Section 03600 GROUTS

Section 03600

_GROUTS

PART 1 - GENERAL

1.1 THE REQUIREMENT

A. The CONTRACTOR shall furnish labor and materials in install concrete mortar, grout, drypack mortar, non-shrink grout, epoxy grout, and non-shrink epoxy grout.

1.2 RELATED WORK SPECIFIED ELSEWHERE A. Section 03071, Epoxies

1.3 REFERENCES

A. American Society for Testing and Materials (ASTM):

1. C 109 - Test Method for Compressive Strength of Hydraulic Cement Mortars

(using 2 inch or 50 millimeter cube specimens)

2. C 531 - Test Method for Liner Shrinkage and Coefficient of Thermal Expansion of

Chemical-Resistant Mortars, Grouts, Monolithic Surfacings, and Polymer Concretes

3. C 579 - Test Method for Compressive Strength of Chemical-Resistant Mortars and Monolithic Surfacings

4. C 827 - Test Method for Change in Height at Early Ages of Cylindrical

Specimens from Cementitious Mixtures

5. C 939 - Test Method for Flow of Grout for Preplaced-Aggregate Concrete (Flow

Cone Method)

6. C 1090 - Test Method for Measuring Change in Height of Cylindrical Specimens from Hydraulic-Cement Grout

7. C 1107 - Standard Specification for Packaged Dry, Hydraulic-Cement Grout

(Nonshrink)

8. C 1181 - Test Methods for Compressive Creep of Chemical-Resistant Polymer

Machinery Grouts

1.4 SUBMITTALS

A. Non-shrink Grout and Non-shrink Epoxy Grout: Submit manufacturer's literature and certified test data prior to installation.

1.5 DELIVERY, STORAGE, AND HANDLING

A. All materials shall be delivered to the jobsite in their original, unopened packages or containers, clearly labeled with the manufacturer's product identification and printed instructions.

B. All materials shall be stored in a cool dry place and in accordance with the manufacturer's recommendations.

C. All materials shall be handled in accordance with the manufacturer's instructions.

1.6 PROJECT/SITE CONDITIONS

A. Refer to manufacturer's literature or contact the manufacturer for any special physical or environmental limitations that may be required for use of products.

1.7 WARRANTIES

A. Non-shrink Grout: The manufacturer shall warranty that the non-shrink grout will never go below its initial placement volume when tested in accordance with ASTM C 1107.

B. Non-shrink Epoxy Grout: The manufacturer shall warranty that non-shrink epoxy grout will show negligible shrinkage or expansion when tested in accordance with ASTM C 531.

PART 2 - PRODUCTS

2.1 MATERIALS

A. Concrete Mortar:

1. General: Consist of concrete mixture with coarse aggregate removed and water quantity adjusted as required.

2. At Exposed Concrete Surfaces Not to Be Painted or Submerged in Water: White cement.

B. Grout:

1. Consist of mixture of portland cement and sand. C. Dry-pack Mortar:

1. Consist of mixture of portland cement and sand. D. Non-shrink Grout:

1. Non-shrink grout shall be a preportioned and prepackaged cement-based mixture. It shall contain no metallic particles such as aluminum powder and no metallic aggregate such as iron filings. It shall require only the addition of potable water.

2. Potable water for pre-soaking, mixing, and curing shall be clean and free of oils, acids, alkalies, organics, and any other deleterious matter.

3. Bleeding: Non-shrink grout shall be free from the emergence of mixing water from within or the presence of water on its surface.

4. Non-shrink grout shall be in accordance with ASTM C 1107.

5. Consistency: Non-shrink grout shall remain at a minimum flowable consistency for at least 45 minutes after mixing at 45 degrees F to 90 degrees F when tested in accordance with ASTM C 230. If at a fluid consistency, it shall be verified in accordance with ASTM C 939.

6. Dimensional Stability (Height Change): Non-shrink grout shall be in accordance with ASTM C 1107, volume-adjusting Grade B or C at 45 degrees to 90 degrees. It shall show 90 percent or greater bearing area under bases or baseplates.

7. Compressive Strength: Non-shrink grout shall show minimum compressive strengths at 45 degrees F to 90 degrees F in accordance with ASTM C 1107 for various periods from the time of placement, including 5,000 pounds per square inch at 28 days when tested in accordance with ASTM C 109 as modified by C 1107.

_{8. Manufacturers: One of the following, Or Equal:}

a. Five Star Products, Inc., Fairfield, CT, Five Star Grout. b. Master Builders, Inc., Cleveland, OH, Masterflow 928.

c. L&M Construction Chemicals, Inc., Omaha, NE, CRYSTEX. E. Epoxy Grout:

1. Consist of mixture of epoxy and sand.

2. Sand: Clean, bagged, graded, and kiln dried silica sand. F. Non-shrink Epoxy Grout:

1. Non-shrink epoxy grout shall be a 100 percent solids, premeasured, prepackaged system containing a two-component thermosetting epoxy resin and inert aggregate.

2. Consistency: Non-shrink epoxy grout shall maintain a flowable consistency for at least 45 minutes at 70 degrees F.

3. Dimensional Stability (height change):

a. Non-shrink epoxy grout shall have negligible shrinkage or expansion (less than 0.0006 in/in) when tested in accordance with ASTM C 531.

b. Compressive Strength: Non-shrink epoxy grout shall show a minimum compressive strength of 10,000 pounds per square inch at 24 hours and

14,000 pounds per square inch at 7 days when tested in accordance with

_{ASTM C 579, Method B.}

c. Compressive Creep: The compressive creep for non-shrink epoxy grout shall not exceed 0.0027 in/in when tested under a 400 pounds per square inch constant load at 140 degrees F in accordance with ASTM C 1181.

d. Thermal Capability: The coefficient of thermal expansion for non-shrink epoxy grout shall not exceed 0.000018 inches per inch per degree F when tested under ASTM C 531, Method B.

e. Manufacturers: One of the following, Or Equal:

_{1) Five Star Products, Inc., Fairfield, CT, Five Star Epoxy Grout.}

2) Master Builders, Inc., Cleveland, OH, Ceilcote 648 CP Plus.

_{3) L&M Construction Chemicals, Inc., EPOGROUT.}

2.2 MIXES

A. Concrete Mortar Mix:

1. Use water-cement ratio that is no more than that specified for concrete being repaired.

2. At Exposed Concrete Surfaces Not To Be Painted Or Submerged In Water: Use sufficient white cement to make color of finished patch match that of surrounding concrete.

B. Grout Mix:

1. For Concrete Repair: Mix in same proportions used for concrete being repaired, with only sufficient water to give required consistency for spreading.

2. For Spreading over the Surfaces of Construction or Cold Joints: Mix with no more water used than allowed by water-cement ratio specified for concrete.

3. For grout otherwise not specified, mix in proportions by weight of one part cement to four parts of concrete sand.

C. Dry-pack Mortar Mix: Use only enough water so that resulting mortar will crumble to touch after being formed into ball by hand.

D. Non-shrink Grout: Mix in accordance with manufacturer's installation instructions such that resulting mix has fluid or flowable consistency and is suitable for placing by pouring.

E. Epoxy Grout:

1. Mix in accordance with manufacturer's installation instructions for mixing.

2. Proportioning:

a. For horizontal work, consist of mixture of one part epoxy as specified in

Section 03071, Epoxies, with not more than 2 parts sand.

b. For vertical or overhead work, consist of 1 part epoxy gel as specified in

Section 03071, Epoxies, with not more than 2 parts sand.

F. Non-shrink Epoxy Grout: Mix in accordance with manufacturer's installation instructions.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Inspect concrete surfaces to receive grout or mortar and verify that they are free of ice, frost, dirt, grease, oil, curing compounds, paints, impregnations and all loose material or foreign matter likely to affect the bond or performance of grout or mortar.

B. Inspect baseplate and anchor systems for rust, oil, and other deleterious substances that may affect the bond or performance of grout.

C. Confirm that newly placed concrete has been cured sufficiently to attain its design strength and limit further shrinkage.

D. Verify that temperature of cementitious or epoxy grout does not exceed manufacturer's recommendations.

3.2 PREPARATION

A. Surface Preparation:

1. Roughen all concrete surfaces by heavy sandblasting, chipping, or other mechanical means to assure bond. Loose or broken concrete shall be removed.

2. All grease, oil, dirt, curing compounds, laitance, and other deleterious materials that may affect bond that were identified in the inspection process shall be completely removed from concrete and bottoms of baseplates. All metal surfaces should have a

2 to 3 mil peak-to-valley profile for epoxy grouts.

3. For cementitious mortars and grouts, concrete surfaces shall be saturated surface dry. Any standing water shall be removed prior to placing grouts.

4. For epoxy grouts, do not wet concrete surfaces with water. Instead, where required, wet surfaces with epoxy for horizontal work or epoxy gel for vertical or overhead work prior to placing epoxy grouts.

B. Forms and Headboxes for Grouts (Cementitious or Epoxy):

1. Forms for grouts shall be built of material with adequate strength to withstand the placement of grouts.

2. Forms must be rigid and liquid tight. All cracks and joints shall be caulked with an elastomeric sealant. All forms shall be lined with polyethylene for easy grout release. Forms carefully waxed with two coats of heavy-duty paste wax shall also be acceptable.

3. Forms shall be 4 to 6 inches higher than the baseplate on one side of the baseplate configuration when using head pressure for placement.

4. A sufficient number of headboxes shall be built to facilitate placement of grouts.

5. Air relief holes a minimum 1/8 inch in diameter shall be provided when required by a baseplate configuration to avoid entrapping air underneath.

3.3 APPLICATION

A. Cement Mortar and Grout:

1. For Defective Concrete Repair:

a. Filling: Filling of voids around items through the concrete.

b. Grout Spreading: Spread over construction joints, cold joints, and similar type items.

2. Concrete Surfaces:

a. Apply epoxy bonding agent to clean, roughened, and dry surfaces before placing mortar or grout.

3. Placing:

a. Exercise particular care in placing portland cement mortar or grout since they are required to furnish structural strength or impermeable water seal or both.

b. Do not use cement mortar or grout that has not been placed within

30 minutes after mixing. B. Epoxy Grout:

1. Apply in accordance with manufacturer's installation instructions.

2. Use where specified herein or where indicated on the Drawings.

3.4 PLACEMENT

A. The CONTRACTOR shall make arrangements to have a grout manufacturer's representative present for a pre-construction meeting and during initial grout placement. Grout shall only be installed after the final equipment alignment is correct and accepted by the ENGINEER.

1. Grouts shall be mixed in accordance with the manufacturer's recommendations.

2. A mortar mixer with moving paddles shall be used for mixing grouts. For cementitious grouts, pre-wet the mixer and empty out excess water before beginning mixing.

3. Cementitious Grouts:

a. Non-shrink cementitious grout shall be added to a premeasured amount of water that does not exceed the manufacturer's maximum recommended water content.

b. Mix cementitious grouts per manufacturer's instructions for uniform consistency.

c. Grouts may be drypacked, flowed, or pumped into place. All baseplate grouting shall take place from one side of a baseplate to the other to avoid trapping air. Do not overwork grouts.

d. Do not retemper grout by adding more water after stiffening.

e. Hydrostatic head pressure shall be maintained by keeping the level of the grout in the headbox above the bottom of the baseplate. The headbox should be filled to the maximum level and the grout worked down to top of baseplate.

4. Epoxy Grouts:

a. Epoxy grouts shall be mixed in complete units. Do not vary the ratio of components or add solvent to change the consistency of the mix.

b. Pour the hardener into the resin and mix for at least one minute and until each mixture is uniform in color. Pour the chemical components into the mortar mixer wheelbarrow and add the aggregate. Mix until aggregate is uniformly wetted. Overmixing will cause air entrapment in the mix.

c. All epoxy grout shall be flowed into place using a headbox. All grouting shall take place from one side of a baseplate to the other in a continuous flow to avoid trapping air.

d. Hydrostatic head pressure shall be maintained by keeping the level of grout in headboxes above the bottom of baseplates. Headboxes shall be filled to the maximum level and grout worked down to the bottom of baseplates.

e. Epoxy grouts shall not be cut back after setting. The final level of grout will be as installed with all chamfer edges built into the formwork.

3.5 CURING

A. Cementitious Grouts:

1. Grouts must be cut back to the lower edge of baseplates after reaching initial set. Provide a 45 degree angle cut back.

2. Clean equipment and tools as recommended by the grout manufacturer.

3. Cure Grouts in accordance with manufacturer's specifications and recommendations. Keep grout moist for a minimum of 3 days. The method needed to protect grouts will depend on temperature, humidity, and wind. Wet burlap, a soaker hose, sun shading, ponding and, in extreme conditions, a combination of methods shall be employed.

4. Grouts shall be maintained above 40 degrees F until they have attained a compressive strength of 3,000 pounds per square inch or above 70 degrees F for a minimum of 24 hours to avoid damage from subsequent freezing.

B. Epoxy Grouts:

1. Cure grouts in accordance with manufacturers' specifications and recommendations. Do not wet cure epoxy grouts.

2. Consult the manufacturer for appropriate cure schedule. In no case should any surface in contact with grout be allowed to fall below 50 degrees F for a minimum of

48 hours after placement.

3. Equipment and tools shall be cleaned immediately with a strong liquid detergent and water solution before grout hardens.

3.6 FIELD QUALITY CONTROL

A. Non-shrink cementitious grouts shall be tested for 24 hour compressive strength in accordance with ASTM C 109.

B. Non-shrink grouts shall be tested for 24 hour compressive strength in accordance with ASTM C 579 (Method B).