· Where grouting area and floor space are of sufficient size, up to 50% (by weight) of pea gravel...
Transcript of · Where grouting area and floor space are of sufficient size, up to 50% (by weight) of pea gravel...
CEMENT-BASED VS. EPOXY GROUT
OftenUNISORB® V-1® Non-Shrinkcement-based grout or UNISORB®
StandardV-100®epoxygroutwillprovideequally beneficial long range resultsinthesameapplication.Thefollowingpointsdescribethefeaturesofeachoftheseproducts.
COST WhencomparingequalvolumesofV-1® and StandardV-100®,theepoxycostisuptosixtimesgreater.Itisreadilyapparentthereneedtobesomegoodreasonstousethemoreexpensiveprod-uct.Inmanycasesthereisnotagreatdifferenceintheappliedcost.ThisisaresultofphysicalpropertiesassociatedwiththeStandardV-100® thatpermitsuse of smaller quantities, as well asotheroperationalbenefitsthatreduceinstallationcosts,ascontained in thefollowingparagraphs.
MIXING V-1® (aswithmost cement-basedproducts)requiresonlytheadditionofwater.Mixingisusuallydonemechani-cally inamortarmixer,withcleanuprequiringonlytheuseofwater.StandardV-100® uses pre-measured compo-nents,andincludesapaddletypestirrertobeusedwithavariablespeeddrill.
TIME CONSTRAINTS Whentimeisanissueconsiderthefollowing.V-1® shouldhavea24-hourcure before work continues, with athreedaycurebeforefinalalignment.TheStandardV-100® isstrongerthantheconcretefoundationinlessthan8hoursandfinalalignmentcanusuallybedonewithin24hours.Inaddition,epoxygroutsareusedondryconcretewhicheliminatestheneedforpre-soaking.
WORKING TIMEWorking time should be consideredwhenselectinggrout.V-1®allows30-45minutesinwhichtofinishpouringgrout,whileStandardV-100®allowsonly10-15minutes.WithDeepPourV-100® youhave45-60minutes.
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CHEMICAL RESISTANCE BothV-1®andStandardV-100®areresistanttochemicalsnormallyfoundin the industrialenvironment.This in-cludesoils,coolants,andotherfluids.AgoodruletofollowwithV-1® isthatif the concrete floor can be exposedtothechemical,thegroutcanbealso.ThisputsV-1® inaclassaboveotherproductsthatrequiresealingtomaintaintheirproperties.
ItisreasonabletoexpectV-1® groutto react as the concrete would tochemicals since after cure it is basi-cally sand and cement. Actually, it isoften more chemically resistant andholdsuplongerthantheflooraroundit.This isbecauseit isamoredensematerial than the concrete and thechemicalattackcannotpenetrate thesurface.Therefore,whiletheconcreteisbeingattackedfromwithin,thegroutisonlybeingetchedfromthesurface.Needlesstosay,ifitisknownthattheremaybesomechemicalattackandthefloorissealedtoresistthisattack,thegroutshouldalsobesealed.StandardV-100®alsooffersexcellentresistancetochemicalattack.
TEMPERATURE CONSIDERATIONS Themixing,placingandcuringofbothV-1®andV-100®areaffectedbyambienttemperatures.Inwarmertem-peraturesgroutscurefaster,resultinginbothshorterworkandcuretimes.Incooler temperatures these times areextended. At temperature extremesspecialproceduresshouldbeusedtoassurepropergroutplacement.
After cure, V-1® is suitable forelevated temperatures as high as1000°F,withlittlelossincompressivestrength.StandardV-100® is capableof withstanding temperatures up to150°F.Hi-TempV-100®andXtraTempare formulated for maximum servicetemperaturesfrom325°Fto425°F.
CROSS-SECTIONAL AREA StandardV-100® ismorefluidthanV-1® andcaneasilyflowintothincross-sectionswhilemaintainingfullstrength.V-1® canonlybemademorefluidbyusing additional water, which lowersthestrength.Directionsoncontainersshouldalwaysbefollowedtoachieveoptimumresults.
Cement-based products requirewatertoundergoachemicalreactioncalledhydration,andstarttolosewa-terassoonastheyareplaced.Waterlosscanresultthroughevaporationorabsorptionintotheconcretefoundation.Becauseofwaterloss,sufficientcross-sectionalthicknessofthecement-basedgroutmust bemaintained tobe surethatthereisalargeenoughvolumeofwatertofullyhydrateallofthecement.Forthisreasona1”minimumgroutpadthicknessisrecommended.
Becauseepoxygroutproductsdonot undergo hydration, the StandardV-100® grout pad is often only 1/4” to1/2”thick.Insomecasesthegrout“pad”isjustapuddlewithalevelingdevicesettinginit.
ANCHOR HOLE SIZE Thetwofactorslistedabove(fluidityandwatercontent)alsoaffectthesizeoftheanchorhole.AmuchsmallerholeisrequiredwhenusingStandardV-100®
whichimpactscostintwoways:
(1)Volumeismuchsmallerwhenusingepoxygrout.Inatypicalanchorinstallationa3"diameterholewouldbeusedwithV-1® whilea11/2"diameterholeisrecommendedwhenusingStan-dardV-100®.Thisreducesthevolumeby75%,thusreducingthedifferenceinmaterialcost.
(2)Costisalsoreducedinthepro-cess of placing smaller holes. In theexampleabove,the11/2"diameterholecouldbemadewithahammerdrill(atoolmostshopshave)usingshopem-ployees.The 3" diameter hole wouldbemadewithacoredrill.Thecoredrillisusuallyrentedor thewholeprojectcontractedtosomeonewhospecializesinthisfield.
PHYSICAL PROPERTIES V-1 UNISORB CONCRETE WTFPHYSICAL PROPERTIES NON-SHRINK REPAIR COMPOUND (UCRC) (Wind Turbine Formula)
CompressiveStrength(psi)24Hours 6,565 6,200 8,07928Days(Ultimate) 11,875 10,100 13,278TensileStrength(psi)(28Days) 568 564 —FlexuralStrength(psi)(28Days) 1,700 1,237 —TypicalPourDepth 1"-2" 1/16"-2" 1"-3"PlacementTime 45-60minutes 10minutes 20-30minutesYield .40cu.ft./48# .40cu.ft./50# .40cu.ft./50#
GROUT COMPARISON CHARTSGROUT WITH AGGREGATE
GROUT COMPARISON CHARTSThefollowingproductsaretypicallyusedformachineryinstallationandsummarizedbelowforeasycomparison:
Physical properties shown are the result of independent labora-tory testing performed per industry recognized test procedures. Laboratory properties aid in determining suitability of the product for the intended application. Field test results may vary due to procedures or ambient conditions such as temperature and humidity. Laboratory reports are available on request.
CEMENT-BASED GROUT
Wheregroutingareaandfloorspaceare of sufficient size, up to 50% (byweight) of peagravel aggregatemaybeused.Peagravelshouldbestandardsize(3/8"dia.)andmaybepurchasedfromUNISORB.Priortouse,thepeagravel should be washed and dried.However, it is importanttoPRE-WETthepeagravelbeforeitisaddedtothecement-basedgrout.
EXAMPLE:TruckloadmixingofV-1Non-Shrinkgroutwithpeagravelusingthefollowingquantities:
● (51) 48# bags of V-1 Non-Shrinkgrout(2,448lbs.)
● (24)50#bagsofWETpeagravel(1,200lbs.)
● (50-55)Gallonsofwater
*Forstandardpackagingseepage6.
NOTE: The addition of aggregate filler may affect the final strength of cement-based and epoxy grouts by ± 20%.
GROUT WITH AGGREGATE
PHYSICAL PROPERTIES STANDARD V-100 DEEP POUR V-100 WTF-E V-100 DCR V-100 CR HI-FLOW V-100CompressiveStrength(psi) 6Hours 9,000 — — — — 3Days 15,250 11,600 14,020 — — 7Days(Ultimate) 16,800 14,000 15,470 17,000 17,000TensileStrength(psi) 4,800 1,536 2,350 3,000 5,500FlexuralStrength(psi) 6,800 4,600 4,800 6,000 8,100TypicalPourDepth 1/4"-1" 3"-8" 3/4"-8" 11/2"-8" 1/4"-2"PlacementTime 10-15minutes 60minutes 60minutes 20-25minutes 20-25minutesYield 11#kit.10cu.ft. 1cu.ft./kit 1cu.ft./kit 1cu.ft./kit 22#kit.21cu.ft. 22#kit.21cu.ft. 52#kit.49cu.ft. 55#kit.53cu.ft.
Abagofpeagravelweighs50lbs.In thisexample,amixing ratioofap-proximately50%peagravel(byweight)wasusedtoobtainonecu.yd.ofgrout(27cu.ft.).
EPOXY GROUT
Unisorb recommends the use ofDeepPourV-100epoxygroutforlargeordeeppours.Thisproductincludesthepropersizeandamountofaggregate.IfDeepPourV-100isnotreadilyavail-able,ortimeconstraintsareanissue,
crushedgraniteortheequivalentmaybeusedasanaggregatewithStandardV-100epoxygrout.
The crushed granite should bewashedanddriedbeforeusing,howeveritisimportantthatitisNOTpre-wet.Fillthe grout cavity with crushed graniteandthenfill thevoidswithStandardV-100epoxygrout.
Grout Yield With 50%Type (By Wgt.) Aggregate
V-1 .53cu.ft./48#bag UCRC .53cu.ft./50#bag WTF .53cu.ft./50#bag
YIELD
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GROUT VOlUMES fOR ANCHOR HOlESSElECTED GROUT PACKAGING & YIElD
Thegroutvolumechartbelowwaspreparedtohelpdeterminetheamountofgroutrequiredforvarioussizegroutholes. The chart assumes the groutholesarecylindricalinshape. Todetermine theamountofgroutrequiredrefertothefollowing:1. Determinethegroutholediameter
anddepth.Readthevolumeinthechart,i.e.,a3"diameterx10"deep
holeequals70.7cu.in.2. Multiplythe70.7bythenumberof
holes,i.e.,ifthereare30groutholes,multiply70.7cu.in.x30toget2,121cu.in.
3. Dividethisnumber(2,121cu.in.)bytheratedyieldofthestandardgroutpackage.Inthepreviousillustrationtomakeagroutpourusing11#KitsofStandardV-100epoxygroutyou
woulddivide2,121cu.in.by173cu.in. per kit (12.3 kits).This can beroundedto13-11#KitsofStandardV-100 epoxygrout.
4. Keepinmindthattheabovecalcula-tionsareexactandoffernosafetyfactorformorematerialusagethanisplanned,i.e.,iftheholesareslightlylarger.Youwillneedtoallowforyourownmarginofsafety.
VOLUME OF GROUT REQUIRED FOR ONE HOLE (Cubic Inches)
HoleDepth- HoleDiameter-Inches Inches 1.5 2 2.5 3 3.5 4 5 6 4 7.1 12.6 19.6 28.3 38.5 50.3 78.5 113.1 5 8.8 15.7 24.5 35.3 48.1 62.8 98.2 141.4 6 10.6 18.8 29.5 42.4 57.7 75.4 117.8 169.6 7 12.4 22.0 34.4 49.5 67.3 88.0 137.4 197.9 8 14.1 25.1 39.3 56.5 77.0 100.5 157.1 226.2 9 15.9 28.3 44.2 63.6 86.6 113.1 176.7 254.5 10 17.7 31.4 49.1 70.7 96.2 125.7 196.3 282.7 12 21.2 37.7 58.9 84.8 115.5 150.8 235.6 339.3 14 24.7 44.0 68.7 99.0 134.7 175.9 274.9 395.8 16 28.3 50.3 78.5 113.1 153.9 201.1 314.2 452.4 18 31.8 56.5 88.4 127.2 173.2 226.2 353.4 508.9 20 35.3 62.8 98.2 141.4 192.4 251.3 392.7 565.5
SELECTED GROUT PACKAGING & YIELD
V-1 Non-Shrink 48#Bag = .40cu.ft. (691cu.in.)UNISORB ConcreteRepairCompound(UCRC) 20#Pail = .16cu.ft. (276cu.in.) 50#Pail = .40cu.ft. (691cu.in.) 50#Bag = .40cu.ft. (691cu.in.)
WTF(WindTurbineFormula) 50#Bag = .40cu.ft. (691cu.in.)
StandardV-100 11#Kit = .10cu.ft. (173cu.in.)Ship-SafeStandardV-100 22#Kit = .21cu.ft. (363cu.in.) 55#Kit = .53cu.ft. (916cu.in.)DeepPourV-100 ThreePartKit = 1cu.ft. (1,728cu.in.)
DCRV-100 63#Kit = .50cu.ft. (864cu.in.) 125#Kit = 1.00cu.ft. (1,728cu.in.)
AdhesiveV-100 24.5#Kit = .26cu.ft. (450cu.in.)
CRHi-FlowV-100 22#Kit = .21cu.ft. (358cu.in.)Ship-SafeCRHi-FlowV-100 52#Kit = .49cu.ft. (846cu.in.)
WTF-EV-100(WindTurbineForumula) 125#Kit = 1.00cu.ft. (1,728cu.in.)
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RECOMMENDATIONS fOR GROUTING MACHINERYBy WAYNE H. WHITTAKER, V.P./G.M., Unisorb Installation Technologies, Jackson, MI
Thegroutingofmachinebaseplatesandbearingplates,andofanchoring/alignmentequipmenttoafoundationarelow-costapproachesthatprovideahighqualitymachine-to-foundationconnec-tion.Asuccessfulinstallationdependson: propergroutselection,basedonapplication; foundation preparation;formingmethodemployed;andcarefulattentiontotheactualapplicationofthegroutingmaterial. Grout Selection—Selectinggroutfor a particular application should in-cludeanevaluationofthesefactors:1. Cost—Comparethecostofmixed
grout, ready for placement.Yieldscan vary considerably from onemanufacturer to another, and drypowder to price comparisons aremisleading,astheamountofmixingwaterrequiredwillalsovary.
2. Strengths—Applied loads shouldbe evaluated carefully to ensurethat the bearing capacity of thegroutisnotexceeded.Compressivestrengthsreportedbymanufactur-ers are based on tests run underlab conditions; actual field-curedvalues forcementitiousgroutswillbeapproximately80percentofthelabresult.
3. Ease of handling and placement—Thefollowingfactorsareimportant:A. Flowability.Theeasewithwhich
thematerialenterssmallcavitiesand travels under larger baseplatesisusuallymeasuredeitherbytheASTM-C230testorCorpsofEngineersSpecCRD-621flowconetest.FortheASTM-C230test,theresultsareexpressedasadimensionlessnumber rang-ing from 100 to 150, with 150themostflowable.TheCorpsofEngineers’resultsrangefrom30secondsto10seconds,with10secondsthemostflowable.
B. Tendency to separate whenmixedorhandledexcessively.Insomematerialsthatusemetallicadditives or have aggregatesofwidelyvaryingsizes,theag-gregatestendtoseparateifthematerialisovermixedorhandledexcessively.
C. Ability to be pumped or vi-brated, particularly on largerinstallations. Again, separationistheproblem.Theabilitytobevibratedorpumped isaprimeconcernwhengroutingcavitiesare small, when placement is
difficult,orwhengroutmustbeflowedlongdistances.
D. Expansion or non-shrinkprop-erties.Themainobjectiveistoselectamaterialthatwillexpandenough to assure full bearingcontactwithmachinebaseandfoundation (a few tenths to 1percentorsoisnormal).Whenlargegrout-to-machinecontactareasareencountered,agroutwithacontrolled internalpres-sure development should beselected toprevent thegrout’sexpansionfromdisturbingalign-ment.Theactual expansionofagroutistypicallymeasuredbyeither theASTMC-1090-88orASTM-C827-87 early volumechange method; the result isexpressedasapercentage.
E. Maintenance requirements. Whatwillberequiredtokeepthegrout functional in theenviron-mentintowhichitwillbeplacedisthemainconcern.Forexample,agroutthatistobeusedinanoily environment should be arelatively impermeable type. Agroutwithaporousstructurewillrequireapaintcoat topreventpenetration by oils and otherchemicals.
Otherspecialconsiderationsincludeabilitytowithstandthermalcyclingandhightemperatures,abilitytoresistacids,and susceptibility to spaulding underfreeze-thawcycling. Materials inusetodayrangefromslightly modified sand and cementmixtures to chemically sophisticatedepoxymaterialswithstrengthsfivetosixtimesthatofstandardconcretes. Cementitious Grouting Materi-als—The simplest grouting materialconsists of sand and cement mixedatapproximatelya50-50ratio.Simplesand and cement mixtures shrink oncuring,usuallyfrom2to3percent,mak-ingtheiruseinhighloadorprecisionapplicationsquestionable.Cementitiousgroutsinusetodayhavebeenmodifiedtoexpandratherthanshrinkoncuring.
1.Foundationformingandfinishingtolerancesmay be relaxed. Because grout providesthefinallinkbetweenthemachineandthefoundation,thefoundationisusuallyfinished11/2to3in.belowthedesiredmachinebaselevel.Athickerorthinnergroutpadcanbeused,as thespecific situation requires, tocompensateforthevariancesencounteredinactualfoundationconstruction,eliminatingtheneedforprecisionfoundationwork.
2.Groutingprovidesarigidmachine-to-founda-tionconnection.Asthegroutisplacedintothecavity,intheplasticorfluidstate,itconformsprecisely to the machine base and to thefoundation,providinga100percentbearingcontactbetweenfoundationandgroutpad,andgroutpadandmachinebase.
3.Anchoring/alignment equipment can bepositioned within a precast or core-drilledgrouting cavity at the time of machine in-stallation.Asthefoundationisconstructed,groutingcavitiesarecreatedbyprecastingorcoredrilling(whilethefoundationisgreen)attheapproximatelocationofeachsupportoranchorpoint.
Whenthefoundationhascuredsufficientlyto support machine loads, the machine ismoved intopositionon the foundationandsupportedbytemporaryblocks.Theanchor-ing/alignmentequipmentisthenassembledtothemachinebasewiththeanchorboltandbaseofthealignmentdevice(ifoneisbeingused)projectingintothegroutingcavity.Groutisthenplacedintothecavityandallowedtocure,completingthemachine-to-foundationconnection. This approach eliminates therequirement for time-consuming, precisepresettingofanchorboltsoralignmentequip-ment,significantlyloweringthecostofmorecomplexinstallations.
4.Existingfoundationsmaybeeasilyadaptedtonewequipment.Coredrillinganexistingfoundation to accept new anchoring/align-mentequipment,whichisinturngroutedintopermanentposition,eliminatestheneedforremovingandreplacinganotherwisesoundfoundation if the equipment it supports isbeingrelocatedorreplaced.Whenproperlyinstalled,theseanchorsexhibitholdingpowerequaltoorbetterthanthatofanchorssetintothefoundationasitwasconstructed.
GROUTING ADVANTAGES
(cont.)
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RECOMMENDATIONS fOR GROUTING MACHINERY(continued)
Thereareseveralbasicexpansionmechanismsinusetoday.Oneinvolvestheadditionofironfilingstothesand-cement mixture. The filings expandslightly when water is added to themixture,causingthedesiredexpansion. Other systems include the use ofcarbonparticles(evolvedgascausesexpansion)andtheuseofchemicallycompensated“TypeK”cements(whichpromote growth within the cementpaste). Epoxy Grouting Materials—Theepoxygroutsconsisttypicallyofabaseresinandhardener thataremixedatthe jobsite immediately beforeplace-ment.(Somesystemsmayalsorequiretheadditionofafilleratthispoint.)Anadvantage of epoxy materials is theabilitytowithstandsignificantlyhighershockloadsthancementitiousmateri-als.Epoxiesalsocanbeusedinmuchthinnercrosssectionsthancementitiousmaterials;thisfeaturemaybedesirableincertainapplications. The epoxy grouts typically exhibitslightshrinkageoncuringbutusuallythethinnersectionused(andextremelysmallamountofoverallshrinkageen-countered)minimizestheproblem. When theapplication isunusuallyseverefromashockloadingstandpointoristobeusedinaverythinsectionrequiringhighflowability,highstrength,and rapid cure rate, an epoxy groutshouldusuallybechosenratherthana cementitious one. Setting anchorboltsisanapplicationparticularlywellsuitedtotheepoxymaterialbecausearelativelysmallquantityisusedandtheshortcuretimeisanadvantage.Epoxygroutsarewidelyusedforapplicationssuchasinstallinglargeengines,com-pressorunits,crushersandshredders,and other equipment imparting largedynamicloadstotheirfoundations. Foundation Preparation —Theconcretesurfacestowhichthegroutwillbeappliedmustbecarefullycleaned,leavingthesurfacefreefromallforeignmaterial,grease,oil,etc.Ifanoldfoun-dationisbeingreused,besurethattheuppersurfacesaresound.Ifunsoundconcreteisencountered,itwillbenec-essarytochipbacktosoundconcrete.Theobjectiveistoplacegroutagainstsound,cleanconcreteonly.
For Cementitious Grouts● Don’texceedrecommendedwaterlevelsinanattempttoachievegreaterflowability.Using
morewaterthanspecifiedbythemanufacturermayresultinsegregationofthematerialormayinterferewiththenon-shrinkmechanism.
● Don’tovermixorundermix.Refertothegroutmanufacturer’sminimumandmaximummixingtime recommendation.Overmixingmaycausesegregation inmetallic-typematerialsandunnecessaryairentrainmentinothermaterials.Undermixingmaynotaccomplishadequateblendingofdryingredientsandmaypreventproperwettingofmaterialswhichcouldresultinthegrout’s“falsesetting”andotherproblems.
● Don’tusecuringcompoundsorbondingagentsunlessspecificallyapprovedbythegroutmanufacturer.
● Dowetthefoundationthoroughly.Otherwise,waterwillbedrawnfromthenewlyplacedgrouttooquickly,interferingwithpropercuring.
● Dousecleanmixingwater.Chemicalcontaminantsmayinterferewiththeproperexpansionofthematerial.
● Doreadtheindividualmanufacturer’sinstructions,especiallywhenplacinggroutattempera-turesbelow45°F(7°C)andabove90°F(32°C)astherequirementforspecialmeasuresvariesconsiderably.
For Epoxy Grouts● Don’tplaceepoxygroutswhenwaterispresent(oncecured,waterisnoproblem).● Dobesurethefoundationiscleanandfreefromoilorgrease.● Dodesignforthinsections,avoidinglargepours.● Dofamiliarizejobsitepersonnelwiththemanufacturer’srecommendedhandlingandsafety
precautions.
DO’S AND DON’TS
(cont.)
Forming Recommendations—Inpreparingformsforretainingfluidgrout,keep in mind that the most effectivemeans of achieving a good machinebase-to-grout contact is to place thematerial fromonesideonly.Thema-terial should flow under the machinebeinggrouted,and,whileitisflowing,contactbetweentheuppersurfaceoftheadvancinggroutandthemachinebaseshouldbemaintained.Thisapproachwillensurethatnoairbecomestrappedbetweenthegroutandmachinebase,Fig.1.
Itisimportanttomaintainclearancesbetweenthemachinebase,foundation,andforms.Adequateclearanceshouldbeprovidedbetweentheformandbaseplateonthepoursidetopermitmate-rialtobeintroducedrapidlyenoughtomaintain grout base contact. Use ofa sheet metal or wooden chute mayprovehelpfulinintroducingthemixedgrout intotheform.Theformsshouldalsobehighenoughtopermitthefluidgrouttobebroughtupthesideofthemachinebaseabout 1/2 inch tomakesurethatfullbearingcontactisrealized.Sufficient grout must be available sothattheentirecavityisfilledinasingle,continuouspour.
The form should be carefully de-signed and constructed to preventleakage because modern grouts aremuchmoreflowable thanconcrete. Itis recommendedthatcaulkoracon-structionadhesivebeusedtosealtheindividual form components to eachotherandtosealthecompletedformtothefoundation.Epoxygrouts,whichare extremely flowable, require extraattentiontothesealingtopreventpos-sibleformleaks. Application—Itisdesirable,insomecases, to grout anchoring/alignmentequipmentinplace,pouringabearingpadandsettingananchorboltsimulta-neously,Fig.2.Theanchorboltcavitymustbecompletelyfilledwithgrout.Afilledcavitycanbeattainedbypouringthegroutslowlyatfirsttomakesurenoairistrapped.Forunusuallydeepholes,itmaybeadvisabletouseanairbleedtubethatiswithdrawnwhenthecavityisfull,Fig.3. Analternateapproachisthefunneland hose method. A highly flowablegroutisrequiredforthisapproach,andthetipofthehoseshouldbeinsertedintotheanchorboltcavityandwithdrawnslowlyasthegroutlevelrises.
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RECOMMENDATIONS fOR GROUTING MACHINERY(continued)
MACHINE BASELEVELING/ALIGNMENT DEVICE
FORM FOR RE-TAINING FLUID GROUT
ANCHOR BOLT
FOUNDATION
PRECAST OR CORE-DRILLED GROUTING CAVITY
ANCHOR BOLT
AIR IS EX-PELLED
LEVELING/ALIGNMENT DEVICE
AIR BLEED TUBE
1 IN. MINIMUM DIAMETER
RUBBER HOSE
FUNNEL
MACHINE BASE
GROUT
PLYWOOD OR METAL CHUTE
2 IN. X 2 IN. WOOD FORM
DESIRED FINISH GROUT LEVEL
SEALING BEAD OF CAULKING MATERIAL OR ADHESIVE
1 1/2 IN. TYPICAL
3"
Fig. 1. The grouting material should be placed from one side only to achieve good machine base-to-grout contact. This approach ensures that no air is trapped between the grout and machine base.
Fig. 2. This application, recommended when leveling/alignment equipment is grouted, simultaneously providing a bearing pad and anchor bolt.
Fig. 3. If the anchor bolt cavity is very deep, an air bleed tube might be advisable. It should be withdrawn after the cavity is filled. An al-ternate approach is to use a funnel and hose. A highly flowable grout is required, and the tip of the hose should be withdrawn slowly as grout level rises.
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RECOMMENDATIONS fOR GROUTING MACHINERY(continued)
“The time spent in thoroughly planning the grouting installation will pay off in fewer problems in the machine's performance.”
Fig. 6. For large pours, a ready-mix truck and concrete pump are recommended.
INSPECTION HOLES
GROUT IS PUMPED THROUGH HOLE IN PLATE TO OUTER EDGES
PUMP
READY MIX TRUCK OR MIXER
TEMPORARY PIPE FITTING
Fig. 5. When large areas are grouted, the pour should be divided into sections. Sections 1 and 2 should be poured and allowed to set before the center section is poured.
POUR NO. 3
POUR NO. 1
POUR NO. 2
GROUT
BASE PLATE FOAM STRIPS
FORMS
Fig. 4. Air bleed holes should be provided when blind cavities are grouted. The holes also provide visual assurance that all cavities are filled.
FORMGROUT
AIR BLEED HOLES TYPICAL FLOOR PLATE
Airbleedholesshouldbeprovidedwhen blind cavities are grouted, Fig.4.Theairbleedholesserveasecondfunctionofprovidingvisualassurancethatallcavitiesarefilled.
When working with a larger pour,itmaybeadvisabletobreakthepourintosectionsformoreconvenienthan-dlingbyusingpolyethylenefoamstrips,Fig. 5.The outside cavities are filledfirst, and the grout is allowed to setbeforethefoamstripsareremoved.Theremainingcentercavityisfilledlast.
Manyofthecurrentlyavailablegrout-ing materials can be pumped with astandardconcretepump.Thisapproachisfrequentlyusedwhenextremelylargepoursarerequired.Themainproblemismixingthenecessaryamountofmate-rialquicklyenoughtopermitasinglecontinuouspour.Astandardready-mixtruck and concrete pump work well,Fig.6.
Afirst-qualitygroutinginstallationisthekeytosuccessfulmachineinstalla-tion.Thetimespentinthoroughlyplan-ningtheinstallationwillpayoffinfewerproblemsinthemachine’sperformance.
■
Informationinthisarticlehasbeenupdatedtomeetproductandapplication
standardsinusein1998.
REPRINTEDFROM
PlantEngineering
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Mix Ratio Waterper48lb.bag 3.67qts. 3.84qts. 4.00qts. 4.32qts. ASTMC-1107 Requirements
Flow Consistency Plastic Flowable Fluid FluidFlowTable(5drops)ASTMC-230 109 135 150 ----- Plastic 100-125FlowCone(5min.)ASTMC-939 ----- ----- 42sec. 27sec. Flowable 125-145FlowCone(30min.)ASTMC-939 ----- ----- ----- 28sec. Fluid 10-30 sec.FlowCone(60min.)ASTMC-939 ----- ----- ----- 35sec.
Compressive Strength (PSI) per ASTM C-109 TestAge Minimum 16Hours 4965 4275 3538 2075 ----- 1Day 6565 5950 4905 4200 1000 3Days 9085 8415 8290 7060 2500 7Days 10040 9520 9585 8605 3500 28Days 11875 11605 11125 10210 5000
Vicat Needle Test per ASTM C-191 InitialSet 5hrs.3min. 5hrs.22min. 6hrs.17min. 6hrs.30min. ----- FinalSet 5hrs.41min. 6hrs.26min. 7hrs.0min. 7hrs.28min. -----
Change in Height (%) at Early Ages ASTM C-827 AtFinalSet +0.55 +1.49 +1.43 +1.23 0.0-4.0
Change in Height (%) ASTM C-1090 TestAge 1Day +0.04 +0.01 +0.01 +0.00 0.0-0.3 3Days +0.04 +0.02 +0.01 +0.00 0.0-0.3 14Days +0.05 +0.03 +0.01 +0.00 0.0-0.3 28Days +0.05 +0.03 +0.01 +0.00 0.0-0.3
V-1® NON-SHRINK GROUT (Cont.)
Shown below are selectedphysicalpropertiesofV-1Non-ShrinkGrout. Since the physical propertieschangewiththeamountofwaterused,the chart shows properties at fourwater levels. The four were chosento show the properties for a plastic,flowable,andfluidconsistency,andatmaximumwater. Phys ica l p roper t ies a tmaximumwaterarecompared to theASTMC-1107requirementsinthefarright column. ASTM C-1107 includestestingandacceptancecriteriaformostphysical properties of non-shrink ce-
mentbasedgrouts.UnisorbV-1Non-Shrink Grout meets or exceedsthe requirements of ASTM C-1107Grade C. Grade C is the designa-tionforgrouts thathaveanon-shrinkmechanism active both in the fluidstate and cured state. The fact thattheexpansion is+0.00atmax.watershows the precise nature of the pro-prietary expansion agent, overcom-ing post hardening shrinkage of thecementwithoutexcessiveexpansion. Thecompressivestrengthsat1, 3, 7, and 28 days are determinedin accordance with the specification
PHYSICAL PROPERTIES
outlined in ASTM C-109, “Stan-dard Test Method for CompressiveStrengthofHydraulicCementMortars”.Additional cubes were tested at16 hours to show early strengthdevelopment.Theresultssummarizedinthechartbelowshowthatthe28daystrengthrequirementofASTMC-1107,5000psi,ismetin3daysevenatthehigh water level. These values areshowningraphicforminthechartonthepreviouspage. UnisorbV-1Non-ShrinkGroutispackagedinamoistureresistantbag.
Physical properties shown are the result of independent laboratory testing performed per industry recognized test procedures. Laboratory properties aid in determining suitability of the product for the intended application. Field test results may vary due to procedures or ambient conditions such as temperature and humidity. Laboratory reports are available on request.
Flexural Strength7Days 1670psi28Days 1700psiHigh Temperature evaluationCompressive Strength 70oF 11000psi 800oF 11000psi 900oF 9700psi1000oF 8400psi
Tensile Strength7Days 535psi28Days 568psiYoungs Modulus of Elasticity6x106psiExpansion and Bleeding of FreshlyMixed Grouts @ Max. Water (ASTM C-940) VolumeExpansion +1.00% Bleed 0.00%
13
ASTM C-1107 DATA
UNISORB® CONCRETE REPAIR COMPOUND (UCRC)UCRC EXTENDED SET
PHYSICAL PROPERTIES
UCRC UCRC EXTENDED
Compressive Strength (CRDC-227/ASTMC-109) SET
WaterTo100# 6.5qts. 6.5qts.1hour 2,700psi 1,500psi3hours 4,000psi 2,700psi1day 6,200psi 4,600psi7days 8,400psi 6,100psi28days 10,100psi 7,400psi
Compressive Strength With 50% Pea Gravel Added (ASTMC-39)1day — 4,300psi7days — 5,400psi28days — 6,300psi
Coefficient of Thermal Expansion (ASTMC-531) 7.46x10—6in./in./°F —
Tensile Strength (ASTMC-190)7days 544psi —28days 564psi —
Flexural Strength (ASTMC-348)7days 1,185psi —28days 1,237psi —
Flow (ASTMC-929) 145(25drops,5min.) —
Vicat Needle Test @ 75° F (ASTMC-191)InitialSet 18min. 33min.FinalSet 20min. 37min.
Bond Strength (ASTMC-882)1day 1,500psi 1,700psi7days 3,100psi 2,200psiTypical Pour Depth 1/16in.-2in.UCRCmeetsorexceedsthespecificationsforScalingResistance(ASTMC-928),Freeze-Thaw(ASTMC-666),andRapidHardeningMaterialsforConcreteRepair(ASTMC-928).
Physical properties shown are the result of independent labora-tory testing performed per industry recognized test procedures. Laboratory properties aid in determining suitability of the product for the intended application. Field test results may vary due to procedures or ambient conditions such as temperature and humidity. Laboratory reports are available on request.
PACKAGING/YIELD50#Bag=.40cu.ft.(691cu.in.)20#Pail=.16cu.ft.(276cu.in.)50#Pail=.40cu.ft.(691cu.in.)
UNISORB® CONCRETE RE-PAIR COMPOUND (UCRC) Acement-based,flowable,fastset-tingproductdesignedforuseinsettinganchorboltsandfillingholesandlargecracksinconcretefloors,roads,side-walks,foundations,etc.Itiswellsuitedto high traffic wear areas. Edges ofrepairscanbefeatheredtoblendintothesurroundingarea.
PERFORMANCE ADVANTAGES UCRC employs special poly rein-forcing fibers to achieve exceptionalstrength and durability. Unlike mostcement-basedproducts,UCRCisself-sealingandrequiresnosealantwhenused outdoors.This product requiresnopre-wettingandcanbeopened totrafficin20minutestoonehourafterpouring(dependingonweightoftraffic).Itisalsoidealforsettinganchorbolts,particularlywhenshortinstallationtimesareimportant,becauseofitsfastsettingtime.
BASE PREPARATION Allcontactsurfacesmustbecleanedofoil,grease,scale,etc.Unsoundcon-crete should be chipped out leavingthesurfacelevel,butrough.Theareatoberepairedshouldbechippedtoaminimumdepthof1/2".
APPLICATION TECHNIQUES UCRCcanbemixedinawheelbar-
Consult the specific Material Safety Data Sheets (MSDS) for all safety data.
row or cement mixer. Only the exactamountneededforaparticularprojectshouldbemixed,duetoitsfastsettingtime.Exactratiosshouldbefollowedformixtureofproductandwater.Mixdrypowderwithwateratthejobsitetoformatrowelablemixture.Placeinareatoberepairedandtroweltodesiredfinish.Allowtocure.
TEMPERATURE CONSIDERATIONS
Usestandardhightemperaturecon-cretingtechniquesforconditionsover90°F,andlowtemperaturetechniquesforconditionsbelow45°F.
PEA GRAVEL
Whenexceedingathicknessof2"to3",peagravelshouldbeadded.Use3/8"peagravel,1partgravelto2partsgroutbyweight.
UCRC EXTENDED SET UCRCisalsoavailable inan“Ex-tendedSet”formulationtoallowlongerworktime.(Seeabovechart.)
16
18
STANDARD V-100® EPOXY GROUT
PHYSICAL PROPERTIES
Consult the specific Material Safety Data Sheets (MSDS) for all safety data.
STANDARD V-100® A two-component, 100% solids,filled epoxy resin system of superiorquality, offering excellent flowability,highresistancetoimpactandextremelyrapidcure.
Thisgroutistheproductofchoicewhereeaseofplacement,suitabilityforuse under extremely high loads, andminimalcrosssectionthicknessesarenecessary. Other materials such asconcreteorweakergroutsmaydevelopstructuralflawswhensubjectedtohighconcentratedloads.
StandardV-100® isaperfectchoicefor:
•Groutingmachinebases
•Settinganchorbolts
•Settinglevelingwedges
•Settingsoleplates
•Repairingdeterioratedfoundations
TherapidstrengthdevelopmentofStandardV-100® permits loads tobeapplied much sooner after groutingthanwithothermaterials.Itsexcellentflowabilitypermitsuseinextremelythincross-sections.
IMPORTANT ADVANTAGES:PERMANENCE Eliminates need for periodic
regrouting.Savesdowntime,laborandlost production. Resistance to oils,greases,acids,alkaliesandsolventsismuchgreaterthanthatofcement-basedmaterials.Tensileandflexuralstrengthsareat least15timesthatofconcreteand compressive strength is about 5timesthatofconcrete.
PACKAGING Standard V-100® is packaged inakitwiththebaseresinpackedinanoversized container large enough toserveasamixingvessel.Thehardenerportionofthekitisaddedtothebaseresinatthejobsite.Astirringpaddleisincludedwhichwillfitastandard1/4"elec-tricdrill.Afteramixtimeof2-3minutes
Physical properties shown are the result of independent labora-tory testing performed per industry recognized test procedures. Laboratory properties aid in determining suitability of the product for the intended application. Field test results may vary due to procedures or ambient conditions such as temperature and humidity. Laboratory reports are available on request.
a15minuteworkingtimeremainsforplacementofthematerial.ForGelTimevs.TemperatureandMixedViscosityvs.Temperatureseenextpage.
Color GrayGreen
Compressive Strength(ASTMD-695)
6hours 9,000psi
3days 15,250psi
7days 16,500psi
Compression Modulus
7days 436,000psi
Tensile Strength (ASTMD-638) 4,800psi
Heat Deflection Temperature (ASTMD-648) 161°F
Maximum Service Temperature 200°F
Placement Time@77°F 10-15minutes
Tensile Modulus 1.01x106psi
Flexural Strength(ASTMD-790) 6,800psi
Mixed Viscosity(ASTMD-2196) 8,000cps
Adhesion Slant Shear Test(ASTMC-882) 4,200psi
Specific Gravity(ASTMD-792) 1.7
Hardness (Shore D)(ASTMD-2240) 90
Density (cured) 105lbs./cu.ft.
Creep Test(ASTMC-1181)
600psi@150°Fcured24hours@70°F16hours@150°F 1.95x10—2in./in.
Linear Shrinkage (ASTMD-2566) 0.00025in./in.@77°F
Coefficient of Thermal Expansion(ASTMD-696) 2.0x10—5in./in.@77°F
(cont.)
•
•
•
•
•
19
STANDARD V-100® EPOXY GROUT(Continued)
STANDARD V-100® GEL TIME vs TEMPERATURE
Temperature (F)
Gel
tim
e (m
inu
tes)
Thisgraphshowsgeltimeasafunctionoftemperature.Withthecurvebeingbasically linear,agoodruleofthumbis30minutes(approx.)atroomtemp.(72°F)andvariesabout1minuteperdegreetemperaturechange.
Temperature (F)
Mix
ed V
isco
sity
(cp
s)
STANDARD V-100® MIXED VISCOSITY vs TEMPERATURE
Thisgraphshowsviscosityisrelativelyconstantabove80°F,butchangesratherdramaticallybetween70°Fand50°F.Thiscanbeverynoticeablewhenpouringonconcretewhichmaybe10-20°Fcooler than theambientairtemperature.
EASY, FLOW-INTO-PLACE INSTALLATION
Flowsintospacesundermachinesof1/2"orlessandfillscompletelybeforesolidifying.
REGROUTS
Noneedtomoveequipmentorbreakconnections.Justraiseequipment1/2"to3/4"andregroutwithStandardV-100®.
TEMPERATURE CONSIDERATIONS
TYPICAL POUR DEPTH
Thicknessof1/4"upto1"(uncon-fined),upto11/2"underplate.(Multiplelayersmaybeusedforthickerpours.)
SMOOTHER MACHINE OPERATION
Standard V-100® survives impactandvibrationaswellasreinforcedrub-bermaterialsandwillnotdelaminateunderthemostsevereshockloads.
FAST CURE
At77°F,a1/2"thicknesswillsetupforusein8hours.
PACKAGING/YIELD11#Kit=.10cu.ft.(181.5cu.in.)22#Kit=.21cu.ft.(363.0cu.in.)55#Kit=.53cu.ft.(907.5cu.in.)
DEEP POUR V-100® EPOXY GROUT
PHYSICAL PROPERTIES
Compressive Strength (ASTMD-695)1day 11,000psi3days 11,600psi7days 14,000psi
Tensile Strength (ASTMD-638) 1,536psi
Tensile Modulus 72,000psi
Mixed Viscosity(ASTMD-2393) 37,000cps
Heat Deflection Temperature 136°F
Maximum Service Temperature (ASTMD-648) 250°F
Hardness(ShoreD)(ASTMD-2240) 90
Placement Time@70°F 60minutes
Flexural Strength (ASTMD-790) 4,600psi
Flexural Modulus of Elasticity 2,154,000psi
Coefficient of Thermal Expansion (ASTMD-696) 1.7x10—5in./in./°C
Creep Test (ASTMC-1181)600psi@150°Fcured24hours@70°F16hours@150°F 7.09x10—3in./in.Linear Shrinkage (ASTMD-2566) 0.0003in./in.@72°FTypical Pour Depth 3in.-8in.
PACKAGING/YIELD3PartKit=1.00cu.ft.(1,728cu.in.)
Physical properties shown are the result of independent labora-tory testing performed per industry recognized test procedures. Laboratory properties aid in determining suitability of the product for the intended application. Field test results may vary due to procedures or ambient conditions such as temperature and humidity. Laboratory reports are available on request.
DEEP POUR V-100® A three-component, 100% solids,epoxy resin system specifically de-signed for use where pour sectionsexceed3"therebypermittingtheuseofamorehighlyfilledmaterial.DeepPourV-100® offers excellent compressivestrengthscoupledwithrapidcuretimesforapplicationswherelargervolumesarerequired.
DeepPourV-100® isideallysuitedfor:● Deepgroutingoflargemachine
bases● Settinglargeanchorbolts● Settinglargelevelingwedges● Settinglargesoleplates● Deeprepairsinfoundations
Thisgroutisspecificallyformulatedforpoursasthickas8"anddevelopsthesamehighstrengthandchemicalresistanceasStandardV-100®.Easeofmixingandfastcuremakesthisepoxygroutidealforminimizingdowntimeinindustrieswhereequipmentmustcon-tinuerunningsuchasinsteelmaking,manufacturingandpowergeneration.
IMPORTANT ADVANTAGES:PERMANENCE Eliminatesneedforperiodicregrout-ing. Saves downtime, labor and lostproduction.Resistancetooils,greases,
acids, alkalies and solvents is muchgreater than that of cement-basedmaterials.Tensileandflexuralstrengthsareatleast11timesthatofconcreteandcompressivestrength isabout4timesthatofconcrete.
PACKAGING Thegroutispackagedinconvenientthree-part kits consisting of a resincontainer,ahardenercontainerandtwobagsofaggregate.Astandarddrum-typecementmixerormortarmixermaybeused.
EASY, FLOW-INTO-PLACE INSTAL-LATION Flowsintospacesundermachines,fillscompletelybeforesolidifyingandisselfleveling.
FAST CURE At70°F,an8"thicknesswillbereadyforusein24hours.
SMOOTHER MACHINE OPERATION DeepPourV-100® survivesimpactandvibrationaswellasreinforcedrub-bermaterialsandwillnotdelaminateunderthemostsevereshockloads.
REGROUTS Noneedtomoveequipmentorbreakconnections.JustraiseequipmentandregroutwithDeepPourV-100®.
Consult the specific Material Safety Data Sheets (MSDS) for all safety data.
21
JOINT fIllER V-100® HI-TEMP V-100® EPOXY GROUT
HI-TEMP V-100® Atwo-component,100%solids,ep-oxyresinsystemspecificallydesignedwherehighermechanicalstrengthandhightemperaturestabilityoverregularepoxygroutsisrequired. Hi-TempV-100® isresistanttomostfuels,oils,water,andattackbyacidsandcausticsolutions,making it idealformarineorpowerplantapplications.
PACKAGING Thisepoxygroutproductisconve-nientlypackagedinkitswithamixing
Consult the specific Material Safety Data Sheets (MSDS) for all safety data.
paddle and pre-measured containersofresinand hardener.Touse,pourthehardenerintotheresinandmix3to4minutesuntilauniformcolorappears.
PLACEMENT TIME & CURE TIME Theplacement time(thetimeyouhavetopourbeforeitsets)ofHi-TempV-100® Epoxy Grout will vary withambient temperatures. The averageplacementtimeat77°Fwillbe30-40minutes.Incoolerweatheryouwillhavemoretimetopourmaterial,andinhotterweatheryouwillhavelesstime.Curetime(thetimebeforethegroutisstrongenoughforuse)willalsodependontheairtemperatureandthetemperatureofthefloorandmachinerybeinggrouted.Theaveragecuretimefromthelastpourtomachinerystartupwillbe24hoursat70°F.Incoolweatherthegroutwillcureanddevelopstrengthmoreslowlythaninhotweather.Temperatureofthefoundation concrete should be takeninto consideration along with the airtemperaturewhencalculatingthecuretimeneeded.
JOINT FILLER V-100®
26
PHYSICAL PROPERTIESTensile Strength(ASTMD-412) 430psi
Hardness (ShoreA) 60
Placement Time @ 77° F(1lb.mass) 60min.(FullKit) 15-20min.Cure Time 24hours
Mixed Viscosity 2,200cps
PACKAGING/YIELD2Gal.Kit=.25cu.ft.(432cu.in.)
(1/2"x1/2"grooveupto144linearft.)
A two-component, 100% solids,filledepoxysystemdesigned toseal theexposededgeofInertiaBlockisolationmaterial while providing an excellentappearancetotheinstallation.Itcuresovernightatroomtemperaturetoagray,cementcoloredflexiblemastic.
JointFillerV-100® isconvenientlypackagedina2gallonkit,andits1:1mixing ratio allows the mixing of theamountnecessaryfortheapplication.Donotmixmorethancanbeplacedin15min.
This material is resistant to andpreventstheentryofwater,lubricants,coolantsandotherfluidsintothejoint.Itisalsotoughandpunctureresistant,effectively keeping chips and other
PHYSICAL PROPERTIES
Compressive Strength(ASTMD-695) 19,000psiTensile Strength(ASTMD-638) 4,500psiFlexural Strength(ASTMD-790) 9,200psiMixed Viscosity(ASTMD-2393) 13,000cpsHeat Deflection Temperature(ASTMD-648) 266°FMaximum Service Temperature 325°FHardness(ShoreD) 90Gel Time@72°F 40-50mins.Creep Test (ASTMC-1181)600psi@150°Fcured24hours 1.62x10—3in./in.Typical Pour Depth 1/4in.-1/2in.(Multiplelayersmaybeusedforthickerpours.)
PACKAGING/YIELD21#Kit=.20cu.ft.(345cu.in.)47#Kit=.45cu.ft.(776cu.in.)
Physical properties shown are the result of independent labora-tory testing performed per industry recognized test procedures. Laboratory properties aid in determining suitability of the product for the intended application. Field test results may vary due to procedures or ambient conditions such as temperature and humidity. Laboratory reports are available on request.
debrisfromenteringtheisolationjoint.Whencured,thematerialremainspli-ableenoughtopreventtheunwantedtransmissionofvibrationsbetweentheInertiaBlockandtheshopfloor.
XTRA-TEMP V-100® EPOXY GROUT
PHYSICAL PROPERTIES
CURE CYCLE(ToDevelopUltimateProperties)
Heatfor8hrs.@75°FHeatfor4hrs.@200°FHeatfor4hrs.@400°F
Physical properties shown are the result of independent labora-tory testing performed per industry recognized test procedures. Laboratory properties aid in determining suitability of the product for the intended application. Field test results may vary due to procedures or ambient conditions such as temperature and humidity. Laboratory reports are available on request.
PACKAGING/YIELD20#Kit=.19cu.ft.(330cu.in.)44#Kit=.43cu.ft.(735cu.in.)
APPLICATION CHARACTERISTICS
Characteristic PartA PartB PartA/BColor Tan Blue GreenDensity lbs./gal. 14.5 7.8 13.8 (Kg./l) (1.737) (0.935) (1.654)MixingRatio Partsby: Weight 15 1 — Volume 8 1 —PlacementTime@77°F 50minutesina5lb.massPeakExothermicTemperature 170°Fina5lb.mass
Compressive Strength(ASTMD-695) 20,000psi
Tensile Strength(ASTMD-648) 5,500psi
Flexural Strength(ASTMD-790) 7,900psi
Mixed Viscosity(ASTMD-2393) 7,000cps
Heat Deflection Temperature(ASTMD-648) 320°F
Maximum Service Temperature 425°F
Hardness(ShoreD) (ASTMD-2240) 90
Creep Test (ASTMC-1181) 600psi@150°Fcured24hours 1.01x10—3in./in.
Typical Pour Depth 1/4in.-1/2in.(Multiplelayersmaybeusedforthickerpours)
XTRA-TEMP V-100® Atwo-component,100%solids,ep-oxyresinsystemspecificallydesignedfor applications where mechanicalstrengthandveryhightemperaturesta-bilityarerequired.Thisgroutisresistanttomostfuels,oils,water,andattackbyacidsorcausticsolutions.
Thisproductisconvenientlypack-aged inkitscontainingpre-measuredamountsofresin,hardenerandamixingpaddle.Itisalsoavailableinbulk,withthebaseresinpackagedin55gallondrumsandthehardenerpackagedin5gallonpails.
Theplacement time(thetimeyouhavetopourbeforeitsets)willvarywithambienttemperatures.Theplacementtimeat77°Fwillbe50-60minutes.Incoolweatheryouwillhavemoretimetopourmaterialandinhotweatheryouwillhavelesstime.
Curetime(thetimeittakesbeforethegroutdevelops itsultimatephysi-cal properties) is also dependent onambient temperatures and servicetemperature. With the recommendedcuretemperaturethemachinerystartupmaybein24hours.Thegroutmayalsobecuredfor7daysatambienttem-peratureswiththeservicetemperatureprovidingtheheatforthefinalcure.
Consult the specific Material Safety Data Sheets (MSDS) for all safety data.
27
28
ADHESIVE V-100® EPOXY GROUTlOW-TEMP V-100® EPOXY GROUT
ADHESIVE V-100®
Atwo-component,100%solids,epoxyresinsystem.Thisversatile,easy-to-handleadhesivehasapaste-likeconsistency,shortcuretimeandbondstomostsurfaces.
AdhesiveV-100®isidealfor:
● Bondingsteelplatestoconcrete
● Bondingofwood
● Bondingofplastic
● Bondingofceramictiles
● Bondingoffiberglass
LOW-TEMP V-100® Atwo-component(resinandhard-ener),100%solids,solventfree,epoxyresin system designed to be pouredwhenairtemperaturesarebetween25°Fand65°F.Thismakesthisanidealgrout for use in cold climates whereoutdoorpoursarerequired.Optimumpouring range is 45°-55° F which al-lowsforbestworklifeandinstallation.Low-TempV-100®mustbestoredat,orwarmedto,45°-65°F.DonotuseLow-TempV-100®attemperaturesabove65°F;theworklifeistooshortandcrackingmayresult.
Touse,pourthehardenerintotheresinandmixuntilauniformcolorap-
Linear Shrinkage(ASTMD-2566) 0.00021in./in.@40°FHardness (ShoreD)(ASTMD-2240) 95Mixed Viscosity(ASTMD-2393) 20,000cps@40°FGel Time 120min.@40°FWork Time 30min.@40°FCreep Test (ASTMC-1181)600psi@150°Fcured24hours 1.76x10-2in./in.Typical Pour Depth 1/2in.-2in.
PHYSICAL PROPERTIES (CON'T)
● Industrialfillingorpatching
● Verticalandoverheadsurfaces
PACKAGING
AdhesiveV-100® ispackagedinaconvenientkitconsistingofonegallonofresinandonegallonofhardener.Touse,simplymixaportionoftheresinandthehardenerata1:1ratio-by-volumein a separate container. Be sure touseseparatetrowelsfortheresinandhardener.Mixthoroughlyandapply.Donotmixbothcontainerstogetherunlessyouareusingalloftheadhesiveinoneapplication within the allowed worklife.Containerswithunmixedmaterialcanberesealedforfutureuse.Mixedadhesivecannotberesealedforfutureuse.
PLACEMENT TIME Theplacementtimeofthisadhesivematerial (the time you have beforeit sets) will vary according to the airtemperature.Averageplacementtimeat 70°F is approximately 45 minutesfor one (1) pint of mixed material. Incoolerweatheryouhavemoretimetoworkwiththematerial.Inhotweatheryouhavelesstime.
CURE TIME Theaveragecuretimeat70°Fwillbe4-5hours.Airtemperatureaboveand
below70°F,aswellasthetemperatureofthesurfacesonwhichtheadhesiveisbeingapplied,willaffectcure time.Prewarmingthepartsorsurfaceswillacceleratethecuretime,butdonotheatthesurfacesabove100°F.
PACKAGING/YIELD24.5#Kit=.26cu.ft.(450cu.in.)
PHYSICAL PROPERTIES
Compressive Strength (ASTMD-695) 14,000psi
Tensile Strength (ASTMD-638) 5,200psi
Flexural Strength (ASTMD-790) 11,000psi
Tensile Shear Strength (ASTMD-1002) 2,400psi
Heat Deflection Temperature (ASTMD-648) 147°F
Hardness(ShoreD) 90
Gel Time (ASTMD-2471)14floz 1hour@77°F1/16"film 2hours@77°F
Recommended Thickness 1/32in.to1/4in.
pears, usually 2-3 minutes. Pour thismaterialimmediatelyaftermixing;worklifeismuchshorterthanwithstandardepoxy.Forquestionsonspecificapplica-tionspleasecontactUnisorbEngineer-ing.
PACKAGING/YIELD23#Kit=.22cu.ft.(380cu.in.)50#Kit=.47cu.ft.(812cu.in.)
Compressive Strength (ASTMD-695) 9,500psi@40°F 18,700psi@72°FTensile Strength (ASTMD-638) 6,100psiFlexural Strength (ASTMD-790) 10,500psiHeat Deflection Temperature(ASTMD-648) 153°FMaximum Service Temperature 200°F
PHYSICAL PROPERTIES
Consult the specific Material Safety Data Sheets (MSDS) for all safety data.
BASIC APPlICATION TECHNIQUES (EPOXY)
These are the basic applicationtechniquestofollowwhenusingmostUNISORB®Epoxygroutingproducts.RefertothespecificProductDatasheetandinstructionsonthelabelforinforma-tionrelevanttotheproductbeingused.
CONCRETE SURFACE PREPARATION
Remove all oil, grease and con-taminationfromconcrete.Removelooseandweakconcretefromthefoundationsurfaces by chipping down to soundaggregate.Light sandblastingoracidetchingmaybesufficientbutmustbecompletelyneutralizedbeforegrouting.Theconcretemustbedryandhavenowaterinanchorboltholes.
2
DAM PERIMETER LEAVING ADEQUATE VENTING
1
LEVEL MACHINE WITH 1/4" - 3/4" CLEARANCE
4
POUR UNDER MACHINE AND LET HARDEN
3
MIX GROUT (2-3 MINUTES)
MACHINE
BASE
APPLICATION TECHNIQUES FOR EPOXY GROUTING
(cont.)
METAL SURFACE PREPARATION
Base plates or sole plates to begroutedshouldbesandedorblastedtoabaremetalcondition.Ifitisimpossibletogroutwithin8hoursofsandblasting,the surface should be primed with ahigh-qualityepoxyprimer.
FORMING
If not already recessed, dam thegroutareaandcarefullysealtheforms.Aheavybodycaulkingcompoundsuchas RTV Silicone should be used toprovideawatertightcondition,andforeasyremovalafterthegrouthassetup.Installthedamhighenoughtoallowthegrout tobuildat leasta2"head.The
formsshouldbeplacedbetween2-6"awayfromtheperimeterofthemachinebasetoallowfortheairtoescapeandtoprovideforagroutshoulderaroundthebaseplate.
PREPARATION OF EPOXY GROUT
Storethematerialbetween70-80°F.Donotmixuntilreadytopour.ForpotlifeinformationconsultthespecificProductDatasheet.Generally,twopeoplework-ingwiththegrout(onemixingandonepouring)isthebestprocedure.
TWO PART EPOXY
Whenreadytomix thegrout,firstthoroughlypre-mixtheresin.Whilestir-ringtheresin,slowlyaddthehardener.Topreventsplashing,pourinasteadystreamapproximately6"high.Mixingtime should be about 2-4 minutes,dependingonkitsize.Besuretomixcompletelyaroundthepailperimeter,movingthestirrerupanddownandataslightangleuntilauniformcolorappearswithnostreaks.Ajiffymixer,orsimilarstirrer in a variable speed drill worksbestformostepoxygroutingmaterials.Stirrerbladesmustbelongenoughtotouchthebottomofthepail.
THREE PART EPOXY
The threepart formulacontainsaresin,ahardenerandagroutfiller.Whenreadytomixthegrout,pourtheresininadrumofatleast10galloncapacity.Usingajiffymixeroravariablespeeddrill,thoroughlymixthehardenerintotheresin.Slowlyaddthetwobagsofaggregate filler so that all surfacesbecome wet as it is mixed. Continuetomixuntiltherearenodrystreaks.Amortarmixermaybeused,butdonotusearotatingdrum-type.Donotaddwater.
29