Equipment Grouting Guide

01. Selecting the Right Grout for Your Application

Choosing the right grout is critical to equipment performance and long-term durability. The decision between cementitious grout and epoxy grout depends on your project’s load demands, vibration levels, temperature swings, and chemical exposure. To avoid installation problems, review product data sheets or consult an expert familiar with your site conditions. If you need help, Indcon’s team can guide you through the grout selection process.

Each type of grout fits different application needs:

• Cementitious grout (such as Five Star Grout) works well in static load conditions, precast concrete installations, and structural steel grouting. It offers high compressive strength, positive expansion, and straightforward placement.

• Epoxy grout (like Five Star DP Epoxy Grout) is better suited for dynamic equipment, chemical processing environments, and high-impact settings. It delivers excellent chemical resistance, high bond strength to steel, and low creep under sustained load.

02. Surface Preparation: Ensuring a Strong Bond

Proper surface preparation is essential to achieving a strong bond between the grout and baseplate. Without it, even the best grout can fail due to poor adhesion. Cleaning and profiling the substrate ensures long-term performance, especially in demanding industrial environments.

For Cementitious Grouts (e.g., Five Star Grout):

• Remove all oil, grease, dust, and debris from concrete and steel surfaces.
• Roughen concrete to expose coarse aggregate. Follow ICRI surface profile guidelines (CSP 6 to 9).
• Pre-soak concrete with clean water for 8 to 24 hours before grouting. Remove standing water before placement.

For Epoxy Grouts (e.g., Five Star DP Epoxy Grout):

• Surfaces must be dry. Epoxy grouts do not bond well to moisture.
• Remove all contaminants and mechanically roughen concrete for improved adhesion.
• Prepare steel surfaces to a commercial blast finish (SSPC-SP6) to promote maximum bond strength.

03. Formwork: Containment for Proper Placement

Formwork plays a key role in successful grout placement. Well-sealed, rigid forms help shape the pour, contain the material, and prevent leaks during installation. A simple test: if your forms can hold water, they can hold grout. Form failure can result in wasted material and poor support, so proper construction is critical.

Best practices for grout formwork:

• Use rigid, liquid-tight, and non-absorbent form materials that can handle the weight and pressure of the grout.
• Secure all joints to eliminate movement and prevent leaks or grout displacement during the pour.
• Maintain 1 to 2 inches of clearance around baseplates to allow for complete flow and coverage.
• For cementitious grout, apply a form release agent on areas where bond is not desired.
• When working with epoxy grout, coat form surfaces with multiple layers of paste wax to prevent bonding.

04. Mixing: Achieving the Right Consistency

Proper mixing is critical for grout performance. The right consistency ensures full flow, maximum strength, and long-term stability. Cementitious and epoxy grouts require different mixing techniques, so follow the correct method for your application to avoid weak spots, poor bonding, or shortened working time.

For Cementitious Grouts (e.g., Five Star Grout):

• Use a mortar mixer for large batches. A drill with a paddle attachment works for small mixes.
• Mix for 4 to 5 minutes until the grout is smooth and free of lumps.
• Follow the manufacturer’s water guidelines carefully. Typical water range is 7 to 11 quarts per 100 lb bag. Do not exceed this limit.

For Epoxy Grouts (e.g., Five Star DP Epoxy Grout):

• Pre-condition all components to 70°F to 80°F before mixing.
• Start by blending Component A (resin) and Component B (hardener) until fully mixed.
• Slowly add Component C (aggregate) while mixing in a mortar mixer.
• Use 4 bags of aggregate for high-flow applications or 5 bags for standard-flow consistency.
• Limit mixing time to reduce air entrapment and heat buildup, which can affect strength and pot life.

05. Placement: Pouring or Packing for Full Support

Grout placement should begin immediately after mixing to avoid setting delays and ensure proper flow. Whether you’re using cementitious or epoxy grout, correct placement techniques help eliminate air pockets, improve contact under the baseplate, and deliver full bearing support.

For Cementitious Grouts (e.g., Five Star Grout):

• Pour continuously from one side to help push air out and avoid voids beneath the baseplate.
• Maintain a minimum grout thickness of 1 inch (25 mm).
• For placements over 6 inches (150 mm), extend the mix with clean, damp, coarse aggregate that meets ASTM C33 standards.
• Cement grout can be poured, dry packed, or pumped, depending on jobsite needs.

For Epoxy Grouts (e.g., Five Star DP Epoxy Grout):

• Pour from one side to promote full contact and reduce the risk of trapped air.
• Use a headbox to improve grout flow and help with air displacement under the equipment.
• Maintain a minimum placement thickness of ½ inch (13 mm) and do not exceed a maximum of 18 inches (457 mm) per lift.
• Epoxy grout is self-leveling, but a plunger or paddle can help guide flow in tight areas.

06. Curing: Protecting the Grout for Maximum Strength

Curing is one of the most important steps in equipment grouting. Rushing this phase can lead to reduced strength, cracking, or early failure. Cementitious and epoxy grouts require different curing methods, but both need protection from environmental stress during this period. Allow the full cure time before placing equipment into service to ensure reliable, long-term performance.

For Cementitious Grouts (e.g.,Five Star Grout):

• Wet cure for a minimum of 3 days using damp burlap, plastic sheeting, or similar materials to retain moisture.
• After the first 24 hours, apply a curing compound that meets ASTM C309 to prevent water loss and shrinkage.
• Protect the grout from direct sunlight, freeze-thaw cycles, and mechanical loading during the cure period.

For Epoxy Grouts (e.g., Five Star DP Epoxy Grout):

• Epoxy grout does not require wet curing but must be kept dry and shielded from sunlight.
• Avoid any water exposure or contamination during the full cure cycle.
• Allow 24 to 48 hours before applying heavy loads, depending on ambient temperature and product specifications.

07. Equipment Grouting Post-Placement and Cleanup

Once the grout has been placed, verify that equipment remains properly aligned and that there is complete grout coverage beneath the baseplate. Catching issues early prevents long-term problems and ensures the foundation performs as intended.

Post-placement tasks and cleanup steps:

• Confirm full contact under the baseplate and correct any misalignment before the grout sets.
• For cementitious grouts, trim any excess material before it hardens completely to simplify finishing.
• For epoxy grouts, smooth exposed edges with a solvent-wiped trowel while the material is still workable.
• Clean all tools and equipment immediately after use. Cement-based grout can be cleaned with water, while epoxy grout may require a solvent or soap and water. Refer to the product’s technical datasheet for specific cleanup guidance.

08. Additional Equipment Grouting Considerations

Successful equipment grouting depends on more than just placement and cure. Environmental conditions, material quantities, and long-term maintenance all play a role in performance. Keep these factors in mind to avoid problems and extend service life.

Temperature Control:

• Cementitious grout should be protected from freezing until it reaches at least 1,000 psi compressive strength.
• Epoxy grout performs best between 55°F and 90°F. Avoid placement outside this range to prevent issues with bonding and cure rate.

Yield and Material Planning:

• For large volume placements, cementitious grout may require extension with clean aggregate to maintain strength and reduce shrinkage.
• Epoxy grout must be measured and mixed accurately to ensure full coverage and minimize waste.

Monitoring Long-Term Performance:

• Do not place equipment into service until the grout has reached its specified compressive strength.
• Periodically inspect grouted baseplates for cracking, edge deterioration, or other signs of wear that could indicate loading or installation problems.

Final Checklist for a Successful Equipment Grouting

• Concrete substrate roughened and properly prepared
• Formwork sealed, rigid, and secured
• Grout type selected based on load, vibration, and environment
• Mixed in accordance with manufacturer’s instructions
• Placement method used to ensure full contact and eliminate voids
• Curing process followed based on grout type
• Cleanup completed before material sets

Following this equipment grouting checklist helps ensure a strong bond, long service life, and consistent performance across industrial installations. Whether you’re working with epoxy or cementitious grout, proper planning and execution make the difference between a reliable foundation and one that leads to costly failures.

If you need help selecting the right grout or addressing site-specific challenges, Indcon offers expert support and a full line of high-performance grouting materials for industrial applications.

Have questions about product selection or installation methods? Contact us for technical guidance or view our line sheet to see the full range of grout solutions we supply.