Two component injection grouting machine

Types of two-component injection grouting machines

The two component injection grouting machine, also known as double injection grouting machine is widely used. This equipment can be divided into two major types based on discrimination, i.e., pneumatic double-component grouting machine and double electric injection grouting machine, and each of which has its own individual application areas.

• Pneumatic double-component grouting machine: Compared with electric double-component grouting machines, double-component grouting machines are more adaptable to working environments and can work under various temperatures and humidities. Additionally, the robust construction allows it to work for longer hours without needing to rest. The operation of pneumatic double-component grouting injectors is straightforward and does not rely on electrical power, thereby alleviating concerns about electrical safety. Moreover, double-component pneumatic grouting injectors are more portable while still being able to provide high-force outputs, enabling them to be employed in various settings and scenarios.
• Electric double-component grouting machine: As the name suggests, the entire working process of a double-electric grouting injector is controlled by electricity, which makes it easier to perform tasks such as adjusting the amount and pressure of resin and cement. Additionally, higher injection speeds can be attained by electric double-component grouting injectors, thus improving productivity.

Specification & maintenance

The key specifications to note when buying a two component injection grouting machine include the type, volume/ capacity, pressure and flow rate, ratios, power, and weight/ dimensions.

• Machine type: As noted earlier, there are three main types of injection grouting machines: electric, air-powered, and hydraulic pumps. Each works differently and is suited for a particular kind of job.
• Pump volume/ capacity: This refers to the amount of chemical the pump is able to handle. Injection pumps typically handle volumes from 5.0 up to 23.5L/min. larger capacity pumps are used for bigger construction jobs.
• Grouting pressure and flow rate: These two are closely linked. The mixing pump's pressure determines how forcefully the chemical will be injected into the cracks. Construction teams use pressure ranging from 15 up to 30 bar. The flow rate tells us how fast the liquid will move, measured in liters per minute. The flow rate is usually lower than the pump's pressure, typically noted as 10 to 20 liters per minute. 
• Mixing ratio: This refers to how the components of the chemical are blended in the injection machine. Different ratios may range from 60/40 to 80/20, etc.
• Power: This refers to the amount of energy needed to run the machine. For electric grouting machines, it is measured in kilowatts (kW) from 2kw to 5kw. Air-powered injection machines need compressed air from 1 to 2.5m3/h (Cubic Meter per hour).
• Weight/dimensions: A mobile two-component grouting machine weighs up to 500 kg. Larger, non-mobile, skid-mounted weighing systems can weigh more than 1000 kg. Its typical dimensions are 2m length, 1m width, and 1.2 height.

Maintenance

Grouting machines need regular servicing to keep them in good working condition. Here are some useful maintenance tips.

• Inspect and replace all worn-out safety components to keep users safe.
• Service the injection pump regularly. Inspections on a daily basis should look to see if there are signs of wear, shaft seal leak, and any unusual noise or vibration. Address any issues immediately and follow the manufacturer's advice on pump servicing and repairs.
• Advise the operator team on the proper use of chemicals. Using the wrong type can cause damage and early wear to the machine parts.
• Clean the machine thoroughly after each use. Grout material hardens quickly and is tough to remove.
• Lubricate all parts with quality lube products as per the manufacturer's instructions.

Scenarios of two component injection grouting machines

Two component injection grouting machines have a wide range of applications in the construction industry.

• Structural repair

  These machines are used to inject epoxy or polyurethane formulas into weakened structures, like bridges, beams, and columns, to enhance the stability and strength of these structures.

• Leak sealing

  Epoxy and Polyurethane injections made by grouting machines can seal leaks in concrete or rock formations, particularly in dams, wharfs, or below-ground water levels, making the structures water-proof and reducing further erosion.

• Soil stabilization

  These machines can inject stabilizing materials into the soil to enhance load-bearing capacity and prevent landslides and settlements.

• Joint sealing

  The machines precisely inject sealants into construction joints or cracks to create flexible, water-resistant joints that can accommodate structural movement.

• Anchoring

  They can inject adhesive resins into pre-drilled holes to create secure anchors for steel rods or bolts in rock or concrete.

• Micro piling

  Grouting machines can inject slurry or grout into the soil to create small-diameter piles for load transfer in weak soil conditions.

• Construction of frosty layers

  Such machines are often used to construct frost layers in the soil by injecting specific materials to improve soil properties and prevent frost heave.

• Injection of insulation materials

  These machines can be used to inject insulation materials like polyurethane foam into wall cavities or voids for thermal insulation and energy efficiency.

How to choose two component injection grouting machines

When purchasing two component injection grouting machines for sale, make sure to invest in quality equipment. Supply the following key areas to ensure a safe, effective, and profitable grouting operation.

• Advice from people in the industry

  Speak to engineers familiar with grouting systems and specifying engineers. Finding out what systems have proven well in the field is valuable information. Those instantiations can point to suppliers to consider and, more importantly, those to avoid.

• Supplier support

  Look for suppliers that can provide around-the-clock support, training, and repair services. Whenever a system has a problem, it is crucial to have someone available to address it, and great backup makes all the difference.

• Quality, ease of use, and safety

  Invest in a high-quality two-component injection grouting machine that will perform efficiently and reliably for many years. Always put safety first. Choose a system designed for safe operation with well-thought-out features that minimize operator exposure to hazards.

• Cost and value

  Consider more than just the cost of the machine when making a purchase. Take the grouting system's overall value, including its performance, reliability, safety, ease of use, and the level of support provided by the supplier. As experienced engineers know, buying a machine at the lowest cost can be the most expensive choice in the long run due to poor performance, high failure rates, and little supplier support.

• Choose reliable materials

  Consider material compatibility and opt for machines made with durable materials that can withstand the harsh caustic chemicals found in some grout formulations.

Two component injection grouting machine Q & A

Q1: What are the main components of a two-component injection grouting machine?

A1: Advanced two-component injection grouting machines may have different configurations, but the basic components include a pump system, injector system, mixing system, control system, pressure gauge, and valve.

Q2: How does a two-component injection grouting machine work?

A2: The two-component injection grouting machine works by simultaneously, or in some cases, sequentially injecting the two reactive components into the mixing cavity. The two components react chemically after mixing, and the operator uses the injection regulator to inject the formed material into the target cavity.

Q3: What are the advantages of using a two-component injection grouting machine?

A3: The two-component injection grouting machine has many benefits. It can quickly form materials with high density and low permeability. It can protect structures from water intrusion and damage. The machine can inject the components into the smallest voids. It has the capabilities to control the pressure and volume of the injected grout.

Q4: Can all types of grouts be used with a two-component injection grouting machine?

A4: No, not all grouts are suitable for use with the machine. Only those that can provide satisfactory results when injected through the mixing nozzle and pump are acceptable. Generally, rapid-setting chemical grouts are ideal for inversion pumping techniques with two-component injection machines.