SECTION 03600 GROUT PART 1 GENERAL 1.01 SUMMARY A. Related Sections: 1. 03300 - Cast-In-Place Concrete. 2. 03600 - Grout. 1.02 REFERENCES A. American Society for Testing and Materials (ASTM): 1. C109-95 Test Method for Compressive Strength of Hydraulic Cement Mortars. 2. C191-92 Test Method for Time of Setting Hydraulic Cement by Vicat Needle. 3. C531-95 Test Methods for Linear Shrinkage and Coefficient of Thermal Expansion of Chemical Resistant Mortars, Grouts, Monolithic Surfacings, and Polymer Coatings. 4. C579-96 Test Method for Compressive Strength of Chemical Resistant Mortars, Grouts, Monolithic Surfacings, and Polymer Coatings. 5. C827-87 Test Method for Change in Height at Early Ages of Cylindrical Specimens from Cementitious Mixtures. 1.03 SUBMITTALS A. Manufacturer's literature including specifications and printed installation instructions. PART 2 PRODUCTS 2.01 MANUFACTURERS A. Grouting Mortar: 1. Bonsal. 2. Burke. 3. Five-Star Products. Project No. SPECIFICATION GUIDELINES 03600-1
4. Master Builder. 5. Mobil. 6. Thoro. 2.02 NONSHRINK CEMENTITIOUS GROUT A. Exhibit no visible bleeding 2 hours after placement in a fluid consistency of 20 to 30 second flow through CRD C79 Flow Cone. B. Grout shall show no shrinkage and a maximum of 4.0 percent expansion at any time before initial set and tested according to ASTM C827. C. Grout shall show no shrinkage and a maximum of 0.2 percent expansion in the hardened state when tested according to CRD C588. D. Compressive Strength: Minimum of 5,000 psi at 7 days and minimum strengths as listed below according to ASTM C109 modified. 1. 24 Hours: 2,000 psi. 2. 7 Days: 5,000 psi. E. Grout shall show initial set time of not less than 60 minutes when tested according to ASTM C191. F. Grout shall contain no metallic substances, water reducing agents, accelerators super plasticizers, or other materials. G. Technical service shall be provided by the manufacturer of grout upon request of contractor. H. Water shall be clean and free from injurious amounts of oil, alkalies, and other deleterious materials according to AASHTO T26. 2.03 EPOXY GROUT A. Grout shall be flowable and a 100 percent solids system. B. Grout shall show no shrinkage and a maximum of 4 percent expansion when tested according to ASTM C531 (Modified). C. Compressive strength shall be determined by ASTM C579 Project No. SPECIFICATION GUIDELINES 03600-2
attaining the minimum strengths listed below: 1. 24 hours: 5,000 psi. 2. 2 days: 8,000 psi. 3. 7 days: 11,000 psi. D. Peak exotherm temperature of a 2 inch diameter by 4 inch high cylinder of grout shall not exceed 95 degrees F. when tested at 75 degrees F. material and air temperatures. E. Grout shall not exceed a coefficient of thermal expansion of 30 x 10-6 in/in/degrees F. when tested according to ASTM C531. 2.04 GROUT STORAGE A. Grout components shall be delivered to the construction site in moisture proof bags. Bags shall be stored in a dry weatherproof area within a temperature range of 40 to 90 degrees F. B. Remove damp or defective material from the site at expense to the Board. C. Storage time of nonshrink cement grout mix shall be limited to 10 months. PART 3 EXECUTION 3.01 SURFACE PREPARATION A. Concrete surfaces shall be prepared for grouting by removing all oil, grease, laitance, and other foreign substances. B. Roughen surfaces to receive grout by chipping or nail raking of plastic concrete to assure a good bond of grout to existing concrete. Clean thoroughly with water and soak surface for 24 hours before placing cement grout. Surfaces shall be kept completely dry for epoxy grout. C. Metal surfaces of equipment bases to be epoxy grout shall be thoroughly cleaned to bright metal. 3.02 FORMS A. Forms for fluid grout shall be built of materials with Project No. SPECIFICATION GUIDELINES 03600-3
adequate strength to withstand the placement of grout. B. Forms for nonshrink cement grout shall be tight against all surfaces and joints shall be sealed with tape. Form oil shall be used for easy form release. C. Forms for grout shall be watertight with chamfer strips in place. Caulking shall be used on all joints. Forms for epoxy grout shall be lined with polyethylene or waxed for easy form release. D. Forms shall be 4 to 6 inches higher than the base plate on one side of forms when using hydraulic head pressure for placing. E. Provide air relief holes at least 1/4" in diameter at every recessed base plate corner. 3.03 MIXING A. Grout shall be mixed according to manufacturer s recommendations. B. Nonshrink cement grout shall be added to water to obtain the desired consistency. C. Epoxy Grout: 1. Components shall be conditioned to a temperature of between 70 and 85 degrees F. before use. 2. Epoxy hardener shall first be added to resin and thoroughly mixed for 2 to 3 minutes without whipping air into the mix. 3. Low speed mixer or hand stirring shall be used. 4. Mixed resin and hardener shall then be put into clean mortar mixer and the entire bag of aggregate added. 5. Epoxy grout component ratios shall not be altered and no solvents or thinners added to the mix. D. Mix nonshrink cement grout between 3 and 5 minutes for uniform consistency. E. Epoxy grout shall be mixed until aggregate is uniformly wetted. F. Mortar mixer shall be used instead of a concrete mixer for mechanical mixing of grout. Project No. SPECIFICATION GUIDELINES 03600-4
G. Remixing of grout by adding more water or remixing of stiffening grout is not allowed. 3.04 REINFORCEMENT A. Reinforcement and joints for epoxy grout shall be provided when and by methods recommended by the manufacturer of the grout. 3.05 PLACEMENT A. Grout shall be rapidly placed continuously from one side of baseplate only in one direction. B. Grout under base plates to fill all spaces and completely fill anchor bolt sleeves. C. Hydraulic head grouting pressure shall be maintained by keeping the level of grout in the head box above the bottom of the base plate. Head box shall be filled to the maximum level and grout worked down to top of base plate. D. Shims used for temporary leveling of equipment and base plates shall be removed after the grout has obtained sufficient strength to carry the baseplate loading. Voids left by the removal of shims shall be filled with a second placement of grout. 3.06 FINISHING A. Alter cement grout has reached final set, it shall be trimmed back to the level as shown on drawings. B. Top surfaces of epoxy grout may be finished by troweling with a steel trowel moistened with oil before set. 3.07 CURING A. Nonshrink Cementitious Grout: 1. Grout shall be cured according to manufacturer s specifications and recommendations. 2. Forms shall remain in place for 24 hours. 3. Temperature of base plates and supporting concrete shall be maintained between 40 and 90 degrees F. during grouting and for a minimum of 12 hours after placing. Project No. SPECIFICATION GUIDELINES 03600-5
B. Epoxy Grout: 1. Grout shall be cured according to manufacturer s specifications and recommendations. 2. Forms shall remain in place for a minimum of 24 hours after placing grout. 3. Temperature of base plate and supporting concrete shall be maintained between 40 and 80 degrees F. during grouting and for a minimum of 24 hours after placing. 3.08 TESTING A. Contractor shall be responsible for preparing, storing, curing, and transporting the test samples to the laboratory for testing. B. Grout shall develop required compressive strength according to ASTM C109 (modified) for packaged grouts and ASTM C579 for epoxy grout. C. Three test cubes shall be made for each day of grouting. Tests shall be made of one cube at the following intervals: 1. Cement Grout: 24 hours, 7 days, and 28 days. 2. Epoxy Grout: 24 hours, 2 days, and 7 days. D. Test reports shall be submitted to the A/E immediately after the result of each age test is available. END OF SECTION Project No. SPECIFICATION GUIDELINES 03600-6