Professional Documents
Culture Documents
CONSTRUCTION Rev. : 12
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REVISION INDEX
TABLE OF CONTENTS
7.0 DOCUMENTATION................................................................................................................. 7
1.0 GENERAL
1.1 Scope
This Project Specification describes the technical requirements for supplying and installing
cement-based non-shrink grout and epoxy grout.
1.2 Purpose
This Project Specification is for supply and installation of grouts for use between applied
loads (such as foundation plates) and foundations in accordance with the design drawings,
approved erection drawings, and this specification. Grouting refers to all work carried out to
fill the space between concrete surfaces and foundation plates, machinery, steel structures,
or concrete prefabricated elements, in order to achieve adequate transfer of horizontal and
vertical forces.
This Project Specification does not cover grouts for grouting post-installed anchor bolts and
reinforcement bar, masonry, prestressing tendons, concrete repair, waterproofing, or
geotechnical use.
1.3 Definitions
For the purposes of this Project Specification, the following definitions shall apply:
General Definitions:
CONCESSION REQUEST - A deviation requested by the CONTRACTOR,
SUBCONTRACTOR or VENDOR, usually after receiving the contract package or purchase
order. Often, it refers to an authorization to use, repair, recondition, reclaim, or release
materials already in progress or completely furnished or installed but does not meet or
comply with COMPANY requirements. A CONCESSION REQUEST is subject to
COMPANY approval.
COMPANY – Egyptian Refining Company S.A.E.
CONTRACTOR –GS E & C to which COMPANY awarded the Engineering, Procurement
and Construction (EPC) phase of the ERC Refinery Project.
MANUFACTURER/VENDOR – The party that manufactures and/or supplies grouting
materials to perform grouting duties as specified by the CONTRACTOR.
SHALL - Indicates a mandatory requirement.
SHOULD - Use of the word “should” indicate a strong recommendation to comply with the
requirements of this document.
Specific Definitions:
FOUNDATION PLATES — Refers to column base plates and equipment bed plates or sole
plates that are installed on concrete foundations.
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ASTM C939 Standard Test Method for Time of Setting of Grouts for Pre-
placed Aggregate Concrete in the Laboratory.
ASTM C953 Standard Test Method for Setting of Grouts for Preplaced -
Aggregate Concrete in the Laboratory
ASTM C1339 Standard Test Method for Flowability and Bearing Area of
Chemical-Resistant Polymer Machinery Grouts
7.0 DOCUMENTATION
CONTRACTOR shall submit to COMPANY, CONTRACTOR’S documentation
confirming compliance with relevant Codes and Standards for all materials, prior to
commencement of grouting.
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9.0 HANDLING
12 Cement grout materials which have become damp or airset shall not be used.
10.0 SUBMITTALS
The SUB CONTRACTOR/CONTRACTOR shall submit the brand of grout proposed
indicating the physical characteristics as well as copies of laboratory test reports. Test
reports shall include all test data certifying that the selected product will produce grouts of
the qualities specified herein. These certification documents shall be forwarded to the
COMPANY for review and authorization to proceed.
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The SUB CONTRACTOR/CONTRACTOR shall certify that the grout provided conforms
to the test report submitted with its bid.
Test reports shall be submitted in accordance with and shall meet the requirements of ASTM
C1107, Section 12.0.
13.1 Material
13.1.2 Performance certifications for each batch shall be made available for review by COMPANY
in advance of the grout application. Furnish all the test results and physical characteristics of
the products.
13.2.2 The finished product shall result from adding a specified amount of potable water to a
premixed bag. The grout shall pass through a flow cone per ASTM C 939 (fluid
consistency) at 27 seconds + 3 seconds. The grout shall pass through flow cone 45 minutes
after initial mixing without the addition of water.
13.3 Work Prior To Setting Base plates Or Equipment
13.3.1 Concrete foundations shall be at least seven days old prior to surface preparation.
13.3.2 The surface of the foundation under the base plate or equipment to be grouted shall be
chipped and brushed to remove the weak upper layer of laitance, damaged concrete,
dislodged aggregates and any foreign or deleterious material spots. Prior to grouting, loose
concrete or dust shall be removed, preferably by compressed air. After cleaning, the
foundation surface shall be tightly covered to keep it dust and oil free.
13.3.3 Before grouting commences, the concrete surfaces shall be soaked with clean water. Just
prior to grouting, the water shall be removed leaving only a damp film. All standing water
shall be removed from anchor bolt sleeves.
13.3.4 All leveling plates shall be set to the proper elevation. The number and type of leveling
plates will be determined by the CONTRACTOR’S representative in accordance with the
recommendations of the equipment MANUFACTURER or other project documents.
13.3.5 All jackscrews must rest on a steel plate embedded in or grouted to the concrete and not on
the concrete.
13.3.6 Base plates and equipment bases must be uniformly supported prior to grouting in order to
eliminate sag and distortion. Equipment bases should be leveled using both anchor bolts and
jackscrews, as equipment bases sometimes twist in shipment. Caution must be exercised to
avoid introducing pipe stress and misalignment.
13.3.7 Metal surfaces in contact with the grout shall be clean and free of oil, grease, and other
foreign substances.
13.4 Mixing
13.4.1 Cement-based grout shall be mixed in a mortar mixer with moving paddles inside a drum,
not in a concrete mixer with fins attached to a rotating drum.
13.4.2 All mixing equipment shall be free of oil, grease, and other foreign substances. The mixer
shall be washed out and excess water poured out before mixing any grout. Before mixing a
batch of grout, any remaining grout from the preceding batch shall be washed out. Re-
tempering of leftover grout is not allowed.
13.4.3 Mixing shall be adjacent to the area being grouted, with sufficient manpower and
requipment available for rapid and continuous mixing and placing. Mix materials for 3 to 5
minutes until uniform consistency is reached and place immediately.
13.4.4 Grout shall not be mixed in quantities larger than that which can be placed during the
working time specified herein.
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13.4.5 All grout mortar shall be machine mixed to an even consistency. Under no circumstances
shall hand mixing be employed.
13.4.6 Mixing of Grout Materials shall be in strict compliance with MANUFACTURERS printed
instructions.
13.5 Placing
13.5.1 Cement-based non-shrink grout has a limited working time after mixing. This working time
shall be in strict accordance with the MANUFACTURERS printed instruction. Sixty
minutes working time is recommended to avoid rushing the grout placement and frequent
cleaning of equipment. The placing of grout shall be performed only during this specified
working time and any unused grout remaining beyond this time shall be discarded. Place the
grout quickly and continuously to avoid segregation, bleeding, or premature initial set.
13.5.2 When placing cement-based grout, the temperature of the foundation, base plate, and grout
material shall be within the temperature range of 4 to 35 as determined by a surface
thermometer. Maintain this temperature range for 3 days following grouting.
13.5.3 The grouting shall fill all voids between the base plate or equipment base and the foundation
and shall have full surface contact.
Grouting should be extended 25mm past the edge of the base plate and restrained on all four
sides by the formwork. Finished top surface shall slope away from the base plate (approx.
1:25).
Exposed cement-based grout surfaces shall be coated (with an epoxy based product) if future
contamination with lubricants is possible.
13.5.4 Cement-based non-shrink grout shall be placed from one long side of rectangular shape
equipment base or 90, 180, 270, 360 degree of circular shape equipment base to the other in
12 one direction only. The grout shall be poured into a movable head box having an inclined
lane to direct the grout beneath the equipment base in a manner which minimizes trapped air
and bubble formation. The head box should be about 300 x 300 x 300 mm to allow large
volumes of grout to be poured continuously. Alternatively, construct a fixed slanted form
extending about 300 mm above the foundation top along the pour side. The use of vibrators
is not permitted. The use of steel straps is permitted to move grout into position, but
chaining is not permitted because of air entrapment between links.
13.5.5 Pumping grout is permitted and may eliminate the requirement for a head box.
13.5.6 Grout placing shall be continued until it oozes out along the entire perimeter and up through
every interior air relief hole (6 mm minimum diameter) and grout hole. An exception occurs
when grouting such equipment as pumps having an elevated interior base plate. In these
situations, fill under the entire equipment base to the top of the exterior base plate and then
stop grouting for a short period of time to allow the grout to seal the periphery. Complete
the grouting through one of the interior grout holes.
13.5.7 Vertical support for equipment having a structural steel base frame and a stiffened cover
plate is provided by grouting under the base frame. Compliance with the installation
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procedure established herein will preclude unacceptable voids. Incidental voids under the
cover plate are not detrimental. It is important that the cover plate be sealed by grout against
foreign elements.
13.5.8 Vibration from nearby operations can be transmitted into the foundation of the structure
being grouted. It can cause bleeding, settlement, affect setting time, strength, or create a
hidden fracture plane. Vibration can be detected by observing the surface of a shallow pan
of water set on the structure to be grouted. The CONTRACTOR’S representative shall
determine if vibration from nearby operations warrants shutdown of such operations until
the grout has taken its final set.
13.5.9 Shims under steel structure and equipment shall be used as per approved DWG, of a
machined type, and need not be removed.
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The shim that has to be placed on compressor, pump etc.. foundation shall be embedded in a
mortar bed such that the top of the shim is level in all planes.
Shim plates shall be installed in such a manner that they are fully embedded in/surrounded
by the grout to be installed later; minimum cover to shim sides 25 mm.
Load per shim pack shall not exceed 7 N/mm2 under the worst loading condition. In this
case, the grout shall be considered as a filling material only when calculating the
aforementioned bearing stress.
13.5.10 Wedges are restricted to minor steel structures and shall be removed.
13.6.1 Finishing and curing shall be in strict accordance with the MANUFACTURER’S printed
instructions.
13.6.2 Cement-based non-shrink grout shall be protected from extreme drying conditions by
covering all exposed grout surfaces with continually wetted burlap or waterproof paper for a
minimum of 3 days following grouting.
14.1 Material
14.1.1 Non-shrink epoxy grout shall be a pre-proportioned, factory packaged product consisting of
specially formulated resin, hardener, and aggregate.
14.1.2 Performance certifications for each batch, as well as all the test results and physical
characteristics of the products, shall be made available for review by COMPANY in
advance of the grout application.
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14.2.1 The minimum compressive strength shall be 96 Mpa at 7 days when tested using 50 mm
cube specimens in accordance with ASTM C 579 Method B.
14.3.1 Concrete foundations shall be at least seven days old prior to surface preparation.
14.3.2 It shall be ensured that the foundation under the base plate is free of dirt, dust, oil, or grease
and properly roughened or chipped to remove the weak upper layer of concrete, damaged
concrete, and any oil-soaked concrete areas. At least 25 mm between base plate and
foundation top shall be allowed for grouting. When using leveling spindles or jack screws,
the clearance shall be at least 50 mm. Different grout thicknesses produce varying
exothermic reactions, which shall be considered in installation details and procedures.
14.3.4 Concrete surfaces, on which epoxy grout is to be placed, shall be completely dry before
grouting.
14.3.5 For vibrating equipment that is to be epoxy grouted, foundation bolt sleeves or pockets shall
be filled with cement-based non-shrink grout, after the foundation concrete has set, prior to
grouting the base plate.
14.3.6 Metal parts that should not bond to the grout (like jack screws of reciprocating machinery
and parts of the foundation bolts) are to be sealed with tape or grease prior to grouting.
14.3.7 The voids in the bases of all rotating and vibrating equipment shall be filled with cement-
based non-shrink grout through grout holes in the bases after the grout under the bottom of
skids or baseplates is hardened. The grout and vent holes shall then be sealed to encapsulate
the concrete and the equipment bases.
14.4 Mixing
14.4.1 All epoxy grout components shall be conditioned to a temperature range between 10°C to
29°C prior to mixing. Hot weather applications shall be in accordance with
MANUFACTURER’S recommendations. The hardener and resin components shall be
mixed in strict accordance with the MANUFACTURER’S printed instructions. Mixed resin
and hardener shall then be put into a clean low speed mortar mixer and the specified
aggregate added. Mix only until aggregate is completely wetted. Nothing else shall be
added to the mixture. Air entrainment must be avoided.
14.4.2 Mixing shall be adjacent to the area being grouted, with sufficient manpower and equipment
available for rapid and continuous mixing and placing.
14.4.3 Grout shall not be mixed in quantities larger than that which can be placed during the
working time specified herein.
14.5 Placing
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14.5.1 Epoxy grout has a limited working time after mixing. This working time shall be in strict
accordance with the MANUFACTURER’S printed recommendation. Placing of grout shall
be performed only during this specified working time and any unused grout remaining
beyond this time shall be discarded.
14.5.2 When placing epoxy grout, the temperature of the foundation, base plate and grout material
shall be between 10°C and 32°C.
14.5.3 Epoxy grout shall be placed from one long side of an equipment base to the other, in one
direction only. The grout shall be poured into a movable head box having an inclined plane
to direct the grout beneath the equipment base in a manner which minimizes trapped air and
bubble formation. The head box should be about 300 x 300 x 300 mm to allow large
volumes of grout to be poured continuously. Use of vibrators is not permitted. Use of steel
straps to move grout into position is permitted but chaining is not permitted because of air
entrapment between the links.
14.5.4 Epoxy grout placing shall be continued until it oozes out along the entire perimeter and up
through every interior air relief hole and grout hole.
14.5.5 Do not place grout in multiple lifts or layers without consulting with MANUFACTURER’S
representative for written procedures.
14.5.6 Expansion joints for epoxy grout of machinery shall not be placed. Unless otherwise
specified in the mechanical vendor drawings.
14.5.7 Shims under steel structure and equipment shall use as per approved DWG, of a machined
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type, and need not be removed.
The shim that has to be placed on the foundation shall be embedded in a mortar bed such that
the top of the shim is level in all planes.
Shim plates shall be installed in such a manner that they are fully embedded in surrounded
by the grout to be installed later; minimum cover to shim sides 25 mm.
Load per shim pack shall not exceed 7 N/mm2 under the worst loading condition. In this
case, the grout shall be considered as a filling material only when calculating the
aforementioned bearing stress.
14.5.8 Wedges are restricted to minor steel structures and shall be removed.
14.6.1 Finishing and curing shall be in strict accordance with the MANUFACTURER’S printed
instructions.
14.6.2 Epoxy grout cannot be trimmed after set. It must be left at the finished level with required
chamfer strips built into the forms. Further finishing will require grinding.
15.2 MANUFACTURER’S technical representative shall be called to the field office for a pre-
grouting conference to assure that all grouting steps are followed in accordance with the
MANUFACTURER’S printed instructions. The technical representative shall remain at the
jobsite until the CONTRACTOR is assured that the correct procedures are being followed
and the warranty is not in jeopardy. CONTRACTOR shall advise COMPANY if the
MANUFACTURER’S technical representative recommends anything contrary to this
specification.