Table of Contents
Section Title Page
| Purpose | 2 | |
| Scope | 2 | |
| Related Documents | 2 | |
| Materials and Products | 3 | |
| Delivery, Storage, and Handling | 4 | |
| Proportioning and Mixing | 5 | |
| Preparation for Installation | 6 | |
| Placing Grout | 9 | |
| Finishing, Curing, and Protecting | 10 | |
| Sealing | 11 | |
| Additional Requirements for Reciprocating Process Gas Compressors | 12 | |
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1. PURPOSE
1.1 This specification defines for the contractor the minimum requirements for furnishing, storing, and installing grout.
2. SCOPE
2.1 The contractor shall furnish all equipment, materials, and labor necessary to satisfy the contract grouting requirements.
2.2 The work may include, but is not limited to, the following:
Grouting steel column base plates, equipment bases, and sleeved anchor bolts.
Grouting anchor bolts, reinforcing bars, and dowels into existing concrete.
2.3 The type of grout used and the grouting design shall conform to the grout schedule prepared for the specific project.
2.4 A meeting shall take place between the Air Products representative, contractor, grouting contractor, and grout manufacturer’s representative to discuss the grouting materials and methods that are appropriate for the installation. This meeting will address issues such as expansion joint requirements and pour limits. No grouting shall begin until after this meeting has taken place.
2.5 Before or at the pre-installation meeting indicated above, the contractor shall submit to the Air Products representative certified test data and the manufacturers’ literature for the grout to be installed.
3. RELATED DOCUMENTS
3.1 The following codes and standards, of the issues in effect at the time of award of contract, form a part of this specification to the extent indicated by the references thereto.
3.2 Air Products Engineering Document
4WEQ-6804 Painting and Corrosion Protection of New Construction for Design Temperatures to 649°C (1200°F)
3.3 American Concrete Institute (ACI)
347 Guide to Formwork for Concrete
3.4 American Society for Testing and Materials (ASTM)
C31 Standard Practice for Making and Curing Concrete Test Specimens in the Field
C33 Standard Specification for Concrete Aggregates
C39 Standard Test Method for Compressive Strength Cylindrical Test Specimens
C109 Standard Test Method for Compressive Strength of Hydraulic Cement Mortars
(using 2‑inch or 50‑mm cube specimens)
C150 Standard Specification for Portland Cement
C307 Standard Test Method for Tensile Strength of Chemical-Resistant Mortars, Grouts, and Monolithic Surfacings
C531 Standard Test Method for Linear Shrinkage and Coefficient of Thermal Expansion of Chemical-Resistant Mortars, Grouts, Monolithic Surfacings, and Polymer Concretes
C579 Standard Test Methods for Compressive Strength of Chemical-Resistant Mortar, Grouts, Monolithic Surfacings and Polymer Concretes
C827 Standard Test Method for Change in Height at Early Ages of Cylindrical Specimens from Cementitious Mixtures
C1107 Standard Specification for Packaged Dry, Hydraulic-Cement Grout (Nonshrink)
C1181 Standard Test Methods for Compressive Creep of Chemical-Resistant Polymer Machinery Grouts
3.5 Steel Structures Painting Council (SSPC)
SP10 Joint Surface Preparation Specification – Near-White Metal Blast Cleaning
4. MATERIALS AND PRODUCTS
4.1 Cement
4.1.1 Cement shall be an approved brand of Portland cement conforming to ASTM C150 and shall be Type I. Only one brand of cement shall be used throughout the work.
4.2 Aggregate
4.2.1 Coarse aggregate for use in sand-cement grout shall conform to the requirements of ASTM C33 and shall be graded coarse aggregate, Size No. 8.
4.2.2 Fine aggregate for use in sand-cement grout shall conform to the requirements of ASTM C33 and shall be graded fine aggregate, Size No. 1.
4.3 Water
4.3.1 Water shall be clean potable water.
4.4 Nonshrink Cement Grout
4.4.1 Grout shall be a packaged premixed, inorganic, nonmetallic aggregate, and cement-based mortar. Any grout mix that contains corrosive iron, aluminum, expansive cement, gypsum, or gas forming agents will not be acceptable.
4.4.2 Grout shall meet the performance requirements of ASTM C1107 Grade C when tested at 4°C (40°F) and 32°C (90°F).
4.4.3 The grout shall develop a compressive strength of not less than 34.5 megaPascals (MPa) [4,000 lbs per square inch (psi)] with a trowelable mix within 24 hours and a compressive strength of not less than 44.8 MPa (6,500 psi) after 28 days when tested according to ASTM C109.
4.4.4 Nonshrink cement grout shall be one of the following products:
| Masterflow 713 Plus Grout
Building Systems (BASF)
Phone 800-243-6739 |
Five Star Grout
Five Star Products, Inc.
Phone (203) 336-7900 |
4.5 Nonshrink Epoxy Grout
4.5.1 Epoxy grout shall be a three-component (resin, hardener, and aggregate), 100 percent solids epoxy resin system.
4.5.2 Epoxy grout shall develop a minimum tensile strength of 13.8 MPa (2,000 psi) as determined in accordance with ASTM C307. The compressive strength shall be a minimum of 96.5 MPa (14,000 psi) at seven days according to ASTM C579 Method B.
4.5.3 The minimum bond strength to steel shall be 15.2 MPa (2,200 psi).
4.5.4 The vertical volume change at all times before hardening shall be between 0.0 percent shrinkage and 4.0 percent expansion when measured according to ASTM C827 (modified for epoxy grouts by using an indicator ball with a specific gravity between 0.9 and 1.1).
4.5.5 The coefficient of thermal expansion shall be less than 15 x 10-6 in/in/°F when tested in accordance with ASTM C531.
4.5.6 Compressive creep at one year shall be limited to 1.0 x 10-3 mm/mm (1.0 x 10-3 in/in) when tested at 60°C (140°F) and 5.0 x 10-3 mm/mm (5.0 x 10-3 in/in) when tested at 82°C (180°F), both when tested at a 2.8 MPa (400 psi) constant load in accordance with ASTM C1181.
4.5.7 Working time shall be a minimum of 120 minutes.
4.5.8 Epoxy grout shall be selected from one of the following manufacturer’s line of products:
| Chockfast Grouting Systems
ITW Polymer Technologies. 130 Commerce Drive Montgomeryville, PA 18936 Phone (215) 855-8450
|
Five Star Epoxy Grouts
Five Star Products, Inc. 750 Commerce Drive Fairfield, CT 06825 Phone (203) 336-7900 |
The specific grouting material selected shall be based on the recommendations of the grout manufacturer’s representative and shall satisfy the parameters of the application.
4.6 Expansion Joint Material
4.6.1 Expansion joint filler material for use with sand cement and nonshrink cement grout shall be organic uni-cellular nonextruding plastic foam 12 mm (1/2 in) thick, Rodofoam Grade #327 semi-rigid strip, as manufactured by A. C. Horn, Inc., or an approved equivalent.
4.6.2 Expansion joint filler material for use with nonshrink epoxy grout shall be styrofoam.
4.7 Expansion Joint Sealant
4.7.1 Sealant for expansion joints shall be one of the following:
|
Ceilcote EJ-3 (pour) Ceilcote EJ-4 (trowel) The Ceilcote Company Brecksville, OH 44141 (877) 234-5268 |
Phillybond 7C (pour) Phillybond 6A (trowel) ITW Philadelphia Resins Corp. Montgomeryville, PA 18936 Phone (215) 855-8450
|
5. DELIVERY, STORAGE, AND HANDLING
5.1 General
5.1.1 All material shall be delivered to the job site in original, unopened, undamaged packages, clearly labeled with the brand name, date of manufacture, recommended use date, lot number, and all the information necessary for its proper use either marked on or attached to the package.
5.2 Portland Cement and Nonshrink Cement Grout
5.2.1 Any material that becomes damp or otherwise defective shall be immediately removed from the site and replaced with acceptable material.
5.2.2 The material shall be stored in a cool, dry interior area. Temperatures of the stored material shall not be lower than 4°C (40°F) or higher than 32°C (90°F).
5.2.3 The total job storage time of these cementitious materials shall be limited to six months.
5.3 Nonshrink Epoxy Grout
5.3.1 The material shall be stored in a cool, dry interior area. Temperatures of the stored material shall be maintained at 21°C (70°F) plus or minus 3°C (5°F).
5.3.2 Damaged packages or leaking containers shall be removed from the site and replaced with new material.
5.3.3 Material storage time shall be limited to the manufacturer’s recommendations.
6. PROPORTIONING AND MIXING
6.1 Sand-Cement Grout
6.1.1 Sand-cement grout shall consist of the following portions:
|
Material (ASTM Specification)
|
Parts by Volume |
Liters (cubic ft) |
Weight |
| Portland Cement (C150) | 1 1/2 | 35
(1.5) |
50 kg
(144 lbs) |
| Fine Aggregate (C33) | 2 1/2 | 58
(2.5) |
87 kg
(244 lbs) |
| Coarse Aggregate (C33) | 1 | 23
(1.0) |
35 kg
(98 lbs) |
| Water | 3/4 | 18
(0.8) |
18 kg
(50 lbs) |
6.1.2 Sand-cement grout shall be mixed as close as possible to the equipment to be grouted using a revolving drum concrete mixer or a hand mixing mortar box.
6.1.3 Water used in the mixing of sand-cement grout shall be kept at a temperature of 4°C (40°F) to
18°C (65°F). The water may be cooled with ice if necessary.
6.1.4 Grout batches shall be limited to quantities that can be used within 20 minutes. Grout shall not be retempered. Grout which has attained its initial set, or which has contained its mixing water for more than 30 minutes, shall not be used.
6.1.5 Grout shall develop compressive strengths of 20.7 MPa (3,000 psi) at 28 days. Samples shall be made and cured in accordance with ASTM C31. Compressive testing shall be according to ASTM C39.
6.2 Nonshrink Cement Grout
6.2.1 Grout shall be prepared in strict accordance with the manufacturer’s recommendations. Mixing shall be with a mechanical mortar mixer with moving blades inside the drum. Hand mixing will not be permitted. Grout shall be mixed as near as possible to the location being grouted.
6.2.2 The grout components shall be conditioned for 24 hours before mixing to the temperature specified by the grout manufacturer to produce the best results.
6.2.3 Pre-wet the mixer and empty the excess water. Water shall be accurately measured or weighed and shall be added slowly to ensure efficient mixing and to obtain the desired consistency. Mixing shall be continued for a minimum of five minutes after adding the water, or longer if necessary, to obtain uniform consistency throughout the batch. For locations where the grout must be flowed into place, additional water may be used in batching, but not in excess of the maximum amount recommended by the manufacturer. Mixing water having a temperature above 27°C (80°F) shall not be used.
6.2.4 Grout batches shall be limited to quantities that can be placed in 45 minutes. Retempering shall not be allowed. Grout that has stiffened because of delay in placing shall be discarded.
6.2.5 Test specimens shall be molded, cured, and tested according to ASTM C109. The cured grout specimens shall develop a minimum compressive strength of 34.5 MPa (5,000 psi) in seven days.
6.3 Nonshrink Epoxy Grout
6.3.1 All grout materials shall be stored in a controlled environment of 18°C (65°F) to 27°C (80°F) for 48 hours before mixing.
6.3.2 Mixing of epoxy grout shall be in strict accordance with the manufacturer’s instructions.
6.3.3 Mixing equipment shall be free of all foreign material, moisture, oil, shall be in good working order, and be properly sized.
6.3.4 A mortar mixer with moving blades shall be used for three component materials. Mixing speed shall be 15 to 20 rpm. At least one spare mortar mixer shall be onsite before starting an epoxy grout pour.
6.3.5 Do not vary the ratio of components or add solvent to change the consistency of the mix.
6.3.6 A representative of the grout manufacturer shall be on site for the initial pour unless directed otherwise by Air Products.
6.3.7 Do not vary the ratio of components or add solvent to change the consistency of the mix.
7. PREPARATION FOR INSTALLATION
7.1 Preparation of Surfaces
7.1.1 Concrete Surfaces
7.1.1.1 All concrete surfaces that will be in contact with grout for column base plates and equipment bases shall be chipped with a bush hammer or hand chipping gun to expose a minimum of 50% aggregate so as to remove all laitance, unsound concrete, oil- or grease-stained concrete, and provide a rough surface for good bonding. Use of jackhammers is strictly prohibited. The resulting concrete surface shall be free of dust or loose particles. If air hoses are used to blow off surfaces, oil-entrapment filters should be used to prevent any oil film from being deposited. Concrete surfaces may also be vacuumed when necessary to ensure compliance with environmental regulations.
7.1.1.2 Concrete surfaces prepared as specified in paragraph 7.1.1.1, which will be in contact with nonshrink cement grout, shall be saturated with water and kept constantly wet by means of water-soaked burlap, fog spray, or other approved means, for a period of not less than 24 hours before placement of grout. During placement of grout, the wetted concrete surfaces which will be in contact with grout shall be kept wet, but free from excess water.
7.1.1.3 Concrete surfaces prepared as specified in paragraph 7.1.1.1, which will be in contact with sand cement grout, shall be saturated with water and kept constantly wet by means of water-soaked burlap, fog spray, or other approved means, for a period of not less than eight hours before placement of grout. During placement of grout, the wetted concrete surfaces which will be in contact with grout shall be kept wet, but free from excess water.
7.1.1.4 Concrete surfaces prepared as specified in paragraph 7.1.1.1, which will be in contact with epoxy grout, shall be dry and free of oil.
7.1.1.5 It is recommended that the concrete cure for 28 days before any grouting. If the grouting installation cannot wait for the concrete to cure 28 days, the concrete must have a minimum cure of seven days and a minimum compressive strength of 20.7 MPa (3,000 psi)before surface preparation or grouting.
7.1.1.6 When recommended by the grout manufacturer’s representative, concrete surfaces shall be warmed or cooled to temperatures specified for best results.
7.1.1.7 The concrete surfaces of pockets that have been formed in the foundation concrete to facilitate the placement of anchor bolts shall be prepared as specified in paragraph 7.1.1.1.
7.1.2 Metal Surfaces
7.1.2.1 Metal surfaces that will be in contact with nonshrink or sand-cement grout shall be cleaned of oil, grease, laitance, rust, scale, dirt, and loose material by sandblasting or power tool cleaning, if necessary. If air hoses are used to blow off surfaces, oil-entrapment filters should be used to prevent any oil film from being deposited.
7.1.2.2 Using clean solvent and rags, solvent wash these surfaces as required with xylol (or equivalent highly volatile solvent that leaves a nonfilm residue) to achieve a clean, fast-drying surface.
7.1.2.3 Dry prepared surfaces with clean rags immediately after washing.
7.1.2.4 Check base or bed plates and the proposed method of placing grout to determine the steps necessary to prevent trapping air beneath the plates. Provide 6 mm (1/4 in) air relief holes if needed.
7.1.2.5 Where epoxy grout will be used, reinforcing bars, dowels, anchor bolts, and metal surfaces of machinery bases shall be supplied either not painted or with a paint system that is compatible with epoxy grout. Said items shall be cleaned to the requirements of SSPC-SP10, near white blast. If grouting is not to be done immediately, surfaces may be primed in accordance with 4WEQ-6804 with the intermediate and top coat omitted. Where the machinery base has been supplied with an epoxy grout compatible paint system, the surfaces that will be in contact with the grout shall be cleaned per paragraphs 7.1.2.2 and 7.1.2.3.
7.2 Holes in Concrete
7.2.1 Holes drilled in hardened concrete for epoxy grouting of anchor bolts, reinforcing bars, and dowels shall be drilled with a rotary impact drill to a diameter indicated on the drawings. Care shall be taken to ensure that the appropriate grout is selected for the annular space provided. The hole shall be cleaned to remove concrete dust. Do not use compressed air to dry the hole unless it is oil-free air. The hole shall be clean and dry before introduction of the epoxy.
7.3 Annular Space at Anchor Bolt Sleeve
7.3.1 The sleeve shall be carefully cleaned of all debris, dried, and protected from the entry of any foreign material until the equipment or base plate is in place.
7.3.2 Except where indicated on the grout schedule, the pipe sleeve shall be grouted before grouting the equipment or base plate.
7.3.3 Where bolt stretch is required but no significant lateral loads must be transferred to the foundation (for example, compressors), the bolt sleeve shall be filled with elastomeric material or expanding urethane foam to prevent the annular space around the bolt from being filled with grout. Requirements are specified on the drawings.
7.3.4 Anchor bolts and jack screws in compressor installations shall have their threads protected from bonding to the grout. Anchor bolts shall utilize foam pipe insulation or moldable foam sealed to prevent grout ingress to the threads. The height of the foam shall be such that installation of the compressor shall crush the foam to create a good seal to the concrete and metal surface. Jack screws shall be lubricated with a non-melt grease or wrapped with duct tape.
7.3.5 Where bolt stretch is required and significant lateral loads must be transferred through the bolt to the foundation (for example, cold boxes and distillation columns), the bolt shall be coated with wax/grease and the sleeve shall be filled with grout before the bolt has been tensioned to the specified value. Normal installation sequence shall be to grout the equipment base and bolt sleeve, allow grout to cure, then tension the anchor bolt.
7.4 Forms
7.4.1 Forms for flowable grout shall conform to the grout manufacturer’s recommendations. The method of forming shall permit rapid and complete filling of the space to be grouted and shall keep the grout in full contact with the underside of the base plate until the grout has hardened. Forms shall be strong, tight, and braced such that they will not leak or buckle under the weight of the flowable grout. On the side where grout is to be placed, allow at least 100 mm (4 in) clearance between the form and the base and enough height to provide 300 mm (12 in) or more head of grout. On all other sides, the contractor shall provide not less than 50 mm (2 in) or more clearance and several inches of height for head of grout.
7.4.2 Forms for grout shall be sturdy, strong, and shall be installed according to ACI 347.
7.4.3 When placing sand-cement or nonshrink grout, the inside of wood forms shall be thoroughly drenched and maintained wet. Metal or fiber forms shall be coated with nonstaining mineral oil or a soft paste wax.
7.4.4 When placing epoxy grout, the inside of forms shall be thoroughly waxed with two heavy coats of soft paste wax. Wax coating shall be applied with the forms not in place to avoid getting wax on the concrete. The forms may be lined with a smooth plastic sheet instead of a wax coating. Care must be taken to avoid wrinkles in the plastic sheet.
7.4.5 Use of liquid wax on forms in any grouting application is prohibited.
7.4.6 Forms should be caulked to prevent leakage of grout and loss of head.
7.4.7 Areas that are not to be grouted, such as oil pans or air circulation spaces, must be sealed off before the equipment is lowered into place. Expandable fabric hose, oakum or hemp rope, and styrofoam are acceptable materials to block off these areas.
7.4.8 When placing epoxy grout, all internal and external corners of the form shall be fitted with a 45‑degree chamfer.
7.4.9 To maintain a clean appearance of the equipment and aid cleanup, mask areas adjacent to where the grout will be poured to protect the equipment from grout splashing.
8. PLACING GROUT
8.1 General
8.1.1 Unless otherwise permitted by the grout manufacturer and approved by the engineer, grout shall not be placed when the temperature of the foundation, base plates, equipment, or grout is below 4°C (40°F) or over 32°C (90°F). When necessary, temperatures shall be established and maintained by use of heated enclosures or by the use of sunshades, fans, water sprinkling, water‑soaked new burlap or other engineer-approved methods. Grout shall never be placed at a higher or lower temperature than the grout manufacturer recommends.
8.1.2 Grout shall not be placed until the item to be grouted is in final position and fastened. Items of equipment and columns shall be brought to proper elevation and alignment, leveled, or plumbed as applicable. Anchor bolts shall not be tightened in installations where bolt stretch is critical, such as compressors, until the grout has cured.
8.1.3 Expansion joints shall be installed according to the recommendations of the grout manufacturer’s representative but should generally be placed on 0.9 to 1.2 m (3 to 4 ft) centers. The location of the expansion joints should not restrict the flow of the grout during placement. Expansion joints are incorporated into large pours and at sharp corners to reduce cracking.
8.1.4 Dowels between the concrete and the grout may be required to restrict edge curl in certain applications. Application details shall be resolved with the grout manufacturer’s representative.
8.2 Sand-Cement Grouting
8.2.1 Sand-cement grout shall be placed as soon as proper mixing of the material has been achieved.
8.3 Nonshrink Cement Grouting
8.3.1 Flowable grout shall be used for compressor and motor bases or other similar conditions where dry packing methods are not effective. Grout shall be poured from one side only to avoid entrapping air. Provisions shall be made in advance to relieve entrapped air from beneath foundation plates.
8.3.2 Grout shall be placed quickly and continuously to avoid undesirable effects of overworking, which results in segregation, bleeding, and disturbing initial set.
8.3.3 If recommended by the manufacturer, flexible steel strapping shall be used for rodding the grout beneath the base plate. The strapping shall be moved slowly back and forth to help flow the grout into place to ensure that voids between anchor bolts and sleeves are filled and that air entrapment is minimized.
8.3.4 Unless permitted by the manufacturer, grout shall not be vibrated. Adjacent operating machinery, if any, shall be shut down until the grout takes its initial set.
8.3.5 To assist in placing the grout, a headbox shall be used. The headbox is used to produce a hydrostatic head and shall remain filled until all grout has been placed.
8.3.6 For large base plates, the grout may be placed using standpipes or a grout pump through center holes. Continuous flow of the grout under this pressure grouting method is imperative, and air relief holes shall be provided at the high point of each section. Before commencing the grouting, the contractor shall obtain from the engineer written approval of his grouting procedure.
8.4 Nonshrink Epoxy Grouting
8.4.1 To avoid entrapping air, grout shall be poured from one side only. Provisions shall be made in advance to relieve entrapped air from beneath foundation plates.
8.4.2 Application of epoxy grout shall be in strict conformance to the manufacturer’s recommendations. Surfaces to be exposed to the epoxy shall be clean, dry, and sound before application.
8.4.3 A headbox maintaining hydrostatic head pressure shall be maintained by keeping the level of grout in the headbox above the bottom of the baseplate. The headbox shall be filled to the maximum level and grout worked down to top of baseplate.
8.4.4 No grout shall be placed in the depressed portion of the crankcase under a reciprocating compressor frame. This space is kept open to help dissipate the heat generated by the machine.
8.4.5 Under no circumstances shall vibration be used to help the epoxy grout flow. Use push tools with flat ends to help distribute the grout, using long strokes rather than short jabs. Violent ramming of the grout shall not be permitted.
8.4.6 After pouring, brush all exposed grout areas using a paintbrush with ITW Philadelphia Resins IMPAX IXT-59 Solvent or Air Products approved equal to provide a smooth, glass-like finish. Repeat as necessary.
9. FINISHING, CURING, AND PROTECTING
9.1 General
9.1.1 Shims, wedges, and jackscrews that have been used for alignment shall be removed after the grout has cured and before the anchor bolts are tightened. Openings resulting from this removal shall be filled with the grouting material used for the installation.
9.2 Edge Finish
9.2.1 Nonshrink Cement Grout
9.2.1.1 Nonshrink grout shall be finished according to the manufacturer’s recommendations. Excess grout shall be removed and cut back as shown on the drawings.
9.2.1.2 Just before the grout has reached its final set, the grout must be cut back to the lower edge of the plate. A vertical cut is recommended.
9.2.2 Nonshrink Epoxy Grout
9.2.2.1 Areas shall be cleaned of excess grout and troweled or ground to a smooth finish to match the surrounding concrete.
9.2.2.2 Epoxy grout cannot be trimmed after set. It must be left at final placement level with all chamfer strips built into the forms.
9.2.2.3 After removal of the forms, sharp corners shall be rounded using a grinder.
9.3 Curing and Protection
9.3.1 General
9.3.1.1 During the curing period, grouted equipment shall not be operated nor shall grouted base plates of structural steel be subjected to lateral forces.
9.3.1.2 In exposed areas, temporary shelters shall be provided to either shade the grouting work in the summer or to enclose an area that is heated in the winter. Use of coke-fired salamanders or heaters is prohibited in any applications.
9.3.2 Sand-Cement Grout
9.3.2.1 Temperature of the foundation or bed plate must be between 2°C (35°F) and 24°C (75°F) for
24 hours after placement.
9.3.3 Nonshrink Cement Grout
9.3.3.1 Grout shall be kept moist for a minimum of three days. The method needed to protect the grout 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.
9.3.3.2 In exposed areas, temporary shelters shall be provided to either shade the grouting work in the summer or to enclose an area that is heated in the winter. Use of coke-fired salamanders or heaters is prohibited in any applications.
9.3.3.3 Temperature of the foundation or bed plate must be between 4°C (40°F) and 32°C (90°F) for
24 hours after placement.
9.3.3.4 In compressor installations, allow nonshrink cement grout to cure for a minimum of seven days before tensioning anchor bolts.
9.3.4 Nonshrink Epoxy Grout
9.3.4.1 Epoxy grout shall be cured according to manufacturer’s recommendations.
9.3.4.2 Do not moist cure epoxy grout.
10. SEALING
10.1 All surfaces of nonshrink cement grout exposed to weather or at oxygen compressors shall be sealed with Impax SCS 100 coating as manufactured by ITW Philadelphia Resins Corp. or Air Products approved equal. A flexible, oil-resistant sealant shall also be used at the junction of the grout and base to avoid the possibility of water and oil seeping underneath the base.
10.2 All expansion joints shall be filled with a flexible, oil-resistant sealant. Sealant shall be poured 12 mm (1/2 in) deep by the width of the joint material. Typical joint sealant material is specified in paragraph 4.7.1.
10.3 On installations utilizing epoxy grout where the equipment is installed on a pedestal and the grout extends to the edge of the concrete block, the interface between the concrete and grout shall be painted to provide a finished appearance. Use red ITW Philadelphia Resins IMPAX HPU High Performance Urethane Coating or Air Products approved equivalent.
Appendix A
Additional Requirements for Reciprocating Process Gas Compressors
A1. These additional requirements shall apply to reciprocating process gas compressors because of the cyclical lateral loading of the grout.
A2. The compressor shall be grouted using the Chockfast Red grouting system provided by ITW Philadelphia Resins Corp. Use of any other material requires approval of the Air Products machinery engineer.
A3. The entire foundation above finished grade shall be sealed to prevent oil ingress into the concrete. For areas that extend 150 mm (6 in) beyond the edge of the compressor frame, a compatible anti-slip additive shall be mixed with the sealer.
A4. All corners and sharp edges to be grouted shall be rounded by the installation contractor to avoid a stress concentration. The outside corners of all skids shall have a 50 mm (2 in) radius. The Air Products machinery engineer shall be notified of any modifications made to the equipment.
A5. Placement of grout forms and expansion joints shall strictly adhere to the recommendations of the grout manufacturer’s representative.
A6. Jacking pads shall be supplied for each jack bolt location. These shall be a minimum 75 mm (3 in) diameter round bar or plates with rounded corners and at least 13 mm (1/2 in) thick. Various thicknesses may be required for each installation because of variations in the concrete surface.
A7. After the grout has fully cured, the anchor bolts shall be torqued to achieve a bolt tensile stress of 1/3 of the yield strength of the bolt material using light mineral oil as a thread lubricant. Grout softness shall be checked with a dial indicator. Equipment movement at each anchor bolt shall not exceed 0.025 mm (0.001 in) after torquing.
A8. When non-galvanized anchor bolts have been used, the threads shall be sealed after final torque with silicone caulk.