Prime Practices

Anchoring Bolts, Dowel Bars and Rebar with Epoxy

Call: 1-800-321-7212

Epoxy Application Guide

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.

How-To: Anchoring Bolts, Dowels and Rebar With Epoxy

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.

Selecting the correct product

Use Prime Bond 3000 or Prime Bond 3100 to produce pourable grout for horizontal applications.

Use Prime Bond 3900 LPL for horizontal applications where long pot life is desired.

Use Prime Gel 2100 or Prime Gel 2000 to produce non-sag grout for vertical and overhead applications.

 

Application procedures

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.

C.  Mixing

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.

Ratios and yields                                        

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

D.  Installation
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.

E.  Curing
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.

F.  Cleaning
Prior to curing, epoxies may be removed from tools and equipment using Xylene or lacquer thinner.