003.01 - MS Sikadur 42-HES - Base Plate

Sikadur 42-HES_ FINAL1
Author:J.Nabih
Date:28/04/2008
Method Statement for Application
Base Plate Grouting with

Sikadur 42-HES
Scope:
Method Statement for Application procedure of base plate grouting with an
Construction
Epoxy grout. (Sikadur ®-42 HES).
Product
- Sikadur®-42-HES
Description
Sikadur 42-HES is solvent-free, self-levelling, three-component epoxy grout,
based on a combination of epoxy resins and specially selected high strength
fillers.
The information, and, in particular, the recommendations relating to the application and end-use of Sika products,
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 practice, the differences in materials, substrates and actual site
conditions are such that no warranty in respect of merchantability or of fitness for a particular purpose, nor any
liability arising out of any legal relationship whatsoever, can be inferred either from this information, or from any
written recommendations, or from any other advice offered. The proprietary rights of third parties must be
observed. All orders are accepted subject to our current terms of sale and delivery. Users should always refer to
the most recent issue of the Product Data Sheet for the product concerned, copies of which will be supplied on
request
Sika Gulf BSC

Bldg. 925, Road 115, Tel.: +973 17738188
Sitra Area 601 Fax : +973 17732476
P.O.Box 15776 http://www.sika.com.bh
Adliya, Kingdom of Bahrain e-mail: sika.gulf@bh.sika.com
1/13
-2-
Sikadur®-42 HES
Pre-proportioned, epoxy, baseplate grouting system
Tools Required
The appropriate mixer should be selected according to the quantity of epoxy grout.
Low speed electrical mixer (max. 500rpm) and stirring paddle, air compressor,
Mechanical tools for blast cleaning such as Grinding ,Sandblasting or high pressure
water jet (100-150 bars), mixing clean pails, hand tools.
Construction
Preliminary Works
Prepare a grout tight formwork and kept to the strict minimum the surface area of
exposed grout. Allow a pressure head for the formwork “mouth” and enough air
escape at the opposite end – refer to sketch.
Estimate the required quantity of Sikadur 42 HES for the daily usage to ensure
sufficient material for each use and no unnecessary stoppages are encountered.
Consumption
Approx. 20 Kg/m2 of Sikadur 42-HES yields to 10mm thick layer.
Sika Gulf BSC

Bldg. 925, Road 115, Tel.: +973 17738188
Sitra Area 601 Fax : +973 17732476
2/13
-3-
Preparation
Substrate and baseplate contact area must be dry, clean, sound, and free of standing
water. Remove dust, laitance, oils, grease, curing compounds, waxes,
impregnations, foreign particles, coatings and disintegrated materials by mechanical
means ( i.e., sandblasting, bush hammering).
The underside of the base plate must be clean and free from oil, grease, rust,
scale or other loosely adherent material. Sandblast uncoated steel baseplates to a
commercial white finish for maximum adhesion (or prepare to SA 2.5). Apply grout
immediately to prevent re-oxidizing. Concrete substrate shall have reached its
desired strength (full cured), and must be dimensionally stable.
Chamfering for the concrete edges where sharp edges exist. Approx 5 cm is
Construction
required. Refere to attached sketches.
Working at high temperatures:

- It is recommended to apply Sikadur®-42HES at temperatures < 35 °C,
- Prior to use store the unmixed materials in a cool, preferably temperature controlled
environment, avoiding exposure to direct sunlight or other heat sources.
Preconditioning of the product is min for 24 hours prior to application.
- 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.
- When both the materials and/or the substrates are too hot, the potlife will decrease
dramatically!
- Baseplate should be shaded from direct sunlight for a minimum of 24 hours before
epoxy grouting, and 48 hours after grouting.
Forming
The flowable consistency of the epoxy adhesive grout system requires the use of
forms to contain the material around the baseplates. In order to prevent leakage or
seepage, completely seal all forms (e.g. Sikaflex®-11 FC). Apply polyethylene film or
wax to all forms to prevent adhesion of the grout. Prepare form work to maintain a
minimum (100 mm) liquid head to facilitate placement. A grout box equipped with an
inclined trough attached to the form will enhance the grout’s flowability and minimize
air encapsulation. Projected anchor bolts should be wrapped with neoprene foam
rubber (or similar) to prevent grout from adhering to the bolts.
Pour the mixed grout into the prepared forms from one or two sides only to prevent
air entrapment.
Pouring side: Erect formwork approx. 200 mm (or 20% of traveling distance) from
the base plate edge
Opposite of the filling side: Erect the formwork at least 50 mm above the grouting
level
Sika Gulf BSC

Bldg. 925, Road 115, Tel.: +973 17738188
Sitra Area 601 Fax : +973 17732476
3/13
-4-
Construction
Control Joints:
Control joints (expansion joints) can be installed using 15mm thick neoprene
compressible boards. 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.
The use of expansion joints is recommended on large pours to minimize the potential
for cracking in the epoxy grout (maximum (1.20 m) spacing in each direction.
Mixing
Mix the entire contents of Components ‘A’ & ‘B’ for 2 minutes with the suitable
mixing paddle on a low-speed (300 - 450 rpm) drill, taking care not to entrain
air during mixing. It is critical to the performance of the grout that there are no
appreciable air bubbles in the grout. Slowly add the entire contents of
Component ‘C’ and mix until uniformly blended (approx. 3 minutes).
Strip the sides of the container with a long spatula to ensure no unmixed
grout remains stuck to the container.
Application
Pour the mixed grout into the prepared forms from one side only (through the “mouth”
of the formwork) to eliminate air entrapment. Baseplate should have vent holes
around periphery to prevent air pockets from developing. Maintain the liquid head to
ensure intimate contact with the base plate. Plungers may be used to ease
placement. Place sufficient epoxy adhesive grout in the forms to rise slightly (≈ 3
mm) above the underside of the base plate.
Grout depth of (25 mm) minimum required & Maximum grout depth is (50 mm) per
one layer. In case pf greater grouting thickness several layers should be applied and
observing the min waiting times -12-16 hrs at 20-23 degree C.
Do not exceed waiting time of 48 hours at 20-23 degree C, if it is expected to be
exceeded please consult our technical department.
For grouting of concrete pockets with relatively smaller dimensions thickness of layer
maybe increased to 100-120mm per layer, please consult our technical department
for recommendations and technical support.
Depending on the size of the base plate, in order to help the grout to flow through the
end, it might be necessary to rod the grout with a thick wire.
Sika Gulf BSC

Bldg. 925, Road 115, Tel.: +973 17738188
Sitra Area 601 Fax : +973 17732476
4/13
-5-
Maintain a pressure head while pouring and ensure that the process is continuous to
avoid air entrapment.
For proper seating in base plate applications, allow grout to rise above the bottom of
the base plate. This will force the material to the plate bottom and achieve a
maximum effective bearing area (EBA).
For large volumes, apply in more than one layer, ensuring that the previous layers
have hardened and cooled.
Construction
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 HES Epoxy Grout
= Grout flow direction
Sika Gulf BSC

Bldg. 925, Road 115, Tel.: +973 17738188
Sitra Area 601 Fax : +973 17732476
5/13
-6-
Construction
Remarks and Recommendations:

Preventing Grout Edge Curling:
Problem of Edge curling:
The Solution for Edge curling:
Sika Gulf BSC

Bldg. 925, Road 115, Tel.: +973 17738188
Sitra Area 601 Fax : +973 17732476
6/13
-7-
Construction
It is recommended that the exposed edge distance-Shoulder (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:
◊ Grouting from the shortest side:
◊ Grouting down / with any slope or decline:
Sika Gulf BSC

Bldg. 925, Road 115, Tel.: +973 17738188
Sitra Area 601 Fax : +973 17732476
7/13
-8-
◊ Grout from one side only:

◊
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.
Sika Gulf BSC

Bldg. 925, Road 115, Tel.: +973 17738188
Sitra Area 601 Fax : +973 17732476
8/13
-9-
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.
Construction
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:
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:
◊ 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 )
Sika Gulf BSC

Bldg. 925, Road 115, Tel.: +973 17738188
Sitra Area 601 Fax : +973 17732476
9/13
- 10 -
Construction
Safety
Health and safety instructions on the latest Technical Data Sheet must be strictly
observed.
For more information, please refer to the Safety Data Sheets (available upon
request).
Sika Gulf BSC

Bldg. 925, Road 115, Tel.: +973 17738188
Sitra Area 601 Fax : +973 17732476
10/13
- 11 -
Checklist and Summery:
The most important preparation steps for installation of Sikadur®-42 HES Epoxy
Grout are:
- Accurate calculation of the amount of Epoxy Grout needed

- Check temperatures during the grouting procedure < 35 ºC
- Check the potlife of Sikadur®-42HES at the temperatures and compare it with the
volume and geometry of the grouting area. if 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. a Grouting
in several layers or lifts may be necessary.
- Make a programme for the whole procedure. Check the staff available and trained to
Construction
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 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 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
- Ensure adequate protection of adjacent equipment and finished floor areas etc around
the grouting area.
Formwork 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.
Sika Gulf BSC
Bldg. 925, Road 115, Tel.: +973 17738188
Sitra Area 601 Fax : +973 17732476
11/13
- 12 -
- 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.
- Make air release holes at the highest points within any enclosed areas of the
machinery/equipment.
Application / Installation Checklist:
- In several layers grouting case, the last lift must be kept to a maximum 50 mm
Construction
- For proper seating, allow the grout to rise above the bottom (approx. 3 mm) of the
base plate .
- Hotter ambient substrate or material temperatures will influence the curing and
flow characteristics of Sikadur®-42 HES
- 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.
Mixing 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 spandle
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!
- Slowly add the entire contents of component C and mix until the grout is
homogeneously blended (approx. 3 min) and a completely uniform colour.
- Leave Sikadur-42HES to stand and mature in the mixing vessel for several
minutes (approx. 1-2 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
Application 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
Sika Gulf BSC

Bldg. 925, Road 115, Tel.: +973 17738188
Sitra Area 601 Fax : +973 17732476
12/13
- 13 -
- 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
Kindly find attached Technical Data Sheet.

For any further information, please do not hesitate to contact our Technical
Department.
Thanks and best regards,
Technical manager
Eng. Joseph Nabih
Mobile No.: +97339901839
E-mail:nabih.joseph@bh.sika.com
Sika Gulf BSC

Bldg. 925, Road 115, Tel.: +973 17738188
Sitra Area 601 Fax : +973 17732476
13/13

003.01 - MS Sikadur 42-HES - Base Plate

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003.01 - MS Sikadur 42-HES - Base Plate

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Sikadur 42-HES_ FINAL1

Method Statement for Application

Base Plate Grouting with

Epoxy grout. (Sikadur ®-42 HES).

Sika Gulf BSC

Sika Gulf BSC

required. Refere to attached sketches.

Working at high temperatures:

Sika Gulf BSC

Sika Gulf BSC

Sika Gulf BSC

Remarks and Recommendations:

The Solution for Edge curling:

Sika Gulf BSC

◊ Grouting from the shortest side:

◊ Grouting down / with any slope or decline:

Sika Gulf BSC

◊ Grout from one side only:

Placing grout in several layers:

1. Chemically Bonded (without mechanical adhesion)

Sika Gulf BSC

2. Mechanically Bonded (with mechanical adhesion)

The Placing of large volumes:

Sika Gulf BSC

Sika Gulf BSC

- Accurate calculation of the amount of Epoxy Grout needed

Application / Installation Checklist:

- Prior to placement, ensure that all surfaces are dry

Sika Gulf BSC

Kindly find attached Technical Data Sheet.

Thanks and best regards,

Sika Gulf BSC

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