Larsen & Toubro Limited

SECTION 03600

GROUTING

PART 1 - GENERAL

1.1 SUMMARY

A. General: This Specifications covers non-shrink and epoxy grouting, portland cement grout for
minor elements and bonding agents for bonding of new concrete to existing condition in
accordance with requirements of the Sub-Contract Documents. The Sub-Contractor shall bear full
responsibility for the work of this specification including but not limited to the following:

1. The Sub-Contractor shall furnish all materials for grout in accordance with the provisions
of this Section and shall form, mix, place, cure, repair, finish, and do all other work as
required to produce finished grout, in accordance with the requirements of the Contract
Documents.

2. Responsibility for the final selection of materials, sizes, thickness, types, locations of
fixings and related accessories, all in accordance with specified standards detailed herein
and submit samples for review to the Contractor prior to manufacture.

3. Compliance with the requirements of the National Building Codes of Indian 2005,
Revised Common Building Rules of Municipal Administration and Urban Development
Department - The Government of Maharashtra, Airports Authority of India and other
applicable local regulations. Submit all information necessary to the relevant statutory
authorities to obtain approval in timely manner so as to comply with the construction
programme.

B. Related Work Specified Elsewhere

1. Section 03350 Vacuum Dewatered Flooring

2. Section 03351 Granolithic Flooring

3. Section 03410 Precast Structural Concrete

4. Section 04220 Concrete Unit Masonry

5. Section 05520 Metal Railings, Stairs & Ladders

6. Section 09303 Vitrified Tiles

7. Section 09750 Interior Stonework.

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1.2 REFERENCES

A. General: Comply with the applicable provisions of the referenced standards except as modified by
governing codes and the Sub-Contract Documents. All references to Indian, British, Australian,
American and other standards, regulations and requirements of statutory bodies and shall mean
the latest published editions at the time of Subcontract. Where such standards, regulations and
requirements are amended and affect the Subcontractor's responsibilities during the course of the
works, the Subcontractor shall immediately inform the Sub-Contractor of his intentions in respect
of the revisions. Where a recommendation or suggestion occurs in the referenced standards,
such recommendation or suggestion shall be considered mandatory. In the event of conflict
between referenced standards, this specification or within themselves, the more stringent
standard or requirement shall govern.

American Standards

1. ASTM C 109 Test Method for Compressive Strength of Hydraulic Cement

Mortars (Using 2-in or 50-mm Cube Specimens)

2. ASTM C 531 Test Method for Linear Shrinkage and Coefficient of Thermal Expansion of
Chemical- Resistant Mortars, Grouts, and Monolithic Surfacings.

3. ASTM C 579 Test Methods for Compressive Strength of Chemical-Resistant

Mortars and Monolithic Surfacings.

4. ASTM D 696 Test Method for Co-efficient of Linear Thermal Expansion of plastics.

5. ASTM C 827 Test Method for Early Volume Change of Cementitious Mixtures.

6. C 882 − Test Method for Bond−Strength of Epoxy−Resin Systems Used with Concrete.

7. ASTM C 1107 Standard Specification for Packaged dry hydraulic cement grout
(non-shrink)

8. ASTM D 696 Test Method for Co-efficient of Linear Thermal Expansion of plastics.

International Standards Organization (ISO)

1. ISO 13007- Part 1: 2004: Ceramic tiles -- Grouts and adhesives; specifies the values
of performance requirements for all tile adhesives,

2. ISO 13007- Part 2: 2005: Ceramic tiles -- Grouts and adhesives; test methods for
adhesives.

3. ISO 13007- Part 3: 2005: Ceramic tiles -- Grouts and adhesives; terms, definitions
and specifications for grouts.

4. ISO 13007- Part 4: 2005: Ceramic tiles -- Test methods for grouts.

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1.1 SYSTEM DESCRIPTION

A. System Description

1. General: Cement or Epoxy grout for flooring systems, railing system bases, anchor
bolts/fasteners capable of withstanding the types of loads and of accommodating the
kinds of movement, and the other functions for which they are designed.

B. Performance Criteria

1. Compression Strength: Provide Cementitious or Epoxy grouts capable of achieving high

early strength without displaying abnormal creep within the grouting system.
Achievement of high strength properties shall not be detrimental nor lower the
performance characteristics of the grout.

2. Loads: Design, engineer, fabricate and install expansion joint cover assemblies so that
the installed joints will withstand the live loads and dead loads and the inward and
outward pressures (including wind uplift) shown on the drawings.

3. Movement: Select and apply grouting systems that is capable of accommodating

movement and variation in joint widths through compression and flexure of its internal
web structure. Design the composition such that the grout is capable of accommodating
impacts as well as the following:

a. Vertical Shear: upward and downward

b. Horizontal Shear: outward and inward

c. Rotation: outward and inward

4. Consistency: The consistency of grouts shall be that necessary to completely fill the
space to be grouted for the particular application. Dry pack consistency is such that the
grout is plastic and moldable but will not flow.

5. Temperature: Mix and apply grout in the temperature range specified by the
Manufacturer. Grout to perform without buckling, adhesion failure, undue stress on
members or anchors, and other detrimental effects. Select type of grout in conformance
to the ambient temperature.

6. Volume Change: Use grouts which indicate small amounts of shrinkage during cure if
required. Change in volume shall not be abnormal so as to cause reduction in anticipated
performance values. Epoxy grouts shall not display more than 0.5% to 1% of volume
change.

7. Seismic Requirements: Design to withstand minimum lateral movements within the

structural components without failure. Grout shall accommodate the stresses formed on
account of the seismic movement without causing failure of the primary system.

8. Chemical Resistance: Use grouting system capable of providing successful resistance to

dilute acids. The applied or selected grout shall be capable of withstanding the acidic or
alkaline environment without reduction in its performance characteristics.

C. Fire Rating: Where shown or required, provide grouts with desired fire resistive properties at
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locations indicated or required to provide fire resistive ratings not less than the rating of adjacent
construction or assembly supported by it.

D. Downtime and speed of construction: Select type of grout capable of achieving desired strengths
or beyond to reduce the downtime for machinery and to achieve faster speed of construction.

E. Product Options: Information on Drawings and in Specifications establishes requirements for

grouting system’s performance characteristics. Performance characteristics are indicated by
criteria subject to verification by one or more methods including established engineering
methodology (i.e., calculations) preconstruction testing, field testing, and/or in-service
performance.

F. Modifications: Make modifications of work shown only as may be necessary to meet performance
requirements and coordinate the Work. Maintain the general design concept without altering
performance requirements and submit to the Contractor for review, variations in details and
materials which do not adversely affect durability or strength.

1.2 SUBMITTALS

A. Product Data: Submit for Contractor’s action. Submit manufacturer's specifications and
installation instructions for using mortars, adhesives and grouts as well as other data as may be
required to show compliance with the Sub-Contract Documents.

B. Drawings: Shop drawings to indicate grout hole layout, tile layout, groove patterns, color
arrangement, thresholds and setting details.

C. Mix design data: Submit for Contractor’s action. Submit a mix design for the project indicating
sources and types of grout materials, with volumetric properties, and field test data from previous
projects indicating compressive strength achieved under the described field conditions.

D. Methodology Statement: A general work procedure plan outlining the spacing, location, depth and
quantity of grout to achieve the specified criteria of this specification. Locations of application shall
be dimensionally referenced to the Sub-Contract Drawings.

E. Samples: Submit for Contractor’s action. Label samples to indicate product, characteristics, and
location in the Work. Samples will be reviewed for color and appearance only. Furnish sufficient
samples to establish the full range of colors and textures for materials exposed in the finished
work. Provide the following:

1. Submit colour samples illustrating full color range and colour compatibility of the
contiguous elements.

F. Quality Control Submittals: Submit for Contractor’s information

1. Test Reports

a. Sub-Contractor to submit certified test results verifying the compressive strength,

shrinkage and expansion requirements specified herein; and manufacturer’s
literature containing instructions and recommendations on the mixing, handling,
placement and appropriate uses for each type of non-shrink and epoxy grout
used in the work.
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2. Certificates

a. Document Review: Before commencing work, submit a written statement signed

by the Contractor and the Applicator certifying that the Sub-Contract Documents,
shop drawings and product data have been reviewed with material
manufacturers' qualified technical representatives and that they agree the
selected materials are proper, compatible with contiguous materials and
adequate for the application shown.

B. Closeout Submittals: Submit for Contractor’s documentation

1. Warranties: Special warranties as specified.

1.2 QUALITY ASSURANCE

A. Basis of Design: When particular manufacturers’ materials, products or processes are specified
for an item of Work, any one thereof is acceptable for the Contractor to choose. An alternative
material, product or process will be considered if the Contractor submits a written substitution
request together with such information as may be necessary to assist the Contractor in
determining whether the proposed substitution is acceptable; the burden of proof rests solely
upon the Sub-Contractor.

B. Qualified Installer: The grouting shall be performed by a firm having minimum five (05) years
experience in the application of specified materials on comparable projects. The firm shall have
the approval of and have been trained by the grouting materials manufacturer. The installer shall
provide evidence of successful completion of work of similar scope to that shown and specified
for this Project using similar systems.

C. Single-Source Responsibility: Obtain grouts from one source from a single manufacturer of
repute. Manufacturer awarded the Project shall be experienced in successfully producing grouts
similar to those indicated for this Project, shall have sufficient production capacity to produce
required units without causing delay in the Work and shall be required to provide and sign a
warranty with the installer as specified herein.

D. Manufacturer's Representatives: Do not start with grouting until the manufacturer has a qualified
representative at the project site or at the start of the Work and periodically during the work, to
ensure proper application of the system.

E. Regulatory Requirements: Comply with applicable requirements of the laws, codes, ordinances
and regulations of State and Municipal authorities having jurisdiction. Obtain necessary approvals
from authorities.

F. Mock-Ups:

1. Visual Mock-Ups: Demonstrate application along with aesthetics and performance in

mock-ups for the contiguous assemblies. Alter or revise mock-up, as directed, to obtain
the approval of the Contractor. The approved mock-ups shall serve as a standard of
quality for specified items for the project and may remain as a permanent part of the
Work if in same condition as new at time of final acceptance. The approval of the visual
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mock-up does not relieve the Sub-Contractor of its obligation to perform the work in
accordance with the Sub-Contract Documents

2. Testing Mock-Up: Provide grouted assemblies and contiguous elements for testing
mock-up in composite configurations designed to fulfill the performance criteria, and
representing the elements which will be used in the final work. Extent of mock-up is
shown on the Drawings.

1.3 DELIVERY, STORAGE AND HANDLING

A. Packing, Shipping, Handling, and Unloading: Deliver materials in manufacturer's unopened

containers fully identified to show name, brand, type, grade and thickness.

B. Storage and Protection: Store, protect and keep materials dry. Cover with manufacturer's
standard protective paper or wrapping. Store in clean, dry locations, away from uncured concrete
and masonry. Cover with waterproof paper, tarpaulin or polyethylene sheeting in a manner that
permits air circulation within covering.

1.4 WARRANTIES

A. Warranties specified in this Article shall not deprive the Contractor of other rights the Contractor
may have under other provisions of the Sub-Contract Documents and are in addition to and run
concurrent with other warranties and guaranties made by the Sub-Contractor under requirements
of the Sub-Contract Documents.

1. Special Warranty: Provide a written warranty for a period of minimum 10 (ten) years,
signed by the manufacturer of the grout and installer awarded the Work, warranting that
the grouting will be free of defects in material or workmanship and that there shall be no
reduction in performance resulting from defects during the warranty period. Failures,
include but are not limited to:

a. Failure of the system to meet performance requirements including but not limited
to disengagement of components, excessive deflection, inability to move over
complete range of scheduled displacement, failure to return to original position,
racking, warpage, damage to materials integral with or attached to;

b. Excessive water leakage or air infiltration for exterior joints.

c. Tearing (cohesive failure) of component and loss of component bonding

(adhesive failure);

d. Upon notification of defect, within the warranty period, make the necessary
repairs at the convenience of the Contractor.

2. Other Special Warranties: As may be applicable under provisions of Sub-Contract

Documents.

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PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Acceptable Manufacturers: Products specified herein by proprietary designation. Establish the

quality standards as required. Equivalent products produced by other manufacturers will be
considered provided they meet those established standards. Provide grouts by any one of the
following manufacturers.

1. STP Limited, India

2. Sika, India

3. BASF Construction Chemicals (India) Pvt.Ltd

4. Fosroc Chemicals (India) Ltd.

2.2 CEMENT GROUT

A. Cement grout shall be composed of one part cement, three parts sand and the minimum amount
of water necessary for the mixture to flow under its own weight. Where needed to match the
colour of adjacent construction, white cemnt shall be blended with regular cement as needed. In
addition, where needed, an approved admixture may be added to increase workability at a low
water/cement ratio. The minimum compressive strength at 28 days shall be 281 Kg/sq.cm.

2.3 PREPACKED GROUTS

A. Non-Shrink Grout:

1. Non-shrink grouts shall be a prepackaged, inorganic, non-gas liberating when tested in

accordance with ASTM C 1107, non-metallic, cement-based grout requiring only the
addition of water. Manufacturer’s instructions shall be printed on each bat or other
container in which the materials are packaged. The specific formulation for each class of
non-shrink grout specified herein shall be that recommended by the manufacturer for the
particular application.

2. Class A non-shrink grouts shall have a minimum 28 day compressive strength of

350Kg/Sq.cm; shall have no shrinkage (0.0%) and a maximum 4% expansion in the
plastic state when tested in accordance with ASTM C 827; and shall have no shrinkage
(0.0%) and a maximum of 0.2% expansion in the hardened state when tested in
accordance with CRD C 621.

3. Class B non-shrink grouts shall have a minimum 28 day compressive strength of 350
Kg/Sq.cm and shall meet the requirements of CRD C 621.

4. Grouts shall show initial set time of not less than 60 minutes when tested in accordance
to ASTM C 191.

5. Non-shrink grouts shall not contain any metallic substances, water reducing agents,
accelerators, super plasticizers or other materials.
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6. Application:

a. Class A non-shrink grout shall be used for the rpair of all holes and defects in
concrete members which are water bearing or in contact with soil or other fill
material, grouting under all equipment nase plates, and at all locations where
grout is specified in the Sub-Contract documents; except for those applications
for Class B non-shrink grout and epoxy grout specified herein. Class A non-
shrink grout may be used in place of Class B non-shrink grout for all
applications.

b. Class B non-shrink grout shall be used for the repair of all holes and defects in
concrete members which are not water-bearing and not in contact with soil or
other fill material, grouting under all base plates for structural members, and
grouting railing posts in place.

B. Epoxy Grout:

1. Epoxy grout shall be a pourable, non-shrink, 100 % solids system. The epoxy grout
system shall have three components: resin, hardener and specially blended aggregates,
all premeasured and prepackaged. The resin shall not contain any non-reactive diluents.
Resins containing butyl glycidyl (BGE) or other highly volatile and hazardous reactive
diluents are not acceptable. Variation of component ratios is not permitted unless
specifically recommended by the Manufacturer. Manufacturer’s instructions shall be
printed on each container in which the materials are packaged.

2. The chemical formulation of the epoxy grout shall be that recommended by the
Manufacturer for the particular application.

3. The mixed epoxy grout system shall have a minimum working life of 45 minutes at 24o C.

4. The epoxy grout shall develop a compressive strength of 350Kg/Sq.cm in 24 hours and
700 Kg/Sq.cm in seven days when tested in accordance with ASTM C 579, Method B.
There shall be no shrinkage (0.0%) and a maximum 4% expansion when tested in
accordance with ASTM C827.

5. The epoxy grout shall exhibit a minimum effective bearing area of 95%. This shall be
determined by a test consisting of filling a 50mm diameter by 100 mm high metal cylinder
mould covered with a glass plate coated with a release agent. A weight shall be placed
on the glass plate. At 24 hours after casting, the weight and plate shall be removed and
the area in plan of all voids measured. The surface of the grout shall be probed with a
sharp instrument to locates all voids.

6. The peak exotherm of a 50 mm diameter by 100 mm diameter high cylinder shall not
exceed 35oC when tested with 24oC material at laboratory temperature. When tested,
the Co-efficient of Thermal Expansion shall be in conformance to ASTM C531 or ASTM
D696.

7. Sub-Contractor to demonstrate the ability of the epoxy grout system to completely fill the
size and depth of the intended hole, blockout, or area before the system is submitted for
consideration by the Contractor.
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8. Application: Epoxy grout shall be used to embed all anchor bolts and reinforcing steel
required to be set in grout, and all other applications required in the Sub-Contract
Documents.

2.4 CURING MATERIALS

A. Curing materials shall be as specified in the Specifications for Structural Concrete for cement
grout and as recommended by the Manufacturer of prepackaged grouts.

PART 3 – EXECUTION

3.1 SURFACE PREPARATION:

A. Concrete surfaces shall be prepared for grouting by removing all oil, grease, laitance, and other
foreign substances.

B. Roughen surfaces to receive grout by chipping or nail raking of plastic concrete to assure a good
bond of grout to existing concrete. Clean thoroughly with water and soak surface for 24 hours
before placing cement grout. Surfaces shall be kept completely dry for epoxy grout.

C. Metal surfaces of equipment bases to be epoxy grout shall be thoroughly cleaned to bright metal.

3.2 FORMS:

A. Forms for fluid grout shall be built of materials with adequate strength to withstand the placement
of grout.

B. Forms for non-shrink cement grout shall be tight against all surfaces and joints shall be sealed
with tape. Form oil shall be used for easy form release.

C. Forms for grout shall be watertight with chamfer strips in place. Caulking shall be used on all
joints. Forms for epoxy grout shall be lined with polyethylene or waxed for easy form release.

D. Forms shall be 100 mm to 150 mm higher than the base plate on one side of forms when using
hydraulic head pressure for placing.

E. Provide air relief holes at least 6 mm in diameter at every recessed base plate corner.

3.3 MIXING:

A. Grout shall be mixed according to manufacturers recommendations.

B. Non-shrink cement grout shall be added to water to obtain the desired consistency.

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C. Epoxy Grout:

1. Components shall be conditioned to a temperature of between 21 and 29 degrees C.

before use.

2. Epoxy hardener shall first be added to resin and thoroughly mixed for 2 to 3 minutes
without whipping air into the mix.

3. Low speed mixer or hand stirring shall be used.

4. Mixed resin and hardener shall then be put into clean mortar mixer and the entire bag of
aggregate added.

5. Epoxy grout component ratios shall not be altered and no solvents or thinners added to
the mix.

D. Mix non-shrink cement grout between 3 and 5 minutes for uniform consistency.

E. Epoxy grout shall be mixed until aggregate is uniformly wetted.

F. Mortar mixer shall be used instead of a concrete mixer for mechanical mixing of grout.

G. Remixing of grout by adding more water or remixing of stiffening grout is not allowed.

3.4 REINFORCEMENT:

A. Reinforcement and joints for epoxy grout shall be provided when and by methods recommended
by the manufacturer of the grout.

3.5 PLACEMENT:

A. Grout shall be rapidly placed continuously from one side of base plate only in one direction.

B. Grout under base plates to fill all spaces and completely fill anchor bolt sleeves.

C. Hydraulic head grouting pressure shall be maintained by keeping the level of grout in the head
box above the bottom of the base plate. Head box shall be filled to the maximum level and grout
worked down to top of base plate.

D. Shims used for temporary levelling of equipment and base plates shall be removed after the grout
has obtained sufficient strength to carry the base plate loading. Voids left by the removal of shims
shall be filled with a second placement of grout.

3.6 FINISHING:

A. After cement grout has reached final set, it shall be trimmed back to the level as shown on
drawings.

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B. Top surfaces of epoxy grout may be finished by towelling with a steel trowel moistened with oil
before set.

3.7 CURING:

A. Non-shrink Cementitious Grout:

1. Grout shall be cured according to manufacturer's specifications and recommendations.

2. Forms shall remain in place for 24 hours.

3. Temperature of base plates and supporting concrete shall be maintained between 4 and
27 degrees C. during grouting and for a minimum of 12 hours after placing.

B. Epoxy Grout:

1. Grout shall be cured according to manufacturers specifications and recommendations.

2. Forms shall remain in place for a minimum of 24 hours after placing grout.

3. Temperature of base plate and supporting concrete shall be maintained between 4 and
27 degrees C. during grouting and for a minimum of 24 hours after placing.

3.8 TESTING:

A. Contractor shall be responsible for preparing, storing, curing, and transporting the test samples to
the laboratory for testing.

B. Grout shall develop required compressive strength according to ASTM C109 (modified) for
packaged grouts and ASTM C579 for epoxy grout.

C. Three test cubes shall be made for each day of grouting. Tests shall be made of one cube at the
following intervals:

1. Cement Grout: 24 hours, 7 days, and 28 days.

2. Epoxy Grout: 24 hours, 2 days, and 7 days.

D. Test reports shall be submitted to the Contractor immediately after the result of each age test is
available.

3.9 PROTECTION

A. Protect exposed grouted work during construction period to prevent damage.

B. Restrict movement and disturbance to the grout supported systems until the setting of grout.

END OF SECTION

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