of view the thickness of the pad over the
Backing material and bonding pads were made in
foot of the anchor could be compressed to a thinner
section than desired. This was a quality check premix, with 1:1 sand:cement ratio and NEG AR
poinl. Glass .F.iberchopped strands.

In preparing the test samples the backing material

Since the mid-eighties the method of producing
bonding pads has changed to one of several
methods. One method uses spray material worked
into a ball of GFRC and forced over the "L anchor"
and hand compressed. The other method uses a
pre-mix of chopped strand with matrix the same
as used for the panel. A range of glass contents
and fiber lengths are used.
was cast first and the back surface in the vicinity
of the bonding pad was "roughened" to expose
fibers. The bonding pad was then applied to the
backing and formed around the.anchor by hand.
The test samples were then air cured at 60-65° F
and 60% RH and tested at 28 days.

All samples were tested in the equilibrium state
(i.e. not dried or soaked).
The test specimen was clamped around the
perimeter and the load was applied to the anchor
with a: hand operated hydraulic cylinder. No
attempt was made to measure the rate at which
the load was applied but care was taken to try to
apply.the load in a consistent manner from test
sample to test sample.
Three samples of each formulation were tested and
the average failure load computed.
fiber length
I 1/2" 1" 112"
~ 5% 837lbs 1187lbs 817 Ibs
content 3% 837 847 583
Table 1: Average failure load in pounds vs glass
content vs tiber length
The failure load for each type of sample is shown
in Table I
A survey of manufacturers who make bonding
pads from material sprayed into a container
showed that typical failure loads range from 900-
1100 Ibs, fiber length being 1 1/4 inch and content
ranging between 3%-5%. From this it would
appear that there is little difference between pads
made from premix from those made from sprayed
material.
Both 5% and 3% glass content samples with 1inch
fiber showed the highcst load capability.
Although theory would suggest ~at the samples
containing 1 112 inch fibers should be the
strongest, the poorer workability and
compactibility of the bonding pads with these
fibers probably contributed to the lower than
expected strengths. This effect was particularly
noticeable at the 5% glass con lent level.
The bonding pads containing 1 inch and 1/2 inch
fibers at both glass contents had good workability
and compactibility.
Within the limitations of the test parameters
considercd, the optimum bonding pad formula
should contain 1 inch fibers at 5% glass content.
Note: The data given is only valid for the express
purpose of the comparison test program described
in this reporL The data should not be used to derive
design data or to make strict comparisons with
data produced on other test machines.
Samples ofZircretc were analysed by ErHn, Hime
Associates, a division of Wiss, Janney, Elstner
Associates Inc. to determine if the cements contain
"high alumina" conponents that could lead to long-
term distress. The conclusions of the tests were
as follows: .
"Based on the analyses the cement systems are
primarily that for a Type K expansive cement. No
high alumina cement components were detected,
and thus no long-term distress due to 'conversion'
.
of calcium aluminate hvdrates will occur .,.
Contact Molloy & Associates for more details
about these tests or other information on the
excellent long term properties of Zircrete and its
manufacture.
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Nippon Electric Glass America Inc., 2604 W. Marshall Drive, Suite 102,
Grand Prairie, TX 75051. Tel: 9726021740, Web: www.negamerica.com
les
Basic Formulation
1: 1 Sand/cement
5% polymer solids weight of dry cement weight
0.33 water/cement
5% glass fiber

PolyPI ex Polymer
1. Take weight of cement, say 94 lbs. Multiply by 5%=4.7Ibs= weight of polymer solids required.
2. PolyPlex emulsion contains 47% polymer solids, 53% water, so weight of emulsion required =4.7 = 10 Ibs .
.47

Mix Water
Take water:cement ratio required, say .33 approximately
Water required = 94 x .33 = 311bs approx.
PolyPI ex emulsion contains 53% water, then 10 Ibs polymer emulsion will contribute 5.3 lbs of mix water required.
Therefore, extra mix water required = 25.71bs

Batch Mix formulation then is:

Cement 941bs
Sand 941bs
Polymer 10 lbs
Water 25.71bs
Superplasticizers as required
Total M= 223.71bs

Glass fiber content

Glass fiber content is calculated on the total mix weight, including the weight of glass fiber.
Let weight of glass fiber = G Ibs
Batch mix weight = M Ibs
% glass fiber =P
P=~ x 100
G+M

G=EM-
100 - P
for basic formulation P= 5
M=223.7
G= 11.8lbs

Cement 94lbs
Sand 94lbs
Polymer 10Ibs
Water 25.71bs
Glass Fiber 11.8 Ibs
Superplasticizer as required