Table Of ContentTHE
GROUTING
HANDBOOK
A Step-by-Step Guide to Heavy Equipment Grouting
DON HARRISON
Gulf Publishing Company
This book is dedicated to my wife Paja, who has put up with
me and my travels since my AMOCO days, and to my son
Eric, who seems to be following in my footsteps.
The Grouting Handbook
Copyright (cid:14)9 2000 by Gulf Publishing Company, Houston, Texas. All
rights reserved. This book, or parts thereof, may not be reproduced in
any form without permission of the publisher.
Gulf Publishing Company
Book Division
P.O. Box 2608 [] Houston, Texas 77252-2608
10 9 8 7 6 5 4 3 2 1
Library of Congress Cataloging-in-Publication Data
Harrison, Don (Donald M.)
The grouting handbook / Don Harrison.
p. cm.
ISBN 0-88415-887-X (alk. paper)
1. GroutingmHandbooks, manuals, etc. I. Title.
TA775.H37 2000
621.8--dc21 00-025170
Printed in the United States of America.
Printed on acid-flee paper (o~).
The information, opinions, and recommendations in this book are based on the author's
experience and review of the most current knowledge and technology and are offered
solely as guidance on grouting for the process industries. While every care has been
taken in compiling and publishing this work, neither the author nor the publisher can
accept any liability for the actions of those who apply the information herein.
Contents
Preface, ix
! The Foundation . . . . . . . . . . . . . . . . . . 1
The Initial Machinery Foundation Design, 1
Reciprocating Compressor and Engine Foundations, 1
Skid-Mounted Equipment Foundations, 3
Foundations for Centrifugal Pumps, 3
Foundation Mass to Equipment Weight Ratio for Pumps, 7
Soil Conditions, 7
Concrete for the Foundation, 9
Adding Water to the Concrete Mix at the Job Site, 9
The Concrete Mix, 11
Placing Concrete in Hot Weather, 13
Pouring Concrete in Cold Weather, 14
Concrete Curing for Machinery Foundations, 15
Methods for Curing Concrete, 15
Types of Portland Cement, 16
Contamination of the Foundation, 18
Guidelines for Use of Epoxy Grout on Oil-Saturated Concrete, 18
The Acceptable Moisture Content in Concrete, or How Soon Can
We Pour the Epoxy Grout on the New Concrete? 20
2 Anchor Bolts...................22
The Basics of Anchor Bolts, 22
Measuring Equipment Pull-Down at the Anchor Bolts, 25
Determination of Anchor Bolt Pullout Strengths, 26
Machinery Reliability Starts with the Anchor Bolts, 29
How Anchor Bolts Behave, 29
Conventional Procedures for Achieving Initial Anchor Bolt
Tension, 35
Types of Material Normally Used for Anchor Bolts of
1-11/2 in. in Diameter, 36
Typical Ways of Applying, or Measuring, Anchor Bolt Preload
or Tension, 36
Seven Possible Causes of Loss of Preload in Anchor Bolts, 37
Bolt Tensioning Devices Currently Available, 42
The Easy Way To Observe and Monitor Anchor Bolt Preload,
Both Initial and Residual, 45
Load-Generating Washers, 48
Ultimate Systems, 50
Conclusion, 50
Proper Anchor Bolt Tensioning, 51
The Following Are Rules of Thumb for Anchor Bolt Tensioning, 52
"Is It Safer to Over-Tighten an Anchor Bolt Than To
Under-Tighten It?" 53
3 Cement Grout .................. 54
A Comparison between Epoxy and Cement Grouts, or
Which Product Should We Use? 54
Conclusion, 59
Merits of Epoxy Grouts versus Cement Grouts, 59
Cementious Grouts: Cement Grouting in Real Life, 60
Concrete Surface Preparation, 60
Temperature, 61
Mixing Cement Grout, 62
Placing and Curing, 63
Cement Grouting in Hot Weather, 63
Recommended Temperature Guidelines for Hot Weather, 64
iv
When Cooling Cannot Be Accomplished, 65
Cement Grouting in Cold Weather, 66
Recommended Temperature Guidelines for Cold Weather, 66
4 Epoxy Grout................... 69
An Introduction to Epoxies, 69
The Chemistry of Epoxy Grout, 70
General Characteristics of Epoxy Grouts, 71
Terminology, 73
ASTM C 1181 Calls for, 77
Conclusion, 79
General Installation Procedures for Epoxy Grout, 80
Concrete Temperature, 80
Ambient Temperature and Its Effect on Epoxy Grout, 81
Epoxy Grouting in Cold Weather, 81
Epoxy Grouting in Hot Weather, 82
Epoxy Grout Flow versus Clearance, 83
5 Selecting an Epoxy Grout . . . . . . . . . . 8S
6 The Use of Rebar and Expansion Joints
in Epoxy Grout ................. 89
Edgelifting: Cause and Cure, 92
Why and When To Use Expansion Joints in Epoxy Grout, 94
Suggested Expansion Joint Locations and Basic Construction
Material, 95
The Secondary Seal, 97
The Primary Seal, 97
Mixing Elastomeric Epoxy Expansion Joint Compound
and Sand, 98
Other Methods for Expansion Joint Design, 98
7 Cracking in Epoxy Grout . . . . . . . . . 100
Thermal Stress Cracks, 100
Mechanical Stress Cracks, 100
Vertical Cracks, 101
Horizontal Cracks, 102
8 Making Deep Pours with Epoxy Grout 104
Grout and Concrete Removal, 105
Grout Placement, 105
What Is the Possibility of Cracking? 106
Is Making Deep Pours with Epoxy Grout Too Costly? 106
9 Surface Preparation of Concrete and
Steel....................... 107
Surface Preparation of Concrete for Grouting, 107
The Preparation of a Steel Surface, 110
How Well Is the Primer Bonded to the Steel Plate or
Machine Base? 110
How Clean Does the Primer Surface Need To Be When the
Grout Is Poured Against It? 110
10 Pressure Grouting .............. 112
Pressure Grouting Machinery Base Plates To
Eliminate Voids, 112
Pump Grouting 116
11 . . . . . . . . . . . . . . . .
The Different Ways of Grouting API and ANSI Pump Bases, 116
Conventional Epoxy Grouting of Pump Baseplates, 121
Pregrouting of API- and ANSI-Style Pump Baseplates, 126
Skid Grouting 130
12 . . . . . . . . . . . . . . . . .
Conventional Grouting of Skid-Mounted Equipment, 130
Is the Epoxy Grout Compatible with the Paint on the Skid? 134
Manpower Requirements for Mixing and Pouring
Epoxy Grout, 134
Pour the Grout and Set the Skid, 135
Skid Chocking, 136
13 Epoxy Chocking................ 137
Epoxy Chocking, 137
Epoxy Chock Configuration, 145
14 Grouting Specifications........... 146
Machinery Grout Specifications, 146
The OEM Grouting Specifications, 147
vi
The E&C Firm Specifications, 148
End User Specifications, 148
Material Specifications and Procedures for Epoxy Grouting or
Chocking of Reciprocating Engines and Compressors, 148
Material Specifications and Procedures for Epoxy Grouting
of API and ANSI Pump Baseplates, 154
Material Specifications and Procedures for Epoxy Grouting of
Baseplates, Rails, or Soleplates, 160
Material Specifications and Procedures for Full Bed Epoxy
Grouting for the Skid Section of Mechanical Equipment, 166
General Specifications for Epoxy Injection of Grouted Baseplates, 173
References 176
Index 177
About the Author 181
oo
VII
This Page Intentionally Left Blank
Preface
The information contained in this book has been collected over a 20-
year period. It came from actual experiences, letters, papers, and partial
copies of documents forwarded to me from various sources. I had many
discussions with those whom I consider to be quite knowledgeable on spe-
cific subjects that are directly related to grouting. I learned a lot from the
numerous technical conferences, seminars, and meetings I attended.
I have not written every word in this book, and it certainly is not my intent
to plagiarize anyone. There are some who will not agree with what is con-
tained within this book; some will say I' ve written too much; and others will
say I didn't put enough in this book. A lot of the material contained herein
is from copies of papers and letters that were sent to me over the years by
others. The intent of this book is to put down in writing, and in a logical
sequence of events, this collected knowledge so that it can be used as a
handy reference. The reader will soon see that it is not just a matter of pour-
ing grout under a piece of equipment but that numerous sequential steps and
procedures can make or break a grout job.
I once had a fellow tell me that he had 25 years of experience in machin-
ery grouting. After observing this individual's approach to grouting for a
few days, it was obvious that he had about three weeks of experience, recy-
cled more than 1300 times. Unlike a fine wine, improper grouting proce-
dures and techniques do not improve with age. A bad grout job is a bad
grout job no matter what you try to do to it later.
ix
Description:Based on twenty years of research and field experience, this book collects a vast amount of information into a handy reference for mechanical and civil engineers. It focuses on four basic elements of grouting: load carrying capability of the foundation soil; mass design, concrete mix and installatio
