Why Choose Substructure for Epoxy Encapsulations?
In a word: EXPERIENCE
There are numerous ways in which Substructure has innovatively handled the myriad problems of the epoxy encapsulation process in order to achieve better results for our clients.
The Importance of a Clean Surface
For instance, a crucial first step in the epoxy encapsulation process is often overlooked by both contractors and, surprisingly, engineers: a uniformly clean surface.
In order to achieve the optimal bond strength between the epoxy grout and the structural member, the structural member must be flawlessly clean. Any marine growth or corrosion (even a coating of flash rust) acts as a release agent and prohibits an effective bond. Without the existence of a good bond and the resulting monolithic structure, water intrusion will occur and the corrosion problem will continue.
Cleaning is traditionally accomplished by divers and surface personnel utilizing a water blaster or mechanical device that manually removes marine growth, previous coatings, and surface corrosion. However, this rarely, if ever, produces a uniformly clean surface capable of bonding to the epoxy grout.
A Better Cleaning Process
As a result of this obvious deficiency in the installation process, Substructure created a high pressure cleaning collar that not only assures a flawless surface, it also eliminates the need to use divers in the cleaning process and can clean a pile in less than an hour. This collar employs orbital jet technology and is powered by a state-of the-art 20,000 PSI water-blaster unit.
As with most projects, preparation and attention to detail consistently produce superior results.
The Need for Commercial Plural Component Pumps
An additional problem overcome by Substructure was the surprising lack of commercially available plural-component pumps that were capable of pumping the high-aggregate epoxy into the FRP jackets.
Available pumps normally used for this application are too large and unsafe and often produce a finished product that is improperly blended. Further more, they are prone to a variety of mechanical failures. These pumps performed poorly in virtually all respects, as they were never designed to pump such high-aggregate plural components.
The Solution: Build Our Own Pumping System
The solution to this problem resulted in a lengthy development process. Over a period of three years, Substructure has created several prototype pump units specifically designed to mix and pump high-aggregate plural components.
The latest and most advanced model is now complete. It is compact, efficient, safe, and reliable. Patents are now pending on both the pump and a newly designed static mixer (USPTO application number 10/907,351; application filed March 30, 2005).
These technological advancements, coupled with a wealth of encapsulation installation experience, are why Substructure remains at the cutting edge of this field. Put our expertise to work for you!
