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Method Statement Sikadur - 42: Epoxy Resin Based Grout Corporate Construction
Method Statement Sikadur - 42: Epoxy Resin Based Grout Corporate Construction
Method Statement Sikadur - 42: Epoxy Resin Based Grout Corporate Construction
Method Statement
Sikadur®-42
Epoxy Resin based Grout
Corporate Construction
Construction
Scope:
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.
Table of Contents:
1. System Description ..............................................................................3
1.1. References......................................................................................................3
1.2. Limitations .......................................................................................................4
2. Products ................................................................................................5
2.1. Pre-Project Preparation ...................................................................................6
6. Equipment – Tools..............................................................................41
1. System Description
• Fasteners
• Tie rods
• Crash barrier posts
• Fence and railing posts
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
1.1. References
1.2. Limitations
According to the Product Data Sheet, certain limitations are given:
Please refer to the PDS (Product Data Sheet) to confirm the details of these
requirements.
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 +5°C and +30ºC.
Construction
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 +20°C to +45ºC and on substrates from +15°C
to +45ºC.
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 +5°C and +30ºC.
Larger volume packaging is available and this varies from country to country. Please
contact your local Sika Company for sizes and packaging availability.
The most important preparation steps for installation of Sikadur®-42 Epoxy Grout are::
volume and geometry of the grouting area. à 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). à Grouting in several
layers or lifts may be necessary. à 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 à 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
Please also check the Installation Record & Checklist. This document helps to
ensure that all of the important steps for successful Grouting are complied with.
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
Construction
The following protective equipment is essential for anyone working with any epoxy
resin based products and these instructions must be strictly adhered to:
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.
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!
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.
Construction
Wear hard hats Wear safety shoes with Wear ear protection. For
steel toe caps use of mixing equipment
à 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.
Cleaning of Tools:
Uncured material can be removed with Sika Colma Cleaner.
• 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
Construction
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.
Surface preparation:
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.
Baseplates:
Construction
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.
Construction
After scabbling:
Remove friable material etc. by
blastcleaning or…….
Cleaning:
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
Construction
encapsulation.
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 à 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
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
Construction
Enclosed
Air
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
Construction
3.3. Mixing
Pre-batched units:
Construction
Important Notes:
Always mix only that quantity of Sikadur®-42 grouts that can be used within its potlife.
Never reduce the mixing time.
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:
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:
Construction
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)
4. Application / Installation
Checklist:
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!
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 3°C.
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
Construction
the component, the base plate for example and the relative humidity, but you can also
use traditional analogue instruments.
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)
Construction
The point of their intersection in the table below is the dew point surface temperature in [°C]
Example: Ambient temperature: 34°C, relative Humidity (rh): 60%
result the dew point surface temperature is: 25,1°C.
[°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
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
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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
444
2
5
6 6
Construction
7
3
1. Formwork
2. Feed Hopper Chute
3. Substrate (e.g. Concrete)
4. Anchor Bolt
5. Equipment Base Plate (e.g. steel)
6. Air Release Hole (if necessary)
7. Sikadur®-42 Epoxy Grout
4
2
Construction
6 6
1
1. Formwork
2. Feed Hopper Chute
3. Substrate (e.g. Concrete)
4. Anchor Bolt
5. Equipment Base Plate (e.g. steel)
6. Air Release Hole (if necessary)
7. Sikadur®-42 Epoxy Grout
Grouting of Bolts:
• 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 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.
®
Sikaflex
(Self Leveling) Stretching Length
Concrete Base
Anchor Bolt
Grout
Crack Crack
Construction
Develops closes
Concrete
Epoxy Grout
Y
Crack
Concrete Base
û
X<Y
ü
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 distance Do not grout from the long
across the base plate distance across the base plate
ü û
Grouting down / with any slope or decline:
Grouting down along the slope Do not grout against/up the slope
ü û
Grout from one side only:
ü û
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
30/43
N°: 850 42 01
Author: Marco Poltéra
Date: 11/2007
Stagnated Material:
Freshly applied grout which has temporarily stopped moving can be ‘reactivated’ and
kept moving by using a suitable steel chain. à see picture below.
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
Construction
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
Construction
~3mm
Equal with
baseplate
Checklist:
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.
• Applying the third layer, after the second layer has again cooled down. Etc.
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.
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.
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
Control Joints:
Control joints (expansion joints) can be installed using ¾ 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
Quality Control:
Example:
Retained samples according to
ASTM C 579 as shown in the
picture.
Specimen size: 2 inch or 5cm
cubes
ü û
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
38/43
N°: 850 42 01
Author: Marco Poltéra
Date: 11/2007
Surface:
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.
Formwork:
If the formwork was well prepared with release agent as recommended earlier, it
should now be easy to remove.
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
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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.
6. Equipment – Tools
Mixing Paddles:
Construction
Mixers:
Vacuum Cleaner
Kärcher
Industrial Vaccum Cleaner
HILTI:
Construction
Makita:
Milwaukee:
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
Construction
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.