MasterFlow 648

High-strength, high-flow, chemical resistant epoxy grout

DESCRIPTION
MasterFlow 648 is a three-component epoxy resin-based • Excellent freeze/thaw resistance for equipment in low
precision grout used to secure critical equipment for proper temperature service environments
alignment and transmission of static and dynamic loads. • Resists water and chloride intrusion for use in wet and
With carefully balanced physical properties and excellent aggressive environments
resistance to chemical attack, elevated service • Resists impact and dampens torque to protect equipment
temperatures, vibration and torque, MasterFlow 648 is and extend service life
formulated for easy installation, with good flow • Extended working time
characteristics suitable for pouring or pumping in • Pumpable for maximum productivity on large grout
thicknesses from 10mm up to 150mm, low dust generation installations
and soap and water clean-up. • Durable bond to concrete and steel optimizes load
transfer
MasterFlow 648 is available in all regions of the world, • Meets the requirements of EN 1504-6
supported by trained Master Builders Solutions sales and • Can be applied in thickness from 10 to 150 mm
technical personnel with experience in the specification and • Globally available for consistent project results.
installation of epoxy grouts on every continent.
APPLICATION METHOD
FIELD OF APPLICATION (a) Surface Preparation
MasterFlow 648 is used for assembling and fixing of the The concrete should be free of frost, curing membranes,
following items: waterproofing treatments, oil stains, laitance, friable
• Industrial turbines, generators and compressors material and dust. The concrete surfaces should be chipped
• Very large reciprocating compressors and if there is a water leakage it must be drained or properly
• Industrial turbines, generators and compressors. plugged. Surfaces should be dry. Particular attention
• Rolling, stamping, grinding, drawing and finishing mills. should be paid to bolt holes to ensure that these are dry.
• Forging hammers. Use vacuum and/or oil free compressed air to remove free
• Rail tracks, crane rails. standing water. The concrete areas to be grouted should
• Paper machine sole plates. not be primed or sealed.
• Machinery and equipment requiring high strength
maximum bearing. Base plates, bolts, etc. must be clean (SA 2½) and free of
Note: For wind turbine installations please refer to our oil, grease and paint etc. to obtain proper adhesion. Set and
MasterFlow 9000 series grouts. align equipment. If shims are to be removed after the grout
has set, then lightly grease them for easy removal. Priming
FEATURES AND BENEFITS the metal surfaces is only required when a long delay
• High early and ultimate strengths for rapid turnaround between cleaning and grouting will allow corrosion and
• Low creep maintains equipment alignment contamination.
• Retains physical properties at elevated temperatures
increasing the service range A head box should be installed with the formwork to ease
• Low-dusting for added worker comfort and safety the pour and flow of the mixed grout:
• 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

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MasterFlow 648
High-strength, high-flow, chemical resistant epoxy grout

Ensure formwork is secure and watertight to prevent (c) Application Underplate

movement and leaking during the placing and curing of the Lengths of metal strapping laid in the formwork prior to
grout. The area should be free of excessive vibration. Shut placing may be necessary to assist grout flow over large
down adjacent machinery until the grout has hardened. In areas and in compacting and eliminating air pockets. Have
hot weather, base plates and foundations must be shaded sufficient manpower, materials and tools to make mixing
from direct sunlight. Bags and buckets of grout should be and placing rapid and continuous. Where grout must flow
stored in the shade prior to use. In cold weather, the some distance, make the initial batch slightly more fluid or
temperature of base plates and foundations should be flowable than required; this lubricates the surfaces and
raised to over 10°C. avoids blockage of the grout that follows. The grout shall be
poured continuously and from one side only, to avoid
(b) Mixing entrapment of air while grouting.
The fill ratio is the weight of the aggregate to combined
resin and hardener components. MasterFlow 648 is Maintain a constant hydrostatic head, preferably of at least
designed to be utilised at a variable fill ratio (resin /
aggregate) from the standard 1 / 6.7 ratio to as low as 1 / 5 15 cm. On the side where the grout has been poured, allow
(hi-flow version). 10 cm clearance between the side of the form and the base
plate of the machine. On the opposite side allow 5-10 cm
The standard 57.5 litre unit of MasterFlow 648 includes clearance between the formwork and the base plate.
100kg (four 25kg bags) of Part C aggregate. This can be
reduced to as low as 3 bags yielding 51.5 litres. 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
Resin and filler components can be purchased separately. cracking can occur. Avoid shoulders wherever possible.
Unlike most epoxy grouts, MasterFlow 648 maintains high
bearing area when fill ratios are decreased. In addition, If shoulders are required, they should be firmly anchored
physical properties including high temperature performance with reinforcing to the substrate to prevent debonding.
are maintained. By determining the proper fill ratio for a Make sure grout fills the entire space to be grouted and
particular project and purchasing accordingly, the cost per remains in contact with the plate throughout the entire
litre, flow and physical properties are optimised. A guideline grouting placement.
for suggested fill ratios is shown in the following table. Note: Do not use vibrator for placing the grout!

Thin pours or Standard COVERAGE

Temperature 2,000 kg / m3 Filling ratio 1 / 6.7 (1 set resin + 4 bags)
long distance grouting
> 30°C 4 bags 4 bags 1,750 kg / m3 Filling ratio 1 / 5 (1 set resin + 3 bags)
20 - 30°C 3.5 – 4 bags 4 bags
> 10 - 20°C 3 – 3.5 bags 3.5 bags
FINISHING AND CLEANING
After the pour is complete, remove uncured epoxy from the
mixer, wheelbarrow and tools with soap and water or a
In using this guide the temperature of the foundation and
citrus degreaser. Cured material can only be removed
plate is the critical concern, however, grout and ambient
mechanically.
temperature are also important.

CURING
Add all the contents of the hardener container to the resin
Full cure is reached in 7 days after the application at a
part and mix thoroughly for at least 3 minutes. Transfer to a
constant temperature of 23 ºC
mechanical mixer. Add the aggregate, mixing thoroughly
until a uniform consistency is obtained. At low temperatures
(10°C) the flow characteristics of MasterFlow 648 will be
reduced and installation times increased.

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MasterFlow 648
High-strength, high-flow, chemical resistant epoxy grout

WORKING TIME HANDLING AND TRANSPORT

The following chart is a guide for the working time of a Usual preventive measures for the handling of chemical
MasterFlow 648 grout at various ambient temperatures. products should be observed when using this product, for
example do not eat, smoke or drink while working and wash
Temperature Working time hands when taking a break or when the job is completed.
at 30°C 50 – 60 minutes
at 21°C 90 – 120 minutes Specific safety information referring the handling and
at 10°C 120 – 150 minutes transport of this product can be found in the Material Safety
Data Sheet. For full information on Health and Safety
PACKAGING matters regarding this product the relevant Health and
MasterFlow 648 is available in the following package sizes: Safety Data Sheet should be consulted.

Disposal of product and its container should be carried out

Part A Part B Part C Set Yield
according to the local legislation in force. Responsibility for
11.35kg 3.55kg 25kg 114.9kg this lies with the final owner of the product.
57.5 l
pail pail bag (1A+1B+4C)
CONTACT DETAILS
STORAGE Master Builders Solutions UK Ltd,
19 Broad Ground Road
Store at ambient temperatures, out of direct sunlight, in
Lakeside
cool, dry warehouse conditions and clear of the ground on
Redditch
pallets protected from rainfall prior to application. The resin
Worcestershire
parts need to be protected from frost!
B98 8YP
Tel: +44 (0) 1527 512255
SHELF LIFE
Fax +44 (0) 1527 503576
24 months if stored at above mentioned storage conditions.
www.master-builders-solutions.com/en-gb
WATCH POINTS
© Master Builders Solutions UK Ltd
• 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
MasterFlow 648. This is however no sign of physical
weakening of the product.
• In case of thicker applications and complex geometries
consult your local Master Builders Solutions
representative.

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MasterFlow 648
High-strength, high-flow, chemical resistant epoxy grout

Product Data
Property Standard Data Unit
Chemical Base - Epoxy -
Colour - Grey -
Layer Thickness minimum 10
- mm
maximum 150
Fresh Mortar Density filling ratio: 1 / 6.7 approx. 2.0
- g/cm3
filling ratio: 1 / 5 approx. 1.75
Working Time 10 ºC 120 – 150
23 ºC - 90 – 120 Minutes
30 ºC 50 – 60
Application Temperature (ambient and substrate) - +10 - +30 °C
Flow Time full plate contact < 20
ASTM C1339 Minutes
to back of box < 30
Bearing Area ASTM C1339 ≥ 85 %
Compressive strength (50x50mm cubes) 1 day ≥ 72
ASTM C579 N/mm²
7 days ≥ 97
Elasticity Modulus (7 days) filling ratio: 1 / 6.7 ≥ 15,000
EN 13412 N/mm2
filling ratio: 1 / 5 ≥ 12,000
Adhesion to concrete 7 days EN 1542 ≥ 3.0 N/mm2
Adhesion to steel 1 day EN 12188 ≥ 10.0 N/mm2
Adhesion to Concrete after Freeze-Thaw
EN 13687-1 ≥ 2.0 N/mm2
(50 cycles with salt) 28 days
Slant Shear Strength (7 days) 50 º slope 76
60 º slope EN 12188 61 N/mm2
70 º slope 73
Pull-out strength at 75 kN load EN 1881 ≤ 0.6 mm
Creep under tensile load for 3 months at 50 kN load EN 1544 ≤ 0.6 mm
Shrinkage 28 days EN 12617-4 ≤ 0.2 mm/m
Water tightness under pressure Internal method passed, no leakage -
Thermal expansion coefficient 7 days EN 1770 3.7 x 10-5 1/K
Peak exotherm Internal method approx. +43 °C
Glass transition temperature EN 12614 +80 °C
Reaction to fire (1) EN 13501-1 class Efl -
Reaction to fire (2) EN ISO 11925-2 no ignition -

Note: Technical data shown are statistical results and do not correspond to guaranteed minima.

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MasterFlow 648
High-strength, high-flow, chemical resistant epoxy grout

Mechanical Strength at: +10 ºC +23 ºC +30 ºC

1 / 6.7 1 / 6.7 1 / 5.0 1 / 6.7
Filling Ratio (resin / aggregate):
(1xA+1xB+4xC) (1xA+1xB+4xC) (1xA+1xB+3xC) (1xA+1xB+4xC)
8 hours - ≥ 40 ≥ 35 ≥ 50

Compressive Strength 16 hours - ≥ 70 ≥ 60 ≥ 75

acc. to EN 12190 [N/mm²] 1 day ≥ 30 ≥ 75 ≥ 65 ≥ 80
(40x40x160mm prisms) 3 days ≥ 80 ≥ 85 ≥ 68 ≥ 85
7 days ≥ 90 ≥ 95 ≥ 70 ≥ 95
8 hours - ≥ 16 ≥ 17 ≥ 20

Flexural Strength 16 hours - ≥ 22 ≥ 20 ≥ 22

acc. to EN 12190 [N/mm²] 1 day ≥ 15 ≥ 25 ≥ 22 ≥ 25
(40x40x160mm prisms) 3 days ≥ 25 ≥ 27 ≥ 23 ≥ 27
7 days ≥ 28 ≥ 30 ≥ 25 ≥ 28
Note: Technical data shown are statistical results and do not correspond to guaranteed minima.

Chemical Resistance acc. to EN 12808-1

Change in
Test liquids according to EN 13529
compressive strength
Group Description Test Liquid after 72 hin %after 500 h
47.5% toluene + 30.4% isooctane
DF 1 Gasoline + 17.1% n-heptane + 3% methanol <5 < -20
+ 2% 2-methyl-propanol-(2)
Fuel oil, Diesel fuel and other unused 80 % n-paraffin (C12 to C18) +
DF 3 < -5 < -5
combustion motor oils 20 % methylnaphthalene
All hydrocarbons as well as mixtures 60% toluene + 30% xylene +
DF 4 <1 <3
containing benzene with max. 5 Vol. % 10% methylnaphthalene
Mono- and polyvalent alcohols (up to a 48 Vol.-% methanol +
DF 5 < -10 < -15
max. 48 vol.-% methanol), glycol ethers 48 Vol.-% IPA + 4% water
50 % ethyl acetate +
DF 7 All organic esters and ketones < -5 < -5
50 % methyl isobutyl ketone
Mineral acids (non-oxidizing) up to 20%
DF 10 and inorganic salts in aqueous solution Sulphuric acid (20%) < -5 < -30
(pH<6) except HF
Inorganic lye (except oxidizing) and
DF 11 Sodium hydroxide solution (20%) < -5 < -10
inorganic salts in aqueous solution (pH>8)
Aqueous solutions of inorganic non-
Aqueous sodium chloride
DF 12 oxidizing salts with a pH value between 6 < -5 < -5
solution (20%)
and 8
- Concentrated acids Phosphoric acid (85%) < -15 < -5
- Concentrated acids Hydrochloric acid conc. (37%) < -10 < -30
- Concentrated acids Sulphuric acid (70%) <5 <5
- Oxidizing acids Nitric acid (10%) < -15 < -20
Note: Severe chemical attack may lead to discolouration of MasterFlow 648. This is however no sign of physical weakening of the product.

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MasterFlow 648
High-strength, high-flow, chemical resistant epoxy grout

MasterFlow 648 - Master Builders Solutions UK Ltd, Version 2

Health and Safety Spillage

*For full information on Health and Safety matters regarding this product the Chemical products can cause damage; clean spillage immediately.
relevant Health and Safety Data Sheet should be consulted.
DISCLAIMER
The following general comments apply to all products. “Master Builders Solutions UK Ltd" (the Company) endeavours to ensure that
advice and information given in Product Data Sheets, Method Statements and
As with all chemical products, care should be taken during use and storage to Material Safety Data Sheets (all known as Product Literature) is accurate and
avoid contact with eyes, mouth, skin and foodstuffs, (which may also be tainted correct. However, the Company has no control over the selection of its products
with vapour until the product is fully cured and dried). Treat splashes to eyes for particular applications. It is important that any prospective customer, user or
and skin immediately. If accidentally ingested, seek medical attention. Keep specifier, satisfies him/her-self that the product is suitable for the specific
away from children and animals. Reseal containers after use. application. In this process, due regard should be taken of the nature and
composition of the background/base and the ambient conditions both at the time
Solvent Based Products of laying/applying/installing the material and when the completed work is to be
Use in well ventilated areas; avoid inhaling. Suitable respiratory equipment may brought into use.
be needed, eg when spraying. Can cause skin, eye irritation. Wear protective
eye shields and gloves during use. Do not smoke or allow sparks or naked lights Accordingly, no liability will be accepted by the Company for the selection, by
when stored or in use. others, of a product, which is inappropriate to a particular application.

Resin Products Products are sold subject to the Company's standard conditions of sale and all
Can cause irritation, dermatitis or allergic reaction. Use protective equipment customers, users and specifiers, should ensure that they examine the
particularly for skin and eyes. Use only in well ventilated areas. Company's latest Product Literature.

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