GROUTING749501_A4-P________1.0_EN

Atox mill grouting Procedure for foundation parts

Approved date: 21-Dec-2009 Created by: BGR Approved by: RH

Doc. No.

749501-1.0

Atox mill grouting procedure for foundation parts 749501-1.0

Atox mill grouting procedure for foundation parts: The importance of establishing a good foundation for the mill cannot be over stressed. Poor grouting will cause problems when the mill is operating. It is strongly recommended that a representative from the grout manufacturer be present so as to ensure the grout is correctly mixed and poured. The grouting procedure for the ATOX Mill is of cementitious. The cementitious grout surrounds and fills the large areas in the foundation.

WARNING

Failures of machine components have occurred because of improper grout specification. Voids that occur due to shrinkage of grout or incorrect installation techniques of grout will not adequately support the machine. The purpose of the grout is to ensure that the machine and foundation concrete mass act together as one mass in order to dampen vibrations. This can only be achieved if there is intimate contact between the grout and the machine; as well as intimate contact between the grout and the concrete. Master Builders or other competent grout specialists must be hired to supervise the installation including preparation of concrete; selection of grout material, tools and equipment; mixing; placement; and curing. If grout installation is not proper, repairs to the machine and to the grout will be absolutely necessary and will be very expensive.

1.1 General sequence of foundation work 1. Preparation of concrete foundation and equipment. 2. Installation of equipment and anchor bolts. 3. Alignment of Gear & motor bases, hydraulic cylinder mounting brackets and mill Housing, Make sure that the surfaces of the equipment are free from oil, grease, paint etc. 4. Cementitious grout with non shrink for anchor bolts. 5. Time delay for grout cure. 6. Final alignment of all base frames and housing 7. Complete cementitious grout for all base frames and mill housing. 8. Time delay for grout cure. 9. Paint the grout and concrete.

1.2 Concrete preparation: Independent of the grouting method used, the base concrete should be poured with a rough surface and water cured. Before placing the mill base frames in place, all lattice and weak concrete must be removed. If the base concrete was cast smooth, bush, hammer or chip the surface to leave a sound, clean rough surface. (A continuously rough surface will develop the full shear strength of the concrete under the grout). During the installation of the frame, care must be taken to avoid oil and grease spillage. The concrete surface must be re cleaned and saturated with water for 24 hours just prior to pouring the grout material. Remove free water from the concrete just before starting the grout pouring.

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The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

Atox mill grouting procedure for foundation parts 749501-1.0

1.3 Pocket grouting for anchor bolts: The anchor bolts are grouted into pockets in the concrete. The bolts must be degreased and be absolutely free from oil and paint. Place the mill housing and all base frames with anchor bolts. The top of the anchor bolt must be extended a certain distance above the top of the steel member being bolted down. This distance is specified on the drawings. Cover the anchor bolt top portion, only as indicated on the installation drawings, with duct tape or tubular urethane foam to prevent the anchor bolt from bonding to the cementitious grout. The duct tape or tubular urethane foam, properly installed on the anchor bolt, will allow the anchor bolt to stretch whentotensioned. After allthen baseuse frames housing are aligned and levelled in close proximity the final position, non and shrink cementitious grout to grout all the anchor bolts of base frames and mill housing. Allow at least 7 days for the grout to cure before tensioning all the anchor bolts. Agitation straps should be used to level the grout as it is poured, and to remove air from under the flanges.

1.4 Foundation preparation for final grouting Preparation of foundation: Concrete support structure for ATOX Mill, main gear units, and other heavy machinery must be executed with an appropriate surface reinforcement, however, as a minimum 7 kg/m2. When determining the reinforcement, account must be taken of the influences from the equipment, including temperature loads by connecting with frame and supporting beams by means of a cross reinforcement. The lateral face reinforcement of the concrete support must be carried to level where it covers the construction joint between the first pour and grouting which is executed after the equipment has been mounted In order to grout the layer between the upper most beams of the frame, a wall (shuttering) must be placed on either side of the centre section of the frame. This may e.g. take the form of a 3 mm plate which is tack welded to the stiffening ribs of the beams, a plate which remains inserted, or a wooden shuttering which leaves a smooth surface when it is removed.

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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Atox mill grouting procedure for foundation parts 749501-1.0

1. 2. 3. 4. 5.

Grout the holding down bolts here after coarse alignment of the equipment. Do not forget wedges or shims on either side of the bolt. Bend down the side face reinforcement. Spot welding to all frames / housing. Support height specified on drawings.

1.5 Final grouting: Having finally aligned tightened the anchor bolts to the specified torque valuethe andequipment then groutand or embed the up equipment. Concrete used for the execution of support structures must have a 3-day cube Strength σT ≥ 30 MN/m2, corresponding to 3-day cylinder strength of σC ≥ 25 MN/m2. The compressive strength per ASTM C-109 must be around 7,000 psi, fluid consistency. When proportioning mortar and concrete, use correctly graduated additives having an adequate maximum stone size to ensure good placement properties. It may be required to use special grouting mortars for particular applications. Prior to grouting or embedment of the equipment, the parts to be grouted and embedded must be degreased and cleaned. Remove (chip off) any oil spillage, grease stains and impurities on the concrete in the construction joint. Embed the support flange only if it is shown on the drawings or required in the instruction manuals. The lateral face reinforcement of the concrete support must be carried to level where it covers the construction joint between the first pour and grouting which is executed after the equipment has been mounted.

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The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

Atox mill grouting procedure for foundation parts 749501-1.0

The grout material should be poured outward from under the top plate of the bedplate for gear. It is extremely important that no voids exist under or around the flanges. The outer edge of grout will have to be troweled with a slope from bottom corner of the top plate to the top of the concrete. The inner area of the gear frame should be filled with grout to within 1520 mm of the top of the plate. The grout should be covered with wet rags or burlap until troweled smooth. Finally after the completed installation of mill section paint the foundation with epoxy paint to avoid oil seepage in to the foundation in case any oil spillage during maintenance. --------O---------

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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