SikaFlow®-648
(former MasterFlow® 648)
High-strength, high-flow, chemical resistant epoxy grout
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SikaFlow®-648 is a three-component epoxy resin-based precision grout used to secure critical equipment for proper alignment and transmission of static and dynamic loads. With carefully balanced physical properties and excellent resistance to chemical attack, elevated service temperatures, vibration and torque, SikaFlow®-648 is formulated for easy installation, with good flow characteristics suitable for pouring or pumping in thicknesses from 10 mm up to 150 mm, low dust generation and soap and water clean-up. SikaFlow®-648 is available in all regions of the world, supported by trained sales and technical personnel with experience in the specification and installation of epoxy grouts on every continent.
- High early and ultimate strengths for rapid turnaround
- Low creep maintains equipment alignment
- Retains physical properties at elevated temperatures increasing the service range
- Low-dusting for added worker comfort and safety
- Very low shrinkage for full baseplate contact and load transfer
- Excellent flowability with high bearing area for even load distribution
- Variable fill ratio for desired flowability
- Excellent adhesion to steel and concrete for optimum load transfer and vibration dampening
- High chemical resistance enables use in challenging environments
- Excellent freeze/thaw resistance for equipment in low temperature service environments
- Resists water and chloride intrusion for use in wet and aggressive environments
- Resists impact and dampens torque to protect equipment and extend service life
- Extended working time
- Pumpable for maximum productivity on large grout installations
- Durable bond to concrete and steel optimizes load transfer
- Meets the requirements of EN 1504-6
- Can be applied in thickness from 10 to 150 mm
- Globally available for consistent project results.
Usage
SikaFlow®-648 is used for assembling and fixing of the following items:- Industrial turbines, generators and compressors
- Very large reciprocating compressors
- Industrial turbines, generators and compressors.
- Rolling, stamping, grinding, drawing and finishing mills.
- Forging hammers.
- Rail tracks, crane rails.
- Paper machine sole plates.
- Machinery and equipment requiring high strength maximum bearing.
Advantages
- High early and ultimate strengths for rapid turnaround
- Low creep maintains equipment alignment
- Retains physical properties at elevated temperatures increasing the service range
- Low-dusting for added worker comfort and safety
- Very low shrinkage for full baseplate contact and load transfer
- Excellent flowability with high bearing area for even load distribution
- Variable fill ratio for desired flowability
- Excellent adhesion to steel and concrete for optimum load transfer and vibration dampening
- High chemical resistance enables use in challenging environments
- Excellent freeze/thaw resistance for equipment in low temperature service environments
- Resists water and chloride intrusion for use in wet and aggressive environments
- Resists impact and dampens torque to protect equipment and extend service life
- Extended working time
- Pumpable for maximum productivity on large grout installations
- Durable bond to concrete and steel optimizes load transfer
- Meets the requirements of EN 1504-6
- Can be applied in thickness from 10 to 150 mm
- Globally available for consistent project results.
Packaging
The standard 57.5 litre unit of SikaFlow®-648 includes 100kg (four 25kg bags) of Part C aggregate. This can be reduced to as low as 3 bags yielding 51.5 litres.
Part A | 11.35 kg |
Part B | 3.55 kg |
Part C | 25 kg bag |
Set | 114.9 kg (1A+1B+4C) |
Yield | 57.5 l |
Refer to the current price list for available packaging variations.
Refer to the current price list for available packaging variations
Color
Dark Grey
Product Details
Shelf Life
24 months if stored at below mentioned storage conditions.
Storage Conditions
Store at ambient temperatures, out of direct sunlight, in cool, dry warehouse conditions and clear of the ground on pallets protected from rainfall prior to application. The resin parts need to be protected from frost!
Density
2,000 kg / m3 Filling ratio 1 / 6.7 (1 set resin + 4 bags) 1,750 kg / m3 Filling ratio 1 / 5 (1 set resin + 3 bags)
Effective Bearing Area
> 85 % | (ASTM C1339) |
Compressive Strength
Mechanical Strenght at: | (EN 12190) |
Test specimen size: 40 mm x 40 mm x 160mm
Temperature | +10 ° C | +23 ° C | +23 ° C | +30 ° C |
Filling ratio (resin/aggregate) | 1 / 6.7 (1xA+1xB+4xC) | 1 / 6.7 (1xA+1xB+4xC) | 1 / 5.0 (1xA+1xB+3xC) | 1 / 6.7 (1xA+1xB+4xC) |
8 hours | - | 40 N/mm2 | 35 N/mm2 | 50 N/mm2 |
16 hours | - | 70 N/mm2 | 60 N/mm2 | 75 N/mm2 |
1 day | 30 N/mm2 | 75 N/mm2 | 65 N/mm2 | 80 N/mm2 |
3 days | 80 N/mm2 | 85 N/mm2 | 68 N/mm2 | 85 N/mm2 |
7 days | 90 N/mm2 | 95 N/mm2 | 70 N/mm2 | 95 N/mm2 |
Test specimen size: 50 mm × 50 mm × 50 mm
Curing time | Measured value |
1 day | 72 N/mm2 |
7 days | 97 N/mm2 |
Modulus of Elasticity in Compression
≥ 15 000 N/mm2 (filling ratio 1/ 6.7) ≥ 12 000 N/mm2 (filling ratio 1/ 5) | (EN 13412) |
Flexural Strength
Mechanical Strenght at: | (EN 12190) |
Test specimen size: 40 mm x 40 mm x 160mm
Temperature | +10 ° C | +23 ° C | +23 ° C | +30 ° C |
Filling ratio (resin/aggregate) | 1 / 6.7 (1xA+1xB+4xC) | 1 / 6.7 (1xA+1xB+4xC) | 1 / 5.0 (1xA+1xB+3xC) | 1 / 6.7 (1xA+1xB+4xC) |
8 hours | - | 16 N/mm2 | 17 N/mm2 | 20 N/mm2 |
16 hours | - | 22 N/mm2 | 20 N/mm2 | 22 N/mm2 |
1 day | 15 N/mm2 | 25 N/mm2 | 22 N/mm2 | 25 N/mm2 |
3 days | 25 N/mm2 | 27 N/mm2 | 23 N/mm2 | 27 N/mm2 |
7 days | 28 N/mm2 | 30 N/mm2 | 25 N/mm2 | 28 N/mm2 |
Shear Strength
Slant shear strength: (7 days) | (EN 12188) |
50 ° slope | 76 N/mm2 |
60 ° slope | 61 N/mm2 |
70 ° slope | 73 N/mm2 |
Tensile Adhesion Strength
Adhesion to concrete: | ≥ 3.0 N/mm2 (7 days) |
Adhesion to steel: | ≥ 10.0 N/mm2 (1 day) |
Creep
≤ 0.6 mm | (EN 1544) |
Creep under tensile load for 3 months at 50 kN Load
Pull-Out Resistance
≤ 0.6 mm | (EN 1881) |
Pull-out strength at 75 kN Load
Shrinkage
≤ 0.2 [mm/m] | 28 days |
Coefficient of Thermal Expansion
3.7 × 10–5 1/K | (EN 1770) |
Thermal Resistance
+80 °C | (EN 12614) |
Glass transition temperature
Water Tightness
Water tightness under pressure | passed, no leakage |
Chemical Resistance
Chemical Resistance according to EN 12808-1
Test liquids according to EN 13529
Group | Description | Test liquid | Change in compressive strength after 72 h [%] | Change in compressive strength after 500 h [%] |
DF 1 | Gasoline | 47.5% toluene + 30.4% isooctane + 17.1% n-heptane + 3% methanol + 2% 2-methyl-propanol- (2) | < 5 | < -20 |
DF 3 | Fuel oil, Diesel fuel and other unused combustion motor oils | 80 % n-paraffin (C12 to C18) + 20 % methylnaphthalene | < -5 | < -5 |
DF 4 | All hydrocarbons as well as mixtures containing benzene with max. 5 Vol. % | 60% toluene + 30% xylene + 10% methylnaphthalene | < 1 | < 3 |
DF 5 | Mono- and polyvalent alcohols (up to a max. 48 vol.-% methanol), glycol ethers | 48 Vol.-% methanol + 48 Vol.-% IPA + 4% water | < -10 | < -15 |
Group | Description | Test liquid | Change in compressive strength after 72 h [%] | Change in compressive strength after 500 h [%] |
DF 7 | All organic esters and ketones | 50 % ethyl acetate + 50 % methyl isobutyl ketone | < -5 | < -5 |
DF 10 | Mineral nonoxidizing) up to 20% and inorganic salts in aqueous solution (pH<6) except HF | Sulphuric acid (20%) | < -5 | < -30 |
DF 11 | Inorganic lye (except oxidizing) and inorganic salts in aqueous solution (pH>8) | Sodium hydroxide solution (20%) | < -5 | < -10 |
DF 12 | Aqueous solutions of inorganic non-oxidizing salts with a pH value between 6 and 8 | Aqueous sodium chloride solution (20%) | < -5 | < -5 |
- | Concentrated acids | Phosphoric acid (85%) | < -15 | < -5 |
- | Concentrated acids | Hydrochloric acid conc. (37%) | < -10 | < -30 |
Note: Severe chemical attack may lead to discolouration of SikaFlow®-648. This is however no sign of physical weakening of the product.
Freeze Thaw De-Icing Salt Resistance
Adhesion to concrete after freeze-thaw:
≥ 2.0 N/mm2 (28 days) (50 cycles with salt) | (EN 13687-1) |
Reaction to Fire
class Efl | (EN 13501-1) |
no ignition | (EN ISO 11925-2) |
Application
Layer Thickness
Minimum grout depth: 10 mm Maximum grout depth: 150 mm
Peak Exotherm
43 °C | (internal method) |
Flowability
Full plate contact: < 20 minutes to back of box: < 30 minutes | (ASTM C1339) |
Ambient Air Temperature
+10 °C min. / +30 °C max.
Mixing Ratio
Component A : B : C = 3.2 : 1 : (21–28) by weight Liquid / Solids = 1 : (5–6.7) by weight
Dew Point
Substrate temperature during application must be at least 3 °C above dew point to avoid condensation.
Substrate Temperature
+10 °C min. / +30 °C max.
Open Time
The following chart is a guide for the working time of a SikaFlow®-648 grout at various ambient temperatures.
+10 °C | +21 °C | +30 ° |
120 - 150 minutes | 90 - 120 minutes | 50 - 60 minutes |
The open time begins when the resin and hardener are mixed. It is shorter at high temperatures and longer at low temperatures. The larger the quantity mixed, the shorter the pot life. To obtain longer workability at high temperatures, the mixed grout may be divided into portions. Another method is to chill components A+B and C before mixing them (i.e. only when application temperatures are above +20 °C).
Cure Time
Full cure is reached in 7 days after the application at a constant temperature of 23 ºC.
Coverage
Set 114.9kg (1A+1B+4C) = 57.5 l
NOTES ON INSTALLATION
Do not apply at temperatures below +10 ºC nor above +30 ºC.
Do not add solvent, water, or any other material to the grout.
Do not alter the resin or hardener proportions.
Cold material will exhibit decreased flowability and reduced strength development.
Chamfering the concrete edge helps reduce thermal cracking. Following proper installation procedures also reduces the potential for cracking.
Severe chemical attack may lead to discolouration of SikaFlow®-648. This is however no sign of physical weakening of the product.
In case of thicker applications and complex geometries consult your local Sika representative.
SUBSTRATE PREPARATION
The concrete should be free of frost, curing membranes, waterproofing treatments, oil stains, laitance, friable material and dust. The concrete surfaces should be chipped and if there is a water leakage it must be drained or properly plugged. Surfaces should be dry. Particular attention should be paid to bolt holes to ensure that these are dry. Use vacuum and/or oil free compressed air to remove free standing water. The concrete areas to be grouted should not be primed or sealed. Base plates, bolts, etc. must be clean (SA 2½) and free of oil, grease and paint etc. to obtain proper adhesion. Set and align equipment. If shims are to be removed after the grout has set, then lightly grease them for easy removal. Priming the metal surfaces is only required when a long delay between cleaning and grouting will allow corrosion and contamination. A head box should be installed with the formwork to ease the pour and flow of the mixed grout:
Ensure formwork is secure and watertight to prevent movement and leaking during the placing and curing of the grout. The area should be free of excessive vibration. Shut down adjacent machinery until the grout has hardened. In hot weather, base plates and foundations must be shaded from direct sunlight. Bags and buckets of grout should be stored in the shade prior to use. In cold weather, the temperature of base plates and foundations should be raised to over +10°C
MIXING
The fill ratio is the weight of the aggregate to combined resin and hardener components. SikaFlow®-648 is designed to be utilised at a variable fill ratio (resin / aggregate) from the standard 1 / 6.7 ratio to as low as 1 / 5 (hi-flow version).
The standard 57.5 litre unit of SikaFlow®-648 includes 100kg (four 25kg bags) of Part C aggregate. This can be reduced to as low as 3 bags yielding 51.5 litres.
Resin and filler components can be purchased separately. Unlike most epoxy grouts, SikaFlow®-648 maintains high bearing area when fill ratios are decreased. In addition, physical properties including high temperature performance are maintained. By determining the proper fill ratio for a particular project and purchasing accordingly, the cost per litre, flow and physical properties are optimised. A guideline for suggested fill ratios is shown in the following table. In using this guide, the temperature of the foundation and plate is the critical concern, however, grout and ambient temperature are also important. Add all the contents of the hardener container to the resin part and mix thoroughly for at least 3 minutes. Transfer to a mechanical mixer. Add the aggregate, mixing thoroughly until a uniform consistency is obtained. At low temperatures (+10°C) the flow characteristics of SikaFlow®-648 will be reduced and installation times increased.
APPLICATION
Lengths of metal strapping laid in the formwork prior to placing may be necessary to assist grout flow over large areas and in compacting and eliminating air pockets. Have sufficient manpower, materials and tools to make mixing and placing rapid and continuous. Where grout must flow some distance, make the initial batch slightly more fluid or flowable than required; this lubricates the surfaces and avoids blockage of the grout that follows. The grout shall be poured continuously and from one side only, to avoid entrapment of air while grouting. Maintain a constant hydrostatic head, preferably of at least 15 cm. On the side where the grout has been poured, allow 10 cm clearance between the side of the form and the base plate of the machine. On the opposite side allow 5-10 cm clearance between the formwork and the base plate. Due to differences in temperature between the grout under the base plate, and exposed shoulders that are subject to more rapid temperature changes, debonding and / or cracking can occur. Avoid shoulders wherever possible. If shoulders are required, they should be firmly anchored with reinforcing to the substrate to prevent debonding.
Make sure grout fills the entire space to be grouted and remains in contact with the plate throughout the entire grouting placement. Note: Do not use vibrator for placing the grout!
CLEANING OF TOOLS
After the pour is complete, remove uncured epoxy from the mixer, wheelbarrow and tools with soap and water or a citrus degreaser. Cured material can only be removed mechanically.