240K C2 CS 15 012 C PDF

SOCIEDAD MINERA CERRO VERDE S.A.A.
CERRO VERDE PRODUCTION UNIT EXPANSION
PROJECT NO. A6CV
GROUT CONSTRUCTION SPECIFICATION
DOCUMENT NO. 240K-C2-CS-15-012 REV. C

25 APRIL 2012
Z:\103_PROJ_ADMIN\109_ENG DOCS\109.8R_CS\15-Structural\240K-C2-CS-15-012_Grout\240K-C2-CS-15-012-C.doc
Sociedad Minera Cerro Verde S.A.A. Cerro Verde Production Unit Expansion Project No. A6CV
Document No. 240K-C2-CS-15-012 Revision C
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GROUT CONSTRUCTION SPECIFICATION TABLE OF CONTENTS 1. GENERAL...................................................................................................................................................... 5 1.1 Summary ..........................................................................................................................................5 1.2 References .......................................................................................................................................5 1.3 System Description...........................................................................................................................6 1.4 Submittals .........................................................................................................................................8 1.5 Quality Assurance ............................................................................................................................9 1.6 Site Conditions .................................................................................................................................9 PRODUCTS................................................................................................................................................. 10 2.1 Product Delivery and Handling .......................................................................................................10 2.2 Materials .........................................................................................................................................10 2.3 Equipment and Components ..........................................................................................................10 2.4 Design Criteria ................................................................................................................................11 2.5 Mixes ..............................................................................................................................................11 2.6 Inspection and Tests ......................................................................................................................11 2.7 Identification and Tagging ..............................................................................................................11 2.8 Surface Preparation and Finish ......................................................................................................11 2.9 Preparation for Shipment................................................................................................................11 EXECUTION ................................................................................................................................................ 11 3.1 Examination ....................................................................................................................................11 3.2 Preparation .....................................................................................................................................12 3.3 Installation.......................................................................................................................................15 3.4 Field Quality Control .......................................................................................................................18 3.5 Adjustment and Cleaning ...............................................................................................................18 3.6 Protection........................................................................................................................................19 ATTACHMENTS.......................................................................................................................................... 19
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3.
4.
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1.
GENERAL 1.1 Summary A. Scope of Specification This specification prescribes the minimum requirements for the furnishing and installation of grout for use between applied loads (e.g. column base plates or equipment bed plates) and foundations. B. Work Not Included This specification does not cover grouts for grouting anchor bolts and rebar, masonry, prestressing tendons, concrete repair, waterproofing, or geotechnical use. For special grouting applications, see design drawings. C. Related Documents The following documents describe items of related work: 240K-C2-DC-10-002 240K-C2-CS-15-011 240K-C2-CS-15-021 240K-C2-CS-15-022 D. Definitions Buyer: The party that awards the contract to fabricator. May be the owner or owner's authorized agent. Owner: The owner of the proposed structure. 1.2 References A. Referenced publications within this specification shall be the latest revision, unless otherwise specified; and applicable parts of the referenced publications shall become a part of this specification as if fully included. Applicable Codes and Standards Design, manufacture and testing shall conform to requirements stated in this Specification and under Section 1.1C Related Documents, as applicable. Equivalent codes and standards will be considered. ACI American Concrete Institute 304R 351.1R ASTM Guide for Measuring, Mixing, Transporting, and Placing Concrete Grouting between Foundations and Bases for Support of Equipment and Machinery General Site Conditions Design Criteria Structural Concrete and Reinforcing Construction Specification Fabrication of Structural and Miscellaneous Steel Construction Specification ( to follow) Erection of Structural and Miscellaneous Steel Construction Specification ( to follow)
B.
American Society for Testing and Materials C33 Standard Specification for Concrete Aggregates
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GROUT CONSTRUCTION SPECIFICATION C109 C150 C191 C531 Standard Test Method for Compressive Strength of hydraulic Cement Mortars (Using 2 inch or 50mm Cube Specimens) Standard Specification for Portland Cement Test Method for Time of Set of Hydraulic Cement by Vicat Needle Test Method for Linear Shrinkage and Coefficient of Thermal Expansion of Chemical Resistant Mortars, Grouts, and Monolithic Surfacings Test Method for Compressive Strength of Chemical Resistant Mortars and Monolithic Surfacings Standard Test Method for Change in Height at Early Ages of Cylindrical Specimens from Cementitious Mixtures Standard Test Method for Bond Strength of Epoxy-Resin System Used with Concrete by Slant Shear Standard Test Method for Measuring Changes in Height of Cylindrical Specimens of Hydraulic Cement Grout Standard Specification for Packaged Dry, Hydraulic Cement Grout (Non-shrink) Standard Test Methods for Compressive Creep of Chemical Resistant Polymer Machinery Grouts Standard Test Method for Flowability and Bearing Area of Chemical-Resistant Polymer Machinery Grouts Standard Test Method for Indicating Moisture in Concrete by Plastic Sheet Method
C579 C827 C882 C1090 C1107 C1181 C1399 D4263 CRD
Corps of Engineers C621 Specification for Non-shrink Grout
OSHA
Occupational Safety and Health Administration CFR 1910D: Occupational Safety & Health Standards Walking Working Surfaces, Code of Federal Regulations
1.3
System Description A. Design Requirements 1. 2. Foundation plates for equipment and structures shall be grouted to provide full uniform load transfer between bottom of plate and concrete foundation. Load transfer to foundation must be through grout, not through shims or other leveling devices.
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GROUT CONSTRUCTION SPECIFICATION 3. Applications by Grout Types (if grout type is not specified on drawings, use nonmetallic non-shrink cement based grout). a. Non-shrink Cement Based Grout Grouting of machinery, pumps, compressors and other equipment having dynamic operating forces shall be in strict compliance with the equipment manufacturers recommendation. (1) Metallic non-shrink grout shall be Embeco 885 manufactured by Master Builders, Cleveland, Ohio, or approved equal. Metallic non-shrink grout shall be used for all major equipment supports subjected to dynamic force or impact loading at the following applications: (i) (ii) (iii) (iv) (v) (vi) (vii) Primary crushers Secondary crushers Ball mills and motors HPGR crusher and motor Regrind mills All machinery and pumps with drives of 500 horsepower and above Compressors, generators, vessels and heat exchangers, blowers, motors, pumps and other rotating equipment having total weight greater than 1400 kg (3000 lb)
(2)
Nonmetallic non-shrink grout shall be Masterflow 713 Plus manufactured by Master Builders, Cleveland, Ohio or approved equal. Nonmetallic non-shrink grout shall be used in the following applications: (i) (ii) (iii) Equipment with cast bases Equipment on base frames with cover plates Column base plates
b.
Non-shrink Epoxy Grout (1) (2) Use only in areas specified on design drawings. Use only in areas recommended by equipment vendors.
B.
Performance Requirements 1. Non-shrink Cement Based Grout a. Plastic Volume Change No shrinkage (0.0 percent) and 4.0 percent maximum expansion before initial set as measured in accordance with ASTM C827. b. Hardened Volume Change No shrinkage (0.0 percent) and 0.4 percent maximum expansion in the hardened state as measured in accordance with CRD C-621. c. Compressive Strength Minimum 51.8 MPa (7500 psi) at 28 days when tested according to ASTM C109.
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GROUT CONSTRUCTION SPECIFICATION d. Working Time Consistency greater than 100 percent for a minimum of 45 minutes at 24 degrees C (75 degrees F), if tested according to applicable consistency sections of ASTM C1107 at 15 minute intervals e. Creep Resistance Equal or less than 0.015mm per 25mm (0.0006 of an inch per inch) at 21 degrees C (75 degrees F), for a minimum of 1 year (extrapolated data not acceptable), if tested according to creep test (ASTM C1181). f. g. 2. Free from chemically produced gas, oxidizing catalysts, inorganic accelerators, chloride, and metallic particles. Nonstaining
Non-shrink Epoxy Grout a. Volume Change No shrinkage (0.0 percent) and 2.0 percent maximum expansion at all ages as measured in accordance with ASTM C827, modified to use an indicator ball with a specific gravity between 0.9 and 1.1. b. Effective Bearing Area No less than 95 percent bearing area or high bearing area when tested in accordance with ASTM C1339. c. Compressive Strength A Minimum 110 MPa (16,000 psi) at 7 days if tested in accordance with ASTM C579. d. Thermal Expansion A Maximum of 0.00137mm per 25mm per degree C (0.000030 of an inch per inch per degree F) when tested in accordance with ASTM C531. e. Creep Resistance Equal or less than 0.127mm per 25mm (0.005 of an inch per inch) at 60 degrees C (140 degrees F), for a minimum of 1 year (extrapolated data not acceptable), with a load of 2.8 MPa (400 psi) if tested according to creep test (ASTM C1181). f. Bond Strength Minimum bond strength of 14 MPa (2000 psi) between epoxy grout and concrete (ASTM C882).
1.4
Submittals A. Submit quality control program for review and acceptance, 15 days before installation. The program shall include all forming, handling, mixing, placing, .joint locations, joint details, curing, testing, and inspection procedures. Copy of test reports, including test data, shall be certified by an independent laboratory, verifying that manufactured grouts meet or exceed performance requirements as tested according to ASTM C109, ASTM C531, ASTM C579, ASTM C1107, ASTM C1181 and ASTM C1339. Provide manufacturer's installation instructions, detailed Product Datasheets, and Material Safety Datasheets for manufactured grouts.
B.
C.
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GROUT CONSTRUCTION SPECIFICATION 1.5 Quality Assurance A. General 1. 2. 3. Refer to Section 1.1.C Related Documents and Section 2.6 Inspection and Tests. Supplier shall not substitute major component sub-suppliers after award of a Purchase Order without Buyers written approval. Supplier shall be solely and entirely responsible for the performance of grout. Supplier shall guarantee that the grout will operate satisfactorily to the conditions and requirements of this Specification and Data sheets. Buyer reserves the right to witness any tests or inspections to ensure that components conform to Quality Assurance requirements. Supplier shall notify Buyer in advance of all tests and grant free access to manufacturing facilities, including those of his sub-suppliers, for such inspections. Supplier shall supply Buyer with the complete list of documentation that Supplier intends to produce for review. Such documents shall cover manufacturing, quality control, inspection procedures, deficiency evaluation and correction. Inspection reports shall be made available for inspection by the Buyer. All defects in excess of agreed acceptance criteria shall be reported immediately to the Buyer by Supplier and evaluated by Suppliers engineering departments for possible corrective action. All corrections proposed shall be subject to Buyers approval.
4.
5.
6. 7.
B.
Qualifications 1. Supplier shall provide an experienced project team of personnel who are working under direct supervision of a full time project manager, supported by a full time engineering manager, who carries total responsibility for all aspects of the work. All key people shall be subject to approval of the Buyer. Supplier shall supply, on request, the current qualifications and experience of the following personnel on staff or with sub-suppliers; project manager, design engineers, quality control engineers, and field erection representatives.
2.
1.6
Site Conditions A. Environmental Requirements 1. Non-shrink Cement Based Grout Maintain temperature of foundation, base plate and grout between 4 degrees C (40 degrees F) and 32 degrees C (90 degrees F), as measured by surface thermometer, during grouting and for a minimum of 24 hours following grouting and until grout has reached minimum compressive strength. 2. Non-shrink Epoxy Grout Condition grout components to a temperature between 21 degrees C (70 degrees F) and 27 degrees C (80 degrees F) before mixing. During grouting and for at least 24 hours following grouting, maintain temperature of foundation, base plate, and grout between 15 degrees C (60 degrees F) and 32 degrees C (90 degrees F), as measured by surface thermometer. 3. No grouting shall be installed at temperatures below 4 degrees C (40 degrees F), unless work is protected and artificial heat is applied during and for 3 days after grouting.
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GROUT CONSTRUCTION SPECIFICATION 2. PRODUCTS 2.1 Product Delivery and Handling A. Delivery 1. 2. 3. 4. B. Deliver manufactured grouts in manufacturer's packaging including installation instructions. Deliver non-shrink cement based grout in sound, dry packages. Deliver epoxy grout hardener and resin in sealed, pre-measured containers. Deliver grout aggregate in sound, dry packages.
Storage and Handling 1. 2. 3. 4. 5. Store manufactured grouts in accordance with the manufacturer's printed instructions. Store non-shrink cement based grout, cement, and cementitious materials in accordance with ACI 304R. Do not store manufactured grouts for more than six (6) months, or the period of time recommended by manufacturer. Do not store cement based manufactured grouts at a temperature below 4 degrees C (40 degrees F) or above 32 degrees C (90 degree F). Do not store epoxy hardener and resin at a temperature below 15 degrees (60 degrees F) or above 32 degrees C (90 degrees F).
2.2
Materials A. Non-shrink Cement Based Grout Premixed, pre-proportioned, factory packaged product consisting of a mixture of cement, sand, and inert materials. B. Non-shrink Epoxy Grout Pre-proportioned, factory packaged product consisting of specially formulated resin, hardener, and aggregate. When mixed together, the components form a pourable, 100 percent solids grout. C. Mixing Water Mixing water shall be potable and free of oils, acids, alkalines, organics, and other deleterious materials.
2.3
Equipment and Components A. Grout Mixer Mortar mixer with moving paddles inside a drum; do not use concrete mixer with fins attached to rotating drum. B. Grout Pump Positive displacement type such as diaphragm or piston pump; screw pump not acceptable. C. Cleaning Clean mixing equipment and tools to ensure they are free from dirt, oil, grease, grout reside, or other deleterious materials.
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GROUT CONSTRUCTION SPECIFICATION 2.4 Design Criteria Observe the following guidelines for epoxy grout installations in order to minimize creep and edge curling: A. B. 2.5 Total equipment weight plus total bolt torque load divided by surface area of grout does not exceed 3.45 MPa (500 psi). Projection of grout bed beyond edge of bearing plate is less than thickness of grout bed.
Mixes All grout shall be mixed strictly in accordance with manufacturers recommendations.
2.6
Inspection and Tests Confirm that manufactured grouts meet performance requirements, Section 1.3, when tested according to ASTM C109 and CRD C621.
2.7
Identification and Tagging Manufactured grouts shall be factory packaged in bags or containers clearly marked to identify components and with printed manufacturer's mixing and installation procedures listed.
2.8
Surface Preparation and Finish Refer to Section 1.1.C Related Documents.
2.9
Preparation for Shipment Refer to Section 1.1.C Related Documents.
3.
EXECUTION 3.1 Examination A. B. C. D. E. F. G. H. I. Verify that concrete surfaces are free from ice, frost, dirt, grease, oil, curing compounds, paints, impregnations, and loose material or foreign matter likely to affect bond or performance of grout. Verify that newly placed concrete has cured sufficiently to attain design strength, typically 3 to 7 days, prior to surface preparation. Verify that foundation surfaces to be grouted are level within 1/2 of an inch. Verify that concrete surfaces to receive cement based grouts are wet. Verify that base plates are free from rust, oil, and other deleterious substances; tightly bonded paint is acceptable. Verify that concrete surfaces to receive non-shrink epoxy grouts are dry. Verify that required foundation plates are set to proper elevations. Verify that cement based grout materials are not damp and have not air set; discard damp or air set materials. Verify that non-shrink epoxy grout resin has not crystallized; discard crystallized material.
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GROUT CONSTRUCTION SPECIFICATION 3.2 Preparation A. Cement Based Grouts 1. Concrete Surfaces a. b. Concrete foundations shall be cured for 7 days minimum before surface preparation. Roughen surface by chipping, sandblasting, or other mechanical means to produce a fractured aggregate profile and to assure bond of grout to all concrete surfaces. Final concrete surfaces shall be level within 12 mm (1/2 inch). Remove oil soaked concrete, loose or broken concrete, or concrete with hairline cracks down to solid concrete. Finished surfaces must be firm and rough. Wash surface clean; saturate with water for at least 24 hours before placement of grout. Just before grouting, remove excess water with clean compressed air, leaving surface damp; remove water from anchor bolt sleeves. Place watertight forms as needed.
c. d. e. f. 2.
Metal Surfaces in Contact with Grout Clean foundation plates to remove dirt, oil, grease, or loose paint; tightly adhered paint is acceptable.
3.
Foundation and Leveling Plates a. b. Set leveling plates to the proper elevation. Set, align, and firmly anchor foundation plates before grout is placed.
4.
Formwork a. b. Provide formwork as needed for non-shrink cement based grout. Design forms for rapid, continuous, and complete filling of space to be grouted. Forms shall be strong, securely anchored, and shored. Caulk or seal to prevent excessive leakage. For fluid or flowable grouts, design forms to be at least 25 mm (1 inch) clear of base plate or equipment base and top of form to be at least 25 mm (1 inch) above bottom of adjacent base plate or higher ,as required to achieve enough head for grout to flow across width of plate. Attach chamfer strip to forms where chamfered edge is required. Install vent holes in areas where air pockets may form during grouting; minimum diameter 3 mm (1/8 of an inch). Coat forms with form oil or heavy wax consistent with manufacturers recommendation to prevent grout adherence and absorption. Firmly anchor forms in place.
c.
d. e. f. 5.
Anchor Bolts and Sleeves Clean anchor bolt block-outs and sleeves to remove deleterious materials.
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GROUT CONSTRUCTION SPECIFICATION B. Non-shrink Epoxy Grout 1. Concrete Surfaces a. Concrete foundations shall be at least 7 days old before surface preparation. Concrete shall be fully cured and dry before surface preparation. Dryness shall be verified by testing the surface in accordance with ASTM D4263. Roughen surface by chipping, sandblasting, or other mechanical means to produce a fractured aggregate profile and to assure bond of grout to all concrete surfaces. Final concrete surfaces shall be level within 12 mm (1/2 inch). Remove oil soaked concrete, loose, or broken concrete, or concrete with hairline cracks down to solid concrete. Finished surfaces must be firm and rough. Clean surface using dry compressed air or dry brush; remove debris from anchor bolt sleeves using dry oil-free compressed air. Place liquid tight, leak-proof forms for grout. Place control joints and reinforcing bars as needed.
b.
c. d. e. f. 2.
Metal Surfaces in Contact with Grout a. Metal surfaces in contact with epoxy grout shall either be sandblasted to SSPC-6 grade just prior to grouting or have an epoxy primer coating compatible with the proposed epoxy grout. Prepare equipment surfaces to be in contact with non-shrink epoxy grout in accordance with recommendations of the grout manufacturer just prior to grouting.
b. 3.
Foundation and Leveling Plates a. b. c. d. e. f. g. h. i. When bond is not desired between epoxy grout and plates, apply paste wax to clean plate, allow to dry and buff. Set leveling plates to the proper elevation. Set, align, and firmly anchor foundation plates before grout is placed. Determine need to remove or retain shims subject to the equipment manufacturer's instructions. For epoxy grouts with a flow greater than 145 percent, provide 13 mm (1/2 inch) minimum clearance below and around plates. For epoxy grouts with a flow less than 145 percent, provide 38 mm (1-1/2 inch) minimum clearance below and around plates. For base plates wider than 915 mm (3 feet), provide an additional 25 mm (1 inch) of clearance for each additional 915 mm (3 feet) of width. For shims, wedges, or blocks to be removed, coat with paste wax to prevent grout from adhering. For grout pours deeper than 4 inches, provide reinforcing bars as shown on drawings.
4.
Formwork a. Design forms for rapid, continuous, and complete filling of space to be grouted. Forms shall be strong, securely anchored, and shored. Caulk or seal to prevent excessive grout leakage.
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GROUT CONSTRUCTION SPECIFICATION b. Design forms to be at least 25 mm (1 inch) clear of base plate or equipment base; top of form to be at least 50 mm (2 inches) above bottom of adjacent base plate or higher, as required to achieve enough head for grout to flow across width of plate. Attach chamfer strip to forms where chamfered edge is required. Install vent holes in areas where air pockets may form during grouting; minimum diameter 3 mm (1/8 of an inch). Coat forms with heavy wax or use other methods as recommended by the epoxy grout manufacturer to prevent grout adherence and absorption. Firmly anchor forms in place.
c. d. e. 5.
Control Joints and Reinforcement a. b. c. d. e. f. Place joints on 915 mm to 1,220 mm (3 feet to 4feet) centers; extend joints full depth and full length from form to form. Control joint shall not be placed under base plates. Joint Thickness Thickness to be 6 mm (1/4 of an inch) Joint Material Closed cell styrofoam, thick rubber, or wood strips covered with polyethylene tape Provide reinforcing bars for pours 100 mm (4 inches) or deeper as shown on drawings.
6.
Cold Weather a. b. Keep temperature of surfaces to be in contact with grout at or above 10 degrees C (50 degrees F) for at least 24 hours before grouting. Keep temperature of grout components between 21 degrees C (70 degrees F) and 27 degrees C (80 degrees F) right up until mixing and grouting.
7.
Hot Weather a. b. Use shading or conditioning to keep temperature of base plates below 32 degrees C (90 degrees F); surface must be kept absolutely dry. Protect concrete, steel, and forms from direct sunlight beginning at least 24 hours before grouting.
8.
Adjacent Surfaces Apply wax or oil, or protect with polyethylene sheeting so that grout splatters or over pour shall not adhere.
9.
Anchor Bolts and Sleeves Clean anchor bolt blockouts and sleeves to remove deleterious materials. Prior to grouting, anchor bolt sleeves shall be filled with a non-bonding fill material.
10.
Deep Pours and Extreme Temperatures Consult manufacturer's technical department for recommendations for extremely deep pours or extreme temperature conditions.
C.
Mixing Equipment Clean mixing equipment and tools to ensure they are free from oil, dirt, grease, grout residue, or other deleterious substances.
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GROUT CONSTRUCTION SPECIFICATION D. Instructions Carefully read and understand manufacturer's instructions as supplied with grout before starting. 3.3 Installation A. Precautions 1. Vibrations from nearby operations can be transmitted into foundations being grouted. These vibrations cause bleeding and settlement, affects setting time and strength, or creates hidden fracture planes. Observe surface of a shallow pan of water set on foundation being grouted to detect vibration. Shutdown nearby operations if vibrations are detected until grout has taken final set.
2. 3. B.
Cement Based Grouts 1. Mixing a. b. c. d. e. f. g. Use a mortar mixer. Do not use a concrete mixer. Mix grout adjacent to area being grouted; have sufficient manpower and equipment to mix and place grout rapidly and continuously. Mixing equipment must be free from oil, dirt, grease, leftover grout, and other deleterious substances; discard leftover grout from previous batch. Wash out mixer with clean water; empty out water, leaving mixer wet. Mix only that quantity of grout that can be placed within the working time of the grout. Do not add admixtures or ingredients not specified or included with manufactured grout. Add dry grout components to mixer and dry mix; add pre-measured amount of potable water to mixer; mix grout for no less than three (3) or more than five (5) minutes; place grout immediately.
2.
Placing a. b. c. d. e. f. Grout may be flowed, or pumped into place. Place grout within the working time of the grout; discard grout that is not placed within working time of grout. Re-tempering of grout is not allowed. Place grout quickly and continuously to avoid segregation, bleeding, or premature initial set. Do not place grout in layers. Place grout from one (1) side of plate to the other to avoid trapping air. Place grout from one (1) long side of equipment base to the other, in one(1) direction only. If grout must be placed through grout holes, place from one (1) hole continuously until grout has passed a second hole. Maintain a liquid head pressure at the first access hole until a head pressure has been established at the next hole. Continue placing grout from next grout hole in similar fashion. Flowable Grouting (1) Use moveable head box having an inclined plane to direct grout beneath equipment base in a manner to minimize trapped air and bubble formation.
g.
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GROUT CONSTRUCTION SPECIFICATION (2) (3) h. For placing large volumes of grout continuously, use head box with a minimum of 0.085 cubic meter (3 cubic foot) volume. Fill head box to top and plunge grout down to top of base plate; continue until grout rises above bottom of base plate on far side.
Pumping Grout (1) Use on large installations and multiple installations; for bases with shear keys, stiffeners, or other obstructions; for grouting over great distances; or if venting air is not possible. Rinse pump, hose, and nozzle with water; wash cleansing plug through line to ensure it is clear; pump grout slurry through before starting. Start grouting at far end of space to be grouted; slowly back out nozzle so that it is always within the grout to prevent air entrapment. Continue placing grout until grout oozes out along entire perimeter and up through every interior vent hole and grout hole.
(2) (3) (4) i.
Equipment with Elevated Interior Plate (1) (2) Grout under entire equipment base to top of exterior plate. Continue placing grout until grout oozes up through every interior vent hole and grout hole.
3.
Finishing a. b. Cutback to lower edge of plate, just before grout has reached final set. A 45 degree angle cutback is preferred; a vertical cutback is acceptable.
4.
Curing a. b. c. Keep forms in place for at least 24 hours for flowable grouts. Keep grout moist for at least 3 days and protect from rapid drying. Cure grout according to manufacturer's recommendations on package, or in their latest specification or literature.
C.
Non-shrink Epoxy Grout 1. Mixing a. Condition grout components to a temperature between 21 degrees C (70 degrees F) and 27 degrees C (80 degrees F) before mixing. Do not use a concrete mixer. Use a mortar mixer for large volume placement. A mortar mixer has rubber edged rotating blades which lift the material during mixing and facilitate good flow. Mix grout according to manufacturer's instructions. Use only the pre-measured components supplied; do not add solvent to change mix consistency. During hot weather, do not allow mixed resin and hardener to remain without aggregate for more than 5 minutes. Mix only that quantity of grout that can be placed within working time of the grout.
b. c. d. e.
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GROUT CONSTRUCTION SPECIFICATION 2. Placing a. Check ambient temperature; for temperatures below 4 degrees C (40 degrees F), or above 32 degrees C (90 degrees F), refer to manufacturer's mixing and placement procedures for cold weather or hot weather requirements. During grouting and for at least 24 hours following grouting, maintain temperature of foundation and base plate between 4 degrees C (40 degrees F) and 32 degrees C (90 degrees F), as measured by surface thermometer and until grout has reached minimum compressive strength. Place grout within the working time of the grout; temperature shall affect working time of epoxy grout; discard grout that is not placed within working time of the grout. During hot weather, place grout in the evening or later, when the temperature is dropping. Place grout quickly and continuously to avoid cold joints and voids under base plate. Place grout from one (1) side of plate to the other to avoid trapping air. Place grout from one (1) long side of equipment base to the other, in one (1) direction only. If grout must be placed through grout holes, place from one hole continuously until grout has passed second hole; continue placing grout from next grout hole in similar fashion. After the baseplate is full, six inch high stand pipes shall be maintained over each grout hole to continue the purging of air. Once the grout has started to take an initial set (determined by an increase in grout temperature and no flow of grout at the vent holes) the standpipes can be removed and excess grout cleaned from all surfaces. Check for leaks constantly; seal leaks immediately to prevent voids. Flowable Grouting (1) (2) (3) (4) (5) j. Use moveable head box having an inclined plane to direct grout beneath equipment base in a manner to minimize trapped air and bubble formation. Use for placing large volumes of grout continuously. Use head box with minimum .085 cubic meter (3 cubic foot) volume. Fill head box to top and plunge grout down to top of base plate; continue until grout rises above bottom of base plate on far side. Always keep surface of grout in head box above top of base plate to prevent trapping air.
b. c. d. e. f. g.
h. i.
Equipment with Elevated Interior Plate (1) (2) Grout under entire equipment base to top of exterior plate. Continue placing grout until grout oozes up through every interior vent hole and grout hole.
3.
Finishing Follow manufacturer's recommendations for finishing grout surfaces.
4.
Curing a. b. Cure grout according to manufacturer's instructions. Do not moist cure epoxy grout.
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GROUT CONSTRUCTION SPECIFICATION c. d. 3.4 Keep forms in place overnight except for fast curing grouts. Keep temperature of base plate, foundation, and grout between 10 degrees C (50 degrees F) and 32 degrees C (90 degrees F) for at least 24 hours after placing grout.
Field Quality Control A. Technical Services 1. 2. 3. 4. B. Before grouting with manufactured grout, call manufacturer's technical representative to pre-grouting conference at the job site. Review grouting steps and manufacturer's instructions with those who shall actually be doing the grouting. Have representative remain at worksite as long as required to ensure correct procedures are being used and that manufacturer's warranty is not in jeopardy. Advise Engineer if representative recommends materials or procedures contrary to this specification.
Cement Based Grouts 1. 2. 3. Make two (2) sets of three (3) test cubes in the field for each batch of grout mixed and placed. Make test cubes according to applicable provisions of ASTM C109. Cure cubes in the field for 3 days in the same way as the placed grout is cured; after 3 days transport cubes to testing lab for compressive strength testing. Do compressive strength tests on cubes according to applicable provisions of ASTM C109; test one set at 7 days, and the other set at 28 days.
C.
Non-shrink Epoxy Grout 1. 2. 3. Make two (2) sets of three (3) test cubes in the field for each batch of grout mixed and placed. Make test cubes according to applicable provisions of ASTM C579, Method B. Cure cubes in the field for 3 days in the same way the placed grout is cured; after 3 days, transport cubes to testing lab for compressive strength testing. Do compressive strength tests on cubes according to applicable provisions of ASTM C579, Method B; test one set at 3 days, and the other set at 7 days.
D. 3.5
Submit written reports on each test as soon as results are available.
Adjustment and Cleaning A. Cement Based Grouts 1. 2. 3. B. Wash mixing equipment and tools with water before grout residue hardens. Rinse pump and hoses with water to remove grout immediately after grouting is complete. Remove grout splatters from adjacent Work.
Non-shrink Epoxy Grouts 1. 2. 3. As soon as grouting is complete, or if delays occur, clean mixing equipment and tools with solvent Be extremely cautious when using volatile solvents around powered equipment or open flame. Remove grout splatters from adjacent work.
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GROUT CONSTRUCTION SPECIFICATION 3.6 Protection A. Cold Weather Keep temperature of grout, plate, and foundation above specified temperature for specified curing time. B. Hot Weather Keep grout, plate, and foundation shaded and cool for specified curing time. 4. ATTACHMENTS Not applicable.
End of Specification
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SOCIEDAD MINERA CERRO VERDE S.A.A.

CERRO VERDE PRODUCTION UNIT EXPANSION

PROJECT NO. A6CV

GROUT CONSTRUCTION SPECIFICATION

DOCUMENT NO. 240K-C2-CS-15-012 REV. C

Document No. 240K-C2-CS-15-012 Revision C

GROUT CONSTRUCTION SPECIFICATION

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Document No. 240K-C2-CS-15-012 Revision C

Document No. 240K-C2-CS-15-012 Revision C

GROUT CONSTRUCTION SPECIFICATION

This page is intentionally blank.

Document No. 240K-C2-CS-15-012 Revision C

GROUT CONSTRUCTION SPECIFICATION

Document No. 240K-C2-CS-15-012 Revision C

C579 C827 C882 C1090 C1107 C1181 C1399 D4263 CRD

Corps of Engineers C621 Specification for Non-shrink Grout

Document No. 240K-C2-CS-15-012 Revision C

Document No. 240K-C2-CS-15-012 Revision C

Document No. 240K-C2-CS-15-012 Revision C

Document No. 240K-C2-CS-15-012 Revision C

Document No. 240K-C2-CS-15-012 Revision C

Surface Preparation and Finish Refer to Section 1.1.C Related Documents.

Preparation for Shipment Refer to Section 1.1.C Related Documents.

Document No. 240K-C2-CS-15-012 Revision C

Document No. 240K-C2-CS-15-012 Revision C

Document No. 240K-C2-CS-15-012 Revision C

Document No. 240K-C2-CS-15-012 Revision C

Document No. 240K-C2-CS-15-012 Revision C

(2) (3) (4) i.

Document No. 240K-C2-CS-15-012 Revision C

Finishing Follow manufacturer's recommendations for finishing grout surfaces.

Document No. 240K-C2-CS-15-012 Revision C

Submit written reports on each test as soon as results are available.

Document No. 240K-C2-CS-15-012 Revision C

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