What Is Epoxy Grout?

Industrial-grade epoxy grout is a compound consisting of an epoxy resin combined with an engineered aggregate. The resulting material exhibits excellent resistance to damage and degradation resulting from chemical corrosion, heat, moisture, vibration, repeated dynamic loading, and other operational and environmental stresses. These qualities make it highly suitable for application beneath the base plates of process machinery and other heavy equipment used for industrial purposes as its durability and longevity help ensure the units remain securely mounted to the sole plates affixed to the concrete foundation.

There are numerous types of epoxy grout available. Many of them have bond strength, chemical resistance, and alignment performance that surpass cementitious grout in most applications.

Epoxy grouts are suitable for a range of different applications as they provide advantageous properties.

How Epoxy Grout Works

The application of industrial-grade epoxy grout underneath the base plates of heavy machinery can provide full contact load transfer to the concrete foundation, which helps isolate vibrations and ensure secure installation. However, the compound must be applied properly to achieve these benefits. The typical epoxy grout application process is as follows:

Surface Preparation

Surface Preparation

The surfaces of the base/sole plates are sandblasted to a “white metal” condition. If grout application will not occur within 24 hours of surface preparation, the plates need to be primed with a non-aqueous primer. Additionally, the anchor bolts should be coated with a thick layer of paste wax or grease.

Mixing

Mixing

The epoxy grout needs to be mixed prior to application. This process can vary depending on the type of grout. For example:

  • Two-component grout consists of a resin and a hardener. First, the resin is premixed, and then the hardener is poured into it. Finally, the mixture is mixed until it is uniform in color, which typically takes three to four minutes.
  • Three-component grout consists of a resin, a hardener, and an aggregate. First, the hardener and resin are mixed until a uniform color is attained. This mixture is then poured into a mortar mixer and combined with aggregate. Finally, the compound is mixed until all of the aggregate is wetted, which typically takes three to four minutes.

Application

Application

Once the epoxy grout mixture is prepared, it can be placed immediately. Sweeping the grout from one base side to the other helps eliminate air entrapment, which can interfere with the performance of the grout.

How Epoxy Grout Works

The application of industrial-grade epoxy grout underneath the base plates of heavy machinery can provide full contact load transfer to the concrete foundation, which helps isolate vibrations and ensure secure installation. However, the compound must be applied properly to achieve these benefits. The typical epoxy grout application process is as follows:

  • Surface Preparation

    The surfaces of the base/sole plates are sandblasted to a “white metal” condition. If grout application will not occur within 24 hours of surface preparation, the plates need to be primed with a non-aqueous primer. Additionally, the anchor bolts should be coated with a thick layer of paste wax or grease.

    Surface Preparation
  • Mixing

    The epoxy grout needs to be mixed prior to application. This process can vary depending on the type of grout. For example:

    • Two-component grout consists of a resin and a hardener. First, the resin is premixed, and then the hardener is poured into it. Finally, the mixture is mixed until it is uniform in color, which typically takes three to four minutes.
    • Three-component grout consists of a resin, a hardener, and an aggregate. First, the hardener and resin are mixed until a uniform color is attained. This mixture is then poured into a mortar mixer and combined with aggregate. Finally, the compound is mixed until all of the aggregate is wetted, which typically takes three to four minutes.
    Mixing
  • Application

    Once the epoxy grout mixture is prepared, it can be placed immediately. Sweeping the grout from one base side to the other helps eliminate air entrapment, which can interfere with the performance of the grout.

    Application

Advantages of Using Epoxy Grout

Epoxy grout offers a number of advantages over traditional cementitious grout, such as:

Higher Strength

While cement grout is generally less expensive than epoxy grout, it is best suited for smooth running equipment that exhibits minimal or static load impact. In contrast, epoxy grout can be specifically developed for a range of demanding environments, including those with excessive temperatures, vibrations, weather factors, and chemical interactions.

Faster Strength Development

Industrial epoxy grouts cure and develop compressive strength much quicker than cement grouts. They cure within hours and feature the same characteristics as month-old, fully cured cement grout. As a result, grouting-to-equipment startup can be performed within a single day, which practically eliminates machinery downtime.

Easier Anchor Setting Requirements

The excellent compressive and tensile strength, fast cure times, and high bond strength of epoxy grouts are ideal for anchoring. Additionally, epoxy grouts minimize the risk of voids and entrapments that can form near the bolts during the setting of heavy equipment or process machinery. In combination with anchor bolts, they help keep large generators, wind turbines, metalworking mills, and other industrial equipment securely in place.

When to Use Epoxy Grout

Epoxy grouts are a suitable alternative to cementitious grouts for many applications. However, they are the ideal option for ensuring secure installation and stabilization of industrial equipment in demanding environments. Since the compounds offer greater bond strength, alignment performance, and chemical resistance than cementitious grouts, they are better at withstanding extreme conditions.

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.

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ProductComponentsViscosity
@25°C
cps
Pot life
@ 22°C,
min.
Compressive
Strength, psi
Service
Temperature
-°F(°C)
Depth
of Pour
(in.)
Water
Absorption
30 days @
22°C, %
Safety
Data Sheet
(SDS)
Technical Specs
K-005 Quick FillTwo8,0002016,500200° (93°)10.40
to access the Safety Data Sheets (SDS)
K-020 Non-Corrosive Quick FillTwo10,0002015,000175° (79°)10.50
K-028 Deep PourThree37,0004515,900250° (121°)80.15
to access the Safety Data Sheets (SDS)
K-840 Non-Corrosive Deep PourThree37,0004515,200250° (121°)80.17
to access the Safety Data Sheets (SDS)
K-829 Rapid Strength GroutThree28,0006017,300300° (149°)20.22
K-009 High PerformanceTwo13,0003019,000325° (163°)1/20.23
to access the Safety Data Sheets (SDS)
K-052 XTra TempTwo7,0006017,200425° (218°)1/20.50
to access the Safety Data Sheets (SDS)
K-021 Crane RailTwo25,0004517,800250° (121°)20.14
to access the Safety Data Sheets (SDS)
K-011 Acid ResistantThree20,0002017,500325° (163°)20.24
K-027 Water ImperviousTwo7,5002518,000225° (107°)10.30
to access the Safety Data Sheets (SDS)
K-837 Non-Corrosive Pumpable GroutTwo8,0002016,000225° (107°)10.30
K-026 Low TempTwo4,000718,700200° (93°)20.50
to access the Safety Data Sheets (SDS)