What is Epoxy Grout?
Two-component epoxy grouts are formulated in such a way that after mixing with water, they turn into mortar with the least amount of shrinkage and are easily used for grouting, planting rebar or filling cavities and repairing concrete. It is also used to adjust the height of the base plate and the column plate. Epoxy grout (two-component epoxy grout), made of epoxy resin with fine-grained stone materials that work in spaces with a thickness of 20 to 100 mm; In addition, it gives epoxy grout high durability, strength, waterproofness and economic efficiency. Finally, the resulting product is a high-strength, cost-effective and versatile two-component epoxy grout that can be used in a wide range of large and small construction projects.
Epoxy grout has become more and more popular among tile contractors and builders. Unlike cement grout, which is made from a cementitious powder mix, epoxy grout is made from epoxy resins and a filler powder. The grout is extremely durable and almost completely stain proof. Regular grout isn’t waterproof, so unlike epoxy grout, it can absorb water when it’s wet and stain easily. If you’re tired of scrubbing the gunk off your grout, epoxy grout could be your solution.
Epoxy grout is made from two different resins mixed with a filler, making it very waterproof and bettered suited to harsher cleaning products. Epoxy thinsets offer greater bond strength and chemical resistance than cementitious grouts.
The difference between two-component epoxy grout and cement grout
Unlike cement grout, which is made from a mixture of cement powder, epoxy grout is made of two components of epoxy resin, hardener. The different properties of cement grout and epoxy can be mentioned as follows:
- Epoxy grouts have excellent damping properties of dynamic forces compared to cement grouts.
- Epoxy grout provides better bonding and adhesion than cement grout between the foundation concrete and the base plates.
- Epoxy grout hardens faster than regular grout, so less time is required to work with the mixture than conventional grout.
- Epoxy grout has a high chemical resistance, which is much higher than concrete and cement-based grout.
- The adhesion resistance of epoxy grouts is much higher than cement grout, so it can withstand shear forces and transmit lateral forces caused by wind, earthquake and Electra on the column plate.
- Epoxy grouts do not require any curing except for the use of protective coatings for temperatures above 20 degrees or canopies, but cement-based grouts are cured by spraying water for 5 hours or using the curing agent.
- The purchase price of epoxy grout can be 3 to 5 times higher than ordinary grout.
- The coefficient of thermal expansion of epoxy grouts is directly related to the components of the product and should be in line with the ratio of the coefficient of heat of steel and concrete. The most pessimistic reports are 10 millionths of an inch per square inch of temperature rise per degree Fahrenheit. The coefficient of thermal expansion for Portland cement-based grouts is approximately 5.5.
How to calculate grout volume?
Calculating and estimating the amount of grout required is of great importance. For this purpose, in order to facilitate the process of calculating the required amount of grout, Afzir Reinforcement Company has designed an online calculator tool that proposes the required amount of grout in accordance with the operating conditions of your project.
Choosing the right grout and the right way to do it
Choosing the best grout that is suitable for the operation we are considering needs to be considered. On the other hand, the proper method of grouting and proper mixing of its two components guarantees the quality of work. The choice of the appropriate grout and the method of its implementation depends on different environmental conditions and various considerations and requirements. For example, gravity grouting is recommended only for small base plates, or for the executive surface, which has a large area, we should pay more attention to the flow rate and fluidity of the grout. The following tips will help us choose a grout and how to apply it.
The use of expandable grouts in special situations is more appropriate due to the special weather conditions in which the moisture of the grout can be lost due to air temperature and lack of proper curing.
Grouting is done in two forms of gravity and with a pump. Applying grout with a pump allows the grout to be poured with constant pressure and evenly and there is no need to worry about air being trapped in the grout.
In the grouting method with a pump, the maximum resistance can be achieved with the minimum grout thickness. However, in the gravitational method of gravity casting, corresponding to the dough, fluid and fluid states of the grout, it will be possible to obtain the required strength depending on the observance of the restrictions related to the minimum thickness of the grout.
Cement-based grouts are not suitable for severe vibrations and any vibration will cause them to crack and break.
Epoxy grouts and polymer grouts are recommended for operations that require high tensile flexural strength and adhesion, so they are suitable for bolts, rebars and grouts under columns and baseplates.
International standards include epoxy grout based on ACI 351.1R-99
fluidity and efficiency of epoxy grout
Regarding the efficiency of epoxy grout, the scientific judgment of the user, along with experience and engineering vision, determines whether the epoxy grout has sufficient fluidity and efficiency to lay grout under the base plate of the column. The user must also consider the efficiency time (when it takes from the start of mixing the two components to the drying and unusability of the epoxy grout) so that the grout mixing is done before drying.
After pouring under the plate, clean epoxy resin usually shows a few percent shrinkage. Most of this shrinkage occurs when the epoxy resin is in a liquid state, so before it dries and withstands mechanical stresses, the epoxy grout shrinks in size and no shrinkage occurs.
It is noteworthy that the long-term compressive strength of epoxy grout is generally 50 to 100% higher than hydraulic cement grout mixed to a smooth consistency. Power also grows much faster. At normal temperatures, specially formulated epoxy resins may be loaded in less than 24 hours after application. Epoxy grouts have high tensile strength and give high strength to clean and rough steel and concrete surfaces. Higher strength and resilience allow the grout to absorb more energy than hydraulic cement grout during impact loading.
Epoxy grout layer thickness
Use in structures depends on the distance between the base plate and is usually not less than 25 mm. The minimum thickness of epoxy grout depends significantly on the practicality of pouring concrete under the base plate. ACI 351.1R-99 offers a minimum grout thickness of 25 mm. Of course, the thickness should increase by 13 mm for every 300 mm increase in grout flow.
- High compressive, tensile and flexural strength
- Quick and easy implementation
- Using the highest quality materials to make grout
- Possibility of grouting in different thicknesses
- Minimum amount of creep under constant loading
- Resistant to constant dynamic loads
- Resistant to chemical environments
- Use it as a repairing grout to fill cavities and holes in concrete
- Grouting in confined spaces under columns, equipment and industrial machinery with fixed and moving loads.
- Installation of transmission cables and crane base
- Installation of screws and rebar planting and bolt planting in concrete
- Grouting in bridge seats
- Grouting on surfaces that require high resistance to mechanical loads and chemical and waterproof effects.
- Buckets A = 20 kg and B = 10 kg
|Working time (32℃)||
|Mixing ratio ( parts A:B )||
|Tensile strength (7 days)||
|flexural strength (7 days)||
- In this section, we will deal with grout recipe.
- Minimum run thickness: 20 mm.
- Maximum run thickness: 100 mm.
- Do not apply at temperatures below 5 ° C. (Suitable grout temperature is more than 5 ° C.)
- Do not dilute with solvent as it will reduce its compressive and tensile strength.
- The age of the substrate concrete should be between 21 and 28 days, depending on the curing and drying conditions.
How to prepare the substrate
The concrete surface should be clean and free of water and grease as much as possible, and damaged concrete should be removed.
You can use approved chemicals to clean the concrete surface.
Open the bucket and remove the sheet, pour the hardener (component B) into the resin bucket (component A) and stir the mixture with a spatula or hand mixer until it becomes a uniform color.
You can also use a low speed mixer and a quick mixer as long as the mixing does not create air bubbles in the material. Excessive mixing can reduce the quality of grout.
Execution of grout
The grout should be poured continuously from one side to remove air.
Continuous flow of grout is essential
Adequate grout must be available before starting
When grouting, pay attention to the service life (Pot Life) of the product.
Epoxy grout must be cured to retain moisture. The grout is applied using coating materials (curing) or using a wet sack after pouring the grout and according to the weather conditions, it lasts up to three days and then creates a favorable compressive strength for loading.
- Do not breathe epoxy grout vapor.
- Air-purifying devices and masks is recommended to minimize the inhalation of harmful gases in cases where the concentration of grout vapor is high. Do not place any epoxy material near the fire. Because when an epoxy material burns, dangerous vapors are released.
- Avoid skin or eye contact. In case of contact, wash skin with soap and water. In case of contact with eyes, rinse immediately with plenty of water.
- Before using epoxy grout, read all the precautions, specifications and properties listed on the product.
Technical documentation request
Frequently Asked Questions
What is two-component epoxy grout used for?
Two-component epoxy grout (ERG™ 200 code) is one of the types of epoxy base grout that is used in situations where the distance between the bottom of the column plate and under the base plate and the bed needs to be filled and the structural load is evenly distributed.
What are the components of epoxy grout?
Epoxy grout consists of two components, epoxy resin and hardener epoxy resin and is used as a very strong filler or adhesive to install and connect two structural sections and create high static and dynamic resistance.
What are the properties of two-component epoxy grout?
Epoxy grout is a two-component of the grout family that has high compressive, flexural and adhesion resistance. Also, two-component epoxy grout or grout is easy to apply and clean, with a bacteriostatic agent and Bio Block technology, ideal for injecting ceramic tiles.
Why is it recommended to use epoxy grout over cement grout for foundations?
Epoxy grout provides better bonding and adhesion than cement grout between the foundation concrete and the column plate and plates.
What is the effect of high tensile strength of epoxy grout on its performance on concrete and steel surfaces?
Higher strength and elasticity allow the grout to absorb more energy than cement grouts when loaded by impact.
What is the mixing ratio of epoxy grout components?
The components are combined in a ratio of 2 to 1. In fact, for every 2 components A, 1 component B must be mixed.
Where is epoxy two-component grout used?
Epoxy two-component grout for grouting floors and walls in shops, grouting industrial floors and walls, grouting in swimming pools, grouting tanks containing harmful chemicals, grouting ceramic tiles, acid-resistant tile adhesives, gluing marble doors and windowsills and It is also used to adjust the height of the base plate and the column plate.
What is the packaging of two-component epoxy grout?
Two-component epoxy grout is packaged in buckets A = 20 kg and B = 10 kg.
What is the difference between epoxy grout and cement grout?
Unlike cement grout, which is made from a mixture of cement powder, epoxy grout is made of two components of epoxy resin and hardener, which has a dynamic and static load bearing and higher resistance than cement-based grout. It also runs faster than cement grout.
Is the purchase price of epoxy grout more suitable or cement grout?
The purchase price of epoxy grout can be 3 to 5 times higher than cement grout, but according to the desired application and use, the type of grout can be selected.