Grouting Large Anchor Bolts

Technical Bulletin # 615C

Bulletin Description
This bulletin promotes the use of CHOCKFAST  Red or ESCOWELD 7505E/7530 as a grout for setting
large anchor bolts in large, deep anchor bolt pockets. Typical 2-part epoxy chocking compounds (like
CHOCKFAST Gray), while good for use in smaller holes, should not be used in such cases because the
exothermic heat created by their large mass may crack the epoxy.
Deep anchor bolt pockets - up to 2 meters (6 ft) long and 200mm (8”) wide - may be filled conveniently
with a single placement of CHOCKFAST Red or ESCOWELD 7505E/7530.
The gentle exotherm of CHOCKFASTRed and ESCOWELD 7505E/7530 allows grout placement
around large bolts to be executed with a single pour in extremely hot and humid climates with negligible
shrinkage.

Design Considerations
Most process machinery is critically aligned M52 (2 in.) Bolt
within hundredths of a millimeter tolerance. D Typical
Therefore, final horizontal leveling pours in
contact with critically aligned baseplates,
rails, soleplates or coupled machinery should
be limited to a depth of 100mm (4”).
Machine Base

2
Two separate grout pours are required:
12D
30 - 100mm
The first pour in the Anchor Bolt Pocket filled
 (1¼ - 4 in.)
1 is made using CHOCKFAST Red or
ESCOWELD 7505E/7530

The Final Leveling Pour under the critically

aligned machinery is then made using 1.5 - 2m
2
CHOCKFAST RED or ESCOWELD (4 - 6 ft) Wrap bolt with
7505E/7530 tape to allow it
1
to free-stretch 10D
during
tensioning

150 - 200mm
(6 - 8 in.)

ITW POLYMER TECHNOLOGIES

130 Commerce Drive  Montgomeryville, PA 18936  215-855-8450  Fax 215-855-4688
www.chockfastgrout.com  www.escoweld.com

77

Date 06/2006
General: Every reasonable effort is made to insure the
technical information and recommendations on these data
pages are true and accurate to the best of our knowledge
at the date of issuance. However, this information is subject
to change without notice. Prior versions of this publication
are invalid with the release of this version. Products and
information are intended for use by qualified applicators
that have the required background, technical knowledge,
and equipment to perform said tasks in a satisfactory
manner. Consult your local distributor for product
availability, additional product information, and technical
support.
Warranty: ITW Polymer Technologies, a division of Illinois Tool
Works Inc., warrants that its products meet their printed
specifications. This is the sole warranty. This warranty
expires one year after product shipment.
Warranty Claims: If any product fails to meet the above,
ITW Polymer Technologies will, at its option, either replace
the product or refund the purchase price. ITW Polymer
Technologies will have no other liability for breach of
warranty, negligence, or otherwise. All warranty claims
must be made in writing within one year of the date of
shipment. No other claims will be considered.
Disclaimer: ITW Polymer Technologies makes no other
warranty, expressed or implied, and specifically disclaims
any warranty of merchantability or fitness for a particular
purpose.
78
Grouting Large Anchor Bolts
Bulletin No. 615C, Page 2
Suggestions concerning the use of products are not
warranties. The purchaser assumes the responsibility for
determining suitability of products and appropriate use.
ITW Polymer Technologies’ sole liability, for breach of
warranty, negligence or otherwise, shall be the
replacement of product or refund of the purchase
price, at ITW Polymer Technologies’ election. Under no
circumstances shall ITW Polymer Technologies be liable
for any indirect, incidental or consequential damages.
Modification of Warranty: No distributor or sales
representative has the authority to change the above
provisions. No change in the above provisions will be
valid unless in writing and signed by an officer or the
Technical Director of ITW Polymer Technologies. No
term of any purchase order shall serve to modify any
provision of this document.
Mediation and Arbitration: If any dispute arises relating
to products or product warranties, either the purchaser
or ITW Polymer Technologies may a) initiate mediation
under the then current Center for Public Resources
(CPR) Model Procedure for Mediation of Business
Disputes, or b) initiate a non-binding arbitration under
the rules of the American Arbitration Association for the
resolution of commercial disputes.
 Standard Chock Design

For Integral Gas Compressor Engines

Technical Bulletin # 643E

Bulletin Description
There are a number of combinations and methods of installing CHOCKFAST grout to mount equipment.
The method chosen usually depends on the type of equipment, the loads, operating temperature and
mounting arrangement. There is, however, one standard or preferred method of grouting that ITW
Polymer Technologies feels is optimal for most integral gas compressor engines. The Preferred Chock
Design for new engine / compressor installations or repairs under old engines has the following
components:
 CHOCKFAST Red or Red SG, if necessary, to bring the foundation up to the appropriate level.
 CHOCKFAST Blue to provide a high-strength, temperature resistant cap on top of the CHOCKFAST
Red.
 CHOCKFAST Black or CHOCKFAST Orange as individual chocks around the anchor bolts.

Design For New Engine Foundations

Pour the new concrete foundation to within 3-1/2" (90 mm) of final height of the bottom of the engine
bedplate. Allow the concrete to cure for at least 21 days under proper temperature and moisture
conditions so it achieves full strength.
After the concrete is completely cured, divide the foundation into controlled sections with maximum
dimensions of 1-1/2" (40mm) thick x 42" (1.1m) long x 42" (1.1m) wide. Closed-cell neoprene foam
rubber works well as an expansion joint. Mix and pour the CHOCKFAST Blue 1-1/2" (40mm) thick over
the concrete to provide a high-strength cap. Allow the grout to cure at least one day. (Please see
Bulletin No. 642 entitled "CHOCKFAST Installation Procedures" for additional information on
constructing forms, mixing and pouring CHOCKFAST.)
After the CHOCKFAST Blue has fully cured, build a mold under the engine and on either side of each
anchor bolt for the CHOCKFAST Black. Each chock will be approximately 2" (50mm) thick and will
typically extend the full width of the baseplate. The length of each chock is determined based on the
Total Chock Area that will keep the Total Chock Loading (deadweight plus the sum of all bolt tensions) 
2
500 psi (35 kg/cm ). Use either the engine manufacturer's recommended bolt tension or the Rule of

CHOCKFAST Black Chocks

CHOCKFAST Blue
cap over Red
CHOCKFAST
Use CHOCKFAST Red Black chock
to build up the foundation

Chip the surface of the

concrete foundation

ITW POLYMER TECHNOLOGIES

130 Commerce Drive  Montgomeryville, PA 18936  215-855-8450  Fax 215-855-4688
www.chockfastgrout.com

91
 Std Chock Design Gas Compressor Engines
Bulletin No. 643E, Page 2

Thumb that says the sum of all bolt tensions must be  4 times the deadweight of an integral gas
compressor engine or  2-1/2 times the deadweight of a standard diesel engine.
After final check of machinery alignment mix and pour CHOCKFAST Black into each as directed.
CHOCKFAST Orange may also be used to create the individual chocks.

Design For Rebuilt Engine Foundations

Chip out all oil saturated and cracked concrete until strong, clean concrete is exposed. Build a form
around the foundation so the CHOCKFAST Red rebuilds the foundation to within 3-1/2" (90 mm) from
the machinery bedplate surface to allow capping with CHOCKFAST Blue and CHOCKFAST Black epoxy
chocks.
Create controlled sections on top of the concrete by dividing the area to be filled with expansion joints.
When using CHOCKFAST Red, the maximum recommended size for each section is 18" (450 mm) thick
x 7' (2.15 m) long x 7' (2.15 m) wide. Expansion joints can be made quickly and easily with 1" (25mm)
thick closed cell Styrofoam sheet or 3/4" (18 mm) redwood. Expansion Joint Compound should be used
to seal the top and bottom of expansion joint. Wait between consecutive layers until the underlying layer
has cooled back to below 85°F (29°C) or ambient.

After the grout has curred, remove

12 mm (½") of the Styrofoam
expansion joint and fill with
Expansion Joint Compound.

Styrofoam
expansion joint

Secondary Seal made

with Exansion Joint
Compound and sand.

After the underlying layers of CHOCKFAST Red have cured, pour a CHOCKFAST Blue cap 1-1/2"
(40mm) thick over the top of the Red. CHOCKFAST Blue should be poured in controlled sections with
maximum dimensions of 1-1/2" (40mm) thick x 42" (1.1m) long x 42" (1.1m) wide. Closed-cell neoprene
foam expansion joints or anchored with Expansion Joint Compound slurry are used. (Please see Bulletin
No. 642 entitled "CHOCKFAST Installation Procedures.")
After a final check of the machinery alignment subsequent to pouring CHOCKFAST Blue, 2" (50mm)
thick CHOCKFAST Black chocks are poured. When this CHOCKFAST has completely cured, back out
the jacking bolts and torque the compressor’s anchor bolts should be tensioned to either the
manufacturer's recommendation or the Rule-of-Thumb that the total bolt tension  4 times the
deadweight of the complete compressor should be used. In both cases, the total static load on the
chocks (deadweight plus total bolt tension) 500 psi ( 35 kg/cm2).
NOTE: There may be reasons to deviate from this standard such as lack of sufficient bedplate area or
unusually rough running that require higher loading. Please consult the CHOCKFAST representative
or ITW Polymer Technologies before deviating from the standard recommendation.
CHOCKFAST Orange can be used in place of CHOCKFAST Black. In fact, CHOCKFAST Black
superceded Orange for standard compressor installations, as CHOCKFAST BLACK is easier to use and
provides improved heat dissipation in the foundation. CHOCKFAST Orange is available for special
applications where its lower viscosity and variable hardener ratio are advantageous. Standard pour
thickness for Orange is 2" (50mm) and loading parameters are identical to CHOCKFAST BLACK.

92
 Std Chock Design Gas Compressor Engines
Bulletin No. 643E, Page 3

Alternative Designs
As you can see from the above, soleplates or rails are not included in the Preferred Design. Soleplates,
however, may already exist or be required by the customer as part of a new or repair chocking. When
soleplates are required they can be grouted in place using CHOCKFAST Blue following the Preferred
Design in other respects and allowing 1-1/2" (40mm) of grout under the soleplate. Existing soleplates
that are still securely grouted can have steel chocks replaced by CHOCKFAST BLACK or CHOCKFAST
ORANGE.
If changes in cross section have to be made to accommodate jack pockets, pipe lead-throughs, etc., it is
important that no sharp corners be created in the CHOCKFAST. At least 2" (50mm) radius curves should
be used. Similarly, all soleplate or rail edges immersed in the CHOCKFAST should be radiused. It is
prudent to put a divider where a crack may be initiated.
Special circumstances may require other methods to be used. The CHOCKFAST system is versatile, but
only experienced persons should consider departing from ITW Polymer Technologies'
recommendations.
There are times when continuous grouting under the equipment bedplate is required rather than
individual chocks. In these cases there is typically a concern over the inherent rigidity of an engine.
When continuous grouting is required for integral gas engine compressors or diesel engines, ITW
Polymer Technologies recommends using CHOCKFAST Blue for the final 1-1/2" (40mm) grouting layer
directly in contact with the bedplate. Controlled sections should be used as described previously and
CHOCKFAST RED should also be used if deeper repair is necessary.
*NOTE: The above parameters are the parameters within which we like to operate and they provide for
an inherently conservative design. There are circumstances, such as unavailability of bedplate area,
which cause loadings to rise. Please contact ITW Polymer Technologies with regard to special
circumstances.

Date 06/2006

General: Every reasonable effort is made to insure the
technical information and recommendations on these data
pages are true and accurate to the best of our knowledge
at the date of issuance. However, this information is subject
to change without notice. Prior versions of this publication
are invalid with the release of this version. Products and
information are intended for use by qualified applicators
that have the required background, technical knowledge,
and equipment to perform said tasks in a satisfactory
manner. Consult your local distributor for product
availability, additional product information, and technical
support.
Warranty: ITW Polymer Technologies, a division of Illinois Tool
Works Inc., warrants that its products meet their printed
specifications. This is the sole warranty. This warranty
expires one year after product shipment.
Warranty Claims: If any product fails to meet the above,
ITW Polymer Technologies will, at its option, either replace
the product or refund the purchase price. ITW Polymer
Technologies will have no other liability for breach of
warranty, negligence, or otherwise. All warranty claims
must be made in writing within one year of the date of
shipment. No other claims will be considered.
Disclaimer: ITW Polymer Technologies makes no other
warranty, expressed or implied, and specifically disclaims
any warranty of merchantability or fitness for a particular
purpose.
Suggestions concerning the use of products are not
warranties. The purchaser assumes the responsibility for
determining suitability of products and appropriate use.
ITW Polymer Technologies’ sole liability, for breach of
warranty, negligence or otherwise, shall be the
replacement of product or refund of the purchase
price, at ITW Polymer Technologies’ election. Under no
circumstances shall ITW Polymer Technologies be liable
for any indirect, incidental or consequential damages.
Modification of Warranty: No distributor or sales
representative has the authority to change the above
provisions. No change in the above provisions will be
valid unless in writing and signed by an officer or the
Technical Director of ITW Polymer Technologies. No
term of any purchase order shall serve to modify any
provision of this document.
Mediation and Arbitration: If any dispute arises relating
to products or product warranties, either the purchaser
or ITW Polymer Technologies may a) initiate mediation
under the then current Center for Public Resources
(CPR) Model Procedure for Mediation of Business
Disputes, or b) initiate a non-binding arbitration under
the rules of the American Arbitration Association for the
resolution of commercial disputes.

93
This Page Left Intentionally Blank

94

Technical Bulletin # 660A
Bulletin Description
These illustrations represent hold down bolt arrangements commonly encountered in the installation of
equipment and machinery with which CHOCKFAST and ESCOWELD products are used.
Poor Better Good
Notch
Grout
12D
D Sole Plate
Tape
Sealed
10D
PVC
Closed-cell pipe
neoprene foam
sleeve
Grout or Chocking
Compound
Date 08/2005
General: Every reasonable effort is made to insure the
technical information and recommendations on these data
pages are true and accurate to the best of our knowledge
at the date of issuance. However, this information is subject
to change without notice. Prior versions of this publication
are invalid with the release of this version. Products and
information are intended for use by qualified applicators
that have the required background, technical knowledge,
and equipment to perform said tasks in a satisfactory
manner. Consult your local distributor for product
availability, additional product information, and technical
support.
Warranty: ITW Polymer Technologies, a division of Illinois Tool
Works Inc., warrants that its products meet their printed
specifications. This is the sole warranty. This warranty
expires one year after product shipment.
Warranty Claims: If any product fails to meet the above,
ITW Polymer Technologies will, at its option, either replace
the product or refund the purchase price. ITW Polymer
Technologies will have no other liability for breach of
warranty, negligence, or otherwise. All warranty claims
must be made in writing within one year of the date of
shipment. No other claims will be considered.
Disclaimer: ITW Polymer Technologies makes no other
warranty, expressed or implied, and specifically disclaims
any warranty of merchantability or fitness for a particular
purpose.
ITW POLYMER TECHNOLOGIES
130 Commerce Drive  Montgomeryville, PA 18936  215-855-8450  Fax 215-855-4688
www.chockfastgrout.com  www.escoweld.com
95
Common Hold Down Bolt
Arrangements
Closed-cell neoprene
foam sleeve
Best
Chocking
Compound
Coupling Grout
RTV
Sealant
Sleeve
Hand hole for
access to nut
Tack weld nut
Suggestions concerning the use of products are not
warranties. The purchaser assumes the responsibility for
determining suitability of products and appropriate use.
ITW Polymer Technologies’ sole liability, for breach of
warranty, negligence or otherwise, shall be the
replacement of product or refund of the purchase
price, at ITW Polymer Technologies’ election. Under no
circumstances shall ITW Polymer Technologies be liable
for any indirect, incidental or consequential damages.
Modification of Warranty: No distributor or sales
representative has the authority to change the above
provisions. No change in the above provisions will be
valid unless in writing and signed by an officer or the
Technical Director of ITW Polymer Technologies. No
term of any purchase order shall serve to modify any
provision of this document.
Mediation and Arbitration: If any dispute arises relating
to products or product warranties, either the purchaser
or ITW Polymer Technologies may a) initiate mediation
under the then current Center for Public Resources
(CPR) Model Procedure for Mediation of Business
Disputes, or b) initiate a non-binding arbitration under
the rules of the American Arbitration Association for the
resolution of commercial disputes.