1.         PURPOSE

 

1.1       This fabrication and erection specification defines requirements for grouting between the undersides of structures and equipment, and the tops of foundations. This specification defines the types of grout and provides requirements for preparation and installation.

 

 

2.         Scope

 

2.1       This specification applies to grouting of all equipment and structures in Air Products Europe (AP-E) sites.

 

 

3.         related documents

 

None

 

 

4. GENERAL

 

4.1       Grouting shall conform to this specification and to the drawings of the structure and/or equipment manufacturer.

 

4.2       When a proprietary (nonshrink or epoxy) grout is used, any specifications and instructions of the manufacturer shall be strictly followed. When epoxy grout is used, a representative of the manufacturer shall be in attendance to oversee the operations, or the contractor shall employ a specialist supervisor experienced in the use of epoxy grout.

 

4.3       Types and thicknesses of grouting for various applications are specified in Table 1. The instructions shown on the table shall be observed unless the drawings require otherwise. In case of conflict, grout thickness shown on the equipment manufacturer’s drawing shall be used.

 

4.4       When grouting is specified as an infill to skids or structural steel base-frames, primary and secondary grouting shall be used (see Figure 1). The primary grouting shall be as specified in Table 1; secondary grouting shall be with sand/cement grout.

 

4.5       Vibration from the operation of other equipment might affect the installation and subsequent performance of grout. Such equipment shall be shut down before placing grout, and kept shut down until the grout has hardened.

 

 

5. MATERIALS

 

5.1       Sand/Cement Grout Mix for sand/cement grout shall be 2 parts of ordinary Portland cement to 5 parts sand, with no more than 17 litres of water per 50 kg sack of cement.

 

5.2       Nonshrink Grout shall be one of the following approved materials:*

 

5 Star Non-Shrink (SBD Construction Products Ltd);

Conbextra HF (Fosroc International Services Ltd);

Pagel-grout V1 (PSB Arnfried Pagel Ing).

 

5.3       Epoxy Grout shall be one of the following approved materials:*

 

Ceilcote 648-I Epoxy (Ceilcote UK Ltd);

Epoxy (SBD Construction Products Ltd);

Conbex EP (Fosroc International Services Ltd or H.I.M. Chemie);

Chockfast Red (ITW Philadelphia Resins).

 

* For manufacturers’ addresses, see Appendix A.

 

5.4       Sealant shall be flexible and oil resistant, and shall be poured or brushed on to clean, dry, oil-and wax-free primed surfaces.

 

5.5       Grout containing metal particles shall not be used.

 

 

6. PREPARATION OF FOUNDATIONS

 

6.1       Before equipment is set up, the surface of the foundation shall be chipped with a power hammer to expose the coarse aggregate and so create a key for the grout; then thoroughly clean the surface of loose concrete particles, oil, grease, and dirt.

 

6.2       Carefully clean projecting anchor bolts (including the threads) of oil, grease, and concrete laitance. Do not interfere with any specified antibonding agent. If the anti-bonding coating is damaged, reapply a heavy coating of the antibonding agent or bituminous paint.

 

6.3       Seal compressor cast-in anchor bolt sleeves at the top to exclude grout (see Figures 2 and 3).

 

6.4       Pockets for loose bolts shall be left unsealed and shall be filled with grout to anchor the bolt in position. Loose bolts shall be de-bonded over the top 300 mm or 12 x diameter of bolt, whichever is the greater, by wrapping the bolt with bitumen impregnated tape or similar. The full length of the thread shall be left untaped.

 

6.5       Sand/Cement and Nonshrink Grout:  Thoroughly soak the roughened surface of the concrete with water at least eight hours before the grout is to be placed (or as long as recommended by the grout manufacturer), and keep it wet until placing the grout begins.

 

 

7. PREPARATION OF EQUIPMENT

 

7.1       Thoroughly sandblast all surfaces that will be in contact with grout, to remove dirt and potentially loose rust and scale. Completely remove all paint, except as specified below. Obtain a clean, dry surface, removing oil and grease by washing with Xylene or a similar solvent, and dry it with clean rags immediately afterwards.

 

7.2       Epoxy Grout:  If the surfaces that will receive epoxy grout have been supplied cleaned and painted with epoxy paint, it is only necessary to degrease them as described above.

 

7.3       Mask all surfaces that are not to be grouted. Cover all wedges, packers, and levelling screws with modelling clay or glazed putty to prevent grout from adhering to them and to facilitate their removal.

 

 

8. FORMWORK

 

8.1       Formwork shall be securely constructed, and strong enough to withstand the pressure of the grout.

 

8.2       Nonshrink and Sand/Cement Grout:  Coat the inside of wooden formwork with nonstaining mineral oil.

 

8.3       Epoxy Grout:  Coat the inside of the formwork with two heavy coats of soft floor paste or car wax.

 

8.4       Seal off inaccessible areas that are not to be grouted, such as oil sumps and air-circulation spaces, before the equipment is lowered into position, so that the grout will not spread into adjacent areas. Grout can be contained by a pliable, expandable fabric hose such as a canvas fire hose, or other soft, compressible material.

 

 

9. MIXING

 

9.1       Mix grout as near as possible to the place in which it is to be used. If there is any delay in placing it, discard it when it has stiffened; do not retemper it for re-use. Do not add water, and do not remix.

 

9.2       Sand/Cement and Nonshrink Grout:  Keep the temperature of the water between 10°C and 30°C.

 

9.3       Epoxy Grout:  Place the grout within 30 minutes of mixing it.

 

 

10. INSTALLATION

 

10.1    The method of placing grout shall be planned beforehand, and steps shall be taken to ensure that air will not be trapped under base or bedplates.

 

10.2    The curing of the grout, and its subsequent performance, might be adversely affected by vibration from other equipment. Such equipment shall be shut down before placing grout, and shall not be started again until the grout has hardened.

 

10.3    Install proprietary grouts strictly in accordance with the manufacturer’s instructions. Place all grout quickly and continuously, to avoid overworking, segregation, bleeding and disturbing the initial set. Pour it from one side only, to avoid entrapping air. Shape or form the unconfined edges of grout in accordance with Figures 2 or 3. Leave the formwork in place until the grout has set.

 

10.4    If two-phase (primary and secondary) grouting is used when entirely filling a base structure, allow the primary grout to cure fully before placing the secondary grout.

 

10.5    Epoxy Grout:  Make sure that the foundation is completely dry when the grout is applied.

 

 

11. CURING

 

11.1    Successful curing of all grout is dependent on the temperature of the air, the foundation, and the equipment. Refer to the manufacturer’s instructions for the working and curing times of proprietary grout, and various temperatures.

 

11.2    Sand/Cement and Nonshrink Grout

 

11.2.1 Keep the surfaces of the foundation wet but free from excess water. Keep the temperature of the foundation and bedplate above 2°C during grouting and for the next 24 hours. If this temperature is above 24°C, cool the foundation and bedplate by sprinkling them with water, covering them with wet sacking, and protecting them with sunshades.

 

11.2.2 After installation and for seven continuous days thereafter, sand/cement and nonshrink grout shall be protected to permit proper curing.

 

11.2.3 Protection shall consist of preventing the grout from losing its moisture by covering it either with PVC sheets or with hessian, canvas, or similar absorbent materials kept saturated with water.

 

11.3    In exposed locations when heated enclosures are impracticable, infrared heaters or oil heaters may be used to raise the temperature of the equipment bedplate. Coke-fired heaters shall not be used.

 

 

12. REMOVAL OF PACKERS*, BOLT-TIGHTENING AND FINISHING

 

12.1    Do not operate the equipment until anchor bolts are tightened. Do not tighten bolts until the grout has cured: wait at least seven days after placing sand/cement grout, or follow the manufacturers’ instruction for proprietary grouts. Before tightening the bolts, remove shims and wedges, and slacken back jacking screws by a half-turn or more.

 

12.2    Sand/Cement Grout:  Do not remove packers until after the grout has hardened for at least seven days. Regrout all voids with the same material.

 

12.3    Epoxy and Nonshrink Grout:  Do not remove packers until after the grout has fully cured and hardened in accordance with the manufacturer’s instructions. Regrout all voids with the same material.

 

12.4    To avoid the possibility of water and oil seeping in during operation at the junction of the grout and the base of the equipment, apply a flexible, oil-resistant sealant around all anchor bolts and jacking or levelling screws, and around the base (see Table 1 and Figures 2 and 3).

 

*Note:  In this section, “packers” include wedges and jacking screws.

 

 

13. SAFETY PRECAUTIONS FOR EPOXY GROUT

 

13.1    Workmen shall wear goggles and rubber gloves when handling epoxy grout. Grout spilled on skin or clothing shall immediately be washed off with water.

 

13.2    Work areas shall be well ventilated to protect workers from fumes of the liquid and hardener. Smoking, welding, cutting, and other processes involving naked flames shall not be permitted within 8 m of the mixing and grouting areas. This prohibition shall be prominently displayed by suitable signs properly posted at access points.

 

 

14. CHANGE LOG

 

Rev.	Date	Subject Matter Expert	Description of Revision
0	April 2007	Ian Bigg	New document

 

 

 

 

Table 1

 

Grouting Schedule

(see paragraph 4.3)

 

Type of equipment, machinery or structure	Minimum thicknesses of grout (refer also to the manufacturer’s drawings)				Edge Finish Detail
	Sand/ Cement	Nonshrink	Epoxy
Cold boxes and building columns, pipe supports and racks	30 mm*	….	….		Fig 2
Coolers, vaporizers, pipe racks, miscellaneous pipe and equipment supports	30 mm	…..	…..		Fig 2
Pumps and centrifugal blowers with direct grouting to base or with separate soleplates	30 mm	…..	…..		Fig 2
Pumps, centrifugal blowers and expansion turbines with drivers mounted on common base plates	30 mm	…..	…..		Fig 2
Storage vessels, flat-bottomed or supported on legs, pedestals, or skirts	30 mm	…..	…..		Fig 2
Centrifugal compressors with direct grouting to base	…..	30 mm	…..		Fig 2
Centrifugal compressors, gear-cases, motors and turbines mounted on a fabricated steel base structure	…..	30 mm			Fig 2**
Centrifugal compressors, gear-cases, motors and turbines mounted on individual soleplates***	…..	30 mm	…..		Fig 2**
Packaged machinery and process equipment mounted on a fabricated steel base structure	…..	30 mm	…..		Fig 2**
Reciprocating compressors with drivers either with direct grouting to base or with separate soleplates	…..	…..	50 mm		Fig 3**
Reciprocating compressors with drivers mounted on a fabricated steel base structure	…..		30 mm		Fig 3**
Lobe-type blowers	…..	30mm****	…..		Fig 2

Notes:

*          Use epoxy grout when the direct bearing pressure exceeds 5 N/mm2.

**        Apply sealant to the exposed surfaces of grout and nuts.

***     A soleplate is a loose plate underneath the base of equipment, which allows the equipment to be realigned by inserting shims between its base and the soleplate.

****    Base frame to be filled in accordance with clause 4.4.

 

 

Figure 1

 

Two-Phase (Primary and Secondary) Grouting

 

 

 

 

 

 

Figure 2

 

Sand/Cement and Nonshrink Grouts

 

 

 

 

 

Figure 3

 

Epoxy Grout

 

 

 

 

 

 

 

 

 

 

Appendix A

 

Suppliers’ Addresses

 

(Correct at the time of publication)

 

 

Fosroc International Limited

Bourne Road, Aston, Birmingham B6 7RB

Tel:      0121 328 6866

Fax:      0121 327 2843

 

 

 

PSB Arnfried Pagel Ing Spezial-Beton-Fabriken Gmbh & Co KG

Therbeckenring 9, D-4300 Essen 11, Federal Republic of Germany

Tel:      00 49 201 673040/684879

Telex:   857469 PAGEL D

 

 

 

SBD Construction Products Limited

Dickens House, Maulden Road, Flitwick, Bedfordshire MK45  5BY

Tel:      01525 718877

Fax:      01525 718988

 

 

 

ITW Philadelphia Resins

Avenue De Broqueville 275

1200 Wol-S-Lambert

Brussels

Belgium

Tel:      00 32 2 770 6292

Fax:      00 32 2 770 7360