STS03601(Epoxy grout specification)

COMPLETE REVISION October 2001

Process Industry Practices Structural

PIP STS03601 Epoxy Grout Specification

PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES In an effort to minimize the cost of process industry facilities, this Practice has been prepared from the technical requirements in the existing standards of major industrial users, contractors, or standards organizations. By harmonizing these technical requirements into a single set of Practices, administrative, application, and engineering costs to both the purchaser and the manufacturer should be reduced. While this Practice is expected to incorporate the majority of requirements of most users, individual applications may involve requirements that will be appended to and take precedence over this Practice. Determinations concerning fitness for purpose and particular matters or application of the Practice to particular project or engineering situations should not be made solely on information contained in these materials. The use of trade names from time to time should not be viewed as an expression of preference but rather recognized as normal usage in the trade. Other brands having the same specifications are equally correct and may be substituted for those named. All Practices or guidelines are intended to be consistent with applicable laws and regulations including OSHA requirements. To the extent these Practices or guidelines should conflict with OSHA or other applicable laws or regulations, such laws or regulations must be followed. Consult an appropriate professional before applying or acting on any material contained in or suggested by the Practice.

This Practice is subject to revision at any time by the responsible Function Team and will be reviewed every 5 years. This Practice will be revised, reaffirmed, or withdrawn. Information on whether this Practice has been revised may be found at www.pip.org.

© Process Industry Practices (PIP), Construction Industry Institute, The University of Texas at Austin, 3925 West Braker Lane (R4500), Austin, Texas 78759. PIP member companies and subscribers may copy this Practice for their internal use. Changes, overlays, addenda, or modifications of any kind are not permitted within any PIP Practice without the express written authorization of PIP.

PRINTING HISTORY November 1996 Issued October 2001 Complete Revision Not printed with State funds

COMPLETE REVISION October 2001

Process Industry Practices Structural

PIP STS03601 Epoxy Grout Specification Table of Contents 1. Introduction .................................. 2 1.1 Purpose ............................................. 2 1.2 Scope................................................. 2

2. References ................................... 2 2.1 Process Industry Practices ................ 2 2.2 Industrial Codes and Standards ........ 2 2.3 Government Regulations ................... 3

3. Definitions .................................... 3 4. General ......................................... 3 4.1 Field Quality Control of Epoxy Grout ....................................... 3 4.2 Testing ............................................... 4 4.3 Submittals .......................................... 4 4.4 Safety................................................. 4

5. Products ....................................... 4 5.1 Materials ............................................ 4

6. Execution...................................... 5 6.1 6.2 6.3 6.4

Application ......................................... 5 Preparation ........................................ 5 Installation of Epoxy Grout................. 6 Disposal ............................................. 7

Process Industry Practices

Page 1 of 7

PIP STS03601 Epoxy Grout Specification

1.

COMPLETE REVISION October 2001

Introduction 1.1

Purpose This Practice provides the contractor with a specification for supply and installation of epoxy grout for machine baseplates and soleplates.

1.2

Scope The contractor shall furnish all equipment, materials, labor, and supervision and shall perform all operations necessary for the foundation surface preparation, formwork, proper mixing, placing, finishing, and curing of epoxy grout, where indicated by the contract documents. Any conflicts or inconsistencies between this Practice, the design drawings, the epoxy grout manufacturer’s specifications and recommendations, the machine or equipment manufacturer’s recommendations, or other contract documents shall be brought to the attention of the buyer for resolution before the performance of work. The following items are referenced within this Practice but are to be completed by others:

2.

•

Installing and leveling equipment or machine soleplates and baseplates

•

Aligning equipment and machinery

References When adopted in this Practice or in the contract documents, the latest edition of the following codes, standards, specifications, and references in effect on the date of contract award shall be used, except as otherwise specified. Short titles will be used herein when appropriate. 2.1

Process Industry Practices (PIP) − PIP STS03001 - Plain and Reinforced Concrete − PIP REIE686 - Recommended Practices for Machinery Installation and Installation Design

2.2

Industrial Codes and Standards • American Petroleum Institute − API 610, Appendix L - Baseplate and Soleplate Grouting • American Standard Testing Methods (ASTM) − ASTM C531 - Standard Test Method for Linear Shrinkage and Coefficient of Thermal Expansion of Chemical-Resistant Mortars, Grouts, Monolithic Surfacings, and Polymer Concretes − ASTM C579 - Standard Test Method for Compressive Strength of ChemicalResistant Mortars, Grouts, Monolithic Surfacings and Polymer Concretes

Page 2 of 7

Process Industry Practices

COMPLETE REVISION

PIP STS03601 Epoxy Grout Specification

October 2001

− ASTM C882 - Standard Test Method for Bond Strength of Epoxy-Resin Systems Used with Concrete by Slant Shear − ASTM C1181 - Standard Test Methods for Compressive Creep of ChemicalResistant Polymer Machinery Grouts 2.3

Government Regulations Federal Standards and Instructions of the Occupational Safety and Health Administration (OSHA), including any additional requirements by state or local agencies that have jurisdiction where the epoxy grout is to be installed, shall apply, including the following: − Code of Federal Regulations, OSHA Part 1910 and Part 1926

3.

Definitions buyer: The party who awards the contract to the contractor. The buyer may be the owner or the owner’s authorized agent. buyer’s inspector: The authorized representative of the buyer with authority to act in the interest of, and on behalf of, the buyer in all quality assurance matters contractor: The party responsible for the supply and installation of the epoxy grout. Unless otherwise noted, the term contractor shall apply also to the contractor’s subcontractor(s) and/or vendors. contract documents: Any and all documents, including design drawings, that the buyer has transmitted or otherwise communicated, either by incorporation or by reference, and made part of the legal contract agreement or purchase order agreement between the buyer and the contractor manufacturer: The party that produces and warrants the performance of the product

4.

General 4.1

Field Quality Control of Epoxy Grout 4.1.1

The contractor shall be solely responsible for the quality control of all contractor-supplied materials, installations, and workmanship, including those items or installations supplied by any of the contractor’s subcontractors or vendors.

4.1.2

Notwithstanding the contractor’s responsibility for quality, the epoxy grout manufacturer shall provide a technical representative who will be on-site for at least the first day of epoxy grout placement to review the set-up and to ensure that the epoxy grout manufacturer’s installation instructions are followed. This requirement may be waived by written notice from the buyer or as otherwise directed in the contract documents.

4.1.3

The contractor and epoxy grout manufacturer’s technical representative shall complete the appropriate Grouting Checklists found in Chapter 5, Section 4,

Process Industry Practices

Page 3 of 7

COMPLETE REVISION

PIP STS03601 Epoxy Grout Specification

October 2001

of PIP REIE686 and shall submit these to the owner’s representative before starting to place epoxy grout. 4.1.4 4.2

The buyer reserves the right to make inspections at any time during mixing of the materials and during execution of all epoxy grout work.

Testing 4.2.1

After initial prequalification, epoxy grout may be sampled and tested if required by the contract documents. 4.2.1.1 Minimum sample frequency is one per shipment or per manufacturing lot of grout. Each sample shall consist of sufficient cubes to complete the required tests. 4.2.1.2 Test each sample for compressive strength and linear shrinkage. See Section 5.1.1 of this Practice.

4.3

4.4

Submittals 4.3.1

When required in the contract documents or if an alternate epoxy grout is proposed before installation, the contractor shall submit to the buyer the manufacturer’s literature and certified test data for the epoxy grout and shall indicate the product’s properties as required by this Practice.

4.3.2

Fifteen days before installation, the contractor shall submit to the buyer, for review and acceptance, a written quality control program describing in detail how compliance with this Practice will be ensured. The program shall include all forming, handling, mixing, placing, joint locations, joint details, curing, testing, and inspection procedures.

Safety The contractor shall comply with the safety requirements specified in the contract documents.

5.

Products 5.1

Materials 5.1.1

Epoxy grout for equipment or machine baseplates shall meet the following physical properties (see API 610 Appendix L): 5.1.1.1 Minimum compressive strength (ASTM C579, Method B modified): 12,000 psi (80 MPa) at 7 days 5.1.1.2 Maximum linear shrinkage (ASTM C531): 0.080 percent 5.1.1.3 Maximum coefficient of thermal expansion (ASTM C531): 30 x 10-6 inch/inch/°F (54 x 10-6 mm/mm/°C) 5.1.1.4 Maximum creep (ASTM 1181): 0.005 inch/inch (5 x 10-6 mm/mm), tested at 70°F (20°C) and 140°F (60°C) with 400 psi (2.8 MPa) applied vertical load

Page 4 of 7

Process Industry Practices

COMPLETE REVISION

PIP STS03601 Epoxy Grout Specification

October 2001

5.1.1.5 Minimum bond strength of epoxy grout to concrete (ASTM C882): 2000 psi (14 MPa) 5.1.2

6.

All materials shall be delivered to the job site in original unopened packages and shall be stored in accordance with the manufacturer’s recommendations. All materials and tools shall be stored in a clean and organized manner.

Execution 6.1

Application 6.1.1

6.2

Epoxy grout thickness shall be as indicated in the contract documents.

Preparation 6.2.1

Foundations shall be suitably prepared before installation of formwork for grout. 6.2.1.1 Remove laitance and oil-soaked or damaged concrete with chipping hammer to sound fractured aggregate, or to a minimum of the top 1 inch (25 mm) of concrete. 6.2.1.2 When surface chipping is complete, remove all dust and loose particles with clean, dry, oil-free air. 6.2.1.3 After cleaning, protect the foundation surface from contamination by applying protective sheeting.

6.2.2

Suitable shelter or enclosures shall be provided to protect the foundation and baseplate from direct sunlight, dew, rain, or other inclement weather. During cold weather, adequate enclosures and heating shall be provided to maintain foundation and baseplate temperature within the acceptable range specified by the grout manufacturer. This temperature shall be maintained until the grout has cured or until directed by the grout manufacturer.

6.2.3

Formwork for epoxy grout shall be constructed to be liquid-tight with adequate strength, rigidity, and dimension to permit epoxy grout placement. 6.2.3.1 Attach grout forms to concrete with drilled anchors or other method when approved by the buyer. Power nailing is not permitted. 6.2.3.2 Apply three coats of paste wax to the inside surface of forms or use other methods as recommended by the epoxy grout manufacturer to prevent grout adherence. Oil or liquid wax is not permitted. 6.2.3.3 Install 1-inch (25-mm) 45° chamfer strips at each vertical corner and at the horizontal surface of the grout forms. 6.2.3.4 Seal all form joints and interface between forms and concrete foundation using grout manufacturer’s recommended sealant.

6.2.4

Process Industry Practices

Anchor bolts shall be protected by sleeves, and exposed threads shall be wrapped with duct tape to prevent adherence of epoxy grout. Anchor bolt sleeves shall be extended to the underside of the mounting plate, or the area

Page 5 of 7

COMPLETE REVISION

PIP STS03601 Epoxy Grout Specification

October 2001

from the top of the anchor bolt sleeves and the bottom of the mounting plate shall be sealed to exclude epoxy grout. 6.2.5

Expansion joints in epoxy grout shall be spaced at a maximum of 48 inches (1.4 m) unless otherwise specified in the contract documents. 6.2.5.1 Expansion joints shall be made from closed-cell neoprene or polyethylene foam board, having a minimum thickness of 1 inch (25 mm) unless otherwise noted in the contract documents. 6.2.5.2 Expansion joints shall be fixed into position to prevent movement and shall be sealed at formwork and at the concrete base to prevent epoxy grout from passing around or underneath the joint during placement.

6.3

Page 6 of 7

6.2.6

Concrete surfaces in contact with the epoxy grout shall be clean and dry at time of placement. Air used for blowing shall be clean, dry, and oil-free.

6.2.7

Reinforcement shall be installed as indicated in the contract documents and in accordance with PIP STS03001.

Installation of Epoxy Grout 6.3.1

Equipment and machine baseplates and soleplates shall be prepared and installed according to the requirements of PIP REIE686 before grouting.

6.3.2

Epoxy grout shall be stored, mixed, placed, and cured in accordance with manufacturer’s written requirements, including temperature restrictions.

6.3.3

Dust and dirt accumulation shall be removed with clean, dry, oil-free air from surfaces that are to receive grout.

6.3.4

An adequate quantity of grout shall be on hand before starting to mix and place grout. No partial units of epoxy, resins, hardener, or aggregate shall be used. The ratio of components shall not be varied, and solvent shall not be added to change the grout consistency.

6.3.5

Grout placements shall be started at one end of the forms, and the cavity shall be filled completely while advancing toward the other end to prevent air entrapment.

6.3.6

To avoid separation of aggregate from resin binder, vibration or other forms of dynamic distribution are not permitted.

6.3.7

The forms shall be checked for grout leaks frequently. Leaks will not selfseal and may cause voids in the grout if not stopped. All leaks shall be sealed to prevent voids from forming in the grout.

6.3.8

The grout shall be checked for voids after the grout has cured. Any voids shall be filled according to the epoxy grout manufacturer’s instructions.

6.3.9

Exposed expansion joints shall be sealed with the epoxy grout manufacturer’s recommended sealant.

Process Industry Practices

COMPLETE REVISION October 2001

PIP STS03601 Epoxy Grout Specification

6.3.10 Epoxy grout cannot be cut back after cure. The final level of the epoxy grout shall be flush with the top of horizontal chamfer edges built into the formwork. 6.4

Disposal All materials shall be converted to solid waste for proper disposal. The procedure for making solid waste in any type of hardener container is as follows: a. Mix the hardener with the resin. This mixture is considered inert. b. Pour excess hardener/resin mixture into the hardener container. c. Close container and shake until excess hardener mixes with excess hardener/resin mixture. This final mixture in the hardener container is considered inert for proper solid waste disposal.

Process Industry Practices

Page 7 of 7