Polyester grout

Urethane grouts Urethane industry Urethane linkages Urethane plastisol Urethane polyesters Urethane polymers... 

In this book I have confined discussion to those polymeric materials which are cured by chemical reaction and which have found widespread application in the construction industry. As such, the book covers materials based on epoxies, polyurethanes, silicones, polysulphides, alkyds and polyesters. In addition, there is a chapter on hybrid polymer systems and one on acrylics. It is true that acrylic emulsions are not strictly thermosetting polymer systems, but their widespread use and importance made their exclusion difficult. These materials find use as coatings, sealants, adhesives, grouts, flooring compounds, repair compounds and waterproofing agents. 

Technologies offered by unsaturated polyesters to the construction industry are directed at specific areas such as anchoring grouts, resin mortars and concretes, coatings and lighting sealants. The properties that make unsaturated polyesters more useful for construction are (Boeing, 1964 Demmler and Schlag, 1971 Manson, 1985) ... 

Polyester anchoring grouts are used mainly for securing bolts, bars, tendons or dowels in drilled or formed holes in concrete, masonry or natural rock. They are particularly suitable where rapid installation and rapid strength gain are required. They are also used in areas where a high degree of corrosion protection is needed. 

Polyester anchoring grouts are supplied in two components, consisting of measured quantities of resin base and catalysed filler. The two components are mixed before application. 

Polyester anchoring grouts are of two types pourable grouts and thixotropic grouts. Pourable products are designed for vertically downwards or declining anchor holes prior to insertion of the anchor unit. The... 

Specific areas of application for polyester anchoring grouts are (Fosroc International, undated a) ... 

The chlorination tower lining is tile set in a polyester or vinyl ester mortar with a Portland cement grout backing. The hypochlorite and peroxide units do not need the resistance of the resin mortar, therefore, Portland cement mortar can be used. Caustic extraction towers are occasionally lined with tile set in Portland cement mortar even though the alkaline operating conditions may soften the tile. To minimize the softening effect, the tile should have an extremely tight, well fired body. 

Chemical grouts (except for epoxies and polyesters) have little strength compared to cement, and the actual strength of a solid mass of chemical grout is of academic interest only. However, the strength of soil formation stabilized with chemical grout is of very practical interest. 

Polyesters and expoxies have been used to seal cracks in rock formations and to anchor rock reinforcement members in drilled holes. The mechanical properties of these materials are much better than those of Portland cement. However, the chemicals are (relative to other grouts) very expensive and very viscous. Rendering them less viscous by using diluents so that they will penetrate sands makes them even more expensive. Because of their limited application as grouts, polyesters and epoxies are not detailed further. 

RESIN GROUT A grout system composed of essentially resinous materials such as epoxys, polyesters, and urethanes. (In Europe, refers to any chemical grout system regardless of chemical origin.)... 

Polyester cements were originally developed as grouting materials for brickwork in chlorine dioxide bleaching systems under the trade name of VitroplastThese products which are also used for the production of cultured marble and large pipes are discussed in detail in Chapters 6 and 7. 

As described in Chapter 1, the original silica-filled unsaturated polyester mortar, called Vitroplast is used as a grouting composition for joining bricks for filling cracks, as a monolithic floor or wall coating, and as a casting composition for articles, such as drain pipes and bathroom fixtures. 

There are two basic methods by which steel bolts and bars may be anchored into concrete, masonry or brickwork utilising epoxy or polyester resin grouts(5). The first involves inserting a deformed bar or bolt into a preformed or drilled hole into which the resin grout has been poured (Fig. 7.3). 

The second type of system is marketed as encapsulated packs of polyester or epoxy resin within which there is a thin skin to keep the two eomponents separated. The capsules are placed in the hole and are fractured when the bolt or bar is inserted and turned (Fig. 7.4). In all such systems it is essential that the fixing is mechanically rotated in the hole to ensure correct mixing of the resin components. The requirements for drilling and cleaning the hole are similar to the poured grout systems but the hole size should be strictly in accordance with the manufacturer s instructions. This is to ensure that the pre-measured volume of resin in the pack completely fills the annulus between the bolt and the hole. 

The concept of encapsulated packets of resin has proved most popular for polyester resin grouts. The degree of intimate mixing required is not so critical as with epoxies, curing rates are faster and installation can take place at lower temperatures. The range of applications is enormous - the fixing of reinforcement starter bars, foundation bolts, machinery and base plates, barriers and safety fences, railway and crane rails, etc. 

A preaccelerated, high reactivity orthophthalic polyester resin for mortar/grouting applications. 

A preacceierated, thixotropic, rapid gel and cure, orthophthalic polyester specifically designed for anchor bolt fixing, mortar and grouting. 

The same polyester resins are used to formulate mortars and grouts as are used to formulate monolithic surfacings and polymer concretes. Carbon and silica fillers are used in the formulations. Polyester resins have a shelf life limitation and should be stored below 60 F (15°C). Any of the polyester-type resins provide suitable resistance to normal atmospheric corrosion (see Table 10.3). 

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