AURELIAN

Auseneg

ECFN-AUS-Cl-0 1 00-sP E-0 1 007

Revision C

Aurelian Ecuador S.A.

Fruta del Norte Gold Project
Grouting
Eng i neering Specification

Client
Rev Date Descr¡ption Prepared Checked Approved
Approval

Mahmoud
A 20 1 7-05-08 lssued internal review Charles Nelson
Ashour
Mahmoud
B 201 7-06-09 lssued for Project review Charles Nelson
Ashour
Mahmoud
c 201 T lOT 106 lssued for Use , A&,ou, fr//ç,"".

ECFN-AUS-Cl-01 00-sPE-01 007

Rev: C
Table of Contents
1 General 1
1.1 Scope 1
1.2 Work Included 1
1.3 Related Work 1
2 Abbreviations / Definitions 1
2.1 Abbreviations 1
2.2 Definitions 2
3 Reference Documents 2
3.1 American Standards 2
4 Quality and Submittals 3
4.1 Quality Assurance 3
4.2 Submittals 3
5 Products 3
5.1 Structural Steel Grouting 3
5.2 Mechanical Grouting 4
6 Execution 5
6.1 Preparation 5
6.2 Mixing 5
6.3 Formwork 5
6.4 Installation 6
6.5 Finishing and Curing 6
6.6 Delivery and Storage 7
6.7 Inspection and Testing 7

ECFN-AUS-CI-0100-SPE-01007
Rev: C
1 General
1.1 Scope

This specification establishes the technical requirements for grouting of structural steel components
and mechanical equipment, including baseplates; shear pockets, anchor rod sleeves, and
equipment base frames.

1.2 Work Included

This specification applies to all operations associated with, but not necessarily limited to, the
following:

 Supply of component grout materials: cementitious and epoxy grouts

 Preparation of substrate surfaces

 Preparation of grouting formwork, if required

 Installation and curing of grout

 Testing and Inspection

1.3 Related Work

ECFN-AUS-CI-0100-SPE-01005– Concrete Engineering Specification

ECFN-AUS-ST-0100-SPE-01001– Supply, Fabrication, and Erection of Structural Steel

Engineering Specification

ECFN-AUS-MC-0100-SPE-01003– Installation of Mechanical Equipment Engineering Specification

ECFN-FDN-EN-0100-REP-00001– Technical Specification for Site Conditions

2 Abbreviations / Definitions
2.1 Abbreviations

The abbreviations listed below, where used in this specification, have the following meaning:

ASTM American Society for Testing and Materials

ACI American Concrete Institute

ECFN-AUS-CI-0100-SPE-01007 Page 1
Rev: C
2.2 Definitions

Approval: Approval from the Client

Approved: Approved by the Client

As directed: As directed by the Client

Client, Company Buyer, Purchasers, Owner, Engineer:

These are synonymous terms and shall mean the contractual party (and its respective
authorized agents) who manage and supply direction to the contractor and to whom
the contractor refers all matters that is purchasing the goods or services from the
seller.

Contractor, Seller, Supplier, Vendor:

These are synonymous terms and shall mean the contractual party that is providing
the goods or services to the Owner.

3 Reference Documents
The work shall comply with the rules and provisions of the latest editions and amendments of the
listed standards. References are made to North American standards within this specification;
alternately, European standards may be used. The contractor is to seek approval from the Client
prior to substituting these.

3.1 American Standards

Unless otherwise stated, the work shall be executed according to the latest edition of the following
codes and standards:

ACI 318 Building Code Requirements for Structural Concrete and Commentary

Standard Specification for Packaged Dry, Hydraulic-Cement Grout (Non-

ASTM C1107
shrink)

Standard Specification for Liquid Membrane-Forming Compounds for Curing

ASTM C 309
Concrete

Standard Specification for Liquid Membrane-Forming Compounds Having

ASTM C1315
Special Properties for Curing and Sealing Concrete

ECFN-AUS-CI-0100-SPE-01007 Page 2
Rev: C
4 Quality and Submittals
4.1 Quality Assurance

The quality of work shall be controlled to meet the requirements of this specification, the referenced
codes and standards.

The contractor shall have a quality management system (QMS) that controls the specified
inspections and testing of their material and/or services.

The Client reserves the right to evaluate the contractor’s QMS documentation and to decide if the
systems meet the project requirements. The Client, or his representative, also reserves the right to
perform inspections, monitoring and quality audits of the Contractor’s QMS at any time during the
period of the contract to verify compliance with, and maintenance of, the quality system and
contract requirements.

4.2 Submittals

Standard submittals – engineering document requirements are summarized in the Vendor Drawing
and Data Requirements (VDDR).

The following documents shall be submitted to the Client for review prior to the start of fabrication:
 Certifications for grout products used
 Contractor QMS and quality control manual
 Installation and curing procedures

5 Products
5.1 Structural Steel Grouting

Unless otherwise indicated on drawings, site prepared grouts shall not be used. Only pre-mixed
non-shrink non-metallic cementitious grout with a minimum 28-day compressive strength of 50
MPa shall be used. Grout shall conform to ASTM C1107 grade C.

Grouts shall be free of oxidizing and inorganic agents and free of inorganic accelerators, including
chlorides. Pre-mixed grouts shall be factory-packed and, upon delivery to the site, shall require
only the addition of water.

Unless otherwise indicated on the drawings, the following pre-mixed grouts are approved for use:

 Sika Grout 212

 Masterflow 100
 Fosroc Conbextra GP

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Rev: C
5.2 Mechanical Grouting

Unless noted otherwise on drawings, the following grouts for mechanical equipment shall be used:

NOTE: Grouting requirements specified by an equipment supplier will take precedence over this
specification. See supplier drawings for specific grouting requirements.

5.2.1 For bearing plates subject to light vibrations or to low rotating speeds (500 rpm):

 Masterflow 928

 Embexo 636

 In-Pakt Premix

 Sika M-Bed Fiber Grout

5.2.2 For bearing plates subject to high vibrations, high rotating speeds or thermal stresses (refiners,
compressors, blowers, and kilns: (service temperatures at bearing plates to be verified)

 Masterflow 885

 Masterflow 648 CP Plus

 Nordbak

 Epoxangrout

 Five Star DP Epoxy Grout (up to 60°C)

5.2.3 For bearing plates in corrosive areas or locations exposed to chemical action:

 Masterflow 648 CP Plus

 Nordbak

 Epoxangrout

 Sikadur 42-MP (up to 60°C)

 Five Star DP Epoxy Grout (up to 60°C)

ECFN-AUS-CI-0100-SPE-01007 Page 4
Rev: C
6 Execution
6.1 Preparation

The concrete element on which the grout bears should have attained its design strength before
grouting. Concrete should be clean, sound and shall have a roughened surface in order to ensure
bond with the grout.

Before placing steel components or equipment on foundations, chip away defective concrete and
laitance, and clean all surfaces, leaving a surface free from oil, grease, dust and loose particles.

Shear key pockets and anchor rod sleeves shall be free of dirt and debris. If required, the top of
anchor rod sleeves shall be cut open to ensure unobstructed flow of grout into sleeves.

Care shall be taken not to treat concrete surfaces to be grouted with curing compounds or sealers.

The bottom and sides of sole plates and base plates shall be thoroughly cleaned to bare metal,
entirely free of all dirt, rust, oil, grease and loose material. Plates shall be aligned and levelled in
their final position and maintained in that position during grouting.

The surface on which grout is to be placed shall be thoroughly saturated with clean, potable water
for twenty-four hours, prior to grouting. At the time of grouting, the concrete shall have optimal
saturation after removal of excess water and debris with oil-free compressed air.

Prior to grouting, the contractor shall advise the Owner that preparation has been completed and is
ready for final inspection.

Follow manufacturer’s instructions during hot weather conditions, the grout shall be protected
against loss of moisture at all times.

6.2 Mixing

Mix grouts in a 5-gallon pail with a vertical shaft paddle mixer or paddle-type mortar mixer; do not
use a concrete site mixer and do not mix by hand.

Mix grout adjacent to the element being grouted. Have sufficient manpower and equipment
available for rapid and continuous mixing and placing and keep the grout continuously agitated.
Use only clean potable water for mixing.

Closely follow the grout manufacturer’s recommended precautions and procedures for mixing. Do
not re-temper grout. Discard grout that, after mixing, shows stiffening before use.

6.3 Formwork

Forms shall be built of materials of adequate strength and shall be securely anchored to withstand
the pressure of the grout during grouting operations.

Supply and install forms that are compatible with the proposed grout placement method. They
shall be designed for fast, continuous and complete filling of the void.

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Rev: C
 When installing the side form, slope the form at a 45° angle and pour directly on the inclined
surface. On other sides, install forms at 50 mm minimum from the side of the baseplate and a
minimum of 25 mm higher than the underside of the base plate.

A headbox or a pump shall be used for base plates over 600 mm in width. The headbox shall be at
least 150 mm above the baseplate bed.

6.4 Installation

In general, the placement temperature for cement-based grout shall comply with normal concrete
placement temperatures. Abnormal temperature grouting shall be approved by the Owner and the
grout manufacturer.

Place grouting material quickly and continuously by the most practical means permissible: pouring,
pumping or under gravity pressure.

Whenever practicable, grout shall be poured from one side of the plate only, to allow it to flow
across to the open side. Sufficient head shall be provided so that the grout flows out of the
inspection holes and spreads on the other side to a minimum height of 25 mm above the underside
of the baseplate.

A limited amount of strapping is recommended to help spreading of the grout under baseplates.
Strap from the opposite side from where the grout is being poured.

The final installation shall be thoroughly compacted and free from air pockets. Do not vibrate the
placed grout mixture, or allow it to be placed, if the area is being vibrated by nearby equipment.

For large areas requiring the use of special pouring procedures or grout pumps, the grout
manufacturer should be consulted for recommendations, but final procedures must be approved by
the Owner.

6.5 Finishing and Curing

When the grout has reached a stiff putty consistency, remove the forms and bevel grout shoulders
at a 45° angle away from the bottom of the steel components.

Care should be taken when bevelling, so as not to draw or pull the grout away from the underside
of the plates or allow it to sag. The finished shoulders shall be protected immediately, to prevent
rapid moisture loss.

Grout shall be cured by keeping it wet and covered with curing membrane or wet rags or in
accordance with the grout manufacturer's instructions immediately after final finishing has taken
place.

When final set is reached, wet rags shall be removed and all exposed grout surfaces shall be
treated with an approved curing compound (compliant with ASTM C 309 or preferably ASTM C
1315) or sealant to further minimize the moisture loss.

Shims, wedges and blocks which are used to support the base plates in position during alignment,
leveling and installation of grout, may be removed as directed by the Owner once the grout has
cured. For this purpose, the shims should be protected from bonding, with a plastic sheet or other

ECFN-AUS-CI-0100-SPE-01007 Page 6
Rev: C
 non-deleterious material. Voids created from removed shims shall be immediately grouted
following the same procedures.

6.6 Delivery and Storage

Non-shrink grouts should be shipped from the manufacturers, palletised, shrink-wrapped, and
delivered to the site in sound, dry packages. They should be stored in a dry and protected area.
The temperature should be maintained at approximately 21°C, but not below 5°C, and not above
32°C. Any materials which become damp or otherwise defective should be immediately removed
from the site.

The total job storage time of non-shrink grout should be limited to six months, or the manufacturer's
recommended storage limit, whichever is less. For critical applications, it is recommended that a
sample be sent to the manufacturer, if the material has been stored for more than six months, for
verification of the properties.

6.7 Inspection and Testing

The contractor shall inspect and provide quality control to ensure the compliance of all material and
workmanship.

ECFN-AUS-CI-0100-SPE-01007 Page 7
Rev: C