Product Overview

MC-Grout 500 is an ultra-fine cementitious injection grout from MC-Bauchemie produced from a specially milled blend of Portland cement and supplementary materials ground to a Blaine fineness of 8000 to 12000 cm2 per gram — approximately 4 to 6 times finer than ordinary Portland cement (Blaine approximately 2800 to 3500 cm2 per gram) — with a maximum particle size D100 below 16 microns and D95 below 12 microns. This ultra-fine particle size distribution is the critical parameter that defines the injection penetrability of MC-Grout 500: penetrability into a crack or fissure is limited by the largest particles in the grout — ordinary Portland cement grout cannot penetrate cracks narrower than approximately 0.2 mm (200 microns) because the 80 to 100 micron maximum cement particles bridge across and block the crack entry; MC-Grout 500 with 16 micron maximum particle size can penetrate cracks as narrow as 0.05 to 0.08 mm (50 to 80 microns) — the same crack width range accessible only to chemical injection resins (epoxy, polyurethane, sodium silicate), but at a fraction of the chemical grout cost and with the durability, alkalinity, and environmental acceptability of a cementitious system. The applications divide into two principal categories: structural concrete crack injection — filling micro-cracks in reinforced and prestressed concrete structures (cracks 0.05 to 0.2 mm width) that are too fine for ordinary Portland cement grout and where chemical injection is specified by cost or chemical resistance considerations; and geotechnical grouting — sealing fine rock fissures and soil macro-pores in foundation grouting, rock mass permeability reduction curtains, and tunnel face pre-grouting ahead of TBM advance in water-bearing ground. A specific and technically critical application for MC-Grout 500 is post-tensioned duct grouting: the narrow annular void between the PT tendon and the duct wall (5 to 15 mm gap) requires a very fluid, low-bleed, non-shrink cementitious grout that completely fills the duct without voiding — the ultra-fine particle size of MC-Grout 500 ensures complete duct fill without particle bridging at tendon contact points. Space Arc Engineering supplies MC-Grout 500 for geotechnical contractors, bridge post-tensioning specialists, and structural grouting firms across Ghaziabad, Delhi NCR, Noida, and Uttar Pradesh.

Applications

• Post-tensioned duct grouting for bridges and buildings — filling the annular void around post-tensioned steel tendons and strands inside the PT sheathing duct in post-tensioned bridge girders, box girders, continuous bridge decks, and post-tensioned building transfer slabs, to provide corrosion protection to the tendons and monolithic structural bonding between the tendon and the concrete — MT-Grout 500 ultra-fine particle size ensures complete duct fill at the tendon-duct contact points where ordinary cement grout voids
• Rock fissure curtain grouting for dam foundations — injecting MC-Grout 500 under pressure into fine rock fissures in the foundation rock of concrete gravity dams, earth dams, and barrage foundations to create a grout curtain that reduces groundwater seepage through the foundation rock and prevents piping and internal erosion — ultra-fine grout penetrates fissures that standard cement grout injection cannot reach
• Rock stabilisation ahead of tunnel boring — pre-grouting fine fissures and water-bearing joints in the rock mass ahead of the tunnel face advance using directional drill holes and MC-Grout 500 injection to seal water inflows and stabilise the ground before TBM penetration into potentially unstable water-bearing rock zones
• Micro-crack injection in prestressed concrete structures — sealing fine hairline cracks (0.05 to 0.15 mm width) in prestressed concrete bridge beams, viaduct segments, and post-tensioned slabs where the crack width is below the penetrability threshold of ordinary Portland cement grout and structural re-bonding of the cracked section is required without the cost of epoxy injection
• Historic masonry consolidation grouting — injecting MC-Grout 500 into fine cracks and voids within historic brick and stone masonry walls, arches, vaults, and columns to consolidate structurally weakened masonry without introducing high-strength or high-stiffness materials that are incompatible with the historic masonry modulus — the ultra-fine cementitious grout penetrates the fine pore network of lime-mortared historic masonry without disrupting the historic fabric
• Void filling behind tunnel lining segments — filling the annular void and fine gaps behind precast concrete segmental tunnel lining rings after TBM advance, using MC-Grout 500 as a supplementary grout behind the primary pea-gravel or foam fill to eliminate all residual voids that could cause lining deflection under ground pressure

Key Advantages

• Ultra-fine penetrability to 50 micron crack width — maximum particle size below 16 microns allows injection into cracks as fine as 50 to 80 microns — the same penetrability range as chemical injection resins but using a cost-effective, durable, cementitious system that is chemically stable, alkaline (protecting steel against corrosion), and environmentally acceptable in ground applications where chemical grout injection permits may be restricted
• Non-shrink low-bleed formulation — the ultra-fine grout is formulated with shrinkage-compensating agents and a polymer stabiliser to achieve zero bleed water separation and zero volumetric shrinkage — critical for post-tensioned duct grouting where any void from bleed water accumulation or shrinkage leaves the tendon unprotected against corrosion and reduces the structural bonding between tendon and concrete
• High injectability at low pressure — the ultra-fine particle size and optimised rheology allow MC-Grout 500 to be injected at low pressures (0.5 to 3 bar) through fine cracks and fissures without fracturing the surrounding concrete or rock — low injection pressure is essential for historic masonry consolidation and fine concrete crack injection where high pressure would cause further damage
• Long pump life at design water-solid ratio — the grout maintains injectability for 30 to 60 minutes after mixing at the design water-solid ratio — sufficient for systematic grouting of multiple injection ports from a single batch, enabling efficient grouting of long crack segments or multiple fissure zones without premature grout stiffening in the pump or hose
• Cementitious long-term stability — unlike polyurethane or epoxy injection resins that can degrade in the alkaline concrete environment over 20 to 30 years, cured ultra-fine cementitious grout is chemically stable in concrete, rock, and soil environments for the full 50 to 100 year design life of the grouted structure — no long-term loss of sealing performance or structural contribution
• IRC:SP:65 and MoRTH compliance for PT duct grouting — MC-Grout 500 is formulated to meet the grouting material requirements of IRC:SP:65 (Guidelines for Design and Construction of Post-Tensioned Concrete Road Bridges in India) and MoRTH Standard Specifications for Road and Bridge Works — enabling specification on NHAI and state highway post-tensioned bridge construction contracts