Epoxy Mortar Application Method
1. Preparing
EngageEpoxy MortarOn the concrete surface, the superficial mortar must be chiseled away to reveal the solid subgrade, ensuring that the grouting surface is clean, dry, and free of grease. The external edge of the concrete joint for grouting should be beveled with a 25mm thick chamfer to increase the bonding area between the grout material and the foundation; the metallic surfaces to be bonded should be free of rust (meeting the glossy requirement of SSPC-SP6). For products used in vertical or roof anticorrosion projects, the construction area should be coated with an epoxy resin mixture of hardener to base ratio 1:0.25 before construction, serving as the底层 for the work.
2. Mold making
For those requiring formwork templates, the templates must be sturdy and well-joined. The inner side should be coated with grease, wax, or adhered with PVC tape for easy demolding. To facilitate pouring and installation of the casting funnel, leave at least 100mm of space between the casting side formwork and the equipment base, and ensure it is at least 100mm above the equipment's bottom plate.钉 a 25mm thick 45-degree angle wood molding on the formwork's inner side at the casting level height to prevent cracks caused by stress concentration at the edges of the casting body.
Construction Temperature
Environmental temperature includes both surface and air temperature. To achieve optimal working conditions, the material should be placed in an environment of 15-25°C for 24 hours prior to grouting; during construction and the following 24 hours, the environmental temperature should be controlled between 5-32°C, with 20°C being ideal. Avoid high temperatures during summer construction; if necessary, set up a shading canopy. In winter, when temperatures are low, a warming canopy should be erected in the grouting area to raise the temperature, ensuring the construction environment is above 5°C, with midday being the preferred time for construction. Mixed material should be used within 15-30 minutes.
4. Mixed
1) Thoroughly mix A (resin, 15.4kg per drum) and B (curing agent, 3.8kg per drum) using a portable mixer (200-250 rpm) for about 3 minutes.
2) In a low-speed, high-power mixer (15-20 rpm), add C (aggregate: 4 bags, 25kg per bag) to mix with A and B compounds. Stir thoroughly until the aggregate is fully saturated, which takes approximately 2-3 minutes. The mixing ratio is: Epoxy Resin: Hardener: Epoxy Aggregate = 1:0.25:6.5
3) To ensure the workability of the mixture (easier for construction operations) during lower temperatures, the amount of C (filler) can be appropriately reduced (depending on the temperature).
4) For equipment grouting, to ensure the mixture achieves the desired flowability, the amount of C (aggregate) can be appropriately reduced.
5. Terms of Use
1) When using grouting, it should be poured from one side to the other; during the grouting process, it can be compressed but not vibrated to prevent air from getting trapped. When the grouting distance exceeds 1.5 meters, use a high-position funnel method for grouting, utilizing the principle of gravity pressure difference to assist. The grouting work must be completed continuously and as quickly as possible. The thickness of a single grouting application should be controlled between 25mm and 350mm. When the grouting area exceeds 1.8m x 1.8m, expansion joints should be set in the grouting area. The depth of a single bolt hole grouting can reach 1500mm.
2) khyzd.com is used for engineering applications such as corrosion prevention. For the application of epoxy mortar, first, evenly apply a layer of epoxy mortar primer to the concrete substrate surface (epoxy resin: hardener in a weight ratio of 1:0.25), while brushing and spreading the epoxy mortar. The area of a single application of epoxy mortar should not be too large; it should be segmented and overlapped, with each section not exceeding 10m², and the overlap interval should be greater than 24 hours. When performing segmented construction, the joints should be staggered. If the thickness of the epoxy mortar layer on the vertical or overhead surface exceeds 10mm, it should be applied in layers. Only when the current layer is sticky to the touch but has started to set, should the next layer be applied. If the layer is fully cured during the application, it is recommended to evenly apply a layer of epoxy mortar primer (epoxy resin: hardener in a weight ratio of 1:0.25) to the layer's surface while brushing and spreading the epoxy mortar. Since epoxy mortar is a highly adhesive material (its viscosity increases with decreasing temperatures), it can be gently pressed during application to ensure a good bond with the base.
3) After the epoxy mortar application is complete, it is recommended to use it three days later (depending on the temperature).
6. Inspect Tightly
After the use of the epoxy mortar, striking the equipment base with a hammer: a tinkling sound indicates a dense grouting layer, while a dull sound suggests an hollowed grouting layer.
7. Surface polishing and demolding
After the use of the epoxy mortar, before initial setting, to achieve an aesthetic effect, the exposed surface can be smoothed with a trowel; for surfaces requiring smoothness, apply a coat of epoxy mortar primer (epoxy resin: hardener in a weight ratio of 1:0.25) evenly on the surface. After final setting, the mold can be removed. Cleaning tools after construction can be done with clean water or solvent.
