PILEMEDIC® SYSTEM
PileMedic® Accessories: Spacers, Epoxies and Underwater Grout
The parts that go inside and around a PileMedic® jacket: patented plastic spacers that set the annular space and hold the rebar, grout ports, QuakeBond™ epoxies that cure underwater, and underwater grouts that fill the jacket.
- Patented spacers, U.S. Patent 10,808,412
- Epoxy that bonds and cures underwater
- Washout-resistant underwater grout
SPACERS
Spacers Set the Annular Space and Hold the Rebar
Placing rebar exactly and holding the specified clear cover takes time on any column or pile repair, and it is harder underwater. PileMedic® spacers do both jobs. Standard spacers come in 1/2 in. and 1 in. combo, 2 in., 3 in. and 4 in. stand-offs and hold assorted rebar diameters, so there is no separate rebar support to build.
Spacer assemblies are banded around the pile at regular intervals with the supplied nylon banding. They keep the laminate centered and round as it is wrapped and lowered, and they set a uniform gap for the grout, which keeps grout volume and added dead load down.
- 1/2 in. and 1 in. combo spacers, used with epoxy grout with or without GU50C carbon strips
- 2 in. and 3 in. spacers take #4 or #6 bars
- 4 in. spacers take #4 or #7 bars
- Protected by U.S. Patent 10,808,412, Spacers for Repair of Columns and Piles
SPACER TYPES
PileMedic® Spacers and Fittings
QuakeWrap® stocks four standard spacer sizes and skirt pins. Other shapes are made to order.
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1/2 in. and 1 in. Combo Spacers
For thin annular spaces filled with epoxy grout, with or without GU50C carbon strips.
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2 in., 3 in. and 4 in. Spacers
Set the stand-off and hold the bars at the specified cover. 2 in. and 3 in. spacers take #4 or #6 bars, and 4 in. spacers take #4 or #7 bars.
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Skirt Pins
Long pins on a zip tie near the bottom of the jacket. They hold the skirt that keeps grout in the annular space.
Bottom seal options -
Special Spacers
Corner bars for square piles, clips for steel H-pile flanges and other shapes can be custom made when a project requires them.
Which spacers fit your piles?
Send the pile shape, size and rebar layout. Our team will recommend the right PileMedic® spacers and provide specifications for your engineer.
GROUT INJECTION PORT
Grout Ports That Install From Outside the Jacket
PileMedic® grout injection ports go in from the outside after the jacket is built. Drill a 2 3/8 in. hole through both plies of laminate, screw the port in, and turn the locking ring by hand to seal it against the jacket.
The grout pump hose connects with a quick-release valve. When pumping is done, a guillotine-style slide drops into the slot to stop grout from flowing back, and the hose comes off.
- Installs from outside, no access inside the jacket needed
- Quick-release hose connection
- Slide-in shutoff prevents backflow
EPOXIES
QuakeBond™ Epoxies for PileMedic®
220UR bonds the laminate plies to each other. 320LV fills the annular space. Both cure underwater. Values are from the product data sheets.
| Property | QuakeBond™ 220UR paste | QuakeBond™ 320LV resin |
|---|---|---|
| Main use | Bonds laminate overlaps, in air or underwater | Fills the annular space, alone or with sand and pea gravel |
| Mix ratio | 2:1 by volume | 2:1 by volume |
| Consistency | Non-sag paste, high tack | 780 cps mixed at 77°F (ASTM D2196) |
| Pot life at 77°F | 30 minutes | 30 minutes gel time, 20 minutes working time |
| Full cure | 12 hours | Not stated on the PDS [Confirm with QuakeWrap] |
| Tensile strength (ASTM D638) | 4,360 psi | 7,900 psi (54.5 MPa) |
| Compressive strength (ASTM D695) | 11,700 psi (80.7 MPa) | 11,200 psi (77.2 MPa) |
| Adhesion | Over 1,200 psi to blasted steel; over 350 psi to damp concrete | Over 800 psi to concrete, 100% concrete failure |
| Coverage or yield | 50 sq ft per gallon at 30 mils; 60 sq ft per gallon at 20 to 25 mils on laminate | Up to 70 lb of sand and 3/8 in. gravel per gallon |
| Packaging | 3 and 15 gallon kits, 900 mL cartridges | 15 gallon kits (5 gallon pails or 55 gallon drums) |
| Application temperature | 50 to 90°F | Precondition components to 65 to 85°F |
Not sure which fill to specify?
Our team will recommend the right epoxy or grout for your pile repair and provide data sheets for your engineer.
UNDERWATER GROUTS
PileMedic® UW Grout and Grout Additive
Cement-based fills for the annular space. Use a non-shrink grout mixed to the manufacturer's directions, and place it by tremie below water.
| Property | PileMedic® UW Grout | PileMedic® UW Grout Additive |
|---|---|---|
| What it is | Pumpable, cement-based, non-shrink, non-metallic underwater grout | Powder admixture for Portland cement concrete or mortar placed underwater |
| Use | Pile encapsulation for concrete, timber and steel; ½ in. up to several inches thick | Reduces washout, segregation and laitance; improves bond to submerged concrete and steel |
| Compressive strength, 1 day (ASTM C109) | 5,400 psi plastic; 4,600 flowable; 3,300 fluid | Not applicable |
| Compressive strength, 28 days (ASTM C109) | 11,000 psi plastic; 9,200 flowable; 8,200 fluid | Not applicable |
| Compliance | Corps of Engineers CRD-C 621, ASTM C1107, USDA accepted | Not listed |
| Mixing | 6 to 8.5 pints of water per 50 lb bag; mechanical mixer required | 20 lb pail per cubic yard, mixed 5 to 10 minutes in the truck |
| Yield | About 0.45 cu ft per 50 lb bag | Based on a 6.5 to 7.0 bag cement mix |
| Packaging | 50 lb bags and 3,000 lb super sacks | 20 lb pails |
| Shelf life | 1 year unopened | 12 months unopened |
EPOXY GROUT
PileMedic® UW Epoxy Grout
A three-component, 100% solids, moisture-insensitive epoxy grout that displaces water and cures underwater. It encapsulates concrete, timber and steel piles above and below water, and can be poured into the jacket or pumped. Values are from the product data sheet.
| Property | PileMedic® UW Epoxy Grout |
|---|---|
| Components | Part A resin, Part B hardener, Part C aggregate |
| Liquid mix ratio | 2:1 by volume; aggregate loading is adjustable |
| Viscosity | 100 to 500 cps |
| Gel time (200 g mass) | 40 minutes |
| Tack free time at 73°F | 12 to 24 hours |
| Tensile strength, 7 days (ASTM C307) | 1,500 psi wet; 2,500 psi dry |
| Bond strength, 7 days (ASTM C882) | 1,800 psi wet; 3,000 psi dry |
| Compressive strength, 7 days | 6,000 psi wet; 11,000 psi dry |
| Tensile bond strength, 7 days (ASTM C1583) | Over 250 psi |
| Linear shrinkage (ASTM C531) | 0.01% |
| Lift thickness in one pour | Up to 4 in. above water, 7 in. underwater; up to 10 in. and 20 in. when extended with 3/8 to 1/2 in. aggregate (max. 1:1 by weight) |
| Placement | Pour or pump through a tube of at least 1/2 in. to the lowest point, keeping the tube end 6 in. below the grout surface (tremie) |
| Packaging and yield | 2 gal of resin (Part A), 1 gal of hardener (Part B) and two 55 lb bags of aggregate (Part C). 3 gal of mixed epoxy with 100 to 150 lb of aggregate yields about 1 to 1.5 cu ft |
| Shelf life | 2 years unopened, stored at 40 to 95°F |
| Minimum substrate temperature | 40°F (5°C) |
RAPID PILE REPAIR KIT
Everything for the Repair in One Kit
PileMedic® materials can be packed as a Rapid Pile Repair Kit with the laminate, epoxy, spacers and grout additive together, so a crew arrives with what the repair needs. The installation guide lists the contents of one kit: a 58 x 42 x 45 in. crate of about 1,700 lb that repairs 200 linear feet of pile, based on a 25 in. diameter pile, with grout not included. [Confirm with QuakeWrap the kit is still offered and its current contents and coverage: the same guide page and the 2023 Rapid Pile Repair Kit fact sheet also show an older figure of about 300 linear feet per box.]
- PileMedic® laminates, 3,000 sq ft
- Epoxy cartridges and static mixers, 130 cartridges
- PileMedic® spacers, 1,275 pieces, plus zip ties
- Underwater grout additive for 1 cu yd of grout
- Foam and skirts for the bottom seal
PileMedic® Accessories FAQs
What do PileMedic® spacers do?
They set the annular space between the pile and the jacket, hold the reinforcing bars at the specified cover, and keep the jacket centered and round as it is wrapped. Assemblies are banded around the pile every 2 to 3 ft.
What rebar sizes do the spacers take?
2 in. and 3 in. spacers take #4 or #6 bars. 4 in. spacers take #4 or #7 bars. 1/2 in. and 1 in. combo spacers are used with epoxy grout, with or without GU50C carbon strips. Special spacers, such as clips for steel H-pile flanges, can be custom made.
Which epoxy bonds the laminate underwater?
QuakeBond™ 220UR, a two-part structural paste with a 2:1 mix ratio. It is moisture tolerant, has a high tack in air and underwater, and reaches full cure in 12 hours.
What can fill the annular space?
PileMedic® UW Grout, Portland cement concrete or mortar with PileMedic® UW Grout Additive, PileMedic® UW Epoxy Grout, or QuakeBond™ 320LV epoxy, alone or mixed with sand and pea gravel for wider gaps. The design sets the fill.
Can I order accessories on their own?
[Confirm with QuakeWrap whether spacers, epoxies, grouts and ports are sold separately from PileMedic® laminates. No ordering page was found on pilemedic.com or quakewrap.com.]
PILEMEDIC® SYSTEM
More of the PileMedic® System
Need Spacers, Epoxy or Grout for a Pile Repair?
Tell us the pile type, size and site conditions. Our team will recommend the right PileMedic® system and accessories and provide specifications for your engineer.