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CONTENTS :
1. General information
2. Suggestions for a good grouting job
3. Materials and equipment required
4. Grouting
5. Ste testing of grout
6. Do's and Dnt's for Flowgrout grouts
7. Common problems encountered during grouting
1. GENERAL INFORMATION
1.1 FLOWGROUT 60 is a ready to use grouting
compound in powder form, available in 25 kg
sacks, packed in double lined LDPE inner sack
and an outer HDPE woven sack.
1.2 FLOWGROUT 60 is a non-shrink, free flow,
ultra high strength grouting compound. The
expansion of the grout commences after about 20
minutes. Mixed grout should be consumed within
30 minutes after mixing. If the ambient
temperature is very high (say above 40oC) and
humidity also is low, the grout tends to lose
moisture fast and thus the fluidity is reduced.
Under such circumstances, mixed grout may have
to be consumed immediately after mixing.
1.3 FLOWGROUT 60 requires only the addition of
water. Under certain specific conditions,
addition of pea gravel or washed and dried (SSD)
coarse aggregate of size 5-12mm is permitted. No
other addition should be made under any
circumstances.
1.4 FLOWGROUT 60 yields a free flowing grout
when mixed with water at a water/powder ratio of
0.18. under no circumstances, more water should
be added. Water should be precisely measured for
each batch of grout mixed. When mixing large
quantities (more than 100 kg per batch), slight
reduction of water is possible. However, a trial
mix should be made with reduced water to
ascertain whether the fluidity obtained is
sufficient for the job. Maximum addition 0.18
but vary with temperature/size of batch mixer.
1.5 FLOWGROUT 60, being a cementitious grout,
should be thoroughly protected from moisture
till it is used.
1.6 Each bag of grouting compound, when mixed
with the specified 18% water, yields 13.2 litres
of mixed grout.
1.7 Like all cementitious materials, FLOWGROUT
60 also should be cured for atleast 7 days.
Curing may commence when the grout has reached
'final set'. This takes, depending on the
weather conditions (temperature, humidity and
wind velocity) approximately 6-8 hours after
mixing.
1.8 FLOWGROUT 60 gains strength rapidly.
Typically, it gains a strength of around 250kg/sq.cm
in 24 hours, around 450 kg/sq.cm. in 3 days,
around 550 kg/sq.cm. in 7 days and around 650
kg/sq.cm in 28 days.
1.9 Loads can be transferred on to the
foundation 3 days after the grouting with
FLOWGROUT 60 or as required based on design
loads etc.
2. SUGGESTIONS FOR A GOOD GROUTING JOB
2.1 Keep the gap plate minimum but not less than
30mm.
2.2 Preparations are very important. Proper
surface reparation and shuttering are essential.
2.3 Materials and equipment as listed must be
kept ready before starting of the grouting
operation.
2.4 In hot and dry climates where temperatures
are more than 40oC, grouting may be carried out
in the evenings. Water cooled by ice blocks may
also be used for grouting.
2.5 Sufficient labour force should be arranged.
2.6 Location of mixer, material etc. are
important. Mixer should be located as close to
the grouting site as possible.
2.7 If site testing of grout is required, please
ensure that the product is tested as per the
section enclosed and the casting of cubes and
testing is done in the presence of
representatives from your side and fairmate.
2.8 Prior visit to the site to study the
conditions by the Engineer incharge of grouting
is a must. This helps in eliminating many of the
problems to be encountered later.
2.9 A meeting of
a. the contractor who is given the job
b. the civil engineers connected with the
project
c. the erection engineer incharge of grouting
d. Fairmate representatives
One or two days before starting the work will
help clearing all the doubts and to arrive at
necessary strategies to carry out the grouting
job effectively.
2.10 Please feel free to ask for any special or
expert technical help or support fro Fairmate if
found necessary.
3. MATERIALS AND EQUIPMENT REQUIRED
3.1 Hammer, nails, chisels etc.
3.2 Wire brush & cleaning tools
3.3 Carpentry tools for formwork
3.4 Sufficient lengths of MS angles or smoothly
planed timber
3.5 Reebol formcote for coating the wooden
shuttering
3.6 A suitable mould releasing agent (Reebol)
3.7 Masonry tools like pan, trowel etc.
3.8 Air blower
3.9 Mixer or drill and paddle for mixing the
grout
3.10 Plastic buckets or cans to carry the grout
and pour it
3.11 A measuring can be measure the quantity of
water precisely
3.12 One or two pans of FLOWGROUT 60 / Renderoc
plug to seal any leakages
3.13 Two or three large drums for stirring water
for the grouting
3.14 A powerful torch light to examine darker
areas
3.15 Sufficient lengths of hose pipe
4. GROUTING
Grouting is done in two stages
4.1 Bolt pocket grouting
4.2 Base plate or base frame grouting
4.1 Bolt Pocket Grouting
4.1.1 The inside of the bolt pockets is cleaned
free from debris etc., using oil free compressed
air. If the walls of the pockets are smooth,
they should be roughened by using wire brush or
chisels, and then cleaned.
If any oil or grease deposits are observed on
the walls of the bolt pockets they should be
thoroughly cleaned.
4.1.2 After cleaning, the pockets are filled
with water and left for 1 day before grouting.
Place the grout after removing all the water
using a hand pump and compressed air.
4.1.3 While grouting bolt pockets, which are
difficult for areas a funnel and a hose pipe (of
about 1” ID). For pockets with sides / diameter
more than 100 mm. 5-12mm coarse aggregates in
the proportion of 50 to 100% by weight of
FLOWGROUT 60 may be mixed. In that case, the
hose pipe should be of larger dia(say about
60mm)
4.1.4 The bolt pocket are filled with grout upto
25mm below the top surface. This is to form a
key with the second stage when grouting of base
plate or base frame is done.
4.2 Base Plate Grouting :
Preparation and Formwork :
Initial Preparation
4.2.1 The underside of the base plate should be
thoroughly cleaned to remove all dust, loose
particles, etc., using compressed air. The
foundation should be well chipped before the
base plate is in position.
4.2.2 Where edges of the foundation concrete are
damaged or uneven, the same should be repaired
with FLOWGROUT 60 mortar to get an even edge so
that the formwork can be set up with least
amount of gap around the foundation.
Refer figures 1 (a) & 1 (b)
4.2.3 Formwork
(a) Smooth planed timber (coated earlier with
Reebol Formcote) coated with Reebol or any
other good mould releasing agent preferably in a
single piece is used along side for shuttering.
(b) 1 inch thick foam strips are fastened or
pasted on the surface of shuttering timer, where
the timber will eat flush with the concrete
surface Refer Fig.2.
The shuttering is placed flush against the
concrete surface using struts and other means of
fastening. Refer Fig. 3.
Wherever the pedestals extend beyond the
concrete foundation below, it should be ensured
that the shuttering edge is in flush against the
bottom of the pedestal and absolutely no gap is
present between the two. Here again, a strip of
1' foam parted to the edge will help.
(c) The shuttering on all sides should be about
50mm from the edge of the base plate except at
the pouring side which may be about 100-150mm.
i.e., showulder width should be restricted to
50mm on all sides and 150mm on pouring side.
(d) A pouring hopper may be built on one side or
formwork. The pouring hopper may be about 400mm
high. 200mm wide at bottom and should have a
draw gate mechanism. This is for building
suitable head for grout to flow.
(e) The gaps and corners between shuttering and
concrete should be sealed using FLOWGROUT 60
mixed to a stiff paste. This is to make the
shuttering leakproof.
(f) For long base plate stop ends can be built
using FLOWGROUT 60 mixe to mortar consistency to
divide the area into bays.
(g) Compressed air is blown to clean the
concrete surface free from debris, dust, prices,
etc.
(h) Water is filled to a height of atleast 50mm
on the concrete foundation. Any serious leaks
from the shuttering is rectified using FLOWGROUT
60 mortar. The water is left to stand for
atleast 24 hours prior to grouting so that the
surface is saturated.
4.2.4 Mixing placing and Curing
(a) After the shuttering work is complete and
has been checked for leak proof nature, the
grouting area is saturated with water 24 hours
prior to grouting.
(b) The water is removed using a siphon and the
area is made clean and free from dust, loose
particles, wooden pieces etc., using an air
blower.
(c) The materials and equipment procured and
placed near the site is checked once again to
ensure that nothing is missing and everything is
in perfect order.
(d) The quantity of grout estimated and that
procured is checked to avoid troubles later. 10%
extra material is to be kept as a factor of
safety. It should be ensured that the labour
force arranged is sufficient.
(e) The mechanical mixer is started and about
80% - 85% of the water to be added is placed
into the mixer.
(f) FLOWGROUT 60 is added slowly bag by bag into
the mixing drum with the mixer running.
(g) Next the balance 15-20% water is added.
(h) Mixing is carried out for 5 minutes.
(i) The grout is checked to ensure that there
are no lumps and there is no segregation and
bleeding.
(j) The grout is unloaded into buckets and
transported by labour and placed or poured in
the proper place.
(k) Pouring is kept continuous and from one side
only.
(l) The shuttering is observed all round to
detect any leaks. The touch may be used for this
purpose. If there is small leakage it should be
arrested using FLOWGROUT 60 powder.
(m) Grouting is continued till the whole area is
grouted.
(n) Curing is started after the grout reaches
touch hard state. (about 6-8 hours)
(o) The shuttering may be removed after 24
hours.
(p) Curing must be continued for a minimum
period of 7 days.
5. SITE TESTING OF GROUT
5.1 If site testing of FLOWGROUT 60 is
necessary, it should be done the following way.
Normally, compressive strength is tested at the
site either before grouting or after grouting,
by casting cubes.
5.2 The cube moulds should be of size 70.6mm x
70.6mm x 70.6mm and should carry ISI mark as per
IS : 4031
Each mould should have a bottom plate, which is
usually a separate piece.
The inside faces of the cube moulds and the
faces of the bottom plate should be free from
defects like pitting, rust etc. They should be
machined smooth.
5.3 The cube moulds should be coated with a very
thin coat of release agent, e.g. Fairmate.
(Grease or waste oil should not be used.
5.4 Grout should be mechanically mixed using a
water / powder ratio of 0.18.
5.5 No rodding or vibrating should be done while
casting the cubes. FLOWGROUT 60 is self
compacting. The grout should be poured into the
cube mould using a spatula. However, after the
mould is filled completely with FLOWGROUT 60,
the grout should be mildly agitated, especially
at the corners using a thick rod to expel
entrapped air.
5.6 After leveling the grout in the mould using
a straight edge, say a hacksaw blade, a
restraint plate should be placed carefully on
the mould without entrapping air. Refer figures
9(a) and 9(b).
5.7 It is convenient to place one mould above
the other such that the top restraint plate will
act as the bottom plate of the top mould.
Remember to keep a restraining plate on the top
most mould also.
5.8 15 cubes may be cast while grouting, three
each for testing after 1,3,7 and 28 days and
three more as reserve to test at another
laboratory, incase of doubt.
5.9 Cubes should be demoulded after one day, and
must be marked on the top/bottom with a pencil
suitably.
5.10 Cubes should be immediately immersed in
water for curing till they are tested for
strength, note drying out of cubes at an early
age will affect strength.
5.11 While testing, the loading should be done
along the axis perpendicular to the pouring
axis.
5.12 The rate of loading / stressing should not
exceed 350 kgs/sq.cm. per minute (35 N/mm2 per
minute)
The machine in which the cubes are tested should
be in good working condition and calibrated
accurately)
5.13 Contact our sales engineer at your place or
Fairmate Chemicals Pvt. Ltd, Vadodara for
testing any other properties of FLOWGROUT 60
6. DO'S & DON'TS FOR FLOWGROUT 60
6.1 DO
6.1.1 Store FLOWGROUT 60 in a well inclined
space protected from moisture.
6.1.2 Checked everything for damages and expiry
date before using.
6.1.3 Mix mechanically.
6.1.4 Use mixed grout within 30 minutes
depending on temperature and humidity.
6.1.5 Ensure shuttering is strong and leakproof
6.1.6 Start curing as soon as grout reaches
touch hard state
6.1.7 Cure grout atleast for a period of 7 days.
6.2 DON'TS
6.2.1 Mix more water than specified i.e. 4.5
litres/bag of FLOWGROUT 60
6.2.2 Mix any other ingredient like sand, cement
etc. to the grout
6.2.3 Have exposed edges larger than necessary.
50mm on all sides and 100-150mm on
pouring side is ideal.
6.2.4 Use vibrators
6.2.5 Pour grout from two different sides.
7. COMMON PROBLEMS ENCOUNTERED DURING GROUTING
7.1 Formation of Lumps
Add the grout slurry into the mixer during
mixing to avoid this or put 1 or 2 concrete
cubes or big stones in the mixer. This will
break the lumps.
7.2 Segregation & Bleeding
Check the quantity of water added and ensure
proper mixing.
7.3 Leaking of grout
Arrest the leakage using FLOWGROUT 60 powder. |
