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ARIZ 311a

September

5

1996

5 Pages

METHOD OF TEST FOR FLOW OF GROUT

MIXTURES FLOW CONE METHOD

A Modification of California Test Method 541

S OPE

1. a This method is intended to be used for determining the flow of grout

mixtures as described

in

this test method.

b This test method may involve hazardous material, operations, or

equipment. This test method does not purport to address all of the safety concerns

associated with its use. It is the responsibility of the user to consult and establish

appropriate safety and health practices and determine the applicability of any

regulatory limitations prior to

use.

c See Appendix A1 of the Materials Testing Manual for information

regarding the procedure to

be

used for rounding numbers to the required degree of

accuracy.

d Metric SI units and values are shown

in

this test method with

English units and values following in parentheses. Values given for metric and English

units may be numerically equivalent soft converted for the associated units, or they

may

be

given

as

rounded or rationalized values hard converted . Either the metric or

English units along with their corresponding values shall

be

used

in

accordance with

applicable specifications. See Appendix A2 of the Materials Testing Manual for

additional information on the metric system.

PP R TUS

2.

Requirements for the frequency of equipment calibration and verification

are found

in

Appendix A3 of the Materials Testing Manual. Apparatus for this test

procedure shall consist of the following:

a Flow cone conforming to the dimensions indicated

in

Figure

1.

b Stop watch accurate to 0.1 second.



ARIZ 311a

September 5 1996

Page 2

c Rubber stoppers.

d Sample container

four liter minimum capacity [a 152.4

mm

x 304.8

mm

6 inch x 12 inch concrete cylinder mold is adequate].

e Supporting ring for flow cone and stand [a 19 liter 5 gallon bucket

may be used], see figure 2

S MPLE

3

A representative sample shall be approximately 4 liters

grout.

PRE UTIONS

4 a This test must be performed at a location that is free from vibration.

b The cone must be kept clean from cement build-up, especially in or

near the orifice and nozzle.

PRO EDURE

5

a Determination of Efflux Time

1 Dampen flow cone and allow any excess water to drain.

Place the cone in the supporting ring and insert the rubber stopper.

2 Level the cone, then pour the grout from the sample container

into the cone until the grout Surface is level with the bottom of the holes in the side

the cone.

3 Remove the stopper and start the stopwatch simultaneously.

4 Stop the stopwatch at the first break or change in the

continuous flow of grout from the discharge tube.

5 Dispose

the tested grout sample; rinse the equipment.



ARIZ 311a

September 5 1996

Page 3

b) Determination of Efflux After Quiescence

1

Fill cone with grout

as

previously described, using the

remainder of the 4 liter sample.

2) Allow grout to rest in cone for 20 minutes ± 15 seconds from

the instant the cone is filled. After the 20 minute quiescent period, remove the stopper

and determine efflux time

as

described above.

X MPL

6.

Quiescent time T

Q

is

the amount of time that a sample of grout remains

undisturbed quiescent) in the flow cone and is expressed

in

minutes. Efflux time T

is the amount of time that a sample of grout requires to run out of the flow cone after

the plug is removed, expressed

in

seconds.

a) Efflux time at the pump discharge:

TE

11 seconds when TQ= 0 minutes)

b) Efflux time of grout sample at TQ= 20 minutes:

T

E

at TQ= 20)

T

E

at TQ=

0

+ 3 seconds,

and

TE at TQ= 20) s TE at TQ= 0) + 8 seconds

NOTE: The above mathematical expressions for quiescent time

of 20 minutes are expressed

as

follows: The efflux

time after 20 minutes must be at least 3 seconds greater

than the initial efflux time Quiescent Time = Zero) and

not more than 8 seconds greater than the initial efflux

time.

R P RT

7. Report the efflux time to the nearest 0.1 seconds for both TQ=O and TQ=20.



ARIZ 311a

September 5, 1996

Page 4

A 177.8 mm 7

inches

50.8 mm 2

inches

190.5 mm 7 1/2

inches

12.7

mm

1/2

inch

E

= 38.1

mm

1 1/2

inches

VOLUME 1725 cc

A

\

I

I

I

\\

.. . .

I

\\

I

II

I

II I

I

II

J

Grout Flow Cone

FIGURE 1



ARIZ a

September 996

age

Grout Flow Test pparatus

FIGURE



Designation: C 939 – 97

Standard Test Method for Flow of Grout for Preplaced-Aggregate Concrete (Flow ConeMethod)1

This standard is issued under the fixe designation C 939; the number immediately following the designation indicates the year of original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A

superscript epsilon (e) indicates an editorial change since the last revision or reapproval.

This specificatio has been approved for use by agencies of the Department of Defense.

1. Scope

1.1 This test method covers a procedure, used both in the

laboratory and in the field for determining the time of efflux of

a specifie volume of flui hydraulic cement grout through a

standardized flo cone and used for preplaced-aggregate (PA)

concrete; however, the test method may also be used for other

flui grouts.

1.2 It is for use with neat grout and with grouts containingfin aggregate all passing a 2.36-mm (No. 8) sieve.

1.3 This test method is intended for use with grout having

an efflux time of 35 s or less.

1.4 When efflux time exceeds 35 s, flowabilit is better

determined by flo table, found in Test Method C 109, using 5

drops in 3 s.

1.5 The values stated in SI units are to be regarded as the

standard.

1.6 This standard does not purport to address all of the

safety concerns, if any, associated with its use. It is the

responsibility of the user of this standard to establish appro-

priate safety and health practices and determine the applica-

bility of regulatory limitations prior to use.

2. Referenced Documents

2.1 ASTM Standards:

C 109/C109MTest Method for Compressive Strength of

Hydraulic Cement Mortars (Using 2-in. or 50-mm Cube

Specimens)2

C 938 Practice for Proportioning Grout Mixtures for

Preplaced-Aggregate Concrete3

3. Summary of Test Method

3.1 The time of efflux of a specifie volume of grout from a

standardized flo cone is measured.

4. Significanc and Use

4.1 This test method is applicable to the determination of

the fluidit of various flui grout mixtures.

5. Interferences

5.1 The presence of solid particles retained on the 2.36-mm

(No. 8) sieve or lumps of unmixed material in the grout may

cause the grout to flo unevenly through the discharge tube of the flo cone or stop the flo completely. Uneven flo will

result in slower transit of the grout, thereby indicating a false

consistency.

6. Apparatus

6.1 Flow Cone, with dimensions as shown in Fig. 1. The

discharge tube shall be stainless steel. The body can be

stainless steel, cast aluminum, or other essentially noncorrod-

ing metal.

NOTE 1—Cones with high-density polyethylene bodies are acceptable

for fiel use in situations where precision as described in this test method

is not required.

6.2 Receiving Container , capacity 2000 mL, minimum.6.3 Ring Stand or other device, capable of supporting the

flo cone in a vertical, steady position over the receiving

container.

6.4 Level , carpenter’s or similar.

6.5 Stop Watch, least reading of not more than 0.2 s.

6.6 Grout Mixer , conforming to Practice C 938.

7. Test Sample

7.1 The grout test sample shall be in excess of 1725 mL and

shall be representative of the grout in the mixer.

7.2 When sampling and testing is being done for the

purpose of proportioning or comparing mixes or for qualifying

materials, the temperature of the dry materials and mixingwater shall be such that the temperature of the freshly mixed

grout is 73.4 6 3°F (23 6 1.7°C), unless otherwise specified

8. Calibration of Apparatus

8.1 Mount the flo cone firml in such a manner that it is

free of vibration. Level the top to assure verticality. Close the

1 This test method is under the jurisdiction of ASTM Committe C-9 on Concrete

and Concrete Aggregatesand is the direct responsibility of Subcommittee C 09.41 on

Concrete for Radiation Shielding.

Current edition approved July 10, 1997. Published June 1998. Originally

published as C 939 – 81. Last previous edition C 939 – 94a.2 Annual Book of ASTM Standards, Vol 04.01.3 Annual Book of ASTM Standards, Vol 04.02.

1

Copyright © ASTM, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959, United States.



outlet of the discharge tube with a finge or a stopper. Introduce1725 6 5 mL of water into the cone. Adjust the point gage to

indicate the level of the water surface. Then allow the water to

drain.

8.2 Before firs use of the flo cone with grout and

periodically thereafter, check the accuracy of the cone by

fillin it with water as described in 8.1. After checking or

adjusting the point gage, start the stop watch and simulta-

neously remove the finge . Stop the watch at the firs break in

the continuous flo of water. The time indicated by the stop

watch is the time of efflux of water. If this time is 8.0 6 0.2 s,

the cone may be used for determining the time of efflux of

grout.

9. Procedure

9.1 Moisten the inside of the flo cone by fillin the cone

with water and, 1 min before introducing the grout sample,

allow the water to drain from the cone. Close the outlet of the

discharge tube with a finge or a stopper. Introduce the grout

into the cone until the grout surface rises to contact the point

gage, start the stop watch, and simultaneously remove the

finge or stopper. Stop the watch at the firs break in the

continuous flo of grout from the discharge tube, then look

into the top of the cone; if the grout has passed sufficiently,such that light is visible through the discharge tube, the time

indicated by the stop watch is the time of efflux of the grout. If

light is not visible through the discharge tube, then the use of

the flo cone is not applicable for grout of this consistency. At

least two tests having times of efflux within 1.8 s of their

average shall be made for each grout mixture.

9.2 The test for time of efflux shall be made within 1 min of

drawing of the grout from the mixer or transmission line. When

grout is being placed over a significan period of time, the time

of efflux may be determined at selected intervals to demon-

strate that the consistency is suitable for the work.

10. Report10.1 Report the following information:

10.1.1 Identificatio of sample,

10.1.2 Identificatio of materials in the sample, the propor-

tions, and whether laboratory-prepared or taken from the fiel

production mix,

10.1.3 Average time of efflux to nearest 0.2 s and time

interval from completion of mixing at which the test was made,

and

NOTE 1—Other means of indicating grout level may be used as long as accurate indication of grout level on volume is obtained.

FIG. 1 Cross Section of Flow Cone

C 939

2



10.1.4 Temperature, ambient and of the sample at the time

of test.

11. Precision and Bias

11.1 Precision —The following within-laboratory, multiple-

operator precision applies. The single laboratory standard

deviation has been found to be 0.88 s. Therefore, results from

two properly conducted tests on the same material should not

differ by more than 2.49 s.

11.2 Bias —No statement on bias can be prepared because

there are no standard reference materials.

12. Keywords

12.1 flo cone; grout; preplaced—aggregate concrete; time

of efflux

The American Society for Testing and Materials takes no position respecting the validity of any patent rights asserted in connection

with any item mentioned in this standard. Users of this standard are expressly advised that determination of the validity of any such

patent rights, and the risk of infringement of such rights, are entirely their own responsibility.

This standard is subject to revision at any time by the responsible technical committee and must be reviewed every fiv years and

if not revised, either reapproved or withdrawn. Your comments are invited either for revision of this standard or for additional standards

and should be addressed to ASTM Headquarters. Your comments will receive careful consideration at a meeting of the responsible

technical committee, which you may attend. If you feel that your comments have not received a fair hearing you should make your

views known to the ASTM Committee on Standards, 100 Barr Harbor Drive, West Conshohocken, PA 19428.

This standard is copyrighted by ASTM, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959, United States. Individual

reprints (single or multiple copies) of this standard may be obtained by contacting ASTM at the above address or at 610-832-9585

(phone), 610-832-9555 (fax), or [email protected] (e-mail); or through the ASTM website (http://www.astm.org).

C 939

3



N°: 850 64 03 Author: H-J. Stich

Date: Apr. 02 2008

Sika Services AG, Speckstrasse 22, CH-8330 Pfäffikon / Switzerland

Scope:Installation ofSikaplan® WP 1100 – 15HL, -20HL, -30HL

(Sikaplan® - 9.6, -14.6, -24.6)Sikaplan

® WP 1100 - 15HL2, - 20HL2, 30HL2

System Information and

Method StatementCorporate Construction

Basement waterproofing with membranes

The information, and, in particular, the recommendations relating to the application and end-use of Sika products, are givenin good faith based on Sika’s current knowledge and experience of the products when properly stored, handled and appliedunder normal conditions. In practice, the differences in materials, substrates and actual site conditions are such that nowarranty in respect of merchantability or of fitness for a particular purpose, nor any liability arising out of any legalrelationship whatsoever, can be inferred either from this information, or from any written recommendations, or from any otheadvice offered. The proprietary rights of third parties must be observed. All orders are accepted subject to our current termssale and delivery. Users must always refer to the most recent issue of the Technical Data Sheet for the product concerned,copies of which will be supplied upon request.




Date: Apr. 02 2008


Table of Contents:1. Introduction 3

1.1 General information 3

1.2 Construction requirements 4

1.3 Waterproofing system 5

2. Products 6

2.1 Product characteristics 6

2.2 Ancillary products 6

3. Installation 8

3.1 General information for installation 8

3.2 Substrate preparation 9

3.3 Protective layer 11

3.4 General membrane installation recommendations 113.5 Waterproofing termination details 13

3.6 Fixings on vertical areas 15

3.7 Waterproofing details in horizontal and vertical areas 16

3.8 Installation of waterproofing membranes 19

3.9 Compartment waterproofing with waterstops 20

4. Welding methods 23

5. Quality control 24

6. Cleaning and inspection of completed waterproof ing 26

7. Protection of completed waterproof ing 26

8. Proposal for bills of quantities 28

9. Standard details 41




Date: Apr. 02 2008


1. INTRODUCTION

1.1 General background information

Building structures with basements below ground usually need to be watertight.

Waterproofing works dependant on the basement’s structure are required to preventleaks into the structure and to protect the structure against the harmful influences ofaggressive ground- or seawater.Highly flexible single layer, or if required double layer Sikaplan® WP waterproofingmembranes can protect a structure against water from damp soil contact, percolatingwater and groundwater under hydrostatic pressure.In situations with leaking waterproofing membranes caused by mechanical damage tothe membranes, whether a loose laid and single, or double layer systems, infiltratingwater might underflow and spread uncontrolled between the installed membrane andthe structure. A compartment system with waterstops and specially welded single or double layermembranes, combined with injectable hoses provides the possibility of control andrepair by injection if required during service life. Additional advantages are fast installation procedures, the high crack bridging ability ofthe installed membranes, plus minimal requirements for substrate preparation.This Method Statement describes the installation procedure and details with theSikaplan® WP waterproofing membranes based on plasticised PVC.

Limitations of membrane installations: A successful waterproofing system requires detailed design and specification bythe engineer prior to the membrane installation works being carried out onsite.The structure must be designed and built in such a way that the Sikaplan® WPwaterproofing membrane system can adequately fulfil its function during its longservice life.Installation procedures must only be performed by skilled and experiencedmembrane waterproofing contractors. The site personnel must be trained in correctlywelding of the Sikaplan® WP sheet membranes.




Date: Apr. 02 2008


1.2 Construction requirements

The main criteria for the correct design and execution of the Sikaplan® WP flexiblesheet membrane waterproofing system against groundwater ingress in undergroundstructures are:• type and purpose of structure• waterproofing of structures in open cut excavation, or shafting between secant pile-

or diaphragm walls• circumference of the waterproofing (the level of waterproofing and its terminations)• type and design of the retaining walls• piled foundations and the pile cap location• lowering of groundwater level during construction (sump pumping methods)• condition of the substrate to be waterproofed• thermal insulation details and requirements• dimensions of the structure (length, width, depth)• groundwater levels (max., min., average, immersion depth of structure)• condition of groundwater (aggressive water, salt water, polluted water)

• expansion joint details and design• construction phases construction/day work jointing of structure(construction schedule)

• requirements for single, or double-layer waterproofing system with vacuum control

All elements protruding from or through the waterproofing membrane and cast intothe concrete, i.e. well shafts, service pipes, anchors, etc. must be made ofcorrosion-free steel quality (i.e. stainless V2A or V4A steel), or other non corrodingmaterials. The elements must be designed with flanges in order to allow watertightsealing of the membranes around them.

In order to avoid any kind of damage to the installed waterproofing membrane and to

ensure their performance the following requirements from the substrate must be met:

• the structure must be designed to minimise movement due to temperature,settlement and concrete shrinkage contraction etc.

• reinforcement bars in the concrete must be min. 30mm below surface• all steel elements must be stainless, or anticorrosive materials (i.e. cast iron,V2A, V4A steel quality, aluminium)

• the surface of the substrate being waterproofed must be smooth to avoidpuncturing the membrane under the future influence of hydrostatic pressure




Date: Apr. 02 2008


1.3 Waterproofing system

The installation procedure for waterproofing membranes depends on the:• chosen excavation system i.e. open with free access to external walls, orinternally with retaining walls

• project design• damp soil contact, percolating water, or water under hydraulic pressure• immersion depth below groundwater level• chosen membrane type and its fixing methods• chosen waterproofing system, i.e. drainage system, waterstop system, active controlsystem

Drainage system Waterproofing against damp soil contact andpercolating water using with single layer membraneswithout compartment. This system is not resistantagainst water under hydrostatic pressure.

Waterstop system Waterproofing against water under hydrostatic

pressure, combining single layer membranes andWaterstops – forming compartments (the mostcommon standard waterproofing solution).

Active control system Waterproofing against water under hydrostaticpressure, combined with double layer membranesand waterstops – compartments (allows highestsecurity of water tightness – continual monitoringand vacuum testing).

The following installation instructions are divided into single operations, applicableaccording to each kind of project. The operational sequences must then be definedaccording to the project design and the specification requirements.

Membrane installation sequences: Single layer or double layer membrane systemOpen with free access to external walls:• without retaining walls• with retaining walls(apart from the structure)

Installation sequence of themembrane is in two phases:1. lining below the basement slab

• cast in place concrete structures(slab, walls, roof)

2. lining of walls and roofInternally without access to externalwalls:

• diaphragm walls• driven or cast pile walls

Installation sequences of membrane inone, or two phases:

• lining below basement and atretaining walls• cast in place basement, wall- and

roof structure




Date: Apr. 02 2008


Subject to other local requirements, the specification of the membrane thickness isaccording to estimated immersion depth and consequent potential water pressure.

membrane thickness

Moisture and water ingress(to be combined with a drainage system)

1.5 mm

Hydrostatic pressure 0m - 10m 1.5 mm

Hydrostatic pressure 10m - 20m 2.0 mmHydrostatic pressure exceeding 20m 3.0 mm

2. PRODUCTS

2.1 Product characteristics

Standardproduct(with signal layer 0.6

mm)

Sikaplan® WP 1100 -15HL (Sikaplan

® 9.6)

Sikaplan®

WP 1100 -20HL (Sikaplan

® 14.6)

Sikaplan® WP 1100 -30HL (Sikaplan

® 24.6)

Standardproduct(with signal layer0.2 mm, available oninquiry)

Sikaplan®

WP 1100 -15HL2 Sikaplan®

WP 1100 -20HL2 Sikaplan®

WP 1100 -30HL2

Colours top layer: yellow / reverse layer: dark greySpecials(transparent acc. toFrench Standard, onrequest)

Sikaplan® WP 1100 -20H transparent (Trocal® T 2.00mm)

Material PVC-p membrane, homogeneous, not bitumen resistant

Use Waterproofing of all types of structures, situated below ground

against groundwater ingress

Membranethicknessand roll sizes

according to the respective product data sheets

Suitable

• against ageing or weathering during installation works• against aggressive influences occurring naturally in groundwater• against salt water• against accidental puncturing• against algae and micro-organisms• against hydrostatic pressure

• to be resistant against root penetrations• to remain flexible at low temperatures




Date: Apr. 02 2008


2.2 Ancillary products

Sikaplan® WP laminated metal str ip F 100

Colour of top layer light grey

Size and thickness of strip 100mm x 2000mm

Use linear fixing of Sikaplan

®

WP 1100waterproofing sheets. Metal strip to becut and preformed to profiles withsuitable tools in metal workshops

Sikaplan® WP Disc 80/10mm

Colour yellow, black

Size 80mm dia. x 10mm thickness

Use spot fixing of Sikaplan® WP 1100

waterproofing sheets in vertical areas

Sika® Waterbar, type AR / DR / AR Inject

Colours grey, yellow

Size according to the product data sheet Use Compartments and linear fixings of Sikaplan®

WP 1100waterproofing sheets exposed to groundwater underhydrostatic pressure

Sika® Dilatec, type E / ER joint sealing strips

Colour grey (white fleece edge strips) Size according to the product data sheet Use joint sealing strips, bonded with Sikadur ® -31 epoxy

adhesive on concrete for compartments and linear

fixings of Sikaplan® WP 1100 waterproofing sheetsexposed to groundwater under hydrostatic pressure

Sika® Control - and Injection Flange

Sikaplan® WP TrumpetFlange

Sikaplan® WP ControlSocket

Colour black yellowSize according to the product data sheet Use access pipe for control of water-tightness and injection

of compartment waterproofing system, incl. control-tubes, connecting pipes, etc.

Sikaplan® WP protection sheets

Sikaplan® WP Protectionsheet-20H

Sikaplan® WP Protectionsheet-20HE

Material PVC-p membrane, homogeneous, not bitumen resistant

Use Protection of installed waterproofing membranesagainst mechanical damage

Colours grey grey, surface embossed

Sheet thickness and rolldimensions

according to the respective PDS




Date: Apr. 02 2008


Sikadur ® - 31 EP adhesive, normal and rapid

normal rapid

Material two part epoxy adhesive

Use at ambient temperature of+ 10°C until + 30°C

at ambient temperature of+ 5°C until + 15°C

Colour grey Application according to the respective PDS and MSDS

Membrane Cleaner

Sarna Cleaner Sika-Trocal® Cleaner 2000

Material solvent containing solvent-free

Use cleaning of contaminated membrane surfacesColour clear liquid

Application according to the respective PDS and MSDS

3. INSTALLATION

3.1 General background information for installation

Installation of Sikaplan® WP waterproofing sheets must only be performed

by skilled and experienced waterproofing contractors, trained in Sikaplan® WPmembrane welding and installation.

In finalising their tender submissions the waterproofing contractor must have thepossibility to inspect the site conditions beforehand.

Installation works can be performed in dry weather conditions and ambient

temperature at least min +5°C.

Membrane rolls, geotextile rolls, etc. must be stored in horizontal positions in dryareas and protected against exposure to weathering on site.

In order to prevent damage of the installed waterproofing membranes, unauthorisedindividuals must be prevented from having access to the installation site during andfollowing the waterproofing works.

Waterproofing contractor's personnel must only wear suitable shoes with rubber soles,when walking on installed membranes. Smoking and open fires must not bepermitted on site. Heat welding machine operators must be trained and instructed on

the safety of electrical equipment for site welding procedures.

In order to prevent mechanical damage by third parties, the installed membranesmust be temporarily protected and/or must be kept under surveillance until theirfinal covering with protective layers.




Date: Apr. 02 2008


3.2 Substrate preparation

Substrates of blinding, or concrete surfaces below foundation slabs:The surface of the concrete or mortar must be smooth (steel trowel finish) andedges / corners must be rounded with min. radius 5cm. Any projections in thecementitious substrate must be removed by chiselling and grinding; nails and wiresor loose stones must be removed. Any protective mortar layer thickness must bemin. 5cm, if necessary with light reinforcement, to be covered min. 3cm. Themaximum aggregate diameter of mortar screeds must not exceed 4mm. The wholesurface must be thoroughly cleaned using high pressure water. Ponding watermust be removed and the whole surface must be dried using compressed air.

Substrate surfaces for refurbished concrete structures:Old linings, as well as any debonded rendering and screeds must be removed.Larger cracks and honeycombing must be broken out and reprofiled withrepair mortars. Water infiltration must be sealed, either with waterproofing mortars, orby injection with acrylic resin, or micro-fine cement grout. New rendering and screedsmust be applied on blast clean substrates, its maximum aggregate diameter must notexceed 4mm and its surface must be steel-trowel finished. Edges must be chamfered.

The whole surface must be thoroughly cleaned using high pressure water.Ponding water must be removed and the whole surface dried using compressed air.




Date: Apr. 02 2008


Substrate surfaces for new concrete structures:The surface of the concrete must be smooth (steel trowel finish, resp. first classformwork quality) and edges must be chamfered. Reinforcement steel bars mustbe covered min. 3cm. Any projections in the cementitious substrate must be removed by chiselling andgrinding; nails and wires must be removed. Honeycombed concrete must bebroken out and reprofiled with repair mortar. Water infiltration through cracks ofconcrete structures, or along steel elements must be sealed, either withwaterproofing mortar or by injection of acrylic resin, or micro-fine cement grout. Themaximum aggregate diameter of rendering and mortar screeds must not exceed 4mm.The whole surface must be thoroughly cleaned using high pressure water. Pondingwater must be removed and the whole surface must be dried using compressed air.Substrate preparation procedure prior to application of Sikadur ® -31 EP adhesivesmust be according to its product data sheet.

Substrate surfaces of shotcrete / gunite:Unevenness of a shotcrete surface must not exceed the ratio of length to depthunevenness of 5 : 1 and its min. radius must be 20cm. The shotcrete surfacemust not contain broken aggregates. Local water infiltration, must be sealedeither with waterproof plugging mortar, or drained with perforated hoses.It is recommended to spray a fine gunite layer on shotcrete surfaces with a min.thickness of 5cm and its aggregate dia. not exceeding 4mm (if the above mentionedshotcrete requirements can not be fulfilled). Steel elements (girders,reinforcement mesh, anchors etc.) must be covered min. 3cm.The surface of shotcrete, resp. gunite must be clean and free of loose debris (no loosestones, nails, wires, etc.).




Date: Apr. 02 2008


3.3 Protective layers

The waterproofing membrane to be installed must be protected against hard substrateswith a geotextile cushion layer. The geotextile must be based on of Polypropylene nonwoven fabric, needle punched, or thermally cured (chemically cured geotextiles arenot compatible with membranes and therefore must not be used).The geotextile must have min. unit weight of 500g/m2 for use on smooth concretesubstrates. Geotextiles must be loose laid and must be overlapped min. 100mmon horizontal areas and be free of loose materials. The physical properties ofgeotextiles must fulfil the requirements of any relevant local standards for theprotection of membrane waterproofing systems.

3.4 General membrane installation recommendations

The installation procedure for waterproofing membranes depends on the:

• excavation method (open cut / internal)• project design• chosen membrane type and its fixing methods• chosen waterproofing system (single layer / double layer)




Date: Apr. 02 2008


As an outline guideline the following work sequences can be considered to be normalpractise:

Open cut excavation system:The structure is built in an excavated space with free access to the edges of slabsand external walls, or the excavation is retained with driven steel piles with workingspace between external walls and these retaining walls. Membrane installation isperformed in two phases:

1. below basement slab, prior to concreting2. to external walls

1st phase (horizontal)• installation of geotextile on prepared substrate• installation of waterproofing membrane, incl. details• installation of 2nd layer waterproofing membrane, incl. details(if specified)

• formation of compartments (if specified)

• preparation of membrane edges for overlapping and welding towaterproofing at walls - installation of protective layer onmembrane

Construction of basement slab and walls; installation of waterstops (if specified)

2nd phase (vertical)• installation of geotextile• installation of membrane, incl. details and welding of membraneat prepared slab-wall junctions

• installation of 2nd layer waterproofing membrane, incl. details(if specified)

• protective layer on installed membrane as specified




Date: Apr. 02 2008


Diaphragm wall / Shafts / Internal working space only system:The structure is built in excavated space, retained with secant pile walls, or diaphragmwalls. Membrane installation performed in one phase: below the basement slab(horizontal), and to the retaining walls (vertical), prior to the pouring of the concreteslab and wall structures.

horizontal• installation of geotextile on prepared substrate• installation of waterproofing membrane, incl. details• installation of 2nd layer waterproofing membrane, incl. details(if specified)

• formation of compartments (if specified)• preparation of membrane edges for overlapping and welding towaterproofing at walls - installation of protective layer onmembrane

vertical

• installation of geotextile• installation of membrane, incl. details and welding of membraneat prepared slab-wall junctions

• installation of 2nd layer waterproofing membrane, incl. details(if specified)

• formation of compartments (if specified)

Construction of the basement slab and walls on to the completed waterproofingThe above mentioned guidelines are divided in single operations with various fixingoptions, according to the design of each project. The operational-sequencesmust be precisely defined according to the individual requirements.




Date: Apr. 02 2008


3.5 Waterproofing termination details

Where not specified in the relevant standards, waterproofing must be terminatedmin. 1.00m above max. groundwater level and min. 0.15m above ground level. Thevertical waterproofing may be linear fixed at terminations at the top of loose hangingmembranes if the height does not exceed 4.00m (exception: compartment systemswith waterstops). Waterproofing, which exceeds 4.00m high, requires intermediatelinear, or spot fixings at max. vertical distances of 2.00m.

With Sikaplan® WP laminated metal strips:

Unrolling and positioning of the geotextile protective layer, overlapped 100mm and

fixed with Sikaplan® WP laminated metal strip, formed to profiles and left loose

hanging on the wall. Mounting of Sikaplan® WP laminated metal – profiles (size

100mm x 2000mm, mounting holes ø 5mm at 150mm centres). The top of the profilesmust be positioned min. 1.00m above max. groundwater level and min. 0.15m aboveground level.

Between each profile there must be a gap of 5mm. The profiles must be fixed withcountersunk screws (dia. 4.5mm/lenght 20mm, stainless steel) and dowelsinto the reinforced concrete. The gaps between profiles must be covered with20mm-adhesive tapes. The profiles must not go across expansion joints.The gap between the concrete surface and profile must be sealed with a permanentlyelastic silicone based sealant (i.e. Sikasil® C).The bonding of sealant on the substrate requires application of a suitable primer.Once the membrane is fixed by the profiles the waterproofing must be protectedagainst UV-light and mechanical damage.

With Alumin ium-sheet metal, formed in to prof iles (by others):

Unrolling and positioning of geotextile protective layer, overlapped at edges 100mmand temporarily fixed into the substrate (i.e. with nails).Unrolling and positioning of the waterproofing membrane, min. 80mm overlapped heat-welded, and temporary fixed to the substrate (i.e. with adhesive tapes).Mounting of Aluminium-profiles (size 1.5mm x 40mm x 4000mm, mounting holesø 5mm in distance of 150mm). The top level of the profiles must be positioned min.1.00m above max. groundwater level, and min. 0.15m above ground level. Betweeneach profile must be a gap of 5mm. The profiles must be fixed with stainless steelscrews (dia. 4.5mm/lenght 20mm) and dowels into reinforced concrete.The gaps between the profiles must be covered with 20mm-adhesive tapes.The profiles must not cross expansion joints. The gap between the concretesurface and the profile must be sealed with a permanently elastic siliconesealant (i.e. Sikasil® C). The bonding of sealant on its substrate may require theapplication of a suitable primer. Once the membrane is fixed with the profiles, thewaterproofing membranes must be protected against UV-light and mechanicaldamage.

Caution: due to the incompatibility of Aluminium metal with concrete, cement or mortar,the mounted profile must not be in direct contact with cementitious substrates.




Date: Apr. 02 2008


With Sikaplan® W flat profile 30/4 V4A:Unrolling and positioning of geotextile protective layer, overlapped at edges 100mmand temporarily fixed into substrate (i.e. with nails).Unrolling and positioning of the waterproofing membrane, min. 80mm overlapped heat-welded, and temporarily fixed on substrate (i.e. with adhesive tapes).Mounting of Sikaplan® W flat profiles 30/4 V4A (size 4mm x 30mm x 2000mm). The toplevel of the profile must be positioned min. 1.00m above max. groundwater level, and0.15m above ground level.Between each profile must be a gap of 5mm. The profiles must be fixedwith countersunk screws (stainless steel) and dowels into reinforced concrete.The mounted profile must not cross expansion joints. The gap between the concretesurface and the profile must be sealed with a permanently elastic silicone sealant (i.e.Sikasil® C ). The bonding of the sealant on the substrate requires the application of asuitable primer. Once the membrane is fixed with the profile, the waterproofing must beprotected against UV-light and mechanical damage on site.

Welded at Sika

®

Waterstops, type AR / DR:Mounting of Sika

® Waterstops, type AR, with the flat side facing the formwork, seams

(also for T- junctions- and expansion joints-elements) heat welded.The top level of the waterstop must be min. 1.00m above max. groundwater level,and min. 0.15m above ground level. After concreting works, unrolling andpositioning of the geotextiles, provisionally fixed (i.e. with adhesive tapes), resp.terminated under waterstops and loose hanging. The flat surface of the waterstopsmust be clean, free of dust, cement, mortar etc. and free from oil or grease. Heatwelding of waterproofing membrane onto the waterstops (membrane loose hanging).Once the membranes are fixed to the waterstops, the waterproofing must be protectedagainst UV-light and mechanical damage.

Welded at bonded Sika® Dilatec, type ER joint sealing strips:

Bonding of Sika® Dilatec, type ER joint sealing strips with Sikadur

® -31 EP adhesive on

prepared concrete substrates. Preparation of substrate according to product data sheetfor Sikadur ® -31 adhesive.The top level of the glued strip must be min. 1.00m above max. groundwater level,and min. 0.15m above ground level. After bonding works, unrolling and positioning ofthe geotextiles, provisionally fixed (i.e. with adhesive tapes), resp. terminated underbonded joint strips and loose hanging. The exposed surface of the bonded strips mustbe clean, free of dust, remains of cured EP adhesive, etc. and free from oil or grease.Heat welding of waterproofing membranes onto the exposed part of bonded joint strips(membrane loose hanging).

Once the membrane is welded to the joint tape, the waterproofing must be protectedagainst UV-light and mechanical damage.




Date: Apr. 02 2008


3.6 Fixings on vertical areas

Intermediate fixings on walls:Required for wall height, exceeding 4.00m and for compartment systems


Mounting of Sikaplan® WP laminated metal sheets strips.

(size 100mm x 2000mm / mounting holes ø 5mm at 150mm centres).The strips must be fixed in horizontally directions and at a vertical distance ofmax. 2.00m on the loose hanging geotextile. Between each strip must be a gapof 5mm. The strips must be fixed with countersunk screws (dia. 4.5mm/lenght 20mm,stainless steel) and dowels into reinforced concrete.The gaps between the profiles must be covered with 20mm-adhesive tapes.The profiles must not cross expansion joints.

Heat welding of the waterproofing membrane onto the mounted Sikaplan® WP

laminated metal strips.

On Sika® Waterstops, type AR / DR:Mounting of waterstops (PVC / one side ribbed) with the flat side fixed to theformwork, seams (also cross junctions and for expansion joints) heat welded. Thepositioning of the waterstops must be according to the engineers compartmentconcept. After concreting works, unrolling and positioning of the geotextiles,provisionally fixed (i.e. with adhesive tapes), resp. terminated underwaterstops and loose hanging. The flat surface of the waterstops must be clean(dust, cement, etc.) and free from oil or grease. Heat welding of the waterproofingmembrane onto the waterstops (membrane loose hanging).

On glued Sika® Dilatec, type E joint sealing str ip:

Gluing of Sika® Dilatec, type E joint sealing strip with Sikadur

® -31 EP adhesive on

prepared concrete substrate. Preparation of substrate according to product data sheetfor Sikadur ® -31 adhesive.The positioning of the glued strip must be according to the design engineerscompartment concept. After gluing works, unrolling and positioning of the geotextiles,provisionally fixed (i.e. with adhesive tapes), resp. terminated under glued joint stripand loose hanging. The exposed surface of the glued strip must be clean, free of dust,remains of cured EP adhesive, etc. and free from oil or grease. Heat welding ofwaterproofing membrane onto the exposed part of glued joint strip (membrane loosehanging).

Spot fixing with Sikaplan® WP Disc on shotcrete / gunite:

Fixing of Sikaplan®

WP Disc discs (ø 80mm) on geotextile into shotcrete / gunite, or concrete (the geotextile is fixed with this operation also).The fixing of discs must be executed with the aid of nail guns into the shotcrete, or withdowels into predrilled holes in the concrete (i. e. Hilti DX nail gun system / Hilti type DXnail / washer and compatible cartridges). The grid distance must be min. two fixings each membrane roll width in the horizontal direction and 2.00m in the vertical direction.Heat welding of the waterproofing membrane onto the fixed discs.




Date: Apr. 02 2008


Spot fixing with suspenders made of Sikaplan® WP 1100 membrane straps:

Cut straps of Sikaplan® WP 1100 membrane from roll (size approx. 50mm x 200mm)

Fixing of Sikaplan® WP 1100 membrane straps on geotextile into shotcrete / gunite, or

concrete (the geotextile is fixed with this operation also).The fixing of membrane straps must be executed with the aid of nail guns into theshotcrete, or with dowels into

predrilled holes in the concrete (i. e. Hilti DX nail gun

system / Hilti type DX nail / washer and compatible cartridges). The grid distance mustbe min. two fixings each membrane roll width in the horizontal direction and max.2.00m in the vertical direction. Heat welding of the waterproofing membrane onto thefixed straps.

Fixings on vertical corners


Mounting of Sikaplan® WP laminated metal strips (size 100mm x 2000mm, once folded

to L-shape 50mm x 50mm / mounting holes ø 5mm in distance of 150mm in eachsection). Between each profile must be a gap of 5mm.

The profiles must be fixed with countersunk screws (dia. 4.5mm/lenght 20mm,stainless steel) and dowels over geotextile into reinforced concrete.The gaps between the profiles must be covered with 20mm-adhesive tapes.Heat welding of the waterproofing membrane onto the mounted profile.

With Alumin ium-metal strips (suppl ied by others) in membrane overlaps:Mounting of Aluminium-strip (size 4mm x 20mm x 4000mm, edges rounded /mounting holes ø 5mm in distance of 150mm) at edge (seam overlap) ofwaterproofing membrane roll. Between each profile must be a gap of 5mm. Theprofiles must be fixed with countersunk screws (dia. 4.5mm/lenght 20mm, stainlesssteel) and dowels into reinforced concrete. Heat welding of the overlappingmembrane roll over the fixing.

3.7 Waterproof ing details on hor izontal and vertical areas

Membrane intersection between horizontal - vertical areas (prayer seams):Below foundation slap (suitable for single layer waterproofing only): Loose layout and heat welding of waterproofing membrane (horizontal) over thegeotextile and the mortar screed below the foundation slab. The edge of themembrane must extend approx. 1.00m over the intersection line.Loose layout of geotextile strip (width approx. 0.40m) at the intersection line onthe installed membrane. The extended membrane part must be lapped over the

geotextile strip as provisional loop and heat welded on installed waterproofingmembrane. After installation of compartment, loose layout the geotextile on theprepared waterproofing membrane (incl. over provisional loop), to be overlaid with PE

foil 0.30mm (its overlaps sealed with adhesive tapes), or alternatively with Sikaplan®

WP protection sheets.




Date: Apr. 02 2008


Application of protective mortar layer on the PE-foil (cement min. 300kg / m³,aggregate ≤ ø 4mm, thickness min. 5cm ).Once the concreting works of slab and walls are completed, the protective layers(mortar screed, geotextile) must be careful removed. The provisional loop ofmembrane must be cut off and the geotextile strip removed. Heat welding of thevertical waterproofing on clean membrane of their horizontal waterproofing as a‘prayer’ seam. The protective layers over finished ‘prayer’ seam must be reformed as abase for the protective layers for the walls.

At retaining walls, or at formwork of foundation s lap:Loose layout and heat welding of waterproofing membrane (horizontal) over thegeotextile and the mortar screed below the foundation slab. The temporary edge of themembrane must extend to vertical wall up to 0.50m above surface level of foundationslab and fixed temporary at retaining wall, or at formwork of foundation slab.If double layer waterproofing system is chosen, install second layer of waterproofingmembrane. After installation of compartment, loose layout the geotextile on the prepared

waterproofing membrane, to be overlaid with PE foil 0.30mm (its overlaps sealed withadhesive tapes), or alternatively with Sikaplan® WP protection sheets.

Application of protective mortar layer (cement min. 300kg / m³, aggregate ≤ ø 4mm,thickness min. 5cm ).




Date: Apr. 02 2008


Membrane penetrations:Waterproofing details at penetrations (pipe-/anchor steel flanges, etc.) assupplied must be fixed by others prior to the membrane waterproofing works.The surface of steel must be smooth, clean and free of oils and grease. Creation ofsealing rings (min. one piece each penetration), made of waterproofing membrane.Cut to size according to the size of flange. Cut an opening in the waterproofingmembrane, its size must be equal to the size of the penetration.Overlapping seams of membrane must be bypassed around penetration by usingseparate membrane piece. Do not allow membrane overlaps within flanges.Membrane must be welded outside of flange, when double layer membrane systemhave to be installed.The prepared sealing ring must be heat welded on waterproofing membrane within theflange. Holes in equal diameter than bolts must be punched through both, themembrane and the sealing ring, exactly at the locations of bolts.The prepared piece of waterproofing membrane, incl. welded sealing ring must thenbe slipped over the base flange and be fixed to the pressure flange (the membranemust not be loose or creased and the membrane sealing rings must not be

‘ fishmouthed’).

Bridge over expansion joints:Mounting of support steel over expansion joints in walls and on roof slabs below

ground (for waterproofing of structures without compartment system only):One sided mounting of stainless steel sheets (size 200mm x 2000mm / fixing-holes,dia. 5mm, distance 150mm).The one-sided fixings must be made with countersunk screws and dowels (dia.4.5mm / 20mm length / stainless steel). Between the metal sheets must be a gapof 2 - 3mm, which must be covered with 20mm adhesive tape?




Date: Apr. 02 2008


3.8 Installation of waterproofing membranes

Vertical waterproofing:Check surfaces of geotextiles and mounted metal profiles etc. for loose debris orsharp projections prior to membrane installation.Membranes must be unrolled and installed vertically on walls according to chosenfixing method:

• PVC - laminated metal strips / profiles:heat welding of waterproofing membrane onlaminated metals

• Aluminium-profiles: acc. to separate description• Aluminium-strips: acc. to separate description• Sika Discs: acc. to separate description• Surface waterstop: acc. to separate description• glued joint sealing strips: acc. to separate description.

Operational sequences:

1. cut the membranes to the approx. size required2. consider min. 80mm membrane overlaps3. fix membranes with the selected fixing method at termination and at

intermediate fixing points on the wall4. repeat 1. - 3. with next membrane roll5. heat welding of vertical overlaps in direction from bottom to top

welding of installed membrane at prepared details (i.e. penetrations)6. repeat 1. – 5. for second layer, if double layer membrane system is specified

Horizontal waterproofing:

Check surfaces of geotextiles and mounted metal profiles etc. for loose debris andsharp projections prior to membrane installation.Irregular shapes of basement slabs need consideration of the membrane layingdirection on the bottom (i.e. the most optimised regarding cut loss and membraneconsumption)

Operational sequences:

1. cut the membranes to the approx. size required2. consider min. 80mm membrane overlaps3. unroll and position the membrane and consider membrane lap at edges for

intersection to vertical waterproofing

4. temporary ballasting of positioned membrane (i.e. with sand bags)5. repeat 1. - 4. with next sheet

welding of membrane overlapswelding of installed membrane at prepared details (i.e. penetrations)welding of membrane lap with vertical waterproofing at edges of basement slabs

6. repeat 1. – 5. for second layer, if double layer membrane system is specified




Date: Apr. 02 2008


3.9 Compartment of waterproofing with surface waterstops:

Surface waterstops for compartments, must be made of heat weldable plasticisedPVC, compatible to PVC waterproofing membrane and profiled with ribs on one side,or it must be made of glued joint strips on base of PVC. Dependent on the type ofstructures waterproofing membranes must either be heat welded on surfacewaterstops, resp. on glued strips , or surface waterstops must be heat welded onwaterproofing membranes:

open excavation shafting / internally fined

Basement slabs waterstop on membrane waterstop on membraneWalls membrane on waterstop waterstop on membrane

Roof slabs membrane on glued tape(Sika® Dilatec system)

membrane on glued tape(Sika® Dilatec system)

For single layer waterproofing system, each compartment area of the waterproofing

must not exceed 150m². According to the type of structure and construction schedule, the layout and positioningof waterstops, resp. glued joint sealing strips must be planned with the consultant.Surface waterstops, to be prepared and fixed during concreting works, must be fixedfirmly at the formwork. Cross- and T-junctions of waterstops must be factory welded, orprepared by skilled welding worker in local workshop.




Date: Apr. 02 2008


For double layer waterproofing system, the compartment must be performed accordingto following specifications: According to the type of structure and construction schedule, the layout and positioningof waterstops must be planned with the consultant. Surface waterstops, to be preparedand fixed during concreting works, must be fixed firmly at the formwork.1. compartments within membrane layers: each field must not exceed 100m2 2. compartments with waterstop on top layer of membrane: each field must not

exceed 600m2 3. compartments with waterstop on top layer of membrane: each field must not

exceed 400m2 in walls4. positions of control and injection pipes5. positions of weldings between membrane layers and waterstops6. positions of weldings between membrane layers




Date: Apr. 02 2008


Heat welding of waterproof ing membranes on flat sur face of Sika® Waterbar,

cast in concrete:Install geotextile cushion layer on concrete substrate, provisionally fixed (i.e. withadhesive tapes), resp. terminated close to waterstop. The flat surface of waterstopmust be clean (dust, cement, etc.) and free from oil or grease. Projecting weldingseams on waterstops must be peeled off with knives. Heat welding of Sikaplan® WPwaterproofing membranes on Sika® Waterstop type AR / DR. Strip heat welding ofwaterproofing membrane (with the membrane edge at both sides of joint openings) onSika® Waterstops, type DR in case of expansion joints. The remaining gap ofmembrane over joint opening must be covered a with membrane strip (width > 20cm)to be welded on both membrane edges.

Heat welding of Sika® Waterbar on ins talled waterproofing membranes:

The surface of installed membrane must be clean and free of oil and grease. Thewelded seams must be inspected for water tightness and the membrane edge mustbe chamfered (i.e. with peeling knives). Projecting welding seams on waterstops mustbe peeled off with knives. Waterstops may be heat welded directly to membrane, if the

side laps of used waterstop type exceeds 50mm by using of hand held manual welder.Direct welding of waterstops with side laps less than 50mm requests the use of semiautomatic welding machine type Leister Triac Drive.Strips of Sikaplan® WP waterproofing membranes must be preliminary heat welded onflat reverse of waterstop, if such welding tool is not available and the widths of sidelaps are less than 50mm.Operational steps as follows:Heat welding of Sikaplan® WP waterproofing membrane strips (width 20cm: ≤ 10cmwelding on waterstop / ≥ 10cm for later welding on waterproofing membrane) on bothflat sides of waterstop. The seams of membrane strips must be butt-jointed (no overlapseam), staggered to waterstop joints. The prepared waterstop must then be heatwelded with the remaining laps of membrane strips.

Mounting of Sikaplan® WP Contro l Socket or Trumpet – Flange:

The control- and injection pipe PVC flange, connected with clamping rings to metalpipes or plastic hose. Its min. total length is equivalent to the thickness of the wallor slab. The purpose of the pipes are access for control of water tightness and ifrequired, injection of grouts into each compartmentalised waterproofing area. Thecorrect function of these pipes requires min. three pipes in each compartment, oneon the lowest, one in the middle and one on the highest point. The position of pipeopenings at the internal side of a structure must allow easy access for later use.The pipes must be mounted on reinforcement bars. The PVC flange must be fixedto the formwork or spot welded on the installed waterproofing membrane. It mustbe secured during concreting works so that no cement slurry can penetrate into thepipe.




Date: Apr. 02 2008


Waterproofing termination with waterstops to pile caps: Erect formwork around pile caps at the level of the basement slab. Mounting ofsurface waterstop (in plasticised PVC, profiled with ribs to one side), to be fixed withthe flat side at inside of formwork and its butt joint welded.The top level of pile cap must not exceed the level of waterstop. Mounting ofreinforcement according to the consultant. Pouring of grouting mortar (i.e. Sika® Grout), within space of waterstop and concrete of pile head. Cover top level of pilehead with Sikadur ® -42 EP mortar. After removal of formwork, the surface of waterstopmust be cleaned (free from cement, oil and grease). Heat welding of waterproofingmembrane at waterstop.

4. WELDING METHODS

Sikaplan® WP waterproofing membranes may be welded by usingsuitable heat welding machines:• Seam overlaps of membranes must in all cases be min. 80mm• the width of the finished welded seam (single or double seam) must be at least

> 30mm• prior to welding procedure, membrane surfaces must be dry, clean, and free ofdust, oil and grease etc.

• Sikaplan® WP membrane surfaces must be cleaned preliminary to welding procedure

in case of polluted surface with Sarna Cleaner or Sika-Trocal® Cleaner 2000• prior to any heat welding work conduct a welding test with membrane specimen(mandatory in order to adjust welding temperature and speed of the machine)

• for continuous welding quality, it is recommended to run welding equipmentconnected with own circuit, or using its own generating set (automatic weldingmachine: 360V, hand held welding gun: 220V, resp. 110V according to regulations)

• welding machine operators must be trained and experienced in heat weldingtechnology according to local regulations and to operate electrical devices in wet,or humid conditions

Recommended machines and tools

Manual weldings:• hand held welding gun type Leister Triac S, Triac PID, 220 V, resp. 110 V(www.leister.com)

• hand held welding gun type BAK Rion, 230 V (www.bak-ag.com)• heat nozzles 40mm and 20mm, or 30mm all purpose-nozzle• hand held pressure (Silicone) roller with ball bearing (available from same supplier asof welding machine), width 20mm and 40mm

• reserve heating element

Semi-automatic welding for horizontal and vertical waterproof ing:• hand held semi-automatic, self-propelled welding machine, type Leister TriacDrive, 220V, resp. 110V (adjustable temperature and speed)(www.leister.com)

Automat ic welding for hor izontal and vert ical waterproofing:• automatic, self-propelled, types Leister Twinny S, Twinny T, Comet (adjustabletemperature, speed and pressure), 220/380V (www.leister.com)

• automatic, self-propelled, types BAK Mion, Comon (adjustabletemperature, speed and pressure), 230 V (www.bak-ag.com)




Date: Apr. 02 2008


Leister X – 84 automatic Leister Twinny S automatic

Leister Comet automatic Leister Triac Drive semi-automatic

5. QUALITY CONTROL

Testing of welded seams: All welded seams must be tested for water-tightness.Testing methods depend on available testing equipment and/or clients specification.

Testing methods:

Visual test with screw driver:• correctly heat welded single seams show continuous welding ‘rope’ at seam edge.Irregular, or interrupted rope can be the sign of voids or capillaries in the seam

• glide the head of screw driver (approx. size 2) with slight pressure along seamedge and check visually

• any voids or capillaries must be rectified with hand held welding gun and 20mmSilicone roller




Date: Apr. 02 2008


Physical test with air pressure testing k it (for double seam weldings only):• all double seams must be tested with compressed air testing kit, containing testingneedle, reverse flow valve, manometer gauge and air pressure pump (manual, orelectric)

• seal air channel with clamp at both ends of welded seam

• insert testing needle, connected with reverse flow valve and manometer at onemembrane overlap end. Connect testing needle with hose of manual, or electriccompressed air pump.

• inflate air channel until pressure of 2.0 bar is achieved. Close reverse flow valve.Disconnect hose from testing needle. Check air pressure 20 minutes after inflationprocedure.

• the welded seam can be regarded as tight, if the pressure decrease is less than20%. Release clamp from membrane ends. Heat weld membrane patch overmembrane penetration, caused by insertion of testing needle with hand held weldingmachine. Sign approved and tight seam with marking pen. Record the test in papersheet form. Repeat this procedure at all double seams.

• if test of double seam welding fails, inflate double seam again and search for leaks.Once detected, repair with membrane patch to be heat welded with hand heldwelding machine over defective area.

• any voids or capillaries must be rectified with hand held welding gun and 20mmSilicone roller at welding temperature

Physical test with vacuum bell:This test requires the following testing kit:• vacuum bell (Plexiglas, metal frame with rubber-pressure lips, reverse flow valve,manometer gauge, hose connection)

• vacuum pump• soap solution• marking pen (chalk pen only)

Test procedure:• apply soap solution over seam edge within the range of vacuum bell• press vacuum bell over area, treated with soap solution and build-up vacuum• visual check of seam under vacuum (bubbling soap solution shows leak)• remove vacuum bell and clean seam with rag• any leaks must be rectified with hand held welding gun and 20mm Siliconeroller at welding temperature, or if required, closed with welded membrane patch




Date: Apr. 02 2008


6. CLEANING AND INSPECTION OF COMPLETED WORK

The membrane surface must be cleaned and inspected before installation ofwaterstops, control and injection pipes and protection layers over membrane. Thisprocedure can be performed when one section of the waterproofing is completed, or

after completion of the whole area.Representatives from the waterproofing contractor and from the client must inspectthe completed works. The inspection must be recorded in a written report to besigned by both parties.The waterproofing contractor must keep original labels (incl. batch No.) of deliveredand installed membrane rolls, incl. inspection report in his files.

7. PROTECTION OF WATERPROOFING

Preparation works prior to installation of protection layers on completed waterproofing:The membrane surface for the protective measures must be clean (free from loosestones, sand, construction waste, etc.).

The installation of waterstops and control- and injection pipes (if compartment systemis specified) must be completed and welded seams approved.

Open cut excavation

Under basement slabs:• loose layout of geotextile 500g/m², min. 100mm overlapped.Waterstops for compartments must be kept unprotected.Use provisional ballast for geotextile with sandbags

• as alternative, loose layout of Sikaplan® WP protection sheets min. 80mmoverlapped.Waterstops for compartments must be kept unprotected.Use provisional ballast on protection sheets with sandbags

• loose layout of Polyethylene foil 0.30mm as separation-/slip layer ongeotextile, overlap 100mm to be sealed with adhesive tapes

• application of protective mortar layer (cement min. 300kg/m³, thickness min.50mm, reinforced with wire mesh if required). The waterstops of compartmentsmust be left unprotected/exposed.

At external walls:• geotextile 500g/m², 100mm overlapped, suspended on top and free hanging• as alternative, Sikaplan® WP protection sheets 80mm overlapped, suspended on top

and free hanging• erect brickwork firmly on the waterproofing• alternatively guniting, thickness min. 50mm, with light reinforcement mesh, facedwith glass fleece, to be suspended on top




Date: Apr. 02 2008


On roof slabs below ground:• loose layout of geotextile 500g/m², min. 100mm overlapped.Use provisional ballast for geotextile with sandbags

• as alternative, Sikaplan® WP protection sheets, min. 80mm overlapped.Use provisional ballast for protection sheet with sandbags


• application of protective mortar layer (cement min. 300kg/m³, thickness min.50mm, if necessary use reinforced wire mesh).

Shafting / internally

Below basement slabs:• loose layout of geotextile 500g/m², min. 100mm overlapped.Waterstops for compartment must be kept unprotected.Use provisional ballast for geotextile with sandbags

• as alternative, loose layout of Sikaplan® WP protection sheets min. 80mm

overlapped. Waterstops for compartments must be kept unprotected.Use provisional ballast for protection sheets with sandbags• loose layout of Polyethylene foil 0.30mm as separation-/slip layer ongeotextile, overlap 100mm to be sealed with adhesive tapes

• application of protective mortar layer (cement min. 300kg/m³, thickness min.50mm, use reinforced wire mesh if required). The waterstops of compartment mustbe kept unprotected / exposed

At retaining walls:• direct placing of concrete on the waterproofing membrane• formwork for construction-/expansion joints require a soft medium on membranesurface (i.e. plastic hose, cut-off in longitudinal direction and capped over the

formwork edge)• Reinforcement bars must be held with spacers (material compatible to plasticisedPVC) min. 50mm from the membrane surface

• Provisional layout of non-combustible mineral wool insulation boards to protectthe membrane against sparks from steel welding works

• for special cases or on request, gunite protective layer, thickness min. 50mm,reinforced with suspended light mesh and glass fleece (waterstops forcompartments must be kept free).

On roof slabs below ground:• loose layout of geotextile 500g/m², min. 100mm overlappedUse provisional ballast for geotextile with sandbags

• as alternative, loose layout of Sikaplan® WP protection sheets min. 80mmoverlapped. Use provisional ballast for protection sheets with sandbags


• application of protective mortar layer (cement dosage min. 300kg/m³, thicknessmin. 50mm, use reinforced wire mesh if required).




Date: Apr. 02 2008


8. PROPOSAL FOR BILLS OF QUANTITIES

PROJECT WATERPROOFING WORKSProject: .................................................................................................................Part /Lot: .................................................................................................................

Waterproofing system: Waterproofing of structures against hydrostatic pressurefrom outsideFlexible waterproofing with Sikaplan® WP waterproofingmembranes, loose laid and linear fixed with,or without compartment system

Specialist waterproofing contractor:…………………………………………………………………………………………………...

pos. scope of work quantity unit unit rate total

1. InstallationSupply and erecting of allscaffoldings, machinery’s and

equipment, required forwaterproofing works, incl,demounting and removalafterwards lump sum

1.1. Provision of scaffoldings lump sum

1.2 Provision of dewatering pumpslump sum

2. Preparation of substrates Cleaning and drying with broomsor compressed air from dust(compressed air supplied from

main contractor) incl, inspectionof substrate

2.1 Horizontal areas Horizontal and sloped areas lessthan 15% m²

2.2 Vertical areas Vertical and sloped areas above15% m²

2.3 Drying of substrate Drying of substrate with warm airdryer or according to contractorsrecommendations m²

2.4 Removal of ponding water,cleaning and drying of wet areaswith wet-and dry vacuum cleaner

m²

2.5 Removal of cement laitance inwidth of 30cm by blast, cleaningor abrasive mechanical method,incl. cleaning and drying aspreparation for bonding works

m’




Date: Apr. 02 2008



3. Protection layersSupply and apply of protectivelayers for the mechanicalprotection of waterproofingmembrane.

Sheet membranes, according toconsultants specificationsthickness .....................mmmin. overlap 80mmmaterial: PVC-p homogeneousbrand name: Sikaplan® type: WP…………………

Geotextiles, according toconsultants specifications

unit weight .....................g / m²unit weight .....................g / m²min. overlap 100mmmaterial:Polyester/Polypropylene nonwoven fabric, needle punchedbrand name……………………type.........................................type.........................................

3.1 Horizontal and sloped areas lessthan 15%, loose laid m²

3.2 Vertical and sloped areas above

15%, spotwise fixed as permanufacturers instruction m²

3.3 Supply and apply of separation /slip layer, according toconsultants specificationsunit weight .....................g / m²Thickness ......................mmmin. overlap 100mm to be sealedwith adhesive tapesmaterial:……………………..brand name:.........................type......................................

m²

3.4 Supply and apply of protectivemortar layer for horizontal area(cement dosage > 300kg/m³,thickness 50mm, steel trowelfinish m²

3.4.1 Supply and apply ofreinforcement mesh forprotective mortar layer,ø............/...........mm m²




Date: Apr. 02 2008


pos. scope of work quantity Unit unit rate total

4. Waterproof ing membranesSingle layer waterproofingSupply and apply of singlelayer waterproofingmembrane system on baseof plasticised PVC,according to consultantsspecification, overlaps min.80mm heat welded withelectr. welding machine, incl.testing of welded seams asper suppliersrecommendations, linearfixed at all terminations,edges and cornersMaterials:

Membranethickness:........mmMembrane type:brand name: Sikaplan® typeWP 1100 -….. Auxiliary products:Membrane cleaner:Sikaplan® WP Cleaner 2000Fixing elements:Sikaplan® WP PVC-laminated metal strip Aluminium profile, size……..

Metal strips, size……………Sikaplan® WP disc, dia........Sika® Waterbar, type AR…..Sika® Dilatec PVC-p jointsealing strips, type………

4.11 Horizontal and sloped areasless than 15%, loose laid,overlaps heat welded, excl.fixings m²

4.12 Vertical and sloped areasabove 15%, installed as persuppliers recommendation,excl. fixings m²

4.13 Waterproofing of sumps andchannels in horizontal area:effective area until max.10m², excl. fixings m²

4.14 Waterproofing of returns andrecesses in vertical areas:effective area up to max.10m², excl. fixings m²




Date: Apr. 02 2008



4.2 Double layer waterproofing Supply and apply of doublelayer waterproofingmembrane system on baseof plasticised PVC,according to consultantsspecification, overlaps min.80mm heat welded with,both layers heat welded tobuild compartmentalisation,incl. testing of welded seamsas per suppliersrecommendations, linearfixed at all terminations,edges and cornersMaterials:

Membrane 1st

layerthickness:........mmMembrane 2nd layerthickness:........mm

Membrane type:Brand name: Sikaplan® type: WP 1100 - …….type: WP 1100 - …….

Auxiliary products:Membrane cleaner:

Sika®

- Trocal Cleaner 2000Fixing elements:Sikaplan® WP PVC-laminated metal strip Aluminium profile, size……..Metal strips, size……………Sikaplan® PVC-p disc, dia.....Sika® Waterbar, type AR……Sika® Dilatec PVC-p jointsealing strips, type………

4.21 Horizontal and sloped areasless than 15%, loose laid,

overlaps heat welded, excl.fixings m²

4.22 Vertical and sloped areasabove 15%, installed as persuppliers recommendation,excl. fixings m²

4.23 Waterproofing of sumps andchannels in horizontal area:effective area until max.10m², excl. fixings m²




Date: Apr. 02 2008



4.24 Waterproofing of returns andrecesses in vertical areas:effective area up to max.10m², excl. fixings m²

5. Fixing of waterproofing5.1 Supply and mounting offixing elements forwaterproofing termination, tobe fixed with stainless steelscrews and dowels (distance150mm) into reinforcedconcrete min. 1000mmabove max. groundwaterlevel, incl. sealing withpermanent elastic sealantson top, or with PVC-p strips,

glued with EP-adhesive,suitable for on-welding ofPVC-p waterproofingmembranes

5.1.1 Aluminiumprofile, size1.5mm x 40mm, twice folded(max. length4000mm/element), fixed withscrews, ø 4.5mm x 20mm m'

5.1.2 Sikaplan® WP PVC-laminated metal strip,size 100mm x 2000mm to be

cut and twice folded as persuppliers instruction on site,fixed with countersunkscrews ø 4.5mm x 20mm,incl. heat welding ofwaterproofing membrane onPVC-laminated metal profile

m'

5.1.3 Metal strip stainless, size4mm x 30mm (length2000mm/element), fixed withcountersunk screws, incl,

overlapping withwaterproofing membraneand heat welding m'




Date: Apr. 02 2008



5.1.4 Supply and apply PVC-p joint sealing strips, suitableto glue with EP-adhesive onconcrete at walls, incl. gluingon prepared substratePVC-p strip,Brand name: Sika® Dilatectype…………………………size………………………….type of EP adhesive………………………………..

m’

5.2 Supply and mounting offixing elements for fixing ofwaterproofing membrane atvertical areas, to be fixedwith stainless steel screws

and dowels (distance200mm) into reinforcedconcrete.

5.2.1 Sikaplan® WP PVC-laminated metal strips,size 100mm x 2000mm,fixed with countersunkscrews, ø 4.5mm x 20mm,incl. heat welding ofwaterproofing membrane

m'

5.2.2 Metal strip, size 4mm x30mm (length 2000mm

/element), fixed withcountersunk screws, incl.overlapping of waterproofingmembrane and heat welding m'

5.3. Supply and mounting offixing elements for fixings ofwaterproofing membrane atvertical corners and edges,to be fixed with stainlesssteel screws and dowels(distance 200mm) intoreinforced concrete

5.3.1 Sikaplan® WP PVC-laminated metal strip,size 100mm x 2000mm,folded to angle size 50mm x50mm, both shanks fixedwith countersunk screws, ø4.5mm x 20mm , incl. heatwelding of waterproofingmembrane

m'




Date: Apr. 02 2008



5.3.2 Metal strip, size 4mm x30mm (length 2000mm/element), fixed withcountersunk screws, incl.overlapping of waterproofingmembrane and heat welding m'

5.4 Supply and mounting offixing elements for fixings ofwaterproofing membrane athorizontal corners andedges, to be fixed withstainless steel screws anddowels (distance 200mm)into reinforced concrete

5.4.1 Sikaplan® WP PVC-laminated metal strip,

size 100mm x 2000mm,folded to angle size 50mm x50mm, both shanks fixedwith countersunk screws, ø4.5mm x 20mm , incl. heatwelding of waterproofingmembrane

m'

5.4.2 Metal strip, size 4mm x30mm (length 2000mm/element), fixed withcountersunk screws, incl.overlapping of waterproofing

membrane and heat welding m'5.5 Supply and mounting of

fixing elements for spotwisefixings of waterproofingmembrane at vertical areas,plasticised PVC Discs, to benailed with suitable nailingtechnique into shotcrete, orspike into predrilled hole intoreinforced concrete(horizontal distance2pcs./membrane roll width,vertical distance 2.00m)

5.5.1 Sikaplan® WP PVC-p Discs,ø 80mm, fixed with nail gun,incl. compatible nail andwasher pcs




Date: Apr. 02 2008



6. Expansion joint (withoutcompartment system)

6.1 Supply and mounting ofsupport for waterproofingmembrane as bridge over joint openings with stainlesssteel sheet, size 1.5mm x200mm, fixed one-sided withcountersunk stainless steelscrews and dowels intosubstrate, loose layout ofwaterproofing membraneover sheetsType of metalsheets:..............................

6.1.1 In vertical and sloped areas

above 15% m'6.1.2 In horizontal and sloped

areas below 15% m'

7. Compartment system

7.1 Supply and mounting ofplasticised PVC-profile assurface waterstops forconstruction joints, one sidewith flat surface, to be fixedat formwork, resp. heatwelded on installedwaterproofing membrane,incl. heat welding of seams

7.1.1 Sika® Waterbar type: ……… width:...............................mm

m'

7.1.2 Sika® Waterbar Cross junction: type: ……….prefabricatedsize: ..........mm x ............mm

pcs

7.1.3 Sika® Waterbar T- unction:type:………..prefabricatedsize: .............mm x .........mm pcs

7.1.4 Sika®

Waterbar Inner corner junction, horizontal:type:................ prefabricatedsize: ........mm x ..............mm pcs

7.1.5 Sika® Waterbar Inner corner junction, vertical:type:............... prefabricatedsize: .........mm x ...........mm pcs




Date: Apr. 02 2008



7.1.6 Supply and heat welding ofstrip (width 20cm) ofwaterproofing membrane onboth reverse sides ofwaterstop(if direct welding ofwaterstop on membrane notpossible) m'

7.2 Supply and mounting ofplasticised PVC-profile assurface waterstops forexpansion joints, one sidewith flat surface, to be fixedat formwork, resp. heatwelded on installedwaterproofing membrane,

incl. heat welding of seams7.2.1 Sika® Waterbar

type:..................................... width:...............................mm m'

7.2.2 Sika® Waterbar Cross junction:type:...............prefabricatedsize: ..........mm x ............mm

pcs

7.2.3 Sika® Waterbar T-junction:type:................ prefabricatedsize: .............mm x .........mm

pcs

7.2.4 Sika® Waterbar Inner corner

junction, horizontal:type:................ prefabricatedsize: ........mm x ............mm pcs

7.2.5 Sika® Waterbar Inner corner junction, vertical:type:................ prefabricatedsize: .........mm x .............mm

pcs

7.2.6 Welding of waterproofingmembrane strip,type:......................................width 20cm on flat surface of

waterstop, prior to mountingof surface waterstop(if direct welding ofwaterstop on membrane notpossible) m'




Date: Apr. 02 2008


pos. scope of work quantity unit unit rate total 7.3 Supply and apply of PVC-p

joint sealing strips, gluedwith EP-adhesive onhorizontal areas, wherewaterstop installation is notpossible, strip suitable foron-welding of PVC-pwaterproofing membranes

7.3.1 PVC-p joint sealing strips,suitable to glue with EP-adhesive on concrete atwalls, incl. gluing onprepared substrate andwaterproof intersection towaterstops at wall-roof junctions

PVC-p strip,Type Sika® Dilatectype………………………….type of EP adhesive, type:Sikadur ® -31 m’

7.4 Supply and mounting ofcontrol and injection flange,type:Sikaplan Trumpet Flange,according to membranesuppliers, or waterproofingcontractors instruction

at formworks, resp. atreinforcement, incl.measurements aftermounting pcs

7.5 Supply and mounting ofcontrol and injection flange,type:Sikaplan WP Control Socket,according to membranesuppliers, or waterproofingcontractors instruction, incl.mounting of control tubesand connecting pipes pcs




Date: Apr. 02 2008


pos. scope of work quantity unit unit rate total 8. Penetrations

8.1 Waterproofing ofpenetrations, cast instructure with fixed and

pressure flange on base ofstainless steel materials,incl, on site creation ofsealing rings made ofwaterproofing membrane,steel type:.............................thickness:........................mm

8.1.1 Well shaftsø:….................................mmø:….................................mm

pcspcs

8.1.2 Pipe penetrationsø:….................................mm

ø:.....................................mm

pcs

pcs

8.1.3 Anchor boltsø:……..............................mmø:.....................................mm

pcspcs

8.1.4 Foundation pile headsø………...........................mmø………...........................mm

pcspcs

8.2 Suplayer and mounting ofplasticised PVC-profile assurface waterstops forwaterproofing ofpenetrations of pile heads,one side with flat surface, tobe fixed at pile head -formwork incl. butt weldingand heat welding ofwaterproofing membraneafterwards, according tospecification

8.2.1 Sika ® Waterbartype: AR............................ width:..............................mm

effective length m'8.2.2 Sealing of foundation pile

head with grouting mortar forthe sealing betweenconcrete and waterbar, incl.coating of pile head withEP – layer, type Sikadur ®-42ø………...........................mmø………...........................mm

pcs.pcs.




Date: Apr. 02 2008


pos. scope of work quantity unit unit rate total 9. Cleaning and inspection of

installed waterproofing

9.1 Cleaning of installedwaterproofing with brooms,vacuum cleaner

9.1.1 Horizontal and sloped areasless than 15% m²

9.1.2 Vertical and sloped areasabove 15% m²

9.2 Inspection of installedwaterproofing and weldedseams to checkwatertightness, incl. repair ofdetected leaks by onweldingof membrane patches

9.2.1 Horizontal and sloped areas

less than 15% m²9.2.2 Vertical and sloped areas

above 15% m²

10. Addi tional works(Day work rates)

10.1 Waterproofing contractor’spersonnel

10.1.1 Resident Project Engineer /Contracts Manager

h

10.1.2 Skilled waterproofing

Installer

h

10.1.3 Labourer h

10.2 Material

10.2.1 Waterproofing membranetype: Sikaplan® WP………..

m²

10.2.2 Protective layer type:.................................

m²

10.2.3 Fixings: PVC laminatedmetal strip type Sikaplan® WP

m’

10.2.4 Fixings: stainless steel strip,

type/size…………………… m’10.2.5 Fixings: Sikaplan® WP

PVC-p disc pcs

10.2.6 Sika® Waterbar, type…………………………

m’

10.2.7 Control- and injectionflanges, type:………………. pcs

10.2.8 Cleaner, Sikaplan® WPCleaner 2000

lt




Date: Apr. 02 2008


pos. scope of work quantity unit unit rate total 10.3 Equipment / tools

10.3.1 Hire of el. heat welding gun(hand welder and pressureroller)

h

10.3.2 Hire of el. heat welder(automatic) h

10.4.1 Hire of el. submersible pump.............l/min.

h

10.4.2 Hire ofcompressor.................l/min.

h

10.4.3 Hire of el. generatingset................V

h

10.4.4 Hire of el. switch box h

10.4.5 Hire of movable scaffolding /staging

h




Date: Apr. 02 2008


9. STANDARD DETAILS

Floor assembly with waterbar:

1 Substrate: blinding concrete

2 Protection layer: geotextile PP 500 to 1000 g/m2

3 Waterproofing: Sikaplan® WP 1100 waterproofing membranes4 Protection layer: geotextile PP 500 to 1000 g/m2 and separation- / slip

layer PE film, thickness > 0.20mm,

or alternatively Sikaplan®

WP protection sheet -HE5 Compartment with PVC-p waterstop: Sika® Waterbar type AR6 Reinforced concrete

7 Consolidated ground

8 Protective mortar screed




Date: Apr. 02 2008


Floor to wall intersection joint, with waterbar

1 Reinforced concrete2 Compartment with PVC-p waterstop: Sika® Waterbar type AR

3 Waterproofing: Sikaplan

®

WP 1100 waterproofing membranes4 Protective layer: geotextile PP 500 to 1000 g/m2

5 Wall - substrate: shotcrete, or formworked concrete6 Diaphragm wall: reinforced concrete

7 Protective layer: geotextile PP 500 to 1000 g/m2 and separation- / sliplayer PE film, thickness > 0.20mm,or alternatively Sikaplan® WP protection sheet -HE


9 Substrate: blinding concrete






Date: Apr. 02 2008


Wall compartment joint with Sika Waterbar; Sikaplan waterproof ing

membrane hot welded onto it (plan view)

1 Protection with brickwork or reinforced concrete layer2 Protective layer: geotextile PP 500 to 1000 g/m2

3 Waterproofing: Sikaplan

®

WP 1100 waterproofing membranes4 Protective layer: geotextile PP 500 to 1000 g/m2

5 Reinforced concrete6 Compartment with PVC-p waterstop: Sika® Waterbar type AR

7 Heat welding




Date: Apr. 02 2008


Detail of control-/ injection pipe for compartment system with trumpet-flange

1 Cover nut, supplied by others

2 Steel pipe with internal threaded hole (approx. ¼’’) supplied by others,length according to wall/slab thickness, temporary fixed with wires atreinforcement bars

3 Reinforced concrete

4 Clamping rings, hose nipple Ø 18 mm with external threaded hole (approx.1/4’’) supplied by others

5 Sikaplan

®

WP trumpet flange, pipe Ø 18 mm, length 168 mm, flange Ø 200mm, spotwise hot air welded at the waterproofing membrane

6 Waterproofing: Sikaplan® WP 1100 waterproofing membranes

7 Protective layer: geotextile PP 500 to 1000 g/m2 and separation- / sliplayer PE film, thickness > 0.20mm,or alternatively Sikaplan® WP protection sheet -HE

8 Protective layer: geotextile PP 500 to 1000 g/m2

9 Protective mortar screed10 Waterproofing substrate according to specification




Date: Apr. 02 2008


Well-shaft


2 Rubber sealing ring

3 Cover bolts in blind holes4 Fix clamp flange for closing cover, welding watertight

5 Steel pipe

6 Protective layer: geotextile PP 500 to 1000 g/m2 7 Waterproofing: Sikaplan® WP 1100 waterproofing membranes

8 Protective layer: geotextile PP 500 to 1000 g/m2 and separation- / sliplayer PE film, thickness > 0.20mm,

or alternatively Sikaplan

®

WP protection sheet -HE9 Protective mortar screed

10 Pressure flange ring

11 Clamp flange ring with threaded bolts, ring tight welded to steel pipe

12 Additional membrane layer for clamp sealing in pressure flange13 Appropriate flat gasket

14 Drain holes15 Drainage layer

16 Steel anchor




Date: Apr. 02 2008


Wall flashing; change from pressure to non pressure water

1 Sealant: Sikaflex® 11FC incl. primer for metal and concrete substrate

2 Metal flashing

3 Sikaplan® WP protection sheet-15H/-20H

4 Waterproofing: Sikaplan® WP 1100 waterproofing membranes5 Protective layer: geotextile PP 500 to 1000 g/m2

6 Waterproofing: Sikaplan® WP 1100 waterproofing membranes

7 Compartment with PVC-p waterstop: Sika®

Waterbar type AR8 Reinforced concrete

9 Wall - substrate: shotcrete, or formworked concrete10 Diaphragm wall: reinforced concrete

11 Sikaplan® WP control and injection socket 14 mm PVC only spot weldedonto membrane, alternatively Sikaplan® WP trumpet flange, pipe Ø 18 mm,length 168 mm, flange Ø 200 mm, spotwise hot air welded at thewaterproofing membrane with steel pipe

12 Groundwater level

Y Area positive waterproofing applicationX Area negative waterproofing application




Date: Apr. 02 2008


Typical flashing detail at pile heads

1 Protective mortar screed2 Substrate: blinding concrete

3 Consolidated ground

4 Foundation pile: reinforced concrete


7 Protective layer: geotextile PP 500 to 1000 g/m2 and separation- / slip

layer PE film, thickness > 0.20mm,or alternatively Sikaplan® WP protection sheet -HE


9 Rigid waterproofing layer with Sikadur ® – 42 EP-resin

10 Waterproofing intersection with PVC-p waterstop: Sika® Waterbar type ARaround pile head

11 Heat welding of Sikaplan® WP 1100 waterproofing membranes on Sika® waterbar





Date: Apr. 02 2008


Pipe penetrationsWith double clamped f lange (for area positive waterpoofing application)


3 Ev. protective layer: geotextile PP 500 to 1000 g/m2 and separation- / sliplayer PE film, thickness > 0.20mm,or alternatively Sikaplan® WP protection sheet -HE

4 Fixed clamp flange, stainless steel5 Appropriate flat gasket

6 Loose clamp ring, stainless steel

7 Bolt with locking nut and tapered washer, stainless steel8 Watertight weld

9 Pipe, stainless steel

10 Prepared piece of waterproofing membrane Sikaplan® WP with press cuthole for bolt

11 Heat welding





Date: Apr. 02 2008


Watertight wall joint to Sika waterbar

1 Heat welding

2 Compartment with PVC-p waterstop: Sika® Waterbar type AR3 Waterproofing: Sikaplan® WP 1100 waterproofing membranes

4 Protective layer: geotextile PP 500 to 1000 g/m2 5 Reinforced concrete

- Protective, drainage and slide layer according to project requirements

- Protection layer adapted to backfill material (earth, gravel etc.). Backfillmaterial placed and compacted in layers



WSDOT Materials Manual M 46-01.03 Page 1 of 4January 2009

WSDOT Test Method for ASTM C 9391

Flow of Grout for Preplaced-Aggregate Concrete (Flow Cone Method)

This standard is issued under the xed designation C 939; the number immediately following the

designation indicates the year of original adoption or, in the case of revision, the year of last revision.

A number in parentheses indicates the year of last reapproval. A superscript epsilon (e) indicates an

editorial change since the last revision or reapproval. This specication has been approved for use byagencies of the Department of Defense.

1. Scope

1.1 This test method covers a procedure, used both in the laboratory and in the eld, for

determining the time of efux of a specied volume of uid hydraulic cement grout through

a standardized ow cone and used for preplaced-aggregate (PA) concrete; however, the test

method may also be used for other uid grouts.

1.2 It is for use with neat grout and with grouts containing ne aggregate all passing a No. 8

(2.36 mm) sieve.

1.3 This test method is intended for use with grout having an efux time of 35 s or less.1.4 When efux time exceeds 35 s, owability is better determined by ow table, found in Test

Method C 109, using 5 drops in 3 s.

1.5 The values stated in SI units are to be regarded as the standard.

1.6 This standard does not purport to address all of the safety concerns, if any, associated with

its use. It is the responsibility of the user of this standard to establish appropriate safety and

health practices and determine the applicability of regulatory limitations prior to use.

2. Referenced Documents

2.1 ASTM Standards:

C 109/C109M Test Method for Compressive Strength of HydraulicCement Mortars (Using 2 in or 50 mm Cube Specimens)

C 938 Practice for Proportioning Grout Mixtures for Preplaced-Aggregate Concrete

3. Summary of Test Method

3.1 The time of efux of a specied volume of grout from a standardized ow cone is measured.

4. Signicance and Use

4.1 This test method is applicable to the determination of the uidity of various uid grout

mixtures.

5. Interferences5.1 The presence of solid particles retained on the No. 8 (2.36 mm) sieve or lumps of unmixed

material in the grout may cause the grout to ow unevenly through the discharge tube of the

ow cone or stop the ow completely. Uneven ow will result in slower transit of the grout,

thereby indicating a false consistency.

1 This Test Method is based on ASTM C 939-97.



Page 2 of 4 WSDOT Materials Manual M 46-01.03January 2009

C 939 Flow of Grout for Preplaced-Aggregate Concrete (Flow Cone Method)

6. Apparatus

6.1 Flow Cone, with dimensions as shown in Figure 1. The discharge tube shall be stainless steel.

The body and discharge tube can be stainless steel, cast aluminum, or other essentially non-

corroding metal.

Note 1: Cones with high-density polyethylene bodies are acceptable for eld use in situations

where precision as described in this test method is not required.

6.2 Receiving Container , capacity 2000 mL, minimum.

6.3 Ring Stand or other device, capable of supporting the ow cone in a vertical, steady position

over the receiving container.

6.4 Level, carpenter’s or similar.

6.5 Stop Watch, least reading of not more than 0.2 s.

6.6 Grout Mixer, conforming to Practice C 938.

7. Test Sample

7.1 The grout test sample shall be in excess of 1725 mL and shall be representative of the grout in

the mixer.

7.2 When sampling and testing is being done for the purpose of proportioning or comparing mixes

or for qualifying materials, the temperature of the dry materials and mixing water shall be such

that the temperature of the freshly mixed grout is 73.4 ± 3°F (23 ± 1.7°C), unless otherwise

specied.

8. Calibration of Apparatus

8.1 Mount the ow cone rmly in such a manner that it is free of vibration. Level the top to

assure verticality. Close the outlet of the discharge tube with a nger or a stopper. Introduce

1725 ± 5 mL of water into the cone. Adjust the point gage to indicate the level of the water

surface. Then allow the water to drain.

8.2 Before rst use of the ow cone with grout and periodically thereafter, check the accuracy of

the cone by lling it with water as described in 8.1. After checking or adjusting the point gage,

start the stop watch and simultaneously remove the nger. Stop the watch at the rst break

in the continuous ow of water. The time indicated by the stop watch is the time of efux

of water. If this time is 8.0 ± 0.2 s, the cone may be used for determining the time of efux

of grout.

Note: It is imperative that the water be completely still prior to allowing it to ow from the

cone, any movement will cause the time of efux to increase.





Page 4 of 4 WSDOT Materials Manual M 46-01.03January 2009

C 939 Flow of Grout for Preplaced-Aggregate Concrete (Flow Cone Method)



Template for local translation, only for internal use

N°: 850 21 01 Author: D Taylo

Date: Jan 2010

Sik S i AG / Tüff i 16 / CH 8048 Zü i h / S it l d

C

o n s t r u c

t i o n

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 fo

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





Date: Jan 2010


C

o n s t r u c

t i o n

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





Date: Jan 2010


C

o n s t r u c

t i o n

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 oconformity

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

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 mosrecent 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 productsstandards, 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





Date: Jan 2010


C

o n s t r u c

t i o n

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 mechanicairritation to the eyes, skin, nose and throat.

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

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

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

Always wash hands with suitable soap aftehandling 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 bondConcrete 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 ocontamination. 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 grouin 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 aidisplaced 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 sufficien

pressure head while pouring. Ensure a process of continuous pouring to avoid aientrapment 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 propecuring 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 othesuitable 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. undebase plates and machine bases.

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

Aggregate can be added after the wateand powder have been mixed togetherThis 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 aggregateThese 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 materiacompleted. 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



F LOW OF G ROUT M IXTURES (F LOW C ONE M ETHOD ) T X DOT D ESIGNATION : T EX -437-A

C ONSTRUCTION D IVISION 1 – 2 E FFECTIVE D ATE : J ULY 2008

Test Procedure for

FLOW OF GROUT MIXTURES FLOW CONE

METHOD)

TxDOT Designation: Tex-437-A

Effect ive Date: July 2008

1. SCOPE

1.1 This test method covers two procedures, used both in the laboratory and in the field, for

determining the time of efflux of a specified volume of fluid hydraulic cement grout

through a standardized flow cone.

1.2 The values given in parentheses (if provided) are not standard and may not be exact

mathematical conversions. Use each system of units separately. Combining values from

the two systems may result in nonconformance with the standard.

2. APPARATUS

2.1 Refer to ASTM C 939 for the test apparatus.

PART I—METHOD 1

3. SCOPE

3.1 Use this method with neat grout, grout containing fine aggregate all passing a No. 8

(2.36 mm) sieve, and grout having an efflux time of 35 sec. or less.

4. PROCEDURE

4.1 Refer to ASTM C 939 for the test procedure.

PART II—METHOD 2

5. SCOPE

5.1 Use this method for thixotropic grouts with a required efflux time of 9 to 20 sec.

immediately after mixing and 30 sec. maximum with 30 min. standing time after initial

mixing and remixed for 30 sec. before testing.

Texas Department

of Transportation



F LOW OF G ROUT M IXTURES (F LOW C ONE M ETHOD ) T X DOT D ESIGNATION : T EX -437-A

C ONSTRUCTION D IVISION 2 – 2 E FFECTIVE D ATE : J ULY 2008

6. PROCEDURE

6.1 Use a test sample of at least 4600 ml and representative of the grout in the mixer. When

sampling and testing for the purpose of proportioning or comparing mixes or for

qualifying materials, the temperature of the dry materials and mixing water should besuch that the temperature of the freshly mixed grout is 23 ±1.7°C (73.4 ±3°F), unless

otherwise specified.

6.2 Moisten the inside of the flow cone by filling the cone with water. One min. before

introducing the grout sample, allow the water to drain from the cone. Close the outlet of

the discharge tube with a finger or a stopper.

6.3 Introduce the grout, immediately after mixing, into the cone until the grout reaches the

top surface of the cone. Start the stopwatch and simultaneously remove the finger or

stopper.

6.4 Stop the watch when the receiving container is filled to the 1000 ml calibration mark. Thetime indicated by the stopwatch is the grout efflux time. The efflux time of the grout

immediately after mixing will be between 9 and 20 sec. for 1000 ml discharge. If it is not

between 9 and 20 sec., then retest.

6.5 Let the grout stand for 30 min. without further agitation. Remix for 30 sec. and perform

Sections 6.2 through 6.4 again on this sample. The test time of efflux will not be more

than 30 sec. for 1000 ml discharge.

7. REPORT

7.1 Include the following in the report:

Identification of the sample

Identification of materials in the sample, the proportions, and whether the tested

sample represents laboratory-prepared or field-production mix

Average time of efflux to the nearest 0.2 sec. and the time interval from sampling

to testing

Ambient temperature and sample temperature at the time of test.

8. ARCHIVED VERSIONS

8.1 Archived versions are available.



CONSTRUCTION

METHODOLOGY

AND

PROJECT

MANAGEMENT

REPORT

Project

description

The bridge consists of mainly two parts the beam bridge part on either ends of the river bank and the

central part being suspended by carbon fibers. This bridge answers the main needs providing

connectivity across the water body and providing a clear span in between to give way for water traffic .

Project

Area

The project area includes :

•

One km

across

the

cleaveland

bay.

• Northern end of paradise beach near Taj hotel .

•

Cape leseley.

Construction

The following construction methodology and associated details and procedures are indicative and

can be refined by the contractor engaged to undertake the project. This methodology has been

prepared by us to provide a basis for assessment of the amount of work involved , the manpower

required etc and the impacts on environment .

The surveying and inspection of the sites are considered as the usual practice and not included in the

methodology .

Construction methodology

The bridge works can be divided into 4 major parts in the order of commencement of works :

• Laying of foundations, piling works .

• Constructing piers and steel columns to support cables.

• Laying of bridge deck and connecting and tensioning cables .

•

Laying the road, the concrete panels .

Only the works which are done on the site are mentioned. Several works take place off the site like

casting of girders , fabrication of steel parts , mixing of concrete ( batching plants ) etc . All these works

can take place simultaneously with the below mentioned works and do not affect the original expected

time unless there is a delay in transportation or so.



1.) Laying of foundations , piling works :

Foundations part includes the foundations for the piers in beam bridge part and the foundations for

steel columns part . Both parts have pile foundations .

•

Piling works :

The piling works mainly consists of driving the piles into the ocean bed .

Approximate time : 8 months including driving of all the piles into specified locations and constructing

pile caps and conducting pile load tests .

Manpower : 2 engineers, 4 rig operators , 4 helpers, 4 welders ,4 grout mixers , 2 pump operator , 3

hoseman .

Machinery: 2 piling rigs , barges , concrete pumps , concrete vibrators.

2.) Constructing piers and steel columns to support cables :

Constructing piers and steel columns can be done simultaneously as the two works are entirely

different.

• Piers construction :

Approximate time : 8 months .

Manpower : 5 engineers

, 15

fabricators

, 20

for

grouting

,2

surveyors

, 10

helpers

.

Machinery : Concrete pumps , barges .

• Steel columns :

The two steel columns are highly complex and need high amount of steel to be erected, hence heavy

gantry cranes will be required to erect these huge structures.

The columns will be constructed in parts by pre‐assembling the parts, riveted and then mounted.

Approximate time : 4 months

Manpower : 2 crane operators , 2 helpers for crane ,2 surveyors , 4 engineers , 15 for riveting .

Machinery : 2 Heavy gantry cranes , barges , welding machinery , riveting machines.

After construction of these piers and steel columns necessary access channels should be constructed i.e

lifts , platforms at various level to facilitate the next levels of construction .





Construction

Environment

Management

Plan

A construction environmental plan will be prepared and implemented. The plan will outline

environmental management

practices

and

procedures

to

be

followed

during

site

preparation

and

construction. The plan will cover the environmental protection practices, resources and sequence of

activities required to comply with relevant environmental legislation, conditions of any applicable

license, approvals and permits.

The plan will be prepared in accordance with Guidelines and include:

•

A description of activities to be undertaken on the site during the site preparation and

construction stages of the project.

•

Statutory

approvals

and

other

obligations

that

would

be

fulfilled

during

site

preparation

and

construction.

• Details of how the environmental performance of the site preparation and construction works

will be monitored, and what actions will be taken to address identified adverse environmental

impacts. In particular, the following environmental performance issues will be addressed:

o Measures to minimize impacts to heritage.

o Measures to monitor and minimize soil erosion and the discharge of sediment and other

pollutants to land and/or water during construction.

o

Measures to monitor and control noise emissions during construction and

commissioning.

o Measures to manage traffic and pedestrian access during construction.

• A description of the roles and responsibilities for all relevant employees involved n the

construction of

the

project.

• Complaints handling procedures during construction.

Safe

Work

Method

Statement

The requirements state that a work safe method statement must be provided explaining the delivery

and installation of the project whilst ensuring the surrounding heritage fabric. An indicative description

of the methodology likely to be adopted to construct the works is provided in this report. This is based

on the available concept design documents.

Once the detailed design is complete, the Contractor engaged to undertake the works will develop a

detailed safe work method statement which addresses the various activities to be undertaken during

the construction phase, and ensures the safety of the site fabric, construction personnel and the

public.

NOTE : Only the main course and sequence of works is mentioned . In reality each work listed over here

will have several hundreds of smaller works . The management of each of those works will result in a









- 1 -

California Test 541STATE OF CALIFORNIA—BUSINESS, TRANSPORTATION AND HOUSING AGENCY November 2010

DEPARTMENT OF TRANSPORTATIONDIVISION OF ENGINEERING SERVICESTransportation Laboratory5900 Folsom Blvd.Sacramento, California 95819-4612

METHOD OF TEST FOR FLOW OF GROUT MIXTURES(FLOW CONE METHOD)

A. SCOPE

This test method contains the procedure to be used for determining the flow of grout mixtures.

B. REFERENCES

ASTM C 939 – Standard Test Method for Flow of Grout for Preplaced-Aggregate Concrete(Flow Cone Method)

C. APPARATUS

1. Flow cone and supporting ring conforming to the dimensions indicated inFigure 1.

2. Stopwatch having a least reading of not more than 0.1 s.

3. Rubber stoppers, size 00.

4. Sample container – 4 qt minimum capacity (a 6 in. 12 in. concrete mold isadequate).

5. Suitable stand for supporting ring. A 5-gal paint bucket may be used. SeeFigure 2.

D. CALIBRATION

Before the first use of the flow cone, and periodically thereafter, check the calibration of thecone as follows:

1. Mount the flow cone firmly, free of vibration, and with the top vertical. Closethe outlet of the discharge tube with a finger or stopper. Fill the cone with1725 mL ± 5 mL of water. Ensure that the water surface is at, but notoverflowing, the indicators at the top of the Caltrans cone. For the ASTM cone,adjust the point gage to indicate the level of the water surface.

2. After ensuring the accuracy of the volume measurement, refill the cone with

water and simultaneously remove the finger or stopper and begin the stopwatch.Stop the watch at the first break in the continuous flow of water.

3. The cone is calibrated if the volume of the cone is 1725 mL ± 5 mL and theefflux time is 8.0 s ± 0.2 s.

E. SAMPLE

The test sample must be approximately 1 gal of grout.



California Test 541November 2010

- 2 -

F. DETERMINATION OF EFFLUX TIME

1. Dampen flow cone and allow any excess water to drain. Place the cone in thesupporting ring and insert the rubber stopper.

2. Level the cone, then pour the grout from the sample container into the coneuntil the grout surface is level with the bottom of the three holes in the side ofthe cone (Caltrans cone) or makes contact with the point gage (ASTM cone).

3. Remove the stopper and start the stopwatch simultaneously.

4. Stop the stopwatch at the first break or change in the continuous flow of groutfrom the discharge tube. Record the indicated time of efflux to the nearest0.1 s.

5. Dispose of the grout sample and rinse the equipment.

G. DETERMINATION OF EFFLUX AFTER QUIESCENCE

1. Fill cone with grout, as previously described, using remainder of 1 gal sample.

2. Allow grout to rest in cone for 20 min ± 15 s from the instant the cone is filled tothe time the efflux time is to be measured. After the 20-min quiescent period,determine efflux time as described previously in F.3 and F.4 above.

3. Record efflux time of the grout to the nearest 0.1 s.

4. Dispose of the grout sample and clean the equipment.

H. PRECAUTIONS

The cone must be placed in a location that is free from vibration.

The cone must be kept clean from cement buildup, especially in or near the orifice and nozzle.

The presence of solid particles retained on the No. 8 sieve or lumps of unmixed material in thegrout may interfere with grout discharge and result in a false consistency.

I. HEALTH AND SAFETY

It is the responsibility of the user of this test method to establish appropriate safety and healthpractices and determine the applicability of regulatory limitations prior to use. Prior tohandling, testing or disposing of any materials, testers must be knowledgeable about safelaboratory practices, hazards and exposure, chemical procurement and storage, and personal

protective apparel and equipment.

Caltrans Laboratory Safety Manual is available at:

http://www.dot.ca.gov/hq/esc/ctms/pdf/lab_safety_manual.pdf

End of Text(Califo rnia Test 541 contains 3 Pages)



California Test 541November 2010

- 3 -

d

(Optional - From ASTM C939)

Figure 1: GROUT FLOW CONE

Figure 2: GROUT EQUIPMENT



ARIZ 311a

September

5

1996

5 Pages

METHOD OF TEST FOR FLOW OF GROUT

MIXTURES FLOW CONE METHOD

A Modification of California Test Method 541

S OPE

1. a This method is intended to be used for determining the flow of grout

mixtures as described

in

this test method.

b This test method may involve hazardous material, operations, or

equipment. This test method does not purport to address all of the safety concerns

associated with its use. It is the responsibility of the user to consult and establish

appropriate safety and health practices and determine the applicability of any

regulatory limitations prior to

use.

c See Appendix A1 of the Materials Testing Manual for information

regarding the procedure to

be

used for rounding numbers to the required degree of

accuracy.

d Metric SI units and values are shown

in

this test method with

English units and values following in parentheses. Values given for metric and English

units may be numerically equivalent soft converted for the associated units, or they

may

be

given

as

rounded or rationalized values hard converted . Either the metric or

English units along with their corresponding values shall

be

used

in

accordance with

applicable specifications. See Appendix A2 of the Materials Testing Manual for

additional information on the metric system.

PP R TUS

2.

Requirements for the frequency of equipment calibration and verification

are found

in

Appendix A3 of the Materials Testing Manual. Apparatus for this test

procedure shall consist of the following:

a Flow cone conforming to the dimensions indicated

in

Figure

1.

b Stop watch accurate to 0.1 second.



ARIZ 311a

September 5 1996

Page 2

c Rubber stoppers.

d Sample container

four liter minimum capacity [a 152.4

mm

x 304.8

mm

6 inch x 12 inch concrete cylinder mold is adequate].

e Supporting ring for flow cone and stand [a 19 liter 5 gallon bucket

may be used], see figure 2

S MPLE

3

A representative sample shall be approximately 4 liters

grout.

PRE UTIONS

4 a This test must be performed at a location that is free from vibration.

b The cone must be kept clean from cement build-up, especially in or

near the orifice and nozzle.

PRO EDURE

5

a Determination of Efflux Time

1 Dampen flow cone and allow any excess water to drain.

Place the cone in the supporting ring and insert the rubber stopper.

2 Level the cone, then pour the grout from the sample container

into the cone until the grout Surface is level with the bottom of the holes in the side

the cone.

3 Remove the stopper and start the stopwatch simultaneously.

4 Stop the stopwatch at the first break or change in the

continuous flow of grout from the discharge tube.

5 Dispose

the tested grout sample; rinse the equipment.



ARIZ 311a

September 5 1996

Page 3

b) Determination of Efflux After Quiescence

1

Fill cone with grout

as

previously described, using the

remainder of the 4 liter sample.

2) Allow grout to rest in cone for 20 minutes ± 15 seconds from

the instant the cone is filled. After the 20 minute quiescent period, remove the stopper

and determine efflux time

as

described above.

X MPL

6.

Quiescent time T

Q

is

the amount of time that a sample of grout remains

undisturbed quiescent) in the flow cone and is expressed

in

minutes. Efflux time T

is the amount of time that a sample of grout requires to run out of the flow cone after

the plug is removed, expressed

in

seconds.

a) Efflux time at the pump discharge:

TE

11 seconds when TQ= 0 minutes)

b) Efflux time of grout sample at TQ= 20 minutes:

T

E

at TQ= 20)

T

E

at TQ=

0

+ 3 seconds,

and

TE at TQ= 20) s TE at TQ= 0) + 8 seconds

NOTE: The above mathematical expressions for quiescent time

of 20 minutes are expressed

as

follows: The efflux

time after 20 minutes must be at least 3 seconds greater

than the initial efflux time Quiescent Time = Zero) and

not more than 8 seconds greater than the initial efflux

time.

R P RT

7. Report the efflux time to the nearest 0.1 seconds for both TQ=O and TQ=20.



ARIZ 311a

September 5, 1996

Page 4

A 177.8 mm 7

inches

50.8 mm 2

inches

190.5 mm 7 1/2

inches

12.7

mm

1/2

inch

E

= 38.1

mm

1 1/2

inches

VOLUME 1725 cc

A

\

I

I

I

\\

.. . .

I

\\

I

II

I

II I

I

II

J

Grout Flow Cone

FIGURE 1



ARIZ a

September 996

age

Grout Flow Test pparatus

FIGURE



NORSOK STANDARD

PIPING AND EQUIPMENT INSULATION

R-004

Rev. 2, June 1999



This NORSOK standard is developed by NTS with broad industry participation. Please note that

whilst every effort has been made to ensure the accuracy of this standard, neither OLF nor TBL or

any of their members will assume liability for any use thereof. NTS is responsible for theadministration and publication of this standard.

Norwegian Technology Standards Institution

Oscarsgt. 20, Postbox 7072 Majorstua

N-0306 Oslo, NORWAY

Telephone: + 47 22 59 01 00 Fax: + 47 22 59 01 29

Email: [email protected] Website: http://www.nts.no/norsok

Copyrights reserved



Piping and equipment insulation R-004

Rev. 2, June 1999

CONTENTS

1 SCOPE 3

2 REFERENCES 3

2.1 Normative references 32.2 Informative references 3

3 DEFINITIONS AND ABBREVATIONS 3

3.1 Definitions 3

3.2 Insulation classes 4

3.3 Abbreviations 5

4 GENERAL REQUIREMENTS 5

4.1 Introduction 5

4.2 Design 6

4.3 Materials 9

4.4 Installation 12

5 HOT SERVICE AND ACOUSTIC INSULATION 13

5.1 General 13

5.2 Design 13

5.3 Installation 13

5.4 Guidance for insulation thickness 15

5.5 Guidelines for Steam Service and Exhaust Lines 15

5.6 Class 5, Fire Proofing 16

5.7 Guidelines for acoustic insulation 17

6 COLD SERVICE INSULATION 176.1 General 17

6.2 Design 17

6.3 Installation 18

7 COMBINATION OF INSULATION CLASSES 19

7.1 General 19

7.2 Acoustic insulation (6, 7 & 8) combined with Heat conservation (1) or Personnel

protection (3). 20

7.3 Fire Proofing (5) combined with cold service insulation (2, 4 and 9) 20

7.4 Acoustic insulation (6, 7 & 8) combined with cold service insulation (2, 4 and 9) 20

8 QUALIFICATION REQUIREMENTS 208.1 Qualification of insulation system 20

8.2 Qualification of personnel 20

8.3 Qualification of procedures 21

9 INSPECTION AND TEST 22

ANNEX A – KEY DATA FOR INSULATION SYSTEMS 23

ANNEX B – INSERTION LOSS – TEST PROCEDURE 24




Rev. 2, June 1999

FOREWORD

NORSOK (The competitive standing of the Norwegian offshore sector) is the industry initiative to

add value, reduce cost and lead time and eliminate unnecessary activities in offshore field

developments and operations.

The NORSOK standards are developed by the Norwegian petroleum industry as a part of the

NORSOK initiative and supported by OLF (The Norwegian Oil Industry Association) and TBL

(Federation of Norwegian Engineering Industries). NORSOK standards are administered by NTS

(Norwegian Technology Standards Institution).

The purpose of NORSOK standard is to contribute to meet the NORSOK goals, e.g. by replacing

the individual oil company specifications and other industry guidelines and documents for use in

existing and future petroleum industry developments.

The NORSOK standards make extensive references to international standards. Where relevant, thecontents of a NORSOK standard will be used to provide input to the international standardisation

process. Subject to implementation into international standards, this NORSOK standard will be

withdrawn.

INTRODUCTION

The revision 2 of this standard is updated and partly rewritten from industry experience over the last

years. Materials have been given a broader presentation. A new section is added on Qualification

Requirements, addressing requirements to insulation systems, procedures and qualification of personnel.




Rev. 2, June 1999

1 SCOPE

This standard covers the minimum requirements for thermal, acoustic, personnel protection and

fireproofing insulation of pipe work and equipment for offshore / onshore installations.

This standard does not cover insulation of HVAC related items, see NORSOK Standard H – 002

Piping and plumbing.

2

REFERENCES

2.1

Normative references

API RP 521 Guide for Pressure – Relieving and De-pressuring Systems

ASTM-C552 Cellular Glass Block and Pipe Thermal Insulation.ASTM-C592 Mineral Fibre Blanket Insulation and Blanket Type Pipe insulation

ASTM-C303 Test method for Density of Pre formed Block-Type Thermal Insulation

ASTM-C177 Test method for Steady-State Heat Flux Measurement

ASTM-165 Test Method for Measuring Compressive Properties of Thermal Insulation

ASTM-D3833 Test Method for Water Vapour Transmission of Tapes

ASTM-G53 Practise for Operating Light- and Water-Exposure of Non - metallic materials

EN 253 : 1994 Pre-insulated bonded pipe systems for underground hot water networks

IMO Resolution A.653 (16 ) Recommendations on Improved Fire Test procedures for Surface

Flammability of bulkhead, Ceiling and Deck Finish Materials

ISO 834 Fire – resistance tests – Elements of building constructions

ISO 5660 Fire tests – Reaction to Fire – Rate of Heat Release from Building Products

NORSOK S-002 Working Environment

NORSOK M-501 Surface Preparation and Protective Coating

NT Fire 036 Pipe Insulation: Fire spread and smoke production – Full scale test

OTO 93028 Jet fire Test

2.2 Informative references

AGR EmiTeam Insulation Handbook.

Established in 1999 by Statoil, Norsk Hydro and Saga

3

DEFINITIONS AND ABBREVATIONS

3.1 Definitions

NORSOK Norsk Sokkels Konkurranseposisjon, the Competitive standing of the

Norwegian Offshore Sector, the Norwegian initiative to reduce cost on

Offshore projects.




Rev. 2, June 1999

Functional specification As defined in ISO 13879 and ISO 13880: Document that specifies the

requirements expressed by features, characteristics, process conditions,

boundaries and exclusions defining the performance of the product,

process or service..

Technical specification As defined in ISO 13879 and ISO 13880: Document that prescribestechnical requirements to be fulfilled by the product, process or service

in order to comply with the functional specification.

Normative references Shall mean normative (a requirement ) in the application of NORSOK

Standards.

Informative references Shall mean informative in the application of NORSOK Standards.

Shall Verbal form used to indicate requirements strictly to be followed in

order to conform to the standard and from which no deviation is

permitted, unless accepted by all involved parties.

Should Verbal form used to indicate that among several possibilities one is

Recommended as particularly suitable, without mentioning or

Excluding others, or that a certain course of action is preferred but

Not necessarily required.

May Verbal form used to indicate a course of action permissible within

the limits of the standard.

Can Verbal form used for statements of possibility and capability,

Whether material, physical or casual.

3.2 Insulation classes

Heat conservation Class 1The purpose is to reduce heat losses and to maintain temperatures for the efficient operation of the

process.

Cold medium conservation Class 2

The purpose is to maintain low temperature and control heat input to the process.

Personnel protection Class 3

Surfaces with operating temperatures below -10 °C or above 70°C and are confined to a distance of

not more than 2,1 m vertically and 0,8 m horizontally away from walkways and normal working

areas shall be guarded by screens. Insulation shall only be used where guards are not practical.

Frost proofing Class 4

Insulation/heat tracing to prevent freezing, solidification and condensation.

Fire proofing Class 5

The purpose is to reduce the heat input and limit the temperature to 400°C on piping, vessels and

equipment in a hydrocarbon fire situation lasting for 30 minutes according to ISO 834.

Fire proofing according to any other fire scenarios shall be specified in each project. Selected fire

proofing shall be documented and if necessary fire tested.




Rev. 2, June 1999

Acoustic insulation Class 6, 7 and 8

The acoustic insulation is defined as the arithmetic average of the insertion loss in the three octaves

bands 500 Hz, 1000 Hz and 2000 Hz.

Based on documented insertion loss, each project may select materials or combinations of materials

to cover the required insertion loss at actual frequencies. Ref. Annex 2 “Insertion loss – Test procedure“ for this Standard. This selection shall not conflict with any other requirement of this

standard, and Company shall approve each combination.

Valves and flanges shall be insulated when and as required by Company.

Acoustic insulation Class 6

Reduction of noise in the area 500-2000 Hz by 10 dB.





External condensation and icing protection Class 9

The purpose is to prevent condensation on piping and equipment with operation temperatures below

ambient.

For combination of insulation classes see clause 7.

3.3

AbbreviationsAISI American Iron and Steel Institute

ASTM American Society for Testing and Materials

DN Diameter Nominal

EN European Norm

HSE Health, Safety and Environment

IMO International Maritime Organisation

ISO International Organisation of Standardisation

NT Nordtest

P&ID Piping & Instrument Diagram

4

GENERAL REQUIREMENTS

4.1

Introduction

General requirements for thermal insulation (hot and cold) are given in this clause. Specific

requirements for hot service and acoustic insulation are stated in clause 5, and cold service

insulation in clause 6.

Pre insulated piping may be used in relevant classes.




Rev. 2, June 1999

Alternative insulation may be used if the proposed materials and methods satisfy the functional

requirements in this specification. Approval by Company is required.

4.2 Design

4.2.1 General

Piping and equipment shall be insulated according to the insulation class, operating temperature and

insulation thickness stated in the P&ID and Data sheets.

All insulation shall be covered with weather protection designed and installed to prevent ingress of

water during normal operation throughout the design life.

Insulation adjacent to flanges in piping and equipment shall be terminated to allow removal of bolts

without damage to insulation. Minimum free space from the flange to the nearest part of the

insulation shall be equal to the bolt length +25 mm. The termination of the weather protection shall be waterproof.

When a rigid type of insulation is used, provision shall be made for longitudinal expansion and

contraction.

4.2.2 Vessel insulation

Insulation of all vessels shall be supported on rings with a distance of 900 mm c/c installed on the

vessel. Rings shall also be provided around nozzles above DN 200 mm.

Block insulation shall be fastened with mechanically tightened metal bands or with bonding

adhesive.

Insulation on vessel heads shall be fastened with bands spaced not more than 300 mm centres. The

bands shall be fixed to the fixing ring installed on the vessel.

Vessels of diameter 1500 mm and smaller shall be insulated as piping.

4.2.3

Removable insulation of flanges and valves

Removable insulation for flanges and valves, like tailor made jackets or pre formed insulation

boxes, shall be suitable for quick removal and reinstallation.

All tailor made jackets shall fit the actual valve/flange/equipment and secure adequate overlap toincoming insulated pipes.

4.2.3.1 Outer material of tailor made jackets

The outer material shall be silicone rubber proofed fabric made from glass fiber. Other materials

may be used provided that the material properties can be documented to be equal or better than

silicone rubber.

The material shall be suitable for use against temperatures between -30 oC and +230 oC.

The silicone rubber coating shall prevent water being absorbed by the insulation material.

The outer material shall be non-combustible or at least self-extinguishing, and tested according to

IMO Resolution A.653 (16) or similar.






Rev. 2, June 1999

4.2.3.7

Identification of tailor made jackets

Each removable insulation cover shall be provided with an identification plate with the following

information:

- Vendor name

- Line number - Tag number

- Cover number

- Certificate number

The vendor shall also identify each cover on drawings and store this information according to the

vendor quality system.

The identification number system shall be easily read prior to and after installation and shall be

placed under the flap fastener. The identification plate shall be made of a material resistant to water

and/or chemicals.The numbering system for identification of individual cover shall be provided by Company after

contract award.

4.2.4 Insulation of instrument and instrument tubing

For insulation of instruments, insulated cabinets with hinged doors shall be used. Instrument tubing

of max DN 25 may be insulated with cellular rubber for temperatures up to 100 OC. For

temperatures above 100 OC, glass fibre rope and jacketing may be used.

4.2.5 Piping insulation

Insulation on long vertical pipe runs shall be supported on rings spaced on 6400 mm maximum

centres installed on the piping. Width of rings shall be half the thickness of the insulation material.

4.2.6 Metallic jacketing

Flat heads are not allowed on top of vertical vessels.

Removable insulation covers shall be provided for removable vessels heads.

The bottom heads of skirt supported vessels may be covered with flat metallic jacketing.

Jacketing for flanges and valves shall be formed such that it sheds water.

Longitudinal seams of metal jackets on horizontal or sloping pipelines shall be located maximum 60

degrees away from the lowest point of the circumference.

All seams on metallic jacketing shall be provided with a metal seam sealant to become water proof.

4.2.7

Non metallic jacketing

For pipe insulation a non-metallic weather protection may be used instead of metallic jacketing for

all classes except class 5. Fire proofing. The non metallic weather protection must fulfil the

requirements in clause 4.3.7 and be verified with tests. Use of combustible non metallic jacketing in

enclosed areas shall be subject of approval in writing with regard to HSE aspects.

It is recommended to apply aluminium foil between cellular glass and the non metallic jacketing.




Rev. 2, June 1999

4.2.8 Heat traced piping

Heat traced piping shall be wrapped with 0,05 mm aluminium foil prior to insulation to protect the

heating cables and improve the heat distribution.

Where heating cables penetrate the jacketing, edge protection shall be provided to prevent damage

to the cable. A permanent sealer shall be applied in order to prevent ingress of water.

4.2.9 Drains

For all insulation systems and insulation classes for piping and equipment (except for class 2, 5 and

9) there shall be 15 mm diameter drain holes in all low points, and a minimum of one hole every 3

metres on horizontal runs.

Compact pre-insulated piping system does not require low point drain.

4.3 Materials

4.3.1

GeneralInsulation materials for classes 1, 2, 3, 4, and 9 shall consist of cellular glass. Materials for class 5,

6, 7 and 8 shall be cellular glass in combination with mineral wool, mineral fibre or ceramic fibres.

All insulation materials shall have a neutral pH value.

Insulation concept shall be non combustible, non-toxic and water tight/water repellent. The

materials shall not release toxic or corrosive gases when exposed to fire. No asbestos or asbestos

products shall be used. No lead or lead products shall be used unless accepted by company.

These requirements are not applicable to pre-insulated pipe systems.

In dry rooms where no sprinkler deluge system exist mineral wool may be used on pipes/vessels

with an operating temperature above +40 OC. Indoor areas with regular water cleaning or testing of

sea-water deluge system are not considered dry. The system shall have drain holes according to

clause 4.2.9.

For steam and exhaust pipe, mineral wool may be used with stainless steel jacketing.

Mineral wool shall under no circumstances be applied on stainless steel materials like AISI 316,

duplex, 6Mo etc.

4.3.2 Fire insulation materials

The material shall withstand relevant temperatures while maintaining its fire protection properties.

For jet fire protection high duty fibres that withstand temperatures above 1150 OC shall be

considered.

4.3.3 Cellular glass

Cellular glass shall have the following properties:

Conform to ASTM C552 and be suitable for temperatures from –260 OC to 430 OC

The density shall be within 125 kg/m3 +/- 10 % as per ASTM C303

Thermal conductivity, not greater than 0,0039 W/mK as per ASTM C177

Average compressive strength per ASTM C165: 490 kPa

Water vapour transmission: Zero

Linear expansion coefficient: 8,5 x 10

-6

/

O

C




Rev. 2, June 1999

4.3.4 Mineral wool

Mineral wool shall be manufactured with a phenol binder. The specific flow resistance for the

mineral wool shall be minimum 2,0 x 10 4 Pa s/m 2 .The density shall be within 90-120 kg/m 3

4.3.5

Sealers, Tape

Joint sealers and tape shall be permanently flexible through a relevant temperature range and shall

be capable of withstanding repeated expansion and contraction.


Metallic jacketing shall be stainless steel or sea water resistant Al-alloy. For fire protection the

jacketing material shall be stainless steel.

4.3.6.1 Stainless steel

Stainless steel metal jacketing shall be type AISI 316, 2B finish.

Stainless steel sheets for pipes and vessels up to DN 450 shall have a thickness of 0,5 mm. For

dimensions above DN 450 the thickness shall be 0,7 mm.

4.3.6.2 Aluminium alloy

Aluminium alloy jacketing shall be type A1Mn1 (AA 3103) or equal.

Aluminium sheets for pipes and vessels up to DN 450 shall have a thickness of 0,7 mm. For

dimensions above DN 450 the thickness shall be 0,9 mm.

4.3.7 Non metallic jacketing

4.3.7.1 Fire characteristics incl. Smoke and toxic gases

According to ISO 5660 and additional techniques. No additional acceptable amounts of smoke/fumes beyond what is produced in a HC fire. In addition to what ISO 5660 specifies,

concentration of various vapours, fumes and gases shall be documented according to the chemical

composition of the material. Based on these tests the material can be subject to application

restrictions.

Flame spread as per IMO Res. A.653 (16) equal to self extinguishing properties.

4.3.7.2 Weathering/durability.

500 hours Weather-O-meter testing according to ASTM G53 incl. wet/dry-cycling. (UV-B313).

Less than 70 % loss of lustre. The material shall maintain 90 % of its strength properties after the

Weather-O-meter test.

4.3.7.3 Material parameters

Water vapour transmission: 10g/m /24h as per ASTM D3833.

Mechanical properties: Min. Tensile strength 6.9 MPa (1000 psi).

Elongation at break min.10 %.

The material shall not decompose at temperatures from –20 OC to 70 OC .

Any possible shrinkage or temperature unsuitability of the tape material shall be documented.

4.3.7.4

Application

The tape material shall be suitable for application at RH up to 90 % and down to +5 OC . New

materials shall be subject to a pilot test for verification of the application performance.




Rev. 2, June 1999

4.3.7.5 General

Storage stability of the tape shall be minimum 6 months.

Technical specifications and HSE data sheets shall be in Norwegian.

Types of non-metallic weather proofing shall be subject to Company approval.

4.3.8

Bonding adhesive

For temperatures up to 140 OC adhesive shall be used for bonding of insulation to vessels. When

the adhesive cures it shall constitute a flexible bond that absorbs mechanical and thermal stress.

Bonding adhesive shall not be used above 140 OC.

4.3.9 Anti-abrasive coating

The high temperature anti-abrasive coating may be a high strength gypsum cement with inert

mineral fillers applied on the inner surface of the insulation sections. When dry, the cement shall

form a hard surface protection against abrasion.

Anti-abrasive coating shall be used to prevent damage to cellular glass and painting due to vibration

where applicable.The low temperature anti-abrasive coating shall be a one component urethane based coating.

The anti-abrasive coating shall be suitable for application at service temperatures.

4.3.10 Metallic foils

Aluminium foils as an initial wrapping over heat traced piping and equipment shall be soft temper

foil, 0,05 mm thick.

If heat tracing is used to any type of stainless steel piping, then aluminium foil with polyester on one

side shall be used.

The polyester coated side to be applied towards the pipe to prevent galvanic corrosion.

4.3.11

Accessories

Vendor to specify standard (material, dimension, type) regarding accessories such as rivets, toggle

latches, bands, wires, clips, breather springs etc. all in AISI 316 materials.

4.3.12

Pre-insulated pipe systems

Pre-insulation shall consist of an insulation layer and a watertight outer jacket. Dimension of outer

jacket shall be in accordance with EN 253: Casing pipe dimensions.

The insulation system must withstand minimum 0,3 MPa pressure to the outer surface. It must be

designed for clamping on the outer jacket or water tight insulation of supports.

Field insulation of field joints and other accessories shall give same insulation and weather

protection as for straight pipes.

The insulation system shall fulfil class 1 in accordance with NT Fire 036.

In addition to what ISO 5660 specifies, concentration of various vapours, fumes and gases shall be

documented according to the chemical composition of the material.

For pipe systems with heat tracing a groove (duct) shall be formed in the insulation tight to the main

pipe. The groove (duct) shall be dimensioned to allow space for the heating cable and material for

the application




Rev. 2, June 1999

4.4 Installation

The Insulation Handbook established by Statoil, Norsk Hydro and Saga may be used to secure a

uniform and acceptable design of the insulation work.

4.4.1

General

The insulation materials and the external jacketing shall be installed in such a way that water does

not enter the insulation material or between the insulation and the pipe / equipment surface during

design life.

Surfaces to be insulated shall be clean and dry. The application of the insulation shall not be started

before the mechanical completion certificate for coating has been issued. Surfaces to be insulated

shall be treated in accordance with NORSOK M-501.

Discontinued insulation work shall be properly covered to avoid damage and ingress of water to the

insulation clean and dry.

Single layer insulation shall be applied with longitudinal joints staggered. In double-layer

applications, joints of the outer layer shall be staggered with respect to the inner layer joints. All

insulation shall be installed with all joints tightly glued together. Voids within the insulation are notacceptable.

If insulation work precedes testing of pipe work, welds and joints shall be left uninsulated to allow

inspection during testing.

Insulation on valves shall leave the packing gland accessible.

To secure cellular glass pre-formed sections in place, adhesive glass fibre reinforced tape or

stainless steel banding shall be used. Wire shall not be used.

4.4.2 Pre insulation

The service pipe, insulation and jacket shall be one compact construction. Insulation and jacket

must follow the thermal movement of the service pipe. All welding must be controlled, pressure

tested, documented, approved and surface treated before the final insulation is performed.


The crimps on jacketing shall have the following minimum dimensions; depending on outside

diameter (including insulation):

Up to 300 mm: 10 mm 5 mm radius

Between 300 mm and 600 mm: 13 mm 6,5 mm radius

Above 600 mm: 16 mm 8 mm radiusAll jacketing seams shall be installed by ‘roof tile’ principle and the application of joint sealer shall

be inside the jacketing.

Metallic jacketing for vessel insulation shall be edge crimped and overlapped 75 mm on

longitudinal and circumferential seams. Vessel jacketing shall be provided with bands on all overlap

seams and support rings ( 400 mm c/c ).

Head covers on vessels shall overlap shell covers by 100 mm.

On vessel jackets, breather springs shall be used on bands if required for expansion.




Rev. 2, June 1999

On vertical vessels and piping, "S" clips shall be used to keep the jacket sheets from sliding.

Minimum 4 clips per seam.

Metallic jacketing shall be fastened with stainless steel bands. Only for difficult details such as

bends, T-pieces etc. pop rivets (or equivalent) may be used.

Metallic jacketing for pipes and fittings shall be roller formed and edge crimped at longitudinal

seams. Circumferential seams shall be crimped 50 mm from the edge wherever possible.

Circumferential seams shall be overlapped minimum 50 mm. Longitudinal seams for outside

diameters up to 150 mm shall be overlapped 30 mm and 50 mm above.

5

HOT SERVICE AND ACOUSTIC INSULATION

5.1 General

This clause describes the requirements for the following insulation classes:

• Class 1, Heat conservation.

•

Class 3, Personnel protection.

• Class 5, Fire proofing.

• Class 6, 7 and 8, Acoustic insulation.

5.2 Design

Guidance for the choice of insulation thickness for heat conservation and personnel protection is for

cellular glass given in table 2. If a specific temperature has to be maintained, the thickness of the

insulation material in question has to be specified in each case.

The following equipment shall not be insulated for heat conservation class 1 except for steam

services or when otherwise specified:

1. Vessel man way covers, nozzles and flanges.

2. Exchanger nozzles and flanges.

3.

Valves and piping flanges.

4. Control valves, line valves and fittings, which are to be removed periodically.

5. Expansion and rotation joints, slide valves and similar equipment.

6.

Steam traps.

Flanges operating at temperatures above 450 OC shall be insulated and protected with sheet metal

jacketing.

5.3 Installation

The following requirements apply in addition to those in clause 4.5

Insulation sections shall be installed according to manufacturer’s standard procedure.




Rev. 2, June 1999

5.3.1 Block insulation for vessels / cellular glass

Block insulation for vessels:

1. Insulation for vessel heads shall be curved blocks or standard flat blocks cut to fit.

2. For single layer and outer layer of multi layer insulation, banding shall be placed approximately

30 mm on each side of all butt joints with intermediate bands at a maximum of 300 mm centres.The inside layer of multi layer installations shall be banded at a maximum 450 mm centres.

5.3.2

Blanket insulation on vessels / ceramic fibres / mineral wool

Blanket insulation on vessels:

1. The last piece of insulation in each layer shall have a snug fit to make all joints tight. Contraction

joints are not required for resilient insulation materials.

2. The meeting edges of blankets shall be tied together with stainless tie wire.

5.3.3 Prefabricated pipe section insulation / cellular glass / mineral wool

Prefabricated insulation shall be applied as follows:1. Insulation pipe sections shall be tightly butted together and secured to pipe with stainless steel

bands.

2. Insulation shall be secured with bands over the outer layer at each side of radial joints and at the

centre of each section.

3. Spacing of bands for the inner layer of multi layer insulation need only be sufficient to hold

sections in place until the outer layer is secured.

4. To cover elbows and other irregular surfaces, sections may be cut and fitted in the field.

5.3.4

Blanket insulation for piping / ceramic fibres / mineral wool

Blanket insulation shall be used for dimensions where pipe sections are not available.

1.

Insulation joints shall be butted firmly together and secured with stainless steel wire or bands.

2. Insulation shall be secured with bands over the outer layer at each side of radial joints and at the

centre of each section.

3. Fittings and flanges shall be insulated with blankets. Insulation shall be secured by wire or band.

5.3.5 Pre insulation for piping

Pre insulation shall be applied as follows:

1. The concept shall give a compact construction.

2. Insulation ends shall be water proof




Rev. 2, June 1999

5.4 Guidance for insulation thickness

Table 1 applies to Heat conservation (class 1) and personnel protection (class 3)

Table 1. Thickness in millimetres for cellular glass.

DN Maximum operating temperatures oC

mm 100 150 200 250 300 350 400 420

20 30 30 30 30 50 50 50 50

25 30 30 50 50 50 50 50 50

32 30 30 50 50 50 50 50 50

50 30 30 50 50 50 50 80 80

65 30 30 50 50 50 80 80 80

80 30 50 50 50 50 80 80 80

100 50 50 50 50 50 80 80 100

150 50 50 50 50 80 80 80 100200 50 50 50 50 80 80 80 100

250 50 50 50 50 80 80 100 100

300 50 50 50 50 80 80 100 100

350 50 50 50 50 80 80 100 100

400 50 50 50 50 80 80 100 100

450 50 50 50 50 80 80 100 100

500 50 50 50 50 80 80 100 100

600 50 50 50 50 80 80 100 100

Above 600 and

flat surface

50 50 80 80 100 100 100 150

The material thickness given above is guidelines only. They shall be adjusted up to the closest

standard thickness given by the manufacturer. Thickness of 80 mm and above can be built up in two

layers if required.

For other materials or pre insulation the guidelines above may be used to the nearest standard

thickness.

5.5

Guidelines for Steam Service and Exhaust Lines

Steam Service and Exhaust lines will normally have an operating temperature enablingeventual wet insulation to dry out. In such cases mineral wool may be used if accepted by Company.

Steam lines utilising mineral wool pipe sections shall be of nominal density 140 kg/m3. Weather

protection shall be stainless steel jacketing.

Exhaust lines utilising mineral wool mattresses shall be of nominal density 105 kg/m3, with

galvanised wire mesh at one side. Weather protection shall be stainless steel jacketing.




Rev. 2, June 1999

Table 2 Thickness in millimetre for mineral wool

Steam service Turbine exhaustDN

Operating temperatures oC Operating temperatures oC

mm 200 250 300 400 200 300 400 500 600 700 800

25 30 40 50 60

38 40 50 50 60

50 50 50 60 80

80 50 50 60 80

100 50 50 70 80

150 50 50 80 80

200 50 50 80 100

250 50 50 80 100

300 50 50 80 100

350 50 50 80 100

400 50 50 80 100450 50 50 80 100

500 50 50 80 100 50 100 130 150 175 175 200

600 50 50 100 100 50 100 130 150 175 200 200

And above 50 50 100 100 50 100 130 150 175 200 200

5.6 Class 5, Fire Proofing

The purpose is to reduce the heat input on piping, vessels and equipment in a hydrocarbon fire

situation.

If the material strength of equipment will be reduced by being subjected to a fire, this must be taken

into account in the evaluations, of regulations relating to explosions and protection of installationsin the petroleum activities. With regard to evaluations of depressurising time, a recognised standard

such as API RP 521 may be used. If passive fire protection is used, the material strength can be

retained for a longer period of time and thereby affect the depressurising time.

Required insulation thickness, and combination of insulating materials, shall be calculated on an

individual basis, and the following shall be taken into consideration:

1.

Extrapolations of test results are not acceptable. New systems or combination of materials shall

be subject to relevant fire tests prior to acceptance.

2. Type of fire.

3. Properties of pipe work and vessel material

4.

Content of pipe work and vessel5. Depressurisation time for the exposed system

6. Properties of the insulating material

7. Only metallic weather proofing shall be used on Class 5, accept on valves and flanges where

removable jackets may be used. A weather proofing membrane can be installed under the

metallic cladding to reduce the risk of water ingress and corrosion under insulation.






Rev. 2, June 1999

In order to avoid frost formation or condensation on pipe supports, insulated prefabricated pipe

supports shall be used.

6.3 Installation

The following requirements apply in addition to those in clause 4.5.A smooth outer insulation surface must be obtained to provide an effective vapour seal.

6.3.1

Block insulation for vessels

Block insulation for vessels:

1. All block edges shall be smeared with a thin coat of joint sealer when single layer insulation and

the outer layer of a multi layer insulation are applied. The remaining joints shall be left dry,

except where vapour seals or contraction joints are required,

2. Termination of insulation on all layers, including contact surfaces where removable insulation

covers are installed, shall be vapour sealed.

6.3.2

Piping insulation

Prefabricated insulation of cellular glass shall be applied as follows:

1. All joints of single layer and outer layer of a multi layer insulation shall be applied with butt

edges smeared with joint sealer before installation.

2. Anti-abrasive compound shall be applied to the inner bore and allowed to dry before application.

Anti abrasive compound when required, is preferred factory applied.

3. Bands or glass fibre reinforced tape shall be used to secure each layer of insulation, including the

outer layer. Bands or tape shall be installed on 275 mm centres, and at least 25 mm back from

butt joints. Wire shall not be used.

4. Prefabricated flange and fitting covers shall be applied in the same manner as pipe insulation,

except that non-removable joints shall be cemented with adhesive.

6.3.3 Pre insulation for piping.

Pre insulation shall be applied as follows:

1. The concept shall give a compact construction without any spaces or voids.

2. Insulation ends shall be water proof.

3. For heat tracing a groove (duct) suitable for the heat tracing cable shall run along and close

to the pipe inside the insulation.

6.3.4

Guidance for insulation thickness

6.3.4.1 Frost proofing, Class 4 piping and equipment with heat tracing:

Thickness of insulation for piping and equipment shall be:

1. 40 mm up to and including nominal diameter 200 mm.

2. 50 mm above 200 mm and flat surface.

6.3.4.2 Frost proofing, Class 4 piping and equipment without heat tracing:

Thickness of insulation for piping and equipment shall be:

1. 30 mm up to and including nominal diameter 80 mm.

2. 40 mm above 80 mm and flat surface.




Rev. 2, June 1999

Table 3 applies to cold service insulation, class 2 and 9, and condensation protection.

Table 3. Thickness in millimetres for cellular glass.

DN Minimum temperatures oC

mm 5 0 -10 -20 -30 -40 -50 -60 -70 -80

25 30 30 50 60 60 75 75 90 90 100

32 30 50 50 60 75 75 75 90 100 100

50 30 50 50 60 75 90 90 100 100 100

65 50 50 50 60 75 90 90 100 100 125

80 50 50 60 75 75 100 100 100 125 125

100 50 50 60 75 75 100 100 100 125 125

150 50 50 60 75 90 100 100 125 125 125

200 50 50 75 75 90 100 125 125 125 150

250 50 50 75 75 100 100 125 125 150 150

300 50 50 75 75 100 100 125 125 150 150350 50 50 75 75 100 100 125 125 150 150

400 50 50 75 75 100 100 125 125 150 150

450 50 50 75 75 100 100 125 150 150 150

500 50 75 75 75 100 100 125 150 150 150

600 50 75 75 75 100 100 125 150 150 175

The material thicknesses given above are guidelines only. They shall be adjusted up to the closest

standard thickness given by the manufacturer. Thickness of 100mm and above can be built up in

two layers if required.

For other materials or pre insulation the above guideline may be used to nearest standard calculated

according to the thermal conductivity.

7

COMBINATION OF INSULATION CLASSES

7.1 General

Below guidelines are given for insulation systems in cases where insulation shall serve more than

one purpose:

Two digits in the line number on the P&ID will indicate the insulation class and the insulation

symbol will show insulation material and thickness.

Insulation Class 1 will be shown as 01 etc. Insulation systems with combination of class 1 an 5 can

be identified with the two digits 15 in the line number or other project specific combinations.

7.1.1

Fire proofing (5) combined with Heat conservation (1) and or Acoustic insulation (6, 7

& 8).

Use class 5 fire proofing and relevant class for acoustic insulation builds up. Select the thickness

from the insulation class with the greatest thickness. Stainless steel jacketing shall be used.




Rev. 2, June 1999

7.2 Acoustic insulation (6, 7 & 8) combined with Heat conservation (1) or Personnel

protection (3).

Use Acoustic insulation build up. Select the thickness from the insulation class with the greatest

thickness.

7.3

Fire Proofing (5) combined with cold service insulation (2, 4 and 9)

Use cellular glass for the cold service and add a layer with the required thickness of accepted fire

protection material. A vapour barrier outside the fire protection to be included to reduce intrusion of

water/vapour into the fire protection. Stainless steel jacketing shall be used.

7.4 Acoustic insulation (6, 7 & 8) combined with cold service insulation (2, 4 and 9)

Use acoustic insulation build up, but add an outer layer of cold service insulation. The thickness of

the acoustic insulation will allow a similar reduction in the thickness of the cold service insulation.

However, minimum thickness of the cold service insulation shall be 30 mm.

8 QUALIFICATION REQUIREMENTS

8.1 Qualification of insulation system

The requirements for qualification prior to use are applicable to insulation class 5.

The fire resistance shall be decided in accordance with recognised standards and/or calculation

models.

Tests shall be carried out on complete insulation system installed on a test piece on a relevant

dimension.

The following shall identify the fire technical requirement relating to insulation materials:

1. Requirement in NPD ” Regulation for explosion- and fire protection”.

2.

For pool fire, the insulation system shall be qualified and the fire resistance shall be decided in

accordance with recognised standards and/or calculation models, for example ISO 834 “Fire

resistance tests” or equivalent

3.

Insulation used for passive fire protection against a jet-fire shall be tested in according with

OTO 93 028 the test method “Jet-fire resistance test of passive fire protection materials”.

8.2 Qualification of personnel

8.2.1 Qualification of insulation fitters

Operators shall be qualified to tradesman level as insulation fitter or sheet metal worker.

The personnel shall have a relevant knowledge of health and safety hazard, use of protection

equipment, insulation materials, application of insulation materials, insulation systems surface

requirements, and how to avoid corrosion under insulation.

If not qualified to tradesman level, personnel shall be subject to a test in accordance with this for

Standard classes 1, 4 and 5.

The test shall be supervised by a qualified supervisor and examined by qualified QC personnel.

An examination certificate shall be issued if the candidate passes the test. Inspection personnel shall

have access to site test procedures.




Rev. 2, June 1999

The test shall be carried out on a test piece, composed of a DN 100 pipeline containing at least one

valve, two flanges, one T piece, one trunnion support and one standard clamped support.

Both valve box and one flange shall be insulated with AISI 316 material to insulation system

Class 5.

Alternatively a suitable location on the installed pipelines, which as a minimum consist of the same

parts as described for the test piece, may be selected to which the Insulation Procedure Test (IPT)shall be carried out

8.2.2

Qualification of Supervisors, Foremen and QC personnel

Personnel carrying out inspection or verification shall be qualified to tradesman level and shall be

accepted as inspector by company.

Supervisors and foremen shall be qualified to tradesman level and shall have documented minimum

3 years experience with insulation work corresponding to work described in this standard.

All QC- and supervision personnel shall be familiar with the requirements in this standard.

8.3 Qualification of procedures

8.3.1 Insulating Procedure Specification (IPS)

A detailed IPS based on the requirements of this standard shall be established. The IPS shall as a

minimum contain the following:

1.

Detailed sketches, which show the system, build up for each insulation class to be used. (also for

combination of systems)

2. Type of materials to be used in the individual layer (product data sheet)

3.

Type of removable insulation covers for flanges and valves

4.

Dimension of materials

5. Inspection plan

The qualified IPS shall be followed during all insulation work

Following changes in the insulation application parameters requires the IPS to be re-qualified:

1. Any change of insulation material

2.

Change of system build up

3. Change type/manufacture of removable insulation covers

8.3.2

Insulation Procedure Test (IPT)

An IPT shall be used to qualify all insulation procedures. A test piece (ref. 8.2.1 as applicable),

alternatively a suitable location on the lines to be insulated, may be selected to which the IPT shall

be performed.

The IPT shall be qualified under realistic conditions likely to be present during insulation

installation.

Inspection requirements for the IPT shall be as given in clause 9 and the inspection plan in IPS.




Rev. 2, June 1999

9 INSPECTION AND TEST

Work during production, at delivery and all other pertinent phases, shall be duly inspected.

Reasonable access to workshop and personnel for inspectors shall be allowed for.

Inspection shall be carried out at each stage of the work, but as a minimum before second layer of

multi layer insulation is applied and before jacketing is applied.




Rev. 2, June 1999

ANNEX A – KEY DATA FOR INSULATION SYSTEMS

Insulation

class

Insulation

Materials

Jacket

Material

Other Comments /

Build-up

Class 1

Heat

Conservation

Cellular glassMineral wool at temp.

higher then 420 OC

Non-metallic weather- proofing membrane.,

or Stainless Steel / Al

Class 2

Cold Service

Insulation

Cellular glass Non-metallic weather-

proofing membrane.,


Vapour barrier

Class 3

Personnel

Protection

Either:

Class 1 – 9

Or

Perforated sheet metal

guards

In accordance with

classes 1 – 9 as

applicable

Perforated guards to be of

stainless steel.

If insulation is used, it shall be

designed so that the jacket

temperature do not exceed 70 O

CClass 4,

Frost Proofing


proofing membrane.,


Vapour barrier

Class 5,

Fire proofing

Cellular glass +

Ceramic fibre

or

mineral wool

when necessary

Stainless steel Insulation materials are dependant

on protection requirements, and

must be accepted in writing by

client for each case

Class 6,

Acoustic

Insulation – 10dB

Cellular glass

Ceramic fibre or

Mineral wool

Heavy synthetic sheet

Non-metallic weather-

proofing membrane.,


30mm Cellular glass + 25mm

“fibres” + metallic jacketing (or

aluminium foil + non-metallic

jacketing)

Class 7,

Acoustic

Insulation – 20dB

Cellular glass

Ceramic fibre or

Mineral wool



proofing membrane.,

or Stainless Steel /Al


“fibres” + heavy synthetic sheets

+ metallic jacketing (or

aluminium foil + non-metallic

jacketing)

Class 8,

Acoustic

Insulation –30dB

Cellular glass

Ceramic fibre or

Mineral wool



proofing membrane.,



“fibres” , + 2 x heavy synthetic

sheets + 25mm fibres + 2 x

heavy synthetic sheets + metallic jacketing (or aluminium foil +

non-metallic jacketing)

Class 9,

External

Condensation


proofing membrane.,


Vapour barrier

These key data are not applicable for pre insulated pipe systems.




Rev. 2, June 1999

ANNEX B – INSERTION LOSS – TEST PROCEDURE

General

The acoustic properties of pipe insulation can be characterised by the insertion loss. Today, there are

no national or international test standards established for such measurements. This attachmentdescribes a "survey" method for measuring the acoustic insertion loss of pipe insulation systems.

This method should be used to determine the "Classes of Acoustic Pipe Insulation" as defined in

NORSOK R-004, rev. 2.

Frequency dependent Insertion Loss

The frequency dependent insertion loss is defined by the following equation:

ILi = L pU, i - L pI, i

ILi : Insertion loss at the frequency "i"

L pU : Reference measurement of the bare pipe. The noise level at 1,0 m distance from

the uninsulated pipe, calculated as the logarithmic average of all microphone

positions.

L pI : Measurements of the insulated pipe. The noise level, logarithmic average, in the

same microphone positions after the insulation system is applied.

Although the acoustic classes of insulation are described by a single value derived from the three

1/1-octave band levels 500, 1000 and 2000 Hz, measurements should be performed in 1/3-octave

bands in a broader frequency range. This will provide important additional information to be used in predictions of sound radiation from various pipelines.

For all other measurements than site tests, measurements shall be performed in 1/3 octave band

levels and as a minimum cover the frequency range of 100-5000 Hz.

ACOUSTIC CLASSES - Average insertion loss

The acoustic insulation is defined as the arithmetic average of the insertion loss in the three

1/1-octave bands with centre frequencies at 500, 1000 and 2000 Hz:

IL = (IL500 + IL1000 + IL2000)/3

The 1/1-octaveband levels shall be calculated from the measured 1/3-octaveband levels after a

linearisation of the reference spectrum (L pU) - i.e. a correction shall be added or subtracted to the

L pU,i-values to obtain a "flat" (linear) spectrum. The L pI,i-values shall be adjusted correspondingly.

3 dB shall be subtracted from the calculated average insertion loss (IL), before defining the acoustic

class of the pipe insulation as described in NORSOK R-004.




Rev. 2, June 1999

Test arrangement

A pipe of at least 5 metre length should be used for the test. The pipe diameter should be in the

range of 200 - 400 mm, and the pipe wall should have a thickness of 8 – 12 mm.

If the normal pipe diameter that the insulation will be used for is outside than this range, the system

may be tested for the relevant diameter. Considerations about the effect of other dimensions should be given in the test report.

The pipe may be set into vibration in several ways. For a survey purpose it may be unfeasible to use

a "natural" source like for instance the noise from a valve for the test, unless there is a suitable test

spot within a process area, which can be screened of from other sources.

A sound source of appropriate power to create sufficient high noise level in the pipe may therefore

be used. The source must be placed in separate room or an insulated enclosure (box) with sufficient

sound insulation to prevent false noise to interfere with the measurement results.

The measurements may be performed in a reverberant room, a semi reverberant soundfield or in free

field conditions. The number of measurement positions should then be at least 5 randomly

distributed at for instance 1 metre distance from the bare pipewall. The sound pressure

measurements and averaging of the noise levels should be performed in accordance with recognised

standards for such measurements. Methods described in ISO 3740 – 3746 and

ISO 11200 – 11204 may be used as reference for calibration, measuring technique, microphone

positions, requirements to and influence of background noise, environmental contribution form the

test place (room), etc. If intensity measurements are used in stead of measurements in discrete

positions the relevant intentional standard shall be given, for instance ISO 9614-2.

The noise from the source shall enter the measurement site mainly through the pipe wall, also after

the pipe insulation has been applied to the pipe. Both the source end of the pipe and the oppositeend (passive end) must therefor be insulated sufficiently to reduce the contribution from these

sources to an insignificant level.

Measurement procedure

A system to check the "sound source" should be established in order to ensure a constant excitation

during the test. This may for instance be a microphone placed at a fixed position inside the pipe.

A calibration test of the instrumentation shall be carried out before and after the test. The

microphone positions must be kept at the same places; to ensure that environmental reflections

contributes similarly to the measured levels through all series of measurements.

The background sound level must be checked, and if the level is within 10 dB below the lowest

noise level from the pipe, the measured levels shall be adjusted. Background levels which is less

than 5 dB below the lowest 1/3 octaveband levels should not be accepted.

During the test one should also check any influence from "false" sources such as leaks, radiation

from supports, radiation from pipe ends, radiation from source room etc.




Rev. 2, June 1999

Report

The following should be reported from the test:

Test arrangement

•

dimensions of pipe

• pipe ends and support structure

• type of excitation

• test environment

Measurement procedure

•

sound source check

• calibration

• measurement positions

•

background noise

• limitations / influence of leaks / “false noise”

Materials tested

• name / code / vendor

• attachment with material certificates (vendor information)

Test results

•

1/3 octave band values of reference level (for instance levels inside the pipe)• unlinearised 1/3 octave band levels outside pipe

• Linearised 1/3 octave band levels and the corresponding 1/1 octaveband levels outside the

uninsulated pipe (corrected for background noise).

•

1/3 octaveband levels corrected for linearisation, and the corresponding 1/1 octave band levels

outside the insulated pipe (for each system) included any corrections for background noise.

• Insertion loss for each system in 1/3 octaveband and 1/1 octavebands in the frequency range

covering at least 100 – 5000 Hz.

• Calculated average insertion loss and specification of insulation class.

•

Discussion of results and limitations.





percent based on absolute volume, may be substituted for an equivalent amount of portland

cement in the grout mixture unless otherwise specified in section 14 of this specification.

Aggregates shall conform to the requirements of ASTM C 33 for fine and coarse aggregate for

concrete, or as shown on the construction drawings.

Water shall be clean and free from injurious amounts of oils, acid, alkali, organic matter, or other

deleterious substances.

Air-entraining admixtures shall conform to the requirements of ASTM C 260. If air-entraining

cement is use, any additional air-entraining admixture shall be of the same type as that in the

cement.

Curing compound shall conform to the requirements of ASTM C 309. Unless otherwise

specified, the compound shall be type 2.

Other admixtures, when required, shall be as specified in section 14 of this specification.

3. Subgrade preparationThe subgrade surface on which the rock riprap, filter, bedding, or geotextile is to be placed shall

be cut or filled and graded to the lines and grades shown on the drawings. When fill to subgrade

lines is required, it shall consist of approved material and shall be compacted to a density equal to

the adjacent existing soil material.

Rock riprap, filter, bedding, or geotextile shall not be placed until the foundation preparation is

completed and the subgrade surface has been inspected and approved by the NRCS.

4. Placement of rock riprap

Method 1 Equipment-placed rock—The rock riprap shall be placed by equipment on the surface

and to the depth specified. It shall be installed to the full course thickness in one operation and in

such a manner as to avoid serious displacement of the underlying material. The rock for riprap

shall be delivered and placed in a manner that ensures the riprap in place is reasonably

homogeneous with the larger rocks uniformly distributed and firmly in contact one to another

with the smaller rocks and spalls filling the voids between the larger rocks.

Rock riprap shall be placed in a manner to prevent damage to structures. Hand placing is required

as necessary to prevent damage to any new and existing structures.

Method 2 Hand-placed rock—The rock riprap shall be placed by hand on the surface and to the

depth specified. It shall be securely bedded with the larger rocks firmly in contact one to anotherwithout bridging. Spaces between the larger rocks shall be filled with smaller rocks and spalls.

Smaller rocks shall not be grouped as a substitute for larger rock.

5. Filter or beddingWhen the contract specifies filter, bedding, or geotextile beneath the rock riprap, the designated

material shall be placed on the prepared subgrade surface as specified. Compaction of filter or

bedding aggregate shall be as specified on the construction drawings. The final surface of such

NRCS-ME (462-56 5/09



material shall be finished reasonably smooth and free of mounds, dips, or windrows.

6. Design of the grout mixThe mix proportions for the grout mix shall be as specified on the construction drawings and/or in

the construction details in section 14 of this specification. During installation, the engineer may

require adjustment of the mix proportions whenever necessary. The mix shall not be altered

without the approval of the engineer.

7. Handling and measurement of grout materialMaterial shall be stockpiled and batched by methods that prevent segregation or contamination of

aggregates and ensure accurate proportioning of the mix ingredients.

Except as otherwise provided in section 14 of this specification, cement and aggregates shall be

measured as follows:

• Cement shall be measured by weight or in bags of 94 pounds each. When cement is

measured in bags, no fraction of a bag shall be used unless weighed.

• Aggregates shall be measured by weight. Mix proportions shall be based on the batch

weight of each aggregate saturated, surface-dry weight plus the weight of surface moistureit contains at the time of batching.

• Water shall be measured, by volume or by weight, to accuracy within 1 percent of the total

quantity of water required for the batch.

• Admixtures shall be measured within a limit of accuracy of plus or minus 3 percent.

8. Mixers and mixingThe mixer, when operating at capacity, shall be capable of combining the ingredients of the grout

mix into a thoroughly mixed and uniform mass and of discharging the mix with a satisfactory

degree of uniformity.

The mixer shall be operated within the limits of the manufacturer's guaranteed capacity and speedof rotation.

The time of mixing after all cement and aggregates have been combined in the mixer shall be a

minimum of 1 minute for mixers having a capacity of 1 cubic yard or less. For larger capacity

mixers, the minimum time shall be increased 15 seconds for each cubic yard or fraction thereof of

additional capacity. The batch shall be so charged into the mixer that some water will enter in

advance of the cement and aggregates, with the balance of the mixing water introduced into the

mixer before a fourth of the total minimum mixing time has elapsed.

When ready-mix grout is furnished, the contractor shall furnish to the engineer at the time of

delivery a ticket showing the time of loading and the quantities of material used for each load of

grout mix delivered.

No mixing water in excess of the amount required by the approved job mix shall be added to the

grout mix during mixing or hauling or after arrival at the delivery point.

9. Conveying and placingThe grout mix shall be delivered to the site and placed within 1.5 hours after the introduction of

the cement to the aggregates. In hot weather or under conditions contributing to accelerated

NRCS-ME (462-56 5/09





has been completed. The compound shall be applied at a minimum uniform rate of 1 gallon per

175 square feet of surface and shall form a continuous adherent membrane over the entire surface.

Curing compound shall not be applied to surfaces requiring bond to subsequently placed grout

and/or concrete. If the membrane is damaged during the curing period, the damaged area shall be

resprayed at the rate of application specified for the original treatment.

Grout mix shall not be placed when the daily minimum temperature is less than 40 degrees

Fahrenheit unless facilities are provided to ensure that the temperature of the material is

maintained at a minimum temperature of 50 degrees Fahrenheit and not more than 90 degrees

Fahrenheit during placement and the curing period. Grout mix shall not be placed on a frozen

surface. When freezing conditions prevail, rock to be grouted must be covered and heated to

within a range of 50 to 90 degrees Fahrenheit for a minimum of 24 hours before placing grouting

material.

11. Inspecting and testing fresh groutThe grout material shall be checked and tested throughout the grouting operation. Sampling of

fresh grout shall be conducted in conformance with ASTM C 172. The volume of each batch will

be determined by methods prescribed in ASTM C 138.

The engineer shall have free access to all parts of the contractor's plant and equipment used for

mixing and placing grout during the period of the contract. Proper facilities shall be provided for

the engineer to sample material and view processes implemented in the mixing and placing of

grout as well as for securing grout test samples. All tests and inspections shall be conducted so

that only a minimum of interference to the contractor's operation occurs.

For ready-mixed grout, the contractor shall furnish to the engineer a statement-of-delivery ticket

for each batch delivered to the site. The ticket shall provide as a minimum: weight in pounds of

cement, aggregates (fine and coarse), water; weight in ounces of air-entraining agent; time of

loading; and the revolution counter reading at the time batching was started.

12. Measurement and payment

For items of work for which specific unit prices are established in the contract, the volume of

riprap and the volume of filter layers or bedding is determined to the nearest cubic yard from the

specified thickness shown on the drawings and the area in which acceptable placement has been

installed. The volume of grout is determined from the calculated batch volume and the number of

mixed batches delivered to the site and placed in accordance with the specification. The area of

geotextile is determined to the nearest square yard from measurements of geotextile material

installed according to the contract requirements. Payment is made at the contract unit price for

each type of rock riprap, filter or bedding, concrete grout, and geotextile. Such payment is

considered full compensation for all labor, material, equipment, and all other items necessary and

incidental to the completion of the work.

13. Construction Operations

Construction operations shall be done in such a manner that erosion and air and water pollution

are minimized. The owner, operator, contractor or others will conduct all work and operations in

accordance with proper safety guidelines for the type of construction being performed.

The completed job shall be workmanlike and provide a good overall appearance.

NRCS-ME (462-56 5/09



NRCS-ME (462-56 5/09

14. Items of work and construction details





SURFACE PREPARATION:First remove all dirt, oil, grease or contaminants from

surfaces to be grouted. Then remove all loose material.

Metals which will come in contact with grout must be de-rusted, or freed of paints, oils and greases. To avoidentrapment of air, provide air relief openings where required.Prior to placement of grout, thoroughly soak or dampen all

concrete areas to be grouted. Then remove excess water fromvoids and holes.

FORMING:For machinery bases and column base plates: Follow

standard forming procedures, which permit complete and proper placement of fluid grout, including use of head forms.All support elements should be anchored to prevent

movement. Do not remove supports until grout hassufficiently hardened. Wood surfaces, which absorbmoisture, should be pretreated with forming oils. Whengrouting edges of concrete which are less than 1” thick, cut

edges back to form a uniform butt.

PLACEMENT:Follow the standard grouting procedure and

recommendations of ACI for the placement and curing toconcrete. Use chains, rods, or tamping devices to compactgrout, taking care to remove all air voids. For optimum

results, air temperature should be near 72° F. Pour groutquickly and continuously, striking off exposed areas.Finished PRO GROUT 90 should be cured for 72 hours for

base plate application.

SHELF LIFE:When stored in original, un-opened container, one year.

Rotate your stock.

LIMITATIONS:Set Times

CRD-C-614 Initial Set Final Set

Minimum Flow 3 hrs. 25 min. 5hrs. 14 min.

Moderate Flow 3 hrs. 49 min. 6 hrs. 28 min.

High Fluidity 4 hrs. 52 min. 7hrs. 55 min.

Mix consistency Minimum flow Moderate Flow High Fluidity(Plastic) (Pourable) (Pumpable)

Per 50 lb. Bag 7.25 pints 7.75 pints 8.75 pints

Waterdemand

Per 50 lbs. Per 50 lbs. Per 50 lbs.

COMPRESSIVE STRENGTH (psi) CRD-C-227

1 Day 5220 4650 3855

3 Day 5645 5625 5165

7 Day 6380 6605 5965

28 Day 7775 7805 6950

These are conservative data and individual applications willmost likely yield higher strengths.

GENERAL INFORMATION:

Please contact CGM, Inc. at any of the following numbersfor customer service or technical assistance:

Voice: 215-638-4400Toll Free: 800-523-6570Fax: 215-638-7949

E-mail:Sales /Technical: [email protected]

[email protected]: [email protected] Inside Sales: [email protected]

On the web @: www.cgmbuildingproducts.com

WARRANTY:CGM INC. warrants this product to be free of manufacturing defects. The sole responsibility and maximum liability of CGM under this warranty shall be at CGM’soption, either (1) to replace the defective product in the form the product was purchased but not in the form the product was installed or used, or (2) to refund the purchase

price of the product. In no event shall CGM be liable to the purchaser or to any third party for any loss or damage, of any type, including but not limited to incidentaland/or consequential damage, resulting from the purchase or use of this product. In the event of any claim under this warranty, written notice must be given by registered

mail.This warranty is in lieu of all other warranties, expressed or implied, including but not limited to warranties of merchantability and fitness for a particular purpose.Information contained herein is for evaluation purposes only. While CGM believes this information to be true and accurate as of this printing of this material, CGM shallhave no obligation to notify purchasers of any error which is subsequently discovered in this information. CGM reserves the right to modify or improve any of its products,

at any time without prior notice.

CGM, INC., 1445 FORD RD., BENSALEM, PA. 19020, VOICE: 215-638-4400 FAX: 215-638-7949

WEB: www.cgmbuildingproducts.com

mailto:[email protected]





http://cgmbuildingproducts.com/

http://www.cgmbuildingproducts.com/



http://cgmbuildingproducts.com/







Test Method Nev. T426C

September 16, 2013

1

State of Nevada

Department of Transportation

Materials Division

METHOD OF TEST FOR FLOW OF GROUT MIXTURES

(Flow Cone Method)

SCOPE

This test method covers the procedure, used both in the laboratory and in the field, for determining the flow

of grout mixtures by measuring the time of efflux of a specified volume of grout from a standardized flowcone.

APPARATUS

1. Flow Cone, with dimensions as shown in Figure 1. The discharge tube shall be stainless steel.

The body can be stainless steel, cast aluminum, or other non-corroding metal.

2. Receiving container, minimum capacity of 2000 mL.

3. Ring stand or other suitable device, capable of supporting the flow cone in a vertical, steady

position over the receiving container.

4. Level, carpenter's or similar.

5.

Stop watch, accurate to the nearest 0.1 second.

6. Rubber stopper for grout cone.

7. Scale, minimum capacity of 45 kg (100 lb), sensitive to 0.1.

CALIBRATION OF APPARATUS

1. The flow cone shall be firmly mounted in such a manner that the top will be level and the cone

free from vibration. The discharge tube shall be closed by placing a rubber stopper from the

underneath side into the lower end. A quantity of water equal to 1725 ± 5 mL shall be introducedinto the cone to indicate the grout level as per Figure 1. Calibrate the cone in accordance with the

manufacturer’s recommendation.

SAMPLE

1. The test sample specimen shall consist of 1725 ± 5 mL of grout.




September 16, 2013

2

PROCEDURE

Moisten the inside surface of the flow cone. Place rubber stopper into the outlet of the discharge tube.

Introduce grout into the cone until the grout surface rises into contact with the grout level as per Figure 1.

Start the stopwatch and remove the rubber stopper simultaneously. Stop the stopwatch at the first break in

the continuous flow of grout from the discharge tube. The time indicated by the stopwatch is the time ofefflux of the grout. At least two tests shall be made for any grout mixture. Results from two properly

conducted tests on the same material should not differ by more than 2 ½ seconds.

A recommended procedure for insuring that the interior of the cone is properly dampened, fill the cone with

water and, one minute prior to adding the grout sample, allow the water to drain from the cone.

For the specifications on the time of efflux, refer to the Standard Specifications and Special Provisions.

REPORT

On the Daily Construction Report NDOT form 040-056 shall include:

1. Average time of efflux to the nearest 0.2 seconds

2. Temperature of grout sample at the time of test

3. Ambient temperature at the time of test

4. Composition of the sample




September 16, 2013

3



UFC 3-220-0616 January 2004

UNIFIED FACILITIES CRITERIA (UFC)

GROUTING METHODS AND

EQUIPMENT

APPROVED FOR PUBLIC RELEASE; DISTRIBUTION UNLIMITED



UFC 3-220-0616 January 2004

1

UNIFIED FACILITIES CRITERIA (UFC)

GROUTING METHODS AND EQUIPMENT

Any copyrighted material included in this UFC is identified at its point of use.Use of the copyrighted material apart from this UFC must have the permission of thecopyright holder.

U.S. ARMY CORPS OF ENGINEERS (Preparing Activity)

NAVAL FACILITIES ENGINEERING COMMAND

AIR FORCE CIVIL ENGINEER SUPPORT AGENCY

Record of Changes (changes are indicated by \1\ ... /1/)

Change No. Date Location

This UFC supersedes TM 5-818-6, dated 27 February 1970. The format of th is UFC does notconform to UFC 1-300-01; however, the format will be adjusted to conform at the next revision.The body of this UFC is the previous TM 5-818-6, dated 27 February 1970.



UFC 3-220-0616 January 2004

2

FOREWORD\1\The Unified Facilities Criteria (UFC) system is prescribed by MIL-STD 3007 and providesplanning, design, construction, sustainment, restoration, and modernization criteria, and appliesto the Military Departments, the Defense Agencies, and the DoD Field Activities in accordancewith USD(AT&L) Memorandum dated 29 May 2002. UFC will be used for all DoD projects and

work for other customers where appropriate. All construction outside of the United States isalso governed by Status of forces Agreements (SOFA), Host Nation Funded Construction Agreements (HNFA), and in some instances, Bilateral Infrastructure Agreements (BIA.)Therefore, the acquisition team must ensure compliance with the more stringent of the UFC, theSOFA, the HNFA, and the BIA, as applicable.

UFC are living documents and will be periodically reviewed, updated, and made available tousers as part of the Services’ responsibility for providing technical criteria for militaryconstruction. Headquarters, U.S. Army Corps of Engineers (HQUSACE), Naval FacilitiesEngineering Command (NAVFAC), and Air Force Civil Engineer Support Agency (AFCESA) areresponsible for administration of the UFC system. Defense agencies should contact thepreparing service for document interpretation and improvements. Technical content of UFC isthe responsibility of the cognizant DoD working group. Recommended changes with supportingrationale should be sent to the respective service proponent office by the following electronicform: Criteria Change Request (CCR). The form is also accessible from the Internet sites listedbelow.

UFC are effective upon issuance and are distributed only in electronic media from the followingsource:

• Whole Building Design Guide web site http://dod.wbdg.org/.

Hard copies of UFC printed from electronic media should be checked against the currentelectronic version prior to use to ensure that they are current.

AUTHORIZED BY:

______________________________________DONALD L. BASHAM, P.E.Chief, Engineering and ConstructionU.S. Army Corps of Engineers

______________________________________DR. JAMES W WRIGHT, P.E.Chief EngineerNaval Facilities Engineering Command

______________________________________KATHLEEN I. FERGUSON, P.E.The Deputy Civil Engineer

DCS/Installations & LogisticsDepartment of the Air Force

______________________________________Dr. GET W. MOY, P.E.Director, Installations Requirements and

ManagementOffice of the Deputy Under Secretary of Defense (Installations and Environment)

http://www.wbdg.org/pdfs/ufc_implementation.pdf

http://www.wbdg.org/ccb/browse_cat.php?o=29&c=4

http://dod.wbdg.org/

http://dod.wbdg.org/

http://www.wbdg.org/ccb/browse_cat.php?o=29&c=4

http://www.wbdg.org/pdfs/ufc_implementation.pdf



DEPARTMENT OF

DEPARTMENT

TM 5-818-6

AFM 88-32

THE ARMY TECHNICAL MANUAL

OF THE AIR FORCE MANUAL

GROUTING METHODS

AND EQUIPMENT

DEPARTMENTS OF THE ARMY AND THE AI R FORCE

FEBRUARY 197

TAGO 8061A





TM 5-818-6/AFM 88-32

2



TM 5-818-6/AFM 88-32

SECTION 1. INTRODUCTION

1. PURPOSE AND SCOPE. This manual was prepared to provide guidance

in the use of pressure grouting as a means to correct existing or anticipated

subsurface problems. Information on procedures, materials, and equipmentfor use in planning and executing a grouting project i’s included, and types of

problems that might be solved by pressure grouting are discussed. Methodsof pressure grouting that have proven to be effective are described, and

various types of grouts and their properties are listed.

2. GE NER AL CONSIDE RATI ONS.

a. Purposes of Pressure Grouting. Pressure grouting involves the injec-tion under pressure of a liquid or suspension into the voids of a soil or rock

mass or into voids between these materials and an existing structure. Theinjected grout must eventually form either a gel or a solid-within the treated

voids, or the grouting process must result in the deposition of suspended

solids in these voids. The primary purposes of pressure grouting a soil or

rock mass are to improve the strength and durability of the mass and/or toreduce the permeability of the mass.

b. Problems Related to Strength. Typical problems involving strengthproperties of a soil or rock mass include: (a) insufficient bearing capacityfor structural elements such as footings, slabs, or mats; (b) insufficient

strength to preclude sliding failures of embankments or cut slopes; (c) in-herent mass instability of fractured rock formations; (d) sloughing or com-

plete closure of vertical or horizontal tunnels; and (e) general structural

weaknesses due to underground caverns or solution channels or due to voids

that develop during or following construction.

c. Pr oblems Related to Permeabil ity. Problems related to permeability

of a—soil or rock mass include: (a) reduction in strength of foundation mate-rials due to high seepage forces; (b) loss of impounded water from a reser-

voir or storage area; (c) high uplift forces at the base of a water- retaining

structure; (d) piping erosion through or under an earth dam; and (e) inability

to complete excavations, shafts, or tunnels extending below the groundwatertable due to caving and sloughing.

d. Selection of Methods of Treatment. Problems of the nature describedabove can often be treated by pressure grouting. However, other methods of

treatment may be equally satisfactory and adaptable to the project. The se-

lection of pressure grouting as the method of treatment should be based on

an evaluation of all pertinent aspects of the problem, i.e., engineering needs,

subsurface conditions, economic considerations, and availability of qualified

supervisory personnel. In some respects, pressure grouting is an art basedon natural and scientific laws but it requires experience and engineering

3



TM 5-818-6/AFM 88-32

judgment. Rigid rules for the exercise of this art cannot be established, and

only general procedures and guides can be presented in this manual. Forthese reasons, the services of personnel experienced in grouting should al-

ways be utilized.

4



TM 5-818-6/AFM 88-32

SECTION 2. SUBSURFACE INVESTIGATIONS

3. GENERAL RE QUIRE MENTS. An investigation of subsurface conditionssuch as that normally made for foundation design purposes is usually suffi-

cient to determine whether unfavorable conditions are present that can beimproved by grouting. The discovery of any of the following in the course of

these investigations warrants consideration of treatment by grouting if the

success of the project could be affected thereby: soluble rocks or evidencesof solution activity, prominent open joints, broken or intensely jointed rock,

faulting, losses of circulation or dropping of drill rods during drilling, or

unusual groundwater conditions.

4. SPECI AL RE QUIRE MENTS.

a. Exploratory Borings. Specific information on subsurface conditionsis needed to plan the grouting program. In order to determine the scope andestimate the costs of the drilling and grouting operations in rock, informa-

tion on orientation, attitude and spacing of joints, joint openings including

type of filler i f any, boundaries of rock types, location of faults, location of broken zones, depth to sound rock, and position of water table should be

avai lable. The borehole camera or television camera can be of particular

assistance in obtaining this information. If soil is to be grouted, information

on its stratification, density, grain size, and permeability will be required.If these data, as pertinent to the project, cannot be obtained from the design

investigations or from rock exposed by the first excavation at the site, ad-

ditional explorations (borings, trenches, etc. ) should be made to supply the

missing data.

b. Field Tests.

(1) Pressure tests. Pressure testing by pumping measured amounts of

water into exploratory boreholes under known pressures serves a usefulpurpose if the injection of gel-forming grouts is contemplated. The results

of the pressure tests will show the permeability of the soil or rock mass to

water or other fluid of the same viscosity. The best way to determine the

permeabili ty of uniform, porous , water-bearing soil layers is by a pumpingtest, as discussed in Civi l Works Technical Letter 63-16. Pr essure testing

of rock to learn whether it will accept a cement or clay grout is rarely worth-

while. If pressure testing is done for this purpose each tested increment of

borehole should be examined by television or borehole camera to obtain in-

formation on the size of the openings that are presumed to take water.

(2) Test grouting. The most reliable means of obtaining realistic an-

swers to questions on the capability of rock to take a grout containing solids

in suspension is by test grouting. The test-grout program should be planned

not only to provide information on the groutability of the rock, but also on the

5



TM 5-818-6/AFM 88-32

most suitable mixes and probable quantities of grout, if the rock takes grout.

Although recommended for the purpose stated, test grouting is seldom con-

sidered necessary if only cement grouting of rock is involved. Collective

experience from scores of jobsites where cement grouting was performed in

widely varying subsurface situations indicates that cement grout can be in-

jected if one or more of the conditions listed in paragraph 3 has been found

in preconstruction investigations.Test grouting of soils with chemical groutcoupled with exploratory trenches and pits to observe the results is very

helpful in estimating costs and effectiveness, and on large jobs may allow a

considerable saving of costs to be made if representative areas are tested.

By varying grouting techniques, optimum spacing of holes, pressures, in-jection rates, and setting times can be ascertained for each major set of

1

B A s E D O N F I E L D

0.05 0.1 0.2 0.5 1.0 2.0

E F F E C T I V E G R A I N S I Z E O F S T R A T U M M M

(From “Invest iga t ion of Underseepage and i ts Contro l ,

Lower Mississ ipp i River Levees, ” TM 3-424, Vol 1,

Ott 1956, U. S. Army Eng. Waterw ays Exp. Sta .)

Figure 1. D 10 versus in situ coef-

ficient of permeability-Missis -

sippi River Valley Sands

conditions. This permits obtaining

satisfactory coverage with minimum

quantities of drilling and grout.

c. Laboratory Tests.

(1) Permeability. Test proce-

dures for determining the permeabilityof soil samples are described in

E M 1110-2-1906. Laborator y perme-

abilities are generally somewhat

smaller than field permeabilities de-termined from field pumping tests.

(2) Gradation. Procedures for

performing grain-size tests are given

in EM 1110-2-1906. The effective

grain size (D10 size) of Mississippi

River alluvial sands has been corre-lated with field permeability values

and the results of this correlation areshown in figure 1.

(3) Density. The density and void

ratio of undisturbed samples should be

determined for use in making calcula-

tions and in evaluating the stability and

permeability characteristics of the in-

place soil mass. Test procedures are

outl ined in E M 1140-2-1906.

(4) Chemical tests. Chemical analysis of groundwater samples should be

made to determine the presence of calcium sulfate, magnesium sulfate, sod-ium sulfate, organic or mineral acids, and alkalies that may be detrimental

to cement or chemical grouts. The pH of the water should also be determined.

6





TM 5-818-6/AFM 88-32

where

D15

is the 15 percent finer grain size of the medium to be grouted

and

D85 is the 85 percent finer grain size of the grout

N generally should be greater than 25 but in some cases may be as low

as 15, depending upon physical properties of the grout materials. Figure 2

gives a graphic interpretation of this equation. It shows (a) typical grain-

size curves for portland cement, Boston blue clay, ordinary asphalt emul-sion, and special Shellperm asphalt emulsion, and (b) the lower limits (D15)

of sand groutable by the above-described grout materials.

6. P OR T L AND -C E ME NT G R OU T. Portland- cement grout is a mixture of portland cement, water, and, frequently, chemical and mineral additives.The properties of materials generally used in portland-cement grout are

described below.

a. Portland Cements. Five types of portland cement, produced to con-form– to the specifications of ASTM Designation C 150 (see ref 15), are used

in cement grouts.

(1) Type I is a general-purpose cement suitable for most cement grout jobs. It is used where the special properties of the other four types are not

needed to meet job requirements.

(2) Type II cement has improved resistance to sulfate attack, and its

heat of hydration is less and develops at a slower rate than that of type I. Itis often used interchangeably with type I cement in grouting and is suggested

for use where precautions against moderate concentration of sulfate in

groundwaters are important.

(3) Type III cement is used where early strength gains are required in

grout within a period of 10 days or less. It may also be used in lieu of type I or type II in injection work because of its finer grind, which improves

its injectability.

(4) Type IV cement generates less heat than type II cement and developsstrength at a very slow rate. It is rarely used in grouting.

(5) Type V cement has a high resistance to sulfates. It is not often used

in grouts, but its use is desirable if either the soil to be grouted or the

groundwater at the jobsite has a high sulfate content.

b. Mixing Water. Generally, water suitable for drinking may be

8



TM 5-818-6/AFM 88-32

regarded as suitable for use in grout. Ordinarily the presence of harmful

impurities (e. g., alkalies, organic and mineral acids, deleterious salts, or

large quantities of silt) is known in local water sources. If there is reasonto suspect a water source, it should, be tested in accordance with CRD-C 400

(see ref 9).

c. F i ll ers. Fillers in portland-cement grout are used primarily for

reasons of economy as a replacement material where substantial quantities

of grout are required to fill large cavities in rock or in soil. Almost any

solid substance that is pumpable is suitable as a filler in grout to be used in

nonpermanent work. For permanent work, cement replacements should be

restricted to mineral fil lers. Before accepting any filler, tests should be

made in the laboratory or in the field to learn how the filler affects the set-

ting time and strength of the grout and whether it will remain in suspension

until placed. All aspects of the use of a filler should be carefully studied.The economy indicated initially by a lower materials cost may not continue

throughout the grouting operation. Additional personnel and more elaborate

batching facilities may be needed to handle the filler. Some fillers make the

grout more pumpable and delay its setting time. Such new properties may

add to the costs by increasing both the grout consumption and the groutingtime.

(1) Sand. Sand is the most widely used filler for portland-cement grout.

Preferably it should be well graded. A mix containing two parts sand to one

part cement can be successfully pumped if all the sand passes the No. 16

sieve and 15 percent or more passes the No. 100 sieve. The use of coarser

sand or increasing the amount of sand in the mix may cause segregation.

Segregation can be avoided by adding more fine sand or using a mineral ad-

mixture such as fly ash, pumicite, etc. Mixes containing up to 3/4-in. aggre-

gate can be pumped if properly designed. Laboratory design of such mixes

is recommended. Sanded mixes should never be used to grout rock contain-ing small openings and, of course, should not be used in holes that do not

readily accept thick mixes of neat cement grout (water and portland cementonly).

(2) Fly ash. Fly ash is a finely divided siliceous residue from the com-

bustion of powdered coal, and may be used both as a filler and as an ad-

mixture. Most grades of fly ash have about the same fineness as cement

and react chemically with portland cement in producing cementitious proper-

ties. The maximum amount of fly ash to be used in grout mixtures is 30 per-

cent by weight of the cement, if it is desired to maintain strength levels

comparable to those of portland-cement grouts containing no fly ash.

(3) Diatomite. Diatomite is a mineral filler composed principally of

sil ica. It is made up of fossils of minute aquatic plants. Processed diato-

mite is an extremely fine powder resembling flour in texture and appearance.

The fineness of the diatomite may range from three times to as much as

9



TM 5-818-6/AFM 88-32

15 times that of cement. Small amounts of diatomite may be used as admix-

tures to increase the pumpability of grout; however, large amounts as fillerswill require high water- cement ratios for pumpability. As a filler, diatomite

can be used where low strength grouts will fulfill the job requirements.

(4) Fumicite. Pumicite, a finely pulverized volcanic ash, ashstone,

pumice, or tuff, is also used as a filler in cement grout. Like fly ash anddiatomite, it improves the pumpability of the mix and has pozzolanic (hy-

draulic cementing) action with the portland cement.

(5) Other fillers. Silts and lean clays not contaminated with organic ma-

terials are sometimes used as fillers. Leess, a windblown silt containing

from 10 to 25 percent clay, is a suitable filler. Rock flour, a waste product

from some rock-crushing operations, is also used as a filler. Rock flour

produced during the manufacture of concrete sand is very fine but not al-

ways well graded. Grouts containing poorly graded rock flour are fre-

quently highly susceptible to leaching. Most finely divided fillers increasethe time required for the grout to set. It may be expedient to add an accel-

erator, described subsequently, to compensate for this.

d. Admixtures. Admixtures as described herein are substances that

when added to portland-cement grout, impart to it a desired characteristic

other than bulking.

(1) Accelerators. Accelerators cause a decrease in the setting time of

grout. These additives are used to reduce the spread of injected grout, to

reduce the erosion of new grout by moving groundwater $and to increase the

rate of early strength gain. The most commonly used accelerator is calcium

chloride. It can be added to the mixing water in amounts up to 2 percent of

the weight of the cement. Greater percentages of calcium chloride increase

the very real danger of having the mix set up in the grout plant. High alumina

cement and plasters having a calcined gypsum base may be proportioned with

portland cement to make a grout having various setting times. Other accel-erators include certain soluble carbonates, silicates, and triethanolamine.

Small amounts of some accelerators are capable of producing instantaneous

or near instantaneous setting of the grout. Triethanolamine added to some

cements in the amount of 0.2 percent can produce such sets. When using ac-

celerators, competent technical advice should be sought and preliminarytests conducted to determine the behavior of accelerators in the grout mix.

(2) Lubricants. Fly ash and rock flour added to the grout mix increase

its pumpabili ty. Fluidifiers and water- reducing admixtures improve the

pumpability or make possible a reduction in the water- cement ratio whilemaintaining the same degree of pumpability. Most of these substances are

also retarders. Laboratory or field trial mixes should be batched and all

pertinent effects observed and tested before adopting an unknown admixture

for any project.

10



TM 5-818-6/AFM 88-32

(3.) Other effects. Numerous other substances can be added to portland-

cement grout to obtain special effects, Bentonite or other colloids, or finely

powciered metal are added to grout to make it more viscous and stable.

powdered metals unite with hydration products of the cement and release

tiny bubbles of hydrogen, which, in addition to increasing the viscosity, cause

a slight expansion of the grout. Aluminum is the metal most often used. It

is added at the rate of about 1 teaspoonful of aluminum powder per sack of

cement. Very small amounts of carbohydrate derivatives and calciumlignosulfonate may be used as retarders. Sodium chloride is used to brine

mixing water when grouting is performed in salt formations. This preventserosion of in situ rock salt and provides a degree of bonding of grout to salt.Approximately 3 lb of dry salt for each gallon of water will provide a satu-

rated mixture and will result in some retardation of the grout set.

e. Effect of Groundwater. Alkalies, acids, or salts contained in ground-water may cause more damage to portland-cement grouts placed in sandy

soils than to these placed in clays. This increase in damage is a result of

the sandy soils permitting rapid leaching as opposed to clays which tend to

retard groundwater movement. In most clays, sulfate salts are found in verysmall quantities. Rich type V portland-cement grouts will not be damagedby low or moderate concentrations of calcium sulfate salts (gypsum).Portland-cement grouts should not be used in formations containing salts

that consist of high concentrations of magnesium and sodium sulfates. Where

such concentrations are found, the use of chemical grouts should be con-

sidered. Harmful chemicals in groundwater may come from a number of

sources, e.g., manufacturing plant wastes, water from coal mines, leachingfrom coal storage and waste areas, and leaching of sodium or magnesium

matter. Waters of some streams and lakes in the western United States are

very harmful to Portland- cement grouts because of their alkaline content.

f. Effect of Seawater. Crazing and hairline cracks occurring in hard-ened—grouts because of shrinkage, temperature variations, and tension may

permit the infiltration of seawater , which causes chemical decomposition of the grout. During hydration the higher silicates decompose into lower sili-

cates and calcium hydroxide. The calcium hydroxide crystals dissolve

slowly in water, resulting in subsequent decomposition of the clinker grains

and liberation of new quantities of calcium hydroxide thus causing the cement

to deteriorate. The free lime in the grout also reacts with magnesium sulfatein seawater and forms calcium sulfate, causing swelling in the interstices.

Portland-cement grouts for use in the presence of seawater should contain

air- entraining portland cement (type IIA) and waterproofing agents and have

low water-cement ratios. Entrained air in grout increases the impervious-ness of the grout. (Some modification of the usual mixing and dumping fa-cilities may be required when using air- entraining cement to avoid having

the sump tank overflow with froth. ) Waterproofing compounds that have

been found to have a marked increase in promoting various degrees of im-permeability in portland-cement grouts are lime, fine-grained soils, tars,



TM 5-818-6/AFM 88-32

asphalts, emulsions, and diatomite. In addition to portland-cement grouts,

chemical and pozzolan-cement grouts may be considered.

alter to a desired degree, the properties of an existing medium by the mosteconomical means. Therefore, where conditions indicate that local clays

Will produce a grout that will give the desired results, they should be con-

sidered. In the following paragraphs, the properties of clay soils that makethem suitable for a grout material are outlined, tests to be used in deter-

mining the suitability of clays are indicated, and guidance for the design of

clay grouts is provided.

a. Materi al. Soils used as the primary grout ingredient can be divided—into two classifications. One includes the natural soils found at or near theproject with little or no modification required. The second includes com-

mercially processed clay such as bentonite. The selection of a natural or

processed material should be determined by an economic study considering

(1) grout properties necessary, to meet job requirements, (2) quantity of

grout required, (3) availability and properties of natural soils, (4) cost of modifying natural soils, if necessary to meet job requirements, (5) cost of importing a processed material that will meet job requirements, and (6) cost

of mixing grout using either material. Generally, where large quantities of grout are needed, local materials will be more economical. For small

quantities, it is generally more economical to bring in prepared material

than to set up the required mining and processing equipment to use natural

soil. In addition, any specific job may present additional factors to be

considered.

b. Natural Soil s. The use of natural soils is predicated on the existenceof a—suitable material within a reasonable distance of the project. Natural

soils for use as a grout ingredient are of two types: (1) fine-grained soils

with low plasticity that do not have gel properties and are more or less inert

(silt and glacial rock flour) and (2) fine-grained soils of medium to high plas-ticity and with a high ion exchange capacity, which gives the material good

thixotropic and gel properties. The types of soil covered under (1) above

generally are used as fi llers only. The types of soil covered under (2) above

may be used both as fillers and admixtures. The best source of soils for

grouts will be alluvial, eolian, or marine deposits. Residual clays may con-tain excessive coarse-grained material, depending upon the nature of the

parent rock and the manner of decomposition. Glacial clays are generally

the least suitable because of the usually large gravel and sand content. The

properties of soils are for the most part determined by the quantity and type

12



of clay mineralsmontmorillonite,

common and are

TM 5-818-6/AFM 88-32

present. Common clay minerals encountered are kaolinite,

and illite. Kaolinite and montmorillonite are the most

found in various combinations in most fine-grained soils.

Because of its ability to adsorb large quantities of water, a high percentage

of montmorillonite is desirable for clay grouts. The clay minerals will gen-

erally make tip most of the material finer than 2 microns.

c. Processed Clay. The most commonly used commercially processed

clay—is bentonite, a predominantly montmorillonitic clay formed from the

alteration of volcanic ash. The bentonite ore is crushed, dried, and finely

ground to form the commercial products. Most bentonites exhibit a liquid

limit of 350 to 500 and possess the ability to undergo thixotropic gelation.

The gelling property is desirable to produce sufficient strengths in the in-

jected grout to resist removal by groundwater under a pressure head. How-

ever, gelling can also create problems in pumping if not properly controlled.

d. Testing Clays for Grouts. In determining the suitability of a soil as

a grout$sufficient information for most projects can be obtained from a few

common mechani cal tests. Samples of the grout material should be handled

and processed in conducting these tests in the same manner as that in whichthe material will be processed in the field when making the grout. For ex-

ample, if the field procedure calls for air drying the raw material, the labo-

ratory specimen should also be air dried.

(1) Gr adation. One important property of a clay grout is the grain- size

distribution of its solid particles; this can be determined by a hydrometeranalysis (see EM 1410-2-1906). The largest clay particles must be small

enough to readily penetrate the voids in the medium to be grouted.

(2) Atterberg limits. Atterberg limits are indicative of the plasticity

characteristics of the soil. A high liquid limit (LL ) and plasticity index (PI )

generally indicate a high clay mineral content, high ion exchange capacity, or

a combination thereof. Normally, a clay with a liquid limit less than 60 isnot suitable for grout where a high clay mineral content and/or high ion ex-

change capacity is required (see ref 36).

(3) Specific gravi ty. Refer to EM 1110-2-1906. The specific gravi ty (Gs)

of the solid constituents of a soil mass is indicative, to some degree, of

their mineral composition. In addition, the value is needed in computations

involving densities and void ratios.

e. Admixtur es. For the purpose of modifying the basic properties of a

clay—grout to achieve a required result, certain additives can be used.

(1) Portland cement. Portland cements can be used in clay grouts to

produce a set or to increase the strength. The amount of cement required

must be determined in the laboratory so that required strength will be



TM 5-818-6/AFM 88-32

obtained and the grout will be stable. The presence of cement may affect thegroutability of clay grouts,. a point which must be considered. For large

amounts of cement the grout should be considered as a portland-cement

grout with soil additive.

(2) Chemical. There are several chemicals that can be used in soil

grouts to modify the grout properties, but little experience has been reportedin the literature. The effect that a chemical additive will have on a clay

grout will depend on the mineralogical and chemical properties of the soil.Following is a partial listing of electrolytes, as reported by Kravertz (35),

that are used in quantities less than 5 percent, by weight, as stabilizing

agents or flocculants in clay grouts.

Stabilizing Agents Flocculating Agents

Potassium nitrate Aluminum sulfatePotassium carbonate Sodium sulfateSodium aluminate Calcium chlorideSodium silicate Copper sulfate

Lithium carbonate Ferrous sulfateSodium hydroxide

(3) F i l lers. Sands can be used as fillers in clay-cement grouts

voids to be filled are sufficiently large to Permit intrusion of thesewhere

particlesizes. Where large quantities of grout take are anticipated, an econmicalgain will be achieved through use of sand fillers, without loss in quality of

the grout.

f . Proportioning Clay Grout. Once a soil has been determined suitableas a grout material for a given job, it is necessary to determine the water

and admixture requirements to achieve desired properties in the grout. The

grout must have sufficient flowability without excess shrinkage, and after a

specified time, it should develop a gel of sufficient strength. The flowabilitywill depend upon the water- clay ratio, which from the standpoint of bleeding

should be kept to a minimum. To provide a suitable gel, it might be neces-sary to use chemical additives such as sodium silicate to improve the gel

strength at high water-clay ratios. Because of the wide range of physioc-hemical properties of fine-grained soils that affect grout properties, it is

necessary to use a trial procedure to achieve the desired results. Trial

batches with varying proportions of soil, water, and admixtures should be

mixed, duplicating field conditions as closely as possible. Samples from thetrial batches should be tested for stability, viscosity, gel time, shrinkage,

and strength. From the results the most suitable mixtures can be selectedand criteria for changes in the mixture proportions to meet field conditions

can be determined. The batch size for trial mixes should be sufficient to

provide adequate samples for the various tests.



TM 5-818-6/AFM 88-32

8. ASPHALT GROUTS. Large subsurface flows of water are at times diffi-

cult to stop by grouting with cement, soil, or chemical grouts. For theseconditions asphalt grouting has sometimes been used successfully, particu-

larly in sealing watercourses in underground rock channels (see ref 54and 57). Asphalt grout has ‘also been used to plug leaks in cofferdams and in

natural rock foundations. Asphalt is a brown-to-black bituminous substance

belonging to a group of solid or semisolid hydrocarbons. It occurs naturally

or is obtained as a comparatively nonvolatile residue from the refining of

some petroleums. It melts between 150° and 200° F. When used for grout-

ing it is generally heated to 400° or 450° F before injection. Asphalt emul-

sions have also been used for grouting. These are applied cold. In the

emulsion the asphalt is dispersed in colloidal form in water. After injection

the emulsion must be broken so that the asphalt can coagulate to form an ef-

fective grout. Special chemicals are injected with the emulsion for this

purpose. Coal-tar pitch is not a desirable material for grouting since it

melts more slowly and chills more quickly than asphalt grout. When heated

above its melting point, coal-tar pitch also emits fumes that are dangerous

to personnel.

9. CHE MICAL GROUTS. In 1957 there had been some 87 patents issuedfor processes related to chemical groutings (see ref 43). Since then there

undoubtedly have been more. These processes cover the use of many

different chemicals and injection processes. The primary advantages of

chemical grouts are their low viscosity and good control of setting time.Disadvantages are the possible toxic nature of some chemicals and the rela-

tively high cost. Only a few of the more widely known types of chemical

grouts are discussed in the following paragraphs. Because of the variety of

the chemicals that can be used and the critical nature of proportioning,

chemical grouts should be designed only by personnel competent in this field.Commercially available chemical grouts should be used under close consul-

tation with the producers.

a. Precipitated Grouts.—

(1) In this process the chemicals are mixed in liquid form for injection

into a soil. After injection, a reaction between the chemicals results in pre-

cipitation of an insoluble material. Filling of the soil voids with an insoluble

material results in a decrease in permeability of the soil mass and may, for

some processes, bind the particles together with resulting strength increase.

(2) The most common form of chemical grouting utilized this process

with silicates, usually sodium silicate, being the primary chemical. Sodiumsilicate is a combination of silica dioxide (Si02), sodium oxide (Na20), and

water. The viscosity of the fluid can be varied by controlling the ratio of

Si02

to Na2

0 and by varying the water content. Silicate can be precipitatedin the form of a firm gel by neutralizing the sodium silicate with a weak

acid. The addition of bivalent or trivalent cations will also produce gelation.



TM 5-818-6/AFM 88-32

(3) One problem in using sodium silicate in a grout is the prevention of instantaneous gelling prior to injection in the soil mass. This is overcomeby either diluting the silicate and producing a soft gel or by injecting the

silicate and the reactive compound separately in the ground. A third methol

consists of mixing an organic ester with the silicate prior to injection. Theester, by saponification , is slowly transformed into acetic acid, which neu-

tralizes the s odium silicate, and ethyl alchol. The addition of an organic

ester to a chemical grout results in sufficient setting time to permit ade-quate grout injection and a high- strength grout.

(4) Another form of precipitation utilizes a combination of lignosulfiteand bichromate (chrome lignin). Lignosulfite (or lignosulfonate) is a by-

product of the manufacture of cellulose from pulpwood. When lignosulfites

are mixed with a bichromate, a firm gelatinous mass will form. By varying

the concentration of bichromate, the setting time may be controlled through

a range from 10 min to 10 hr. The resulting gel strength will vary depending

upon the nature of the lignosulfite, the concentration of lignosulfite andchrome, and the pH of the mixture. The viscosity incr eases with time. The

hexavalent chromium is toxic and requires special precaution when mixing.

After gelling, the product is not toxic, but under some conditions water willleach highly toxic hexavalent chromium from the gel. Possible contamina-

tion of water supplies should, be carefully considered.

b. Polymerized Grouts. Polymerization is a chemical reaction in which

single organic molecules (monomers) combine together to form long chain-

li ke molecules. There is also cross linking of the molecules, resulting in

rigidity of the product. In this process the soluble monomers, mixed with

suitable catalysts to produce and control polymerization, are injected into

the voids to be filled. The mixture generally has a viscosity near that of

water and retains it for a fixed period of time, after which polymerization

occurs rapidly. Because of the low viscosity, polymer grouts can be used in

soils having a permeability as low as 10-5 cm/sec, which would include

sandy silt and silty sand. The resulting product is very stable with time.The monomers may be toxic until polymerization occurs after which there

is no danger. Some of the more common polymer- type grouts utilize the

following chemicals as the basic material.

(1) Acrylamide. There are available, under several different tradenames, chemical grouts that use acrylamide and one of its derivatives as

a base. One of these consists of a mixture of acrylamide and methylene -

bisacrylamide, which produces a polymerization crosslinking gel when prop-

erly catalyzed, that traps the added water in the gel. These grouts are ex-

pensive, but because of the low viscosity, ease of handling with recommended

equipment, and excellent setting time control, they are suitable for certain

appl ications. The ingredients are toxic and must be handled with care, but

the final product is nontoxic and insoluble in water..



TM 5-818-6/AFM 88-32

(2) Resorcinol-formaldehyde. This resin-type grout is formed by con-

densation polymerization of dihydroxybenzene (resorcinol) with formaldehyde

when the pH of the solution is changed. The reaction takes place at ambient

temperatures. The final product is a nontoxic gel possessing elastic-plastic

properties and high strengths when tested in a mortar form. The grout has

excellent set-time control, instantaneous polymerization, and a low viscosity

prior to polymerization.

(3) Calci um acrylate. Calcium acrylate is a water-soluble monomer that

polymerizes in an aqueous solution. The polymerization reaction utilizes am-

monium persulfate as a catalyst and sodium thiosulfate as the activator. The

rate of polymerization is controlled by the concentration of catalyst and

activator . The solution has a low viscosity immediately after mixing that

increases with time.

(4) Epoxy resin. Many different compounding of epoxy resins are avail-

able commerciall y. Some experiments have been conducted using epoxy res -

ins as grout, and as a result of these experiments, one such epoxy was used

with moderate success to grout fractured granite. The epoxy developed very

good bond with the moist granite, was not too brittle, and the effective vol -ume shrinkage during curing was very low. The details of these experiments

and the field grouting operations are contained in reference 8. A summary

of the physical properties of several commercially available chemical grouts

is given in table 1. The values shown were obtained from various

publications.





T M

SECTION 4. GROUTING METHODS

10. GROUTING PROCEDURES.

a. General. Regardless of the number of exploratory borings or otherpreconstruction investigations, information on the size and continuity of

groutable natural openings in rock below the surface will be relatively mea-ger at the start of grouting operations and only slightly better after the

grouting is completed. The presence of groutable voids can be ascertainedbefore grouting and verified by grouting, but their sizes, shapes, and ramifi-

cations will be largely conjectural. In large measure, the “art” of grouting

consists of being able to satisfactorily treat these relatively unknown sub-

surface conditions without direct observation. The discussions of groutingpractices in this manual are intended to guide the apprentice, but not to re-

place experience. All the procedures and methods presented for groutingrock apply to portland-cement grouting; some of them apply equally well to

grouting with other materials.

b. Curtain Grouting.Curtain grouting is the construction of a curtainor barrier of grout by drilling and grouting a linear sequence of holes. Its

purpose is to reduce permeability. The curtain may have any shape or atti-tude. It may cross a valley as a vertical or an inclined seepage cutoff under

a dam; it may be circular around a shaft or other deep excavation; or it may

be nearly horizontal to form an umbrella of grout over an underground in-

stallation. A grout curtain may be made up of a single row of holes, or it

may be composed of two or more parallel rows.

c. Blanket or Area Grouting. In blanket grouting the grout is injectedinto s—hallow holes dril led on a grid pattern to improve the bearing capacity

and/or to reduce the permeability of broken or leached rock. Such groutingis sometimes called consolidation grouting. Blanket grouting may be used to

form a grout cap prior to curtain grouting lower zones at higher pressures,or it may be used to consolidate broken or fractured rock around a tunnel or

other structure underground.

d. Contact Grouting. Contact grouting is the grouting of voids betweenthe walls of an underground excavation and its constructed lining. These

voids may result from excavation over break, concrete shrinkage, or a mis-

fit of lining to the wall of the excavation. The crown of a tunnel is a commonlocale for contact grouting.

e. Mine and Cavity Filling. Grout may be used to fill abandoned minesor large natural cavities underlying engineering structures to prevent orstop roof collapse and subsidence. The size of these openings permits use of

a grout containing sand or sand and small gravel, If seepage control is in.volved, a second or a third phase of grouting may be required with the



coarser ingredients omitted from the grout to properly seal the smallervoids. Mine maps should be used, if available, to reduce the number of holes

needed to inject the grout. Observation holes should be used to check the

distribution of grout from various injection points. If mine maps are not

available and the size and orientation of haulageways and room spacings can-

not be determined, coverage can be obtained by drilling on a grid pattern. If

the mine workings extend beyond the boundaries of the area requiring treat-

ment, bulkheads of thick grout should be constructed in all mine tunnelscrossing the perimeter of the area to prevent the spread of grout beyond

limits of usefulness. Large solution cavities, like mines, can be groutedwith a coarse grout if sufficiently free from debris and muck. Since grout is

unlikely to displace an appreciable amount of solution-channel filling, it may

be necessary to provide access to the cavities and manually clean them prior

to backfilling with concrete or grout. Cleaning is particularly important if seepage control is the purpose of the treatment.

f. Order of Drilling and Grouting. For grout curtains, holes are ini-tially—drilled on rather widely spaced centers usually ranging from 20 to40 ft. These holes are referred to as primary holes and are grouted before

any intermediate holes are drilled. Intermediate holes are located bysplitting the intervals between adjoining holes; the first intermediates are

midway between primary holes and the second intermediates are halfway be-

tween primary and first intermediate holes. Spacings between holes are

split in this fashion until the grout consumption indicates the rock to be sat-

isfactorily tight. All holes of an intermediate set in any section of the grout

curtain are grouted before the next set of intermediates is drilled. Although

primary holes are most often drilled on 20-ft centers, other spacings are

equally acceptable. If grout frequently breaks from one primary hole toanother, an increase in the primary spacing is indicated. If experience in

apparently similar conditions suggests that a final spacing of between 5 and

10 ft will be satisfactory, a primary spacing of 30 ft may be in order since it

will break down to 7.5 ft with the second set of intermediates. As the split-

spacing technique reduces the intervals between grout holes, the averagegrout consumption per linear foot of hole should also become smaller. If thefinal spacings in a grout curtain constructed in rock that contains no large

cavities are 5 ft or less, the total grout take for neat portland-cement grout

is likely to average less than 0.5 cu ft of cement per l inear foot of hole. In

blanket grouting an area to serve as the foundation for a structure, it is well

to arrange operations so that the final grouting in every section is done

through intermediate holes drilled between rows of previously grouted holes.

This limits the travel of grout in the last holes and permits maximum pres-

sure to be applied to all openings encountered. If the area to be consolidated

is not bounded by natural barriers to grout travel, consideration should be

given to establishing such a barrier by grouting a row of holes around the

perimeter of the area before any other grouting is done. If the blanket-

grouted area is to serve as the capping zone for deeper grouting, it must betightened sufficiently by grouting to prevent appreciable penetration by the

20



higher pressure grout

grout holes necessary

injected into lower horizons. The final spacing of

to accomplish this will depend on the nature and ori-

entation of the groutable openings in the rock, on the orientation of the groutholes, and on the grouting operations. In general, the more numerous the

groutable openings, the more closely spaced the holes must be. Holes on

2- or 3-ft centers may be required in badly broken rock.

g. Inclined Grout Holes. In jointed rock, holes should be drilled to

intersect the maximum number of joints practicable. , This may require di-

rectional drilling. If all the joints dip at angles less than 45 deg, verticalgrout holes wi ll be entirely satisfactory. On the other hand if joints are ver-

tical or almost vertical and the holes are vertical, grouting must be done on

spacings of a few inches to obtain the same degree of coverage possible with

properly inclined holes on 5-ft centers. In practice, holes are usually ’not

inclined more than 30 deg from the vertical because greater inclinations

bring increased drilling costs which offset the savings accruing from fewerholes and wider spacings. The shortest seepage path through the grout cur-

tain is along the joint most nearly normal to it. Therefore, to construct a

grout curtain to control seepage with inclined grout holes, the holes should

be inclined along the plane of the curtain, if the pattern of jointing is at allfavorable. This provides for the greatest number of intersections of joints

trending normal to the curtain. If more than one line of inclined grout holes

is needed to construct the curtain, better coverage of joints trending normal

to it can be obtained by staggering the holes in adjacent rows. Holes should

not be staggered if the joints cross the curtain diagonally.

h. Dr il l Water Loss. Observations of the drill water during drilling

operations can provide much information on the rock encountered by the

drill . The cuttings carried by the water provide information on the type and

color of the rock. Fluctuations in the quantity of the returning water are in-

dictive of rock permeability. An abrupt change in the amount of water re-

turning to the surface usually signifies that the drill has reached a perme-

able horizon. If all the dril l water flows into this permeable zone, all thecuttings produced by the drill will be carried into it also. If drilling is con-

tinued, it is possible that the opening will become so clogged with cuttings

that the drill water cannot enter it and will again vent from the top of thehole. In such fashion, openings of appreciable size can be lost to grouting

but still remain hazards from the seepage standpoint since there is no as-

surance that water percolating through the rock will not remove the cuttings

by piping. Therefore, to avoid clogging major groutable openings with cut-

tings, drilling should be stopped when all the water is lost, and the holegrouted. If there is sudden appreciable gain in water, drilling is also usu-

ally stopped and the hole grouted. This is done, not because of the possibil-

ity of plugging the permeable zone with cuttings, but because an opportunity

is afforded to treat a groutable void of significant size on an individual basis.

The same reason would be sufficient for grouting after a sudden water lossif the possibility of clogging with cuttings did not exist. If the drill rods do

21



TM 5-818-6/AFM 88-32

not drop to indicate a cavity at the point of water loss or gain, it is advisable

to advance the hole 1 or 2 ft beyond that point to be sure that the hole is well

into the permeable zone before grouting. Many cases of a second water losswithin a foot of the first have been recorded. In these cases a cycle of drill-ing and grouting could have been avoided with the extra drilling. Sometimes

specifications are written to provide for grouting if approximately half of the

drill water is lost abruptly or if cumulative losses aggregate about half of

the water being pumped into the hole. J udgment should be exercised in de-ciding that apparent water loss or gain is real. If the water source for the

drill also supplies other operations, pressure fluctuations may cause volume

changes in the drill water that are easily mistaken for losses or gains. Lossof return water caused by blocked bit or a collar of cuttings around the drill

pipe may be construed as complete loss of drill water. In porous rock the

water loss may increase gradually as the hole is deepened. If the pores are

too small to accept the grout, nothing is accomplished by suspending drill-ing operations to grout.

i . Pressure Testing and Pressure Washing.—

(1) Pressure testing as used in drilling and grouting operations is themeasured injection of water into a grout hole prior to grouting. Pressure

washing is the term applied to washing cuttings and other filling out of open-

ings in the rock intersected by the hole. Both operations are done through apacker set in the hole or through a pipe grouted in the top of the hole. In astage-grouting operation (para 11a), pressure testing is used primarily to

determine whether grouting is needed. If the hole does not take water at agiven pressure, it will not take a grout containing solids at that same pres-

sure. Pressure testing will also disclose the likelihood of and/or the poten-tial locations of surface grout leaks and the depth at which a packer must be

set to avoid them. In stop grouting (para 11c), normal pressure-testing

techniques can be used to determine whether grouting is required in the low-

est zone; but in the higher zones, this can be’ done only if the lower zone or

zones are tight at the pressure desired for the upper zone. The use of pres-sure testing with water in a stop-grouting operation to ascertain whether one

or more stops can be eliminated costs as much as checking the hole withgrout. Thus, if the lower zones are not tight, pressure tests in the upperzones need only be used to find locations for seating the packer in fractured

rock or to check for potential surface grout leakage. In stage grouting it is

good practice to always grout the first stage unless the water take in pres-sure testing is zero. The filling of small openings with low-pressure grout

precludes high-pressure grout entering upper rock and heaving it whilegrouting lower zones. The maximum pressure for pressure testing shouldnever exceed the maximum grouting pressure proposed for the same zone.

Generally, it should be lower than the grouting pressure to ensure that therock is not damaged. Careful control of pressure tests in stage grouting is

especially important in this respect. If a hole is tight the pressure test canbe completed in 5 to 10 min after the hole is full of water. If the hole takes

22



water at an increasing rate during the pressure test, the operation becomespressure washing.

(2) Pressure washing a grout hole should be continued as long as an in-

crease in the rate of injection can be observed. If the wash water vents from

surface fractures or from nearby grout holes, the washing should be con-

tinued as long as the venting water is muddy. If two or more holes are in-terconnected, it is often advantageous to reverse- the flow of water in the

subsurface openings by changing the pump line from one hole to another. If

a large, partially filled cavity is encountered, removal of the filling by min-

ing is indicated, since a large volume of water would be required for effec-

tive washing. On occasion grout holes on anticipated final spacings have

been drilled ahead in a section of grout curtain to facilitate. the washing of nearby horizontal openings. After the washing is completed, all the split-

spacing holes are filled with sand to prevent entry of grout from the primary

holes. The intermediate holes are reopened for grouting by washing out the

sand. This procedure is not recommended except for very unusual condi-

tions or as an emergency expedient, because sand from the filled holes may

enter groutable openings and make them ungroutable.

j . Mixes. Water -cement ratios of portland-cement grout can be indi-

cated by either weight or volume. The volume basis is more convenient for

field work and is commonly used. In field mixes a sack of cement is con-

sidered equal to 1 cu ft. The mixes most frequently used range from 4:1 to

0.75:1, by volume. These mixes may also be expressed as 4.0 and 0.75.

Mixes as thin as 20:1 and as thick as 0.5:1 have been used, but mixes thinner

than 6:1 and thicker than 0.6:1 are rare. In general, grouting is started with

a thin mix. Thicker mixes are used as the behavior of the hole during grout-

ing indicates its capacity to accept them. Admixtures and fillers may be

added to portland-cement grout to change setting time, increase the strength,or impart other characteristics to the grout. Sand is often used to provide

additional strength for the contact grouting of tunnels.

k. Pressures.—

(1) The control of grouting pressures is vital to the success of any

grouting operation. This control is maintained by gages on the pump and at

the collar of the hole. The grouting inspector must determine that the gage

at the collar of the grout hole is accurate. Most grouting is done at pres-

sures approaching the maximum safe pressure. An inaccurate gage, espe-

cially one that registers low, could result in the spread of grout into areas

beyond any possible usefulness, or in wasteful surface breakouts, or in dam-

age to a structure by displacing rock in its foundation. In such instances,

grout is not only wasted, but the quantities injected may make tight ground

seem open and require intermediate holes to check the adequacy of the work.A new gage is not necessari ly accurate. A new gage or any gage in use

should be checked frequently against a master gage of known accuracy or

23



against a column of water or mercury. For accurate low pressures, low-pressure gages should be used. The dial of any gage in use should be care-fully inspected. Many gages require a pressure equal to that measured by

one increment on the dial to initiate movement of the indicator needle. In

such a case, the first mark on the dial of a gage showing increments of 5 psi

may actually indicate a pressure of 10 psi. This could be critical for near-

surface grouting where low pressures have to be carefully controlled. For

very low pressures and sensitive conditions, a standpipe is sometimes usedto prevent excessive pressures from being applied. The standpipe extends

only high enough above the top of the hole to obtain the desired pressure by

the weight of the grout column in the pipe. The grout line is inserted into butnot connected to the standpipe. Thus, grout will overflow if it is suppliedfaster than the hole can accommodate it. An adjustment in the height of thestandpipe is required for each mix used if the same pressure is maintained.

(2) There is no way to precisely determine the maximum safe groutingpressure for a particular zone of grouting. A rule of thumb states that 1 lb

of pressure per square inch can be used for each 1 ft of rock and each 2 ft

of soil vertically above the point of grout injection. (Similar coverage isneeded in directions other than vertical. ) The rule of thumb can be modified

with caution as indicated in figure 3. The weight of the column of grout in

Figure 3. Rough guide for grouting pressures

24



the hole may necessitate further

shows the pressure exerted by a

modification of the gage pressure. Figure 4

column of grout 1 ft high for various grout

Figure 4. Pressure of neat cement grout

mixes. If an installation 100 ft below the surface is to be grouted from the

surface, a pressure of 73 psi for 1:1 grout should be added to the gage pres-

sure at the collar of the hole to obtain the effective grouting pressure at the

level of the installation. In any grouting in which the grout may come in con-

tact with a structure partially or entirely underground, the strength of the

structure should be considered. This, rather than the rock or soil load, may

limit the maximum safe grouting pressure. If in doubt, a structural engineer

should be consulted. When a packer is used in a grouting operation, the in-

spector should be aware of the possibility that the gage may be reflecting thepressure required to force the grout through the orifice in the packer ratherthan the pressure needed to inject it into the rock. This condition will not

25



exist for relatively tight holes or for any hole when the capacity of the open-

ing through the packer is greater than that of the combined groutable open-

ings intersected by the hole.

1. Program Objectives. Grouting operations and techniques are notonly influenced by the subsurface conditions encountered, but also by the

purpose and objectives of the grouting program. Is the grouting intended tobe a. permanent treatment, or is it a temporary construction expedient? Is

the tightest cutoff obtainable needed, or is something less than that accept-

able? Should the maximum amount of grout possible be injected into therock regardless of spread, or should an effort be made to restrict the spread

to reasonable limits, or should it be restricted to very narrow limits ? The

answers to these questions and the effects of the often overriding factors of

time and cost form the basis for planning drilling and grouting operations.

The treatment of a reservoir to permanently store a liquid pollutant is an

example of one extreme. Sufficient time and money must be allocated andevery effort and decision designed to provide the tightest seal possible,

otherwise the project cannot be successful. At the other extreme, a grouting

program may be conceived to reduce, but not necessarily to stop, seepage

into an excavation during construction as a measure to save on dewateringcosts. Time will be a factor if grouting delays other work. Cost is a factor,

since the saving on dewatering costs must be a ceiling for grouting costs.

Permanence of treatment is not vital in this case, and grouting techniques

are directed toward constructing the most effective cutoff possible for a

specified expenditure of time and money. In the first case, treatment would

probably consist of grouting a curtain of multiple rows of holes to refusalwith the average grout thinner than 1:1. A wetting agent or fluidifier might

be used. Pressures on all intermediate holes would be kept as, high as safety

from lifting permitted. Holes would be grouted each time an appreciableloss of drill water occurred. Maximum hole spacing after final splitting ineach row would, of course, depend on conditions found, but would likely be

less than 3 ft. In the second case, costs would govern all actions. If holes

were shallow and drilling equipment available, holes would be cheap andspacings could be split to provide good coverage and keep the curtain nar-row. If the grouting zone was deep or if drills could not keep ahead of the

grouting, it would be less expensive to spread the grout farther from fewerholes. Thick mixes and low pressures would be used. Sand or other avail-

able filler would be added to the grout if economical and acceptable for the

openings being grouted. In large openings accelerators would be used to re-duce the spread of grout. Grouting would be stopped well before refusal tokeep labor and plant costs from being disproportionately high. The objec-

tives of most grouting operations fall between the imaginary example cited

above. The objectives for all grouting should be clearly defined so that the

designer, the project engineer, and the inspector will understand them and

can then contribute to their realization.

m. Grouting Techniques. Grouting techniques vary from job to job as

26



C l

m. Groutin g Techniques. Grouting techniques vary from job to job as

dictated by the subsurface conditions and program objectives, from organi-

zation to organization according to policy, and from inspector to inspector

according to judgment and preference. Some of the procedures and itemssubject to modification by policy and field judgment as well as by grouting

objectives are adjustment of mixes, changing grouting pressures, flushing of

grout holes and washing the pump system during grouting, sudden refusal of a hole to accept grout, use of delays to reduce spread of grout, treatment of

surface leaks, and completion of grouting.

(1) Mix adjustment for portland-cement grouts.

(a) The choice of the starting mix may depend on one or more of a vari-

ety of factors: concept of the groutable openings in the rock, time since

drilling, pressure testing or pressure washing, position of water table rela-

tive to the zone to be grouted, and experience with grouting similar rocks. If

the zone is below the water table, if the groutable openings have recently

been wetted, if an appreciable part (but not all) the drill water was lost, or if

the water take in the pressure test was at the rate of about 1 cfm, a starting

mix of 3:1 (3 parts water to 1 part cement, by volume) grout might be the

choice. If the rock is believed to be dry, or a pressure test result of less

than 0.5 cfm has been obtained, it is likely that a 4:1 or thinner grout would

be selected for starting the hole. If all the drill water was lost and the drillrods dropped an observable amount, and if the point of the water loss is be-

low the water table or the rock is still wet from pressure testing or pres-sure washing, the starting mix could be a 2:1 grout. If the hole accepts a few

batches of the starting mix readily without pressure buildup, thicker mixes

should be considered in accordance with the objectives of the grouting pro-

gram. In a relatively tight hole with the pressure quickly reaching the max-

imum allowable, the starting mix, if properly selected, should be continueduntil grouting is complete.

(b) Mixes are usually thickened by batching the new mix in the mixer

and discharging it into the remaining thinner grout in the sump tank. Formost small grout plants, the grout in the pump system (sump tank, pump,

and both pump and return lines) will have essentially the consistency of the

new grout after the second batch of new mix if the sump is pumped as low as

possible for each batch and the grout lines are, not in excess of 100 ft in total

length. If there is reason for an immediate thickening of the mix, the hole

may be temporarily shut off and enough cement added to the grout in the

sump to obtain the consistency desired in the pump system. Mixing is ac-complished by agitation in the sump and by circulation through the pump and

lines. Tables or charts showing cement content of various quantities of fre-

quently used mixes are very useful for changing mixes or determining theamount of cement in a known quantity of grout (figs. 5, 6, and 7). Grout

mixes are thinned by adding water to the sump tank in the amount needed to

obtain the desired water-cement ratio and circulating until all the grout hasthe same consistency.

27



(c) A common grouting practice is to thicken the mix until the desiredpressure is reached and continue with this mix until the hole is completed.

Another somewhat more sophisticated practice is to use the mix that willpermit the injection of cement (not total grout mix but cement portion of themix) at the maximum rate for a given pressure. Maintenance of the maxi-mum rate of cement injection will require more frequent mix adjustments

than the first-mentioned practice, but it tends to shorten the grouting periodand reduce the spread of grout. This procedure also serves to guide the in-spector in the selection of mixes. Groutable openings can be prematurelyblocked and holes lost if the use of too thick grout is attempted. Increasing

the consistency of the grout from 2:1 to 1:1 means that the hole must accept

67 percent more cement for the same rate of grout injection. In many in-

stances it is better to change from 2:1 to 1.5:1 or other mix of intermediate

consistency between 2:1 and 1:1 grout. If one of the objectives of the grout-ing program is to pump the maximum amount of grout (and cement) into the

rock from each hole regardless of spread, mixes should be kept on the thinside.

28



(2) Pressure changes. One policy on grouting pressures advocates the

adjustment of injection rates and mixes as necessary to reach and hold the

maximum allowable pressure for as much of the grouting period as possible.

While the adoption of this policy will result in denser grout, deeper penetra-

tion of groutable openings, and wider grout spread, it will also cause more

lifting, more grout leaks, and more wasted grout, especially if the maximum

allowable pressure is also the estimated maximum safe pressure. When the

maximum safe pressure is exceeded, lifting or grout breakout will take place

no matter how accurately or inaccurately it was estimated. Therefore, the

29



maximum safe pressure should be approached cautiously. A more conserv-

ative policy is to raise the pressure incrementally to approximately three-

fourths of the maximum allowable pressure, hold that pressure constant until

definite slowing of the injection rate is apparent, then raise slowly and by

increments to’ the maximum. This reduces the spread of the grout, but moreimportant it usually permits the inspector to recognize lifting, if it takes

place, and to stop grouting at its inception. When lifting occurs it is often

accompanied by noticeable changes of pressure and grout consumption.These changes last only a short time and may pass unnoticed by the inspector

30



who is raising pressures rapidly with concurrent thickening of mixes to

reach the maximum pressure as quickly as possible. However, the inspec-

tor who has learned the grouting characteristics of the hole by noting the

change in injection rate for each added increment of pressure and who has

observed and recorded the effects of each new mix on both the injection rate

and the pressure has a good chance to notice out-of-character responses in

the behavior of the hole. If the grouting pressure is close to the estimated

maximum safe pressure and the injection rate quickens with a slight drop in

pressure, lifting should be suspected.

(3) Washing pump system and grout holes. Although care and mainte-

nance of equipment are properly a function of the contractor, maintenance

needed to avoid jeopardizing a grouting operation should be directed by the

inspector and provisions there for made in the specifications. Such mainte-

nance includes keeping the pump system clean and in good operating condi-

tion during the grouting process. The pump system should be flushed with

water at intervals that will vary with temperature, mix, and rate of injection.

During extended periods of continuous grouting with thick mixes, it may benecessary to wash the system as often as once each hour. Consideration

should be given to injecting several cubic feet of water into the grout hole atabout the same frequency when using thick mixes, if not contrary to the ob-

jectives of the grouting program. (Washing or flushing to rejuvenate a hole

may not be compatible with efforts to construct a narrow grout curtain. )

Water is usually injected into a grout hole when grouting is suspended due to

an emergency, or when it is stopped intentionally to permit grout already

placed to set. This is done to maintain access to a readily groutable zone

or cavity for additional grouting from the same hole. Every effort should be

made to keep mixes thicker than 1:1 constantly moving. A very brief delay

may cause the loss of the hole. Occasionally loss of hole from emergencydelays can be prevented by jetting a pipe to the bottom of the hole and flush-

ing out the stiff grout. This should be quickly followed by pumping a batch of

water into the hole and, if that is successful, using a thin mix to resume

grouting operations.

(4) Sudden refusal. The sudden refusal of a hole to take grout suggests

several possibi li ties. Extraneous solid matter may have fallen into the grout

and blocked the line, the packer, or the hole; the hole above the zone takinggrout may have collapsed; the mix may be too thick; or the openings in the

rock may be full. The various possibilities should be checked unless suddenrefusal is routine at the site involved. First, if the injection rate is not quite

zero, an attempt should be made to reopen the hole by pumping water into it.

If this does not work, the grout line to and through the packer, if a packer isused, should be examined to-make certain that grout is reaching the hole. As

a last resort a probe can be dropped in the hole to learn whether it is open.

The addition of an inert filler to the grout sometimes causes sudden stoppage

in a hole. Fi llers should be added cautiously if large, cavities are not known

to be present. The filler should be taken out of the mix immediately if i t



appears that it may cause premature stoppage.

(5) Delays. Delays lasting from a few minutes to several hours may beinterposed in the grouting operations to prevent the grout from spreading

beyond a reasonable distance, if in keeping with the grouting objectives. Ac-

celerators may be used in connection with the delays. A succession of de-

lays is sometimes used before a hole is completed. The amount of grout

injected between delays or before the first delay will be a matter of policyand judgment, which should be based on knowledge of subsurface conditions.

As long as the grout is considered to be fulfilling its intended purpose,

grouting should not be interrupted. There is also the possibility that access

from the hole to the void taking the grout will not remain open during the

period of delay, even though water is injected to keep it open. The risk of losing the hole for further grouting and the cost of a new hole should be

weighed against the cost of the grout saved by the delay before ordering the

delay. If delays of several hours are desired, the contractor’s grouting ef-

forts may be directed elsewhere during the period of delay. If the delays are

comparatively short and the contractor is required to stand by with his

grouting equipment, the specifications should state how compensation wil l be

made for the period of waiting.

(6) Treatment of leaks. Grout sometimes follows interconnected nat-

ural openings in rock to break out many hundreds of feet from the point of

injection. Frequent and periodic checks of the area in the vicinity of the

grout hole should be made during grouting operations. The inspector should

observe all known wells, springs, or seeps for unusual discoloration or in-

crease in flow. The area patrolled should be enlarged as the grout consump-tion increases. In the event that a leak occurs, the inspector should estimatewhether it represents essentially all the intake of the grout hole or only a

small part of the total. If all the grout seems to be venting, the pressureshould be reduced, the mix thickened, if not already thick, and a small dike

built to pond thick grout over the leak if possible; then the grouting should be

stopped, The pond of grout will act as a reservoir to keep the vent full untilthe grout sets. If only a portion of the injected grout is venting, it may beworthwhile to expend considerable effort to save the hole. If the leak is in

loose material, the procedure outlined above may be used, except that pump-

ing should not be stopped but slowed to give the thick grout in the pond time

to set. An accelerant may be added to the ponded grout. Sand is a good ma-

terial to create a pond, since excess water in the grout can escape through

it. If the leak is in relatively sound rock, it may be talked with oakum,wicking, burlap, wood wedges, or lead wool. Burlap is particularly good if the grout contains much excess water, since it can seep through the burlapleaving the cement to build up in the fracture. If the grout is not too thick,

brief delays may be tried but without prior injection of water. After the

leaking has stopped, normal operations may be gradually resumed. If the

leaking cannot be completely stopped and represents only a small part of the

grout injected, grouting can be continued at a reduced pressure. Often many

32



grout leaks can be avoided by treating leaks discovered during pressure

testing or pressure washing. At this stage open cracks and fissures may be

filled with a quick-set grout mix. The contractor’s responsibility relative t

talking and other treatment of leaks should be described in the specification

(7) Completion of grouting.

(a) Grouting may be continued to absolute refusal at the maximumgrouting pressure, although this is not usually done. There are two method

that are most frequently used to determine when grouting is complete. One

specifies that grouting shall continue until the hole takes no grout at three-

fourths of the maximum grouting pressure. The other requires that groutin

continue until the hole takes grout at the rate of 1 cu ft or less in 10 min

measured over at least a 5-min period. This is often modified according to

the mix and/or pressure used. The second specification is more readily

correlated with pressure-test results than the first.

(b) If there is doubt about the completeness of treatment in any zone or

area, a check hole or holes should be drilled. Such holes can be drilled torecover core for examination, or they may be drilled for study by the bore-

hole camera or television camera. However, a quicker and less expensive

check can be made by drilling and pressure testing another grout hole. If tight when pressure- tested with water, the rock is satisfactori ly grouted; if

the hole takes water, additional grouting is indicated.

11. DEFINITIONS.

a. Stage Grouting. In this method of grouting, progressively deeperzones-are dr illed and grouted in stages from the top of rock. A stage of

drilling is complete when a predetermined depth of zone is reached or when

a specified condition is encountered. A single zone may include more than

one stage. Holes in a given area are dri lled to their first stage of depth,

grouting is done at low pressure, and the grout within the hole itself is sub-sequently removed by jetting or other methods before it has set sufficiently

to require redril ling. (In the event that the contractor is ordered to leave

the grout in the hole for any stage except the last one, payment for drilling

grout is usually made at the rate of 50 percent of’ the cost of drilling rock. )

Similar stages or cycles of drilling and grouting are repeated as necessary

to reach the bottom of the first zone. After all fi rst-zone grouting of pri -

mary holes in the area has been completed and a minimum period of 24 hr

has elapsed since completion of grouting operations in any given hole, inter-

mediate holes, located by the split-spacing method, are drilled

and grouted to the bottom of the first zone. Upon completion of all

ofsplit-spacing holes. the primary holes are drilled to their second zone.

depth and grouted at higher pressures. The process of dri lling

washing, pressure testing, pressure washing, and grouting at progressivelyhigher pressures is continued until the ground is satisfactorily tight to the

required depth. If any stage of a hole is found to be adequately tight as de-

termined by pressure testing, grouting of that stage is omitted and the hole

left open for drilling in the next lower stage.

3



b. Series Grouting. Series grouting is similar to stage grouting exceptthat each successively d eeper zone is grouted by means of a newly drilledhole to eliminate the need for washing grout out-of the hole before drilling

deeper. Holes at regular intervals are drilled to the depth of the first zoneand individually grouted from the top of rock at low pressure. The split-spacing method of reducing the grout-hole interval is followed until the

uppermost zone refuses grout at the permissible pressure. After the firstzone has been completed, another series of holes is drilled into the second

zone and grouted from the top of rock at higher pressures, following the

same procedure as outlined for the first zone. Additional series of holesmay be drilled, depending upon the final depth bf grouting required. Themaximum pressure is applied to the deepest zone. The justification forusing the higher pressures in the deeper zones in this method, and in the

stage-grouting method, is based upon the assumption that a blanket or bar-

rier, as provided by the previously grouted zones, prevents the escape of

grout through, or the development of serious uplift in, the shallower zones.

c. Stop Grouting. In the stop-grouting method of grouting, the hole isdrilled to full depth and a packer used to separate the hole into segments orzones for grouting purposes. Grouting is started in the lowest zone. Aftercompletion of each zone, the packer is raised to the top of the next higherzone; and grouting is resumed under a maximum pressure commensurate

with the reduction of overlying load. The packer must be left in place aftereach grouting until the pressure on the newly placed grout has dropped to orbelow the maximum pressure contemplated for the next higher zone. The

last stop, or packer setting, is at the top of rock. Usually, the packer is not

removed from the hole until the grouting of all stops in the hole has been

completed.

d. Circuit Grouting. Circuit grouting requires the use of a double-line

grouting system (para 17a). The pump line is attached to a pipe that extendsthrough an expansion plug or packer to within 5 ft of the bottom of the hole.

When grout venting from this pipe fills the hole, if flows through a second

opening in the expansion plug into the attached return line and back to thegrout sump for recirculation. Thus, as soon as the pumping rate exceeds the

rate at which grout is injected into the rock, the grout hole becomes part of

the grout-circulation system. Circuit grouting may be used “to grout a holedrilled to full depth as a one-time operation,or it may be used as a modifi-cation of any of the other grouting methods described.

e. Soil Grouting. The methods described in the preceding paragraphswere developed primarily for grouting rock and may or may not be applica-

ble for grouting soil. Because of the lack of stability of borehole walls that

may be encountered in soil, it may be necessary to provide support whilegrouting is in progress.

34





(2) Disadvantages. The principal disadvantage of stage grouting is theever-present danger of lifting or heaving the rock when grouting without a

heavy confining load. This causes grout waste and may seriously damage the

rock and/or any superjacent structure. Lifting occurs when grout at com-

paratively high pressures is actually injected into and displaces rock near

the surface. Thinly bedded, horizontally stratified rocks are easily l ifted.

To prevent lifting such rocks, it is sometimes necessary to use pipes sev-

eral feet long or to grout all but the first stage through a packer set in areamed-out hole at a depth of several feet. In the first instance the upperfew feet of rock are not grouted; in the second case, one of the advantages of

stage grouting is lost since a packer must be set for each stage of grouting.

A second major disadvantage of stage grouting, as compared with stop grout-

ing, is its higher costs. A drill must be moved to and set up over each grout

hole at least once for each zone in the hole and grout lines must be connected

to the hole equally often. Both items add time and money costs to the job.

Connections to grout holes are usually pay items; more are required for

stage grouting. Labor is expended and grout is wasted for each stage of

grout hole cleaned before deepening. If the cleanout is made prematurely,

grout injected into the rock may flow back into the hole and be wasted also.

b. Series Grouting.—

(1) Advantages. The advantages given above for stage grouting (except“the last listed) apply also to series grouting. Other advantages of series

grouting are that all grouting is done from a new hole in freshly exposed rock

(this provides for a maximum exposure of groutable voids) and grout injected

into the rock is not lost by poorly timed cleanouts as in stage grouting.

(2) Disadvantages. The major disadvantages of stage grouting, i.e.,danger of lifting and increased expenditure of time and money, apply to se-

ries grouting also. The increased amount of drilling makes series grouting

the most expensive of the methods described.

c. Stop Grouting.—

(1) Advantages. The stop-grouting method is the quickest and least

costly method of grouting. This is primarily because of the time and labor

saved by not having to move drills and grout lines repeatedly to and from the

same hole. Grouting through a packer set at depth provides positive knowl-edge that grout under high pressure is not being injected into lightly loaded

rock near the top of the hole, as may be the case in other methods of grout-

ing. Stop grouting is the least likely to produce undiscovered lifting andresulting grout waste. Stop grouting is particularly well adapted to situa-

tions that require the highest pressures in the deepest zones.

(2) Disadvantages. Packers are sometimes hard to seat. This resultsin loss of time and may result in the loss of the packer by blowout. In

36





best suited method. Examples of the latter are reservoir r ims, dam abut-ments, mine shafts or other similar deep excavations, and underground

structures grouted from the surface. In some instances portions of groutholes must be drilled through rock above the horizons requiring treatment.

Since grouting the upper rock is unnecessary, stop grouting is well adapted

to this situation. If sufficient rock overlies the grouting horizon, it may be

possible to grout the entire hole with one stop and with only low or gravity

pressure at the collar of the hole. If the surface rock in the grouting areais thinly bedded and has a nearly horizontal attitude, stop grouting is the best

method o avoid lifting. A stage of grouting is always required if the drill

water is lost before the hole reaches final depth. Stage grouting should beused to prevent natural muds formed by drill cuttings from shales or similar

rocks from filling or obstructing groutable openings at higher horizons. If itis desirable or necessary to consolidate the upper rock before proceeding

with grouting at depth, stage or series grouting is indicated. If it is desired

to grout the foundation of an existing structure at pressures comparable to

the load imposed by the structure, series or stage grouting should be used,especially if the upper part of the foundation is known to contain groutable

voids. In this case great care must be exercised to avoid lifting and tiltingthe structure.

The danger of lifting is less if the rock is massive or mediumbedded, if the joints are at high angles, or if the strata are steeply dipping.

38



SECTION 5. GROUTING EQUIPMENT

13. INTRODUCTION. Guidance for selecting or approving the specializedequipment necessary for a grouting project is provided below, and operational

principles for the equipment are outlined and related to job requirements.

14. DRILLING EQUIPMENT.

a . Percussion Dri ll ing. Percussion dri ll s are operated by air -driven

hammers. The best known types are the jackhammer, drifter, and wagondrill. The drill proper consists of a hollow steel rod, fitted with a fixed ordetachable bit on one end and a shank on the other.

(i) Operation. Percussion drills are used for dri lling in rock. The

percussion drill does not reciprocate. Its shank fits into and is held looselyin the chuck at the forward end of the machine, where it is struck by a

hammer-like piston actuated by compressed air. The compressor capacity

necessary to operate a single-hammer drill ranges from 50 to 200 cfm, de-

pending upon the size of the drill cylinder and the pressure at which air issupplied. During drilling the bit remains in close contact with the rock at

the bottom of the hole at all times except during the slight rebound caused byimpact of the hammer. Drills are provided with a mechanism that causesthe drill steel rod to rotate between blows of the hammer. Cuttings or sludgeare removed from the hole by air or water that passes through the machine,

down the hollow drill steel rod to the bottom of the hole, and then rises up

the hole to the surface. Removal of cuttings by water is preferred for grout-hole drilling but is not mandatory. J ackhammer drills, due to their lightweight, are usually held in position by hand. Drifter-type drills are designedfor tripod or bar mounts. The wagon drill, as commercially available, is

comprised of a drill head mounted in leads that are supported on a track-,

wheel-, or skid-mounted chassis.

(2) Application. Percussion drilling produces acceptable grout holesand, generally, is the most economical method of drilling shallow holes. This

advantage decreases with depth and disappears at depths from 75 to 125 ft

depending on the type of rock. In operation, the edges or wings of the bitwear away so that a progressively smaller hole is drilled. Therefore, when

pertinent, the specifications should state the minimum acceptable size of grout hole.

b. Rotary Drilling. Rotary drilling is the process of making a hole byadvancing a dril ling bit attached to a rotating column of hollow drill pipe.

The drill pipe is turned by a motor at speeds ranging from a few hundred to3,000 or more rpm. Pressure on the bit is applied hydraulically or mechan-

ically. Water is forced through the drill pipe to wash cuttings out of the hole.Drill rigs vary in size from small lightweight machines capable of drilling

39



. ,

types employ a diamond-studded bit to

the hole continuously cleaned by water

the drill rods.

( a ) C o r e t y p e . The core-type bit

end of which is studded with diamonds.

The bit is coiled and

or compressed air pumped through

consists of a hollow steel cylinder, the

The bit is fitted to the lower end of a

hollow steel chamber (core barrel) that is rotated rapidly while the bit is

held firmly against the rock so that the diamonds cut an annular channel in

the rock. The rock that lies within the channel and projects into the barrel

constitutes the core.

(b) Plug type. Two varieties of plug bits are available commercially.

One is a concave type, the head of which is depressed toward the center; and

the other, a pilot type, has a protruding element, cylindrical in shape, but of s mailer diameter than the main bit head. Noncoring diamond bits have a wide

40

.



field of usefulness in foundation grouting. However, they are more costly than

coring bits for drilling in extremely hard foundations and in badly fractured

rock because of greater diamond cost. Since they produce only cuttings, more

diamonds are required to make a given footage of hole than if a large part of

the rock encountered is removed as core. The loss of one or two diamonds

from the center of a noncoring bit (a not infrequent occurrence in drilling

shattered rock) renders the bit useless for further cutting. The plug bit is

less expensive than the core bit in deep holes due to the time saved by nothaving to pull out of the hole to empty the core barrel or to clean a blocked bit.

(c) Size. The sizes of diamond bits are standard and are generally shown

by the code letters EX, AX, BX, and NX. The dimensions of each size aretabulated below. Most diamond-drilled grout holes are EX or AX in size.

There is insufficient advantage in larger bits to justify their use. The possi-

ble advantage that the larger diameter bit may have in encountering more

fractures than the smaller is more than offset by the fact that the greater

economy of the small bit permits a closer spacing of holes for the sameoverall cost.

Size. in.

Code Hole Core

E X 1-7/16 7/ 8A X 1-27/32 1-7/32B X 2-5/16 1-5/8N X 2-15/16 2-1/8

(2) Hard metal bits. Drill bits of hardened steel notched to resemblethe teeth of a saw can be placed on the core barrel to substitute for a morecostly diamond bit. In some soft rocks this type of bit will make a hole muchfaster, is not as easily blocked, and is much cheaper than a diamond bit. Of-

ten the teeth of such bits are faced with one of the alloys of tungsten carbide,

or replaceable inserts of a hard alloy are welded

blank. A noncoring bit can also be made with thecap for a piece of drill pipe with bits of the steel

alloy and adding waterways.

(3) Rock bits. Rock bits, like diamond bits,of a column of hOllOW drill pipe. The bit is made

into holes cut–into the bit

hard alloys by studding therod containing the powdered

are attached to the bottom

of toothed rollers or cones,each of which turns or rolls on the rock as the bit rotates with the drill pipe.

Cutting is accomplished by crushing and chipping. The shape of the teeth,

their attitude and number, and the number of rollers vary. Most bits have

three or four cones or rollers; some have two. The teeth and other parts of the bits subjected to intense abrasion are made of hard alloys. Cuttings and

sludge are washed out of the hole by circulating water or drilling mud through

the drill pipe and back to the surface between the drill pipe and the walls of

the hole. The roller rock bit is not extensively used for grout-hole drillingbecause the smallest available size is approximately the same as that of an

NX diamond bit.

41



(4) Drag and fishtail bits. The drag bit is a general service bit for ro-

tary dril ling. Capable of drilling soft rock and most soils, it is used exten-sively in foundation explorations and grout-hole drilling. The fishtail bit is

so named because of its resemblance to a fish tail. The divided ends of itssingle blade are curved away from its direction of rotation. , Other drag bits

have three or four blades, which may or may not be replaceable. The cutters

or cutting edges of the blades are made of hardened steel or are covered

with hard alloys. Almost any desired size is available.

c. Summary. Drill bit types and the materials in which they are gen-

erally—used are as follows:

Drill Bit Type Principal Use Not Well Suited for

Diamond:

Core Rock and concrete Unconsolidated soils‘Plug Rock Extremely hard rock,

extremely soft rock,

unconsolidated soils,

and shattered orfractured rock

Hard metal

Rock

Drag and fishtail

Percussion

Soft rock, hard clay,

and cemented soils

Rock

Soft rock and soil

Rock and concrete

Hard rock and uncon-solidated soils

Unconsolidated soils

and very hard rock

Hard rock

Unconsolidated soils

15. GROUT PLANT.

a. Grout Mixers . Many types of grout mixers have been used, includinghand-turned dough mixer s, concrete mixers of various sizes, and especiallydesigned grout mixers. Any machine is suitable that has the desired capac-ity and that mixes the grout mechanically to a uniform consistency. Twomixers can be arranged to discharge into the same sump to satisfy high ca-

pacity requirements. Manual stirring of cement and clay grouts in a tub isnot satisfactory except in emergencies. Hand-powered dough mixers are notrecommended because of their limited capacity.

(1) Central Valley-type grout mixer, 8-cu-ft capacity. During the

grouting at several dams of the Central Valley Project, a small, air-

operated, lightweight grout mixer was needed that could be set up and oper-ated in a 5- by 7-ft gallery. The mixer shown in figure 9 was designed for

42





this purpose. It was fabricated in a local shop economically.

(2) Grand Coulee-type grout mixer, 21-cu-ft capaci ty. In the groutingat Hoover Dam, considerable experimenting was done with various equipment

for mixing grout. Concrete mixers were first used but were later discardedfor the type mixer shown in figure 10.

/

The body of this mixer is 30 in. (ID)by 48-1 2 in. long. There are 16 paddles in series of 4 mounted on a

2-in. -diameter shaft. The paddle shaft is supported on the back end by anextended babbitted bearing with cap, and on the other end by a split-cap,

rigid, babbitted pillow block. The body is made of a 3/16 -in. plate with fronthead 1/4 in. thick and a removable back head 3/8 in. thick. The removable

back head not only facilitates the removal of the paddles but also permits

thorough cleaning and chipping out of hardened cement, if necessary. The

shaft has supplemental bearing supports in the heads that consist of bronze -

bushed, welded-in steel hubs.

top, 14 in. in diameter at its junction with the body, and 14 in. high. There is

2.65-hp air motor that makes 65 rpm when supplied with air at 100 psi. I ts

consumption is approximately 85 cfm. A bolted coupling connects the motorto the mixer. The body is supported on two welded reinforced saddles at-tached to 4-in. I -beam skids which are not shown in the figure.

(3) Grand Coulee-type grout mixer, 27-cu-ft capacity. For the contrac-tion joint grouting at Grand Coulee Dam, two 27-cu-ft mixers, as shown in

figure 11, were purchased. They are simil ar to the 21-cu-ft model. These

mixers are easy to run and to clean and are very flexible. They handle

batches of grout made from 1 to 10 sacks of cement and do a thorough job of

mixing. These mixers were powered by air motors.

(4) High-speed colloidal-type mixers. High-speed colloidal-type grout

mixers are commercially available in both the single - and double -drum

types. These mixers are equipped with small centrifugal pumps, which

cause the grout to circulate at high speed while being mixed. Particles of cement may be broken and rounded to a significant degree in high-speed

mixers. This results in an increase in pumpability and penetrability for

portland-cement grout. In an emergency, grout can be pumped at low pres-sures into the foundation or other places with the centrifugal pumps of these

mixers.

(5) Water meters. A satisfactory water meter is the single-disk type,

size 1-1/2 in., and threaded for pipe connection. This type has a 6 -in. verti -

cal register with a long hand that makes one revolution per cubic foot of

water and a short hand that indicates 10 cu ft per revolution. For use in

grouting, the meter should have a reset knob to set the hands to zero and adirect-reading totalizer. A screen should be provided if sand or rock parti-

cles are present in the water supply.

.

44







(1) Agitator sumps. After mixing, grout should be agitated to preventsettlement while it is being pumped. This can be done by pumping the grout

into a sump equipped with a stirring blade. Figure 12 shows a type of agita-

tor that has proved satisfactory. The agitator should have the same capacity

as the mixer so that one batch of grout can be pumped while the next batch is

being mixed. When emptying the grout from the mixer into the agitator, thegrout should pass through a 1/8-in. -mesh screen to remove pieces of sacks,

strings, wire, ties, or other foreign matter that may be dropped into the

mixer.

16. PUMPS.

Types of Pumps. Pumps for cement grouting should be sufficiently

flexible to permit close control of pressure and to provide for a variable

rate of injection without clogging of valves and feed lines. With constant-

speed pumps, special arrangements of the supply piping systems and valves

are needed to provide close control of the grouting operation. Constant-

speed pumps are powered by electric motors or internal-combustion engines.Variable speed pumps are hand operated, steam driven, or air driven.

(1) Hand pumps. Hand-operated pumps are used infrequently; they are

satisfactory only when the amount of grout to be injected at any one time is

very small. Their weak points are the check valves, which usually become

plugged and stick after a short period of operation, and the packing, which

frequently leaks grout as the pumping pressure is built up.

(2) Ai r-driven pumps. A number of air -driven pumps are commercially

available. The reciprocating slush pump shown in figure 13 is available in

sizes from 20 to 100 gpm at pressures from 200 to 500 psi when supplied

with air at pressures of 100 psi. This type of pump is suitable for most ce-

ment and clay grouting.

(3) Power-dri ven pumps. Power -driven pumps have the same grout

ends as the air -driven pumps, but require an external power source. This

source is connected to the pump by gear, chain and sprocket, or V-belt

drives. A wide variety of power sources are available.

b. Reciprocating Slush Pumps.—

(1) Line -type pumps. The advantage of the line -type slush pump

(fig. 13) is the accessibility of the valves. The discharge valves are located

directly above the suction valves so that both can be removed through the

same opening in the top of the pump “for cleaning or repair. The disadvan-tage of this type of pump is that it requires two types of suction and dis-

charge valves and valve seats.

47



48





(2) Side-pot-type pumps. In the side-pot-type slush pump,

in a separate pot or chamber with its own cover (fig. 14a). The

each valve is

advantage of

this type of pump is that all valves and seats are interchangeable, and since

each valve has a separate cover plate, the suction valves may be removed

and cleaned without disturbing the exhaust valves, as is necessary in the

line -type pump. Disadvantages are that grout usually collects in the bottoms

of the valve pots and that the suction and exhaust ports are inconveniently

arranged for cleaning.

(3) Divided fluid-cylinder valve -pot-type pumps. Although the action of

this type of pump (fig. 14b) is not as smooth as that of a line -type pump, its

interior parts are more readily accessible for cleaning. It is somewhat

heavier than a line -type pump built for the same working pressure, the

valves and seats are interchangeable, and the best pumps of this type have

removable cover plates at convenient places for cleaning grout from the in-terior passageway.

a . S I D E - P O T - T Y P E P U M P

Figure 14. Slush pumps

50



c. Screw-Type Pumps. A double helical screw-type pump, also called

progressing-cavity pump, will pump cement grouts and other slurries.

Pumps of this type will handle solids in suspension and will pass particles up

/to 7 8 -in. size, depending on the size of the pump. They have few working

parts and are fairly free from mechanical trouble. They can be driven by

air motors, gasoline engines, or electric motors. Pumps of this type pres-

ently available will operate up to 600 -psi working pressure. Pumps for

higher pressure may be available in the future. The progressing-cavity typepumps (fig. 15) are suitable for pumping practically all grouts.

d. Centri fugal Pumps. Cement grout and other slurries have beenpumped by centrifugal pumps. The weak points of centrifugal pumps when

used for this type of service are the seals for the impeller shafts and their

bearings. With the proper type of seals and bearings, centrifugal pumps canhandle large quantities of materials at low pressure.

e. Air Pots or Pneumatic Grouters. An air pot is a cylindrical steel

pressure tank from which grout or other material can be forced by com-

pressed ai r. The tank is charged through a gasketed door at the top and dis-

charged through the grout outlet at the bottom of the tank. Taps for air -inlet

and air -exhaust valves and a pressure gage are provided. A small valve-

controlled stream of air is introduced into the bottom of the tank, usually

through the grout outlet, to keep the grout agitated if it cannot be dischargedimmediately. Grout is mixed in a separate mixer and conveyed through pipe

or hose or mechanically to the grout tank. If only one pot is used, groutingmust be intermittent since movement of grout to the hole stops while thechamber is being charged. Continuous flow can be provided by two pots, eachhaving its discharge line connected to the grout line by a wye valve and being

operated so that one pot is charged while the other is discharged. Pots with

twin chambers also provide for continuous injection. The equipment is sim-

ple and can be shop made in an emergent y, or Gunite or pneumatic-

concreting equipment can be adopted as air pots. The principal disadvantage

of air-pot-type equipment for grouting is that the grout in the tank is not vis-ible and air may be injected into the hole before the, operator is aware that

all the grout is out of the chamber. Other less important disadvantages are:

(1) the maximum grouting pressure depends on the air pressure available,

(2) a double -line grouting system (para 17a) cannot be used, and (3) constantattention must be given the gaskets on the doors to avoid air leaks.

17. GR OUT L I NE S.

a. Gener al . There are two primary arrangements of piping used to

supply grout from the pump to the hole. The simpler of the two is thesingle-line system. It consists of a pipe or a hose or a combination of both,

extending from the pump to the header (d below) at the hole. The pump speed

controls the rate of injection. The second arrangement is the double -line orcirculating system. This system has a return line from the header to the





grout sump in addition to the pump line of the single -line system. Thus, if

the header connection to the hole is closed, grout can be continuously circu-

lated from the grout sump to the pump, through the pump line, through the

header, and back to the sump through the return line. While grouting, the

amount of grout entering the hole through the header can be varied by open-

ing or closing a valve on the return line without changing pump speed. Thedouble-line system is generally preferred because it permits better control

of grouting pressures and allows less material to settle out of the mix toplug the lines.

b. Hose. Flexible hose is most commonly used for suction and dis-—char ge lines. If the length of the discharge line is such that pipe is neces-

sary, a short length of hose should be provided at the pump discharge and at

the connection to the grout header. The hose should be not less than

1-1/2-in. diameter (inside) and capable of withstanding the maximum grout-ing pressure with an ample margin of safety. The suction line from thegrout sump and water tank may be either pipe or hose of suitable diameter

and should be as short as feasible. It should be provided with fittings at both

ends. Hose is preferable to pipe because its flexibility permits ready inter-

change of the suction end between the sump and water tanks. Pipe; on the

other hand, requires the installation of valves that will permit the pump todraw either grout or water as the occasion demands. It has been found that

difficulty often arises because of clogging of the water valve on the grout

line side.

c. Piping. Black steel pipe and fittings 1-1/2 in. in diameter are nor-

really-suitable for pressure lines; but where large quantities of grout are to

be injected and the supply line is long, it may be desirable to provide a

larger size pipe and connection hoses. Pipe must be capable of withstandingat least the maximum pressure to be applied in the grouting operation.

d. Grout Header. The grout header is usually assembled as a unit in

order—that it may be moved from one grout hole to another. The assemblyconsists of the operating valves, a pressure gage, pipe, and the necessary

fittings to attach the header to the hole and to attach the grout supply and re-turn lines. The gage and the valves are de scribed in more detail in e and f

below. A header assembly is shown in figure 16. It should be noted that the

pressure gage is so connected that by closing one valve it can be used for

pressure-drop observations without interrupting the circulation of grout in

the pump system.

e. Pressure Gages.—

(1) Reliable pressure gages are essential in pressure grouting. They

constitute the principal index to the behavior of the hole and the stresses that

are being produced in treated material. If the hole is more than 100 ft hori-zontally or 20 ft vertically from the pump, there should be two gages in the

53



OR

V A L V E

grout line, one at the pump and the other at the hole for control. When there

is the possibility of doing serious damage by the application of too muchpressure, all gages should be installed in duplicate. Structures have been

damaged by the unintentional application of excessive pressure occasioned by

gage failure or sticking. Gages, the glass faces of which have been broken,

should be condemned. Dust and grit tend to reduce the accuracy of the gage.

This causes the gage to register falsely and results in pressures higher than

those indicated being applied, with attendant higher grout injection. The gage

used should have a pressure range comparable to that required. Thus, a

200-psi-capacity gage is not appropriate for grouting where a maximumpressure of 50 psi is contemplated.

(2) The moving parts of the gage must, for obvious

tected from direct contact with the grout. The simplest

pressures greater than 200 psi is a short oil- or grease

reasons, be pro-protective device for

-filled siphon (pig-

tail) located between the gage and the grout. This consists of a l/4-in. pipe

with a 3-in. loop in its center. The pipe is filled with a light grade of water -

proof grease. An alemite fitting, located between the gage and the pigtail,

enables the operator to force open the passage should it become obstructed.

However, grease makes the gage sluggish and its readings are not always

consistent due to the effect of temperature changes on the fluidity of the

grease. The most satisfactory device consists of a piece of 1-1/2- or 2-in. -

diameter pipe 18 in. long that is stubbed off vertically above the grout line.The gage is fitted to the top of this stub by means of suitable bushings. All

54



joints should be made tight with litharge and glycerin or lead since thedevice is, in effect, an air dome and any small air leak will render it inef-

fective. The gage is very sensitive with this arrangement and the violent

oscillations of the needle make exact readings difficult; but this objection-able feature can be largely obviated and the gage given additional protection

by installing a gage saver, as shown in figure 17, between it and the air

dome.

f. Valves for Grout Li ne. Plug valves should be used to control the

flow of grout. Pressure relief valves are sometimes installed in the groutline as an added precaution in controlling grout pressures, but should not be

55



relied upon. Vigilance and hand-operated, quick-acting valves afford the

only reliable means of controll ing pressures. There are two types of quick-

acting valves that are satisfactory for the grout lines. These are the so-

called lubricated and nonlubricated plug valves. Lubricated valves should be

installed throughout the entire system except for the first valve above the

grout hole, where a nonlubricated valve should be used. They should be of a

diameter to fit the pipe size, have threads inside, and should be capable of

withstanding nonshock, cold water pressure equal to at least the maximum

pressure to be applied. Both body and plug should be

steel. The plug of the valve should be ground into its

contact over the entire surface of the plug and to give

perfect seating. The valves should be square headed,Walworth Company’ s standard iron cock No. 651.

18. PACKERS.

made of iron or semi-

body to ensure perfect

smooth operation andsimilar and equal to

a. Introduction. There are three general types of grout packers in

common use, the cup leather, the mechanically expanded rubber ring, and the

pneumatically expanded rubber sleeve. Various methods of mechanically ex-

panding the rubber ring or rings have been used, and each has its place for aparticular condition. No effort will be made to illustrate all of the packersthat have been used as all types are frequently modified and improved to fit

local conditions. Each general type does, however, have characteristics

making it most suitable. Initially, AX (2-in.) or BX (2-3/8 -in.) holes were

thought to be the smallest size adaptable to the use of packers, but now theyhave been developed for all sizes from EX (1-4/2-in. ) to NX (3-in.). Some

difficulties arise when smaller holes are used. The packers to be describedhere are all for EX size holes.

b. Cup Leather Removable Grout Packer. The cup leather type shown

in figure 18 is best suited to fairly hard rock where the drilled hole is not

oversize and the walls are relatively smooth and true. This packer when

suitably anchored has been used successfully for grouting pressures up to750 psi. It is simple to construct, easy to maintain, and only requires a

single pipe to lower it in the hole. Where high grout pressures are feasible,

it is probably the best type of packer to use. If it should accidentally become

stuck in the hole, a right-left coupling enables the crew to save the supply

pipe string and the packer itself can be drilled out, if necessary.

c. Mechanical Packer. The mechanically expanded type shown in fig-

ure 19 is adaptable to softer rock than the cup leather type, but it may be

difficult to seat if the drill hole is too much over size. Its positive expandingaction gives it an advantage in that it can be positively seated at any location

if the hole is not too enlarged. When used at depths greater than 20 ft, flush-

joint

Once

used

56

tubing is required and it is somewhat award to handle in a deep hole.

seated the packer too can withstand fairly high pressure and has been

on many jobs.





58



d. Pneumatic Packer. The pneumatic packer shown in figure 20 has

proved suitable in soft and thin-bedded rocks where the drill holes are often

somewhat over size. In fact the EX (1-1/2-in.) size can be seated in a 4-in.

pipe when the proper rubber tubing is used and it is properly attached at theends. The length of rubber sleeve should not be less than 18 in. Under con-

ditions requiring large expansions and relatively high expanding pressure,

double -tapered collars at either end may be necessary to prevent rubber

breakage. It is not suitable for high grout pressures, but it will withstand100 psi under poor conditions and will hold up to 200 psi if the hole is not toolarge or uneven. In weak sedimentary formations of alternating layers of shale and sandstone or lime stone, this packer has proved invaluable. It is

now widely used where low pressures are dictated by foundation conditions.

19. ASPHALT GROUTING EQUIPMENT. Commercial asphalt heaters sim-

ilar to those used by roofing contractors have been found satisfactory forheating asphalt for grouting. The heater should have a baffle near the outlet

to prevent lumps from entering the supply line. Gear pumps, reciprocating

pumps with ball valves, or 1-in. boiler-fed piston pumps have been used to

pump hot asphalt grout through 1-1/2 -in. black iron pipe. Mixers are not

needed for either hot asphalt or asphalt emulsions. A typical hot asphaltgrout plant is shown in figure 21. Cement grouting equipment can be usedfor asphalt emulsions.

20. CHE MICAL GR OUTING EQUI PMENT. The equipment required for

chemical grouting will vary depending on the chemicals being used. Basi-tally this equipment consists of mixing tanks; variable speed, positive -

displacement-type pumps, control valves; and gages so that the proportion-

ing of chemicals can be closely controlled. Self-contained mobile units are

available that include all necessary components for the grout system. Gen-

erally, the se units have been developed by the grout manufacturer and are

designed for a specific chemical process. In any case, all grouting equip-

ment should be of a material that will not react with the chemicals being

used.

21. PL ANT L AYOUT .

a. Cement Grouting.

(1) Plants. The grout plant should consist of a mixer, agitator. sump,

pump and necessary valves, gages, and lines to control the operation. Standby

equipment may be required depending on the nature of the job. Cement grout

plants vary in size from compact systems that may be truck-mounted to

large automated systems that require dismantling for moving. Figures 22

and 23 illustrate the two extremes. In figure 22 both the single and return

line pumping systems are shown with locations of valves and gages. The re-

turn line system is often preferred where grout take is small because of (a) good pressure control with no waste, (b) reduction of grout-line clogging

59









due to sedimentation, and (c) maintenance of circulation with hole closed downIf the grout take is large, a single -line system may be preferred because of

its simplicity.

(2) Operation. The batch system is more satisfactory than continuous

mix. The necessary water for each batch should be run into the mixer and

the cement dumped in as needed. After mixing thoroughly, the batch of grout

should be dumped into the agitator for pumping, and the next batch started in

the mixer to prevent delays between batches. On slow holes or where only

small quantities of grout are injected at one time, one man may be able to

operate both mixer and pump. On some portable plants the pump and mixer

are mounted with control valves arranged so that one man can operate both

pieces of equipment. For large operations, batching systems may be set up

for automatic control with one operator.

b. Clay Grouting.

(1) Plant. Where processed clays such as commercial bentonites are

used as the grout material, the grout plant and operation are similar to those

used in cement grouting. When natural soils are used, the plant may have to

be modified to allow for processing the raw material. Where this is neces-sary, in addition to the basic plant as shown for cement grouting, a drying

63



shed, crusher or grinder, screening equipment, and premixer may be re-

quired. The grout lines and control system are the same as for cement

grouting.

(2) Operation. Normally the batching method is best suited to mixing

clay grouts. For processed clays such as bentonite, the operation is similar

to that for cement. For cement grouts containing bentonite, the cementshould be mixed with water before adding bentonite. When natural soils are

used, the raw material is delivered to the plant by truck, scraper, or con-

veyor and stockpiled under a storage shed if necessary. Where the grout de-sign requires predrying, the soil is spread and worked to facilitate drying.

Predrying may result in easier mixing, better dispersing, and better water

control in the grout. Moist clay will require vigorous mixing for complete

dispersion. The usual procedure is to crush or grind the raw soil and mix

the water to disperse the particles. The mix is then discharged on screening

equipment to remove lumps, foreign matter, and coarse material. The

screened slurry is then run into the mixer for the addition of admixtures or

into the sump for pumping to the holes.

c. Chemical Grouting. The equipment required and the assembly of achemical grout plant are dependent on the chemical system employed. Ade-

quate storage facilities for both dry and liquid components, mixing tools,

proportioning systems, pressure control, and flushing lines are required.When a commercially produced chemical system is used, the manufacturer’ s

recommendations for equipment and operations should be closely followed.

For projects using custom design chemical processes, the plant equipment

and operational procedures should be specified by the person or organization

designing the mix. In any case, extreme caution should be exercised at alltimes to protect workmen from dangerous chemicals and fumes. An ample

supply of water is required on all chemical grouting jobs. Figures 24 and 25show schematic layouts for typical plants used for one of the commercial

chemical grouts.

d. Asphalt Gr outing. The principal items of equipment required for

grouting with hot asphalt are heating tank, pump, supply lines, and gages in

suitable arrangement such as shown in figure 21. The pressure gage is pro-

tected from the asphalt by using a 1-in. nipple and pigtail siphon. The nipple

is filled with grease and the siphon with oil. In cold-weather operations, it

may be necessary to heat supply lines. One method is to insert a heavy, in-sulated iron wire in the grout line. One end of the wire is connected to thebottom of the supply line, and the other to a high-amperage, low-voltage gen-

erator, such as used in commercial welding machines. The machine isgrounded to the supply line to complete the circuit. Steam has also been usedfor heating lines, but has proved cumbersome and costly. When the asphalt is

pumped in the hole, steam will form if water is present in the hole. Some of the steam will be caught in the supply line , and provisions should be madefor bleeding if off to prevent it from blowing back into the heater. Extensive

64



65



precautions should be taken to protect workmen engaged in asphalt-grouting

operations. Gloves, goggles, and ointments for application on exposed skinshould be used by all grouting personnel.

66



TM 5-818-6/AFM 88-32

APPENDIX I

REFERENCES

GENERAL

ARMY, CORPS OF ENGINEERS PUBLICATIONS

Civil Works

1. Technical Letter 63-16 Foundation Pumping Tests.

4 Dec 1963.

Engineer Manuals

2. EM 385-1-1, 1 Mar 1967.

3. EM 1110-2-1906, 10 May 1 9 6 5 .

4. EM 1110-2-3501, Apr 1949.

EM 1110-2-3502, Apr 1948.

EM 1110-2-3503, 19 Aug 1963.

5. EM 1110-2- (in preparation).

Engineer Regulations

6. ER 1110-1-5, 21 Mar .1968.

Guide Specifications

Amendment 2, Ott 1964.

Reports

8. District, Omaha.

Report 1, J uly 1963.

General Safety Requirements.

Laboratory Soils Testing.

Foundation Grouting; Planning.

Foundation Grouting; Equipment.

Foundation Grouting; Field

Technique and Inspection.

Soil Sampling Manual.

Plant Pest Quarantined Areas.

Foundation Drilling and Grouting.

Report of Investigation of Chemical

Grouts for Rock Bonding;

Evaluation of the Effectiveness of

Epoxy Resin and Polyester Resinto Strengthen Fractured Granite at

Norad C.O.C.

67



TM

9.

10.

Report 2, Mar 1964.

Waterways Experiment Station,

Vicksburg, Miss., Aug 1949

(with quarterly supplements).

Waterways Experiment Station,

Vicksburg, Miss., Technical

Memorandum No. 3-408,

J une 1955.

Technical Manuals

11. TM 5-530/AF M 88-51,

24 Feb 1966.

12. TM 5-818-5/AFM 88-5,

Chap. 6 (in preparation).

U. S. DEPARTMENT OF DEFENSE

13. MIL -STD-619B, 6 NOV 1967.

U. S. DEPARTMENT OF THE

14. Bureau of Reclamation,

Denver, Colo., Technical

Memorandum No. 646

J uly 1953 (revised

J une 1957) pp 13, 14,

and 17.

Injection of Epoxy Resin to

Strengthen Fractured Granite

at Norad C.O.C.

Handbook for Concrete and Cement.

Grouting of Foundation Sands and

Gravels, by R. V. Lord, J r.

Materials Testing.

Dewatering and Groundwater Con-

trol for Deep Excavations.

Unified Soil Classification System

for Roads, Airfields, Embankments,

and Foundations.

INTERIOR PUBLICATIONS

Pressure Grouting.

NONGOVERNMENT PUBLICATIONS

15.

16.

American Society for Testing and Materials, ‘ ‘Specification for Portland

Cement, ” ASTM Specification C 150-68, 1968, Philadelphia, Pa.

Burwell, E . B., “Cement and Clay Grouting of Foundations: Practice of

the Corps of Engineer s,” ASCE, Soil Mechanics and Foundations Divi-

sion, J ournal t Vol 84, No. SM1, Paper 1551, Feb 1958.

68



17.

18.

19.

20.

21.

22.

23.

Elston, J . P., “Cement and Clay Grouting of Foundations: Suggested

Specifications for Pressure Grouting, ” ASCE, Soil Mechanics and

Foundations Division, J ournal, Vol 84, No. SM1, Paper 1548, Feb 1958.

King, J . C. and Bush, E. G. W., “Symposium on Grouting: Grouting of

Granular Materials ,“ ASCE, Soil Mechanics and Foundations Divisiont

J our nal z Vol 87, No. SM2, Paper 2791, Apr 1961, Part I , pp 1-32.

Leonard, G. K. and Grant, L. F., “Cement and Clay Grouting of Founda-

tions: Experience of TVA with Clay- Cement and Related Grouts ,“

ASCE, Soil Mechanics and Foundations Division, J ournalz Vol 84,

No. SM1, Paper 1552, Feb 1958.

Lippold, F. H., “Cement and Clay Grouting of Foundations: Pressure

Grouting with Packer s,” ASCE, Soil Mechanics and Foundations Divi-

sion, J ournal, Vol 84, No. SM1, Paper 1549, Feb 1958.

Mayers, A., “Modern Grouting Techniques, ” Grouts and Drilling Muds

in Engineering Practice, Butterworths, London, 1963, pp 7-9.

Simonds, A. W., “Cement and Clay Grouting of Foundations: Present

Status of Pressure Grouting Foundations, ” ASCE, Soil Mechanics and


Sowers, G. F. and Sally, H. L., Earth and Rockfill Dam Engineering

University of Roorkee, Asia Publishing House, India, 1962.

CEMENT-GROUT

ARMY, CORPS OF ENGINEERS PUBLICATIONS

24. Waterways Experi ment Station, Investigation of Shrinkage-Resistant

Vicksburg, Miss., Technical Grout Mixtures, by R. A. Bendinelli.

Report No. 6-607, Aug 1962.


25. “Bibliography on Cement Grouting; Second Progress Report, Committee

on Grouting, ” ASCE, Soil Mechanics and Foundations Division, J ournalt

Vol 89, No. SM4, Paper 3575, J uly 1963, pp 45-89.

26. C lark, B . E ., ‘ ‘Symposium on Grouting: Grouting at Fort Campbell

Theatre Building, ” ASCE, Soil Mechanics and Foundations Division, J ournal, Vol 87, No. SM2, Paper 2792, Apr 1961, Part 1, pp 33-42.

69



Kennedy, T. B., “Pressure Grouting Fi ne Fissures,” ASCE, Soil Me-

chanics and Foundations Division, J ournal, Vol 84, No. SM3, Paper 1731,Aug 1958.

“Symposium on Grouting: Research in Foundation Grout-ing with Cement," ASCE , Soil Mechanics and Foundations Division,

J ournal, Vol 87, No. SM2, Paper 2794, Apr 1961, Part I, pp 55-82.

Klein, A. and Polivka, M., “Cement and Clay Grouting of Foundations:

The Use of Admixtures in Cement Grouts, ” ASCE, Soil Mechanics and


Polatty, J . M., “Symposium on Grouting: Investigation of Sand- CementGrouts, ” ASCE, Soil Mechanics and Foundations Division, J ournal,

Vol 87, No. SM2, Paper 2795, Apr 1964, Part I, pp 83-93.

Swiger, W. F., "Symposium on Grouting: Construction of Rocky Reach

Grouted Cutoff, ” ASCE , Soil Mechanics-and Foundations Division,

J ournal, Vol 87, No. SM2, Paper 2796, Apr 1961, Part I, pp 95-123.

C L A Y


GROUT

32.

33.

34.

35.

36.

37.

70

Grant, L. F. and Schmidt, L. A., J r., ‘ ‘Grouting Deep Solution Channels

Under an Earth Fi ll Dam, ” ASCE, Soil Mechanics and Foundations Divi-

sion, J ournal, Vol 84, No. SM4, Paper 1813, Ott 1958.

Greenwood, D. A. and Raffle, J . R., “Formulation and Application of

Grouts Containing Clay, ” Grouts and Drilling Muds in EngineeringPractice, Butterworths. London, 1963, pp 127-130.

J ohnson, S. J ., “Cement and Clay Grouting of Foundations: Grouting

with Clay-Cement Grouts ,“ ASCE, Soil Mechanics and Foundations

Division, J ourna1, Vol 84, No. SM1, Paper 1545, Feb 1958.

Kravetz, G. A., ‘‘Cement and Clay Grouting of Foundations: The Use of

Clay in Pressure Grouting, ” ASCE, Soil Mechanics and Foundations

Division, J ournal, Vol 84, No. SM1, Paper 1546, Feb 1958.

Leonard, M. W. and Dempsey, J . A., “Clays for Clay Grouting, ” Grouts

and Drilling Muds in Engineering P racti ce, Butterworths, London, 1963,

pp 119-126.

Magnet Cove Barium Corp., “Mud Engineering, ” Houston, Tex.



— 38.

39.

CHEMICAL GROUT


42.

43.

44

45.

46.

47.

48.



72



APPENDIX II

SAMPLE GROUTING LOG

1. In the grouting log (fig. I I-1), the inspector has collected pertinent infor-

mation from the drilling and pressure testing records and knows that he isgoing to grout zone 4 of a primary hole, that the hole is inclined 25 deg from

the vertical, that the top of the zone to be grouted is 68 ft vertically below

the surface, that the hole was pressure-tested at the rate of 0.5 cfm at 10 psi,

and that the top of zone 4 is below the water table. From figure 4 (main

text), he finds that pressures exerted by grout columns of 2:1 and 1:1 grout

1 ft high are 0.61 and 0.73, respectively. Grout columns of these mixes 68 ft

high would exert pressures of about 42 and 49 psi. This means that if 1:1

grout is used, the maximum gage pressure should be 19 psi so that the total

pressure at the top of zone 4 will not exceed 68 psi (1 psi per foot of verti-

cal depth).

2. The inspector decides to start with 4:1 grout, although 3:1 grout would be

an acceptable starting mix considering the pressure-test results and the factthat all of zone 4 is below the water table. After the header is in place with

the valve to the hole closed and the valve on the return line open and the con-

tractor is ready to begin grouting, the inspector asks for a three-sack batch

of 4:1 grout. This should be enough to find out if the hole will take grout. (A

two -sack batch would make little more than enough to cover the suction in-

take to the pump and fill the pump and grout lines. ) A three -sack batch of 4:1 grout will make 13.5 cu ft since a sack of cement (94 lb) has a volume of

only O.5 cu ft when immersed in water. The volume of each batch mixed isentered under the heading ‘ ‘Grout, Cu Ft. ” Note that the first entry in thecolumn headed “Tank Reading” shows 12.0 cu ft of grout in the sump tank.

This reading is made after the grout has been circulated through the pump

and grout lines. The difference between 13.5 cu ft and 12.0 cu ft is the

amount of grout required to fill the pump and lines. After circulating the

grout and getting the tank reading, the inspector is ready to start grouting.

The valve to the hole is opened and the valve on the return line is closed as

required to divert grout into the hole at the pressure designated.

3. Pressure can be obtained as desired without completely closing the re-

turn line. The inspector asks that it be held to 10 psi while he determines

the rate of injection. He does this by measuring the amount of grout in the

tank after 5 min of pumping with a stick gage calibrated to read in cubic feet

for that particular tank. He finds that 9.5 cu ft of grout remain in the tank. ‘

Thus, 2.5 cu ft of grout were pumped into the hole during the first 5 min of

grouting, which gives a rate of 0.5 cfm. Usually the rate of injection, shown

in the seventh column on the sample log, is computed on batch quantities,assuming that the level of grout in the sump tank is the same each time a

new batch is discharged from the mixer. More frequent observations on the

73





rate of injection can be made, if desired, by using the stick gage to measure

the amount of grout pumped during any given time interval. The inspectormay want to check the rate just before changing mixes to be sure that the

last computed rate is continuing. Such observations may be recorded or not

as the inspector wishes. According to the log the hole accepted 4:1 grout

readily, so it is understandable that a thicker mix should be tried. The

thicker 3:1 grout increased the rate of cement injection, although not asmuch as shown for the first batch. The first batch of a thicker new mixdumped into the remnants of the old mix is diluted. In this case the 10.5 cu ft

of the 3:1 mix was diluted by about 6.0 cu ft of 4:1 mix remaining in the tank and circulating through the pump system. This dilution would give a mix of

about 3.3:1 and a cement-injection rate for the first batch of 12.7 cfm rather

than 13.8 as shown. The only time it is necessary to make this computation

is at the completion of grouting if the new mix has not been used long enough

to have its “as -mixed” proportions in the sump tank.

4. A delay of 2 min (1828-1830 hr) occurred as the result of a broken water-

line. The water for the batch of grout discharged at 1816 hr was in the

mixer when the line was broken, otherwise the delay would have been 12 min

longer, since the line was broken 6 min before the batch was needed. It isgood practice to charge the mixer with the water for the next batch imme-diately after discharging. This helps to keep the mixer clean and provides

a small supply of water for emergency use.

5. After a few batches of 3:1 grout, it appeared that the hole would accept

a thicker grout and the inspector changed the mix to 2:1 grout. The change

from 3:1 to 2:1 grout causes a much greater increase in the rate of cement

injection than changing from 4:1 to 3:1 grout. The inspector should carefully

observe the effect of a change to a thick or moderately thick grout on the

injection rate. In the case of the sample log there was some evidence of a

reduction in rate ‘after four batches. In reality it was not until the third

batch of 2:1 grout that the hole was actually receiving 2:1 grout because of

the diluting effect of the 3:1 grout left in the system when the 2:1 grout wasintroduced. The first evidence of a slowing rate of injection appeared in the

fifth batch of 2:1 grout, which was dumped into the sump tank at 1928 hr. De-

spite the increase in pressure, the injection rate was the same as for the

preceding batch with less pressure. It is probable that the inspector wasaware of this slowing and raised the pressure as a consequence of it. Therate continued to decrease even with the pressure at the maximum allowable

(26 psi on the gage and an additional 42 psi by weight of the grout column).

The average rate of injection for the last batch of 2:1 grout mixed (2005 hr)

was 0.5 cfm. It is probable that the rate at the end of the 24-min period of injection for this batch was about 0.3 cfm, although this was not recorded.

Thus, there was reason to think that one more batch of 2:1 grout would fin-

ish the hole. Therefore, the mix was thinned toward thethe grouting period and injecting additional cement. Theraised to compensate for the reduction of pressure from

end of prolonginggage pressure was

the lighter weight

75





APPENDIX III

NOTES FOR THE INSPECTOR

1. STICK GAGES. A stick gage calibrated in cubic feet to measure the vol-

ume of grout in an upright cylindrical tank can be made, if none is available

when the equipment is brought to the jobsite. Given: a tank 2-1/2 ft high

and 3 ft in diameter.

The height of the tank, 30 in., divided by 17.7 gives the depth of a cubic foot

of grout in the tank in inches. Each cubic foot of grout fills approximately

1.7 in. of the tank. The stick gage may be made from a piece of 1- by 2-in.

lumber. For ease in reading, the gage should be marked so that the correctreading for the amount of grout in the tank appears at the rim of the tank

when the tip of the stick touches the grout. If there was 9.0 cu ft of grout in

the tank described in the example, the mark for 9.0 cu ft would be 14.7 in.

above the bottom of the gage. The gage may also be prepared by metering

the water into the sump tank by the cubic foot and marking the gage appro-priately for each level. If the tank has an outside well for the pump suction

or a bulky agitator, this method of calibration is the most accurate.

2. THINNING OR THICKENING CEMENT GROUT.

a. The quickest way to change a given quantity of cement grout from one

mix to another is by using conversion tables or charts. However, the in-

spector should be able to make the necessary computations without hesita-

tion, if such tables or charts are not available.

b. The first step for controlled thinning or thickening of a given quantity

of grout is to determine the amount of cement it contains. This is done by

dividing the cubic feet of grout by the number of cubic feet of grout obtained

from a one-sack batch of that grout, keeping in mind that a sack of cement in

water has a volume of 0.5 cu ft. Examples: Find the number of sacks of ce-ment in 12.6 cu ft of 4:1 grout, 1.5:1 grout, and 0.75:1 grout. In the order

listed, 12.6 is divided by 4.5, by 2.0, and by 1.25, and the sacks of cement in

12.6 cu ft of grout for the three mixes in the same order are 2.8, 6.3, and

40.4.

c. To thin a grout add cubic feet of water equal in number to the number

of sacks of cement in the grout to be thinned multiplied by the difference be-

tween the figures representing the water in the water-cement ratios for thegrout on hand and the mix desired. Example: Find the cubic feet of water

necessary to thin 7.2 cu ft of 1:1 grout to 3:1 grout. The number of sacks of 1.5 or 4.8. The difference between

the figures representing the water in the water-cement ratios of the twomixes (3:1 and 1:1) is two. Two times 4.8 is 9.6. Therefore, 9.6 cu ft of

water must be added to 7.2 cu ft of 1:1 grout to have 3:1 grout.

77



d. To thicken a grout, the volume of the cement solids, in cubic feet

(one~half the number of sacks of cement in the grout) is subtracted from the

cubic feet of grout to obtain the volume of water in the grout. Enough cement

is added to have the desired water-cement ratio with this volume of water.

It is preferable to add only whole sacks of cement.

Examples:

e. Most chemical grouts are liquid grouts consisting of mixtures of liq-uids, and the consistency is usually not changed. The application and pene-

tration of these grouts depend upon the gel or setting time, which can be

regulated as required. As previously noted, chemical grouts vary widely in

their physical properties and should be used under close consultation with or

under the direction of personnel trained in the use of the particular chemi-

cals being used.

3. PRESSURE OF GROUT COLUMN. As in changing grout from one mix to

another, the quickest way to determine the pressure exerted by a column of

grout is by using a chart. In case a chart similar to figure 4 (main text) isnot at hand, the pressure in pounds per square inch exerted by a 1-ft column

of any grout can be found by dividing the weight of a cubic foot of the grout

by 144 (the number of square inches in a square foot). For portland-cement

grout with no fillers or admixtures , it is necessary to know that a cubic footof water weighs 62.4 lb and a sack of cement weighs 94 lb. Thus, for 2:1

grout a one-sack batch of grout contains 124.8 lb of water and 94 lb of ce-

ment for a total weight of 218.8 lb. Since a one-sack batch of 2:1 groutmakes 2.5 cu ft, 218.8 lb must be divided by 2.5 to obtain the weight of 1 cu ft

of the grout. Then 1 cu ft of 2:1 grout weighs 87.5 lb and exerts a pressure

78



batch of the grout and the volume of the batch must be known. The most cer-

tain way to determine the volume of a batch containing several ingredients is

by gaging the sump tank after a batch has been discharged.

4. CHECKING LOW-PRESSURE GAGES. Low-pressure gages should bechecked before each use when that use is to register pressures of less than

5 psi. It is necessary that gages used for the first stage of grouting in stagegrouting and the topmost stop in stop grouting be sensitive to pressures of

2 or 3 psi. The needle of a gage whose dial is marked to show pressures

less than 5 psi can be moved from the peg by lung pressure. This is a quick

check of gage sensitivity. Precise tests can be made as follows: A trans-

parent plastic tube several feet long that can be attached to a gage and filled

with water provides a means of an accurate check of low pressures. Eachvertical foot of water in the tube above the level of the gage exerts a pres-

sure of 0.43 psi. Thus, if the tube is held so that the water level is 5 ft

above the gage, the gage should read slightly more than 2 psi. A U-tube of

mercury can also be used to check low-pressure gages. One end of the open

U-tube is connected to the gage by a tube containing a valve for the injection.of air. Air pumped into the connecting tube causes the mercury to stand at

different levels in each arm of the U-tube. Each 2 in. of differential between

the mercury-column levels represents a pressure of approximately 1 psi. A

differential of 10.17 in. of mercury should register on the gage as 5 psi.

5. LIFTI NG CLUE S. When grout is injected at pressures greater than the

rock can withstand, the rock is lifted or heaved. Surface evidences of lifting

other than grout leaks are sometimes readily discernible, and where struc-

tures are involved damage may be substantial. When structures are presentgrouting should be accomplished without any lifting, and if lifting takes place

grouting should be stopped immediately. It is important, therefore, to rec-ognize signs or clues that lifting may be occurring. The inspector should

watch for changes in the behavior of the hole each time pressure is raised.After the initial rupture of the rock, it may be noted that the pump labors

less, the gage pressure may drop a few pounds, and the injection rate may

increase. All these signs may occur simultaneously. If lifting takes placeat a depth of several feet and is caused by cleaving of bedding planes, the

hole may have a relatively high back pressure. This is a result of the rock pushing back on the grout. It can be checked by closing the valve between the

grout line and the hole. The gage will then reflect the pressure of the grout

in the hole. If it is nearly the same as the injection pressure and does not

fall at a readily visible rate, it should suggest the possibility of lifting. If it

falls rapidly it is pump pressure that is dissipating. Unfortunately, these

signs and clues are not infallible. Some of the clues can be produced bygrouting at least one other subsurface condition. During the grouting of so-

lution channels or cavities compartmented by muck, a hole may show most of

the indications of lifting without having any lifting involved. If grout breaks

79





“pr essu r e” part of pressure grouting. Cement is composed of jagged rock-like particles of matter that are very abrasive without pressure. Under

pressure, cement grout can damage the skin or cause severe injury to the

eyes. It is important that grout pipes and hoses be in good condition and all

connections be properly made. If a grout line breaks while grouting at high

pressure, grout can be ejected many feet with great force. If necessary for

personnel to be exposed to cement dust, goggles should be worn to protect

the eyes. If the weather is windy and dust conditions are severe, exposed

portions of the skin should also be protected to avoid cement “burn.” Waste

grout should be discarded away from the work area as a good housekeeping

practice and to eliminate splashing hazards.



APPENDIX IV

RECORDS AND REPORTS

1. RE CORDS FOR PAYMENT. Records of quantities that are pay items

must be kept for meaningful administration of any contract. Of necessitythese records must be accurate, understandable, and sufficiently detailed

to justify their acceptance if at variance with data presented by the contrac-

tor. Details are very important for a drilling and grouting operation. As

grouting progresses it should be continuously evaluated. Records that mustbe kept of pay items should be expanded to log form so that decisions to

“spl i t-space” or split-space only to a certain horizon, to decrease or in-

crease grouting pressures, to use generally thinner or thicker mixes, or

to make any of the many decisions that may be required can be based on case

histories of operations at the jobsite. Therefore, in addition to listing quan-

tities, when, where, and how the quantities were obtained should also be re-

corded. After completion of the grouting, there is very l ittle surface evi-

dence to indicate the extent of grouting, and there is no way to determine

actual quantities if a running account is not available. A form listing all payitems should be prepared for submittal to the project office on a daily or

shift basis. All quantities listed on this form should be taken from the de-

tailed records kept by inspectors in field notebooks. Notebooks should be

turned in as they are filled for preservation as part of the permanent project

records.

a. Dr illing. It usually is not possible to have a full-time inspector as-

signed to each drilling unit on grout-hole drilling; but if more than one unit

is operating on the’ same shift, a full-time drilling inspector should be

present. In any case the drilling should be inspected several times eachshift to obtain needed data and ensure compliance with the specifications.

The inspector should be available for the start of each new hole and at the

completion of any hole, zone, or stage. If the holes are inclined, he must

make sure that each new hole is started at the correct inclination and in the

right direction. He must make certain that all cuttings are washed out of the hole at the completion of drilling and that the hole is then properly cap-

ped or plugged. For the records he must have hole number, location, ele-

vation, size, inclination data, driller’s name, and the feet drilled for each

hole in which work was done on any date or shift. If pipe, zone, and size of

hole are pay items, quantities for each must be recorded. The recordsshould also show water losses and approximate formation contacts as de-

termined by the driller, if no core is recovered. The hole number and its

location, elevation, and inclination should be shown at the top of a page in a

field notebook. It is preferable to have only one hole to a page, but all in-

formation on that hole may be kept on the page if properly dated. The note-book should be available to the grouting inspector.

82



b. Pressure Testing and Pressure Washing. The pressure-test and

pressure-washing records should show the hole number, location, elevation,

depth of hole, zone, stage or packer setting as appropriate, and the starting

and completion times of all testing and washing. The rate and pressure at

which water is injected must be shown. If water vents from other holes

their numbers and locations should be given. If connecting to a hole is a pay

item and more than one connection per test is made, all the circumstances

involved should be entered in the record. Information on the water table

should be included in the pressure-test book or in the drilling records or

both. A separate notebook should be used to record all pressure-test and

pressure-washing data, and it also should be available to the grouting

inspector.

c. Grouting. The grouting record should be more elaborate than the

other records described because grouting is a more complicated operation

and the grouting log not only serves as a record of the pay quantities, but be-

cause it also is the only detailed record of the grouting treatment in exist-

ence. The interpretation of the grouting logs may have a major bearing on

decisions for further treatment either during or after construction. The log

of grouting operations must contain the hole number, location, elevation, dataon inclination, position in the order of grouting (primary, first intermedi-ate, etc.), information on the portion of hole being grouted (depths and/our

elevations, and stage or zones), and the date and shift the work was done.

The log should show the starting and completion times, the time mixes were

changed, the time water was injected, and the time of delays and the reasons

therefor. Pressures, injection rates, location of leaks, and any other infor-

mation pertinent to the understanding of the operation should be given. The

pay quantities of all ingredients should be shown clearly. If payment is by a

volume or weight unit for both placing and furnishing the ingredients, eachunit placed is also a unit furnished and must be paid for under both items.

If leftover grout from the last batch mixed for any hole is carried forward to

the next hole, it should be accounted for in the log for the new hole. Leftover

grout that is allowable waste as a result of cessation of grouting operationsis paid only under the item or items for furnishing ingredients., since it was

not placed. There are many acceptable forms for grouting logs. The sample

log in appendix II is one of several forms of grouting logs that have been

used for portland-cement grouting. It illustrates how an accurate accounting

of all grout mixed can be made. The record of each batch of grout and its

rate of injection provides detail that is insurance against miscounting batchesand provides data that can be readily scanned for indications of abnormalities

such as lifting. It also permits a supervisor to second guess the inspector

and to evaluate his judgment.

2. RECORDS FOR FUTURE REFERENCE. In addition to records that must

be kept to administer the contract, records should be kept for future refer-

ence. The field notebooks are the basic “as-built” records. However, other

summary- type records are also desirable. If quantities are summarized by

83



tables, drawings locating all holes should accompany the tables. For a grout

curtain, a geologic section through the grout holes is the best presentation.

Holes may be represented by single lines with grout takes shown by zones in

volume of cement and/or other materials. Primary and intermediate holes

should be distinguished. Pressures, mixes, and setting times should be

shown with the holes or in notes. For blanket grouting, mine filling, or con-

tact grouting, a plan view of the grouted area showing hole locations andother pertinent data, as listed above, is usually the best way to show the

grouting. Work sheets similar to such drawings, if kept up to date, are very

useful in evaluating the grouting effort as work progresses and serve as a

base for the “as-built” drawings.

84



APPENDIX V

P A Y M E N T

1. ESTIMATES. The quantities involved in any dri lling and grouting opera-

tion are rarely susceptible to accurate estimating. The estimates needed forbidding purposes should be the best approximations possible, but should not

be considered more than that. The specifications should make provisions for

increasing or decreasing quantities and for eliminating items as warranted

during progress of work under the contract. Often-used bid items are dis-

cussed in the following paragraphs.

2. BID ITEMS AND UNITS OF PAYMENT.

a. Mobilization and Demobilization. This is a lump sum item and is

compensation for assembling all necessary drilling and grouting equipment

on the site and removing it therefrom. Payment for this item does not de-

pend upon the amount of drilling and grouting done. Provisions may be made

for partial payment to the contractor after mobilizing the equipment and forpayment of the remainder of the item when the work is completed and theequipment removed from the jobsite.

b. Drilling. A bid item should be prepared for each type of drilling re-

quired, i.e., grout-hole drilling, drilling exploratory holes for core recovery,

dril ling hardened grout, etc. If more than one size of hole is required, sepa-

rate items are needed for each size. If unusually deep holes are planned for

a part of the job, a separate pay item should be added for this. If stagegrouting is done, it may be desirable to provide separate items for each zone

of dri lling. If part of the holes are vertical and part inclined, separate pay

items should be made for each. The size of grout holes and the type of drill-

ing equipment may be left to the option of the contractor if a particular size

is not needed. Adequate control of size for grouting purposes can be main-

tained by specifying that the hole shall be large enough to permit use of

packers with grout openings of a specified minimum size. The plans and

specifications should indicate clearly the location and extent of the work to

be done and should show limiting depths and inclinations of all holes. The

responsibility of the contractor for cleaning cuttings and sludge out of groutholes after drilling and for keeping them clean and free from surface pollut-

ants until grouted should be cited. Payment is made by the linear foot of hole

drilled. Water and air required for drilling and grouting or any auxiliary

operation are not separate pay items. The contractor is expected to re-

cover the cost of furnishing both air and water under one or more of the

designated pay items.

c. Pipe. Pipe and fittings for use as nipples in grout holes or other use

that–results in permanent embedment should be paid by the pound.

85



d. Pressure Testing and Pressure Washing. This item is usually paidfor by the hour and includes only pumping or injection time measured to

the nearest minute.

e. Furnishing Ingredients for Grout. A separate bid item should be pro-

vided for each ingredient used in the grout (except water). Solids are usually

measured for payment by the cubic foot or pound, liquids by the cubic foot or

gallon. For cement grouting a sack of cement is considered as 1 cu ft. All

costs involved in purchasing, handling, transporting, and storing the ingre-

dient as necessary to have it available at the grout plant when needed areincluded in this item.

f. Connections to Grout Holes. A pay item for connecting the groutlines and header to the hole or packer is often included. Each connection,

as discussed below, is consider-ed a unit for payment purposes. The pur-

pose of this item is to compensate the contractor for time and labor re-

quired to move the grout lines from one hole to another as needed to begin

injection in a new location. Whenever such moves and connections are madein pressure testing or pressure washing, similar payment should be made.

Moving a packer in a hole does not require any relocation of the grout lines;therefore, successive sets in the same hole do not require separate pay-

ments under this item,

g. Placing Gr out. Payment for placing grout comprises compensation

for all mixing, pumping, and cleanup costs. Payment can be made either by

the cubic foot or other appropriate unit of measurement for each ingredient

in the grout, except water, or payment can be made by the hour for pumping

time as in pressure testing. If payment is by volume or weight, a separate

item should be used for each ingredient. Payment by the hour provides for

easy inclusion of periods of ordered short delays. These can be paid for at

a specified percentage of the hourly rate for pumping. Ordered long delays

of indefinite duration should not be included in this item since the contractor

can continue operations at another location during these periods. If thestage- grouting method is to be required, cleaning grout out of holes before

it takes a hard set should be a part of this item.

86





Research Journal of Applied Sciences, Engineering and Technology 5(19): 4727-4732, 2013

ISSN: 2040-7459; e-ISSN: 2040-7467

© Maxwell Scientific Organization, 2013

Submitted: September 27, 2012 Accepted: December 11, 2012 Published: May 10, 2013

Corresponding Author: Van Loc Nguyen, College of Construction Engineering, Jilin University, Changchun 130026, China

4727

Method Cement Post-grouting to Increase the Load Capacity for Bored Pile

Van Loc Nguyen, Lei Nie and Min Zhang

College of Construction Engineering, Jilin, Changchun 130026, China

Abstract: Drilled shafts foundations are used as an indispensable solution for long span bridges in Vietnam. In

order to increase the bearing capacity, aside from the increasing of the pile length and diameter, an interested way

now is treatment of pile bases after concrete placement. This study is aimed at investigating the defect at the bottom

of the bored pile from the sonic test. The injection of hight pressure of cement grout to the shaft and tip of the

defected bored pile was conducted to increase the bearing capacity of pile. The bearing capacity of defected bored

pile is calculated by the TCXD-205:1998 an finite element mothod. After post-grouting technique done, the soil

investigation tests have been carried out to define the properties of treated soils. The analytic mothod, finite element

method an load test also have been applied to determine the bearing capacity of treated bored pile. The results show

that the post-grouting to the shaft and tip of pile can increase two times of bearing capacity of defected bored pile

and about 20% compared to the normal bored pile.

Keywords: Bored pile, load capacity, post-grouting

INTRODUCTION

Nowadays construction demand is increasing, sothe application of new technologies, including theconstruction of bored pile technology is an inevitabledevelopment to the construction industry. Bored piletechnology is a ground stablization measures to handlevery high efficiency but great price. To reduce the costof the pile is a big problem not only for researchers but

also for designers, contractors and consultantssupervision. So it is necessary to find a measure toincrease the load capacity of the pile and reduce thenumber of pile. Axial load capacity in the land of the

bored pile is the sum toe resistance of pile and loadcapacity around of pile. Normally, component the toeresistance of pile only be mobilized at a very low level.According to some experimental research, the bearingcapacity around of bored pile can reach the maximumvalue at about 0.5-1% of the diameter D of thesettlement, while the load capacity of bored pile only bemobilized fully reaching 10-15% of the diameter D ofthe settlement. The reason is that in the process ofconstruction the ground under the bottom of the pile isdisturbed so it needs a large settlement to mobilize thetoe resistance of pile. Further more thick humusdeposited at the bottom of the pile tip also contributedto this problem. This greatly reduces the bearingcapacity of bored pile. The bottom deposit processing

plays an important role in improving the bearingcapacity of bored pile. In the world, the research intothe technologies of handling cleaning the pile bottomand grouting bored pile bottom has been interested andapplied in many countries for along time (such as

China, Taiwan. Thailand, etc.). The bored pile bottomcan be handled by different methods, including Post-Grouting technology, it has many advantages and has

been applied in many countries in the world. TCXD205-1998 gives the Pile foundation - Design standards(build pubisher, Vietnam) (In Vietnamese). TCVN4787:2001 shows the cement methods of taking and

preparing samples. Do et al. (2004) have a research ofthe bottom of the bored piles treatment technology,

collection of scientific reports science and technologyconference of transport 1999-2004.

TCXDVN 269-2002 study the static compression

test experiments method (build pubisher, vietnam)

institute of science and technology transport : report

results of static compression statement bored piles.

Dapp et al. (2010) study the pos grouting drilled saft

tips principal investigator. Many research results show

that Post-Grouting technology is an effectively

technology to handle bored pile bottom, requirements

for construction equipment are quite simple and

construction process as well as quality control is not too

complicated. However it needs to continue to conduct

experiments to evaluate the increase load capacity ofthe pile bottom, due to the grouting to the soils as well

as specific pressure pump, in order to improve the

method of calculating the load capacity of pile handled

by this technology. The application of pressure cement

grouting solution to increase the load capacity of bored

pile of 27 Lang Ha Condominium works is presented in

this study.

In order to increase the bearing capacity, asidefrom the increasing of the pile length and diameter, an



Res. J. Appl. Sci. Eng. Technol., 5(19): 4727-4732, 2013

4728

interested way now is treatment of pile bases afterconcrete placement. This study is aimed at investigatingthe defect at the bottom of the bored pile from the sonictest. The injection of hight pressure of cement grout tothe shaft and tip of the defected bored pile wasconducted to increase the bearing capacity of pile. The

bearing capacity of defected bored pile is calculated bythe TCXD 205:1998 a finite element mothod. After

post-grouting technique done, the soil investigationtests have been carried out to define the properties oftreated soils. The analytic mothod, finite elementmethod a load test also have been applied to determinethe bearing capacity of treated bored pile. The resultsshow that the post – grouting to the shaft and tip of pilecan increase two times of bearing capacity of defected

bored pile and about 20% compared to the normal bored pile.

THE CEMENT POST-GROUTING

TECHNOLOGY INCREASING LOADCAPACITY BORED PILE

Cement post-grouting technology is put a mixtureof liquid grout into pores soil to strengthen the stabilityand increase load capacity. The grout liquid is cementgrout, (mixture of cement and water), cement-soil grout(mixture of cement, soil, water), bentonite grout(mixture of bentonite and water). Cement grout iswidely used and with water- cement ratio from 1/10 to2/1. Cement grout (mixture of cement and water) wasused in this construction.

The parameters of the cement spouting grout for

post-grouting design: The main parameters of thespouting grout correspond to that criteria are

standardized to evaluate and increase spouting grout

quality include:

The density of grout: The optimized density groutdepends on vibrations of grout at about 1.15-1.30T/m3

and is determined by the hydrometer.

Degree of viscosity: Determining the kinematic

viscosity at work by using the 0.5 L conical hopperaccording to the European standard EN445, the

standard of 0.5 L of grout flow speed is about 10-20

seconds, the maximum speed is 25 sec. The viscosity ofwater flow speed is approximately 13 sec.

Degree of water split: Is the ratio of the deposition of

sediment mixture in static conditions after 1-3 h.

Measurement method is pouring amount of grout into a

glass bottle with carved bar length, for about 1-3 h,measure the height grout material deposited under

water (h) and the total height of the grout+water ( H).

The maximum acceptable water split index (H-h)/H is

about 3% to 5%. The water absorption index is theability to split water after 2 h.

Intensity and setting period time: Grout blocks are

gradually agglomerated after at least 3 days and

increased intensity to maximum stable status after about

15-30 days. After a certain number of days, grout block

will be drilled to obtain grout bar for intensity testing.

Minimum grout intensity after 7 days is about 0.25-0.4

kG/cm2.

Selecting the appropriate spouting grout is the first

step in the design of spouting grout technology, based

on the density mass of grout in the ability to penetrate

the grout; it mainly depends on the concentration of

grout.

The mixture concentration of water and cement is

determined:

)(

)(/

swc

csw

r r r

r r r C W

−

−=

where,W/C : The concentration of water and cement

r w : The proportion of water

r s : The proportion of mixture

r c : Mass density of cement

The density of cement block is determined:

w

c

r

C W r f

)/(1

1

+

=

(2)

Theory and the fact show that the ratio W/C =

0.67-: -0.7 corresponding 30% density of cement block,

that is optimal concentration, optimal feature and the

best filled feature grout.

Post-grouting process is performed by the following

stages:

• Constructing bored pile with the nowadays

commonly used technology is grout spouting

technology

o Attached to the steel cage at least 2 bottom sealed

steel pipe D90, symmetry through the center, along

the length of the pile, 10-20cm distance from the

bottom of pile

o

The bottom of the pile spouting grout structure;

after installing steel cages conducting concrete

bored piles

• Drilling the bottom hole of two D90 steel pipes to

soil under the pile tip

• Pumping high pressure water with 80-200 bar to

wash bottom of the pile until the ejected water is as

fresh as pumped water (Fig. 1)

Step post grouting to reinforced the bottom of pile

(Fig. 2)






4730

Fig. 3: Pile simulated was 3D in finite element

Fig. 4: The settlement S = 33.65x10-3m with applied load was14750kN

0.00

-0.05

-0.10

-0.15

-0.20

0% 10% 20% 30%40% 50% 60% 70% 80% 90% 100%

S e t t l e m e n t S ( m )

Pile without pos t grouting

Applied load P

Fig. 5: Applied load-settlement relation pile

With applied load was 14750 kN (by 2 times as appliedload designed) the settlement of pile was 33.65×10-3mand when applied load was 7375kN (as applied loaddesigned), the settlement of pile was 11.91×10-3m.

CALULATING THE LOAD CAPACITY OFPILES AFTER POST-GROUTING

Analytic method: After post-grouting, drill to conductgeological survey and determine the land parameters in

processing areas. After high pressure grouting thecohesion of the soil layer reach C ' = 80kN/m2.

The toe resistance of pile Qp after post-grouting:

• The load capacity unit of the bottom of pile without

grouting, q (% diameter), which must be specified

in any settlement, this value will be fully mobilized

(typically 5% D):

q (% diameter) = Qp/5 = 2712.9 / 5 = 542.5kN

• With given diameter of pile, extreme load bearing

capacity around of pile Qs for the whole depth of

pile: Qs = 4662.3kN

• The largest settlement allowed as a percentage of

the pile diameter: S = 33.65×10-3 m = 22% D

•

Divide extreme load bearing capacity around of pile to pile cross-sectional area to determine the

maximum pressure the pile can withstand when

grout spouted:

Pmax = Qs / A = 4662.3/1.77 = 2634kN/m2 (4)

• Grout pressure index (GPI) (The maximum grout

pressure index and the load capacity of bottom pile

unit without grout spouted):

GPI = Pmax/P (%diameter) = 2634/542.5 = 4.9 (5)

•

Tip Capacity Mulyiplier (TCM) based on the grout pressure index with the appropriate values m and b

taken according to soil conditions with the

designed settlement and allowed settlement of the pile bottom

TCM = m (GPI) +b =1.27×4.9+0.63 = 6.853 (6)

The according to standard m = 1.27; b = 0.63

• The grout spouted, toe resistance of pile unit is the

product of tip capacity mulyiplier and the loadcapacity unit of the bottom of pile without

grouting.

Q phun = (TCM)*q (%diam) = 6.853×542.5

= 3717.7kN (7)

So after post-grouting the pile bottom, the toe

resistance of pile Qp reached

Qp = Q phun 3717.7kN.

After spouting grout the pile's surrounding soil

considered as soil block with parameters cohesion C'=

80kN/m2 and the load capacity around Qs after post-

grouting was Qs = 5226.9kN




4731

Table 2: Load capacity of pile (kN)

Test method

Normal pile------------------------------------------------------------

Pile after post grouting-------------------------------------------------------------------

Applied load P (kN) Settlement S (mm) Applied load P (kN) Settlement S (mm)

Finite Element method 7375 11.91 7375 14

14750 33.65 14750 38.5Static compression test experiments method 7345 16.4

14750 35.6

Table 3: Pile load capacity allows (kN)

Type of pile Normal pile Pile after post grouting Static compression pile after post grouting

Pile load capacity allows (kN) 7375 8944.6 8933.3

Fig. 6: The settlement S = 38.5x10-3m with applied load was14750kN

Fig. 7: Applied load-settlement relation pile

The allowed load capacity of pile after post-

grouting: Qa = Qs + Qp = 5226.9 +3717.7 = 8944.6

(kN).It shown that: After post-grouting to processe pile

and pile bottom the load capacity increase 20% (Qa =

8944.6-7375.3 = 1569.3 = 20% Qa) compared with the

load capacity of the original designed pile.

Finite element method: From the experimental actual

data using Plaxis 3D Foundation software pile

simulated the pile that the bottom land processed by

cement post-grouting to analyze the bearing capacity of

pile. Pile simulated was 3D in finite element is shown

as:

Fig. 8: The results static compression test experiments methodof pile after post grouting

Fig. 3. The settlement result of the pile is shown in

Fig. 6. Since that charting the relationship between the

applied load and the settlement of the pile after

processed in Fig. 7. With applied load was 14750KN

(by 2 times as applied load designed), the pilesettlemeted 38.5×10-3m and the applied load was

7375kN (as applied load designed), the pile

settlemented 14×10-3m.

The results shown in the table Table 2.

Static compression test experiments method: After

finishing pile tip post grouting conducted the static

compression site experiments according TCXDVN

269-2002. The results are shown in Fig. 8 about the

relation of settlement and applied load. The largest

applied load obtained 14750 kN corresponding to two

times as applied load designed. From the graph (Fig. 8)

the allowed load capacity determined Qa = 13400/1.5 =8933.3kN (safety equal to 1.5). The result of the normal

piles load capacity and the load capacity piles after

processed by cement post grouting with the different

calculation methods and site experiments are

summarized in Table 2. And the allowed load capacity

of piles is presented in Table 3.

CONCLUSION

The following conclusions are based on the

research results:

0.000

-0.010

-0.020

-0.030

-0.040

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

SettlementS

(m)

Pile without post grouting

Applied load P

-0.005

-0.015

-0.025

-0.035

00

SettlementS(m)

Applied load-settlement relation pile

Applied load P (kN)

10

20

30

40

50

1 0 0

2 0 0

3 0 0

4 0 0

5 0 0

6 0 0

7 0 0

8 0 0

9 0 0

1 0 0 0

1 1 0 0

1 2 0 0

1 3 0 0

1 4 0 0

1 5 0 0

Chu ky 1

Chu ky 2



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