Method Statement For Grouting

N: 850 42 01 Author: Marco Poltra Date: 11/2007
Method Statement Sikadur-42

Epoxy Resin based Grout Corporate Construction
Storage Place: ICC BU Contractors Key Words: Sikadur-42, Grouting, Epoxy Resin Grout, Reactive Resin Grout Scope:
Construction
Method statement for the application of: Sikadur-42, a range of 3-part, Epoxy Resin based Grouts
The information contained herein and any other advice are given in good faith based on Sika's current knowledge and experience of the products when properly stored, handled and applied under normal conditions in accordance with Sika's recommendations. The information only applies to the application(s) and product(s) expressly referred to herein. In case of changes in the parameters of the application, such as changes in substrates etc., or in case of a different application, consult Sika's Technical Service prior to using Sika products. The information contained herein does not relieve the user of the products from testing them for the intended application and purpose. All orders are accepted subject to our current terms of sale and delivery. Users must always refer to the most 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 77 E-Mail: poltera.marco@ch.sika.com / www.sika.com 1/43
Table of Contents:
1.
1.1. 1.2.
System Description ..............................................................................3

References ......................................................................................................3 Limitations .......................................................................................................4
2.
2.1.
Products ................................................................................................5
Pre-Project Preparation ...................................................................................6
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3.
3.1. 3.2. 3.3.
Safety Measures on Site ......................................................................7

Surface Preparation....................................................................................... 10 Formwork ...................................................................................................... 14 Mixing ............................................................................................................ 17
4.
4.1. 4.2
Application / Installation ....................................................................21

Application Method ........................................................................................ 28 Additional works ............................................................................................ 37
5. 6. 7.
Inspection, Sampling, Quality Control..............................................38 Equipment Tools..............................................................................41 Disclaimer and address of Sika Company .......................................43
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 heavy impact 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 segmental bridge projects Precision seating of base plates Grouting under equipment where access is available
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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 issued by the American Petroleum Institute
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 <50mm Component C must be kept dry Please refer to the PDS (Product Data Sheet) to confirm the details of these requirements.
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2. Products
Sikadur-42 HE Sikadur-42 HE is a three-component, high performance, high precision, solvent-free, moisture tolerant, epoxy resin based grouting system. For use at ambient and substrate temperatures between +5C and +30C.
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Sikadur-42 LE Sikadur-42 LE is a three-component, high performance, high precision, low exothermic, solvent-free, moisture tolerant, epoxy resin based grouting system. For use at ambient temperatures between +20C to +45C and on substrates from +15C to +45C. Sikadur-42 MP Normal and Slow Sikadur-42 MP Normal is a three-component, multi purpose, solvent-free, moisture tolerant, epoxy resin based grouting system. For use at substrate and ambient temperatures between +10C and +30C. Sikadur-42 MP Slow is a three-component, multi purpose, solvent-free, moisture tolerant, epoxy resin based grouting system. For use at substrate and ambient temperatures between +20C and +40C. Sikadur-42 PT Sikadur-42 PT is a three-component, solvent-free, moisture tolerant, epoxy resin based, post tensioning anchorage protection system. For use at substrate and ambient temperatures 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.
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 quantity within this potlife? Also select the appropriate packaging sizes Check the geometry of the grouting area and confirm max. layer thickness of the relevant Sikadur-42 type in the Product Data Sheet (PDS). Grouting in several layers 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 trained to mix the material fast enough to maintain a continuous work and grout flow for this work. The most critical bottleneck during grouting is frequently a lack of human resources (for a continuous work flow which is essential for a successful grouting) Select mixing tools and equipment with sufficient capacity. Confirm power type and availability for the mixing equipment Calculate the time required for preparing and mixing the epoxy grout and include this in the programme. In many cases, at least two working teams are necessary to supply the feed hopper and to maintain the work flow. Do not reduce the mixing time, even when in a hurry Refer to chapter 3.3. Important Notes: This is one of the most common mistakes in grouting work Check the substrate in advance. Ensure that the substrate is in good condition and that 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 bonding with 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 other areas, 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
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Please also check the Installation Record & Checklist. This document helps to ensure that all of the important steps for successful Grouting are complied with.
3. Safety Measures on Site

Personal Protection: The following symbols are typical of the internationally required labelling for epoxy resins and hardeners. In accordance with these, the products should be stored and applied according to the appropriate local regulations. Please also observe any other relevant local regulations (Refer to local PDS and MSDS).
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Corrosive
Dangerous for the environment
Irritant
The following protective equipment is essential for anyone working with any epoxy resin 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 the skin. The use of a barrier cream is more useful and effective than often reputed, they are inexpensive, convenient, and protect well if they are not frequently flushed with solvents. However, barrier creams are only a supplement to and not a replacement for protective gloves, so always wear gloves. Always ensure there is no contamination inside 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 at once. The friction of resin-saturated fabric on the skin can cause serious chemical burns. Wash your exposed skin occasionally during the workday and immediately if any epoxy gets on it. Avoid using solvents since they can help epoxy material penetrate in to the skin and solvents themselves are aggressive and harmful to the skin. If water is no more available at any time or shorten, then clean the contamination with sand instead, it works well. Certain hand cleaners also work without harmful effects. Citrus skin cleaners, for example, are effective and mild. Soap and water takes time, but also eventually works for small areas.
Avoiding skin contact by keeping tools and equipment clean is one of the best ways to protect oneself. Remember, epoxies are very tacky which is partly why they work so well 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:
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Skin cleaner Sika Topclean T No epoxy resin applications should ever proceed without sufficient water being adjacent and available for eye washing. If adequate clean water is not provided then the project should not commence, no matter what the urgency. Numerous workers and observers have suffered injury due to resin entering their eyes when there was no water available to clean them. If a professional eyewash kit is not available, then at the very 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 good enough. Safety glasses or other eye protection obviously help those doing the work but 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 advice immediately after rinsing and cleaning the eyes with the clean water
Dependent on local regulations respiratory masks may be required. Please observe all relevant local regulations.
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Breathing protection required
The following equipment is also generally recommended on construction sites:
Wear hard hats
Wear safety shoes with steel toe caps
Wear ear protection. For use of mixing equipment please refer to the manufacturers advice
Please refer to the local country regulations and the specific construction site requirements. Disposal: Brush away and remove any excess grout into appropriate containers for disposal before it has hardened. Hardened epoxy resin can be disposed of with other combustible waste in a waste incineration plant. In no circumstances, burn the epoxy in an open fire due to the potentially dangerous gases 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).
3.1. Surface Preparation

Requirements for the substrate: Weak concrete must be removed and surface defects such as blowholes and voids must be fully exposed. Mortar and concrete must be older than 28 days (dependent on minimum strength requirements). Confirm the substrate strength (concrete, masonry, natural stone etc). If in doubt, make a test area first. The substrate surfaces must all be sound, clean and free from contaminants such 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 with bond strength testing equipment, as shown on the left. (Proceq or similar)
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Surface preparation: Concrete, mortar, stone: These substrates must be prepared by e.g. blastcleaning to be free from cement laitance, ice, standing water, grease, oils, old surface treatments or coatings and all loose or friable particles must be removed to achieve a contaminant free, open textured surface. Steel: Must be cleaned and prepared thoroughly to an acceptable quality standard equivalent to 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 as possible after preparation and cleaning to prevent re-oxidizing / rust formation on the surfaces.
For optimum results: When grouting areas or equipment that is sensitive to vibration, it is recommended that the contact surfaces are prepared according to the latest edition of the American Petroleum Institutes Recommended Practice 686 Machinery Installation and Installation Design, Chapter 5. Baseplates:
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The underside of the base plate must be clean and free from oil, grease, rust, scale or other loosely adherent material It is recommended that the underside and edges of the base plates are coated with Sikagard-63N to prevent rust formation and ensure a good bond to the grout.
Substrates: There are two main procedures for substrate preparation: blastcleaning and scabbling with chisels. 1. Method: Substrate preparation by blastcleaning:
Substrate preparation by blastcleaning
2. Method: Substrate preparation by scabbling with a chisel: With scabbling it is possible to obtain a larger specific surface area which is then in contact and bonded to the epoxy grout, which also creates a higher mechanical bond between the epoxy and the concrete. However, scabbling also requires blastcleaning afterwards to remove any loose or friable particles such as fractured aggregates remaining on the surface.
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Substrate Preparation by scabbling with a chisel
After scabbling, the substrate can have a reduced bond strength potential due to the impact cracks and micro cracks in the concrete. (see red circle) All of the cracked, friable material and any residual cement laitance (see also in the red circle) must be removed by blastcleaning or high pressure water-jetting after scabbling
After scabbling: Remove friable material etc. by blastcleaning or.
.high pressure water-jetting
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Protection of adjacent steel edges and surfaces:
Protect adjacent steel surfaces with tape
Cleaning:
Remove dust, and any other loose material after blastcleaning or water jetting. Finally brush the substrate and remove the residual dust with a vacuum cleaner.
3.2. Formwork
Forming: The flowable consistency of the Sikadur-42 epoxy grout material requires the use of permanent 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 formers must be sealed. Apply polyethylene film or wax / release agent to all forms to prevent adhesion of the grout. Prepare the formwork to allow and maintain more than 100 mm liquid head to facilitate placement. A grout box equipped with an inclined trough attached to the form work will enhance the grout flow and minimize any air encapsulation.
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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 the base plate. The minimum void depth to be filled with Sikadur-42 epoxy grout beneath the base-plate, should be at least10-25 mm; refer to the specific Product Data Sheet for more detailed information. Where the void beneath the base plate is greater than the maximum allowable grout thickness (please refer to the Product Data Sheet) place the epoxy grout in successive layers 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 edge Opposite of the filling side: Erect the formwork at least 50 mm above the grouting level
200mm 50mm
Feeding Hopper system
Opposite the filling side
Pouring side
Air release: Make some air release holes (tubes or holes etc) at every enclosed high point within the machinery/equipment. (See sketches below)
Air release
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Enclosed Air
First step: Release holes for enclosed air
Control: Fill levels must be even
Second step: Epoxy Grout flows due to hydrostatic pressure from the feed hopper until the correct fill level is attained
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 a suitable sealant such as Sikaflex-11FC+, beneath the formwork, and in any joints 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 possible problems with unrestrained surface shrinkage cracking at a later stage. For free flowing grout application, it is essential to provide a hydrostatic head of the grout. A feed hopper is recommended. Pouring side: Erect formwork approx. 200 mm from the base plate edge. (see sketch 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 and beyond the base plate edge. (see sketch above) Make air release holes at the highest points within any enclosed areas of the machinery/equipment.
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3.3. Mixing
Pre-batched units:
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Add all of component B (hardener) to component A (resin). Make sure the hardener container is fully emptied into the resin component. (Use a spatula.)
Mix both components thoroughly with a low speed electric mixer (300 - 400 rpm). Mix for at least 3 minutes avoiding aeration whilst mixing, until the material becomes uniformly blended in colour and viscosity.
Place the mixed epoxy into an appropriate grout mixing vessel which is big enough to then add Component C (powdered aggregate filler) to produce the whole finished volume of the product (A+B+C Components).
Slowly add the contents of the bag of component C (to keep air entrapment at a minimum). Note: some of Component C may be omitted to meet defined higher flow characteristics. Please refer to the correct mixing ratios written in the individual Product Data Sheet)
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Mix for approximately 5 minutes until uniform and homogeneous so that the C-Component is thoroughly mixed and blended with the resin and hardener.
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 Mixing Tools in this chapter.
Bulk packaging (not pre-batched): First, stir each component thoroughly. Add Components A and B together in the correct proportions (measured by weight) into a suitable grout mixing vessel. Then continue the procedure as described above for the pre-batched units Important Notes:
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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 air entrapment Mix Components A and B in the pail of Component A for 3 min with a paddle attached to a low speed drill (300-450 rpm) Do not thin with solvents. Solvents will prevent proper curing and change the mechanical properties Place the mixed epoxy into an appropriately sized grout mixing vessel to accommodate and mix the whole of Component C Do not change the mixing ratio! refer to the product data sheet for the approved variations in the mixing ratio Slowly add the entire contents of component C and mix until the grout is homogeneously blended (approx. 5 min) and a completely uniform colour Leave Sikadur-42 to stand and mature in the mixing vessel for several minutes (approx. 2-3 minutes) until the majority of entrained air bubbles have dispersed 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 flow characteristics and inconsistent properties in the cured grout Component C must be kept dry
Mixing Tools: For optimum mixing results use a mixing paddle similar to the ones shown below:
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With this design of mixing paddle, you can obtain the best results to mix Resin and Hardener (A+B Component)
With this design of mixing paddle, you can obtain the best results To mix (A+B) and C-Component (Fillers)
For additional information on high performance mixing tools and equipment: See chapter 6.
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) of the base plate (refer to page 32 of this method statement) Colder and hotter ambient substrate or material temperatures will influence the curing and flow characteristics of Sikadur-42 Do not subject epoxy grouts to sudden temperature changes especially during early curing stages Contact Sika Technical Services for advice on control joint spacing for large base plate grouting projects Do not vibrate the Epoxy Grout during placing Wherever possible unrestrained shoulders are to be avoided. These have a tendency to crack and/or debond For optimum bond strength to the substrate, first apply a small amount of epoxy grout 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 first layer of the Sikadur-42 epoxy grout as soon as possible e.g. application is wet on wet When applied to mat damp concrete, brush the grout well into the substrate first.
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Working at high temperatures: It is recommended when working with Sikadur-42 at temperatures above 35C, that the following guidelines should be observed: Prior to use store the unmixed materials in a cool, preferably temperature controlled environment, avoiding exposure to direct sunlight or other heat sources. Refer to the data sheet of the specific product and closely follow the instructions in the section storage conditions. Keep all equipment cool, arranging shade and protection where necessary. It is especially important to keep cool all surfaces that will come into direct contact with 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 a continuous process and that the grout does not stop moving during flow application process. Important Note: When both the materials and/or the substrates are too hot, the potlife will decrease dramatically!
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Working at low temperatures: It is recommended when working with Sikadur-42 at temperatures below 15C, that the following guidelines should be observed: Prior to use store unmixed materials in a warm environment, preferably temperature 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 the instructions in the section storage conditions. Avoid condensation! Ambient temperature during application must be at least 3C 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 will increase, the flow will also be restricted and curing will be delayed!
Dew Point: It is important to pay close attention to avoiding dew point conditions. The application temperature 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 electronic instruments (see graphic) to measure the air temperature, the surface temperature of the component, the base plate for example and the relative humidity, but you can also use traditional analogue instruments.
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Analogue instrument
Electronic instrument
Simple slide rule
With analogue instruments you will have to read the temperature and humidity from these conventional instruments. The dew point is then found by reference to tables or a simple slide rule guide (as supplied to customers by some Sika companies).
If no specific dew point instruments are available on the construction site you can still use 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]
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Example: Ambient temperature: 34C, relative Humidity (rh): 60% result the dew point surface temperature is: 25,1C.
Dew Point Temperature [C] Ambient Temperature [C] 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 relative Air Humidity [%] 30% 35% 40% 45% 50% 55% 60% 65% 70% 75% 80% 85% 90% 95% 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 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 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 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 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 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 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 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 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 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 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 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 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 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 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 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 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
N: 850 42 01 Author: Marco Poltra Date: 11/2007 28 27 26 25 24 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 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 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 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 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 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 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 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 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 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 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 -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
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23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5
-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 -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 -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 -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 -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 -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 -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 -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 -8,5 -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 -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 -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 -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
4 4 4 2 5
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7 3
1. 2. 3. 4. 5. 6. 7.
Formwork Feed Hopper Chute Substrate (e.g. Concrete) Anchor Bolt Equipment Base Plate (e.g. steel) Air Release Hole (if necessary) Sikadur-42 Epoxy Grout
= Grout flow direction
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2 5 1 6 6
7 3
1. 2. 3. 4. 5. 6. 7.
Formwork Feed Hopper Chute Substrate (e.g. Concrete) Anchor Bolt Equipment Base Plate (e.g. steel) Air Release Hole (if necessary) Sikadur-42 Epoxy Grout
= Grout flow direction
4.1. Application Method

Grouting of Bolts: A common application with epoxy resin grouts is heavy duty bolt anchoring on stanchion bases for example.
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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 or by 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 special procedure: Anchor bolt box outs or sleeves should be thoroughly cleaned of all debris and can be filled with a self leveling, flowable Sealant (e.g. Sikaflex-228, Sikaflex 2CSL or similar). The anchor bolts should be wrapped with a flexible insulation tape/material about 6 mm in thickness to prevent bonding of the grout to the anchor bolt. This insulating material should extend from the top of the concrete to the underside of the base plate.
Equipment Base Plate Tape/foam Insulation Sikaflex (Self Leveling) Concrete Base Epoxy Grout
Stretching Length
Anchor Bolt
Preventing Grout Edge Curling: Problem of Edge curling:
Grout Crack Develops Concrete
Construction
Crack closes
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

Heat Flow
The Solution
Equipment Base
X Y
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 the base plate to the formwork be kept less or equal to the thickness (Y) of the grout. This will eliminate edge curling of the grout.
Placing: It is essential that the grout mixing capacity, material supply and labour availability is sufficient to enable the grouting operation to be carried out smoothly and continuously.
Grouting from the shortest side:
Construction
Grouting from the shortest distance across the base plate
Do not grout from the long distance 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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Sika Services AG / Speckstrasse 22 / CH-8330 Pfaeffikon / Switzerland Tel: +41 44 403 13 73 / Fax: +41 44 403 13 77 E-Mail: poltera.marco@ch.sika.com / www.sika.com
Stagnated Material: Freshly applied grout which has temporarily stopped moving can be reactivated and kept 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/placing the material, the material is designed to flow by itself. Do not break the front or the tongue of the grout with the chain!
Construction
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 has to be slightly above the level of the bottom of the base plate to ensure complete fill of the base. The final height of the epoxy grout should be finished level with the bottom of the base or only slightly higher. This will eliminate any subsequent breaking off or edge spalling of the grout should the equipment be subjected to a rapid increase in temperature later on.
Construction
~3mm
Fresh Epoxy Grout after placing
Equal with baseplate
Cured Epoxy Grout
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. Sufficient grout must be available prior to starting, and the time taken to pour a mixed batch must be regulated to the time taken to prepare the next one. The mixed grout must be poured from one side only to eliminate the entrapment of air. A grouting head must be maintained at all times so that a continuous grouting front is maintained. When the grout reaches the open side of the formwork and rises above the underside of the base plate, pouring should continue slowly down the length of the base plate until completed. Ensure, that the hydrostatic height of the grout does not decrease to the level of the bottom of the base plate; keep it above this level. The material in the feed hopper should be continuously fed and supplied.
Construction
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. To achieve 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 down completely first. Grouting of the first layer Applying the second layer as soon as possible after the first layer, but waiting until the first layer has completely cooled down to the ambient temperature Applying the third layer, after the second layer has again cooled down. Etc.
Construction
1. Layer
2. Layer
3. Layer
Keep the surfaces absolutely clean (free from dust, water etc.) until the next layer of grout 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 coarse aggregate to excess so that it is not completely immersed in the layer. If the second layer has a thickness of 4cm, the exposed aggregate should be approx 1-2cm above the level of the first layer (like an iceberg in the sea). Additional note: This coarse aggregate also helps to reduce the heat from the exothermic reaction, because some of the heat is absorbed by the aggregate The aggregate must be complete dry. Place the aggregate within the potlife.
1. Layer
Additional aggregate broadcast in 1. Layer
2. Layer
3. Layer
Keep the surfaces absolutely clean (free from dust, water etc.) until the next layer of grout is applied. The last lift/layer must be kept to a maximum thickness of 50 mm.
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, the following procedure could be a solution: Solution:
Construction
Divide the area and make several lanes (e.g. approx 1m width) using wooden slats 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 the shoulder 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 the grout in the odd sections has cured and the slats have been removed. (See the diagrams on the next page also)
Epoxy Grout Lanes
Prepared Substrate
Example of grouting in several alternate sections
The Procedure for Grouting in several lanes:

Plan view step 1 (below)
Construction
Plan view step 2 (above)
Cross section step 1 + 2 above
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 a short distance past the inside of the base frame. It is not necessary for the control joint to extend across the entire base. Placing of the expansion joints should be located at the cross members of the base.
Construction
5. Inspection, Sampling, Quality Control

Quality Control: For optimal quality control grout some test specimens using the same material as used for the grouting work. Test afterwards e.g. measure the compressive strength, or store these as retained samples for any future evaluation or requirements. Example: Retained samples according to ASTM C 579 as shown in the picture. Specimen size: 2 inch or 5cm cubes
Construction
Check from every side of the grouted bearing plate (with a large nail or similar tool), that the grout level is full below the plate and not just at the shoulder before stopping the grouting flow and procedure. (See sketch below)
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Sika Services AG / Speckstrasse 22 / CH-8330 Pfaeffikon / Switzerland Tel: +41 44 403 13 73 / Fax: +41 44 403 13 77 E-Mail: poltera.marco@ch.sika.com / www.sika.com
Surface: After a certain minutes after the placing of the grout: When there are a few air bubbles on the surface air entrainment, break the bubbles with a fine brush (within the open time, before final curing of the material). Note: Avoiding air entrainment and allowing entrapped air to escape is very important to prevent any bubbles forming and reducing the bond strength under the base plate
Construction
Protection: On completion of the grouting operation, all of the exposed and unexposed areas of grout should be protected from direct sunlight and heat gain by providing shade over the whole area. Also protect the grouted area from rain, dust etc.
Formwork: If the formwork was well prepared with release agent as recommended earlier, it should now be easy to remove.
Removal of cured / hardened material Rotary abrasion with a variety of sanding and grinding discs is the most common removal 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 great deal of dust unless a vacuum device is attached to the grinder - these attachments are readily available now and are efficient enough to allow grinding where necessary, even in the food processing and other clean environments. Incidentally, coarse abrasive discs seem to generate less dust than finer discs, which actually tend to polish the surface. Flexible scrapers such as those used in mechanical chisels / chipping hammers also can be used to remove the excess epoxy. They always work well, but they work best on 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 other slicing the material from the surface with a clean sharp tool. Use a weed burning hot air gun or similar. The initial efforts may be clumsy until the heating and scraping are synchronized, but you can expect high production eventually, with a good finished appearance if the underlying concrete is smooth. If using large hot air burners or grinding with some dust is not acceptable, consider using 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 concrete surface 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.
Construction
6. Equipment Tools
Mixing Paddles:
Construction
twisted bar Mixers:
Collomix Type WK
Collomix CK Duo
Collomix CK
Collomix XM (with exchangeable Mixers)
For more information: www.collomix.com The appropriate mixer should be selected according to the quantity of epoxy grout and the filler content used. For the higher filled epoxy grouts (such as Sikadur-42 LE) and larger quantities mixing equipment with more power is obviously necessary. Vacuum Cleaner
Krcher Industrial Vaccum Cleaner For more information: www.kaercher.com

Typical hand scabbling/chisels for substrate preparation: HILTI:
Construction
HILTI TE 706 For more information: www.hilti.com Makita:
HILTI TE 805
HILTI TE 905
HM1242C For more information: www.makita.com Milwaukee:
HM1211B
HM1100C
PCE 3 Q
Kango 900
Kango 500 S
For more information: www.milwaukeetool.com
7. Disclaimer and address of Sika Company

This Method Statement is provided by Sika as a standard proposal for the application of Sikadur-42 epoxy grout systems. Please also refer to the specific recommendations in the relevant Product data sheet for each material (Sikadur-42 HE, Sikadur -42 LE, Sikadur -42 MP and Sikadur -42 PT) It always remains the responsibility of the structural engineer to confirm the product suitability and the correct method for any given application. Where alternative methods or criteria to those outlined here are to be used, these must first be submitted to Sika Technical Services for prior approval and agreement in writing, before the commencement of any works. Sika can not accept responsibility or liability due to any other variations or conditions.
Construction
For your local Sika contact details visit: www.sika.com

Method Statement For Grouting

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Method Statement For Grouting

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N: 850 42 01 Author: Marco Poltra Date: 11/2007

Method Statement Sikadur-42

N: 850 42 01 Author: Marco Poltra Date: 11/2007

System Description ..............................................................................3

Safety Measures on Site ......................................................................7

Application / Installation ....................................................................21

N: 850 42 01 Author: Marco Poltra Date: 11/2007

N: 850 42 01 Author: Marco Poltra Date: 11/2007

N: 850 42 01 Author: Marco Poltra Date: 11/2007

N: 850 42 01 Author: Marco Poltra Date: 11/2007

2.1. Pre-Project Preparation

N: 850 42 01 Author: Marco Poltra Date: 11/2007

3. Safety Measures on Site

Dangerous for the environment

Wear protective overalls

Wear safety goggles

Wear protective gloves

N: 850 42 01 Author: Marco Poltra Date: 11/2007

N: 850 42 01 Author: Marco Poltra Date: 11/2007

Breathing protection required

The following equipment is also generally recommended on construction sites:

Wear hard hats

Wear safety shoes with steel toe caps

N: 850 42 01 Author: Marco Poltra Date: 11/2007

3.1. Surface Preparation

N: 850 42 01 Author: Marco Poltra Date: 11/2007

Substrate preparation by blastcleaning

N: 850 42 01 Author: Marco Poltra Date: 11/2007

Substrate Preparation by scabbling with a chisel

After scabbling: Remove friable material etc. by blastcleaning or.

N: 850 42 01 Author: Marco Poltra Date: 11/2007

.high pressure water-jetting

Protection of adjacent steel edges and surfaces:

Protect adjacent steel surfaces with tape

N: 850 42 01 Author: Marco Poltra Date: 11/2007

Feeding Hopper system

Opposite the filling side

N: 850 42 01 Author: Marco Poltra Date: 11/2007

First step: Release holes for enclosed air

Control: Fill levels must be even

N: 850 42 01 Author: Marco Poltra Date: 11/2007

N: 850 42 01 Author: Marco Poltra Date: 11/2007

N: 850 42 01 Author: Marco Poltra Date: 11/2007

N: 850 42 01 Author: Marco Poltra Date: 11/2007

N: 850 42 01 Author: Marco Poltra Date: 11/2007

N: 850 42 01 Author: Marco Poltra Date: 11/2007

N: 850 42 01 Author: Marco Poltra Date: 11/2007

N: 850 42 01 Author: Marco Poltra Date: 11/2007

Simple slide rule

N: 850 42 01 Author: Marco Poltra Date: 11/2007

N: 850 42 01 Author: Marco Poltra Date: 11/2007

= Grout flow direction

N: 850 42 01 Author: Marco Poltra Date: 11/2007

= Grout flow direction

N: 850 42 01 Author: Marco Poltra Date: 11/2007

4.1. Application Method

N: 850 42 01 Author: Marco Poltra Date: 11/2007

Preventing Grout Edge Curling: Problem of Edge curling:

Grout Crack Develops Concrete

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.