3-Part Epoxy Grouting System for Pile Capping

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1 Product Data Sheet Edition: 10/10/2012 Identification no. Version no: GCC Sikadur -42 PC Sikadur -42 PC 3-Part Epoxy Grouting System for Pile Capping Product Description Uses Characteristics / Advantages Sikadur -42 PC is a solvent-free, high strength, castable, three-component, solvent free, moisture tolerant, epoxy grouting system specially designed for pile cap applications.. Suitable for use under tropical and hot climatic conditions. Sikadur -42 PC can be used for the following applications; High strength grouting and topping of concrete pile caps and pile heads To fill cavities in concrete Sikadur -42 PC offers many benefits to the user: Solvent-free High early strength Watertight and waterproof Moisture tolerant Corrosion and chemically resistant to aggressive soils Shrinkage-free hardening High mechanical strengths Tough vibration-resistant material Product Data Form Appearance / Colour Packaging Components A + B: Resinous liquid Component C: Powders and aggregates Mixed: Grey 27kg units (A+B+C) Storage Storage Conditions Shelf Life Store in dry conditions in original sealed packaging at temperatures between +5 C and +35 C. Protect from heat and direct sunlight. Minimum 24 months from date of production if stored properly in original unopened, sealed and undamaged packaging. Technical Data Chemical Base Density (at 23 C) Mixing Ratio Layer thickness (per layer) Epoxy Resins and natural aggregates ~ 2.20 kg/lt (mixed) A : B : C = 5 : 1 : 35 parts by weight Add component C according to climatic conditions and desired application behaviour. 10 mm minimum 100 mm maximum 1 Sikadur -42 PC 1/5

2 Change of Volume Creep: 2.76 N/mm 2 (400 psi) / N (+60 C) 0.11% (ASTM C1181) Linear Shrinkage: 0.032% (ASTM C531) 0.02% (EN 52450) Thermal Expansion Coefficient Water Absorption Coefficient W Thermal Stability 2.1 x 10-5 mm/mm/ C (Temp. range -30 C C) (ASTM C531) 3.8 x 10-5 mm/mm/ C (Temp. range +24 C C) 0.055% (7 days) (ASTM C413) Heat Deflection Temperature HDT: HDT = +54 C (7 days / +23 C) (ISO 75) Effective Bearing Area 90% (ASTM C1339) Pot Life ~100 min at 20 C ~ 70 min at 35 C ~ 45 min at 40 C Full Cure (at 25 C) Approximate 14 days Mechanical / Physical Properties Strengths (at 25 C) Compressive strength ~ N/mm 2 (ASTM C579) Flexural strength ~ N/mm 2 (ASTM C580) Tensile Strength ~ N/mm 2 (ASTM D638) Adhesion (on Concrete) ~ 3.5 N/mm 2 (Concrete failure) (Typical values at 7days) E-Modulus N/mm 2 (Compressive) (ASTM D695-96) Elongation ~ 1.6% (ASTM D638) Elongation at Break 0.1 ± 0.05% (7 days at +23 C) (ISO 75) Thermal Compatability No delamination / pass (ASTM C884) Exotherm Peak 38 C (at +25 C) (ASTM D 2471) Strength Development Confirm the strength development by producing cubes on site and testing them for compressive and flexural strength. Application Details Substrate Quality Mortar and concrete should be cured for days or, it must achieve a minimum strength requirement as per ACI 503R recommendations, where a minimum compressive strength of Mpa and pull off strength greater than 1.20 Mpa. Verify the substrate strength (concrete, natural stone etc.). The substrate surface (all types) must be clean, dry and free from contaminants such as dirt, oil, grease, existing surface treatments and coatings etc. Steel substrates must be de-rusted to a standard equivalent to SA 2.5. The substrate must be sound and all loose particles must be removed. Substrate must be dry or mat damp and free from any standing water, ice etc. 2 Sikadur -42 PC 2/5

3 Substrate Preparation Substrate Temperature Application Temperature Material Temperature Substrate Moisture Content Dew Point Concrete, mortar, stone: Substrates must be sound, dry, clean and free from laitance, ice, standing water, grease, oils, old surface treatments or coatings and all loose or friable particles must be removed to achieve a laitance and contaminant free, open textured surface. Steel: Must be cleaned and prepared thoroughly to an acceptable quality standard equivalent to SA 2.5 i.e. by blastcleaning and vacuuming. Avoid dew point conditions. Surface and base plate contact area must be clean and sound. For best results, the substrate shall be dry. Remove dust, laitance, oils, grease, curing compounds, impregnations, waxes, foreign particles, coatings, and disintegrated materials by mechanical means, i.e. chipping with a chisel, blastcleaning etc. All anchor pockets or sleeves must be free of water. Apply grout immediately to prevent re-oxidizing / rust formation. +8 C min. / +40 C max. +8 C min. / +40 C max. Sikadur -42 PC must be applied at mixed grout temperatures between +5 C and +35 C. Store material at temperatures of between 20 C -25 C (room temperature) for at least 48 hours prior to its use. 4% pbw Beware of condensation! Substrate temperature during application must be at least 3 C above dew point to avoid condensation. Application Instructions Mix Ratio Mixing Time Application Methods/ Tools Cleaning of Tools Part A : B : C = 5 : 1 : 35 by weight Pour all of component B into the component A container. Mix with a basket type stirrer connected to an electric mixer of low speed ( rpm). Mix thoroughly until uniformly blended in colour and viscosity and avoid entraining air. Pour the mixture into a suitable mixing vessel and slowly add component C (to keep air entrapment at a minimum). Stir for approximately 5 minutes until mortar of a homogeneous consistency is obtained. Mix only that quantity which can be used within its potlife. Note: Never mix only Component A and B without adding component C (as the exothermic reaction between A and B alone generates excess heat) Prior to application, allow the mix to stand for a short time to allow entrained air to escape. The consistency of the Sikadur -42 PC epoxy grout system requires the use of permanent or temporary forms to contain the material on top of pile head or pile cap and around base plates. In order to prevent leakage or seepage, all of these formers must be sealed. Pour the Sikadur -42 PC mortar onto the pile cap surface or into a prepared opening (hopper) and maintain enough static pressure to achieve the desired flow. The mortar may be spread by steel trowel to the required thickness levels. Ensure that entrapped air can easily escape. Large volumes have to be poured in layers. Pour next layer as soon as the previously applied layer has hardened and started to cool. Avoid Shoulders whenever possible. Opened containers (Comp A & B) must be closed immediately after use. Clean all tools and application equipment with Sika Colma Cleaner immediately after use. Hardened/cured material can only be mechanically removed. Sweep excess grout into appropriate containers for disposal before it has hardened. Dispose of in accordance with applicable local regulations. 3 Sikadur -42 PC 3/5

4 Notes on Application / Limitations Do not thin with solvents. Solvents will prevent proper curing and change mechanical properties. Sikadur -42 PC is a vapour barrier when cured. Cold ambient, substrate or material temperatures will influence the curing and flow characteristics of Sikadur -42 PC. Do not subject cured epoxy grout to sudden temperature changes especially during early curing stages. Protect from direct sunlight. The higher the temperature of the product the quicker the reaction time and the shorter the potlife. For large or specific grouting projects please contact Sika Technical Services Department for advice. 4 Sikadur -42 PC 4/5

5 Value Base Local Restrictions Health and Safety Information Legal Notes All technical data stated in this Product Data Sheet are based on laboratory tests. Actual measured data may vary due to circumstances beyond our control Please note that as a result of specific local regulations the performance of this product may vary from country to country. Please consult the local Product Data Sheet for the exact description of the product uses. For information and advice on the safe handling, storage and disposal of chemical products, users shall refer to the most recent Material Safety Data Sheet containing physical, ecological, toxicological and other safety-related data The information, and, in particular, the recommendations relating to the application and end-use of Sika products, are given in good faith based on Sika's current knowledge and experience of the products when properly stored, handled and applied under normal conditions in accordance with Sika s recommendations. In practice, the differences in materials, substrates and actual site conditions are such that no warranty in respect of merchantability or of fitness for a particular purpose, nor any liability arising out of any legal relationship whatsoever, can be inferred either from this information, or from any written recommendations, or from any other advice offered. The user of the product must test the product s suitability for the intended application and purpose. Sika reserves the right to change the properties of its products. The proprietary rights of third parties must be observed. All orders are accepted subject to our current terms of sale and delivery. Users must always refer to the most recent issue of the local Product Data Sheet for the product concerned, copies of which will be supplied on request. All products are manufactured under a management system certified to conform to the requirements of the quality, environmental and occupational health & safety standards ISO 9001, ISO and OHSAS Sika UAE L.L.C P.O. Box Dubai, United Arab Emirates Phone: Sika Gulf B.S.C (c) P.O. Box Adliya, Kingdom of Bahrain Phone: Sika Saudi Arabia Co. Ltd P.O. Box , Jeddah 21371, Saudi Arabia Phone: Sikadur -42 PC 5/5

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