Method Statement Epoxy

7/26/2019 Method Statement Epoxy

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N: 850 42 01Author: Marco Poltra

Date: 11/2007

The information contained herein and any other advice are given in good faith based on Sika's current knowledge and experience ofthe products when properly stored, handled and applied under normal conditions in accordance with Sika's recommendations. Theinformation only applies to the application(s) and product(s) expressly referred to herein. In case of changes in the parameters of theapplication, such as changes in substrates etc., or in case of a different application, consult Sika's Technical Service prior to usingSika products. The information contained herein does not relieve the user of the products from testing them for the intendedapplication and purpose. All orders are accepted subject to our current terms of sale and delivery. Users must always refer to themost recent issue of the local Product Data Sheet for the product concerned, copies of which will be supplied on request.

Sika Services AG / Speckstrasse 22 / CH-8330 Pfaeffikon / Switzerland

Tel: +41 44 403 13 73 / Fax: +41 44 403 13 77E-Mail: [email protected] / www.sika.com

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Method Statement

Sikadur

-42

Epoxy Resin based Grout

Corporate Construction

Storage Place: ICC BU ContractorsKey Words:Sikadur-42, Grouting, Epoxy Resin Grout, Reactive Resin Grout

Scope:

Method statement for the application of:Sikadur-42, a range of 3-part, Epoxy Resin based Grouts
mailto:[email protected]://www.sika.com/http://www.sika.com/mailto:[email protected]


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Table of Contents:

1. System Description ..............................................................................31.1. References......................................................................................................31.2.

Limitations .......................................................................................................4

2. Products................................................................................................52.1. Pre-Project Preparation ...................................................................................6

3. Safety Measures on Site ......................................................................73.1. Surface Preparation.......................................................................................103.2. Formwork ......................................................................................................143.3. Mixing............................................................................................................17

4. Application / Installation ....................................................................214.1. Application Method........................................................................................284.2 Additional works ............................................................................................ 37

5. Inspection, Sampling, Quality Control..............................................38

6. Equipment Tools..............................................................................41

7. Disclaimer and address of Sika Company .......................................43


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1. System Description

Sikadur-42 Epoxy Grouts are used for:

High strength grouting and fixing of:

Starter bars

Anchors

Fasteners

Tie rods

Crash barrier posts

Fence and railing posts

Under grouting and bedding of:

Precision seating of base plates

Machine bases, base-plates for light and heavy machinery including heavyimpact and vibrating machinery, static engines, compressors, pumps, presses,etc.

Bridge bearings

Mechanical joints (i.e. road/bridge/deck types, etc.)

Sleeper less, direct rail fixing:

Crane tracks

Light rail and permanent way in tunnels

Light rail and permanent way over bridges

Sikadur-42 PT:

To protect the anchorages of post-tensioning tendons or bars on segmentalbridge projects

Precision seating of base plates

Grouting under equipment where access is available

1.1. References

To ensure the correct application of Sikadur-42, please refer to the following

documents:

PDS (Product Data Sheet)

MSDS (Material and Safety Data Sheet)

API 686 Chapter 5*

* Recommended Practices for Machinery Installation and Installation Design issuedby the American Petroleum Institute


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1.2. Limitations

According to the Product Data Sheet, certain limitations are given:

Layer Thickness (minimum and maximum)

Substrate temperature

Ambient temperature

Material temperature

Substrate moisture content

Dew point conditions

Sikadur-42 is a vapour barrier when cured

The last lift/layer must be kept at


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2. Products

Sikadur-42 HESikadur-42 HE is a three-component, high performance, high precision, solvent-free,moisture tolerant, epoxy resin based grouting system. For use at ambient andsubstrate temperatures between +5C and +30C.

Sikadur-42 LESikadur-42 LE is a three-component, high performance, high precision, lowexothermic, solvent-free, moisture tolerant, epoxy resin based grouting system. Foruse at ambient temperatures between +20C to +45C and on substrates from +15Cto +45C.

Sikadur-42 MP Normal and SlowSikadur-42 MP Normal is a three-component, multi purpose, solvent-free, moisturetolerant, epoxy resin based grouting system. For use at substrate and ambienttemperatures between +10C and +30C.

Sikadur-42 MP Slow is a three-component, multi purpose, solvent-free, moisturetolerant, epoxy resin based grouting system. For use at substrate and ambienttemperatures between +20C and +40C.

Sikadur-42 PT

Sikadur

-42 PT is a three-component, solvent-free, moisture tolerant, epoxy resinbased, post tensioning anchorage protection system. For use at substrate and ambienttemperatures between +5C and +30C.

12 kg Packaging of Component A + B + C Packaging A + B

Larger volume packaging is available and this varies from country to country. Please

contact your local Sika Company for sizes and packaging availability.


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2.1. Pre-Project Preparation

The most important preparation steps for installation of Sikadur-42 Epoxy Grout are::

- Accurate calculation of the amount of Epoxy Grout needed- Check temperatures during the grouting procedure Select the correct grade of

Sikadur-42 type for this temperature and application- Check the potlife of Sikadur-42 at the temperatures and compare it with the

volume and geometry of the grouting area. Is it possible to use this quantitywithin this potlife? Also select the appropriate packaging sizes

- Check the geometry of the grouting area and confirm max. layer thickness of therelevant Sikadur-42 type in the Product Data Sheet (PDS). Grouting in severallayers or lifts may be necessary. Refer to chapter 4.1 in this method statement

- Make a programme for the whole procedure. Check the staff available and trainedto mix the material fast enough to maintain a continuous work and grout flow forthis work. The most critical bottleneck during grouting is frequently a lack of humanresources (for a continuous work flow which is essential for a successful grouting)

- Select mixing tools and equipment with sufficient capacity. Confirm power type andavailability for the mixing equipment

- Calculate the time required for preparing and mixing the epoxy grout and includethis in the programme. In many cases, at least two working teams are necessary tosupply the feed hopper and to maintain the work flow. Do not reduce the mixingtime, even when in a hurry Refer to chapter 3.3. Important Notes: This is one ofthe most common mistakes in grouting work

- Check the substrate in advance. Ensure that the substrate is in good condition andthat all cement laitance, oil, dust, dirt and any other foreign material is removed. It

must also be dry and free from any standing water- Check the cleanliness and preparation of the base plate and any metal surfaces.- Ensure that all necessary tools and equipment are available on site (mixers,

trowels etc.)- Check the protective health and safety equipment is available (clothing, gloves,

goggles etc)- Check the formwork requirements and design it according to chapter 3.2 of this

method statement. Prepare the formwork with release agent to prevent bondingwith the grout and all other areas where bonding with the grout is not necessary.Any release agent, wax etc. is strictly forbidden from contact or spillage in all otherareas, this must also be checked

- Check there is adequate sealing (e.g. Sikaflex-11 FC+) of the formwork to prevent

leakage- Design and then ensure there are enough places for air release within the grouting

area (as outlined in Section 3.2 Page 15 of this Method Statement)- Ensure adequate protection of adjacent equipment and finished floor areas etc

around the grouting area

Please also check the Installation Record & Checklist. This document helps toensure that all of the important steps for successful Grouting are complied with.


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3. Safety Measures on Site

Personal Protection:

The following symbols are typical of the internationally required labelling for epoxyresins and hardeners. In accordance with these, the products should be stored andapplied according to the appropriate local regulations. Please also observe any otherrelevant local regulations (Refer to local PDS and MSDS).

The following protective equipment is essential for anyone working with any epoxyresin based products and these instructions must be strictly adhered to:

Wear protective overalls Wear safety goggles Wear protective gloves

In addition to protective clothing it is also recommended to use a barrier cream on theskin. The use of a barrier cream is more useful and effective than often reputed, theyare inexpensive, convenient, and protect well if they are not frequently flushed withsolvents. However, barrier creams are only a supplement to and not a replacement forprotective gloves, so always wear gloves. Always ensure there is no contaminationinside gloves before reusing them.

Ensure sufficient ventilation during application in closed or confined spaces.

If any epoxy resin or hardener component gets on clothing, remove the garment atonce. The friction of resin-saturated fabric on the skin can cause serious chemicalburns. Wash your exposed skin occasionally during the workday and immediately ifany epoxy gets on it. Avoid using solvents since they can help epoxy materialpenetrate in to the skin and solvents themselves are aggressive and harmful to theskin. If water is no more available at any time or shorten, then clean the contaminationwith sand instead, it works well. Certain hand cleaners also work without harmfuleffects. Citrus skin cleaners, for example, are effective and mild. Soap and water takestime, but also eventually works for small areas.

Corrosive IrritantDangerous forthe environment


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Avoiding skin contact by keeping tools and equipment clean is one of the best ways toprotect oneself. Remember, epoxies are very tacky which is partly why they work sowell in construction, so it is important to keep them from sticking to your people on site.

Despite safety precautions, with any instances of skin contact rinse immediately with

clean water and use warm water and soap to thoroughly clean the skin.

A good skin cleaner:

Skin cleanerSika Topclean T

No epoxy resin applications should ever proceed without sufficient water beingadjacent and available for eye washing. If adequate clean water is not provided thenthe project should not commence, no matter what the urgency. Numerous workers andobservers have suffered injury due to resin entering their eyes when there was nowater available to clean them. If a professional eyewash kit is not available, then at thevery minimum one quart of clean water must be present. The water can be in a pail,plastic jug or via a hosepipe, but it must always be directly adjacent to the grouting

operation ie a water source on the opposite side of the building or site is not goodenough. Safety glasses or other eye protection obviously help those doing the workbut they can also create a false sense of security. Do not take risks with health!

Professional eyewash kit available

In the event of any spillage or contact into the eyes, always seek medical adviceimmediately after rinsing and cleaning the eyes with the clean water


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Dependent on local regulations respiratory masks may be required. Please observe allrelevant local regulations.

Breathing protection required

The following equipment is also generally recommended on construction sites:

Wear hard hats Wear safety shoes withsteel toe caps

Wear ear protection. Foruse of mixing equipment please refer to themanufacturers advice

Please refer to the local country regulations and the specific construction siterequirements.

Disposal:

Brush away and remove any excess grout into appropriate containers for disposalbefore it has hardened.

Hardened epoxy resin can be disposed of with other combustible waste in a wasteincineration plant.In no circumstances, burn the epoxy in an open fire due to the potentially dangerousgases which can be released.

Uncured epoxy must be disposed of as hazardous waste. It is forbidden to mix it with

conventional waste.

Always dispose of excess or waste materials in accordance with local regulations.

Cleaning of Tools:Uncured material can be removed with Sika Colma Cleaner.

Cured material can only be removed mechanically (or with heat).


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3.1. Surface Preparation

Requirements for the substrate:

Weak concrete must be removed and surface defects such as blowholes andvoids must be fully exposed.

Mortar and concrete must be older than 28 days (dependent on minimumstrength requirements).

Confirm the substrate strength (concrete, masonry, natural stone etc). If indoubt, make a test area first.

The substrate surfaces must all be sound, clean and free from contaminantssuch as dirt, oil, grease, rust, existing surface treatments and coatings etc.

All loose particles must be removed.

Substrate must be dry or mat damp and free from any standing water, ice etc.

If in doubt, make a test area first and confirm withbond strength testing equipment, as shown onthe left.(Proceq or similar)

Surface preparation:

Concrete, mortar, stone:These substrates must be prepared by e.g. blastcleaning to be free from cementlaitance, ice, standing water, grease, oils, old surface treatments or coatings and allloose or friable particles must be removed to achieve a contaminant free, opentextured surface.

Steel:Must be cleaned and prepared thoroughly to an acceptable quality standard equivalentto SA 2.5 i.e. by blastcleaning and vacuum. Avoid dew point conditions.

All anchor pockets or sleeves must be free of water. Apply the grout as immediately aspossible after preparation and cleaning to prevent re-oxidizing / rust formation on thesurfaces.


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For optimum results:When grouting areas or equipment that is sensitive to vibration, it is recommended thatthe contact surfaces are prepared according to the latest edition of the AmericanPetroleum Institutes Recommended Practice 686 Machinery Installation and

Installation Design, Chapter 5.

Baseplates:

The underside of the base plate must be clean and free from oil, grease, rust,scale or other loosely adherent materialIt is recommended that the underside and edges of the base plates are coatedwith Sikagard-63N to prevent rust formation and ensure a good bond to thegrout.

Substrates:

There are two main procedures for substrate preparation: blastcleaning and scabblingwith chisels.

1. Method:Substrate preparation by blastcleaning:

Substrate preparation byblastcleaning


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2. Method:Substrate preparation by scabbling with a chisel:

With scabbling it is possible to obtain a larger specific surface area which is then incontact and bonded to the epoxy grout, which also creates a higher mechanical bond

between the epoxy and the concrete. However, scabbling also requires blastcleaningafterwards to remove any loose or friable particles such as fractured aggregatesremaining on the surface.

Substrate Preparation by scabblingwith a chisel

After scabbling, the substrate canhave a reduced bond strengthpotential due to the impact cracksand micro cracks in the concrete.

(see red circle)

All of the cracked, friable materialand any residual cement laitance(see also in the red circle) must beremoved by blastcleaning or highpressure water-jetting afterscabbling

After scabbling:Remove friable material etc. byblastcleaning or.


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.high pressure water-jetting

Protection of adjacent steel edges and surfaces:

Protect adjacent steel surfaces withtape

Cleaning:

Remove dust, and any other loosematerial after blastcleaning or waterjetting.Finally brush the substrate andremove the residual dust with avacuum cleaner.


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3.2. Formwork

Forming:The flowable consistency of the Sikadur-42 epoxy grout material requires the use ofpermanent or temporary forms to contain the material until it has hardened ie around

base plates, for example. In order to prevent leakage or seepage, all of these formersmust be sealed. Apply polyethylene film or wax / release agent to all forms to preventadhesion of the grout. Prepare the formwork to allow and maintain more than 100 mmliquid head to facilitate placement. A grout box equipped with an inclined troughattached to the form work will enhance the grout flow and minimize any airencapsulation.

Example of an excellent sealant for formwork: Sikaflex-11 FC+

Pour the mixed grout into the prepared forms from one or two sides only to prevent air

entrapment. Maintain the liquid head to ensure intimate contact to the underside of thebase plate. The minimum void depth to be filled with Sikadur-42 epoxy grout beneaththe base-plate, should be at least10-25 mm; refer to the specific Product Data Sheetfor more detailed information.Where the void beneath the base plate is greater than the maximum allowable groutthickness (please refer to the Product Data Sheet) place the epoxy grout in successivelayers or lifts once the preceding lift has hardened and cooled see chapter 4.1

Pouring side: Erect formwork approx. 200 mm from the base plate edgeOpposite of the filling side: Erect the formwork at least 50 mm above the grouting level

Opposite the filling side Pouring side

FeedingHoppersystem

200mm

50mm


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Air release:

Make some air release holes (tubes or holes etc) at every enclosed high point withinthe machinery/equipment. (See sketches below)

First step:Release holes for enclosed air

Second step:Epoxy Grout flows due to hydrostatic pressure from the feed hopperuntil the correct fill level is attained

Air release

Control: Fill levels must be even

EnclosedAir


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Checklist:

Before fixing any formwork, ensure that the area to be grouted is clean.

The formwork itself must be constructed to be leakproof and prevent any

possible grout loss. This can be achieved by using foam rubber strips or asuitable sealant such as Sikaflex-11FC+, beneath the formwork, and in anyjoints on the formwork.

The formwork should also be constructed in such a way as to keep the final,unrestrained surface area of the grout to a minimum, to avoid any possibleproblems with unrestrained surface shrinkage cracking at a later stage.

For free flowing grout application, it is essential to provide a hydrostatic headof the grout. A feed hopper is recommended.

Pouring side: Erect formwork approx. 200 mm from the base plate edge. (seesketch above)

The grout should be poured from the shortest distance across the base plate

The formwork should be fixed in such a way as to allow easy stripping,

without causing damage or stress on the grout. All dust, dirt and any other foreign materials have to be removed from the

grout area before the last piece of formwork is fixed and sealed.

Opposite the grout filling side: Erect the formwork at least 50 mm above andbeyond the base plate edge. (see sketch above)

Make air release holes at the highest points within any enclosed areas of themachinery/equipment.


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3.3. Mixing

Pre-batched units:

Add all of component B (hardener) to component A(resin).Make sure the hardener container is fully emptiedinto the resin component. (Use a spatula.)

Mix both components thoroughly with a low speedelectric mixer (300 - 400 rpm).Mix for at least 3 minutes avoiding aeration whilstmixing, until the material becomes uniformlyblended in colour and viscosity.

Place the mixed epoxy into an appropriate groutmixing vessel which is big enough to then addComponent C (powdered aggregate filler) toproduce the whole finished volume of the product(A+B+C Components).


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Slowly add the contents of the bag of component C(to keep air entrapment at a minimum). Note: someof Component C may be omitted to meet defined

higher flow characteristics. Please refer to thecorrect mixing ratios written in the individual ProductData Sheet)

Mix for approximately 5 minutes until uniform and

homogeneous so that the C-Component isthoroughly mixed and blended with the resin andhardener.

Important Notes:Always mix only that quantity of Sikadur-42 grouts that can be used within its potlife.Never reduce the mixing time.

Choose an adequate mixing paddle to mix the components. Refer to MixingTools in this chapter.


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Bulk packaging (not pre-batched):

First, stir each component thoroughly. Add Components A and B together in thecorrect proportions (measured by weight) into a suitable grout mixing vessel. Then

continue the procedure as described above for the pre-batched units

Important Notes:

Never mix Component A and B without adding component C !!!(as the exothermic reaction between A and B alone generates excess

heat and smoke)

Checklist:

Choose adequate mixing paddle for proper mixing and to avoid airentrapment

Mix Components A and B in the pail of Component A for 3 min with a paddleattached to a low speed drill (300-450 rpm)

Do not thin with solvents. Solvents will prevent proper curing and change themechanical properties

Place the mixed epoxy into an appropriately sized grout mixing vessel toaccommodate and mix the whole of Component C

Do not change the mixing ratio! refer to the product data sheet for theapproved variations in the mixing ratio

Slowly add the entire contents of component C and mix until the grout ishomogeneously blended (approx. 5 min) and a completely uniform colour

Leave Sikadur-42 to stand and mature in the mixing vessel for severalminutes (approx. 2-3 minutes) until the majority of entrained air bubbles havedispersed before the grouting procedure begins

Avoid splitting pre-batched units to mix. Mix complete pre-batched units only

Never reduce the stated mixing time. This can result in reduced flowcharacteristics and inconsistent properties in the cured grout

Component C must be kept dry


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Mixing Tools:

For optimum mixing results use a mixing paddle similar to the ones shown below:

With this design of mixing paddle, you can obtain the best resultsto mix Resin and Hardener (A+B Component)

With this design of mixing paddle, you can obtain the best resultsTo mix (A+B) and C-Component (Fillers)

For additional information on high performance mixing tools and equipment:See chapter 6.


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4. Application / Installation

First: Refer the following points to the Product Data Sheet

Material Conditioning prior to the works

Substrate and ambient temperature

Minimum grout depth

Maximum grout depth

Checklist:

In every case, the last lift must be kept to a maximum 50 mm

For specific bolt grouting applications please refer to Sika Technical Services

For proper seating, allow the grout to rise above the bottom (approx. 3 mm) ofthe base plate (refer to page 32 of this method statement)

Colder and hotter ambient substrate or material temperatures will influence thecuring and flow characteristics of Sikadur-42

Do not subject epoxy grouts to sudden temperature changes especially duringearly curing stages

Contact Sika Technical Services for advice on control joint spacing for largebase plate grouting projects

Do not vibrate the Epoxy Grout during placing

Wherever possible unrestrained shoulders are to be avoided. These have atendency to crack and/or debond

For optimum bond strength to the substrate, first apply a small amount of epoxygrout to the bottom and the shoulder of the grouting area to wet these parts.Brush this well into the substrate if possible. Then apply the rest of the firstlayer of the Sikadur-42 epoxy grout as soon as possible e.g. application iswet on wet

When applied to mat damp concrete, brush the grout well into the substratefirst.


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Working at high temperatures:

It is recommended when working with Sikadur-42 at temperatures above 35C, thatthe following guidelines should be observed:

Prior to use store the unmixed materials in a cool, preferably temperaturecontrolled environment, avoiding exposure to direct sunlight or other heatsources.

Refer to the data sheet of the specific product and closely follow theinstructions in the section storage conditions.

Keep all equipment cool, arranging shade and protection where necessary. It isespecially important to keep cool all surfaces that will come into direct contactwith the material.

Try to avoid application during the hottest times of the day.

Provide sufficient material, plant and labour to ensure that the application is acontinuous process and that the grout does not stop moving during flowapplication process.

Important Note: When both the materials and/or the substrates are too hot, the potlifewill decrease dramatically!

Working at low temperatures:

It is recommended when working with Sikadur-42 at temperatures below 15C, thatthe following guidelines should be observed:

Prior to use store unmixed materials in a warm environment, preferablytemperature controlled and avoiding exposure to frost or temperatures below+5C.

Cold temperatures will decrease the flow properties of the grout.

Refer to the data sheet of the specific product and closely follow theinstructions in the section storage conditions.

Avoid condensation! Ambient temperature during application must be at least3C above dew point.

Avoid water or ice formation on any surfaces.

Grouting of Anchors: Heat up the steel (20-35C) to activate the Epoxy grout.

Note: When both the materials and/or the substrates are too cold, the potlife willincrease, the flow will also be restricted and curing will be delayed!


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Dew Point:

It is important to pay close attention to avoiding dew point conditions. The applicationtemperature must exceed the dew point by at least 3C.

Definition of the Dew Point:

To check the dew point the following methods can be used: digital electronicinstruments (see graphic) to measure the air temperature, the surface temperature ofthe component, the base plate for example and the relative humidity, but you can alsouse traditional analogue instruments.

Analogue instrument Electronic instrument Simple slide rule

With analogue instruments you will have to read the temperature and humidity fromthese conventional instruments. The dew point is then found by reference to tables ora simple slide rule guide (as supplied to customers by some Sika companies).


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If no specific dew point instruments are available on the construction site you can stilluse the following table to determine the dew point from the temperatures and humidity.

(orange)

Measured ambient temperature in [C](grey)

Measured relative humidity [%]

(yellow)

The point of their intersection in the table below is the dew point surface temperature in [C]

Example: Ambient temperature: 34C, relative Humidity (rh): 60%result the dew point surface temperature is: 25,1C.

Dew Point Temperature [C]

relative Air Humidity [%]AmbientTemperature

[C]30% 35% 40% 45% 50% 55% 60% 65% 70% 75% 80% 85% 90% 95%

45 23,4 26,0 28,2 30,3 32,1 33,8 35,4 36,9 38,2 39,5 40,7 41,9 43,0 44,0

44 22,5 25,1 27,3 29,4 31,2 32,9 34,5 35,9 37,3 38,6 39,8 40,9 42,0 43,0

43 21,7 24,2 26,5 28,5 30,3 32,0 33,5 35,0 36,3 37,6 38,8 39,9 41,0 42,0

42 20,8 23,3 25,6 27,6 29,4 31,1 32,6 34,0 35,4 37,8 37,8 38,9 40,0 41,0

41 20,0 22,5 24,7 26,7 28,5 30,1 31,7 33,1 34,4 35,7 36,8 38,0 39,0 40,0

40 19,1 21,6 23,8 25,8 27,6 29,2 30,7 32,1 33,5 34,7 35,9 37,0 38,0 39,0

39 18,2 20,7 22,9 24,9 26,7 28,3 29,8 31,2 32,5 33,7 34,9 36,0 37,1 38,0

38 17,4 19,9 22,0 24,0 25,7 27,4 28,9 30,3 31,6 32,8 33,9 36,1 36,1 37,1

37 16,5 19,0 21,1 23,1 24,8 26,4 27,9 29,3 30,6 31,8 33,0 34,0 35,1 36,1

36 15,7 18,1 20,3 22,2 23,9 25,5 27,0 28,4 29,6 30,9 32,0 33,1 34,1 35,1

35 14,8 17,2 19,4 21,3 23,0 24,6 26,1 27,4 28,7 29,9 31,0 32,1 33,1 34,1

34 14,0 16,4 18,5 20,4 22,1 23,7 25,1 26,5 27,7 28,9 30,0 31,1 32,1 33,1

33 13,1 15,5 17,6 19,5 21,2 22,7 24,2 25,5 26,8 28,0 29,1 30,1 31,1 32,1

32 12,2 14,6 16,7 18,6 20,3 21,8 23,2 24,6 25,8 27,0 28,1 29,2 30,1 31,1

31 11,4 13,7 15,8 17,7 19,3 20,9 22,3 23,6 24,9 26,0 27,1 28,2 29,2 30,1

30 10,5 12,9 14,9 16,8 18,4 20,0 21,4 22,7 23,9 25,1 26,2 27,2 28,2 29,1

29 9,7 12,0 14,0 15,9 17,5 19,0 20,4 21,7 23,0 24,1 25,2 26,2 27,2 28,1


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28 8,8 11,1 13,1 15,0 16,6 18,1 19,5 20,8 22,0 23,2 24,2 25,2 26,2 27,1

27 8,0 10,2 12,2 14,1 157 17,2 18,6 19,9 21,1 22,2 23,3 24,3 25,2 26,1

26 7,1 9,4 11,4 13,2 14,8 16,3 17,6 18,9 201 21,2 22,3 23,3 24,2 25,1

25 6,2 8,5 10,5 12,2 13,9 15,3 16,7 18,0 19,1 20,3 21,3 22,3 23,2 24,1

24 5,4 7,6 9,6 11,3 12,9 14,4 15,8 17,0 18,2 19,3 20,3 21,3 22,3 23,1

23 4,5 6,7 8,7 10,4 12,0 13,5 14,8 16,1 17,2 18,3 19,4 20,3 21,3 22,2

22 3,6 5,9 7,8 9,5 11,1 12,5 13,9 15,1 16,3 17,4 18,4 19,4 20,3 21,2

21 2,8 5,0 6,9 8,6 10,2 116 12,9 14,2 15,3 16,4 17,4 18,4 19,3 20,2

20 1,9 4,1 6,0 7,7 9,3 10,7 12,0 13,2 14,4 15,4 16,4 17,4 18,3 19,2

19 1,0 3,2 5,1 6,8 8,3 9,8 11,1 12,3 13,4 14,5 15,5 16,4 17,3 18,2

18 0,2 2,3 4,2 5,9 7,4 8,8 10,1 11,3 12,5 13,5 14,5 16,4 16,3 17,2

17 -0,6 1,4 3,3 5,0 6,5 7,9 9,2 10,4 11,5 12,5 13,5 15,5 15,3 16,2

16 -1,4 -0,5 2,4 4,1 5,6 7,0 8,2 9,4 10,5 11,6 12,6 14,5 14,4 15,2

15 -2,2 -0,3 1,5 3,2 4,7 6,1 7,3 8,5 9,6 10,6 11,6 13,5 13,4 14,2

14 -2,9 -1,0 0,6 2,3 3,7 5,1 6,4 7,5 8,6 9,6 10,6 12,5 12,4 13,2

13 -3,7 -1,9 0,1 1,3 2,8 4,2 5,5 6,6 7,7 8,7 9,6 10,5 11,4 12,2

12 -4,5 -2,6 1,0 0,4 1,9 3,2 4,5 5,7 6,7 7,7 8,7 9,6 10,4 11,2

11 -5,2 -3,4 1,8 -0,4 1,0 2,3 3,5 4,7 5,8 6,7 7,7 8,6 9,4 10,2

10 -6,0 -4,2 2,6 -1,2 0,1 1,4 2,6 3,7 4,8 5,8 6,7 7,6 8,4 9,2

9 -7,6 -5,6 -3,9 -2,3 -0,9 0,5 1,7 2,8 3,8 4,8 5,7 6,6 7,5 8,2

8 -8,5 -6,5 -4,8 -3,2 -1,8 -0,5 0,7 1,8 2,9 3,8 4,8 5,6 6,5 7,2

7 -9,4 -7,4 -5,7 -4,1 -2,7 -1,4 -0,2 0,9 1,9 2,9 3,8 4,7 5,5 6,3

6 -10,2 -8,3 -6,6 -5,0 -3,6 -2,7 -1,4 -0,2 1,0 1,9 2,8 3,7 4,5 5,3

5 -11,1 -9,2 -7,5 -5,9 -4,5 -3,3 -2,1 -1 0,0 1,0 1,9 2,7 3,5 4,3


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1. Formwork2. Feed Hopper Chute

3. Substrate (e.g. Concrete)4. Anchor Bolt5. Equipment Base Plate (e.g. steel)6. Air Release Hole (if necessary)7. Sikadur-42 Epoxy Grout

= Grout flow direction

444

5

6 61

3

7

2


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1. Formwork2. Feed Hopper Chute3. Substrate (e.g. Concrete)4. Anchor Bolt5. Equipment Base Plate (e.g. steel)6. Air Release Hole (if necessary)7. Sikadur-42 Epoxy Grout

= Grout flow direction

1 66

4

5

3

2

7


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4.1. Application Method

Grouting of Bolts:

A common application with epoxy resin grouts is heavy dutybolt anchoring on stanchion bases for example.

For this application the following issues are important:

Bolt holes or fixing pockets must be blown clean of any dirt or debris.

All anchor pockets or sleeves must be dry and free of standing water.

Ensure that any enclosed air pockets are released using preformed holes orby inserting a wire and move it to lance the air pockets.

Anchor Bolts for Machinery and Equipment:

Anchor bolts for machinery and equipment need a specialprocedure:

Anchor bolt box outs or sleeves should be thoroughly cleaned of all debris and canbe filled with a self leveling, flowable Sealant (e.g. Sikaflex-228, Sikaflex 2CSL or

similar). The anchor bolts should be wrapped with a f lexible insulation tape/materialabout 6 mm in thickness to prevent bonding of the grout to the anchor bolt. Thisinsulating material should extend from the top of the concrete to the underside of thebase plate.

Equipment Base Plate

Tape/foam Insulation

Sikaflex(Self Leveling)

Concrete Base

Epoxy Grout

Anchor Bolt

Stretching Length


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Preventing Grout Edge Curling:

Problem of Edge curling:

The system at

thermal equilibrium

The system during

the cooling cycle

The system during

the warming cycle

= tensile or compressive stress, due to thermal expansion.

The Solution for Edge curling:

The Causation The Solution

Equipment Base

Epoxy Grout

Crack

Concrete Base

System warming up

Design X less than Y

X < Y

It is recommended that the exposed edge distance (X) of the epoxy grout from thebase plate to the formwork be kept less or equal to the thickness (Y) of the grout. Thiswill eliminate edge curling of the grout.

Y

XHeat Flow

Grout

Concrete

CrackDevelops

Crackcloses


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Placing:

It is essential that the grout mixing capacity, material supply and labour availability issufficient to enable the grouting operation to be carried out smoothly and continuously.

Grouting from the shortest side:

Grouting from the shortest distanceacross the base plate

Do not grout from the longdistance across the base plate

Grouting down / with any slope or decline:

Grouting down along the slope Do not grout against/up the slope

Grout from one side only:

Grouting from one side Do not grout from both sides


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Stagnated Material:

Freshly applied grout which has temporarily stopped moving can be reactivated andkept moving by using a suitable steel chain. see picture below.

Pull the chain slowly not abruptly!

Note: This is only for reactivating the material to keep it moving, not for pulling/placingthe material, the material is designed to flow by itself. Do not break the front or thetongue of the grout with the chain!


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Height of the Epoxy Grout

Place sufficient epoxy grout in the forms for it to rise slightly above the underside(approx. 3 mm) of the base plate.

It is recommended that during placement of the epoxy grout, the level of the grout hasto be slightly above the level of the bottom of the base plate to ensure complete fill ofthe base. The final height of the epoxy grout should be finished level with the bottom ofthe base or only slightly higher.This will eliminate any subsequent breaking off or edge spalling of the grout shouldthe equipment be subjected to a rapid increase in temperature later on.

Fresh Epoxy Grout after placing

Cured Epoxy Grout

~3mm

Equal withbaseplate


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Checklist:

Prior to placement, ensure that all surfaces are dry

Any bolt pockets must themselves be grouted prior to grouting between the

substrate and the base plate. Grout across the shortest width of the equipment/base

Place the grout down/along any slope, not against/up

Continuous grout flow during the grouting operation is essential. Sufficientgrout must be available prior to starting, and the time taken to pour a mixedbatch must be regulated to the time taken to prepare the next one.

The mixed grout must be poured from one side only to eliminate theentrapment of air. A grouting head must be maintained at all times so that acontinuous grouting front is maintained.

When the grout reaches the open side of the formwork and rises above theunderside of the base plate, pouring should continue slowly down the lengthof the base plate until completed.

Ensure, that the hydrostatic height of the grout does not decrease to the levelof the bottom of the base plate; keep it above this level. The material in thefeed hopper should be continuously fed and supplied.


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Placing grout in several layers:

1. Chemically Bonded (without mechanical adhesion)

Epoxy on epoxy achieves a chemical bond with cross linking that is very strong. Toachieve this high bond strength between the layers, the following layer should be

applied as soon as possible, but the prior layer has to be allowed to cool downcompletely first.

Grouting of the first layer

Applying the second layer as soon as possible after the first layer, but waitinguntil the first layer has completely cooled down to the ambient temperature

Applying the third layer, after the second layer has again cooled down. Etc.

1. Layer 2. Layer 3. Layer

Keep the surfaces absolutely clean (free from dust, water etc.) until the next layer ofgrout is applied.The last lift/layer must be kept to a maximum thickness of 50 mm.

2. Mechanically Bonded (with mechanical adhesion)Mechanical adhesion is obtained by filling each layer with some additional coarseaggregate to excess so that it is not completely immersed in the layer. If the secondlayer has a thickness of 4cm, the exposed aggregate should be approx 1-2cm abovethe level of the first layer (like an iceberg in the sea).

Additional note: This coarse aggregate also helps to reduce the heat from theexothermic reaction, because some of the heat is absorbed by the aggregateThe aggregate must be complete dry. Place the aggregate within the potlife.

1. Layer Additional aggregatebroadcast in 1. Layer

2. Layer

Additional aggregatebroadcast in 2. Layer

3. Layer Additional aggregatebroadcast in 3. Layer

Keep the surfaces absolutely clean (free from dust, water etc.) until the next layer ofgrout is applied.The last lift/layer must be kept to a maximum thickness of 50 mm.


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The Placing of large volumes:

Problem:The flow of the material should never stop and the hydrostatic pressure should always

be maintained. If the grouting area is too large for this in a single operation, thefollowing procedure could be a solution:

Solution:

Divide the area and make several lanes (e.g. approx 1m width) using woodenslats with foam block (open celled) or a sealant tape (with enough thickness)on the top and bottom of the slats (so they can be removed after grouting)

Apply release agent on the wooden slats to remove the slats afterwards easily.After the removing of the slats be aware, that no release agent is on theshoulder of the epoxy grout before applying the second step.

Divide the whole area into these sections as appropriate Fill the only the odd and not the even sections numbers first

The even numbers (the next sections between) can be grouted as soon as thegrout in the odd sections has cured and the slats have been removed. (Seethe diagrams on the next page also)

Example of grouting in several alternate sections

Epoxy GroutLanes

PreparedSubstrate


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The Procedure for Grouting in several lanes:

Plan view step 1 (below)

Plan view step 2 (above)

Cross section step 1 + 2 above


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4.2 Additional works

Control Joints:

Control joints (expansion joints) can be installed using inch thick closed cell

polystyrene/Styrofoam. The control joint should extend from the inside of the form to ashort distance past the inside of the base frame.It is not necessary for the control joint to extend across the entire base. Placing of theexpansion joints should be located at the cross members of the base.


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5. Inspection, Sampling, Quality Control

Quality Control:

For optimal quality controlgrout some test specimensusing the same material asused for the grouting work.

Test afterwards e.g. measurethe compressive strength, orstore these as retainedsamples for any futureevaluation or requirements.

Example:Retained samples according toASTM C 579 as shown in thepicture.Specimen size: 2 inch or 5cmcubes

Check from every side of the

grouted bearing plate (with alarge nail or similar tool), thatthe grout level is full below theplate and not just at theshoulder before stopping thegrouting flow and procedure.(See sketch below)


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Surface:

After a certain minutes afterthe placing of the grout:

When there are a few airbubbles on the surface airentrainment, break the bubbleswith a fine brush (within theopen time, before final curingof the material).Note: Avoiding air entrainmentand allowing entrapped air toescape is very important toprevent any bubbles formingand reducing the bond strength

under the base plate

Protection:

On completion of the grouting operation, all of the exposed and unexposed areas ofgrout should be protected from direct sunlight and heat gain by providing shade overthe whole area.

Also protect the grouted area from rain, dust etc.

Formwork:

If the formwork was well prepared with release agent as recommended earlier, itshould now be easy to remove.


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Removal of cured / hardened material

Rotary abrasion with a variety of sanding and grinding discs is the most commonremoval method. The more aggressive the method, the faster the removal rate will be

and the rougher the final surface achieved. Abrading is slow and generates a greatdeal of dust unless a vacuum device is attached to the grinder - these attachments arereadily available now and are efficient enough to allow grinding where necessary, evenin the food processing and other clean environments. Incidentally, coarse abrasivediscs seem to generate less dust than finer discs, which actually tend to polish thesurface.

Flexible scrapers such as those used in mechanical chisels / chipping hammers alsocan be used to remove the excess epoxy. They always work well, but they work beston smooth floor and wall surfaces.

Another method is by heating the epoxy grout followed by scraping. On larger areas

this works well using two operatives, one slightly ahead warming the epoxy, the otherslicing the material from the surface with a clean sharp tool. Use a weed burning hotair gun or similar. The initial efforts may be clumsy until the heating and scraping aresynchronized, but you can expect high production eventually, with a good finishedappearance if the underlying concrete is smooth.

If using large hot air burners or grinding with some dust is not acceptable, considerusing a small electric hot air gun such as a membrane hot air welding tool (Leister).Production is slower, but disruption and odor are negligible.

No matter which procedure is used or what the operatives skill level is, the concretesurface will probably be damaged in some way after removing the epoxy. Do not agree

to grouting specifications that prohibit any damage or blemishes on the surface.

Generally it is advisable to perform a trial first.


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6. Equipment Tools

Mixing Paddles:

twisted bar Collomix Type WK

Mixers:

Collomix CK Duo Collomix CK Collomix XM(with exchangeable Mixers)

For more information: www.collomix.comThe appropriate mixer should be selected according to the quantity of epoxy grout andthe filler content used.For the higher filled epoxy grouts (such as Sikadur-42 LE) and larger quantitiesmixing equipment with more power is obviously necessary.

Vacuum Cleaner

KrcherIndustrial Vaccum Cleaner

For more information: www.kaercher.com
mailto:[email protected]://www.sika.com/http://www.collomix.com/http://www.kaercher.com/http://www.kaercher.com/http://www.collomix.com/http://www.sika.com/mailto:[email protected]


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Typical hand scabbling/chisels for substrate preparation:

HILTI:

HILTI TE 706 HILTI TE 805 HILTI TE 905

For more information: www.hilti.com

Makita:

HM1242C HM1211B HM1100C

For more information: www.makita.com

Milwaukee:

PCE 3 Q Kango 900 Kango 500 S

For more information: www.milwaukeetool.com
mailto:[email protected]://www.sika.com/http://www.hilti.com/http://www.makita.com/http://www.milwaukeetool.com/http://www.milwaukeetool.com/http://www.makita.com/http://www.hilti.com/http://www.sika.com/mailto:[email protected]


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7. Disclaimer and address of Sika Company

This Method Statement is provided by Sika as a standard proposal for the applicationof Sikadur-42 epoxy grout systems. Please also refer to the specificrecommendations in the relevant Product data sheet for each material (Sikadur-42HE, Sikadur-42 LE, Sikadur-42 MP and Sikadur-42 PT)It always remains the responsibility of the structural engineer to confirm the productsuitability and the correct method for any given application.

Where alternative methods or criteria to those outlined here are to be used, thesemust first be submitted to Sika Technical Services for prior approval and agreement inwriting, before the commencement of any works. Sika can not accept responsibility orliability due to any other variations or conditions.

For your local Sika contact details visit:www.sika.com
http://www.sika.com/http://www.sika.com/

Documents

Method Statement Epoxy