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YANACOCHA PROJECT

MINERA YANACOCHA S.R.L.

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:

Lead Engineer Robinson Ucañan


Project Engineer Gordon Grams
Engineering Manager Roger Chapman
Client Simon Briggs

REV. BY ISSUE DATE CHK'D TECH.


APPROV'L
A RU Internal review and approval 28 Feb 02 DV RU

0 RU Issued for construction 21 mar 02 DV RU

COMMENTS
MINERA YANACOCHA S.R.L Project Specification N° 000.215.03600

General Services Agreement 21 Mar 02


Contract N° 04463500 Sheet 2 of 15
Rev 0
FLUOR DANIEL

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

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MINERA YANACOCHA S.R.L Project Specification N° 000.215.03600

General Services Agreement 21 Mar 02


Contract N° 04463500 Sheet 3 of 15
Rev 0
FLUOR DANIEL

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.

B. Not Included in scope of Specification

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.

A. ACI (American Concrete Institute)

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

B. ASTM (American Society for Testing and Materials)

1. ASTM C33-01a Standard Specification for Concrete Aggregates.

2. ASTM C39/C39M-01 Standard Test Method for Compressive Strength of


Cylindrical Concrete Specimens

3. ASTM C109/C109M-01 Standard Test Method for Compressive Strength of


Hydraulic Cement Mortars (Using 2 inch or 50 mm Cube Specimens)

4. ASTM C150-00 Standard Specification for Portland Cement

5. ASTM C191-01 Standard Test Method for Time of Setting of Hydraulic Cement by
Vicat Needle

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MINERA YANACOCHA S.R.L Project Specification N° 000.215.03600

General Services Agreement 21 Mar 02


Contract N° 04463500 Sheet 4 of 15
Rev 0
FLUOR DANIEL

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

7. ASTM C579-01 Standard Test Methods for Compressive Strength of Chemical


Resistant Mortars, Grouts, Monolithic Surfacings and Polymer Concretes

8. ASTM C1107-99 Standard Specification for Packaged Dry, Hydraulic Cement


Grout (Nonshrink)

9. ASTM C1181-00 Standard Test Methods for Compressive Creep of Chemical


Resistant Polymer Machinery Grouts

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

C. SSPC (Steel Structures Painting Council)

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.

1.4 Product Delivery And Handling

A. Delivery

1. Deliver manufactured grouts in manufacturer's packaging including installation


instructions.

2. Deliver nonshrink cement based grout in sound, dry packages.

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MINERA YANACOCHA S.R.L Project Specification N° 000.215.03600

General Services Agreement 21 Mar 02


Contract N° 04463500 Sheet 5 of 15
Rev 0
FLUOR DANIEL

3. Deliver epoxy grout hardener and resin in sealed, premeasured containers.

4. Deliver grout aggregate in sound, dry packages.

B. Storage and Handling

1. Store manufactured grouts in accordance with the manufacturer's printed


instructions.

2. Store nonshrink cement based grout, cement, and cementitious materials in


accordance with ACI 304R.

3. Do not store manufactured grouts for more than 6 months, or the period of time
recommended by the manufacturer.

4. Do not store cement based manufactured grouts at a temperature below 4 degrees C


or above 32 degree C. For temperature out of range indicated follows the supplier
recommendations.

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

A. Provide formwork as needed to properly place grouts.

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.

Firmly anchor forms in place.

1.6 Technical Services

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.

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MINERA YANACOCHA S.R.L Project Specification N° 000.215.03600

General Services Agreement 21 Mar 02


Contract N° 04463500 Sheet 6 of 15
Rev 0
FLUOR DANIEL

Advise Engineer if the grout representative recommends materials or procedures contrary to this specification.

1.7 Design and Field Requirements

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.

Remove grout splatters from adjacent Work.

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.

1.9 Identification and Tagging

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.

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MINERA YANACOCHA S.R.L Project Specification N° 000.215.03600

General Services Agreement 21 Mar 02


Contract N° 04463500 Sheet 7 of 15
Rev 0
FLUOR DANIEL

2.0 NONSHRINK CEMENT BASED GROUT

2.1 General

A. Application (unless noted otherwise on the design drawings)

1. Vessels and heat exchangers.


2. Equipment with cast bases.
3. Equipment on base frames with cover plates.

2.2 Product

A. Materials

Premixed, preproportioned, factory packaged product consisting of a mixture of cement,


sand, and inert 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.

4. Free from chemically produced combustible gas, oxidizing catalysts, inorganic


accelerators, chloride, and metallic particles.

5. Nonstaining.

2.3 Execution

A. Work Prior to Setting Baseplates or Equipment

1. Concrete Surfaces

a. Concrete foundations shall be at least 7 days old before surface preparation.

b. Roughen surface by chipping, sandblasting, or other mechanical means to


produce a fractured aggregate profile at all concrete bonding surfaces. Final
concrete surfaces shall be level within 1/2 inch.

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.

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MINERA YANACOCHA S.R.L Project Specification N° 000.215.03600

General Services Agreement 21 Mar 02


Contract N° 04463500 Sheet 8 of 15
Rev 0
FLUOR DANIEL

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.

f. Place watertight forms as needed.

2. Metal Surfaces in Contact with Grout

Clean foundation plates to remove dirt, oil, grease, or loose paint. Tightly adhered
paint is acceptable.

3. Foundation and Leveling Plates

a. Set, align, and firmly anchor foundation plates before grout is placed.

4. Anchor Bolts and Sleeves

Clean anchor bolt blockouts and sleeves to remove deleterious materials.

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.

6. Do not add admixtures or ingredients not specified or included with the


manufactured 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

1. Grout may be flowed or pumped into place.

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.

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MINERA YANACOCHA S.R.L Project Specification N° 000.215.03600

General Services Agreement 21 Mar 02


Contract N° 04463500 Sheet 9 of 15
Rev 0
FLUOR DANIEL

3. Place grout quickly and continuously to avoid segregation, bleeding, or premature


initial set. Do not place grout in layers.

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.

9. Equipment with Elevated Interior Plate

a. Grout under entire equipment base to bottom of exterior plate.

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.

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MINERA YANACOCHA S.R.L Project Specification N° 000.215.03600

General Services Agreement 21 Mar 02


Contract N° 04463500 Sheet 10 of 15
Rev 0
FLUOR DANIEL

D. Finishing and Curing

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

a. Keep forms in place for at least 24 hours.

b. Keep grout moist for at least 3 days and protect from rapid drying.

c. Cure grout in accordance with manufacturer's recommendations on package, or


in their latest specification or literature.

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. Do compressive strength tests on cubes in accordance with applicable provisions of


ASTM C109. Test one cube set at 7 and one at 28 days. The third cube set shall be
tested at the discretion of the Construction Manager.

4. Test Grout by “hammer test” to check for hollowness/adhesion.

3.0 EPOXY GROUT

3.1 General

A. Application (unless noted otherwise on the design drawings)

1. All machinery and pumps with drives of 500 horsepower and above.

2. Compressors, generators, blowers, pumps, motors and other rotating equipment


having a total weight greater than 3000 lb (13.3KN).

3. All reciprocating machines.

4. All sole plate mounted equipment.

5. Where grout is subject to chemical attack that would be detrimental to a cement


matric.

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MINERA YANACOCHA S.R.L Project Specification N° 000.215.03600

General Services Agreement 21 Mar 02


Contract N° 04463500 Sheet 11 of 15
Rev 0
FLUOR DANIEL

6. Where required by the Equipment Manufacturer.

7. Special applications as shown on the Engineering Drawings.

3.2 Product

A. Materials

Preproportioned, factory packaged product consisting of specially formulated resin,


hardener, and aggregate. When mixed together, the components shall form a pourable
100 percent solids grout.

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

A. Work Prior to Setting Baseplates or Equipment

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.

b. Roughen surface by chipping, sandblasting, or other mechanical means to


produce a fractured aggregate profile at all concrete bonding surfaces. Final
concrete surfaces shall be level within 1/2 inch.

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.

e. Place liquid tight, leakproof forms for grout.

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MINERA YANACOCHA S.R.L Project Specification N° 000.215.03600

General Services Agreement 21 Mar 02


Contract N° 04463500 Sheet 12 of 15
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FLUOR DANIEL

f. Place control joints and reinforcing bars as needed.

2. Metal Surfaces in Contact with Epoxy Grout

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.

b. Prepare equipment surfaces to be in contact with epoxy grout in accordance with


recommendations of the grout manufacturer just prior to grouting.

3. Foundation and Leveling Plates

a. When bond is not desired between epoxy grout and plates, apply paste wax to
clean plate, allow to dry, then buff.

b. Set leveling plates to the proper elevation.

c. Set, align, and firmly anchor foundation plates before grout is placed.

d. Determine need to remove or retain shims subject to the equipment


manufacturer's instructions.

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.

b. Joint Thickness: Thickness to be 6 mm.

c. Joint Material: Closed cell styrofoam, thick rubber, or wood strips covered with
polyethylene tape.

5. Cold Weather

a. Keep temperature of surfaces to be in contact with grout at or above 10 degrees


C for at least 24 hours before grouting.

b. Keep temperature of grout components between 21 degrees C and 27 degrees C


right up until mixing and grouting.

6. Hot Weather

a. Use shading or conditioning to keep temperature of base plates below 32


degrees C and maintain surface absolutely dry.

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MINERA YANACOCHA S.R.L Project Specification N° 000.215.03600

General Services Agreement 21 Mar 02


Contract N° 04463500 Sheet 13 of 15
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FLUOR DANIEL

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.

8. Anchor Bolts and Sleeves

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.

9. Deep Pours and Extreme Temperatures

Consult manufacturer's technical department for recommendations for deep pours


over 4 inches or extreme operating temperature conditions above 60º C.

B. Mixing

1. Condition grout components to a temperature between 21 degrees C and 27 degrees


C before mixing. Do not use a concrete mixer. Use a mortar mixer for large volume
placement. A mortar mixer has rubber edged rotating blades which lift the material
during mixing and facilitate good flow.

2. Mix grout in accordance with manufacturer's instructions.

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

1. Check ambient temperature. For temperatures below 4 degrees C, or above 32


degrees C, refer to manufacturer's mixing and placement procedures for cold weather
or hot weather requirements. During grouting and for at least 24 hours following
grouting, maintain temperature of foundation and base plate between 4 degrees C
and 32 degrees C, as measured by surface thermometer and until grout has reached
minimum compressive strength.

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.

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MINERA YANACOCHA S.R.L Project Specification N° 000.215.03600

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FLUOR DANIEL

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.

b. Use for placing large volumes of grout continuously.

c. Use head box with a minimum 3 cubic foot volume.

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.

10. Equipment with Elevated Interior Plate

a. Grout under entire equipment base to top of exterior plate.

b. Continue placing grout until grout oozes up through every interior vent hole and
grout hole.

D. Finishing and Curing

1. Finishing

Follow manufacturer's recommendations for finishing grout surfaces.

2. Curing

a. Cure grout in accordance with manufacturer's instructions.

b. Do not moist cure epoxy grout.

c. Keep forms in place overnight except for fast curing grouts.

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MINERA YANACOCHA S.R.L Project Specification N° 000.215.03600

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Contract N° 04463500 Sheet 15 of 15
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FLUOR DANIEL

d. Keep temperature of base plate and foundation between 10 degrees C and 32


degrees C for at least 24 hours after placing grout.

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.

3. Do compressive strength tests on cubes in accordance with applicable provisions of


ASTM C579, Method B. Test one cube set at 24 hours and one at 7 days. The third
cube set shall be tested at the discretion of the Construction Manager.

4. Test Grout by “hammer test” to check for hollowness/adhesion.

4.0 ATTACHMENTS

Not Applicable.

End of Specification

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