90206-000-cv-sp-107 specification for grouting in all areas (rev.a0).pdf

Project Name: CONSTRUCTION OF OFF-SPEC

CRUDE TANK AND REQUIRED ITEMS IN KARANJ/PARSI UNITS

Doc. Name: Specification for Grouting

Company Doc. No.: Class: 2 Page: 1 (10)

Proj. Doc. No.: 90206-000-CV-SP-107 Rev.: 00

National Iranian South Oilfields Co. (NISOC)

Specification for Grouting

B.R. : 53-73-90206PROJECT : CONSTRUCTION OF OFF-SPEC CRUDE TANK AND REQUIRED

ITEMS IN KARANJ/PARSI UNITS COMPANY : NATIONAL IRANIAN SOUTH OILFIELDS COMPANY (NISOC)LOCATION : KARANJ/PARSI-KHUZESTAN-IRAN

00 21/01/2012 FOR TENDEING I.R.M. I.R.M. A.B. A.A.L.

REV. DATE DESCRIPTION ORIG. PRP’D CHK’D APP’D







TABULATION OF REVISED PAGES

Page Rev. 0 Rev. 01 Rev. 02 Rev. 03 Rev. 04 Page Rev. 0 Rev. 01 Rev. 02 Rev. 03 Rev. 04

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Contents:

1.0 General Statement

1.1 Scope

1.2 Definition

2.0 APPLICABLE DOCUMENTS

3.0 TYPES OF GROUT

4.0 USES OF GROUT

5.0 GROUT MATERIALS

5.1 General

5.2 Type G1 - Cement-Sand Grout

5.3 Type G2 - Cement - Base Non shrink Grout

5.4 Type G3 - Epoxy Grout

6.0 SURFACE PREPARATION

7.0 FORMWORK

8.0 PLACING, FINISHING AND CURING

9.0 TESTING







1- General Statement1.1- Scope

This project Specification defines the requirements for materials and methods for the

grouting of machines, equipment and structural steel works in CONSTRUCTION OF

OFF-SPEC CRUDE TANK AND REQUIRED ITEMS IN KARANJ/PARSI UNITS

Project.

1.2- Definition

Owner: National Iranian South Oil-Fields Company (NISOC).

2- Applicable DocumentsAmerican Standards

ASTM C33 Standard Specification for Concrete Aggregates.

ASTM C109 Standard Test Method for Compressive Strength of Hydraulic

Cement Mortars.

ASTM C150 Standard Specification for Portland Cement.

ASTM C191 Time of setting of Hydraulic Cement by Vicat Needle Test

Method.

ASTM C531 Standard Test Method for Linear Shrinkage and Coefficient for

thermal Expansion of chemical-Resistant Mortars, Grouts and

Monolithic Surfacing.

ASTM C579 Standard Test Method for Compressive Strength of Chemical

Resistant Mortar, Grouts and Monolithic Surface.

ASTM C827 Standard Test Method for Change in Height at Early Ages of

Cylindrical Specimens for Cementations Mixtures.







3- Types of GroutGrouts specified are of two types:

- Type G1 : Sand-Cement Grout

A Sand -cement grout prepared from basic material on site.

- Type G2 : Cement-Base Non shrink Grout.

A factory prepared shrink controlled grout.

- Type G3 : Epoxy Grout.

Notwithstanding the requirements of this specification, Type G2 shall be stored and

used fully in accordance with the manufacturer’s instructions.

4- Uses of Grout4.1- The various types of grout shall be used as described below. However, the type,

location and extent of any grouting will be defined by the Engineering contractor on

the construction drawings associated with a particular section of work the minimum

thickness shall be 25mm and maximum thickness of grout under the highest point of

machinery base shall be 50mm.

Type G1: Under small pumps and other light equipment.

Its use shall be limited for grouting minor steel structure not assuming

structural function subject to the approval of the owner.

Type G2: Under all reciprocating pumps,

Under all plant air compressors, Under all centrifugal compressors and

other machinery, and machinery of sole plates where specified by

manufacturer, Under all equipment, regardless of size and weight, which, in

the opinion of the Engineer will produce static or dynamic stresses in

excess of those allowable for Cementations grout, unless epoxy grout (type

G3) is specified on drawings. Under Pipe rack and steel structure column

base plates.







Type G3: Shall be applied for grouting of compressors or heavy equipments subject

to vibration and elsewhere if specified on the drawings.

4.2- All types of grout shall be placed as soon as possible after the erection of the

item of structure, plant or equipment.

5- Grout Materials

5.1- General

All materials shall be approved by the Engineer or Owner’s Representative.

All Non shrink grout constituents except water shall consist of pre-measured,

prepackaged materials supplied by the manufacturer.

All grouts shall be non-corrosive, non-staining and resistant to the effects of

moisture. Project authorization shall not absolve the subcontractor from any

responsibilities whatsoever in respect of the work to be carried out.

Cement aggregate shall be delivered to the site in complete and dry bags. The

subcontractor shall be responsible for storing materials for making grout in a dry,

weatherproof area on pallets and within the temperature ranges specified by their

manufacturers.

5.2- Type G1 - Cement-Sand Grout

Cement shall be Portland cement in accordance with ASTM C150. Sand shall

meet all the requirements for fine aggregate as specified in ASTM C33. In

addition, the aggregate grain size shall be between 0.08 and 2.0 mm and

thoroughly washed.

5.2.1- Mix Design

The mix proportions shall be checked on site by trial mixes. The grout

shall be adequately mixed in a paddle-type mortar mixer or by other

suitable mechanical means. The water-cement ratio shall be the minimum

required for adequate flow properties.

The sand-cement mix shall be such that the compressive strength of the

grout at 7 days shall not be less than 28 N/mm2, as determined by tests on

50 mm cubes in accordance with ASTM C109. Neat cement grout shall







not be used. Mix shall be 1:1 for bedding thickness not greater than 25 mm

and 1:2 for bedding thickness not greater than 50 mm. Where bedding

thickness is greater, the mix shall be in accordance with the Engineer’s

instructions.

Other special grout, e.g. rapid hardening or quick setting, shall only be

used with prior written agreement from the Engineer.

5.3- Type G2 - Cement - Base non Shrink Grout

The grout mix shall have a compressive strength not less than 40 N/mm2 at 7

days as determined by tests on 50 mm cubes in accordance with ASTM C109.

Other requirements shall be as follows:

• Plastic volume Change

No shrinkage (0%) and a maximum of 4.0% expansion at any time before

initial set when tested in accordance with ASTM C827.

• Hardened Volume Changes

No shrinkage (0%) and a maximum of 0.2% expansion in the hardened state.

• Initial Set Time

Not less than 45 minutes when tested according to ASTM C191.

• Soundness

The grout shall contain no substances, aluminum powder, fluidizers, super

plasticizers, or other materials known to increase drying shrinkage or

compromise durability.

5.4- Type G3 - Epoxy Grout

Minimum compressive strength shall be 80 N/mm2 at 7 days as determined by

test in accordance with ASTM C579. Epoxy product shall be submitted for prior

approval of the owner and applied in close accordance with manufacturer's

instructions.







6- Surface PreparationThe following surface preparation shall be applied for all grouts:

• Concrete foundation shall be at least 7 days old before surface preparation.

• All laitance shall be removed down to sound concrete.

• Surface to receive grout shall be rough and reasonably level.

• Surfaces shall have been wet-cured or if not, curing compounds shall be removed

by roughening the surface.

The surfaces of concrete, underside of base plate, bolt holes and bolts shall be clean

and free from oil, grease, chemicals, dirt and other harmful matter and thoroughly

blown clean of dust and small particles by compressed, oil-free air prior to grouting.

When cement based grout is used the concrete surface including bolt holes shall be

saturated with clean water prior to grouting.

All excess water shall be removed from the concrete and bolt holes before grouting,

leaving only a damp film.

7- FormworkFormwork shall be provided for grout and shall be compatible with the method of

placing grout specified herein.

Forms shall be designed for rapid, continuous and complete filling of space to be

grouted. Forms shall be of adequate strength to withstand the horizontal forces of the

fluid grout, and shall be caulked or sealed with tape to provide a watertight seal. The

forms shall be coated with form oil heavy wax to prevent grout adherence and

absorption. The forms shall extend a minimum of 25 mm above the underside of the

base plate being grouted and a minimum of 13 mm in plan shall be left between the

form and the edge of the base plate. On the pouring side, the forms shall be located a







minimum of 50 mm away from the edge of the base plate. The top of the forms on the

pouring side shall be sufficiently high, but no less than 150 mm.

8- Placing, Finishing & CuringGrouting shall only commence once the base is leveled and written authorization given

by the Engineer. Placing of grout, base plate and grout material for foundations shall

be at an ambient temperature between 10-24°C. This temperature shall be maintained

within this range for 48 hours following installation and thereafter above 40°C until

strength exceeds 28 N/mm2. Cold water shall be used to extend working time in hot

water. Care shall be taken to ensure that the pocket or base area is completely filled

with grout which must be thoroughly compacted, free from air pockets and in full

contact with the concrete surfaces. All trapped pockets shall be vented to allow full

penetration of the grouting material. Where vent holes have been provided in base

plates these shall be used, during the pouring of grout and then the holes must be filled

with the grout material to the top level of the base plate or hole surroundings.

Place grout rapidly and continuously to avoid cold joints under the base plate. Grout

from one side to the other in 1 direction. Tamp or rod grout to eliminate voids. Be

careful not to over tamp or rod such that air is taken into the grout.

Grout placed by gravity flow shall be applied continuously under a head of not less

than 30 mm and worked until the space is completely filled. The grout shall not be

overworked. Sufficient quantities shall be mixed to ensure complete use within 1 hour.

All bolt holes and sleeves shall be adequately filled and pressure grouting used where

directed by the Engineer. Vibration shall not be used to ensure filling.

Shade the foundation from direct sunlight for at least 24 hours before and 48 hours

after grouting. Where a field service is offered by the manufacturer it shall be utilized.

The manufacturer’s guarantees may be dependent on such involvement.

Cement-based grout is to be trimmed back, after the initial set, to the level shown on

the drawings with surfaces sloped away from the base plate neatly pointed and trawled







off the left in a workmanlike manner. Chamfers 25 mm wide with the side inclined at

45°C must be formed along the whole edge of the base. Exposed edges shall be

protected against damage during the curing period.

Where shims are to be removed, or if wedges were used, they shall be removed after 3

days. On removal of the shims or wedges, the resultant spaces shall be filled with

similar grout. Foundations bolts should then be adjusted for tightness.

All curing compounds and method for application shall be approved by the Engineer

before application may commence.

9- Testing9.1- Test samples for sand-cement grout shall be taken at least once per day or once

every 1.0 m3, whichever is greater. Compressive strength tests on cubes shall

comply with ASTM C109.

9.2- Non shrink cement-base grout shall be tested at least once per day in accordance

with ASTM C109.

9.3- Prepare the following number of cubes for each type of grout and test after the

following periods for required compressive strength according to the schedule:

Grout Type 24 Hrs. 2 Days 7 Days 28 Days

Sand Cement Grout - 2 2 2

Non shrink Cement Grout 3 - 3 3

9.4- If the results of tests indicate that the grout is below the required specification, the

whole of the material shall be removed after the placing of shims, and the base

plate regrouted.