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Tag Archive: epoxy grout

  1. What To Look For In Oil & Gas Epoxy Grout

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    High-quality epoxy grouting solutions are critical for the secure installation and stabilization of on and offshore oil and gas exploratory equipment and structures. There are a wide range of epoxy grouts available that exceed the bond strength, chemical resistance, and alignment performance of more traditional cementitious grouts.

    In this blog, we’ll cover the basics of epoxy grout, suitable applications, and selection considerations for the oil and gas industry.

    What is Epoxy Grout?

    The most simplified definition of epoxy grout is epoxy grout fills the void between steel and concrete in a structure or machinery mount to provide stabilization.

    Epoxy grout has become an increasingly popular option for many applications. Epoxy grout is made from a two-part system containing an epoxy resin and a hardener with an engineered aggregate added to meet the desired specifications. Epoxy grout solutions offer several advantages over cement-based grouts.

    Unlike cementitious grout, epoxy grout is non-porous, which makes it waterproof and highly resistant to stains, mildew, and mold. When cured, epoxy grout is extremely hard and durable. It can be formulated to withstand exposure to harsh chemicals without the need for a sealer, making it ideal for many industrial and commercial applications.

    What to Look For in Oil & Gas Epoxy Grout

    Compatible Oil & Gas Applications

    Offshore oil and gas structures are designed with foundations that withstand the full forces of nature, including powerful ocean conditions.

    Offshore structures are typically constructed with piled and grouted foundations. Pilings are driven through the legs of the structure and into the seabed, leaving a void between the piling and leg. The void is filled with grout, displacing the water. Once cured, the grout bonds the piling and leg together, resulting in a structure able to withstand the power of the ocean. The characteristics of epoxy grout make it an ideal choice for offshore applications.

    Epoxy grout is also commonly used to mount and anchor heavy machinery and provide a secure and stable work surface for the equipment. Unlike traditional cement grout which may crack from vibrational impact, epoxy grout dissipates vibrations, ensuring that proper load transfer between the base and sole plate is maintained

    Epoxy grout is also used to mount the sole plates that attach heavy equipment and machinery to the floor. Epoxy grout between these layers helps to transfer load forces while keeping the plates aligned, level, and stable. When properly installed, epoxy grout provides superior performance able to withstand heat, harsh chemicals, and stress better than cementitious grout.

    Download Our eBook

    Epoxy grouts are able to meet the stringent structural demands of onshore and offshore oil & gas equipment by providing superior bond strength, alignment performance, and chemical resistance relative to traditional cementitious grouts. Our eBook, A Complete Guide to Oil and Gas Epoxy Grouting Solutions, provides a comprehensive overview of epoxy grouts for oil & gas applications.

    Learn More >

    How to Choose an Oil & Gas Epoxy Grout

    When choosing an epoxy grout for oil and gas applications, it is essential to select a type specially formulated with the following features:

    • Extreme environmental condition resistances, such as very high and very low temperatures
    • Fatigue resistance
    • Chemical resistance
    • Non-corrosiveness

    Epoxy grout with these features will ensure long-lasting security, stability, and alignment.

    At Copps Industries, we have several epoxy grout solutions formulated for common conditions encountered in oil and gas applications. For example:

    • X-TRA Temp High Performance Grout (K-052) is formulated for extreme high-temperature applications that require chemical resistance and durability. X-TRA Temp High Performance Grout has a service temperature of as high as 425° F with a very low mixed viscosity of 7,000 cP.
    • Low Temperature (K-026) is designed for cold weather applications, and allows for pouring in air temperatures between 25° F and 60° F, with a mixed viscosity of 20,000 cP at 40° F. Low Temperature (K-026) is an ideal grout for use in cold climates where outdoor pours are required.

    An experienced manufacturer and distributor can assist you in selecting the most appropriate epoxy grout solution for your specific application. When sourcing epoxy grout for your project, ensure that you choose a provider who has an ISO 9001:2015 certification. Adherence to this standard ensures a product that was created under strict quality assurance procedures.

    Oil & Gas Epoxy Grout Solutions at Copps Industries

    At Copps Industries, we are committed to providing our clients with unparalleled service and the highest quality products available. We are an ISO 9001:2015 certified manufacturer and supplier of industrial-grade epoxy, offering a wide range of unique and proven formulated systems. We have been using innovative practices and cutting-edge technology to develop solutions that address complex challenges within a variety of industries since 1979.

    To learn more about epoxy grout solutions for oil and gas applications, please reach out to us today.

  2. Grouting Machinery Base Plates 101

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    In the manufacturing sector, heavy machinery needs to be secured to the concrete below to ensure that it is firmly in place and will provide optimal performance. The mounting process typically involves mounting soleplates/baseplates directly to the concrete below. The grouting of machine baseplates and bearing plates, and of anchoring alignment equipment to a foundation are low-cost approaches that provide a high quality machine-to-foundation connection.

    Grout is poured between the two plate surfaces (normally steel and concrete) components to provide greater stability, alignment, vibration isolation, and leveling. Base plate grouting operations traditionally utilize cement grout. However, many industries are turning towards epoxy grout due to its rapid strength development and superior material properties.

    The following blog outlines the importance of grouting base plates, how to go about the grouting process, and common issues that may arise during the process.

    What Is the Purpose of Grout Under Base Plates?

    Grout acts like a liquid shim between two surfaces and is used to secure the base plates of heavy machinery to the foundation which allows the machinery to function properly. Additionally, the grout reduces operational vibrations that can cause structural damage, machinery malfunctions, and machinery damage.

    There are two primary types of grout that are used for this purpose—epoxy grout and cement grout.

    What Is Epoxy Grout?

    Epoxy grout is made from epoxy resins and an aggregate. This mixture gives the substance its excellent durability, hardness, and water-resistant properties. The rapid strength development, bond strength and chemical resistance supplied by epoxy resin and filler material makes it ideal for situations where vibrations, water, chemicals, and heat are regularly present. ANSI (ANSI A118.3) qualification is an important hallmark of great quality to look out for when evaluating epoxy grout options.

    What Is Cement Grout?

    Cement grout is made with water, cement, and sand. Cement grout comes in a variety of forms (e.g., high-abrasion, fast-setting, etc.) and is used in a range of industrial applications.

    Epoxy Grout vs. Cement Grout

    While cement grouts are implemented throughout a wide range of industries, they make a poor choice for machinery grout for a number of reasons. For example:

    • Cement grout is not designed to resist continuous impact loading and the vibrations of heavy machinery. When exposed to these stresses, the material cracks or otherwise experiences damage, which can have severe ramifications for both the machine and the concrete beneath it. Epoxy grout, on the other hand, has incredible bond strength and natural resistance to vibration.
    • Cement grout can shrink between the base plate and sole plate. If this happens, the grout may crack, threatening the stability of the bond between the two plates. Epoxy grout has low inherent shrinkage, reducing this risk.
    • Cement grouts are also vulnerable to chemical attack which can degrade the grout over time. Epoxy grouts are both water- and chemical-resistant, making them ideal for heavy machinery, especially in facilities exposed to chemicals or wet processing.

    What Is the Machine Base Plate Grouting Procedure?

    Properly grouting a sole plate involves the following steps:

    1. Preparing the surface of the concrete and the sole plates. Before installation of the grout, the surface of the concrete and the plate must be adequately prepared. The surfaces of all components should be free of dust, dirt, and debris that may affect the quality of the grout bond. For the plate, any primers or coatings should also be removed prior to installation.
    2. Pouring the grout. To pour epoxy grout successfully, optimal viscosity, flow rate, and grout temperature conditions must be met—each of these aspects can be advised and verified by the grout manufacturer. A leakproof form should be built to surround the base plate. Using a grout headbox to facilitate the flow of the grout into the form.
    3. Finishing the edges of the base plate. Cement grouts require finishes that are flush to the edge of the plate and chamfered at a slope, while epoxy grouts can be tapered off beyond the edge of the plate.

    During base plate grouting operations, some of the most common problems that arise include:

    • Incorrect grout usage. Make sure you are using the appropriate grout for your unique situation. If you’re using heavy machinery that generates vibrations, you may want to use epoxy grout.
    • Voids in the grout. Always fully mix the grout (i.e., mix the liquids together before adding the aggregate) and ensure that the base plate is level, the headbox is correct size to allow the grout flow correctly.
    • Formation of cracks in the grout. If you’re using cement grout, you must manage the grout expansion under the base plate. If you’re using epoxy grout, you don’t have to worry about this issue due to its low inherent shrinkage provided the depth of pour is considered.

    Contact Copps Industries for Your Epoxy Grout Needs

    When mounting machinery—especially any type that generates or must endure significant vibrations—to base plates, epoxy grouts are the ideal solution. At Copps Industries, we provide a variety of epoxy grout solutions, including:

    For more information on epoxy grouts or our product offerings, contact us today. If you’re ready to get started with an epoxy grout and would like to reach out to the Copps Industries team, please request a quote.