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FD #000.215.03600 MYSRL #4635-1-SP-101 Technical Specification Grouts
FD #000.215.03600 MYSRL #4635-1-SP-101 Technical Specification Grouts
PROJECT N° 04463500
YANACOCHA PROJECT
FD Nº 000.215.03600
MYSRL Nº 4635-1-SP-101
TECHNICAL SPECIFICATION
FOR
GROUTS
Prepared by:
FLUOR DANIEL
APPROVED BY:
COMMENTS
MINERA YANACOCHA S.R.L Project Specification N° 000.215.03600
Table of Contents
Section
1.0 GENERAL.......................................................................................................................................................3
1.1 Summary...........................................................................................................................................3
1.2 References.........................................................................................................................................3
1.3 Submittals.........................................................................................................................................4
1.4 Product Delivery And Handling.....................................................................................................4
1.5 Formwork.........................................................................................................................................5
1.6 Technical Services............................................................................................................................6
1.7 Design and Field Requirements......................................................................................................6
1.8 Equipment.........................................................................................................................................6
1.9 Identification and Tagging..............................................................................................................7
2.0 NONSHRINK CEMENT BASED GROUT.................................................................................................7
2.1 General..............................................................................................................................................7
2.2 Product..............................................................................................................................................7
2.3 Execution...........................................................................................................................................7
3.0 EPOXY GROUT...........................................................................................................................................10
3.1 General............................................................................................................................................10
3.2 Product............................................................................................................................................11
3.3 Execution.........................................................................................................................................11
4.0 ATTACHMENTS.........................................................................................................................................15
/conversion/tmp/activity_task_scratch/558644468.doc
MINERA YANACOCHA S.R.L Project Specification N° 000.215.03600
1.0 GENERAL
1.1 Summary
A. Scope of Specification
This specification prescribes requirements for the furnishing and installation of grouts for
use between applied loads (such as column base plates or equipment bed plates) and
concrete foundations. In case of conflict, the following order of precedence shall apply:
PO (Purchase Order), or contract, then the drawings, then the specifications.
This specification does not cover grouts for grouting anchor bolts, rebar, masonry,
prestressing tendons, concrete repair, waterproofing, or geotechnical use.
C. Terminology
Foundation Plates: Refers to column base plates and equipment bed plates or soleplates
that are installed on concrete foundations.
1.2 References
The publications listed below form part of this specification to the extent referenced. If there is a
discrepancy between the references and this specification, then this specification shall govern.
1. ACI 304R-00 Guide For Measuring, Mixing, Transporting, And Placing Concrete.
2. ACI 351.1R-99 Grouting between Foundation and Bases for Support of Equipment
and Machinery
5. ASTM C191-01 Standard Test Method for Time of Setting of Hydraulic Cement by
Vicat Needle
6. ASTM C531-00 Standard Test Method for Linear Shrinkage and Coefficient of
Thermal Expansion of Chemical Resistant Mortars, Grouts, and Monolithic
Surfacings and Polymer Concretes
10. ASTM C1339-96a Standard Test Method for Flowability and Bearing Area of
Chemical-Resistant Polymer Machinery Grouts
11. ASTM D4263-83(R99) Standard Test Method for Indicating Moisture in Concrete
by the Plastic Sheet Method
1. SSPC, SP-6, 1994 Joint Surface Preparation Standard Commercial Blast Cleaning
NACE No. 3
1.3 Submittals
Copies of test reports, including test data, shall be certified by an independent laboratory, verifying that
manufactured grouts meet or exceed performance requirements in accordance with ASTM C109, ASTM C531,
ASTM C579, ASTM C1107, ASTM C1181 and ASTM C1339 as listed in Sections 2.2 B and 3.2 B.
Provide manufacturer's installation instructions, detailed Product Data sheets, and Material Safety Data sheets for
manufactured grouts.
Prior to placing grout, the contractor shall submit a complete description of proposed curing methods.
Field Compression test reports shall submit on a weekly basis. Compression breaks 3.5 MPa below the specified
design strength at 28 days shall be submitted on the same day.
A. Delivery
3. Do not store manufactured grouts for more than 6 months, or the period of time
recommended by the manufacturer.
5. Do not store epoxy hardener and resin at a temperature below 16 degrees C or above
32 degrees C. For temperature out of range indicated follows the supplier
recommendations.
1.5 Formwork
Design forms for rapid, continuous, and complete filling of space to be grouted. Forms shall be strong, securely
anchored, and shored. Caulk or seal to prevent leakage.
For fluid or flowable grouts, design forms to be at least 1 inch clear of base plate or equipment base and top of form
to be at least 2 inches above bottom of adjacent base plate or higher, as required to achieve enough head for grout to
flow across width of plate. Attach chamfer strip to forms where chamfered edge is required.
Install vent holes in areas where air pockets may form during grouting. Use a minimum diameter of 1/8 inch.
Coat forms with form oil or heavy wax for cementitious grouts to prevent grout adherence and absorption. Use
heavy wax where epoxy grouts are to be used.
Before grouting with manufactured grout, the manufacturer's technical representative shall conduct a pregrouting
conference at the job site. This requirement is to be confirmed with field engineer.
Review grouting steps and manufacturer's instructions with those who shall actually be doing the grouting.
Advise Engineer if the grout representative recommends materials or procedures contrary to this specification.
Foundation plates for equipment and structures shall be grouted to provide full uniform load transfer between
bottom of plate and concrete foundation.
Load transfer to foundation must be through grout, not through shims or other leveling devices. Remove shims
before completing grouting operations.
Projection of grout bed beyond edge of bearing plate shall be no more than 150 mm.
Vibrations from nearby operations can be transmitted into foundations being grouted. These vibrations cause
bleeding and settlement, affect setting time and strength, or create hidden fracture planes. Observe surface of a
shallow pan of water set on foundation being grouted to detect vibration. Shutdown nearby operations if vibrations
are detected until grout has taken final set.
All grout installations for equipment and machinery shall be in accordance with ACI 351.1R
1.8 Equipment
A. Grout Mixer
Use only mortar mixers with moving paddles inside the drum. Do not use concrete
mixers with fins attached to rotating drum.
B. Grout Pump
Use only positive displacement type such as diaphragm or piston pump. Screw pumps
are not acceptable.
C. Cleaning
Clean mixing equipment and tools to ensure they are free from oil, dirt, grease, grout
residue, or other deleterious substances.
Manufactured grouts shall be factory packaged in bags or containers clearly marked to identify
components and with printed manufacturer's mixing and installation procedures listed.
2.1 General
2.2 Product
A. Materials
B. Performance
1. Passes ASTM C1107 as a Grade B or C grout when tested at the minimum and
maximum temperature of 7o to C 32o C at a working time of 45 minutes.
2. Compressive Strength: Minimum 3500 psi (24.1 MPa) at 24 hours and 7500 psi
(51.7 MPa) at 28 days when tested in accordance with ASTM C109.
3. Working Time: Consistency greater than 100 percent for a minimum of 45 minutes
at 24o C, when tested in accordance with the fluid or flowable consistency sections
of ASTM C1107 at 15 minute intervals.
5. Nonstaining.
2.3 Execution
1. Concrete Surfaces
c. Remove oil soaked concrete, loose or broken concrete, or concrete with hairline
cracks down to solid concrete. Finished surfaces must be firm and rough.
d. Wash surface clean and saturate with water for at least 24 hours before
placement of grout.
e. Just before grouting, remove excess water with clean, oil-free compressed air,
leaving surface damp. Remove water from anchor bolt sleeves.
Clean foundation plates to remove dirt, oil, grease, or loose paint. Tightly adhered
paint is acceptable.
a. Set, align, and firmly anchor foundation plates before grout is placed.
B. Mixing
1. Use a mortar mixer. Do not use a concrete mixer unless mixing "bulk bags".
2. Mix grout adjacent to the area being grouted and have sufficient manpower and
equipment to mix and place grout rapidly and continuously.
3. Mixing equipment must be free from oil, dirt, grease, leftover grout, and other
deleterious substances. Discard leftover grout from any previous batch.
4. Wash out mixer with clean water then empty out water leaving the mixer wet.
5. Mix only that quantity of grout that can be placed within the working time of the
grout.
7. Add dry grout components to mixer and mix dry. Add premeasured amount of
potable water to mixer, mix grout for no less than 3 nor more than 5 minutes, then
place grout immediately.
C. Placing
2. Place grout within the working time of the grout and discard grout that is not placed
within the working time of the grout. Retempering of grout is not allowed.
4. Place grout from one side of plate to the other to avoid trapping air.
5. Place grout from one long side of equipment base to the other, in one direction only.
6. If grout must be placed through grout holes, place from one hole continuously until
grout has passed a second hole. Maintain a liquid head pressure at the first access
hole until a head pressure has been established at the next hole. Continue placing
grout from next grout hole in a similar fashion.
7. Flowable Grouting
a. Use a moveable head box having an inclined plane to direct grout beneath
equipment base in a manner to minimize trapped air and bubble formation.
b. For placing large volumes of grout continuously, use a head box with a
minimum of 3 cubic foot volume.
c. Fill head box to top and plunge grout down to top of base plate. Continue until
grout rises above bottom of base plate on far side.
8. Pumping Grout
a. Use on large installations and multiple installations, for bases with shear keys,
stiffeners, or other obstructions and for grouting over great distances or if
venting air is not possible.
b. Rinse pump, hose, and nozzle with water then wash cleansing plug through line
to ensure it is clear. Pump grout slurry through to side first before starting.
c. Start grouting at far end of space to be grouted then slowly back out nozzle so
that it is always within the grout to prevent air entrapment.
d. Continue placing grout until grout oozes out along entire perimeter and up
through every interior vent hole and grout hole.
b. Continue placing grout until grout oozes up through every interior vent hole and
grout hole.
10. Maintain temperature of foundation, base plate and grout between 5o C and 32o C,
as measured by surface thermometer, during grouting and for a minimum of 24 hours
following grouting and until grout has reached minimum compression strength.
1. Finishing
a. Just before grout has reached final set, cutback to lower edge of plate.
b. A 45 degree angle cutback is preferred however a vertical cutback is acceptable.
2. Curing
b. Keep grout moist for at least 3 days and protect from rapid drying.
E. Testing
1. Make 3 sets of 3 test cubes in the field for each placement of grout mixed and
placed. Make test cubes in accordance with applicable provisions of ASTM C109.
2. Cure cubes in the field for 3 days in the same way as the placed grout is cured. After
3 days, transport cubes to testing laboratory for compressive strength testing.
3.1 General
1. All machinery and pumps with drives of 500 horsepower and above.
3.2 Product
A. Materials
B. Performance
1. Bearing Area: No less than 85% Bearing Area or High Bearing Area when tested in
accordance with ASTM C1339.
2. Compressive Strength: Minimum 12,500 psi (86MPa) at 73o F (23 o C ) and 9000
psi (62.1MPa) at 140o F ( 60 o C) when tested in accordance with ASTM C579
Method B at 7 days.
3. Thermal Expansion: Maximum of 0.000015 of an inch per inch per degree F when
tested in accordance with ASTM C531.
4. Creep Resistance: Equal to or less than 0.005 inch per inch at 140o F when tested in
accordance with ASTM C1181.
3.3 Execution
1. Concrete Surfaces
a. Concrete foundations shall be fully cured and dry before surface preparation.
Dryness shall be verified by testing the surface in accordance with ASTM
D4263.
c. Remove oil soaked concrete, loose, or broken concrete, or concrete with hairline
cracks down to solid concrete. Finished surfaces must be firm and rough.
d. Clean surface using dry, oil-free compressed air or dry brush. Remove debris
from anchor bolt sleeves using dry, oil-free compressed air.
a. Metal surfaces in contact with epoxy grout shall either be sandblasted to SSPC-6
grade just prior to grouting or have an epoxy primer coating compatible with the
proposed epoxy grout.
a. When bond is not desired between epoxy grout and plates, apply paste wax to
clean plate, allow to dry, then buff.
c. Set, align, and firmly anchor foundation plates before grout is placed.
e. For shims, wedges, or blocks to be removed, coat with paste wax to prevent
grout from adhering.
4. Control Joints
a. Place joints on 900 mm to 1200 mm centers. Extend joints full depth and full
length from form to form. Control joints shall not be placed under base plates.
c. Joint Material: Closed cell styrofoam, thick rubber, or wood strips covered with
polyethylene tape.
5. Cold Weather
6. Hot Weather
b. Protect concrete, steel, and forms from direct sunlight beginning at least 24
hours before grouting.
7. Adjacent Surfaces
Apply wax or oil, or protect with polyethylene sheeting so that grout splatters or
overpour shall not adhere.
Clean anchor bolt blockouts and sleeves to remove deleterious materials. Prior to
grouting, anchor bolt sleeves shall be filled with a non-bonding fill material.
B. Mixing
3. Use only the premeasured components supplied. Do not add solvent or reduce
aggregate to change mix consistency.
4. Mix only that quantity of grout that can be placed within working time of the grout.
C. Placing
2. Place grout within the working time of the grout and discard grout that is not placed
within this working time.
3. During hot weather, place grout in the evening or later, when the temperature is
dropping.
4. Place grout quickly and continuously to avoid cold joints and voids under base plate.
5. Place grout from one side of plate to the other to avoid trapping air.
6. Place grout from one long side of equipment base to the other, in one direction only.
7. If grout must be placed through grout holes, place from one hole continuously until
grout has passed second hole. Continue placing grout from next grout hole in a
similar fashion. After the baseplate is full, six inch high stand pipes shall be
maintained over each grout hole to continue the purging of air. Once the grout has
started to take an initial set (determined by an increase in grout temperature and no
flow of grout at the vent holes) the standpipes can be removed and excess grout
cleaned from all surfaces.
8. Continually check for leaks. Leaks shall be immediately sealed to prevent voids.
9. Flowable Grouting
a. Use moveable head box having an inclined plane to direct grout beneath
equipment base in a manner to minimize trapped air and bubble formation.
d. Fill head box to top and plunge grout down to top of base plate. Continue until
grout rises above bottom of base plate on far side.
e. Always keep surface of grout in head box above top of base plate to prevent
trapping air.
b. Continue placing grout until grout oozes up through every interior vent hole and
grout hole.
1. Finishing
2. Curing
E. Testing
1. Make 3 sets of 3 test cubes in the field for each batch of grout mixed and placed.
Make test cubes in accordance with applicable provisions of ASTM C579, Method
B.
2. Cure the cubes in the field for 24 hours in the same way the placed grout is cured.
After 24 hours, transport cubes to testing laboratory for compressive strength testing.
4.0 ATTACHMENTS
Not Applicable.
End of Specification