Cementitious Grouting of Machine.do

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N°: 850 21 01 Author: D Taylor

Date: Jan 2010

Sika Services AG / Tüffenwies 16 / CH-8048 Zürich / SwitzerlandPhone: +41 (0) 58 436 23 65 / Fax: +41 (0) 58 436 23 77E-Mail: [email protected]

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Method Statement forCementitious Grouting of Machine

Bases and Base Plates“Sika Services AG”

Storage Place: Corporate Intranet,Key Words: SikaGrout, 311, 314, 318, low shrinkage, high precision, base plates,

machine bases, expanding pouring mortar, ready to useScope: This method statement describes the step by step procedure for

grouting filling voids under machine bases and base plates using acement based grout.





Date: Jan 2010

Sika Services AG / Tüffenwies 16 / CH-8048 Zürich / SwitzerlandPhone: +41 58 436 23 65 / Fax: +41 58 436 23 77E-mail: [email protected]

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Table of Contents:

1. System Description..............................................................................3

1.1. References........................................................................................................ 3

1.2. Limitations......................................................................................................... 3

2.

Products................................................................................................3

2.1. Material Storage................................................................................................ 4

3. Equipment.............................................................................................4

3.1. Hand Tools........................................................................................................ 4

3.2. Mixing Tools...................................................................................................... 4

3.3. Miscellaneous Tools ......................................................................................... 4

4. Health and Safety .................................................................................5

4.1. Risk Assessment .............................................................................................. 5

4.2. Personal Protection........................................................................................... 5

4.3. First Aid............................................................................................................. 5

5.

Envi ronment .........................................................................................6

5.1. Cleaning Tools / Equipment.............................................................................. 6

5.2. Waste Disposal ................................................................................................. 6

6. Preparation ...........................................................................................6

6.1. Concrete ........................................................................................................... 6

6.2. Pre-Wetting Substrate....................................................................................... 6

6.3. Formwork.......................................................................................................... 6

7. Mixing....................................................................................................7

7.1. One Component Products ................................................................................ 7

8. Appl icat ion............................................................................................ 7

8.1.

Before Application............................................................................................. 7

8.2. Pouring Application........................................................................................... 8

8.3. Curing ............................................................................................................... 8

8.4. Application Limits .............................................................................................. 8

9. Inspection, Sampling, Quality Control ...............................................9

9.1. Substrate Quality Control - Before and After Preparation................................. 9

9.2. Before, During and After Application................................................................. 9

9.3. Performance Testing....................................................................................... 10

10. Addi tional Guidance .......................................................................... 10

10.1. Grouting in Confined Spaces.......................................................................... 10

10.2.

Grouting Base Plates...................................................................................... 11

10.3.

Grouting More Than One Base Plate.............................................................. 11

10.4. Grouting Large Areas...................................................................................... 12

10.5. Grouting Thick Applications ............................................................................ 12

11. Yield and Consumption .....................................................................13

11.1. Yield................................................................................................................ 13

11.2. Consumption................................................................................................... 13





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1. System Descript ion

The following refers to a ready to use high performance, low shrinkage, expandingpouring cementitious grouts which are used to form thin bed applications undermachine bases and base plates e.g. SikaGrout-311, /-314 and /-318. Included is

additional guidance provided at the back of the method statement for specific types ofapplications e.g. grouting in confined spaces, increasing volume etc.

1.1. References

This method statement has been written in accordance with the recommendationscontained in European Standards EN 1504: Products and systems for the protectionand repair of concrete structures, and the following relevant parts:

EN 1504 Part 1: Definitions, requirements, quality control and evaluation ofconformity

EN 1504 Part 10: Site application of products and systems, and quality control

of works

1.2. Limitations

Products shall only be applied in accordance with their intended use.

Local differences in product may result in performance variations. The mostrecent and relevant local Product Data Sheets (PDS) and Material Safety DataSheets (MSDS) shall apply.

For specific construction / build information refer to the Architect’s, Engineer’s orSpecialist’s details, drawings, specifications and risk assessments.

All work shall be carried out as directed by a supervising officer or a qualifiedengineer.

This method statement is only a guide and shall be adapted to suit local products,standards, legislation or other local requirements.

2. Products* Table to be adapted for local use (do not include technical or mechanical information)

Sika Product Name(s) Type

SikaGrout® Cement based 1 component, ready to use, free flowing,low shrinkage expanding pouring mortar





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2.1. Material Storage

Materials shall be stored properly in undamaged original sealedpackaging, in dry cooled conditions. Refer to specific informationcontained in the product data sheet regarding minimum and maximumstorage temperatures.

3. Equipment

3.1. Hand Tools

Trowels Sponge Mixing and pouring

3.2. Mixing Tools

Drill and Mixing Paddle Double Mixing Paddle Forced Action Pan MixerSmall quantities Medium quantities Large quantities

3.3. Miscellaneous Tools

Water Spray for pre-wetting surfaces





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4. Health and Safety

4.1. Risk Assessment

The risk to health and safety from falling objects or defects in thestructure shall be properly assessed.

Platforms and temporary structures shall provide a stable and safe areato work. Do not take any unnecessary risks!

4.2. Personal Protection

Work safely!

Handling or processing cement products may

generate dust which can cause mechanicalirritation to the eyes, skin, nose and throat.

Appropriate eye protection shall be worn at alltimes while handling and mixing products.

Approved dust masks shall be worn to protectthe nose and throat from dust.

Safety shoes, gloves and other appropriate skinprotection shall be worn at all times.

Always wash hands with suitable soap afterhandling products and before food consumption.

FOR DETAILED INFORMATION REFER TO THE MATERIAL SAFETY DATA SHEET

4.3. First Aid

Seek immediate medical attention in the event of excessive inhalation,ingestion or eye contact causing irritation. Do not induce vomitingunless directed by medical personnel.

Flush eyes with plenty of clean water occasionally lifting upper andlower eyelids. Remove contact lenses immediately. Continue to rinseeye for 10 minutes and then seek medical attention.

Rinse contaminated skin with plenty of water. Remove contaminated clothing andcontinue to rinse for 10 minutes and seek medical attention.






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5. Environment

5.1. Cleaning Tools / Equipment

Clean all tools and application equipment with water immediately after use. Hardenedmaterial can only be removed mechanically.

5.2. Waste Disposal

Do not empty surplus material into drains; dispose responsibly throughlicensed waste disposal contractor in accordance with legislation andlocal / regional authority requirements. Avoid runoff onto soil or intowaterways, drains or sewers.


6. Preparation

6.1. Concrete

The horizontal concrete substrate shall be in a good sound condition and free fromdust, loose material, surface contamination and materials which reduce bond.Concrete surfaces shall be generally level (within tolerances) and shall not be laid to agradient, so grout flows to the lowest end.

6.2. Pre-Wetting Substrate

Concrete surfaces shall be saturated with clean low pressure water a minimum 2hours before application ensuring that all pores and pits are adequately wet. Thesurface shall not be allowed to dry before application of the grout. Remove excesswater prior to application, and ensure there is no standing water on the surface. Thesurface shall achieve a dark matt appearance without glistening and surface pores andpits shall not contain water.

6.3. Formwork

Formwork shall be clean and fixed in place as soon as possible after the substrate hasbeen prepared. If required, release agents shall be applied to the formwork before

placing into position. Do not contaminate the substrate with the release agent andreduce bond of the grout material from spillage or run-off.

Openings in the formwork shall be protected to prevent ingress of debris orcontamination. Formwork shall be watertight and free from obstructions to allow thefree flow of grout. Formwork shall be designed to allow air and water bleed to escape.

In the case of a long base plate, ensure there is enough pressure head to help the flowof the grout. Divide into sections if necessary and apply the grout in more than onestage.





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7. Mixing

Mixing shall always be carried out in accordance with the recommendations containedin the latest product data sheet (PDS).

Do not use water beyond the stated maximum and minimum limits.

In determining the mixing ratio the wind strength, humidity, ambient and substratetemperature and shall be taken into consideration.

For best results only mix full bags

7.1. One Component Products

8. Application

The product and system shall be appropriate for the type of substrate, structure andexposure conditions which they are required.

8.1. Before Application

Working space shall be clean and tidy with no obstructions.

Record the substrate, ambient temperature and relative humidity. Checkpot life information on bag or in the product data sheet and allow forclimatic conditions e.g. high / low temperatures & humidity.

External applications shall be adequately protected. Do not apply groutin direct sun, windy, humid or rainy conditions, do not apply grout if thereis a risk of frost within 24 hours in unprotected areas.

Make sure blow holes are not obstructed and can allow the escape ofair.

Calculate the required volume for the application. Using the equation insection 10 of this method statement, calculate the consumption of theproduct and make sure there is enough material on job site for the work.

Product Procedure

Sika® MonoTop®

Place minimum recommended water ratio in mixingcontainer.

Progressively add powder whilst mechanicallymixing using low speed (maximum 500 rpm)electric drill.

Add more water if required to suit the desiredconsistency and flow properties but not exceedingmaximum dosage. Mix in total for minimum 3minutes or until the material is homogenous.





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8.2. Pouring Application

Grout shall be poured immediately after mixing into prepared openings(within 15 minutes to optimise expansion properties). Make sure airdisplaced by the grout can escape easily.

Pour the grout through the “mouth” of the formwork allowing thematerial to flow to the opposite end. Always maintain sufficient

pressure head while pouring. Ensure a process of continuous pouring to avoid airentrapment and prevent the grout flow from coming to a stop before the groutingoperation is completed.

Keep pouring until the grout is up to the top of the base plate. This will force thematerial to the underside of the baseplate and achieve an effective bearing areawithout any voids. Always pour grout from opposite ends to any blow holes.

Never grout from two places on the same application as it will be difficult to determine

if the entire void under the base plate has been filled.

Depending on the size of the application, it may be necessary to “rod” the grout with athick chain help the grout flow.

Keep any visible and exposed grout surfaces as small as possible and protect frompremature drying by curing with an appropriate method.

Do not vibrate the formwork.

8.3. Curing

Protect the fresh material from premature drying. Cure exposed area with propercuring methods for 3 days or spray with appropriate curing compound once the groutstarts to stiffen. Suitable curing covers include jute and water, plastic sheets or othersuitable membranes.

8.4. Application Limits

Do not apply a grout as a patch repair or overlay in unconfined areas (horizontal,free applications)

Avoid application in direct sun and/or strong winds.

Do not add water over the maximum recommended dosage.

Always check the material’s pot life and adjust for climate conditions.Temperature of the repair mortar and substrate shall not differ significantly.





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9. Inspection, Sampling, Quality Control

As part of “Good Practice” the grouting contractor shall provide a QC report containingthe following recommended data. For more detailed information refer to EN 1504-10

Annex A, or any other local standards or legislation which may apply.

9.1. Substrate Quality Control - Before and After Preparation

The following checks should be carried out before and after preparation.

Characteristic References Frequency Parameters

Cleanliness ofConcrete

Visual After preparation &immediately before

application

No contamination,loose particles or

defects

Delaminating

Concrete

Hammer

Sounding

After preparationNo delaminating

concrete

Roughness

Visual or EN1766 on

horizontalsurfaces

After preparation

Minimum roughness2 mm (repair area)No laitance layer

(smoothing mortars)

Surface TensileStrength of the

Substrate

EN 1542 After preparation works>1.0 N/mm² forstructural repair

Table 1 QC summary before and after preparation

9.2. Before, During and After ApplicationThe following checks should be carried out before during and after the application.

Characteristic References Frequency Parameters

Temperature(ambient &substrate)

Record During application Within PDS limits

Ambient Humidity Record During application Within PDS limits

Precipitation Record During application

Keep records and

provide protection

Wind Strength Record dailyLess than 8 m/sec or

provide protection

Batch Number Visual All bags Keep records

Table 2 QC summary before during and after application





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9.3. Performance Testing

The following can be used to check the adequacy of the application.

Characteristic References Frequency Parameters#CompressiveStrength on

40x40x160 prismsEN 12190 3 prisms per batch Within PDS limits

Cracking Visual 28 days after applicationNo cracking on

application

Presence of Voids/Delaminating

EN 12504-1Hammer

sounding or*ultrasonic

testing

After applicationNo delaminating

concrete

Adhesion Bond*(pull off)

EN 1542 Min 3 on a test area Within PDS limits

* Optional testing#

Subject to material grain size and local requirements / standards

Table 3 QC summary of performance testing

10.Addit ional Guidance

The following applications offer further guidance in specific situations.

10.1.Grouting in Conf ined Spaces

Use a sloping channel or chute to convey grout to a lowerlevel. Avoid the free fall of the material to preventsegregation of the aggregates.

Maintain a constant flow of grout during application. Applygrout only in one corner making sure there is adequatespace around the application for release of air.





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10.2.Grout ing Base Plates

The following is a typical illustration of a base plate which is not to be used forconstruction purposes.

Note: refer to specialist Engineer’s details for specific information.

10.3.Grout ing More Than One Base Plate

It is not recommended to cast large exposed areas as the grout is likely to crack.

Recommended Not Recommended

1 Formwork with suitable de-bonding agent on inside face

2 Baseplate in steel of the stanchion3 Stanchion / column4 Holding down bolts5 Levelling plates (as specified)6 High performance, low shrinkage expanding mortar e.g. SikaGrout

®311/-314 and

-318 executed separately under each machine baseplate7 Top of concrete foundation89

Air release holes to Engineers specificationCracks due to high stress on corners

1 Formwork with suitable de-bonding agent on inside face

2 Baseplate in steel of thestanchion

3 Stanchion / column4 Holding down bolts5 Levelling plates (as specified)6 High performance, low shrinkage

expanding mortar e.g. SikaGrout®

311/-314 and-318 executed separately undereach machine baseplate

7 Top of concrete foundation





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10.4.Grouting Large Areas

Large horizontal application areas may be subdivided into smallermanageable areas to reduce extent of application and also reducepotential cracking. Proposals shall be agreed with the supervisingofficer or qualified engineer before work proceeds.

10.5.Grouting Thick Applications

The application thickness of SikaGrout® can be increased with the addition of moreaggregate.

* Information to be adapted for local use

This technique only applies for applicationssubject to compression forces e.g. underbase plates and machine bases.

Pre-testing of the modified material shallbe carried out first to determine anacceptable construction method togetherwith new material mechanicalperformances.

Aggregate can be added after the waterand powder have been mixed together.This shall be mixed slowly again to a good

consistency taking care not to aerate the material. No additional water shall be addedto the mix.

The flow behaviour of the material will be affected with the addition of more aggregate.These new characteristics shall be taken into account when using this technique on job site. For example the overall size of the application, ambient and substratetemperatures and variations in local products will affect the overall maximum layerthickness.

Layers may be built up on top of one another to increase the overall constructiondepth. The first layer shall be hardened and exothermic reaction of the materialcompleted. The 1st layer shall be at ambient temperature before applying the second

layer.

Material Appl ication

thickness

*SikaGrout®-314 10 – 40 mm

*SikaGrout®-314 + 40%by weight 4–5 mm to 8-

12 mm washed wellgraded clean roundedaggregate free fromfine graded materiale.g. silts, sands etc.

~20 – 80 mm





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11.Yield and Consumption

11.1.Yield

The yield of a product can be determined from the following equation (assuming nowastage). When calculating the required consumption on job site allow an additional10% of material to maintain pressure head on the grout flow. Remember to calculatethe required volume to the top of the base plate.

Equation: yield (litres) = (weight of powder (kg) + weight of water (kg))density of mixture (kg/l)

Given: weight of water 1 litre = ~1 kg

Example:

Calculate consumption of a bag weighing 25 kg mixed with 3.2 litres of water, whenthe density of the fresh material is 2.3 kg/l.

1 bag of 25 kg yields: (25 + 3.2) = ~12.3 litres of grout 2.3

Therefore, the number of bags required for 1m3 of grout will be:

No of bags required per 1m3 = (1/yield) x 1000

(1/12.3) x 1000 = ~81 bags

11.2.Consumption

Consumption of a product can be calculated as follows:

Calculate how many kg of powder is required to cover a 30 mm thick application overan area 2 m2 (assuming no wastage)

Weight of mixed mortar (kg) = volume (m3) x density (kg/m3)= (2 x 0.030) x 2300

= 138 kg (total)Less weight of water;

If water to powder mixing ratio = *12.0% then;

Required weight of powder = 138 x (100-12.0)/100

= ~ 121 kg powder (or minimum 5 x 25 kg bags) * refer to PDS for exact figure





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The information contained herein and any other advice are given in good faith basedon Sika's current knowledge and experience of the products when properly stored,handled and applied under normal conditions in accordance with Sika'srecommendations. The information only applies to the application(s) and product(s)expressly referred to herein and is based on laboratory tests which do not replace

practical tests. In case of changes in the parameters of the application, such aschanges in substrates etc., or in case of a different application, consult Sika'sTechnical Service prior to using Sika products. The information contained herein doesnot relieve the user of the products from testing them for the intended application andpurpose. All orders are accepted subject to our current terms of sale and delivery.Users must always refer to the most recent issue of the local Product Data Sheet forthe product concerned, copies of which will be supplied on request.

Sika Services AGBusiness Unit ContractorsSpeckstrasse 228330 PfaeffikonSwitzerlandPhone +41 58 436 23 80Fax +41 58 436 23 77www.sika.com

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Cementitious Grouting of Machine.do