Grout and Epoxy Fill Volume Calculator

How is grout or epoxy fill volume found?

A fill needs as much material as the volume of the void it fills. The void is usually a simple shape, so the calculation is a volume calculation. The tool handles three common cases on separate tabs.

Under a base plate

Steel column and machine base plates are grouted over the gap between the plate and the concrete. The grout is usually taken a little beyond the plate: V = (width + 2 × shoulder) × (length + 2 × shoulder) × thickness.

Anchor pockets

Pockets left in the concrete for anchor bolts set later are filled with grout. The volume taken up by the bolt is deducted from the pocket volume. For a rectangular pocket V = (width × length − π / 4 × d²) × depth, and for a round pocket V = π / 4 × (D² − d²) × depth.

Joints and channels

For a joint or channel with a rectangular section, V = width × depth × length is enough.

From litres to kilograms

Material is sold by weight. The product data sheet states how many kilograms are needed per litre of fill, or how many litres one bag yields. For cement based ready mixed grouts the figure is around 2 kg/L. For epoxy products it varies a lot, so enter the number from the data sheet.

Example

Grouting under four 400 × 400 mm base plates at 30 mm thickness with a 50 mm shoulder on each side gives a net volume of 30 litres. With 10 percent waste that is 33 litres, and at 2 kg/L you need 66 kg, or three 25 kg bags.

Limits

The volume is geometric. Rough surfaces, formwork leakage and material left in the pump line are covered by the waste allowance. Minimum and maximum grout thickness are limited by the product.