GIW Technical Series

GROUTING

GIW Slurry pumps are designed to handle the variety of severe load conditions found in normal
hydrotransport operations. Rigid attachment of the pump assembly to the foundation is critical for
alignment, reduced vibration and reliability. Anchor bolts and shims provide solid clamping while
grouting makes the pump base and foundation monolithic to reduce the natural frequency of the pump
assembly. The design specifications, methods and grout material should be selected by the end user and
the contractor to comply with equipment requirements and local codes. Note that this information is
provided as general information and reference only. GIW does not specify grout or processes.
In the past, cement grouts were used, but poor bond and shrinkage often required pressure injection to
eliminate voids. Epoxy grout addresses these issues, provided that the foundation and pump base are
properly prepared. One of the most important factors is the compatibility of any grout with the concrete
foundation and steel base materials. Temperature changes must be accounted for in material choice to
eliminate stresses caused by different expansion rates.
Grouting procedures outlined here are intended as an overview. The contractor should work with the grout
manufacturer to define the correct material and installation specifications for the job. This includes
preparation of foundation and metal base surfaces, rebar, required grout thickness between the base and
foundation, as well as installation methods and temperature constraints.
The gap between the nominal foundation surface and the bottom of the pump base must be defined by the
contractor. This height will vary depending on the type of installation and the grouting material being
used. The distance from the pour point to the form under a solid surface or plate is another factor. With
fluid epoxy grout, the gap is usually 1" to 1-1/2" but will increase when using flowable epoxy or cement
depending on base size and temperature. A rule of thumb is 2” for the first 2 feet, plus ½” of gap per foot
of distance. Colder pour temperatures require an increased gap to allow proper flow. Instructions are
available from grout manufacturers. GIW sub-bases are designed with open I-beam construction to
simplify the grouting process.
The concrete foundation should be properly cured and then chipped to provide a good surface profile for
the grout. It may be necessary to provide a structure over the area to protect the foundation from direct
sunlight and maintain the temperature range required for proper curing.
The pump base should be free from grease, dirt and loose paint when it is grouted. Add any additional
grout or vent holes, and install the leveling screws or jack bolts. If the underside of the base is sandblasted
to "white metal" condition it should be coated with an approved primer to prevent surface rust.
Use a round pad under each jack bolt, typically made from 1/2" thick steel plate with a minimum diameter
of 2", or three times the diameter of the bolt. This provides a bearing area to prevent the jack bolt from
digging into the concrete during leveling. The pads can be secured in place or merely inserted under the
bolt. After the pump base is leveled and the anchor bolts and shims are in place, install grout forms. These
are typically constructed of 3/4" plywood braced with 2" x 4" lumber and waxed to prevent bonding of
the grout to the forms. These forms should be liquid tight and sealed with a good caulking material. All
inside right angles (90°) should be chamfered to a minimum of 1" to 2" to prevent stress concentrations.
The area should be stabilized at the required cure temperature for at least 48 hours prior to and after
grouting. Once the grout is fully cured, the forms are removed and the equipment is installed and aligned.

TECH Grouting 2007-11-15.doc