Press Plate Deep Pour Epoxy Grouting Issues
May 07, 2021
63
| STATEMENT OF PROBLEM: CCC performed deep pour of Micor epoxy grout between the press plates and the concrete piers, for 20 plates. The epoxy grout was required to have a compressive strength of 10,000PSI. CCC constructed a headbox and used safety cones for the pour, following procedure as provided by Micor rep. However the Micor rep was not able to be there to supervise the pour. When the forms were stripped there was voids present under the plates, and the epoxy in the port holes did not have sufficient height. The Micor rep came and determind that 19 of the 20 press plates were not in compliance. COURSE OF ACTION: CCC removed all 20 press plates and had FMG sawcut out the epoxy grout w/ Wire saw. The plates had to be cleaned at a tooling shop. With the assistance of the Micor representative Rusty Beatty, CCC made the needed corrections to ensure successful pour. A mock-up was made to present to the GC and Ford. The 2nd pouring of grout was successful. LESSON LEARNED FOR FUTURE PROJECTS: -It is crucial to have the grout manufacturer technical rep on site to supervise the prepping, mixing, and installation of the grout. -Surface conditions to receive the grout must be deemed suitable. -Verify prior to pour that the correct amount of material is on site (always include 5% waste) -Identify all potential modes of failure in the pre-pour checklist and with the customer. -Insist that a mock-up be completed to ensure success of the system prior to installation on the actual process equipment. This will prove the product and also provide peace of mind to the owner. -Obtain a final buy-off from owner and prime contractor (if applicable). |
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