Procedure for NON-SHRINK & EPOXY GROUTING WORKS -CIVIL
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Procedure for NON-SHRINK and EPOXY GROUTING WORKS
we have following points for this procedure here one by one we will explain.
1. General Point
a. This document describes materials, workmanship and procedures required to supply and place Cement Based, Non-Shrink Grout for Structural and Equipment and Epoxy Grout for Machinery Support.
b. Grout shall be delivered to the job site in sound and stored in a dry area. Maintain storage temperature according to the manufacturer’s written instructions.
c. Any material which becomes damp or otherwise defective shall be immediately removed from the job site.
a. Only approved grouting materials shall be used in site. All grouting materials shall be proportioned products, meeting all the requirements and package according to applicable standards, requiring only the addition of potable water and shall not contain metallic substances that may be potentially harmful to concrete or steel reinforcement.
b. Potable water shall be used in the production of mixing and placement of grout, curing grout and cleaning, wetting and cooling forms. Mixing water shall be free from impurities, oil, acid, salts, alkali, organic matter and other potentially deleterious substances.
c. The pH value of mixing water shall be between 7.0 and 8.0.
Please read also: PROCEDURE/METHOD STATEMENT FOR EARTHWORK
e. Remove laitance and oil-soaked or damaged concrete with chipping hammer to the level of sound, fractured aggregate or to a minimum of the top 25mm of concrete. When surface chipping is complete, remove all dust and loose particles with clean, dry and oil-free air.
f. Concrete surfaces in contact with the grout shall be saturated with clean water for a minimum of 24 hours before grout placement. The surface of the concrete shall be damp but free standing water.
1. Non-shrink grout
a. Grout shall be free of hydrogen gas producing, oxidizing catalysts and inorganic accelerators.
b. Where true non-shrink characteristics are not mandatory, site mixed grout shall use clean well graded sand that meets the requirements of 09-SAMSS-088, Type V Portland cement (as defined by ASTM C150) and potable water. Minimum 28-day compressive strength shall be 13.8 MPA (2,000 psi).
c. Total dissolved solid for mixing and curing water shall not exceed 500 ppm.
d. Grouting of structural base plates, anchor bolts, columns and precast members, i.e: wall panels, beams, etc.
e. Reinforcing shall be in accordance with the manufacturer when the water/cement ratio is 0.4 or less, the grout shall be continuously water cured for a minimum of seven days. Curing compounds shall be in accordance with ASTM C309.
2. Epoxy Grout for Machinery Support
a. The contractor shall comply with the safety requirements specified in the grout manufacturer’s data sheets. Maximum creep (ASTM C 1181) is 0.005 mm/mm tested at 60 degrees C with 400 psi applied vertical load.
b. All materials shall satisfy the following resin component shall consist of a pre-measured, prepackaged, solvent free, liquid epoxy resin specifically formulated for the used grout system.
c. The hardener component shall consist of a pre-measured, prepackaged liquid specifically formulated to produce the specified final properties when mixed with the other component.
d. The aggregate shall be a pre-measured, prepackaged blend of inert, inorganic particulate fillers, such as silica, designed specifically to provide the proper flow, handling and physical properties required for the grout product.
e. The ratio of aggregate to resin and hardener shall be per the manufacturer recommendations. If aggregate ratio is adjusted for field conditions, physical properties shall be obtained at the recommended fill ratio.
f. The resin and catalyst components shall be free of hard sediment, show no gelation in a freshly opened can, and shall be of proper consistency to enable thorough mixing to a smooth homogenous state.
g. The components shall show no gelling when stored for the shelf life indicated on the data sheets from the date of manufacture in unopened containers at temperatures of 32°C. Resin and catalyst containers shall not leak when subjected to normal shipping and storage. Packaging shall meet the requirements of 09-SAMSS-060.
h. All components, resin, hardener, and aggregate shall be properly labeled, including batch numbers, shelf life and storage requirements grout shall be applied only when surrounding temperatures are between 15 oC and 32 oC (60oF and 90oF) unless otherwise specified in the manufacturer’s data sheets. (Appendix L.4.1 of APl-610 , 95 revision).
i. The epoxy grout manufacturer’s recommendations on maximum depth of pour and length to width ratio shall be followed. If the grout pour is 100 mm or deeper, the grout manufacturer recommendations for installing reinforcement rebars shall be followed.
j. The corners of mounting plates shall be rounded to at least a 50 mm radius where feasible to prevent crack-producing stress raisers in the grout.
4) Finishing and Curing
a. Grout surface shall be finished to drain clear of base plates. Exposed grout surfaces shall be no longer than the bottom of steel base plate. Finished exposed grout with wood float or brush finish, exposed edges shall be finished to a 45 degree angle.
b. As soon as the grout is placed and finished, cover exposed edges with wet burlaps or rags (cloth retains moisture more effectively than hessian) keeping them wet for 24 hours until forms are removed.
c. Continue to wet cure for a minimum of 5 days total or applying curing compound which meets ASTM C309 requirements or as per manufacturer’s written instructions. 7.4.5 Suitable shelter or enclosure shall be provided to protect the grouted foundations from direct sunlight and weather.
5) Testing (by Approved Testing Laboratory)
a. Make 2 sets of 3 test cubes in the field each day that grout is mixed and placed. Cure the cubes in the field for 3 days in the same way as the placed grout is cured. After 3 days, transport cubes to the testing laboratory for compressive strength testing. Test compressive strength of one cube set at 7 days and one cure at 28 days in accordance with the applicable provisions of ASTM C109.
b. Compressive strength of the grout shall meet the requirements of ASTM C1107 and shall not be less than the compressive strength of the foundation. The compressive strength of the grout shall be a minimum of 24MPa (3500psi) at 7 days of age and the compressive strength of the grout shall be a minimum of 35MPa (5000psi) at 28 days of age.
6. Safety Control During work activity
1) Personal Protective Equipment will be worn at all times.
2) Barricading of work areas of equipment shall be checked prior to the start of work equipment, tools and materials inspection.
5) Safety Supervisor shall carry out the safety site inspections to
ensure that safety requirements laid out in the Safety Action Plan are followed during the execution of grouting applications.
6) Emergency exit point, assembly area, emergency evacuation plan and emergency numbers shall be posted on the boards.
7) Subcontractors shall not enter or commence work in any deep excavation, deep Manhole,
or other enclosed space, until a valid permit to work has been issued. Where Subcontractor operations may result in a dangerous atmosphere arising during the work activity the permit to work issuing authority shall be made aware of this before permit issue.
8) All personnel involved in the grouting works shall have to undergo Safety Training being conducted by HSE.
3) All equipment for works shall be inspected by Contractor Safety manager or safety supervisor/officer prior start of work to ensure their safe worthiness at work.
4) All Workers shall be prevented from trespassing into the barricaded areas except those who will execute the work. Extended working schedule shall be intimated in advance, proper lighting arrangements, PPE, emergency vehicles and tools shall be arranged with necessary safety personnel engaged in the working area.
1) All of tools and equipment e.g. hand and power tools etc. require special attention and protection for their use and guidelines.
2) All damaged, unsafe or defective tools will be marked, tagged as Unsafe or with a Red Paint and taken away from operation to assure that no one will use such tools on the job.
2) Electrical tool and equipment shall be used in accordance with GFCI requirement.
a) Slow Speed Drill
b) Mixing Paddle
c) Mixing Tank
d) Portable Water Jetting Machine
e) Personal Protective Equipment