3-COMPONENT EPOXY GROUT
DESCRIPTION
A three-component pourable, solvent free epoxy grout based on a high grade epoxy resin and specially graded aggregates. ABADUR-G3 has been designed to reach a roughly 80 percent of its maximum mechanical strength capacity at its very early ages to maintain it as useful for further applications. Once mixing, a flowable grout is produced for use in heavy duty applications and difficult conditions.
ABADUR-G3 is recommended to be applied in 50 to 150 mm thickness and designed to be applicable in temperature range between +15 and +35 °C.
Method
SURFACE PREPARATION
- Concrete should be old enough, if it is newly placed concrete then it needs to be 28 days old and to have reached its design strength.
- Concrete should have attained a minimum compressive strength of 21 MPa, higher strength concrete is recommended for optimum performance of grout.
- All surfaces should be dry, clean, and free from standing water, grease, curing compounds, mold oils, all loosely adhered aggregates and cement particles, etc.
- Chip the concrete surface so aggregates are exposed to ensure all laitance and weak particles are removed. Alternatively use a spray on surface retarder when placing concrete.
- Chamfer the edges of the concrete 45 degrees to 50 mm. width to avoid sharp corners which helps to reduce the potential for cracking.
- Shade the foundation from direct sunlight for at least 24 hours before grouting and 48 hours after grouting.
MIXING
- Before mixing ensure all the components are cool, shaded and dry. If not preconditioned store all components below 25°C for 24 hours before using.
- The temperature of grout, base plate and foundation are more important than the air temperature because they are directly related to the flow of grout.
- Add component A & B in a mixing vessel and mix under slow speed (RPM 400) for approximate 1 minute. Then add component C and continue mixing for further 2 minutes until a flowing uniform grout is achieved.
- Avoid excessive mixing which will result in reduction of working time and heat generation.
APPLICATION
- Grouting operation should be done immediately after mixing completion, in less than 15 minutes. Grout should be applied continuously and from the appropriate height.
- While grouting the base plates ensure there is sufficient pressure head to maintain movement of grout.
- Base plates with a flat base pour the grout from one side through the other across the short dimensions.
- Drop pressure from a higher height may be required to fill larger dimensions and longer distances. In this case, it is recommended to use the Head Box. Head boxes are usually installed along the length and on one side of the foundation.
- If grouting in multiple layers, it is necessary to sprinkle a small amount of 2.5 mm aggregate over the first layer before the grout reaches its setting time. Before placement of 2nd layer brush out loose aggregates from the 1st pour. Another method is to scrabble gently the top surface and make it rough when grout reaches near to its setting time.
- the grout site should be designed in such a way that it is possible for air to escape out of the section under grout. Therefore, ensure entrapped air can escape when grouting closed areas.
- Where grout cannot flow and have smooth movement because of the length of pour pushing aids like steel chains, strips of plywood, etc. can be used.
- The base plate with anchor bolts, dowel, starter bar, etc. should be grouted first followed by the base plate.
Properties
- Ready-to-mix, pre-batched units
- Excellent chemical resistant
- Rapid shrinkage free hardening
- High early and late mechanical strength capacity
- Good impact and vibration resistance
- High adjustable flow (self-levelling)
- Good bonding to most substrates
Application
- Under-grouting and bedding of base plates, bridge bearings, machine bases, seat base-plates for light and heavy machinery including heavy impact and vibratory machinery, reciprocating engines, compressors, pumps, presses, etc.
- Crane tracks
- Reinforcement
Physical and Chemical Properties
APPLICATION CONDITIONS/LIMITATIONS
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Substrate Temperature
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+ 15 ̊C - + 35 ̊C
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Ambient Temperature
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+ 15 ̊C - + 35 ̊C
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Material Temperature
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+ 20 ̊C - + 25 ̊C
Condition the material by also storing at this temperature for 24 hours before use.
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Substrate Moisture Content
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≤ 4% pbw
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Dew Point
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Substrate temperature during application must be at least 3 ̊C above dew point to avoid condensation.
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TECHNICAL PROPERTIES
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Color (A:B:C)
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Brown
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Appearance
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Part A: liquid
Part B: liquid
Part C: powder
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Mixing Ratio (A:B:C)
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3: 1: 18.4 (by weight)
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Density (A+B+C)
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2.2 ± 0.1 g/cm3
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Layer Thickness
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Minimum grout depth: 50 mm
Maximum grout depth: 150 mm
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Flexural Strength
(According to ASTM C 580)
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~ 24 MPa
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Tensile Strength
(According to ASTM C 307)
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~ 11 Mpa
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Drying Time
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Temperature
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Touch dry
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Over-coating
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Full cure
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+15 °C
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16hrs
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20hrs
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13 days
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+25 °C
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12hrs
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16hrs
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7 days
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+35 °C
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9hrs
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16hrs
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7 days
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Pot life
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Material temperature
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+15 °C
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+25 °C
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+35 °C
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Pot life
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80 min
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55 min
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35 min
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.
Considerations
PACKAGING
28kg set.
STORAGE & SHELFLIFE
The shelf life is 6 months if unopened, stored free from frost, moisture and direct sunlight.
Note: In cold seasons, to stabilize the physical condition of the material, it should be stored in an environment with a temperature of 30 ° C for 24 hours before consumption.
Protection and Safty
HEALTH & SAFETY
This product is Flammable. Keep away from heat and open flame .Keep container closed .Use with adequate ventilation. Avoid prolonged and repeated contact with skin. If used in confined areas, observe the following precautions to prevent hazards of fire or explosion or damage to the health:
- Circulate adequate fresh air continuously during application and drying.
- Use fresh air masks and explosion proof equipment.
- Prohibit all flames, sparks, welding and smoking.
MSDS is available at ABADGARAN website.
ABADUR-G3 Data Sheet
