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ChemMasters Installation Guidelines Conset Grout ™ is a prepackaged, cementitious, nonshrink, nonmetallic grout. It is a high early strength grout that may be placed at plastic, flowable and fluid consistencies allowing versatile placement under varying conditions. Conset Grout is approved for use by numerous DOTs. 1.0 General 1.1 Scope This specification covers the performance characteristics and application procedures for providing a cementitious, nonshrink, nonmetallic grout. The grout is flowable and self-leveling. 1.2 Material Description The grout shall be a single component, cementitious grout, that is flowable and self-leveling, such that it may be placed at plastic consistency for increased strength requirements, is nonshrink for maximum load bearing, and can be extended for placements over 2 ”/5 cm deep. 1.3 Typical Applications A. Building Columns, Dowels, Hand Rails, Fence Posts B. Bridge Beams, Highway Barriers C. Boiler Plates, Anchor Bolts, Sewers D. Baseplates, Machine Bases, Bed Plates, Sole Plates E. Underpinnings, Precast Beams, Wall Panels, Precast Columns, Pipes/Sleeves 1.4 Limitations A. Do not apply to frost covered or frozen surfaces or at substrate or ambient temperatures below 40° F./4° C. B. Follow ACI 305 Hot Weather Concreting and 306 Cold Weather Concreting guidelines for placement during extremely hot or cold temperatures. C. ChemMasters recommends the use of ChemGrout Mixer/Pumps for placements under large baseplates or with a difficult configuration. D. Contact ChemMasters Technical Service Staff for special recommendations on precision grouting, dry pack situations or unusual circumstances. E. For close tolerance placement or heavy duty applications subjected to extreme thermal shock or dynamic loading, consider the use of ChemMasters Kemset or Met-Ox Grouts. 1.5 Quality Assurance The repair contractor shall have experience and proficiency specific to the repair type and shall be approved by the engineer and the material supplier. The material supplier shall provide job service as required to assure proper handling and installation of materials. The field representative shall instruct as needed to assure that handling, mixing, placing and finishing of materials are in accordance with specifications. 1.6 Delivery, Storage and Handling The product shall be delivered in the original, unopened containers. It shall be labeled with the manufacturer’s name, product name and lot number. Materials should be stored at the job site under dry conditions and at a temperature of 40°F (4°C) to 90°F (32°C). 1.7 Environmental Requirements All materials used for the repair work shall be VOC compliant. The manufacturer shall supply the appropriate material safety data sheets upon request. 1.8 Site Conditions A. Grouting is best accomplished at temperatures between 40°-90° F/4°-32°C. For extremely low or high temperatures, follow the guidelines established by ACI for cold or hot weather grouting or consult ChemMasters for additional recommendations. B. Job conditions shall be maintained at standards that allow underlayment placement within temperature and cleanliness requirements. Unusual conditions as uncovered during the course of work shall be brought to the engineer’s attention for analysis and disposition. These conditions include but are not limited to poor quality base concrete, random cracks and deep oil penetration. 2.0 Materials 2.1 Approved Materials and Manufacturers 2.1.1 Product Standard Conset Grout, as manufactured by ChemMasters, 300 Edwards Street, Madison, Ohio, 44057-3112, 1-800-486-7866, is considered to conform to the requirements of this specification shall be the grout. Conset Grout is a single component, cementitious grout, requiring only water for mixing. 2.1.2 Substitutions No submittals for substitutions will be accepted after the bid date. All submittals must be made in writing to the engineer with supporting technical data sheets and test data showing complete equivalent performance. 2.2 Packaging/Coverage/Estimating 2.2.1 Packaging Conset Grout is packed in 50 lb./22.7 Kg polylined, moisture proof bags, shipped 60 per pallet, shrink wrapped. 2.2.2 Coverage/Estimating: A. Yield per 50 pound/22.7 Kg bag: 1. Plastic .42 Ft.3 .011 M3 2. Flowable .43 Ft.3 .012 M3 3. Fluid .45 Ft.3 .013 M3 B. VOLUME GROUTING: For applications over 2"/5 cm, Conset Grout may be extended with up to 25 lbs/11 Kg of clean, SSD 3/8”-.95 cm pea gravel per bag. With 9 pints/4.3 L of water, yield will increase to approximately 0.6 Ft.3 /.017 M3 -flow will decrease. 2.2.3 Storage: Store unopened bags in cool, dry area on pallets. Shelf life is one year from date of manufacture when properly stored. 2.3 Engineering Properties The following engineering properties shall be typical of material performance when tested under laboratory conditions at 72°F (22.2°C). 2.3.1 Plastic Properties 126.96.36.199 Set Times (ASTM C-191/Vicat Method): Initial Final A. Plastic 2.5 hours 3.0 hours B. Flowable 3.0 hours 3.5 hours C. Fluid 4.0 hours 4.5 hours 2.3.2 Hardened Properties: 188.8.131.52 Compressive Strength (ASTM C-109): psi —MPa A. 1 day 3 days 7 days 28 days B. Plastic 3500 —24 8000 —55 9000 —62 10000 —68 C. Flowable 3000 —21 7000 —48 8000 —55 9000 —62 D. Fluid 2900 —20 5900 —40 7000 —48 8500 —58 184.108.40.206 Expansion (CRD C-621)—in % A. 1 day 3 days 7 days 28 days B. Plastic +0.07 +0.07 +0.08 +0.18 C. Flowable +0.03 +0.03 +0.04 +0.10 D. Fluid +0.04 +0.04 +0.05 +0.06 2.4 Accessory Materials as manufactured by ChemMasters, 300 Edwards Street, Madison, Ohio, 44057-3112, 1-800-486-7866, is considered to conform to the requirements of this specification. 3.0 Execution 3.1 References A. ASTM C-1107-91a, Grade B B. CRD C-621-92 C. Conset Grout does not contain any gas forming agents D. Refer to ChemMasters MSDS and Technical Data Sheets 3.2 Surface Preparation: A. The concrete substrate upon which the grout will be placed must be clean and free of any curing or sealing compounds, dust, dirt, oil or grease. B. The base should be textured where possible using a small chipping hammer. C. Presoak the substrate with water for 24 hours to prevent premature drying of the grout. Cover with wet burlap or polyethylene sheeting to retain moisture. D. FORMING: Forms will be required for most grouting applications. Top edges of forms must be higher than bottom of baseplate to be grouted. Seal bottom edges of forms so that grout will not leak. Construct forms with a larger gap, at least 2"/5 cm, between form and base being grouted. Use a slant board or construct a head box to direct flow of grout from front to back. Allow at least 1"/2.5 cm gap at backside of form to facilitate flow and allow air to escape in front of grout flow. All forms in contact with the grout must be coated with a release agent such as Release™ or Safe-Slip™ from ChemMasters. 3.3 Mixing: A. A paddle type mortar mixer, grout pump or heavy duty 1/2” drill and mixing prop are required. B. Place about 80%of required water into clean but prewet mixer or container. C. Use only as much water as will be required to properly place the grout. Adding excess water only decreases strength and expansion. D. If aggregate is used, add now. Do not add sand or cement to Conset Grout. E. With mixer blades operating, open bag(s)and gradually empty into mixer, mix for about 1 minute, then add remaining water and mix for 3-4 minutes. F. Following this sequence should eliminate lumping and keep mixer clean and free of excess buildup. Mix enough Conset in each batch to fill void completely to eliminate cold joints or air pockets. 3.4 Application: A. Always place grout from one side only at a steady, continuous flow to push air out in front of grout flow, ensuring maximum surface bearing of the plate or base. B. Do not vibrate grout. . 3.6 Curing: A. Proper curing is required! As soon as grout placement is complete apply a high quality curing compound, such as Polyseal or Safe Cure &Seal 0800 to all exposed grout surfaces. B. Alternately, wet burlap may be used following the guidelines in ACI 351, Grouting for Support of Equipment and Machinery. 3.7 Clean-up: Clean tools and equipment before material dries and hardens with warm water.
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