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• Grout is the thinnest part of the load path and the one nobody sees again. A base plate is set, the space beneath it is filled, and from that moment the whole load of the column, the machine or the bearing passes through that layer.
• Three things end that arrangement early. A grout that shrinks leaves a gap at the edges, so the plate bears on a smaller area than it was designed for. A pour that traps air leaves a void, and under vibration the void grows until the anchor bolts are carrying what the grout was supposed to carry. And a load applied before the grout has reached strength damages it once, permanently.
” None of the three is a product problem. All three are decided by how the pour is set up, which is why the method matters here more than on any other page. “
1 · Machine base, base plate, foundation socket, prefabricated element →
1 · The plant has to run again within the hour →
1 · Deep pockets and sockets, up to 30 cm in one pour →
2 · Crane and tower foundations, bridge bearings, dynamic load, chemical exposure →
3 · Dilatation profiles, rail and metal profiles, heavy-duty industrial floor fixings →
4 · Dowel and starter bar holes →
1 · The plant has to run again within the hour →
1 · Deep pockets and sockets, up to 30 cm in one pour →
2 · Crane and tower foundations, bridge bearings, dynamic load, chemical exposure →
3 · Dilatation profiles, rail and metal profiles, heavy-duty industrial floor fixings →
4 · Dowel and starter bar holes →
When it is preferred:
The standard route for load transfer under steel and concrete. Machine and crane bases, steel column base plates, foundation sockets, column and wall heads, prefabricated element fixing, and any high-strength area under dynamic load.
Three grades cover the same work under different constraints. GROUT (NORMAL) where the programme allows a normal strength gain. GROUT (RAPID) where the surface or the machine has to be back in service within the hour. GROUTX where the pocket is deep, since it can be placed in a single pour up to 30 cm without the layering that ordinary grouts require.
• Concrete substrate sound, clean, and free of laitance, oil and curing compound
• Substrate brought to saturated surface dry: damp throughout, with no free water standing in the pocket
• Anchor bolts, sockets and levelling shims set and checked before mixing
• Formwork built tight against the concrete on all sides, sealed at every edge
• A pouring head formed on one side, high enough to give the grout a head of material to push with
• An escape path left at the far side so displaced air can leave
Nothing is painted onto the concrete before a flowable grout. A bonding slurry brushed into a closed pocket skins over while the formwork is being finished, and by the time the grout arrives it is a film between two things that were supposed to bond. Saturated surface dry is the whole of the preparation.
These are cement-based, high-flow, non-shrink mortars. High flow lets the material travel under a plate and around bolts without being pushed; non-shrink behaviour keeps it in contact with both surfaces once it has set.
The pour is made from one side only. Grout entering from a single point drives the air ahead of it and out of the far side, and the space fills in one direction. Pouring from two sides traps the air in the middle, exactly under the load, where nobody will ever see it.
The head of material above the plate is what keeps the flow moving. When the head drops, the flow stops, and where the flow stops the fill stops.
• Formwork struck after the stated time, not when the surface looks hard
• Exposed grout edges cured and protected against wind and sun
• Load applied according to the strength figures in the data sheet
Pour from one side, keep a head of material above the plate, and stop only when grout appears at the far side. Grout that arrives from two directions meets in the middle and traps the air between them, under the part of the plate that carries the most load.
Key outcomes
• Complete contact under the plate, with no shrinkage away from the edges
• Three grades for the same detail, chosen by the programme and the depth rather than by the load
• Single-pour placement up to 30 cm where the pocket is deep
• Declared under EN 1504-3
Products
• DAUFORM GROUT (NORMAL) · cement-based, high-flow, non-shrink grout, EN 1504-3
• DAUFORM GROUT (RAPID) · same work, trafficable within one hour, EN 1504-3
• DAUFORM GROUTX · cement-based deep-pour grade, placed in a single pour up to 30 cm, otherwise used in the same way as the standard grade
Complementary · Optional
– DAUFORM RPM-L where the pocket or the concrete around it needs repair before grouting
• Substrate sound, dry and mechanically prepared; epoxy will not bond through moisture or contamination
• Oil, grease and curing compound removed
• Formwork built tight and sealed; epoxy grout finds every gap in a form
• Three components mixed in sequence and in full, including the container walls
• Only as much mixed as can be placed within the pot life
Epoxy grout cures by chemical reaction rather than by hydration. It does not need water from the substrate, it does not shrink as it sets, and it reaches compressive and tensile strengths well above a cement grout.
Under vibration, that difference decides the service life of the installation. A cement grout under a crane foundation or a bridge bearing takes cyclic load through a mineral matrix; an epoxy grout takes it through a polymer one, and it also resists the oil, fuel and chemical spillage that surrounds most machines.
The same flow behaviour applies as in the cementitious system: one side, one direction, a head of material, and a way out for the air.
• Formwork struck after the stated cure
• Full cure before the machine is started or the bearing is loaded
• Ambient temperature recorded: epoxy cure time changes with it
Epoxy grout is unforgiving about three things: mixing ratio, surface contamination and temperature. All three are settled before the containers are opened, and none of them can be corrected afterwards.
Key outcomes
• High compressive, tensile and bond strength with no shrinkage
• Resistance to vibration, oils and chemicals
• Declared under EN 1504-3
Products
• DAUPOXY FULLFIX GROUT 3K · three-component flowable epoxy grout, EN 1504-3
Complementary · Optional
– DAUPOXY MORTAR SF 3K where the same works include large-area levelling or structural repair
– DAUFORM GROUTX where the pocket is deeper than the single-lift limit and the exposure does not require epoxy
• Chase or recess cut to the required depth, edges square
• Substrate dry, sound and free of contamination
• Profile offered up dry and checked for level before mixing
• Components mixed in the stated ratio, fully
DAUPOXY FIXER 2K is a trowelled epoxy mortar rather than a poured one. It holds its shape on the trowel, so it can be laid as a bed in a chase, and the profile is pressed into it to level rather than propped and grouted.
Once cured it carries impact and compression without moving, and it resists the water, oils, chemicals and abrasion that industrial floors deliver every day. That combination is why a profile bedded this way stays flush with the floor rather than becoming the edge that damages every wheel that crosses it.
• Profile held to level until the mortar has set
• Full cure before traffic
• Adjacent floor coating applied after the mortar has cured
A trowelled epoxy bed and a poured epoxy grout are not interchangeable. If the detail can be closed and poured, pour it; if it has to be laid and levelled by hand, bed it. Using the wrong one leaves either a hollow or a mess.
Key outcomes
• Profiles and rails set to level and held there
• Resistance to impact, chemicals and abrasion
• Declared under EN 1504-3
Products
• DAUPOXY FIXER 2K · two-component solvent-free epoxy repair and mounting mortar, EN 1504-3
Complementary · Optional
– DAUPOXY FULLFIX GROUT 3K where part of the same work has to be poured rather than trowelled
When it is preferred:
A bar or a bolt has to be set into hardened concrete. Dowel and starter bar holes, connections between an existing element and a new pour, and fixings that will carry load in an industrial floor or a yard slab.
The direction of the hole decides the product. DAUPOXY FIXER 2K holds its shape, so it is packed into horizontal and upward holes and stays there. DAUPOXY MORTAR SF 3K flows and settles, which suits holes drilled downward, where the material can be poured in and the bar pushed through it.
• Hole drilled to the required diameter and depth
• Hole cleaned properly: brushed and blown out until no dust returns.
• This is the step that decides the anchorage
• Concrete dry; epoxy does not bond through moisture
• Bar cleaned of rust, mill scale and oil
• Components mixed in the stated ratio, fully, and only in the quantity that can be placed within the pot life
Epoxy cures by chemical reaction, does not shrink, and bonds to both concrete and steel. In an anchorage that combination is what transfers load: the bar is held by the bond around its full embedded length rather than by friction or by a plug at the mouth of the hole.
The hole is filled from the bottom upward so that no air is trapped behind the material, and the bar is inserted with a turning motion so that the epoxy is worked around the ribs rather than pushed ahead of the bar. Excess material rising at the mouth is the sign that the hole is full.
• Bar held undisturbed and unloaded until the epoxy has cured
• Hole mouth made good
• Load applied only after the stated cure, adjusted for the ambient temperature
The strength of an epoxy anchorage is decided by the cleanliness of the hole, not by the epoxy. Drilling dust left in the hole becomes a release layer between the resin and the concrete, and no product recovers from that. Brush, blow, and repeat until nothing comes back out.
Polyurethane injection resin is not used here. It is made to travel into cracks, which is the opposite of what an anchorage needs; its work is on the concrete repair page.
Key outcomes
• Bars and bolts set into hardened concrete with bond along the full embedment
• One product for horizontal and overhead holes, another for downward holes
• Declared under EN 1504-3
Products
• DAUPOXY FIXER 2K · two-component epoxy mortar that holds its shape, for horizontal and upward holes, EN 1504-3
• DAUPOXY MORTAR SF 3K · three-component flowable epoxy mortar for downward holes, EN 1504-3
• DAUPOXY FULLFIX GROUT 3K · where the same works include larger anchor pockets
Complementary · Note for designed structural connections
– Where the anchorage is a calculated structural connection, the specification will normally call for a product assessed for post-installed reinforcement. The products above are declared under EN 1504-3. See the note at the end of this page.