THIS METHOD STATEMENT COVERS THE PREPARATION & INSTALLATION OF MasterFlow 648 (Formerly Known As MASTERFLOW 648CP), FOR USE IN BEDDING, GROUTING & PRECISION BEARING OPERATIONS. DEVIATIONS FROM THE FOLLOWING PROCEDURES MUST BE AGREED WITH THE ENGINEER.
MasterFlow 648 Installation for Bedding, Grouting & Precision Bearing
METHOD STATEMENT: MasterFlow 648 (Formerly Known As MASTERFLOW 648CP)
1. FOUNDATION PREPARATION:
1.1. Preparation of the concrete surface to which the grout will bond should be carried out before the base plate is installed.
1.2. Prepare the concrete surface using chipping hammers, grit blasting or high pressure water jetting. to leave a roughly textured, clean surface free from all forms of contamination.
Bush hammering or similar methods which can fracture aggregate, but leave it in place are not permitted.
1.3. Preparation should cover the full extent of the surface, which is intended to be in contact with the grout.
1.4. Where it is indicated that bolts are to be anchored within the grout, bolt pocket formers should be shaped to form an inverted cone helping to ensure stresses that build up when the baits are tightened are transmitted to the foundation.
1.5. Bot pocket formers should be made from materials that are easy to remove, but leave a rough concrete surface texture when stripped.
1.6. Ail surfaces and bolt pockets to receive grout must be clean and free of oil, dust, dirt, paint and residua! curing compound.
1.7. All baseplate holding down bolts etc., are to be free of rust, oil, dirt or contaminants that could impair bond.
1. 8. For grout thickness greater than 15cm it is advisable to fix steel reinforcement to control possible cracking. 16mm bars at 20cm centres will be suitable.
2. FORMWORK:
2.1. Before fixing formwork. ensure the foundation area and bolt holes are clean.
2.2. Formwork fitted around the base plate to contain the grout must be as liquid tight as is practical. to prevent resin loss.
2. 3. The top of the formwork should be a minimum of 2.5cm above the underside of the base plate.
2.4. For large base plate pours or when the gap between base plate and foundation concrete is of less than 2.5cm depth, the formwork should be higher to allow a pressure head le build up.
2.5. On the pouring side, which should be the shortest distance across the base plate, a hopper should be constructed. to allow a pressure head sufficient to enable grout to flow to the full width of the pour. The form should be fixed with the top sloping away from the base plate at a45 angle to form a slope down which the grout can be poured.
2.6. Formwork must be coated with a release agent or wrapped with polythene sheet, prior to fixing, to prevent it bonding to the grout.
2.7. If grout is to be pumped. formwork should be constructed to withstand the additional localised pressure
3. PREPARATION FOR GROUTING:
3.1 Before final fixing of the formwork. remove all dirt and debris from within the area to be grouted.
3.2. Ensure sufficient grout is available on hand to complete the intended pour in a continuous process.
3.3. Prior t the grout installation. mixing equipment must be demonstrated to be suitable and in good working order. Back up mixing equipment should always be available in case of
breakdown.
Hot weather grouting
3.4. it grouting is to take place in high ambient temperatures, store bags of grout and resins in a cool place that ill keep the temperature below 30C. Shade the mixing area and the location to be grouted.
Cold weather grouting
3.5. I:the temperature of the base concrete cannot be maintained at or above 10C whilst the grout cures. delay grouting until this can be achieved.
3.6. Keep the resin and aggregate in a warm area prior to use. Try to keep the material temperature above 15C to ease placing.
3.7. If the ambient temperature is likely to fall below 15C during the first 5 days from pouring the epoxy grout application should be warmed by installing space heaters to maintain a temperature within the tented area above 20C. Failure to do this will affect strength development of the epoxy grout.
3.8. If the substrate temperature cannot be maintained at 10C or greater for 4 days from the time of pouring, delay the pour, or seek advice from BASF.
3.9. Adjacent machinery should be shutdown if causing vibrations in the pour site.
3.10. Ensure that the area to be grouted is dry. A damp substrate will reduce or negate the bond.
4. MIXING:
4. 1. Pour the total contents of the base and reactor components into a suitable mixing vessel and mix or 1 minute or until successfully blended.
4.2. While the mixer is stilt turning, add all the aggregate and mix until a uniform {ump free consistency is achieved. Do not over mix. as this can lead to excessive air entrainment. (For variations in fill ratio for thin sections or long pours see datasheet).
5. PLACING:
5.1. All bolt pockets must be tied with grout before pouring the rest of the underplate grout, preferably as a separate operation, to prevent voids being formed.
5.2. Start at one end of the base plate, pouring grout down the slope of the formwwork. When the grout reaches the far side formwork and rises above the bottom of the base plate, move the pouring point slowly along the length of the base plate, always ensuring that the grout has risen up on the opposite side of the base plate before moving along.
5.3. Pour he grout steadily down the slope of the formwork to reduce the possibility of entrapping air.
5.4. Do not pour from different sides of the base plate as this can cause voids, which reduce the effective bearing area.
6. CURING:
6.1. Curing is not required.
7. SHOULDERS:
7.1. T achieve a smooth finish, brush exposed surfaces with CLEANING SOLVENT NO. 2 just before. or as the grout gels.
7.2. Shoulders should not exceed 50mm wide to reduce the danger of cracking or debonding occurring.
METHOD STATEMENT FOR GROUTING (NON-SHRINK)
EPOXY GROUTING APPLICATION WORK PROCEDURE | METHOD STATEMENT