SCOPE
The
scope of grout work shall include but not limited to the Contractor's
furnishing, mixing, placing, curing, inspecting and testing of grout as
required for the work by this specification and as shown on the drawing.
WORK INCLUDED
All grouting for the column bases and stair
bases, bases and support of all mechanical and electrical equipment.
All -routing for anchor bolts including sleves.
All grouting for conduit, piping etc passing
through concrete floor or walls.
Formwork required for placing grout.
WORK NOT INCLUDED
Furnishing and installation of structure,
equipment bases and piping and conduits, including anchor bolts where the
grouting required to be placed.
CODES AND STANDARDS
Comply with the requirements of the applicable
codes and standards published by the following organisations:
ACI American
Concrete Institute
ASTM American
Society for Testing and Materials
CRD Chief
of Research and Development, U.S. Army Corps of Engineers
Conform especially to the applicable provisions
of the following codes and standards
ASTM C 31 Making
and Curing Concrete Test Specimen in The Field
ASTM C 33 Concrete
Aggregates
ASTM C 39 Compressive
Strength of Cylindrical Concrete Specimens
ASTM C 109 Compressive
Strength of Hydraulic Cement Mortars
ASTM C 143 Slump
of Portland Cement Concrete
ASTM C 150 Portland
Cement
ASTM C 309
ASTM C 494 Chemical
admixtures for concrete
ASTM C 1107 Determining
Consistency and Density of Roller-Compacted Concrete Using a Vibrating Table
CRD 621
CRD-C 261-83
QUALITY ASSURANCE/QUALITY CONTROL (QA/QC)
Contractor
shall fully comply with the Project Quality Assurance/Quality Control
Requirements. For submitting Quality
Assurance/Quality Control Procedures and Documentation the provision of Clause “Submittals” of this specification shall
apply.
SUBMITTALS
The installation procedures shall be submitted
by the Contractor for the Owner's Review :
STORAGE
All materials shall be stored in such a manner as
to avoid contamination, evaporation or damage.
Cement shall be stored in weather tight
buildings, bins or silos which will exclude moisture and contaminants.
Liquid admixtures shall be protected from
temperature changes which would adversely effect their characteristics.
TYPES AND USES
Types and specific uses of grout shall conform
to the following Table 4.4.2.6-1 or approved equal:
TABLE 4.4.2.6-1
Type and Specific Uses of Grout
|
Type of Grout
|
Specific Use
(Grouting)
|
|
a)Plastic Grout (Regular sand and cement grout)
|
(1)
Anchor bolts including sleeves and column base plates
(2)
Conduit, piping etc. through concrete floors or walls
|
|
b)
Drypack Grout
|
Equipment bases where required by manufacturer
|
|
c) General Grout Work Nonshrink Grout
|
Bases and support of mechanical and electrical
equipment and as directed by the Owner
|
|
d)
Precision Grouting Nonshrink Grout
|
(1)
Anchor bolts in drilled holes in concrete
(2)
Equipment bases where required by manufacturer or subject to high
repetitive and dynamic loads
|
MATERIAL
Grout components and
products: shall conform to the requirements
specified in Table
4.4.2.6 - 2, unless otherwise indicated.
TABLE 4.4.2.6 – 2
Grout Components and Products
|
Type of
Grout
|
Cement
|
Aggregate
|
Admixture
(if used)
|
Mixing Water
|
Grout Product
|
|
a. Plastic Grout
|
a.1
Portland cement,
ASTM C150
Type II or III, unless otherwise indicated
|
a.2.2
Grout 75mm thick or less Fine aggregate, ASTM C33
a.2.2
Grout thicker than 75mm Fine aggregate, ASTM C33, or coarse aggregate,
Size No. 7 or 8, ASTM C33
|
Conforming to ASTM C494, Type A water-reducing
admixtures; and containing chloride not more than 1% by weight (Use only if
reviewed by the Owner)
|
a.4
Clean, Potable, and free from injurious of oil, acid, salt, alkali,
organic matter and other deleterious substances
|
Not specified
|
|
b. Dry-pack Grout
|
Same as Item a.1
|
Fine aggregate, ASTM C33
|
---
|
Same as Item a.4
|
Not specified
|
|
c.
General Grout Work Non shrink
|
Manufacturer’s standards (this grout shall not
contain oxidizing and gas producing agents, catalysts, inorganic accelerators
and chlorides) ASTM C109
|
Same as Item a.4
|
Not specified
|
||
|
d. Precision Grout
|
Manufacturer’s standards (this grout shall not
contain any metallic aggregates, oxidizing and gas producing agents,
catalysts, and more than 300 ppm chloride) ASTM C109
|
Same as Item a.4
|
Not specified
|
||
Grout Properties: shall conform to the
requirements of Table 4.4.2.6-3, unless otherwise indicated.
TABLE 4.4.2.6 – 3
Property Requirement for Placed Grout
|
Type of
Grout
|
Cement
|
Aggregated
|
Admixture
(if used)
|
Mixing Water
|
Grout Product
|
|
a. Plastic Grout
|
250 kg/cm2 at 28
days unless otherwise specified
|
Plastic with maximum slump 125 mm for grout 75
mm thick or less; and maximum slump 75 mm for grout thicker than 75 mm
|
No requirement
|
No requirement
|
No vesible bleedings
|
|
b. Dry-pack Grout
|
350 kg/cm2 at 28 days unless otherwise specified
|
Stiff with hand shaping workability, and no
measurable slump
|
No expansion
|
Not more than 1.0%
|
No bleeding
|
|
c.
General Grout Work Non shrink
|
600 kg/cm2 at 28 days ASTM – C109
|
Flowable, 35 – 45 cm lateral flow at 22â - 30â C
|
Not more than 0.4% at 7,14 or 28 days CRD621
|
No shrinkage
|
No bleeding
|
|
d. Precision Grout Non shrink
|
800 kg/cm2 at 28 days ASTM – C109
|
Flowable, 35 – 45 cm at 22â - 30â C with time of efflux not more than 30
second. ASTM 1107
|
Not more than 0.4% at 7,14 or 28 days CRD621
|
No shrinkage
|
No bleeding
|
PREPARATION AND MIXING
SURFACE PREPARATION
Concrete surfaces to be grouted shall first be
cleaned and then be uniformly roughened to a minimum depth of 3 mm. Prior to placing grout, all concrete or metal
surfaces to be in contact with grout shall be thoroughly cleaned to remove all
laitance, oil, grease, paint, dirt,
rust, loose mill scale, damaged concrete and any other loose particles that may
interfere with complete bearing and bond or may react with grout
materials. Special care shall be taken
to assure that all waste materials and water are removed from anchor bolt holes
and sleeves in concrete.
The cleaned concrete surfaces to be in contact
with plastic grout shall be dampened
but not saturated and free surface moisture shall be removed just prior to
grout placement,
For dry pack grout, the equipment manufacturer’s
requirements for surface preparation shall be met, but as a minimum the
following are required:
The cleaned surfaces of the concrete to be in
contact with dry pack grout shall be pre-soaked for at least 6 hours before
grouting.
Just prior to placing grout, the concrete surfaces
should be blown with compressed air to remove any free water on these surfaces.
All
cleaned surfaces to be in contact with nonshrink grout shall also be prepared
in accordance with manufacturer's instructions.
For metal surfaces where bond between metal
surfaces and grout is not desired flake graphite, paraffin or form release
agent shall be applied to these surfaces, and no grease or oil shall be used.
SHIMMING AND WEDGING
Prior to placing grout, column base plates and
other structural elements shall be properly supported with shims or wedges, the
smaller dimensions of which shall be oriented in the direction of grout flow or
packing. Mechanical and electrical
equipment sisal] be shimmed or wedged before grouting in strict accordance with
equipment manufacturer's printed instructions.
Unless otherwise specified, shims and wedges to be removed shall be made
of carbon or stainless steel, and those to be left in place shall be made of
stainless steel.
All shims and wedges used for support shall be
carefully removed except those required by the equipment manufacturers to be
left in place, after the grout has set and hardened. The voids resulting from the removal of these
shim, wedges and levelling screws, shall be filled with the same grout unless
otherwise specified. All shims and
wedges shall be coated with a film of paraffin or form ease agent to facilitate
their removal, and no grease or oil shall be used.
FORMWORK
Forms for placing grout shall conform to grout
or equipment manufacturer's commendations and the applicable requirements of
Chapter 4 of ACI 301.
MIXING
Grout shall be thoroughly and uniformly mixed in
proper proportions in accordance with the following requirements and the
grout manufacturer's instructions, in order to obtain the properties indicated
in Table 4.4.2.6 - 3.
Batches of plastic grout for mixing shall be
less than 0.2 m3 and shall be mixed paddle type mortar mixer for not
less than 1 minute, with the water added slowly to assure efficient mixing and
water cement ratio not exceeding 0.5 by weight.
For drypack grout, the equipment manufacturer's
requirements for mixing shall be met, but as a minimum the following are
required:
Drypack grout shall be thoroughly and uniformly
mixed in a paddle-type mortar mixer for at least 5 minutes, and in quantities
that can be placed within one hour.
Grout mix proportion by weight shall be 1 part
of cement to 2-1/4 parts of fine aggregate, with water content that will give a
0.0 mm slump (ASTM C 143) and no exuded water when packing.
Grout shall be remixed every 30 minutes;
however, retempering of grout will not be permitted.
Nonshrink
grout shall be mixed in strict accordance with manufacturer's instructions.
PLACING AND CURING
GENERAL PLACING REQUIREMENTS
Grout shall be placed in strict accordance with
the following requirements and manufacturer's grouting procedures.
Grouting of a plate or base shall be a
continuous operation until the whole plate or base is completely grouted,
except that shimmed and wedged areas shall be grouted in accordance with Clause
as mentioned before.
Special care shall be taken to ensure that space
under grouted base plate or equipment base is entirely filled with grout. For placing plastic grout or non-shrink
grout, grout shall be poured from one side and continuously rodded with care
until it flushes up to the top of the form on all other sides and through grout
holes, if any, of the plate/base. Base
plate with shear bars in more than one direction may be grouted through a
central hole, only if air-relief holes are provided in the vicinity of the
shear bars where air may be trapped.
HOT WEATHER PLACING OF GROUT
Grout temperature during placing shall not
exceed 320C, unless otherwise indicated.
Retarding admixtures shall not be used unless
otherwise indicated.
ADDITIONAL PLACING REQUIREMETS FOR DRYPACK GROUT
Drypack grout placement shall meet the equipment
manufacturer's requirements, but as a minimum the following are required:
Grout shall be placed and packed within one hour
after mixing.
Grout shall be placed and packed in small
amounts to eliminate the possibility of a porous pack. Each layer shall be thoroughly rammed into
place before succeeding layers are placed, and this procedure shall be repeated
until the form is packed full.
ADDITIONAL
PLACING REQUIREMENTS FOR NONSHRINK GROUT
Nonshrink grout shall
be placed in accordance with manufacturers detailed instructions.
CURING
Curing of Plastic Grout
Exposed surfaces of grout shall be cured
immediately after completion of grout finishing and/or form removal by applying
curing compound.
Curing compound shall conform to ASTM C309 and
shall be applied in accordance with manufacturer's recommendations, immediately
after any water sheen -which may develop after finishing has disappeared from
the grout surface.
Exposed surfaces of grout and the plate in
contact with grout shall be protected from heating by the sun for at least a
week after grout placement.
No load shall be applied on the grout until
compressive strength of the grout reaches 75 percent of the specified strength
or until the grout has been moist cured for at least 7 days.
Curing of drypack grout shall meet the equipment
manufacturer's requirements, but as a minimum the following are required:
Exposed surfaces of grout shall be kept
continuously moist for at least 7 days after grout placing. Following moist curing and while the surface
is still damp a coat of curing compound shall be applied.
Moist curing may be achieved by any of the
following methods:
a)
Ponding or continuous sprinkling
b) Application of absorptive mats or fabric continuously kept wet
c)
Application of sand continuously kept wet
Exposed surfaces of grout and the plate in
contact with grout shall be protected from heating by the sun for at least a
week after grout placement.
Curing of Nonshrink Grout
Nonshrink grout shall be cured in accordance
with manufacturer's instructions.
INSPECTION
The Owner may, during the course of the work,
inspect the various phases of the work for full compliance with all
requirements of this specification.
TESTING
All grout for the work shall be tested in
accordance with the requirements of Table 4.4.2.6-4. If requested, reports of the test results
shall be submitted to the Owner for review.
Initial tests shall be performed prior to the
use of the grout. All grout components,
including the water, to be used for the initial tests shall be those specified
for use in the Works.
TABLE 4.4.2.6 – 4
Grout Testing
|
Test
|
ASTM Designation
|
Frequency
|
|
Compressive strength at 7 and 28 days
|
ASTM C109 or
ASTM C31
ASTM C39
CRD-C261-83
|
One test for each grout mix or as directed by
the Owner
|