PDVSA

ENGINEERING DESIGN MANUAL

VOLUME 18–II

ENGINEERING SPECIFICATION

PDVSA N° TITLE

A–213 BONDING AND GROUTING

1 OCT.92 GENERAL REVIEW 9 L.T. R.P. R.R.

0 DEC.85 FOR APPROVAL 9 J.S. J.G. E.S.

REV. DATE DESCRIPTION PAG. REV. APPD. APPD.

APPD.BY José Gilarranz DATE DEC.85 APPD.BY Eduardo Santamaria DATE DEC.85

E PDVSA, 1983 SPECIALISTS

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Index
1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Related Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Quality Assurance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Regulatory Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.6 Submittals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.7 Delivery, Storage, and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Water, Sand, and Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Cement Grouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4 Nonshrink Cement–Based Grout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.5 Nonshrink Epoxy Grout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.6 Bonding Mixtures and Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 EXECUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Surface Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Mixing and Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.5 Curing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.6 Shims and Wedges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.7 Anchor Bolts and Pipe Sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.8 Bonding New Concrete to Existing Concrete . . . . . . . . . . . . . . . . . . . . . . . . 7
3.9 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
APPENDIX 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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1 GENERAL
1.1 Scope
This specification defines the minimum requirements to be met by the designer,
manufacturer and civil contrator for bonding and grouting. The work comprises:
Bonding of new concrete to existing concrete.
Grouting of base plates and equipment bases.
Regular cement grout, nonshrink cement–based grout, epoxy grout, and bonding
mixtures.

1.2 Related Work

Concrete–Materials and Construction PDVSA A–211

1.3 Quality Assurance

1.3.1 Contractor’s Qualification – Experience in similar installations and environmental
conditions using the materials specified.
1.3.2 Manufacturer shall provide technical services for advice on proper procedures
of grout installation to PDVSA.

1.4 Regulatory Requirements

1.4.1 Comply with all applicable Venezuelan laws, standards, and regulations.

1.5 References
The following codes, standards and specifications, including applicable addenda,
shall form a part of this specification to the extent specified herein.
1.5.1 COVENIN – Comisión Venezolana de Normas Industriales
COVENIN 262 – through to 277 (ASTM C 33)
COVENIN 255
COVENIN 484 (ASTM C109)
COVENIN 273 (ASTM C125)
COVENIN 28 (ASTM C150)
COVENIN 493 (ASTM C191)
1.5.2 ASTM – American Society for Testing and Materials.
C33 Standard Speciication for Concrete Aggregates.
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C109 Standard Test Method for Compressive Strength of Hydraulic

Cement Mortars (using 2–in or 50–mm. Cube Specimens).
C125 Standard Definition of Terms Relating to Concrete and Concrete
Aggregates.
C150 Standard Specification for Portland Cement.
C191 Standard Test Method for Time of Setting of Hydraulic Cement by
Vicat Needle.
C531 Standard Test Method for Shrinkage and Coefficient of Thermal
Expansion of Chemical–Resistant Mortars, Grouts, and
Monolithic Surfacings.
C579 Standard Test Methods for Compressive Strength of
Chemical–Resistant Mortar and Monolithic Surfacings.
C827 Standard Test Method for Early Volume Change of Cementitious
Mixtures.

1.6 Submittals
1.6.1 Submit manufacturer’s certification that the supplied grout meets the
requirements of this specification.
1.6.2 Promptly submit copies of strength test results to PDVSA.

1.7 Delivery, Storage, and Handling

1.7.1 Deliver nonshrink cement–based grout and epoxy grout aggregate to the site in
sound, dry bags. Deliver epoxy grout liquid components in sealed hardener and
resin containers. Contractor shall be responsible for storing grout in a dry,
weatherproof area and within the temperature range of 4°C to 32°C or as
indicated by the manufacturer’s recommendations.
1.7.2 Remove any material from the site which becomes damp or otherwise defective.
1.7.3 Limit the total job storage time for nonshrink grout to ten months or as indicated
by the manufacturer’s recommendations.

2 PRODUCTS
2.1 General
2.1.1 Proportion sand–cement dry pack at the site. All nonshrink grouts shall consist
of premeasured, prepackaged materials supplied by the manufacturer, except
water.
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2.1.2 All grouts shall be noncorrosive, nonstaining, and resistant to effects of moisture.

2.2 Water, Sand, and Cement

2.2.1 Water – Conform to COVENIN 28 (AASHTO T26). When conforming water is
unavailable, make mortar test cubes with nonconforming water in accordance
with the requirements of COVENIN N° 484 (ASTM C109) after obtaining written
approval from the Owner. Tested cubes shall have a minimum of 90% of the 28
day specified strength.
2.2.2 Sand – As defined in COVENIN 254 through to 263 (ASTM C125 and C33),
grading for fine aggregates 4.75 mm to 0.15 mm. Sand for bonding mixture shall
pass a 1.2 mm sieve.
2.2.3 Cement N° 28 – ASTM C150 (Type I or Type II).

2.3 Cement Grouts

2.3.1 Plain Cement Grout – Two parts sand for every part cement, by weight; with a 28
day minimum compressive strength of 210 kg/cm2 in accordance with COVENIN
N° 484 (ASTM C109).
2.3.2 Sand–Cement Dry Pack – Two parts sand for every part cement by weight with
a minimum amount of water for dry pack placement.

2.4 Nonshrink Cement–Based Grout

2.4.1 Plastic Volume Change – No shrinkage (0.0%) and a maximum of 0.4% expansion
at any time before initial set when tested according to ASTM C827 to provide a
minimum of 95% of effective bearing area.
2.4.2 Hardened Volume Change – No shrinkage 0.4% and a maximum of 0.1%
expansion in the hardened state when tested according to ASTM C827.
2.4.3 Compressive Strength – Minimum allowable compressive strength at 28 days to
be 420 kg/cm2 as measured by ASTM C109.
2.4.4 Initial Set Time – Not less than 60 minutes when tested according to ASTM C191.
2.4.5 Soundness – Grout shall contain no metallic substances (catalyzed or
noncatalyzed), aluminum powder, water reducing agents, fluidifiers, accelerators,
super plasticizers, or other materials known to increase drying shrinkage and/or
compromise durability.
2.4.6 Grouting and bonding materials shall be selected among Venezuelan
manufacturers, where necessary reference can be made to similar products to
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facilitate the bidding procedure. Priority shall be given to COVENIN and PDVSA
registered and authorized trade marks.

2.5 Nonshrink Epoxy Grout

2.5.1 Volume Change – No shrinkage and a maximum of 0.4% expansion when tested
according to ASTM C827 (modified).
2.5.2 Compressive Strength – Minimum allowable compressive strength at 7 days to
be 420 Kg/cm2 as measured by ASTM C579.
2.5.3 Heat Development – The peak exotherm of a 50 mm diameter by 100 mm high
cylinder of grout is not to exceed 35°C when tested at 24°C material and
laboratory temperatures.
2.5.4 Thermal Expansion – Not to exceed a coefficient of thermal expansion of 54 x
10–6 mm/mm/°C when tested according to ASTM C531.
2.5.5 Irritants – No odor or highly volatile inhalation irritants.
2.5.6 Nonshrink epoxy grout shall be selected among Venezuelan manufacturers,
where necessary, reference can be made to similar products to facilitate the
bidding procedure. Priority shall be given to COVENIN and PDVSA registered
and authorized trade marks.

2.6 Bonding Mixtures and Adhesives

Either bonding mixtures or adhesives may be used to create cohesion or water
tightness between new and existing concrete:
Cement Bonding Mixture – Neat cement and water mixed to the consistency of
creamy paint.
Epoxy Adhesive – Mixture consists of a proprietary epoxy adhesive, mixed and
applied in accordance with manufacturer’s instruction.
Epoxy adhesive shall be approved by PDVSA.

3 EXECUTION
3.1 Surface Preparation
3.1.1 Clean the surface of the existing concrete of grease, oil, paint, laitance, and other
coatings. Roughen the surface to expose the aggregate and thoroughly flush with
clean water.
3.1.2 Before grouting, level and align equipment bases and baseplates in accordance
with recommendations of equipment manufacturer and drawings.
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3.1.3 When cement–based grout or bonding mixture is used, thoroughly soak the
concrete surface until absorption stops. Remove excess water before grouting
or bonding.
3.1.4 When epoxy grouts or adhesives are used, keep all surfaces dry before
application.
3.1.5 Before placement, treat surfaces from which grout is to be removed with an
approved varnish, wax, or oil.

3.2 Forms
3.2.1 Securely anchor forms or back braces to withstand the forces of the placement
of grout.
3.2.2 Provide tight forms (when forms are required) with tape sealed joints for
nonshrink cement based grout. Apply form oil for easy form release.
3.2.3 Provide watertight forms with chamfer strips where chamfer edge is required for
nonshrink epoxy grout. Line forms with polyethylene or apply heavy wax for easy
form release.

3.3 Mixing and Placement

3.3.1 If grouting is to be done when ambient temperatures are not between 4°C and
32°C or if other unusual or difficult conditions exist, the Contractor shall contact
PDVSA and the grout manufacturer for specific instructions.
3.3.2 Add to cement–based grouts the amount of water required for the desired
consistency.
3.3.3 Proceed with grout placement and ensure the filling of all surfaces and the
intimate contact of grouting materials with surfaces grouted. Place grout rapidly
and continuously to avoid cold joints under the baseplate. Grout from one side
to the other in one direction. Tamp or rod grout to eliminate voids.
3.3.4 For nonshrink grout, carefully follow manufacturer’s instructions for concrete
preparation, proportions, mixing, forming, depth of pour, pouring, and curing.
3.3.5 Do not retemper or remix stiffening grout.

3.4 Finishing
3.4.1 Trim back cement–based grout to the level indicated on the drawings after the
grout has reached an initial set. Slope surfaces away from baseplate. Cut back
protruding edges.
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3.4.2 Epoxy grout cannot be trimmed after set. Finish top surfaces to proper slope prior
to initial set.
3.4.3 Apply finish coating over grout holes and vent holes after grout has set.

3.5 Curing
3.5.1 After placement, protect cement–based grout from premature drying, excessively
hot or cold temperatures, and mechanical injury. Maintain grout with minimal
moisture loss at relatively constant temperature for period necessary for hydration
of cement and hardening of grout.
3.5.2 Cure cement–based grout in hot weather, above 32°C in accordance with one of
the methods described in ACI 305 R. Method of curing shall be approved by
PDVSA.
3.5.3 Cure epoxy grout in accordance with manufacturer’s instructions.

3.6 Shims and Wedges

Removal of shims and wedges is not required unless specified by equipment
manufacturer. Completely encase in grout all shims or wedges left in place.

3.7 Anchor Bolts and Pipe Sleeves

3.7.1 For anchor bolt sleeves and pipe sleeves requiring grout, clean all surfaces of oil,
grease, and other foreign substances. Grout anchor bolt sleeves with a flowable
grout and grout pipe sleeves with dry pack.
3.7.2 Where anchor bolts or pipe sleeves are to remain isolated, fill sleeves with a
pliable material such as silicone rubber moulding compound or other material, as
shown on PDVSA’s drawings.

3.8 Bonding New Concrete to Existing Concrete

3.8.1 Apply the bonding mixture by working it into the surface with a stiff brush. Place
new concrete before bonding mixture dries out.
3.8.2 Apply epoxy adhesive in accordance with manufacturer’s instructions.

3.9 Testing
Test each type of grout at least once a week during grouting operations. Test
cement–based grout under COVENIN 484 (ASTM C109) and epoxy grout under
ASTM C579. Prepare the number of cubes for each type of grout and test for
required compressive strength according to the following schedule.
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Grout Type 24 Hrs. 2 Days 7 Days 28 Days

Plain Cement Grout – 2 2 2
Nonshrink Cement Grout 3 – 3 3
Epoxy Grout 3 3 3 –
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1.APPENDIX 1
DESIGN

A.1 DESIGN
A.1.1 General Design Criteria
A.1.1.1 Drawings indicate where nonshrink grout shall be used.
A.1.1.2 Provide grout between top of foundation concrete and bottom of bearing plates.
Grout shall be a nominal thickness of 25 mm with a minimum thickness of 12 mm
in order to avoid feather edging.
A.1.1.3 Use nonshrink grout for the following applications:
All compressors reciprocating pumps greater than 100 hp and centrifugal pumps
greater than 500 hp. Structures with a height to width ratio greater than two; or
with large vibrating equipment, if one column load is over 45.000 kg. Normal
structures if one column load is in excess of 90.000 kg
A.1.1.4 Use nonshrink cement–based grout unless epoxy grout is specified by equipment
vendor or PDVSA.

A.2 DESIGN DETAILS

A.2.1 Epoxy Grout
Differences in thermal coefficients of expansion between epoxy grout and
concrete create stresses at grout edges. Provide grout details that allow for
expansion joints, corner reinforcing, or added epoxy depth at corners to prevent
cracks.
A.2.2 High Temperatures
A.2.2.1 Use high temperature grout where BASE PLATE temperatures will be GREATER
THAN THOSE LISTED BELOW:
Cement–based grout 200°C
Epoxy grout 60°C
A.2.2.2 High temperature cement–based grout is faster setting than standard
cement–based grout.