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American Concrete Institute®
Advancing concrete knowledge
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ISBN 978-0-87031-758—3
ACI 351.1 R-12
of blending very small quantities of aluminum powder between the base plate and the foundation. This type of
into the mixture and the sensitivity of the chemical reac- grout has been formulated in both metallic and nonmetallic
tion to temperature and soluble alkalies in the mixture. The grouts and, when done properly, will meet ASTM C1107/
hydrogen gas is highly compressible and can only produce C1107M-ll requirements. Grouts with expansive cement
expansion while the grout is in the plastic state and cannot systems are discussed further in Chapter 4.
create a positive pressure between the base plate and the 3.2.5 Epoxy grout—Since the late 1950s, epoxy grouts
foundation. Therefore, it cannot produce expansion in the have been used under machine and equipment bases. Epoxy
hardened state. Grouts that produce gas as their only method grouts are usually two-component epoxy adhesive systems
of expansion will ultimately shrink as the grout hardens. mixed with oven-dry aggregate. These epoxy grouts are
Aluminum powder grouts are discussed further in Chapter 4. characterized by high strength and adhesion properties.
Other grouts with some metallic additives such as magne- They are also resistant to attack by many chemicals and
sium powders have also been used. are highly resistant to shock and vibratory loads. Epoxy
3.2.2.2 Air-release system—In the late 1960s, a grout grouts have traditionally shown linear shrinkage; however,
was developed that used specially processed fine carbon. manufacturers have various methods to reduce or eliminate
The carbon particles release adsorbed air on contact with shrinkage. Epoxy grouts, when in their development stages
the mixing water and cause an increase in volume while the in the mid 1950s, were primarily commercially available
grout is in the plastic state. The material is less tempera- epoxy resin systems extended with graded silica aggregate.
ture-sensitive than aluminum powder and insensitive to the Such mixtures were quite strong but also brittle, resulting in
alkali content of the cement used. The air-release system is cracking. They were also difficult to place and were incon-
discussed further in Chapter 4. sistent in performance.
3.2.3 Grouts with oxidizing iron aggregate—1n the 19305, Modifications were made to improve and lessen the
an admixture was introduced that contained a graded iron tendency to crack. The modifications resulted in formula-
aggregate combined with a water-reducing retarder, an tions with higher creep values. Modern epoxy mixtures are a
oxidant (or catalyst), and possibly other chemicals. Sufficient compromise between crack and creep reduction.
volume increase to compensate for settlement shrinkage is Epoxy grouts do not have a standard test method devel-
caused by the oxidation of the metallic aggregate during the oped for the purpose of certification as a nonshrink grout.
first few days after hardening when blended in the field with ASTM C1107/C1107M-11 is a standard specification for
cement, fine aggregate, and water. The advantage of metallic cementitious grouts for the purpose of certification as a
catalyzed grout over that of dry-pack grout is that the nonshrink grout.
consistency is more placeable than that of dry-pack grout.
Metallic catalyzed grouts have a plastic consistency that can 3.3—Selection
be placed with a lower void ratio than that of a dry-pack 3.3.1 General—Both cementitious and epoxy grouts
grout. This will produce a grout pad with a greater bearing have limitations that must be considered when specifying a
capacity (load-carrying capability). Metal oxidizing grouts grout for a specific project. Two considerations that must
are discussed further in Chapter 4. be decided on are: l) the type of load that will be applied
Metallic catalyzed grout may initially show some plastic to the base plate; and 2) the operating temperature at which
shrinkage, but if properly designed, the oxidation of the iron the grout must perform. Uenerally speaking, epoxy grouts
will overcome the initial plastic shrinkage. The expansion can perform at temperatures below 130°F (55°C), whereas
that occurs can and will produce a pressure between the cementitious grout can operate at temperatures up to 400°F
underside of the base plate and the foundation. This pressure (200°C).
(expansive force) will offset any drying shrinkage that can Many of today’s commercially available grouts are well—
occur at a later time. balanced, preproportioned formulations that provide excellent
This is old technology and is generally not in use today. machine stability with minimal cracking or creep-related
The principal reason is unsightly rust stains on the shoulders problems. The use of preblended, prepackaged grouts
of the grout, and the unconfined areas of the grout cause the usually results in more consistent and predictable perfor-
shoulder of the grout to break up even when the grout that is mance than can be obtained with field-proportioned epoxy
confined under the base plate is sound. grout. Most manufactures of preblended grout have quality
3.2.4 Grouts with expansive cements—1n the late 19603, control programs that result in the production of a uniform
grouts were developed that use a system or combination product.
of expansive and other hydraulic cements and additives The following are general categories in which cementi-
to compensate for shrinkage. During hydration of these tious and epoxy grouts should be considered. Cementitious
systems, reactions between aluminates and sulfates occur to grouts are the most versatile as far as consistency, ranging
produce ettringite. Because ettringite has a greater volume from dry-pack to fluid. A cementitious grout having a fluid
than the reacting solid ingredients, the volume of the grout consistency will pass through an ASTM C939-10 flow cone
increases. The reaction occurs from the moment mixing in 30 seconds or less. This cementitious grout would be
water is added and continues at a decreasing rate until some- easier to place compared to an epoxy grout.
time after the grout hardens. 1f properly proportioned, it will 3.3.2 Static loading—Cementitious grouts are almost
compensate for shrinkage by inducing a positive pressure always specified for static or near-statically-loaded equip-
of the grout is affected by the temperature, the soluble alkali 0.05%, whereas settlement shrinkage in grout is generally
content of the mixed grout, and the rate of hardening of on the order of 1.0%.
the grout. The restraint provided to the grout as it develops As for most types of grout, those that are based on expan-
strength limits the amount of expansion. sive cements may be affected by temperature, water content,
4.2.3.2 Cementitious grouts with air-release admixtures— and method of curing. Generally, when used for machine
Several admixtures are available to react with water to bases, expansive cement grouts use other mechanisms, such
release air. The released air causes the grout to increase in as thickening agents, to limit the settlement shrinkage to
volume while plastic. The expansion stops when the capa- a small enough value that ettringite formation required to
bility for releasing air is exhausted or the grout has hardened overcome it will not cause disruption of the hardened grout.
sufficiently to restrain the expansion. The most common air- 4.2.3.5 Other mechanisms—Some preblended machine-
releasing material used is a fine carbon. If the proper dosage base grouts are based on proprietary mechanisms for
is used, it will counteract drying shrinkage and allow the compensating for settlement shrinkage. Several preblended
grout to harden in contact with the baseplate. The expansion grouts minimize or eliminate shrinkage by using water
that is produced is somewhat greater than would be needed to reducers, combinations of hydraulic cements, thickening
prevent shrinkage while grout is in plastic state. Because the agents, or all three additives.
grout is vertically confined, expansion in excess of shrinkage 4.2.4 Strength—The strength of a grout must be sufficient
extends the grout laterally. Unlike gas-generating grouts, to transfer all loads to the foundation. The compressive loads
special methods are not needed for blending fine carbon— result primarily from the weight of the machine. They may
based grouts because a much higher portion of admixture also, however, be due to anchor bolt tensioning and static
is used. Fine carbon admixtures are less sensitive than and dynamic forces resulting from equipment operation.
aluminum powder to temperature and are insensitive to the Typically, compressive strengths of cementitious grouts at
chemistry of the mixture. 28 days are between 5000 and 8000 psi (35 and 55 MPa).
4.2.3.3 Cementitious grouts with metal oxidation admix- Because the bond strength of cementitious grout to steel
tures—The addition of metal particles and an oxidant will not is relatively low, the grout is not generally used to transfer
prevent drying shrinkage but is designed to cause a compen- tensile loads to the foundation.
sating increase in volume in the hardened state. The expan- The compressive strength of most cementitious grouts
sion occurs because the oxidation products have a greater develops more rapidly than conventional concrete. For most
volume than the metal particles. The reaction begins after installations using cementitious grouts, the equipment can
the addition of water and the expansion gradually ceases due be placed in service in 3 to 7 days, depending on the design
to the combination of rigid vertical confinement, the hardening strength requirements and the strength-gain characteristics
and strength development of the cement matrix, and the of the grout, which is mostly temperature driven. If high
diminishing supply of moisture and oxygen. bearing loads are expected, however, longer waiting periods
Machine-base grouts that use this mechanism are usually are required.
preblended, which reduces the chance of proportioning 4.2.5 Elastic and inelastic properties—The modulus of
errors. Such proportioning errors could affect the rate of elasticity of cementitious grouts is typically larger than that
expansion. Also, grouts using this mechanism should be of the underlying concrete because of their greater compres—
used only under rigid bolted confinement. Unconfined areas sive strength. The typical modulus is 3000 to 5000 ksi (20
such as exposed shoulders will disintegrate. to 35 GPa).
The equipment baseplate should be rigid to withstand the The creep of cementitious grouts is approximately the
force exerted on the base by the expansion of the grout so same as concrete. The deformation of grout is usually not
that the alignment of the equipment is not affected. These significant due to the relative thickness of the grout as
grouts should not be used on equipment subject to thermal compared to the foundation. The load-deformation char—
movement, such as turbines or compressors, or be placed in acteristics of hydraulic-cement grouts are not significantly
contact with post-tensioned or prestressed cables, rods, or affected by temperatures less than 400°F (200°C).
bolts due to the corrosive potential of the oxidate. 4.2.6 Durability—Most cementitious grouts have good
4.2.3.4 Ettrlngite formation—The use of expansive resistance to freezing and thawing because of their high
cements in grout will result in the expansive formation of strength and impermeability. Their resistance to chemicals
ettringite during the plastic and hardened states. If prop- is usually the same as that of concrete. lf adjacent concrete
erly formulated, the resulting expansion will compensate foundations, columns, or floors must be protected from
for shrinkage and may cause small compressive stresses to chemical attack, exposed grout shoulders should be given
develop in grout under confinement. similar protection.
Machine-base grouts using the expansive cements covered Air entrainment is unnecessary, as the grout is sandwiched
by ASTM C845-04 do not have sufficient expansion unless between the foundation and the baseplate that protects the
additives are used to reduce settlement and provide expan- grout from water intrusion and the expansive damage that
sion during the plastic state. The standard expansive cements will occur during freezing and thawing.
are formulated to compensate for drying shrinkage in ground
floor slabs. Drying shrinkage is generally on the order of
The dosage of the grouting admixture should be determined 4.4.2.1 Mixers for test batches—Test batches of grout are
from trial batches run at the selected ratio of aggregate to mixed frequently in a laboratory mortar mixer similar to that
cement to optimize volume change and bleeding characteris- specified in ASTM C305-l l. The laboratory mixer and the
tics that are normally specified if critical to the application. field mixer may not achieve equivalent mixing. The water
Initial batches should be run at laboratory temperatures. content for a specific flow may be different using the labora-
Volume change and bleeding should also be determined tory mixer than the field mixer because of mixer efficiency
for specimens cast and maintained at minimum expected and batch size.
placement temperature and at the most flowable consistency 4.4.2.2 Temperature of test batches—Test results obtained
or maximum water content. If specified volume change or on grouts mixed, placed, and maintained at standard labora-
bleeding requirements are not met at the lower temperatures, tory temperatures are sometimes different than the results
admixture dosage may be increased or proportions adjusted. that may be obtained at the maximum and minimum
The proportions of dry-pack grout are not as critical as for placing temperatures permitted in the field. Tests should
grouts of plastic or flowable consistency. Therefore, propor- be performed near both the maximum and minimum field
tioning from trial batches is usually not necessary. Dry-pack placing temperature for volume change, bleeding, working
with an aggregate-to-cement ratio of 2.5 to 3.0 by weight will time, consistency, setting time, and strength.
generally compact well and have compressive strengths of The temperatures of test batches may be varied by
approximately 6000 to 8000 psi (40 to 55 MPa) at 28 days. adjusting mixing water temperature, storing materials at
4.3.4 Water—Unless otherwise allowed by the manu- elevated or lowered temperatures, or a combination of the
facturer or designer of the grout, water for preblended or two. Molds for tests should be brought to the desired temper-
field-proportioned grout should be potable. If the water ature before use and should be maintained at that tempera-
is discolored or has a distinct odor, it should not be used ture for the duration of the test.
unless: I) it has a demonstrated record of acceptable perfor- 4.4.2.3 Batching sequence for test batches—The batching
mance in grout or concrete; or 2) the 7-day compressive sequence and mixing time or procedure used for test batches
strength of specimens made with the water is at least 90% of will affect the results of all tests. For preblended grouts, the
the compressive strength of identical specimens made with contents of the entire bag of grout should be mixed for the
distilled water. test batch. This ensures that segregation of the materials in
If grout or dry-pack is to be placed in contact with high- the bag will not affect the results. If a full bag cannot be
strength steel bolts or stressed rods or in contact with dissim- used, then dry materials should be blended to ensure unifor-
ilar metals, limits should be placed on the chloride and mity. Most manufacturers recommend that some or all
sulfide ion contents of the water. Allowable maximum chlo- water be added to the mixer before the dry preblended grout
ride ion concentration given in various documents ranges and then mixed for 3 to 5 minutes. The recommendations
from 100 to 600 ppm. Little or no information or guidance of the engineer or the manufacturer of the grout should be
is given for sulfide ion content, although it is recognized as followed. The mixing procedure and batching sequence used
a corrosive medium. for making test batches should be recorded. It should be as
close as possible to the procedure to be used in the field.
4.4—Testing 4.4.2.4 Consistency of test batches—The consistency of
4.4.1 General—The following sections discuss the test test batches should be the most flowable consistency that
methods used for evaluation of grouts. The results of these may be used for placement in the field or the maximum
tests are useful for evaluating the properties of grouts both recommended by the manufacturer or designer of the grout.
before and during placement and in service. Field personnel should be prohibited from using higher
Section 5.4.3 covers a test that is applicable to both water contents than were used for tests. The maximum
cementitious and epoxy grouts. Although the test does not water content or flow recommended by the manufacturer of
yield quantitative results, it is useful as an overall measure of preblended grouts should not be exceeded.
workability and in-service performance of a grout. Tests at the minimum permissible flow or water content
The evaluation of cementitious grout should include tests are not usually required because the performance of a grout
for volume change, strength, setting time, working time, is usually improved by lower water contents if it can still be
consistency, and bleeding. For field-proportioned grout, the properly placed.
tests should be performed on grout made from job materials. 4.4.3 Volume change
The proportioning methods for field-proportioned grout are 4.4.3.1 General—Volume change of machine-base grouts
given in Section 4.3.3.5. should be evaluated by using test methods that measure
4.4.2 Preparation of test batches—The equipment and height change from time of placement. The most common
methods used for preparation of test batches may affect the methods used for evaluating the volume-change characteris-
results of many of the tests performed on grout. The condi- tics of a grout are the micrometer bridge described in ASTM
tions of the tests may also affect the applicability of the C1090-10 and the optical method described in ASTM C827/
results to field situations. The following sections discuss C827M-O8. Both tests evaluate volume change by measure-
some of the considerations that should be examined before ment of height change.
preparation of test specimens. ASTM ClO90-lO measures height change from time of
placement to l, 3, l4, and 28 days; ASTM C827/C827M-08
measures height change from time of placement to time of Hold Down Device
setting. Both ASTM C827/C827M-08 and ASTM C1090-10
are test methods used in ASTM Cl 107/Cl 107M-11 to E
g Set Screw
determine nonshrink characteristics of the grout in both the Top
plastic and the hardened state. ASTM CllO7/CllO7M-ll Plate;
1 l: l: I
requires that, to be certified as a nonshrink grout, the vertical
expansion at final set must not be greater than 4% per ASTM
C1090-10 at 28 days, and not less than 0.0% and not greater i
'_-__—61'a'ss_P ate —————— —:
l—n
l”' Eb
than +03% per ASTM C1090-10. \ l lo2\
4.4.3.2 Micrometer bridge (ASTM C1090-10)—The Grout level at-—\ I
the time of
micrometer bridge test method described in ASTM C 1090-10 placement
.
measures height change in grout between the time it is placed
and at 1, 3, l4, and 28 days of age. In this procedure, grout
is placed in a 3 in. (75 mm) diameter by 6 in. (150 mm) high
steel cylinder mold. A clear glass plate is placed on top of
and in contact with the grout and clamped down on the rim
until 24 hours after placing the mixture in the mold. The
position of the surface of the grout at the time of placement
is determined by immediately taking micrometer depth gauge
measurements from a fixed bridge over the cylinder to the
top of the glass plate and later adding the measured thickness
of the plate taken after it has been removed. Movement of
the grout after it has set and the plate has been removed is
measured directly to the surface of the grout for up to 28 days.
Specimens should be prevented from losing or gaining mois-
ture (refer to Fig. 4.4.3.2). Specimens tested in accordance
with ASTM C1090-10 should be maintained in accordance
with ASTM C1107/C1107M-11.
The micrometer bridge method, in some respects, models
an actual baseplate installation. The main difference being
that, in the test, the plate is placed onto the grout instead \ Fixed lndlcator Fixed beam
focusing ball light source
of the grout being placed under the plate. The grout is
completely confined vertically until the plate is removed
24 hours after placement. The advantage that the micrometer Calibrated
decimal
bridge has over simulated baseplate tests is that it provides scales
or motor. A cam on the shaft causes the table to be raised After the grout is struck off, it is covered with a metal
and then dropped a specified distance. The impact causes plate that is restrained from movement by clamps or weights.
the grout to increase in diameter. The average increase in Restraint for at least 24 hours is desirable for all types of
diameter is usually measured after five drops on the table in grouts and is particularly important because unrestrained
3 seconds (for cement tests in accordance with ASTM C150/ expansion usually results in lower strength than would occur
C150M-11, the flow is measured at 25 drops in 15 seconds). in grout under a baseplate. If cubes are stripped in 24 hours,
The consistency is reported as the diameter increase of the they should be placed in saturated limewater until 1 hour
grout expressed as a percent of the diameter of the mold base. before testing.
The flow table will accommodate a flow of 150% before the Many specifications require 2 x 2 in. (50 x 50 mm) cubes
grout runs off the table. to be fabricated in accordance with ASTM C109/C109M-
The flow table is usually only used in a permanent labora- 11. This procedure has been developed for the fabrication
tory although it has been used in field laboratories for large of cubes used to test the compressive strength of portland
projects. cement. The procedure does not address bearing strengths
4.4.4.2 Flow cone—The flow cone specified in ASTM at which nonshrink grout must be tested. This procedure can
C939-10 is used in the field and laboratory to determine and will result in lower compressive strengths than the grout
the consistency of fluid grouts. Grouts of plastic and flow- is capable of producing because the grout is not confined
able consistency generally are not tested by the flow-cone and can expand. ASTM C1107/C1107M-ll addresses the
method. fabrication procedure for grouts of all consistencies.
The flow cone is a funnel with a top diameter of 7 in. (180 4.4.7 Setting and working time—The time of setting
mm) and an orifice diameter of 1/2 in. (13 mm). The grout of grouts is determined by one of the following methods:
is placed to the top of the conical section (1725 mL) with ASTM C191—08, C807—08, C266-08el, C953-10, or C403/
the orifice covered with a finger. The finger is then removed C403M-08. The methods all give a valid reproducible indi-
from the orifice and the time is measured until the cone is cation of the rate of hardening of grout. The initial and final
evacuated completely. The flow cone is also used in the times of setting, determined by the five methods, are not
laboratory and field for making adjustments to water content generally the same. The results from time-of—setting tests
to obtain a desired consistency. should not be used as an indication for the working time of a
4.4.4.3 Slump cone—A slump cone, as defined in ASTM grout. The working time should be estimated by performing
Cl43/Cl43M-10a, has been used occasionally to measure consistency tests at intervals after completion of mixing.
consistency of grout in the field. The slump cones usually
are standard 12 in. (300 mm) cones, but 6 in. (150 mm) CHAPTER 5—NONSHRINK EPOXY GROUTS
cones are sometimes used. Either the slump or the diameter
of the grout is measured. The results are less precise than 5.1—lntroduction
those from a flow table; however, it is often the only prac- This chapter provides an overview of current practices for
tical method for measuring the consistency of plastic and epoxy grouting to support equipment and machinery. This
flowable grouts in the field. chapter describes materials, installation methods, and testing
4.4.5 Bleeding—Bleeding can be measured in the field for epoxy grouts used as load-transfer material between
and laboratory in accordance with ASTM C940—10a. The machine or equipment bases and their foundations.
test method involves placing 800 mL of fresh grout into a
1000 mL graduated cylinder and covering to prevent evap- 5.2—Properties
oration. The bleed water that collects on top of the grout 5.2.1 General—The performance of an epoxy grout under
before initial set is measured. Typical values range from a machine or equipment base depends on the properties of
no bleeding for many preblended grouts to 5% for plain the epoxy grout in both the plastic and hardened states. The
sand-cement grouts with a flowable consistency. Tests for most important properties are placeablility, volume change,
bleeding should be conducted at temperatures corresponding compressive strength, durability, and creep resistance at
to the lowest expected placing temperature. Modifications operating temperature.
of the test using different types of containers and different Epoxy grouts are used frequently where special properties
procedures are sometimes used in the field. such as chemical resistance, high early strength, or impact
4.4.6 Compressive strength—The compressive strength resistance are required. Properties of epoxy grouts may be
of cementitious grouts is determined using 2 in. (50 mm) altered significantly when subjected to high temperatures.
cube specimens. The placing and consolidation procedure in The following sections discuss the more important properties
ASTM C109/C109M-11 is inappropriate for dry-pack, flow- of epoxy grouts.
able, or fluid grouts, but is satisfactory for stiff or plastic 5.2.2 Workability—The physical characteristics of an
consistencies. Fluid and flowable grouts are placed in two epoxy grout while fluid should allow placement of the epoxy
layers and are each puddled five times with a gloved finger. grout under the baseplate. This property depends primarily
The manufacturer of preblended grouts should be on the consistency of the epoxy grout but is also dependent
contacted for recommendations regarding molding, storing, on its ability to flow and maintain these flow characteristics
and testing of specimens. with time. Workability becomes a very important property
to evaluate when grouting large skid-mounted equipment.
Typical skids can be 30 to 35 ft (10 to 12 m) long and 15 permit epoxy grouts to absorb more energy than cementitious
to 18 ft (5 to 6 m) wide with no inspection or access points. grouts when loaded by impact.
This means the epoxy grout must flow 15 to 18 ft (5 to 6 m) 5.2.5 Elastic and inelastic properties—The modulus of
across a blind area. Excellent flow characteristics are neces- elasticity for epoxy grouts varies because of differences
sary to achieve this without creating voids or unsupported in the quantity and type of aggregate and fillers, and the
areas of the skid beams. differing properties of resins and modifiers. In general, the
For epoxy grouts, the user should judge from experience, modulus for filled epoxy grouts ranges from 750 to 2000
testing, and/or visual observations of the mixed epoxy grout ksi (5 to 14 GPa). Epoxy grouts generally exhibit greater
whether the epoxy grout has adequate flowability to allow creep than cementitious grouts and, at higher temperatures
complete placement under the baseplate or skid-mounted (above approximately 120°F [50°C]), the creep of epoxy
equipment. The user should also evaluate the consistency of grouts increases significantly. Special epoxy formulations
the epoxy grout with time to assure that placement can be are available for temperatures up to 300°F (150°C).
completed before stiffening occurs. Additional manpower Significant changes in strength, stiffness, and durability
and mixing equipment may be required to meet this require- properties should be expected. The epoxy grout manufac-
ment. Unless specially prescribed in the product literature, turer should provide specific data in accordance with ASTM
the user should not reduce the amount of aggregate in the C1181-00(2005) at the higher operating temperatures.
mixture (for example, change to a three-bag mixture for a 5.2.6 Durability—Epoxy grouts exhibit more impact
product that only publishes properties for a four-bag mixture) and chemical resistance than cementitious grouts. They
to achieve better flow, as poor base plate contact can result. are unaffected by moisture after hardening, but are quite
5.2.3 Volume change—For use as a machine-base epoxy sensitive to moisture prior to curing. Although epoxies are
grout, the epoxy grout usually contains specially blended resistant to many chemicals that would damage or destroy
aggregate, fillers, other proprietary ingredients, or any cementitious grouts, they are susceptible to attack by ketones
combination thereof, that will reduce or eliminate the and some other organic chemicals. The stiffness and durability
shrinkage that generally occurs in the plastic state. Aggre- of epoxy grouts is reduced at temperatures exceeding the
gate and fillers reduce the temperature during hardening by transition temperatures. This is usually approximately 120°F
reducing the volume of epoxy resin per unit volume. The (50°C). Consult the manufacturer’s literature for more
aggregate and fillers also help restrain the shrinkage. precise information.
Neat epoxy grouts that are mixtures of only the epoxy resin 5.2.7 Thermal properties—Epoxy grout installations may
and hardener (catalyst, converter) do not have the volume- be affected by the differences in coefficient of thermal expan-
change properties necessary for a machine-base epoxy sion of the epoxy and the adjacent concrete. The coefficient
grout. After flowing under a plate, the neat epoxy grout of thermal expansion for epoxy grout is approximately three
will generally exhibit shrinkage of several percent. Most of to five times that for cementitious grout. If a severe change
this shrinkage occurs while the resin is in a liquid state and in temperature occurs, wide grout shoulders or long pours
allows most of the shrinkage to occur without stress buildup. without expansion joints or reinforcement may experience
The epoxy grout may exhibit additional thermal shrinkage. cracks, destruction of the concrete surface, or debonding at
Polymerization of epoxy is an exothermic reaction. The the concrete-epoxy grout interface.
temperature drop that occurs after the completion of the
reaction causes the thermal shrinkage that may result in 5.3—Material requirements
stress buildup and may cause cracking. The materials for machine-base epoxy grouts are usually
Manufacturers specify various methods and placing qualified by performing tests or by obtaining test results or
procedures to control shrinkage to meet specific design certifications from the manufacturer, independent testing
requirements and tolerances. Their recommendations should laboratory, or both.
be followed. The qualifications of epoxy grouts should be based on a
5.2.4 Strength—The long-term compressive strength comparison of test results with predetermined requirements
of epoxy grouts is generally 50 to 100% greater than a for volume change, compressive modulus strength, creep,
hydraulic-cement grout mixed to a flowable consistency. working time, and flow. The performance evaluation test
The strength also develops much faster. At normal tempera- discussed in Section 5.4.3 may be used as an indication of
tures, epoxy grouts may be loaded 24 to 48 hours after place- acceptable performance.
ment. The strength of the epoxy, however, may decrease The temperature and ratio of the polymer bonding system
when subjected to temperatures above approximately 120°F to aggregate should be known and be the basis for setting
(50°C). As many types of equipment operate in the 140 to field requirements. Generally, compressive strength of at
180 OF (60 to 83°C) oil temperature range, loss of physical least 8000 psi (55 MPa) is achieved for most epoxy grouts.
properties at operating equipment temperature must be eval- Qualification requirements for flow, working time,
uated by the designer. thermal compatibility, and creep resistance for epoxy grouts
Epoxy grouts have high tensile strength and give high are necessary and should be established because these prop-
bond strength to cleaned and roughened steel and concrete erties vary greatly among different epoxy grouts.
surfaces. The higher strength and lower modulus of elasticity
removed and the epoxy grout surface inspected for voids and If possible, grout holes for placement should be located
weak surface material. The surface of the epoxy grout under so that grout does not travel more than approximately 48 in.
the baseplate or skid should be evaluated for percentage (1200 mm). The grout holes should be placed so that grouting
of bearing area versus air bubbles or foamy areas. Lack of can be started at one hole and continued at other holes to
uniform bearing area can cause point loading and excessive ensure that the grout flows under all areas of the plate.
surface wear in an operating environment. Holes for pumping epoxy grout are typically 3/4 to 2 in.
When epoxy grouts are tested, the bottom and sides of (19 to 50 mm) in diameter and threaded for standard pipe
the baseplate and I-beams should be thoroughly waxed to threads. Grout holes for free-pouring grout are typically 4 to
prevent bonding of epoxy grout. The plate should be sounded 6 in. (75 to 150 mm) in diameter.
at 3 days and then removed. The use of threaded jack bolts to 6.1.3 Concrete foundation—The concrete foundation
support the plate or l-beams will also facilitate their removal. should be designed to have sufficient stiffness to prevent
The epoxy grout surface should be evaluated for weak areas, flexural tension in the epoxy grout and to prevent thermal
foamy or cellular areas, bubbling, and the amount of large warping caused by temperature differential or change.
irregular placing voids. Because of the higher strengths of For epoxy grouts, the concrete foundation must be fully
epoxy grouts, some users accept uniformly distributed voids cured for typically 21 to 28 days to ensure the excess water
of up to 25% of the bearing area if the resulting baseplate has evaporated. Care must be taken if using a high-early-
bearing stress is less than the allowable stresses provided by strength concrete, as it may meet compressive requirements
the equipment manufacturer. Proper mixing and placing of while still hydrating and before the shrinkage has stabilized.
quality materials should reduce this to the 10 to 15% range. Meeting only the compressive strength requirements for
If the epoxy grout manufacturer requires bonding, the plate high—early-strength concrete does not mean that the excess
should be sandblasted to white metal and the bond evaluated water is gone. Excess water will migrate to the surface of the
by sounding. concrete due to the exothermic reaction of the epoxy grout
5.4.3.5 Flow distance and time test—The epoxy grout during curing. This water can inhibit the bond between the
must be at full depth for the entire distance from one side to epoxy grout and concrete.
the other before it stops flowing. The installer must not try to The concrete surface should be tested for moisture before
pour from both sides to reduce flow distance, as this entraps the epoxy grout is placed. ASTM D4263-83(2005) specifies a
air and creates a low spot under the skid equipment. Unsup- test for moisture. This test uses an 18 in. (457 mm) square
ported beams will vibrate and cause equipment problems of transparent polyethylene film taped to the top of the
and misalignment. concrete. Water drawn to the surface by capillary action will
A flow test of distance versus time at field depth and condense on the underside of the plastic sheet. Run the test
temperature should be run to evaluate the epoxy grout for 16 hours, per ASTM D4263-83(2005), to be sure that
material, placing method, mixing equipment, and labor water, which can be several inches below the top, does not
needed per specific application. reach what will be the grout-concrete interface. Once the
The installer should plan to have the necessary number of epoxy grout starts to cure, water usually cannot interfere
mortar mixers, placing equipment, and workforce needed to with the proper bond developing. The test should be done in
place all of the material within its working time. an area shaded from direct sunlight.
If severe changes in temperature are expected, wide
CHAPTER 6—DESIGN, DETAILING, grout shoulders over 6 in. (150 mm) or long pours should
AND CONSTRUCTION have expansion joints, reinforcement, or both to minimize
cracks or horizontal fractures near the concrete-epoxy grout
6.1—Design and detailing considerations for grout interface.
6.1.1 General—The success of a grouting operation 6.1.4 Anchorage design—The design of anchor bolts or
depends, to a great extent, on the design of the foundation other devices may have an effect on grout performance. For
and machine or equipment base, the clearance provided for vibrating machinery or impact loading, it is important for the
the grout, and the provisions made for obtaining complete grout to be maintained in compression. This can usually be
filling of the space. The following sections discuss some of accomplished by uniformly tensioning the anchor bolts after
the design and detailing requirements for obtaining acceptable the grout has developed a significant portion of its ultimate
grouting. strength.
6.1.2 Machine or equipment bases—The machine base 6.1.5 Clearances—The clearances provided for grout
should be detailed so that grout can be placed beneath the between the machinery or equipment base and the under-
plate without trapping air in unvented corners. If possible, lying foundation is often a compromise between two
perpendicular stiffeners should be placed above the plate. opposing requirements: minimum thickness of grout for
lf grout cannot be placed from one edge and flowed to the optimum economy, and performance versus maximum
opposite edge, air vent holes must be provided through the clearance under the baseplate for ease and proper placement.
plate to prevent air entrapment. A vent hole l/4 to 1/2 in. (6 The job can be jeopardized if the design thickness is too
to 13 mm) in diameter should be placed through the plate at small for the application. Avoid specifying a single grout
the intersection of all crossing stiffeners and at each point allowance for the project. Instead, specify an allowance and
where air may be trapped (refer to Fig. 6.1.2).
A portable headbox with the same configuration may be minutes. Some manufacturers recommend a low-speed drill
used (refer to Fig. 6.2.5.1). and an impeller mixer. The aggregate is usually mixed into
On the side of a plate parallel to the direction of grout flow, the preblended mixture in a mortar box, mortar mixer, or
the forms should generally be less than 1 in. (25 mm) from wheelbarrow for small pours. Do not use a rotating concrete
the plate. For placements where the grout will be pumped mixer.
under the plate through grout holes in the plate, the forms Grout should be stored and installed as required by the
should be at least 4 in. (100 mm) outside the plate on all manufacturers’ instructions and Material Safety Data
sides. The forms should extend at least 1 in. (25 mm) above Sheets. Some individuals have skin sensitization problems
the highest grout elevation under the plate. Forms may also with epoxy grout materials, and proper handling and safety
be built on the top of the plate to prevent excessive spillage should be employed.
onto the top of the plate. Altemately, the top surface can be 6.3.1 Consistency—The consistency needed for place-
waxed or oiled to make cleanup easier. ment of a grout depends on the clearance provided between
6.2.5.2 Farmsfor dry-packing—For placement of dry-pack, the machine base and the foundation, on the complexity of
the forms do not need to be as tight-fitting as for flowable the machine base, and on the method of placement. The
grouts but should be more rigid. The constant compaction of clearances and flow distances provided should be compared
the dry-pack will loosen forms unless they are well braced. with the recommendations given in Section 6.1.5.
If movement of forms occurs during compaction, it may The water content or consistency of the cementitious
result in insufficient compaction. grout should not exceed the maximum or minimum values
6.2.5.3 Epoxy grout—Forms for epoxy grout or other areas determined from qualification tests or recommended by
where bond is not desired should be coated with a thick wax the manufacturer. The water content is determined by the
coating or lined with mylar and be watertight. consistency necessary for placement. In general, the water
All inside corners and horizontal edges should have a content or flow should be the minimum that will reliably
45-degree chamfer strip to break the sharp edge. All outside result in complete filling of the joint space to be grouted.
corners should be rounded with a piece of PVC or other The consistency for placement by dry-packing should
plastic pipe split lengthwise down the middle and adhered be in accordance with the definition for dry-pack consis-
over the inside point of the outside corner, thus creating a tency. The water content should be adjusted if the dry-pack
round, half-moon indention after the forms are removed. becomes rubbery or crumbly.
Where the epoxy grout will be placed from one side of the The consistency for epoxy should be that resulting from
baseplate and flowed to the other side, the forms should be use of the manufacturers’ recommended proportions. Place-
constructed to provide a method for developing head pres- ment should not be attempted with any epoxy grout if the
sure or for using a head-box on the placing side. The forms resulting consistency is not suitable for the existing clear-
should also have sufficient clearance to permit the material ances and flow lengths using the method proposed.
to flow across. 6.3.2 Temperature—The ambient temperature, the grout
The forms on the placement side should extend above the temperature at placement, and the temperature of the founda—
bottom of the plate to form a headbox. The headbox should tion and baseplate all affect the workability, time of setting,
begin 2 to 4 in. (50 to 100 mm) from the plate and slope strength, and flow characteristics of grout. The temperature
away from the plate at approximately 45 degrees. The slope should therefore be adjusted to be within the ranges recom—
on the form permits the epoxy grout to be poured under the mended by the manufacturer for preblended grouts or the
plate with a minimum of turbulence and air entrapment. range of temperature for which grout performance has been
The form on the opposite side should be 2 to 4 in. (50 to evaluated. For temperatures above or below those ranges,
100 mm) from the plate and should extend at least 1 in. additional qualification tests should be performed or docu—
(25 mm) above the bottom of the plate. The height of the mented approval should be obtained from the manufacturer.
headbox depends on the distance the epoxy grout must flow. 6.3.2.1 Cementitious grouts—The temperature of the
In general, the height above the highest epoxy grout eleva- foundation and baseplate may be reduced to within the
tion under the plate should be approximately one—fifth of the permissible placing range for the grout by cooling with ice
travel distance for the epoxy grout. A portable headbox with or cold water. Under cold conditions, ambient, plate, and
the same configuration may be used. foundation temperatures can be increased by using heating
On the side of a plate parallel to the direction of epoxy blankets or heated enclosures. The as-mixed temperatures
grout flow, the forms should generally be less than 1 in. (25 of cementitious grouts may be reduced by using cold water,
mm) from the plate. ice, or precooled dry materials under cold conditions. The
initial as-mixed temperature may be increased by using
6.3—Grout mixing and placing warm water in cementitious grouts or by storing the ingredi-
Grouts should be batched and mixed in accordance with ents for cementitious grouts in a warm area.
manufacturer’s recommendations. In general, the grout 6.3.2.2 Epoxy grouts—The temperature of the founda-
is mixed only long enough to ensure that uniform consis- tion and baseplate may be reduced to within the permissible
tency and complete aggregate wetting are achieved. The placing range for the grout by cooling the enclosed work
liquid components of epoxy grouts are normally mixed in a area. The components of the grout may be precooled to the
bucket using a wooden paint paddle or hand stirrer for 3 to 5
desired temperature. Do not use ice or water to cool the foun- decreases mixing time and increases production. Portable
dation and baseplate because water will prevent bonding. revolving-drum concrete mixers are not recommended
Under cold conditions, ambient plate temperatures and because they will not generally break up lumps. Production
foundation temperatures can be increased by using heating rates are generally lower for revolving-drum mixers because
blankets or heated enclosures. The initial as-mixed tempera- of difficulty in batching bagged material and because of
ture can be increased by storing the ingredients for epoxy buildup of material in the drum. Additionally, the fold in
grouts in a warm area. action of a revolving drum can entrain more air.
6.3.3 Mixing 6.3.3.3 Mixing time—The mixing time should be all the
6.3.3.1 Mixers for cementitious grouts—For plastic, flow- time necessary to provide uniform consistency and break
able, and fluid grouts, horizontal shaft mixers with stationary up all the lumps. For preblended grouts, mixing time should
drums that are normally recommended by grout manufac- comply with the manufacturer’s recommendation. Grout
turers and commonly used are preferable. Vertical shaft should be placed as soon as possible after the completion
mixers may also be used if approved by the manufacturer. of mixing. If the grout must be held in the mixer after the
The mixers should be clean and equipped with rubber— completion of the specified mixing time, the grout should be
tipped blades with close tolerances. They generally provide agitated at slow speed for a short time before dispensing. The
adequate shearing stresses in the fresh grout to break up all time that a batch can be held will be less at higher ambient
lumps and adequately disperse the constituents as well as temperature and may be brand specific.
permit the dry materials to be added with the water while No water should be added to cementitious grouts after the
the mixer is operating, which decreases mixing time and initial mixing is completed.
increases production. Portable revolving-drum concrete 6.3.4 Placing
mixers are not recommended because they will not impart 6.3.4.1 Poured placements—When grouts are to be placed
the necessary shear for mixing the grout. Production rates from the perimeter of a base, the forms should be constructed
are generally lower for revolving-drum mixers because as discussed in Section 6.2.5 so that a pressure head can be
of difficulty in batching bagged material and because of developed in a headbox on one side of the plate. All place-
buildup of materials in the drum. ments should be made from one side and should begin at one
Mixing of small quantities of plastic, flowable, or fluid end of the plate or skid and continue at that point until the
grout in a bucket using a propeller-type mixer and drill motor grout rises above the bottom of the plate on the opposite side
is acceptable, provided that the drill speed is slow enough of the plate or skid. Then, the placement point or portable
to prevent entrapping air into the grout. Hand mixing does headbox should be moved slowly along the side of the plate
not provide sufficient energy to disperse constituents or to from one end to the other or to the next expansion joint
break up lumps and therefore should be prohibited. Caution section. The placement point should be moved at the same
should be observed in using only portions of a package of rate as the face of grout moves along the length of the plate
preblended grout to be certain that all ingredients are repre- on the opposite side. The continuous movement of a single
sented properly in the portion taken. Generally, preblended face of grout prevents air entrapment. Grout should not be
grouts are batched by placing the minimum amount of water placed at various locations along one side because move—
in the mixer followed by the dry grout ingredients and then ment of the grout cannot be monitored and air can easily be
adding more water to achieve the desired consistency unless trapped between placing points. For the same reason, grout
otherwise recommended by the manufacturer. For field- should not be poured toward the center from opposite ends
proportioned grouts, the water should be placed in the mixer or sides. When using expansion joints, pour grout into the
followed by the cement, additives, and aggregate, in that adjoining expansion joint area to provide resistance and
order. weight to prevent the initial joint area from blowing out.
For grouts at dry-pack consistency, mixing is best accom- To encourage flow of grout, headboxes should be used to
plished in a horizontal shaft mortar mixer. Hand mixing, ensure adequate flow. To encourage flow of cementitious
however, may be used. For hand mixing, cement and aggre- grout, steel packing straps may be inserted on the placement
gate should be blended before addition of water. Mixing side and moved slowly back and forth. Chains should not be
should be performed on a watertight platform by repeatedly used because they tend to entrap air bubbles. Some manu-
turning the mass over with a shovel and final mixing accom- facturers of preblended grouts allow limited use of vibra-
plished by rolling and rubbing the material between gloved tors or plungers to assist grout flow. Machine base plates
hands. with stiffeners or other obstructions on the underside should
6.3.3.2 Mixersfor epoxy grouts—For epoxy grouts, mortar be vented. Suggestions on venting are provided in Section
mixers or horizontal shaft mixers with stationary drums that 6.1.2. The grout should be worked toward the vent until
are normally recommended by grout manufacturers and the grout reaches the vent. For thick placements of epoxy
commonly used are preferable. The mixers should be clean grouts, control of heat generation and shrinkage is critical
and equipped with rubber-tipped blades with close tolerance. and the manufacturers’ recommendations for thick place-
These mixers generally provide adequate shearing stresses ments should be followed.
in the fresh epoxy grout to break up all lumps and adequately 6.3.4.2 Pumped placement—When grout is to be placed
disperse the constituents. They also permit the dry materials through holes in the machine base, the forms should be
to be added with the resin while the mixer is operating that constructed as recommended in Section 6.2.5. Pumping
should begin at the grout inlet nearest one end of the plate. these recommendations should be used unless the grout
Grout should be pumped into that inlet until it flows up into manufacturer specifies otherwise.
an adjacent inlet and flows from the entire plate perimeter The exposed surfaces of newly placed grout must be
adjacent to the inlet. The pump line can then be moved to the protected from rapid moisture loss. Moisture loss can be
adjacent inlet and pumping continued. The pump line should prevented by keeping the exposed surfaces wet for a given
be moved to successive inlets until grouting is complete. period of time or by applying a curing compound.
Grout should not be pumped into more than one inlet simul- Continuous moist curing for a few days after placement is
taneously or before grout flow has reached an adjacent inlet generally preferred because the resulting grout surface will
because air may be trapped. have higher strength and will be more durable. Moist curing
When a hose is to be used to pump grout under the plate, is generally achieved by applying wet rags or burlap to the
the hose should be inserted under the plate to the point exposed surfaces. The wet rags or burlap can then be covered
farthest from the point of insertion. The hose should be with plastic to prevent excessive evaporation. Soaker hoses
withdrawn as grout is pumped under the plate, but the hose are sometimes used.
outlet should remain embedded in the grout mass to prevent When moist curing is used, the grout surfaces should
development of air pockets. generally be kept wet and saturated for at least 7 days before
6.3.4.3 Dry-pack placement—Dry-pack placement and the surface is permitted to dry. A shorter period of moist
compaction should begin against a solid backing. The dry— curing is permissible if a curing compound is applied imme-
pack grout should be placed in layers having a compacted diately after moist curing is suspended.
thickness of approximately 1/2 in. (13 mm). Each layer of The main problem with the use of only moist curing is
grout should be compacted over its entire surface with the that it is impractical or difficult to enforce. Frequently, moist
square-cut end of a hardwood rod or board driven with a curing will be initiated correctly, but the grout surface may
hammer. The striking force should be sufficient for compac- be permitted to dry prematurely because of weekends, shift
tion of the material without moving the plate out of align- changes, or other circumstances.
ment. The direction of tamping should be varied so that all After placement of a grout, the foundation and machine
dry—pack is compacted. The surface of each layer should or equipment base should be kept at a temperature that is
be inspected visually by the installer before placement of within the temperature range specified for placing of the
the next layer to ensure that the entire surface has been fresh grout. The temperature should be maintained within
compacted. Just before placement of the next layer, the this range until the grout reaches final set. After final set, the
compacted dry-pack layer should be rubbed with the end of grout should be protected from cold or hot weather condi-
the tamping rod to provide a slight roughness to aid bond to tions until sufficient strength is achieved.
the next layers (refer to Fig. 3.2.1). During cold weather, cementitious grout must be kept
Proper water content has been achieved if the dry-pack warm enough to allow hydration to occur at a significant
does not slough and is not rubbery or crumbly. Batch size rate and to prevent damage by freezing. The grout should
should be small enough to minimize the need for retempering. be maintained above 50°F (10°C) for at least 3 days and
6.3.5 Removal of excess material—No forms, headbox, or protected from freezing for at least 3 additional days. During
epoxy grout (except spillage) should be removed from the hot weather, grout should be kept cool enough to prevent
formed shoulders until the grout has stiffened sufficiently to excessive heat development. If the temperature of the grout
ensure that the grout does not sag below plate level. is excessive at an early age, thermal shrinkage may occur
Epoxy grouts are formed to the desired configuration and when the grout cools to normal ambient temperatures. The
poured to the desired final elevation. The edge of epoxy grouts ambient temperature of the air surrounding the foundation
is not generally cut back to a 45-degree angle; however, if and machine base should be maintained below 100°F (38°C)
required, it can be formed to a 45-degree angle. Epoxy grouts for at least 3 days through the use of shade, wet burlap,
should be finished to remove air bubbles on the surface by soaker hoses, or other procedures.
the manufacturer’s recommendations. Cementitious grouts 6.4.2 Epoxy grams—After placement of an epoxy grout,
can be cut back at a slope of approximately 45 degrees from the foundation and machine or equipment base should be
the bottom of the plate. The sloped surface provides some kept at a temperature that is within the temperature range
later confinement for the grout under the plate and provides a specified for placing the fresh epoxy grout. The temperature
more uniform dispersal of the compressive stresses near the should be maintained within this range until the epoxy grout
plate edge, and can help conduct process fluids or lubricant reaches final set. After final set, the epoxy grout should be
leaking from the equipment away from the machine base. protected from cold or hot weather conditions until sufficient
strength is achieved.
6.4—Curing and protection During cold weather, epoxy grout must be kept warm
6.4.1 Cementitious grams—After cementitious grouts have enough to allow curing to occur at a significant rate and
been placed, they should be protected from excessive mois- to prevent damage by freezing. The epoxy grout should be
ture loss and from extremes in temperature. The following maintained at approximately 70°F (22°C) for at least 1 day
sections give recommendations for moisture retention and and protected from freezing for at least 1 additional day.
cold and hot weather protection. For preblended grouts, During hot weather, epoxy grout should be kept cool enough
to prevent excessive heat development. If the temperature
of the epoxy grout is excessive at an early age, thermal procedure for assuring the correct proportions of hardener
stresses and cracking may occur when the epoxy grout cools and resin is to make a small test cookie and cure in a toaster
to normal ambient temperature. The ambient temperature of oven at an elevated temperature.
the air surrounding the foundation and machine base should 6.5.3 Field samples and tests for cementitious grouts—
be maintained below 90°F (32°C) for at least 2 days through Cementitious grouts with plastic, flowable, or fluid consis-
the use of shade, air chillers, fans, or procedures. tency should be sampled in the field and tested for volume
As the curing of epoxy grouts is generally not affected change, bleeding, and compressive strength. Grouts with
by exposure to air, the main consideration after placing is dry-pack consistency should be tested for compressive
protection from temperature extremes. Temperature of the strength.
foundation and baseplates must also be considered. During The frequency of sampling should be based on the volume
hot weather, epoxy-grouted equipment or baseplates are of grout placed or on the total baseplate area grouted in a
usually shaded to provide uniform curing conditions. specified time period. For preblended grouts, sampling on
The rate of polymerization of an epoxy is related to the basis of volume is more appropriate. A sample should
the temperature of the mixture. At temperatures near 0°F be taken at least every other day. Samples of grout and dry-
(—l8°C), the polymerization of many epoxies will nearly pack should be taken and test specimens made at the instal-
cease. As the temperature of the foundation and machine lation site.
base increases, the temperature of the epoxy increases due to If cores of hardened in-place grout are taken for the
heat flow from the surrounding materials and also from the purpose of determining strength, the user should specify
exothermic polymerization reaction. Because most epoxies that strength be determined on specimens whose length is
are formulated to be placed at temperatures of 70°F (22°C), equal to their diameter. This allows the test to approximate
it is desirable to maintain the air temperature around the the cube strength test that is usually specified for the original
foundation as close to 70°F (22°C) as possible. At higher qualification of the grout. If test samples cannot be obtained
installation temperatures, the polymerization produces that meet the length-to-diameter criteria, the comparison to
higher curing temperatures that will increase the thermal cube strength may not be valid. It should be borne in mind
stress when the epoxy grout cools as well as reduce working that grout is loaded along the short dimension of its position
time. in place rather than in the long dimension as for concrete in
columns, beams, and slabs.
6.5—Quality control/assurance Dry-packing operations require nearly constant inspec-
6.5.1 General—Continuous quality control is required to tion to ensure that the proper layer thickness and compac-
provide quality assurance and guide construction quality. tive effort are being used. A worker can easily increase his/
Quality control should be performed on a regular basis to her production by using large layer thicknesses. If possible,
ensure that: an occasional dry-pack installation should be dismantled to
- The epoxy grout has not exceeded its shelf life. check for areas of insufficient compaction.
- The foundation and baseplate have been properly 6.5.4 Documentation—Documentation must be main—
prepared. tained for all job site inspection and testing. This documen—
- The formwork is tight and has adequate stiffness. tation should include the location of the installation, the
- The required tests are performed at the specific type and brand of grout used, the environmental conditions
frequency. at the time of epoxy grout placement, the condition of the
- The correct placing methods are used. concrete, and the results of all physical tests (for example,
- Proper curing temperature is maintained for the required volume change, bleeding, and strength). The number of units
time. mixed, the time period to place, temperature, aggregate load,
° Shims, wedges, or leveling devices are removed, if mixing equipment, expansion joint locations, and workforce
required, after material has reached full cure. should be documented.
- Temperature of the baseplate material and air are within
specification limits. CHAPTER 7—REFERENCES
The following sections give recommendations for
sampling and testing of grouts. 7.1—Referenced standards and reports
6.5.2 Epoxy grouts flow test for skids—Qualify epoxy American Concrete Institute
grouts to meet new flow requirements for skid-mounted 318-11 — Building Code Requirements for Structural
equipment. As part of the qualification, the epoxy grouts Concrete and Commentary
must be able to flow under the typical skid with distances at
3 in. (75 mm) deep and at 70°F (22°C) before entering the American Petroleum Institute
plastic or thickened state. API 686RP-09 — Recommended Practice for Machinery
After initial qualification, epoxy grouts should be sampled Installation and Installation Design
in the field and tested for compressive strength. The
frequency of sampling should be based on the volume of ASTM International
epoxy grout placed. At least one sample should be taken C33/C33M-ll — Standard Specification for Concrete
from each shipment or production lot. A simple field check Aggregates
C109/C109M-ll — Standard Test Method for Compres- C827/C827M-08 — Standard Test Method for Change
sive Strength of Hydraulic Cement Mortars (Using 2-in. or in Height at Early Ages of Cylindrical Specimens from
[SO-mm] Cube Specimens) Cementitious Mixtures
Cl43/Cl43M-10a — Standard Test Method for Slump of C845-04 — Standard Specification for Expansive
Hydraulic-Cement Concrete Hydraulic Cement
Cl44M-ll — Standard Specification for Aggregate for C939-10 — Standard Test Method for Flow of Grout for
Masonry Mortar Preplaced-Aggregate Concrete (Flow Cone Method)
ClSO/ClSOM-ll — Standard Specification for Portland C940-10a — Standard Test Method for Expansion and
Cement Bleeding of Freshly Mixed Grouts for Preplaced-Aggregate
C157/C157M-ll — Standard Test Method for Length Concrete in the Laboratory
Change of Hardened Hydraulic-Cement Mortar and Concrete C953-10 — Standard Test Method for Time of Setting of
Cl91-08 — Standard Test Method for Time of Setting of Grouts for Preplaced-Aggregate Concrete in the Laboratory
Hydraulic Cement by Vicat Needle C1090-10 — Standard Test Method for Measuring
C230/C230M-08 — Standard Specification for Flow Changes in Height of Cylindrical Specimens from Hydraulic-
Table for Use in Tests of Hydraulic Cement Cement Grout
C266-08el — Standard Test Method for Time of Setting CllO7/CllO7M-ll — Standard Specification for Pack-
of Hydraulic-Cement Paste by Gillmore Needles aged Dry, Hydraulic-Cement Grout (Nonshrink)
C305-ll — Standard Practice for Mechanical Mixing of Cl 18 1-00(2005) — Standard Test Methods for Compres-
Hydraulic Cement Pastes and Mortars of Plastic Consistency sive Creep of Chemical-Resistant Polymer Machinery
C403/C403M-08 — Standard Test Method for Time of Grouts
Setting of Concrete Mixtures by Penetration Resistance C1339-02(2008) — Standard Test Method for Flow-
C404-ll — Standard Specification for Aggregates for ability and Bearing Area of Chemical-Resistant Polymer
Masonry Grout Machinery Grouts
C579-00(2005) — Standard Test Methods for Compres- C1437-O7 — Test Method for Flow of Hydraulic Cement
sive Strength of Chemical-Resistant Mortars, Grouts, Mono- Mortar
lithic Surfacings, and Polymer Concretes D4263-83(2005) — Standard Test Method for Indicating
C580-02(2008) — Standard Test Method for Flexural Moisture in Concrete by the Plastic Sheet Method
Strength and Modulus of Elasticity of Chemical-Resis-
tant Mortars, Grouts, Monolithic Surfacing, and Polymer National Association of Corrosion Engineers (NACE)
Concretes NACE No. 2/SSPC-SP 10 — Near-White Metal Blast
C806-04 — Standard Test Method for Restrained Expan- Cleaning
sion of Expansive Cement Mortar
C807—08 — Standard Test Method for Time of Setting of The Society for Protective Coatings (SSPC)
Hydraulic Cement Mortar by Modified Vicat Needle SSPC-SP-2 — Hand Tool Cleaning
SSPC-SP-3 — Power Tool Cleaning
SSPC-SP-S — White Metal Blast Cleaning
As ACI begins its second century of advancing concrete knowledge, its original chartered purpose
remains “to provide a comradeship in finding the best ways to do concrete work of all kinds and in
spreading knowledge.” In keeping with this purpose, ACI supports the following activities:
- Technical committees that produce consensus reports, guides, specifications, and codes.
- Periodicals: the ACI Structural Journal and the ACI Materials Journal, and Concrete International.
Benefits of membership include a subscription to Concrete International and to an ACI Journal. ACI
members receive discounts of up to 40% on all ACI products and services, including documents, seminars
and convention registration fees.
As a member of ACI, you join thousands of practitioners and professionals worldwide who share a
commitment to maintain the highest industry standards for concrete technology, construction, and
practices. In addition, ACI chapters provide opportunities for interaction of professionals and practitioners
at a local level.
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American Concrete Institute®
Advancing concrete knowledge