Protecting concrete usually means shielding it from the elements of nature or from harsh manmade chemicals. But it’s not just concrete that needs such protection. Corrugated metal pipe, steel surfaces, material hoppers, rail cars and masonry all can come in contact with corrosive or abrasive materials or harsh conditions.
The geotechnical needs of DOTs and other agencies responsible for roads and bridges are vast. Issues include: Culvert repair Soil stabilization Void filling Concrete slab lifting Sinkhole remediation Slope control Slough control in tunneling
The most critical aspects when using epoxies are surface preparation and material mixing. Other factors include proper application technique and the effects of temperature on the mixing, applying and curing of the material.
Information on the technical data sheet for the individual Prime Resins products will help you choose the right product for a specific application, these instructions supplement that information and includes more detail to aid specifiers and applicators alike.
When epoxies are used correctly, they are a premium product for structural concrete repair and preservation; however, there are applications where other materials are appropriate. If you are not sure which product to choose, call your technical consultant or the main number at 800-321-7212.
Epoxy can be used for anchoring bolts, dowels and reinforcing bars, i.e. rebar, into concrete and masonry. These systems exhibit high bond, tensile and compressive strengths and are moisture insensitive after curing.
Use Prime Bond 3900 LPL for horizontal applications where long pot life is desired.
Be sure to use proper personal protective equipment as outlined by OSHA or the relevant work safety authority in your location. Consult the SDS for the specific product you are using for safety, first aid and clean up information.
A. Hole Dimensions
The annular space between anchor and hole should be as small as possible, yet still provide ease of placement. Depth of embedment guidelines:
1- When the substrate has compressive strength of 3000 psi and greater, or the anchor bolts are threaded, the minimum depth is 10 times the bolt diameter.
2- When the substrate has compressive strength less than 3000 psi or when grouting smooth bolts, the minimum depth of embedment is at least 15 times bolt diameter.
B. Surface Preparation
Bolts, dowels or rebar must be clean, dry and degreased.
Dry Drilling: vacuum or blow out hole using oil-free compressed air
Wet Drilling: wash out hole with clean water to remove residue of drilling slurry. Remove standing water. It is preferable to allow the hole(s) to dry.
For ease of mixing and handling, epoxy and aggregate should be conditioned to 70°F (21°C). Stir each component separately, scraping the sides and bottom of the container. Blend both components together and mix completely using a slow speed drill at a maximum 600 RPM for 2-3 minutes. Add clean, dry 30-50 mesh silica sand as specified and mix thoroughly.
|Surface||Epoxy||Max. Amt. 30-50 mesh Silica Sand||Approx. Yield|
|Horizontal||Prime Bond 3000 or
Prime Bond 3100
|2 parts by volume||508 cubic inches|
|Prime Bond 3900 LPL||3 parts by volume||646 cubic inches|
|Vertical/Overhead||Prime Gel 2000 or
Prime Gel 2100
|1 part by volume||369 cubic inches|
For horizontal surfaces, two methods are acceptable.
1- Pour epoxy grout into the hole and insert bolt, dowel or rebar and work it up and down. Lightly tap to ensure complete embedment.
2- Insert bolt, dowel or rebar into drilled hole and pour epoxy grout around it. Use template or wedges if necessary to hold in position.
For vertical and overhead surfaces:
Place epoxy grout into drilled hole with hand or power operated bulk caulking gun with large diameter tip and polyethylene extension tub. Insert bolt, dowel or rebar and work back and forth to ensure complete embedment. Position in place with template or wedges if necessary.
The cure time is dependent upon the temperature of the substrate. To accelerate cure, pre-heat bolts to approximately 150°F (66°C) at the time of installation and maintain artificial heat on bolt and surrounding area.
Prior to curing, epoxies may be removed from tools and equipment using Xylene or lacquer thinner.