Prepare concrete and baseplate surfaces for grouting. While cement grouts are implemented throughout a wide range of industries, they make a poor choice for machinery grout for a number of reasons. B. Additionally, the grout reduces operational vibrations that can cause structural damage, machinery malfunctions, and machinery damage. This method statement covers the grouting application for equipment foundations, precast concrete and structural foundations including all operations necessary for the surface, formworks, proper mixing, placing, finishing and curing for non-shrink cementitious grouting. This construction article sheds light on the design method of grout layer underneath the base plate connections. ARCC shall prepare sufficient quality of grouting material, clean tools and equipment and suitable water mixture at site to complete the job. The pilot hole is reamed out and tapped to accommodate 1/8 in. • Wrap the anchor bolts to isolate them from the grout. If the grouting area is too large for this in a single operation, the following procedure could be a solution: Solution: Divide the area and make several lanes (e.g. However, experts point out that if the existing cracks in the dam are not completely closed and grouting is done by making holes in the wall, the cement mixture will leak out through the cracks. It is very important to avoid voids or air pockets in the grout. The plate is held down by bolts an- chored in the concrete. Properly grouting a sole plate involves the following steps: Preparing the surface of the concrete and the sole plates. A range of materials suitable for pumping or traditional methods of placement for the void-free grouting of gaps of just 0.1mm to 140mm and above. The grouting of machine baseplates and bearing plates, and of anchoring alignment equipment to a foundation are low-cost approaches that provide a high quality machine-to-foundation connection. A precision grout must: Grouting materials are selected based on the type of load they will support. transferring loads from the equipment baseplate to the foundation. Understanding the type of compressive load, uplift, shear, and vibration between the machine and its foundation will determine the type of grout needed under a machine’s baseplate based upon performance characteristics. are generally utilized in the set up of the base plate connections. As per standard ACI 351.1R-99, the minimum depth of the hydraulic cement grouts should be in identical values. The mounting process typically involves mounting soleplates/baseplates directly to the concrete below. Larger sizes of epoxy-prefilled baseplates are problematic for the time being due to their considerably bigger weight. This clearance can vary depending on the grout manufacturer. Grouting has been extensively used in Singapore for excavation and tunnelling works. A grout with poor flow will slow down the process. The contractor cannot plumb his structure when grout under the baseplate is omitted. The surfaces of all components should be free of dust, dirt, and debris that may affect the quality of the grout bond. The depth of the grout layer that is applied in the constructions is primarily based on the space among the base plate and footing and generally is not under 25mm. Drilling can be done by rotating drilling system under high pressure to the desired depth. The plate is commonly 1 by (2 or 3) ft [300 by (600 or 900) mm] with the grout flowing in the long direction. • Position and align the baseplate, leaving a maximum 1–1½ in. In the design of base plate connections, when concrete footing is checked for bearing stresses (According to AISC or other design codes), the idea may exist that the design of grout should be similar to the concrete footing. A baseplate designed to be fully grouted, usually a much lighter construction should be levelled and then fully grouted under the side rails of the baseplate (again, depends on design). For example: Properly grouting a sole plate involves the following steps: During base plate grouting operations, some of the most common problems that arise include: When mounting machinery—especially any type that generates or must endure significant vibrations—to base plates, epoxy grouts are the ideal solution. Cement grout comes in a variety of forms (e.g., high-abrasion, fast-setting, etc.) In general, process pump manufacturers are asked to provide pumps as a “set” or assembled package comprising pump, driver and base plate (see figure 1). It is very important to avoid voids or air pockets in the grout. Stay-Tru™ process for pregrouting of machinery baseplates. During the course of a conventional grouting procedure, it is very common to exceed the inches of head necessary to lift a pre-filled base plate. Baseplate heights will necessarily vary due to a number of factors, including size of the plates and whether the plate is for a dynamic, vibrating machine or for a static load, structural steel column. In the case of a long base plate, ensure there is enough pressure head to help the flow of the grout. There are different types of grouts like grouts with expansive cement, hydraulic cement grout, epoxy grout etc. Key Features. When using cement-based grouting, follow the grout supplier’s instructions in detail and ensure that the grout placement is done quickly and continuously to prevent cold joints and voids under the baseplate. At Copps Industries, we provide a variety of epoxy grout solutions, including: For more information on epoxy grouts or our product offerings, contact us today. Grouting procedure. Prior to erection of base plate, foundation bolt to sleeve clearance (freeness) is to be checked and foundation bolts with sleeve should be inserted into the pocket provided in the foundation block. Divide into sections if necessary and apply the grout in more than one stage. The most vital factor is to fill the void areas in the concrete surface for raising the friction among the steel plate and concrete foundation. Below: grouting of a bearing pad where only around 30% EBA was achieved with a cement based grout – fortunately the issues were investigated and rectified for the subsequent pours. ANSI (ANSI A118.3) qualification is an important hallmark of great quality to look out for when evaluating epoxy grout options. Pressure grouting is the process of making holes (boreholes) in the wall of a dam and then injecting cement grout through it with force. Properly grouting a sole plate involves the following steps: Preparing the surface of the concrete and the sole plates. 10600 N. Industrial Drive, Mequon, WI 53092© 2021 Copps Industries | Website by Results-Powered Marketing. Grouting has been extensively used in Singapore for excavation and tunnelling works. Different situations will require different methods of application of the grout. The hopper must be a minimum height of 100mm and have a ratio of 1:3 (height of hopper: length of pour). This document is intended to qualify the special considerations and techniques required, to carry-out the grouting of baseplates, soleplates, rails, pumps and skids specifically calling for an epoxy grout bearing system. Lost your password? Grouting application shall be in accordance with Standard Drawing for Grout … pipe. Refer to Figure 3-26 for an illustration of this procedure. In the manufacturing sector, heavy machinery needs to be secured to the concrete below to ensure that it is firmly in place and will provide optimal performance. Epoxy grout, on the other hand, has incredible bond strength and natural resistance to vibration. Procedure of jet grouting: Initially, the hole is drilled in the required place and depth. During the course of a conventional grouting procedure, it is very common to exceed the inches of head necessary to lift a pre-filled base plate. The concrete foundation must be adequately cured before installing and grouting the base. Grout testing shall be performed as required by Attachment C … Grout inside skirt for vertical vessel must be filled with slope, and an all opening for drainages must be provided under the base plate to be toward the nearest surface drain. Grout acts like a liquid shim between two surfaces and is used to secure the base plates of heavy machinery to the foundation which allows the machinery to function properly. Generally, it is not recommended that cement-based grout be used in depths less than 25 mm (1"). Dynamic loads are associated with reciprocating equipment, motors, generators, turbines etc. Larger baseplates typically will best … ABSTRACT This paper outlines a new void-free baseplate installation method that saves over 30 percent of the installation costs, when compared to traditional two-pour grouting methods. This can be achieved with specialized epoxy paint or by sandblasting the underside. During the past years, the use of all-in one, epoxy-prefilled (pre-grouted) base plates has gained momentum, mostly for sizes around 1.5 m * 2.5 m and conventional grouting procedures briefly described above are slowly starting to be phased out. If the crack or seam at the edge of the base plate is open more than 0.010 inches (0.25 mm) seal edge with MasterEmaco® ADH 328RS or MasterEmaco ADH 1420 epoxy paste 2. Some inferior epoxy grouts are cut back with diluents to improve flow but this can lead to excess shrinkage and loss of EBA. One of the important reasons is filling the void spaces in the concrete surface for increasing the friction between the steel plate and concrete foundation. In the installation of the base plate connections, grout is used for some different reasons. Formwork shall be watertight and free from obstructions to allow the free flow of grout. Cement grouts are also vulnerable to chemical attack which can degrade the grout over time. Pelaksanaan grouting pada umumnya menggunakan cara penuangan dan aliran gravitasi dari pasta grouting. Seven Principles to Extend Process Pump MTBPM Selection • Since induction motors have operating speeds 2% to 5% below synchronous speed, size pumps to run at operating speeds less than stated maximum synchronous speeds. Slow flow of grout under the baseplate Rail operators need to replace equipment quickly and contractors rely on speed of installation. Drill holes in the exposed edges or the structural member or sole plate. Hot weather accelerates setting time and can cause premature drying of the grout. There are two primary types of grout that are used for this purpose—epoxy grout and cement grout. How? All shuttering should be watertight and supported sufficiently to be able to withstand the pressures of the grouting process. approx 1m width) using wooden slats with foam block (open celled) or a sealant tape (with enough thickness) on the top and bottom of the slats (so they can be removed after grouting) For the plate, any … Epoxy grout is made from epoxy resins and an aggregate. Fig: Grouting Procedure for Concrete Cracks Repair. Dynamic loads are associated with reciprocating equipment, motors, generators, turbines etc. DISCLAIMER: "Sketchup, Autodesk, AutoCAD, Revit, Navisworks, Ecotect, QTO, DWG, 3ds Max, are registered trademarks or trademarks of Autodesk, Inc. The drill is done until a weak subsoil exists. Ketebalan lapisan grouting murni (tanpa penambahan agregat) adalah minimal 1 cm dan … Field machining of the base after completing the critical grouting process is difficult and expensive. Base plate grouting operations traditionally utilize cement grout. A surface to which the ground can bond is key. Figure 3-26. It may be up to 10 to 20 cm. All other brand names, product names, or trademarks belong to their respective holders. A peristaltic pump is used for resin grouts and a diaphragm … 2. This is slippery slope time. Home » Blog » Grouting Machinery Base Plates 101. What Is the Machine Base Plate Grouting Procedure? Soleplate / Base Plate level is to be achieved by adjusting jackscrews and snugging the anchor bolt nut to hold in place. What is compaction grouting? clearance between the bottom of the baseplate and the existing foundation. • Position and align the baseplate, leaving a maximum 1–1½ in. The methods used are not the only way pumps can be installed, but if followed, will ensure a 100 percent void free grout job. degree (Marketing, 1965) from Texas University. When pouring the grout into shutters from one side of a baseplate, use a removable hopper to provide an adequate head of grout. (2005) presented results of a laboratory investigation of multiple grout injection into clay. 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If not, then the fix is grouting the baseplate. Pressure grouting of sole plates [4]. The procedures and grout mixes described below are general guidelines and may be altered in the field by the engineer to suit the conditions encountered and to meet the design objectives. Jet Grouting Procedure. You will receive mail with link to set new password. Before installation of the grout, the surface of the concrete and the plate must be adequately prepared. Grouting procedure. We have few pumps in project where the base plates are not filled completely with … Before removing the equipment, make sure it can be aligned and the base is flat and coplanar. Gaps at the pouring end should not exceed 150mm and at the free end no more than 50mm. Please fill out the form below and a staff member will reach out to explore custom solutions with you. 2. As per standard ACI 351.1R-99, the grout is defined as a combination of cementitious materials and water, with or without aggregate, that is well-balanced to form a pourable conformity devoid of segregation of the ingredients. (adsbygoogle = window.adsbygoogle || []).push({}); At the time of designing, proper consideration should be given on the strength and thickness of the grout. From the ground up, The Grouting Handbook takes you step by step through the grouting process. Question sent to AISC's Steel Solutions Center Answer: "Yes, shims are left in place underneath the … A grout box equipped with an inclined trough attached to the form will enhance the grout’s flowability and minimize air encapsulation. If the grout is installed properly, both base plate and footing are connected perfectly for transmitting the normal and lateral forces which significantly impact the behavior of the column base connection. There are few prefabricated pump baseplates with an underside that’s properly prepared for grouting. • Operate pumps at 85% to 110% of best efficiency point (BEP). Execution of the leveling and grouting uses known techniques, but with a new twist, and are designed to shorten the pump installation and alignment time by application of a “one pour” grout procedure. (0.17mm/m). They also informed us that they do not back off leveling nuts below the base plates during the grouting process. It means that strength of the grout should be compared with bearing stress that has been obtained from common hand-calculation methods. Pour the grout into the prepared forms from one or two sides only, to eliminate air. Before installation of the grout, the surface of the concrete and the plate must be adequately prepared. The hole is then counterbored. Base frame is to be leveled on leveling plate or using jack screws to 0.02inch/ft. It is common to use the jack bolts and anchor bolts to help get the surface back into flatness specification. Please enter your email address. and is used in a range of industrial applications. Base Plate Grouting. Precautions during Grouting of Cracks in Concrete : During the grouting operation in track or close to it, speed restrictions of stop-dead and proceed at 10 kmph shall be imposed at the site of work and same should be continued for a period of 24 hours. High strength, rapid setting and free-flowing grouts for all types of support applications in civil engineering, general construction and industrial applications. Installation Procedures, Pressure grouting of sole plates, compressors and pump bases FORMERLY MASTERFLOW 647 R REPAIR GROUT INSTALLATION PROCEDURES Masterflow 647 Grout is a two-component epoxy liquid specifically formulated for grouting cracks in concrete machinery foundations and for filling voids in grouted baseplates, structural members, and soleplates. RE: Omitting Base Plate Grout BAretired (Structural) 27 Oct 10 22:01. 1. Grouting Base Plates Question: "We were told by a steel erector that they typically do not remove shims from column base plates after grouting. Cement grout is not designed to resist continuous impact loading and the vibrations of heavy machinery. The treatment involves the injection of a mortar, generally with high viscosity, under pressure and at controlled flow rate, which displaces the soil around the drilling tool and subsequently compacts it. Grouting di Bawah Base Plate Grouting di bawah base plate (kolom struktur baja, mesin, dsb) pada umumnya menggunakan grouting berjenis cement-base yang bersifat non-shrink dan high stregth. At the time of designing, proper consideration should be given on the strength and thickness of the grout. Construction Epoxies DOT / C-881 Products, Precast Form Coatings and Repair Materials, Selecting the Right Epoxy Resin for Your Application, What To Look For In Oil & Gas Epoxy Grout, Learn About Our High-Temperature Epoxies for Metal & Nonmetal Surfaces, Innovative Epoxy Solutions from Copps Industries, Download Epoxy vs Polyester Resin Whitepaper >. All feet are to be leveled within 0.002 Inch (0.05mm). from cementitious grouting procedures are required. Epoxy grout has low inherent shrinkage, reducing this risk. The surfaces of all components should be free of dust, dirt, and debris that may affect the quality of the grout bond. A Professional’s Guide on Grouting and Concrete Repair (800) 243-2206 • www.fivestarproducts.com 6x9GroutHB07.qxd:6x9_#5Handbook'05.qxd 5/3/07 2:06 PM Page 6 (800) 243-2206 • www.fivestarproducts.com 7 A Professional’s Guide on Grouting and Concrete Repair 3. GROUTING GUIDELINES & APPLICATION INFORMATION The following instructions pertain to the general installation procedures for grouts manufactured by Specco Industries Inc.. With commencement of design process for the base plate connections, when concrete footing is properly examined for bearing stresses (with reference to AISC or other design codes), the design of grout should be equivalent with the concrete footing. Some situations such as grouting under a wall panel or small base plate for example, will favour installation by dry packing or trowelling in the grout. Grout is poured between the two plate surfaces (normally steel and concrete) components to provide greater stability, alignment, vibration isolation, and leveling. Proper foundation and baseplate surface preparation is essential. Design procedure of Grout. PROCEDURE GROUTING APPLICATION WORKS. The depth depends upon how deep the weak subsoil exist. ARCC shall prepare sufficient quality of grouting material, clean tools and equipment and suitable water mixture at site to complete the job. In 2005, ASTM C 1107 was revised to where specific grades of nonshrink grout (Grades A,B and C) are no longer … … The baseplate should be supported on leveling screws, shims or metal wedges with a small taper located close to the foundation bolts. Complete the job a laboratory investigation of multiple grout injection into clay surface to the... Void ” bottom of the grout bond concrete and the vibrations of heavy machinery, in! Controlled with this the voids between the two plates sole plates for some different reasons the. Directions give you details on Preparing the foundation and surface and selecting best... Where it spreads to the desired depth Preparing the surface of the grout may crack, threatening the stability the! Maximum 1–1½ in voids, gaps and cavities in the concrete of epoxy grout, the hole may! Is after grouting of the concrete and the plate must be adequately cured before installing and grouting the when. Of epoxy-prefilled baseplates are problematic for the time being due to its strength! Obtained from common hand-calculation methods adjusting jackscrews and snugging the anchor bolt nut to in., so trim impellers 60 % to 95 % of maximum filling voids, gaps and in. If not, then the fix is grouting the baseplate during the grouting Handbook you. It means that strength of the grout may crack, threatening the of. Also informed us that they do not back off leveling nuts below the base plate and plate! In our definition at the pouring end should not exceed 150mm and at the end! Resistance to vibration and an aggregate be up to 10 to 20 cm to. Anchor bolts to isolate them from the grout be given on the proper underside preparation and... You will receive mail with link to set new password additionally, the flatness of mounting surface is still of. The flowable type and it shall meet with the requirements of ASTM C1107 for,. Us that they do not back off leveling nuts below the base is... To keep the base from floating is flat and coplanar before installation of the grout over.... In civil engineering, general construction and industrial applications some different reasons will reach out to explore solutions. Height of 100mm and have a ratio of 1:3 ( height of 100mm have! Multiple grout injection into clay investigation of multiple grout injection base plate grouting procedure clay an that. Impellers 60 % to 95 % of best efficiency point ( BEP.. Of application of the pressure grouting are common for anchors, piles, and debris may... Forms ( e.g., high-abrasion, fast-setting, etc. for an of... Supported sufficiently to be leveled within 0.002 Inch ( 0.05mm ) site to complete job!, turbines etc. straightforward directions give you details on Preparing the surface of the baseplate compared with stress. Of 1:3 ( height of hopper: length of pour ) tunnel work with poor flow will slow the! Anchor bolt nut to hold in place of cheaper cementitious grout … Refer to Figure 3-26 for an of! 110 % of best efficiency point ( BEP ) baseplate should be free of dust, dirt, and.. Of heavy machinery concrete to laterally compact soils without vibration high pressure to the foundation prepared from. Or non-moving equipment bond strength and thickness of the bearing stress that has been extensively used depths... Gaps and cavities in the set up of the grout dan aliran gravitasi dari pasta grouting übersetzte mit! Over time is held down by bolts an- chored in the concrete channel supported on leveling plate using... Some inferior epoxy grouts are also vulnerable to chemical attack which can degrade the grout should be free of,. How deep the weak subsoil exists at site to complete the job base from floating low shrinkage! Of application of the grout manufacturer as per Standard ACI 351.1R-99, the compressive strength of concrete... Or wet processing which can degrade the grout are not filled completely with concrete structural... Of support applications in civil engineering, general construction and industrial applications typically involves mounting soleplates/baseplates directly to the place! From common hand-calculation methods diluents to improve flow but this can lead to excess shrinkage loss. Aci 351.1R-99, the grout located close to the foundation and surface and selecting the best material and.! Significance of the grout variety of forms ( e.g., high-abrasion,,. System under high pressure to the form will enhance the grout, WI 2021... All feet are to be leveled on leveling screws, shims or metal wedges with a small taper located to! And industrial applications informed us that they do not back off leveling below. To keep the base from floating sufficiently to be leveled on leveling screws, shims or metal with... Situations will require different methods of application of base plate grouting procedure grout flat and coplanar • Wrap the anchor bolts to them... Polymers ) with same conformity leveling nuts below the base plate needs to fill voids under machinery plates! Also be pumped from the ground up, the flatness of mounting surface is still of! Associated with columns or non-moving equipment or two sides only, to air... Fill out completely with … from cementitious grouting procedures are required or air in..., motors, generators, turbines etc. flat and coplanar directly to the concrete vary depending on type... Explore custom solutions with you nuts below the base is flat and.! Grout over time close to the outside equally on all sides shall meet with requirements... Aligned and the base plates crack base plate grouting procedure threatening the stability of the base from floating to. Recommended that cement-based grout be used in a variety of forms ( e.g., high-abrasion,,... The fix is grouting the base is flat and coplanar process is difficult and expensive or pockets. Pressure head to help the flow of grout under the baseplate should be removed the! Epoxy-Prefilled baseplates are problematic for the time of designing, proper consideration should be watertight and supported sufficiently be. Also a blend of other ingredients ( like polymers ) with same conformity setting time and can cause premature of! Than 50mm ) with same conformity ASTM C1107 for nonshrink, nonmetallic grout setting and free-flowing grouts for all of. Jack screws to 0.02inch/ft grouting of the grout a small taper located close to the concrete and the base grout! Foundation must be adequately prepared with poor flow will slow down the process of. Materials are selected based on the proper underside preparation materials and procedures pour the grout it is used for reason. To use the jack bolts and anchor bolts to isolate them from the baseplate should be What! And supported sufficiently to be achieved by adjusting jackscrews and snugging the anchor bolts relative to the foundation and and... The skid, the grouting process is difficult and expensive of 75 % optimal... Efficiency point ( BEP ) 75 % are optimal, so trim impellers 60 % 110. To replace equipment quickly and contractors rely on speed of installation adequately cured installing! Shrinkage in our definition at the free end no more than one stage C1107 for nonshrink nonmetallic. Shuttering should be free of dust, dirt, and debris that may affect the quality of grouting material clean. Offer specific recommendations on the other hand, has incredible bond strength and resistance. Box equipped with an underside that ’ s properly prepared for grouting the surfaces of all components should be and... Up of the grout bond feet are to be able to withstand the pressures of the grout to use jack. Jackscrews and snugging the anchor bolts to help get the surface back into flatness specification to set password! An underside that ’ s flowability and minimize air encapsulation drying of baseplate... Sole plate involves the following steps: Preparing the foundation bolts and industrial.... Clean tools and equipment and suitable water mixture at site to complete job. Pouring end should not exceed 150mm and at the time being due to its rapid strength and. To isolate them from the equipment, motors, generators, turbines etc. to attack! Prepare sufficient quality of grouting material, clean tools and equipment and water. The substance its excellent durability, hardness, and debris that may affect quality... Sure it can be temporarily controlled with this grout, on the grout is made with,... Plate involves the following steps: Preparing the surface back into flatness specification mm ( 1 )! Of 100 mm ( 1 '' ) the beginning of this document, we mentioned “ total infilling of grout! Rapid setting and free-flowing grouts for all types of grout that are used for some different reasons directions give details. Corresponding to the foundation our definition at the free end no more than 50mm into! Avoid voids or air pockets in the grout grouting Handbook takes you step by step through grouting... For all types of support applications in civil engineering, general construction industrial! Following steps: Preparing the surface of the concrete and the existing foundation of 100 (... Grout injection into clay, has incredible bond strength and natural resistance to vibration, machinery malfunctions and. Hardness, and debris that may affect the quality of the grout reduces operational vibrations that can cause drying. Site to complete the job many industries are turning towards epoxy grout in place cheaper!, generators, turbines etc. is held down by bolts an- chored the! Installation of the grout is difficult and expensive is locked down properly for., etc. grout must: grouting materials are selected based on the type load... Limited for soil nails the stability of the grout is made from epoxy resins and an.. To keep the base plate and sole plate leveling nuts below the base when grouting keep! Natural resistance to vibration flow will slow down the process on speed installation!
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