Epoxy Paste Grouting Compound

Two-component, thixotropic modified epoxy paste. 

Uses

As a grouting medium, either as supplied or converted into a mortar, for fixing dowel bars, bolts or other steel overhead or horizontally into concrete or rock. As a fast-setting non-flow adhesive. Grouting vertically downwards use epidermix 395

Advantages
  • Will not drain from hole, including overhead.
  • Stronger than surrounding concrete and steel.
Properties of Wet Material

Mixing ratio 

Do not split kit 

Density 

1.14 g/cm3 

Colour: Base Activator Mixed 

White Dark Amber Light cream 

Flash point 

> 100°C 

Dilution 

Do not dilute 

Consistency 

Thixotropic paste 

Shelf life 

2 years from date of manufacture 

Storage conditions 

Store under cover in cool place 

Packaging 

500ml 

Fire resistance 

Non flammable 

Surface Preparation

All surfaces must be clean, sound and dry.

Cast concrete must be free of all laitance, dust and foreign matter. Drilled concrete must be free of dust and debris and if wet-drilled must be dry and free of all traces of slurry. Any glaze caused by core drilling must be removed by mechanical roughening to ensure good bonding between the adhesive and the concrete rock surface. Close-fitting burrs attached to a long shaft mounted in a power drill will aid in this respect. Smooth steel should be abrasive blast cleaned and must be free of scale, rust and oily material. Deformed and threaded bars should be oil and grease free and preferably free of rust and scale.

Bonding / Priming

Self priming.

Mixing

Mix both containers individually and ideally use a can opener to remove the lip of the containers. Transfer complete contents of both containers to a large clean board or plate, setting up the components side by side and not one on top of the other. Do not combine the components until other aspects of the job are ready. When ready to mix, combine the ingredients together and blend, using at least two trowels or spatula, until the compound is completely mixed. If a mortar is required, add an equivalent volume of silica grit and continue mixing until a homogeneous material is obtained. 

Properties of Cured Material

 Maximum service temp 

70°C 

Compressive strength @ 25°C 

90 MPa @ 7 days 

Solvent resistance 

Resists: aliphatic solvents, vegetable and mineral oils and greases, petroleum fuels 

Water resistance 

Excellent 

Tensile strength @ 25°C 

21 MPa @ 7 days 

Toxicity 

Non-toxic 

Coverage

Grouting with epidermix 396 – Quantity Calculations: 

The quantity of grouting material can be calculated from the formula: 

0,8 (D + d) (D – d)HN = liters of grout required

1000 

where:

D = diameter of hole in cm

d = diameter of bar in cm

H = depth of hole in cm

N = number of holes 

If the dimensions are taken in centimeters, dividing the answer by 1 000 will give the number of liters of grout required, at a 2:1 filling ratio, half of this volume of epidermix will be needed. At 1:1 filling ratio, three quarters of this volume of epidermix will be needed. These figures make no allowance for site wastage of material. 

Provided deformed or threaded steel, either mild or high tensile, is embedded at least 15 diameters it can be expected that any failure of the assembly will be due to tensile rupture of the steel. Thus epidermix grouting allows the steel to develop its full design strength. Regarding the ratio of hole to rod diameter it has been shown that the ultimate coverage bond stress is at its highest at a ratio of 1,3. This reduces as the ratio increased to 1,67 thereafter remaining constant. By increasing the ratio from 1,3 to 1,5 the ultimate average bond stress is decreased some 15%. At a ratio of 1,67 the ultimate average bond stress has decreased some 20%.

Application

If grouting horizontally or overhead, a mastic gun is required with a length of plastic tubing of sufficient diameter to fit tightly over the gun’s nozzle. The tube must be long enough to reach the back of the hole. 

Fill the gun with the mixed epoxy compound or mortar and pump material into the back of the hole, slowly withdrawing the tube until sufficient material has been deposited to fill the hole once the bar has been introduced. 

The bar should be introduced with a rotary motion to ensure wetting of both bar and concrete, if it is important that the bar is truly horizontal a jig or template must be used until the com-pound has set. 

Properties During Application

Application by 

Trowel or mastic gun 

Volume solids 

100% 

Pot life 

15°C 

20°C 

25°C 

30°C 

35°C 

500ml 

80 min 

60 min 

40 min 

30 min 

20 min 

1L 

60 min 

45 min 

30 min 

22 min 

15 min 

Application temp range 

10°C to 40°C Temperature of metal to be grouted should not exceed 25°C at time of grouting. If application temperature is above 30°C consult. a.b.e®.’s Technical Department for special precautions 

Maximum application rate 

Do not grout unfilled epidermix 396 into a hole larger than 1,5 times bar diameter. When grouting with filled epidermix 396 annulus width should be kept as small as possible. 

Application rate 

If mixed, unfilled epidermix 396 will be sufficient for: 1L annulus volume. 1L mixed epidermix 396 filled with dry silica grit will be sufficient for 1,3L annulus volume filled at a loading of 1:1. these figures do not allow for any wastage, which can run as high as 20 – 25%. 

Fire resistance 

Non-flammable 

Equipment clean-up 

abe® super brush cleaner 

Colour 

Ligh

Cleaning

lean with abe® super brush cleaner, before the epoxy has set, after which rinse well with clean water.

Protection on Completion

Against traffic and spillage until cured. 

Temperature & Relative Humidity

See “Properties of wet material”, ”Cured material”, and “During application”.

Model Specification

Two component, low creep, structural epoxy paste grouting compound for fixing starter bars and bolts horizontally or vertically up. 

The grouting compound shall be epidermix 396, a two component, thixotropic structural epoxy compound applied in accordance with the manufacturers recommendations, a.b.e.® Construction Chemicals.

Packaging

epidermix 396 is supplied in 500ml metal containers. 

Handling & Storage

This product has a shelf life of 24 months if kept in a dry cool place in the original packaging. In more extreme conditions this period might be shortened.

Health & Safety

Wet epidermix 396 is toxic but non flammable. Always ventilate the working area well during application and drying. Always wear gloves and eye protection when working with the material and avoid excessive inhalation and skin contact. If material is splashed in the eye, wash with copious quantities of clean water and seek medical attention. Cured epidermix 396 is inert and harmless. 

When transporting liquids and semi liquids by aircraft, ask for material safety data sheet. 

Important Notice

This data sheet is issued as a guide to the use of the product(s) concerned. Whilst a.b.e.® Construction Chemicals endeavors to ensure that any advice, recommendation, specification or information is accurate and correct, the company cannot – because a.b.e.® has no direct or continuous control over where and how a.b.e.® products are applied – accept any liability either directly or indirectly arising from the use of a.b.e.® products, whether or not in accordance with any advice, specification, recommendation, or information given by the company.

Further Information

Where other products are to be used in conjunction with this material, the relevant technical data sheets should be consulted to determine total requirements. a.b.e.® Construction Chemicals has a wealth of technical and practical experience built up over years in the company’s pursuit of excellence in building and construction technology.