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Polaris Engineering Standard

430.4 Rev.: 7 Page: 1 of 8 Date: 06/14/02

GROUTING TABLE OF CONTENTS I. II. III. IV. V. VI. SCOPE REFERENCES MATERIAL REQUIREMENTS PORTLAND CEMENT GROUT NON-SHRINK GROUT INSTALLATION OF PORTLAND CEMENT AND NON-SHRINK GROUTING EPOXY GROUT INSTALLATION OF EPOXY GROUT APPENDIX A - EPOXY GROUTING INSTRUCTIONS PAGE 2 2 2 3 3 4

VII. VIII.

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Polaris Engineering Standard

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GROUTING I. SCOPE This Standard covers the minimum requirements for grouting machinery, equipment and structures. Where conflicts exist between this Engineering Standard and other Polaris Engineering Standards and/or applicable codes or regulations, the more stringent requirement shall govern. All conflicts shall be brought to Client and/or Polaris Engineerings attention for resolution. Client and/or Polaris Engineering shall be the sole arbiter of any conflicts. II. REFERENCES This Polaris Standard is to be used in conjunction with the latest revision of the standards and codes listed below, unless specifically noted. The terminology "latest revision" shall be interpreted as the revision in effect at the time of contract award. This Polaris Standard may reference specific sections of some of these codes and standards. The revision of the codes and standards being referenced is noted below in parenthesis. This information is provided to identify the subject matter being referenced. Changes or exceptions made to the referenced code or standard shall apply to later revisions as applicable. A. American Society For Testing Materials (ASTM) Standards: 1. 2. 3. C33 C150 C 1107 Standard Specification for Concrete Aggregates (2001) Standard Specification for Portland Cement (2002) Standard Specification for Packaged Dry, HydraulicCement Grout (Nonshrink) (2002)

III.

MATERIAL REQUIREMENTS A. Use Portland Cement grout for grouting small base plates less than 100 sq in., such as ladder pads and base ell supports. Use Non-Shrink grout for grouting all structure column base plates and all vessel and equipment bases except as noted in Paragraph III.C below. Fill machinery bases with non-shrink grout. Use Epoxy grout for grouting centrifugal machinery over 250 horsepower and for all reciprocating machinery.

B.

C.

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IV.

PORTLAND CEMENT GROUT The term "Portland Cement Grout" applies to any mixture of cement, aggregate and water used to fill the space under base plates. A. Materials 1. Cement grout shall conform to ASTM C150, Type II Portland Cement. High-early strength cement or cement with an air entraining agent is prohibited. Aggregate shall consist of sand and/or sand pea gravel and shall conform to ASTM C33.

2.

B.

Proportioning and Mixing Grout 1. Normal Portland Cement Grout shall be a mixture of one part cement and two parts sharp sand. Mix these materials dry with only enough water added to obtain a stiff plastic consistency. Where the space to be grouted is deeper than two inches, pea gravel may be added to the grout mixture. If pea gravel is used, proportion the cement-sand-pea gravel mixture to the ratio 1:2:3. Dry pack grout shall be a mixture of one part cement and two parts sharp sand. Add just enough water so that when the mixture is squeezed into a ball, it will crack. Do not exceed 25% total water content for dry pack grout by weight of cement content.

2.

V.

NON-SHRINK GROUT A. Provide only cementitious non-metallic, prepackaged grout that is ready to use from the Manufacturer. Non-shrink grout shall meet the requirements of ASTM C1107 with a minimum compressive strength of 6000 psi at 28 days Non-shrink grout shall be one of the following products or Client and/or Polaris Engineering approved equal: 1. 2. 3. "CRYSTEX" as manufactured by L & M Construction Chemicals. "MASTERFLOW 928" as manufactured by Master Builders FIVE STAR FLUID GROUT 100 as manufactured by Five Star Products

B.

C.

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D.

Mix and install the grout in strict accordance with the Manufacturer's printed instructions.

VI.

INSTALLATION OF PORTLAND CEMENT AND NON-SHRINK GROUTING A. Surface Preparation: 1. Remove all laitance, other loose materials and oil soaked or damaged concrete from the surface of concrete to receive grout by brushing, cleaning or chipping. Leave the surface rough and irregular with amplitude of 1/4 inch to provide a good bond. Set the elevation of the top of concrete to allow for the grout thickness between the machine or structure base and the concrete. Clean sole plates, base plates and other metal surfaces which will be in contact with the grout. Coat leveling screws, shims or wedges with a lubricant to prevent the grout from adhering. Mask or coat with wax all areas which require protection from grout or splatter. For cementitious grouts, presoak the concrete surface with potable or desalinated water before grouting, being sure to remove free water from the concrete surface and anchor bolt sleeves prior to placement of grout.

2.

3.

B.

Setting and Leveling 1. Use wedges, shims or leveling screws to position the machine at its proper height and to level the machine. Evenly distribute the load over the leveling points used. Removal or retention of shims shall be as recommended by the Equipment Vendor. Wedges shall not be retained. Shims to be retained after grouting shall have full contact with the foundation, and shall be round or have rounded corners.

2.

3.

C.

Placement of Grout 1. Minimum grout thickness under all support members shall be 1-1/2 inches. The grouting material shall solidly fill the spaces to be grouted and shall permanently retain its original volume. Vent all trapped pockets to allow full penetration of the grouting material. Completely fill all anchor bolt sleeves with grout prior to grouting under bases. Completely fill all machinery bases with non-shrink grout.

2.

3.

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4.

All shims which are to be left in place shall be fully encapsulated by the grout. Insure that grout placed under slide plates does not interfere with movement between the sliding surfaces. Grout shall not extend up the sides of base plates and slide plates. Slope grout away from the bottom of base plates to prevent water from standing against the base plates. After attaining sufficient set, remove forms and tool the finished surface smooth, sloping the grout away from the machine or equipment base. Seal around slide plates with silicone sealant.

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6.

7.

8. D. Curing 1.

Immediately after surface finishing of cementitious grout is completed and the grouting material is sufficiently hardened, wet the surface thoroughly (wet burlap may be used), and keep wet a minimum of 5 days to promote slow curing and prevent cracking. Alternate curing methods may be employed with prior approval by Purchaser. After 5 days, if shims are to be removed, or if wedges were used, back off leveling screws, remove all wedges and shims, and fill the resultant spaces with grout. Then torque the foundation bolts to final tightness.

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3.

VII.

EPOXY GROUT

Epoxy grout shall be one of the following products or Client and/or Polaris Engineering approved equal: 1. Masterflow 648 CP Plus as manufactured by Master Builders, division of Chemrex Five Star DP Epoxy Grout as manufactured by Five Star Products

2. VIII.

INSTALLATION OF EPOXY GROUT A. Pregrouting Instructions: 1. All personnel involved in epoxy grouting shall review the Grout Manufacturer's printed instructions accompanying the grout, the installation instructions shown on the equipment Manufacturer's drawings and the instructions given herein. The Purchaser shall resolve any conflicts.

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2.

The Contractor shall hold a pregrouting meeting at the jobsite with the Grout Manufacturer's technical representative in attendance. All aspects of the grouting procedure shall be discussed and any conflicts resolved so that any warranties are not jeopardized. The Contractor shall advise the Client and/or Polaris Engineering if the Manufacturer's Representative recommends anything contrary to the instructions given herein. The manufacturers technical representative must be on site during and prior to all major pours to insure compliance with specific manufacturer requirements. Manufacturers representative shall be notified at least 72 hours prior to on site requirement.

B.

Install epoxy grout in accordance with `Epoxy Grouting Instructions' shown in Appendix A of this Standard and the grout Manufacturer's Recommendations. Do not wet the concrete surface for epoxy grout. Do not adjust the proportions of grout components without written permission from manufacturer. Setting and Leveling 1. Use wedges, shims or leveling screws to position the machine at its proper height and to level the machine. Evenly distribute the load over the leveling points used. Removal or retention of shims shall be as recommended by the Equipment Vendor. Wedges shall not be retained. Shims to be retained after grouting shall have full contact with the foundation, and shall be round or have rounded corners.

C.

2.

3.

D.

Placement of Grout 1. 2. Place epoxy grout per Appendix A of this Standard. Minimum grout thickness under all support members shall be 1-1/2 inches. The grouting material shall solidly fill the spaces to be grouted and shall permanently retain its original volume. Vent all trapped pockets to allow full penetration of the grouting material. All shims which are to be left in place shall be fully encapsulated by the grout. Grout shall extend up the sides of base plates as shown in Appendix A. Slope grout away from base plates to prevent water from standing against the base plates.

3.

4.

5.

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6.

After attaining sufficient set, remove forms and tool the finished surface smooth, sloping the grout away from the machine or equipment base. Seal around base with silicone sealant.

7. E.

Cure epoxy grout in accordance with Manufacturer's recommendations.

Engineering Standard

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Engineering Standard

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