ENGINEERING STANDARD

EI - 014

GROUT

Please discard any previous issue of this Standard.

Revision Number Log

Rev. Date By Pages Approval Remarks
0 26.9.05 PCA HLM APPROVED FOR DESIGN
1 12.3.07 LCA 3 HLM REPLACE REFERENCE IE-010 FOR EI-015
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REVISION No. : 0
DATE : 26.9.05

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TABLE OF CONTENTS

I. SCOPE .............................................................................................................................................3

II. REFERENCES ..............................................................................................................................3

III. MATERIALS ..................................................................................................................................3

IV. APPLICATION...............................................................................................................................4

V. WORKMANSHIP ...........................................................................................................................4

VI. QUALITY ASSURANCE..............................................................................................................10

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I. SCOPE

This Standard indicates the requirements for the use of grouts for bedding structural
steelwork and machine base plates.

II. REFERENCES

Latest revisions of the following documents are referred to in this Standard:

A. ACI 351 IR-93 Grouting for Support of Equipment and Machinery

B. ERBB EI-015 Procedure for Pump Installation

III. MATERIALS

A. General

The application, supply, delivery, storage and placing of the product shall be in
accordance with the manufacturer’s recommendations. The Contractor shall be
responsible for obtaining all necessary approvals, certificates and guarantees from
the manufacturer and the manufacturer’s instructions and guidelines shall be
rigorously adhered to.

Proprietary materials shall be used after the recommended shelf life.

B. Cementitious Grout.

The product shall be proprietary, premixed, nonmetallic, nonshrink with a minimum

compressive strength of 60 MPa at 28 days, measured in accordance with ASTM C-
109 and able to guarantee a minimum effective bearing area of 90%.

It shall be free from metallic aggregates, ferrous or aluminum particles, chlorides and
moreover they shall be no oxidative and non corrosive. Their consistency shall be
very fluid, free of any type of gas releasing product, it shall present good workability
and shall exhibit high mechanical strength and strong adhesive force both to steel
and to hardened concrete in a short lapse of time.

It shall exhibit a prefixed expansion, developed in the first phase of curing, a broad
temperature range of application and shall be free from bleeding.

The product will be FIVE STAR Fluid Grout 100 or equivalent.

C. Epoxy Grout
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The product shall be expansive, nonshrink, low exotherm with a minimum

compressive strength of 95 MPa at 7 days measured in accordance with ASTM
C579, under method B; a minimum tensile strength not less than 12 MPa, measured
in accordance with ASTM C-307 and shall be able to guarantee a minimum effective
bearing area of 90%.

The product will be FIVE STAR DP Epoxy Grout or equivalent.

IV. APPLICATION

The product shall be premixed, nonmetallic, nonshrink with a minimum compressive

strength of 50 MPa at 28 days and able to guarantee a minimum effective bond area
of 90%.

A. Cementitious Grout.

Proprietary cementitious grout shall be used for grouting of steel structures base
plates and for anchoring of machinery with the following characteristics:

Pumps ≤ 99 HP and or 4980 RPM

Rotary Machines
Electrical motors and alternators ≤ 198 HP
Vibrating Machines
Reciprocating Machines
Turbines ≤ 198 HP
Ventilators ≤ 30 HP
Turbo-compressors ≤ 125 HP
Sieves ≤ 30 HP
Vibrating screen beds ≤ 30 HP
Conveyors ≤ 30 HP
Compressors ≤ 50 HP
Pumps ≤ 20 HP
Diesel motors ≤ 50 HP

B. Epoxy Grout.

Proprietary epoxy grout shall be used for anchoring of machinery with greater power
than the above listed.

V. WORKMANSHIP

A. Cementitious Grout.
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A.1.1. Preparation for Grout

For the correct preparation of grouts every manufacturer’s written instruction shall be
followed.

The concrete on which the grout will bear shall be dry and have attained its design
strength before grouting.

Do not wet concrete. All surfaces to be in contact with grout shall be dry and entirely
free of oil, grease and other potential bond-preventing substances.

The bottom surface of structural steelwork and equipment base plates shall be
cleaned of loose rust, oil, grease and dirt.

Roughen the concrete surface by chipping or other mechanical means to remove

any laitance or weak surface layer.

All the surface of anchor bolts to be grouted shall be thoroughly cleaned of oil,
grease and other deleterious substances and shall be dry. Holes shall be dried by
evaporation, compressed air or wicking with absorbent rags. Any compressor used
to blow out water or other substance from surfaces in contact with the grout shall be
equipped with an oil trap in the air line to prevent oil from being blown onto the
contact surface and affecting the bond of the grout.

All surfaces shall be kept completely dry before grouting.

All surfaces from which grout is to be removed after placing shall be treated with a
paste wax or release agent before placement.

A.1.2. Formwork

Formwork shall be agreed with the manufacturer’s representative.

Formwork shall be designed to allow adequate access for the grouting operation.

Formwork shall be securely fixed and of adequate strength to withstand the pressure
and hydrostatic head of grout. Formwork shall be sealed to prevent grout leakage
and remain in place for 24 hours for of grout placement.

Forms shall be designed to provide a hydraulic head. If additional hydraulic head is

required at the point of placement, head boxes may be used.

All chamfer edges required in the grouts shall be incorporated into the forms
because epoxy grout cannot be cut or trimmed after hardening unless a grinder is
used.
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All forms shall be built of materials of adequate strength, securely anchored and
shored to withstand liquid head and the forces developed by plunging the frout into
place.

A.1.3. Mixing

The product shall be mixed strictly in accordance with manufacturer’s instructions.

Preparation shall take place as close to the point of casting as possible. Mixing
ready for use and the addition of water should be effected for mixtures to use within
twenty minutes.

Mixing shall be of 5 minutes duration at least and it is absolutely forbidden to soften

the mortar by the addition of further quantities of water once the mixture has been
prepared.

A.1.4. Placing

The grout shall be prepared and placed in accordance with the manufacturer’s
written instructions.

The placing of grout shall be in accordance with the standard ERBB IE-010 and with
the following requirements.

After the final positioning of the machine or structure base plate, grouting shall be
made introducing the product by around perimeter or by way of appropriate holes
using the most suitable equipment, carefully compacting until all empty spaces and
interstices are perfectly saturated and until the level has reached, on all the
perimeter and through the orifices, a height greater than the highest point of the
baseplate.

Placing shall be executed in the shortest possible time without interruption, with a
constant mix of aggregates and water, taking care that the air may escape in order to
prevent the formation of pockets which may create discontinuities when grout is
cured.

Care shall be exercised when placing grout to ensure that the whole void is filled and
displaced air is allowed to escape.

The grout head should be greater than 300mm and if necessary a header box shall
be used to ensure that a continuous head and flow of grout is maintained during the
grouting operation.

The head of grout shall ensure that the grout will flow as a continuous front beneath
the base plate.
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Voids around bolts shall be completely filled before grout is placed under the base
plate.

Any areas or pockets not to be grouted shall be sealed off.

At the completion of grouting operations, all surplus grout shall be removed,

including any grout splatter onto base plates, equipment and concrete faces.

Within a period not exceeding 24 hours, the work shall be neatly pointed and
trowelled off and left in a workmanlike condition. All exposed edges shall be
adequately protected against damage.

Except as required by the manufacturer’s representative, no grout shall be placed

when the shade air temperature is below 3°C. Grouts shall not be placed in air
temperatures greater than 30°C, or when the base plates are subjected to direct
sunlight.

When a mechanical mixer is used to mix the grout with water, some of the liquids will
wet the mixer; therefore, about five kilograms of aggregate per unit shall be
discarded on the first batch. All following batches shall be mixed in accordance with
manufacturer’s recommendations with no modifications.

A.1.5. Temperature of placement

In hot weather grouting should be made during the most favorable hours or even at
nights.

In cold weather the area to be treated should be heated prior to casting.

The ideal temperature of placing is 20ºC; temperatures between 10ºC and 35ºC are
acceptable for workability of the grout and of his final characteristics. In case of local
higher and lower temperatures, it shall be consulted with the manufacturer’s
representative.

A.1.6. Curing

Exposed edges of grout shall be protected to prevent uneven drying.

During cold weather conditions, care shall be taken to ensure the curing at or above
the minimum temperature recommended by the manufacturer.

B. Epoxy Grout

B.1.1. Preparation for Grout

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For the correct preparation of grouts every manufacturer’s written instruction shall be
followed.

The requirements in paragraph A.1.1 shall be followed.

B.1.2. Formwork

Formwork shall be agreed with the manufacturer’s representative.

Formwork or other leak proof containment is always required for epoxy grout.

The forms require careful attention to prevent any leakage. If forms are not liquid
tight, the grout will leak out and leave voids. Careful waxing forms with two coats of
heavy floor or paste wax, preferably colored, to ensure 100% waxed area shall be
used.

The requirements in paragraph A.1.2 shall be followed.

B.1.3. Mixing

Grout shall be mixed according to the procedures recommended by the

manufacturer.

If a mechanical mixer is used, it shall be a mortar mixer with moving blades inside a
drum as opposed to a concrete mixer with fins on a rotating drum.

For small quantities, the use of a concrete wheelbarrow and a concrete hoe shall be
used. The equipment shall be clean and dry.

For materials prepackaged in one container, the epoxy grout may be mixed in the
container, using a low speed drill of 500 RPM maximum.

It shall not be permitted to vary the ratio of components or add solvent to change the
consistency of the grout. High temperature will increase flowability and reduce pot
life, while cold weather will decrease flowability and extend pot life. The ideal
balance is 24ºC.

The epoxy hardener shall first be added to the pail of resin and thoroughly mixed for
two to three minutes, without whipping air into the mix and until no unmixed streaks
exist.

Pour all mixed resin and hardener into a clean dry mortar mixer with moving blades
or wheelbarrow. Add the entire mix bag of aggregate at once and mix only until the
aggregate is wetted and free of lumps. Overmixing results in excess entrapped air.
To maintain proper proportions of resin, hardener and aggregate, always mix full
units only. Under no circumstances shall partial units be used.
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Before the end of the pot life of the grout, the tools shall be cleaned with solvents as
directed by the manufacturer.

B.1.4. Placing

The grout shall be prepared and placed in accordance with the manufacturer’s
written instructions.

The concrete on which the grout will bear shall be dry and have attained its design
strength before grouting.

Check temperature conditions. Determine if ambient temperature will be between

4ºC and 32ºC at time of grouting. If not compensating procedures shall be followed
as directed by the manufacturer.

Check working time. Temperature affects the consistency of epoxy grout and
therefore can affect placement time. Check placement temperature of materials to
estimate the time available for placing grout.

Grout placement shall proceed in a manner that will assure the filling of all spaces
and intimate contact of grouting materials with the surfaces to be grouted. The
placement shall be rapid and continuous so as to avoid cold joints and voids under
the base plate. All grouting shall take place from one side to avoid trapping air.

When using grout holes or stand pipes, start placing grout in adjacent grout holes or
standpipes only when grout has reached the adjacent hole.

Forms shall be constantly checked for leaks. All leaks must be sealed immediately or
voids will develop.

When hydraulic head pressure is used to flow grout in place, the level of grout in the
head box must never fall below the top of the baseplate, because air will be trapped.
The head box shall be filled to the maximum height and worked down to the top of
the baseplate. This procedure is repeated until the grout moves completely under the
baseplate, pushing air out in front of it, and rising above the bottom of the baseplate
on the far side.

B.1.5. Finishing

Epoxy grout cannot be trimmed after set. It must be left at final placement level, with
all chamfer strips built into forms. To provide a smooth surface, puddle the grout so
all aggregate is covered. Bubbles can be broken by spraying lightly with solvent.
After initial stiffening, finish trowel moistened with low volatility solvent or diesel oil.
All further finishing will require grinding after cure period is complete.
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B.1.6. Curing

Grout shall be cured in accordance with the manufacturer’s specifications and

recommendations. Read and follow the directions printed on packages.

Water interferes with proper curing of epoxy grouts. Do not moist cure epoxy grout.

All forms shall remain in place overnight when fast curing grouts are not used.

B.1.7. Temperature

The temperature of the baseplate, supporting concrete foundation and grout shall be
maintained between 10ºC and 32ºC during grouting and for a minimum of 24 hours
thereafter.

The manufacturer’s instructions shall be followed.

B.1.8. Shoulders

The difference in coefficient of thermal expansion between epoxy grout and concrete
induces stresses in shoulders. The shoulders shall not exceed a maximum of 50 mm
to 75 mm. If wide shoulders are mandatory, special anchoring shall be provided as
shown in figure 1 and the manufacturer be contacted for specific instructions.

Special care shall be taken to trim any shoulder developed during grouting to the
requirement of figure 1.

VI. QUALITY ASSURANCE

The Contractor shall hand over to ERBB a detailed method statement for the
grouting up of all major holding down bolt/base plate and machine base plate
assemblies prior to commencement of grouting.
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FIGURE 1

PROBLEMS AND SOLUTIONS