ITW Polymer Technologies - Chockfast Grout

ITW Polymer Technologies specializes in the manufacture of epoxy grouting products; the ideal way to achieve enhanced reliability and lower operating costs for industrial machinery and equipment worldwide.

Epoxy Grout & Equipment Reliability / A Constructive Relationship

Equipment Reliability is a key component of, and is directly proportional to, profitability with today’s industrial producers. Many users of dynamic industrial machinery know this to be true and go to great lengths to attain greater operating efficiency and reliability in their equipment to achieve lower operating costs. In doing so, greater productivity is possible with a noticeable positive effect on the bottom line.
There is an unlimited number of dynamically-operating machinery and equipment applications in critical industrial service roles . . . .

Pumps Steam and Gas Turbines Compressors Engines Pulverizers Lathes Ball Mills Chippers Generators Wind Turbines Ash Handling Systems	Exciters Blowers Plate Mills Electric Motors Granulators Coker Drums ID Fans Crane & Gantry Rails Separators Fluid Drives Gear Drives	Rolling Mills Presses Mixers Boring Mills Shredders Conveyor Evaporators Clarifiers Rail Car Unloaders Cooling Tower Fans Extruders

In a Diversity of Industries Worldwide . . . .

Chemical Petrochemical Refining Pipeline	Mining Metals Energy Water / Waste Treatment	Pulp & Paper Pharmaceuticals Transportation Manufacturing

Due to the tremendous rigorous operating requirements and severe service environments industrial machinery & equipment are subject to, there are a number of factors that work against the desire to optimize reliability. Deficient machinery performance and outright failure in equipment can many times be attributed to one or more root causes . . . .
Faulty Design Material Defects Fabrication Errors	Processing Errors Assembly or Installation Defects Unintended Service Conditions	Maintenance Deficiencies - Neglect - Ineffective Procedures - Improper Operation

The equipment foundation is a key collaborator in the mission to improve and maintain operating reliability and itself is subject to a wide array of conditions that affect its ability to perform its intended function . . . . . .

Oil - Oil impregnation into the foundation is common within a plant environment.
Vibration - Foundations which experience high physical shock loads or continuous vibration are likely to experience cracks leading to other structural deficiencies.
Poor Adhesion - Cementitious grout used in pump applications often will experience a deterioration of its adhesive bond to the concrete foundation and to the steel baseplate it is supporting.
Chemicals - Particularly in caustic environments within a plant; chemical attack of foundations and other concrete surfaces is a major problem.
Moisture and Chlorides - Many foundations are continuously subjected to moisture. Coastal areas have additional problems caused by salt water introducing chlorides into the concrete, causing rebar and baseplate corrosion.
Heat and Thermal Cycling - Cycles of temperature have an adverse affect on foundations. Cracks, fragmentation and delimitation of existing grout from the concrete foundation are some of the results of heat and thermal cycling.
Age - Age has taken the toll on many plant machinery foundations. The longer a foundation is in service, the longer it is subjected to many or all of the conditions mentioned above.
Poor Installation - Many equipment and foundation problems such as misalignment, baseplate voids and cracks can be attributed to improper preparation and grouting procedures during the initial installation

So where does one begin in the mission to attain greater reliability in their machinery & equipment?
The “Equipment System” In order to plan and achieve the goals of greater operating efficiency & reliability in dynamic equipment and achieve lower operating costs, it is important to understand that the “equipment” itself is just one part of the bigger picture. There are other components that must be taken into consideration that have a direct effect on the outcome.
Components of the “Equipment System”
Equipment Mounting System (If Required) Epoxy Grout Anchoring System Foundation Sub-surface conditions
All components of the “Equipment System” must be addressed and properly engineered when designing for optimum equipment performance.

Design Goals for an Efficient Equipment System

Proper Selection & Engineering of Components – To meet the intended requirements of the system and its intended purpose.
Optimum Equipment Performance – Dependent upon selected system components; their design; installation and maintenance practices.
Costs – Control initial installation as well as equipment life-cycle costs

What Part Does Epoxy Grout Play in Achieving Equipment Reliability?
Maintains Precise Equipment Alignment Epoxy Grout works in collaboration with the anchoring system to maintain the aligned “position” of the equipment critical to efficient performance. Resistance to downward and lateral acting loads on the foundation.
Provides a Superior Structural Conduit Between The Equipment and its Engineered Concrete Foundation Steadfast adhesive bonding to steel and concrete allows efficient load transference from equipment mass (Load & vibration source) to the foundation mass (absorption & dissipation receiver). Enhanced vibration damping properties characteristic of Epoxy Grout assist in additional dissipation of loads & vibration during transference.
Chemical Resistance Assists in extending the service longevity of the Epoxy Grout layer & equipment foundation in severe industrial environments. Protects porous concrete foundation to maintain integrity of the engineered foundation mass.

Other Notable Advantages of ITW Polymer Technologies Epoxy Grouts which Assist in Achieving a Successful Installation and Performance of Equipment . . . . . . .

Exceptional Structural Properties - High Resistance to Compressive, Tensile, Flexural & Shear Loads

Extraordinary Bond Strength to Concrete & Steel

Excellent Vibration Dampening Efficiency

Advanced Resistance to Chemical Attack

Gentle Exothermic Cure Formulations - For Longer Working Times & Deeper Single Cap Pours

Extended Aggregate Guidelines Available to Extend the Epoxy Grouts for Use in Less Critical, but Sizeable Mass Pours.

Fast Curing for Quicker Service Strengths

Pre-measured Components to Promote Consistent Batching and Quality Control

Superior Resistance to Shrinkage, Fretting

Worldwide Product Distribution & Technical Support

So What’s Wrong with Using Cement Grouts?
Cement Grouts have been used for years in much the same role where Epoxy Grouts are used under dynamic industrial machinery & equipment. Q. Why not use cement grouts for the same purpose? A. Because they do not and will not achieve the same results found with epoxy grout. The qualities and service requirements of a grout to perform an enhanced function under dynamic industrial machinery & equipment are only found with the proper use of Epoxy Grout.
Comparison	Epoxy Grout	Cement Grout
Physical Properties	+	-
Vibration Dampening Efficiency	+	-
Resistance to Chemical Attack & Environmental Conditions	+	-
Curing Rate / Strength Gain	+	-
Bonding Capacity	+	-
Resistance to Shrinkage, Fretting	+	-
Pre-Measured Components to Promote Consistent Batching & Quality Control	+	-
Initial Cost - Single Initial Investment	-	+
Cost Efficiency - Cost over time, taking into account grout service life and qualities know to better enhance machinery & equipment performance.	+	-
The Epoxy Grout Maxim “Enhanced, reliable equipment performance attained, in part, through the proper use of Epoxy Grout achieves decreased maintenance and operating costs with greater productivity from your machinery & equipment. This results in an on-going $ savings in maintenance expenditures and increased profitability for your business”
The Right Selection of Products & Components + Best Installation Practices + Best Maintenance Practices = Premium Reliability for your Equipment System

Your Source for Equipment Reliability Solutions