When you’re preparing to install new equipment — whether for an upgrade or a brand-new process — you know every component, its function, and potential failure points. You’ve designed the setup to maximize productivity and efficiency. Now, you need to reduce the risks that could impact your success. One of the most important steps in this process is choosing the right grout for your operating conditions. The right choice will reduce or eliminate performance issues. But before selecting a specific product, you need to answer a key question: Should you use epoxy grout or cement grout?
Start with Three Questions
- Will the equipment be exposed to constant vibration or impact?
– If yes, go with epoxy. - Will chemicals contact the equipment base or surrounding concrete?
– If yes, epoxy is your best bet. - Will the operating environment regularly exceed 150°F?
– If yes, cement is typically the better option.
Once you’ve answered these, you’ll know whether to use epoxy or cement-based grout. From there, match the specific product to the performance demands of your application.
Compressive Strength: Commonly Misunderstood
Compressive strength is often the first thing engineers look at. It’s a measure of the maximum stress a material can handle before failing. For example, if a grout has a 14,000 psi rating, it shouldn’t fail under that level of pressure.
However, in many industrial settings, grout failures rarely result from inadequate compressive strength. Even though epoxy grouts usually have higher strength ratings, advances in cement grout chemistry now allow some cementitious grouts to match or exceed those numbers.
The key is to consider strength over time and under your actual temperature conditions. Always factor in weather or environmental controls during placement.
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Cost Considerations: Value vs. Overkill
Price usually tempers the drive for maximum strength. Epoxy grouts can cost about four times more than cement grouts. And that’s just the base cost — operating conditions like chemical exposure or extreme heat can raise the price even more.
At this stage, many teams ask, “Do we really need that much strength?” In many cases, the answer is no. Choose based on need, not over-specification.
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Chemical Resistance: Match It to the Environment
If your system involves handling or potential exposure to chemicals, your grout must resist those substances while still supporting load transfer and durability.
Standard epoxy grouts typically offer good chemical resistance across the pH spectrum. But exposure to heat, spills, or poor cleaning schedules can challenge even these materials.
Always review the product’s chemical resistance chart or technical data sheet. If the data is missing or unclear, consider lab testing the grout under your specific conditions before committing to a full installation.
Grouts with the best chemical resistance tend to be the most expensive — but a failure in service will cost far more.
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Impact Resistance: Think Beyond Static Load
If your process generates sudden force — like cavitation in pumps, stamping in metalwork, or braking action in roll stops — your grout must handle impact. Epoxy grouts excel here due to their low-modulus, polymer structure. They absorb shock and rebound without damage.
Cement grouts, while great under static loads, are brittle. Thin applications are especially vulnerable. Some cement grouts are modified for better impact resistance, including:
- Metallic grouts: Use metal fillers for added strength and durability.
- Hybrid grouts: Blend epoxy-like performance with the ease of cement grout installation.
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Vibration Dampening: Protect Equipment and Foundations
Vibration slowly degrades equipment alignment, bearing life, and concrete integrity. Epoxy grouts bond tightly to baseplates and frames, helping route energy away from critical components. When placed properly, they can deliver close to 100% effective bearing area.
Epoxy’s flexibility also helps absorb residual vibrations, reducing stress on foundations over time.
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High Temperature Resistance: Know the Limits
If your process includes prolonged exposure to high heat, your grout must handle those conditions permanently.
- Epoxy grouts: Typically rated to 150°F. Above that, they may soften or deform under continuous pressure.
- Cement grouts: Standard versions handle around 350°F. Specialized or hybrid versions can go up to 2400°F.
If heat is a factor, cement grout is usually the safer, more durable choice.
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Flowability: Often Overlooked, But Critical
Grout must flow smoothly into place — especially under baseplates and tight clearances. Unfortunately, flowability is often described in vague terms like “fluid,” “plastic,” or “flowable.” These aren’t helpful unless you’re deeply familiar with the formulations.
A mock-up pour is the best way to evaluate flowability, but it’s rarely feasible. Instead, understand how material type affects movement:
- Cement grouts: Cement reacts with water and lime to form a fluid, lubricated mix that flows easily — if mixed correctly.
- Epoxy grouts: Act like adhesives and resist flow. They stick to everything. Colder temperatures increase viscosity and make placement harder.
Always consider ambient conditions and mix methods to ensure the grout performs as expected.
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Final Thoughts
Choosing between epoxy and cement grout depends on understanding your process environment, load demands, and operating conditions. Use the checklist below to guide your decision:
- Vibration or impact? → Epoxy
- Chemical exposure? → Epoxy
- High temperature? → Cement
- Cost-sensitive? → Cement
- Extreme strength or resistance? → Depends on the need
Matching the right grout to your application ensures performance, reliability, and long-term stability.
