CHOCKFAST - micltd.eu

1 CHOCKFASTBULLETIN 641 APhiladelphia Resins Corporation provides a set of engineered grouting materials specifically formulated for difficult machineryfoundation repair and construction where traditional resin materials fail. Large reciprocating machinery used in the gas trans-mission, process chemicals and power generation industries are a particular specialty of Philadelphia Resins Resins Corporation's materials were originally conceived for the replacement of steel chocks in shipboard ap-plications where over 200 million service hours have been accumulated on CHOCKFAST . Because CHOCKFAST wasformulated for the purpose of replacing steel rather than as an improved cementitious grout, Philadelphia Resins Corporation'sgrouting products are unique. The CHOCKFAST product line is particularly appropriate to grouting applications where high orintermittent loading is grouts serve very well in many applications and CHOCKFAST is not proposed as a universal replacement for them.

2 Theprincipal weaknesses of cement grouts for reciprocating machinery are low tensile strength, friability and susceptibility todeterioration from oil and water penetration. In addition to this the optimum physical properties will only be obtained if themixing and curing of the cement are carried out precisely as specified by the manufacturer. This is difficult to achieve andimpossible to assure in the three component, epoxy resin bonded aggregate type of grouts appeared some years ago they were recognized as beinga great improvement over cement grouts and became widely adopted in the compressor industry. CHOCKFAST ORANGE, CHOCKFAST BLUE and CHOCKFAST GRAY are an equally great improvement over the epoxy bonded aggregates and onlymaterials of this class should be considered for use immediately under heavy duty reciprocating machinery. CHOCKFAST REDis available from Philadelphia Resins for conventional epoxy is many times stronger and much more resilient and shockproof than cement.

3 It is impervious to most liquids andunaffected by freeze/thaw cycles. The physical properties are determined at the time of manufacture and do not depend upon theskill or conscientiousness of a workman. Each of the CHOCK-FAST products are true engineering materials with predictableproperties and OF CHOCKFASTFour types of CHOCKFAST are manufactured and each has its specific uses and known performance capabilities. Decidingwhich CHOCKFAST materials are most suitable for a specific application requires evaluation of application and ORANGEUsed directly in contact with the engine or compressor instead of steel or grout. Provides precision fitted chocks withoutmachining and durability superior to that of steel chocks. It has exceptional temperature resistance. Pours on concrete should notexceed 45mm (1 ") thickness nor 610 mm (24") length as a general rule, though by putting in foam strip dividers virtuallycontinuous lengths can be poured.

4 CHOCKFAST ORANGE is available in kg, 1800 cc (7Y2 lb. 115 in3) units and kg,3600 cc (15 lb. 225 in3) units. CHOCKFAST ORANGE is packaged in slack filled cans and mixed by means of an electricdrilling machine running at about 200 rpm. Recommended mixing blades are available from Philadelphia Resins BLUEAlso has superior temperature resistance, but is formulated for thick pours on concrete. CHOCKFAST BLUE is normally usedunder soleplates or as a base for CHOCKFAST ORANGE chocks, but can also go directly under the engine. When filling under asoleplate at least 25mm (1") thickness should be left for the final pour. Intermediate pours with free surfaces should not exceed37mm (11/2") thickness and m (42") length. When pouring in layers to obtain required thickness, allow each solidified layer tocool to ambient before proceeding with sub sequent pours. CHOCKFAST BLUE is available in 26 kg, 13104 cc (58 lb, 800 in~)units.

5 CHOCKFAST BLUE will require strong wooden or steel shuttering. The unit is supplied in a 5 gallon can, wherein it ismixed with a Kol mixer or a mixing blade driven by a " heavy duty electric drilling machine. The Kol mixer, available fromPhiladelphia Resins Corporation, is more convenient for large volume GRAYMore fluid than CHOCKFAST BLUE but without its high temperature qualities. Used similarly to CHOCKFAST ORANGE forheavy duty direct chocking or grouting, but where continuous long term service temperatures do not exceed 49" C (121" F). Usedextensively for crane rail grouting. For crane rail detail request Bulletin #630. CHOCKFAST GRAY is available in 5 kg, 3100 cc(11 lb. "l 87 in3), 10kg, 6200 cc (22 lb. 374 in) and 22kg, 13640 cc (48 lb. 816 in3) units and can be mixed with an electricdrilling machine running at about 200 rpm. The 22 kg (48 lb.) unit may be more easily mixed with a Kol REDAn epoxy bonded aggregate, comparatively inexpensive, for large volume pours.

6 It is supplied as (226 lb.) unit, 91 kg(200 lb.) aggregate, packaged in four bags, a kg ( lb.) can of resin and a kg ( lb.) can of hardener, so the viscositymay be selected at the time of mixing. To make a zero slump mixture requires more aggregate than is supplied, or the use of lessresin. It is more economical to buy more aggregate than to discard a very flowable mix is required the aggregate content may be reduced. Withholding one bag of aggregate will facilitatepour thickness as thin as 25mm (1") and will reduce unit net volume by (.44 ft3). Typically used to replace the largequantities of concrete removed when eradicating oil penetration of cracks, so as to form a base for CHOCKFAST BLUE and/orCHOCKFAST ORANGE. Pours should not exceed 450mm(18") thickness and m (7') length. Shuttering similar to that forcement is required. A unit is liters ( ) and a 2 cement or mortar mixer is used, the latter being preferable.

7 Theresin and hardener are first mixed in the drum and then the aggregate is added, one bag at a time, allowing each bag load to wetout before adding the pour limitations given for each variety of CHOCKFAST are conservative and usable in almost any conditions. With ex-perience they may often be exceeded quite significantly. Any thickness may be built up by pouring in layers. However each layershould be allowed to cool to ambient before proceeding with subsequent pours. CHOCKFAST will go hard in about one hour at21" C (72" F) with variations dependent upon volume and temperature. At this stage it is said to have gel led, it has not cured andhas not developed its inherent toughness. After about 48 hours it is sufficiently cured for the weight of the machinery and thebolting force to be applied to it and for the machine to operate. Careless manipulation of the bolts or jack screws could result in acrack at this state, but after additional cure time or exposure to heat from a few hours running the CHOCK FAST will cure to itsfull DESIGN CONSIDERATIONST here is no standard, generally agreed, best way of installing an engine or compressor, but there are a few principles that shouldbe common to all methods.

8 By applying these principles when necessary Philadelphia Resins Corporation has made satisfactoryrepairs and modifications to every foundation configuration yet down bolts and foundation cracks are the two most common problem areas and are often related. Ideally, bolts should beeasily removable and replaceable and there are proprietary designs of such bolts available. More important than this, though, isthat the bolts must have sufficient shank length free of grout to permit them to stretch when tightened. As a rule of thumb theyshould have at least 12 diameters free length. The bolts should be parallel to the holes and the nuts should butt against bolts should go down as deeply as possible into the foundation block so that the block is always kept in compressionregardless of engine forces. If the bolts are inside steel tubes, the tubes must not be connected to the soleplates or engine must not be supported on its sump unless it is in the same plane as the bedplate flanges.

9 Some compressors rely onthe sump sides to absorb transverse forces and these may be grouted, but the bottom should not be. The reason for this is thatconcrete continues to shrink for years and the load will inevitably be taken oft the bedplate and cause the machine to the foregoing points are observed then any of the installation methods shown in Bulletin #640 will be satisfactory and probablymany other configurations can be made workable. There is one last precaution to be observed, the concrete likely to be exposedto oil should be sealed with two coats of epoxy paint. PHILLYCLAD 1000 is ideal for GROUTING METHODSB ulletin #640 shows the most common methods of using CHOCKFAST and in conjunction with these notes should enable thecorrect type to be selected. Philadelphia Resins Corporation will gladly advise on standard or special concrete is to be poured in preparation for the CHOCKFAST work then any interfaces between old and new concrete should becoated with PHILLYCLAD 5050 concrete adhesive.

10 Request Bulletin #981. This resin may be applied by spray or brush as anadhesive or injected into cracks in the concrete in order to bond the fractured surfaces. For fine cracks use PHILLYCLAD 1775 injection of PHILLYCLAD adhesives is generally accomplished via standard grease fittings epoxied into holespositioned along fractures on approximately 15 cm (6") centers. The fracture line must be sealed except for small vent areasequally spaced between fittings. PHILLYBOND #6 quick setting epoxy paste is recommended for securing fittings and a cartridge type grease gun with flexible hose extension, PHILLYCLAD is pressured into cracks using moderate and con-tinuous pressure. When resin appears at each vent area, continue pumping to purge crack and insure maximum concrete and CHOCKFAST no adhesive is necessary, the bond to clean concrete is greater than the tensile strength ofthe concrete. When making foundation repairs it is essential to cut back to clean, sound concrete before commencing therebuilding the CHOCKFAST must not bond to an adjacent surface, that surface should be sprayed with release agent or, if it isnot a working surface, it may be waxed or greased.