INTRODUCTION TO

GROUTS
Definition of a Grout :
A fluid material which is designed to be introduced
into a cavity for the purpose of filling it and which will
subsequently harden to give specific physical proper-
ties.
Function of a Grout:
The reason for the filling the cavity dictates the char-
acteristics required in the hardened grout. The two
main functions are : To provide or restore continuity of
strength or transfer of load across the cavity and to
provide a seal against water ingress into or across the
cavity.
Necessity of a Grout :
The usual question asked is why to grout the inter-
face between the base plate and the foundation, why
not erect the machine directly on the foundation?
A concrete surface though it looks perfectly smooth
and plane, it is not so. When looked through a mi-
croscope we will find that the surface is quite uneven.
Fig.1
Properties required in a Grout :
A good grout should have the following properties:
01 Shrink resistance
02 High flowability
03 High early strength
04 Corrosion resistance
05 Creep resistance
06 Chemical resistance
07 Dynamic Load Resistance
08 Pumpability
Principal grout types :
01 Cement And Cement Sand Grouts:
The simplest grout used in the construction industry
is a mixture of cement and water.
Advantages:
Economy, early preparation and
application
Disadvantages:
High shrinkage factors
Poor flow characteristics
Unreliable strengths
Variable performance
02 Cement And Cement Sand Grouts
With Non-Shrink Plasticising
Admixtures:
These additives impart high flow characteristics at low
water cement ratios.
Advantages:
Improved flow and cohesion characteristics
Less water in mix
Non-shrink
Disadvantages:
Variable performance
Unreliable strength
03 Pre-Packed Grouts:
These are factory-made materials utilising accurately
controlled constituents which give precise performance
characterisitics, both in the fluid and hardened states.
Advantages:
Precise characteristics of flow strength & ex
pansion
Consistent performance
Pre-packed - convenient, ready-to-use with
addition of water only
Disadvantages:
Precise water addition incase of cementitious
grouts
Special mixing equipment
Cost
ANCHORS
Definition of an Anchor :
An anchor may be defined as a device or a system
used for anchoring of bolts or rods or any material in
a substrate. The substrate may be rock, concrete,
masonry or soil.
Basic types of Anchors:
01 Expansion and Friction Anchors
02 Cast in Anchors
03 Grouted in Anchors
Grouted in Anchors :
Here an anchor unit is inserted into a drilled or per-
formed hole and set in place using a fluid grout which
subsequently sets and hardens and bonds the unit
into the hole. There is a wide variety of anchor grout-
ing materials and methods.
This is the field in which Fosroc is involved.
Advantages:
Positive bonded anchorage
Designed Anchor strength
Corrosion protection
Ease of use etc.
Disadvantages:
Installations/operations generally slower than
mechanical anchors.
Some grouting systems like traditional
water/cement injection not reliable.
Fast setting systems expensive
Holes in hard materials must be clean and
deformed.
Hole drilling may be difficult/expensive in
reinforced concrete.
GROUTING
PROCEDURE
Grouting is a very important function in any project,
because faulty or erroneous grouting leads to seri-
ous breakdowns.
The various steps to be followed for effective grouting
are :
01 Preparation of Foundation Block
02 Placing and levelling of base frame
03 Cleaning of bolt pockets
04 Cleaning of base frame
05 Preparation of form work and shuttering
06 Grouting
Grouting
01 Bolt pocket grouting
02 Base plate grouting
The procedure is common to both bolt pocket and
base plate grouting. The different steps are
1. Initial preparation
2. Formwork
3. Curing
Dos & Donts for Conbextra Grouts
Do
Store the grout in a well ventilated space
protected from moisture.
Check everything for damages and expiry
date before using.
Mix mechanically.
Use mixed grout within 30 minutes depend-
ing on temperature and humidity.
Ensure shuttering is strong and leakproof.
Start curing as soon as grout reaches touch
hard state incase of cementitious grouts.
Cure grout atleast for a period of 7 days in
case of cementitious grouts.
Dont
Mix more water than specified for cementi
tious grouts.
Mix any other ingredient like sand, cement
etc., to the grout.
Have exposed edges larger than neces
sary. 50mm on all sides and 100-150mm on
pouring side is ideal.
Use vibrators.
Pour grout from two different sides.
Common problems encountered during grouting
a) Formation of Lumps
Add the grout slowly into the mixer during
mixing to avoid this or put 1 or 2 concrete
cubes or big stones in the mixer. This will
break the lumps.
b) Segregation & Bleeding
Check the quantity of water added and en
sure proper mixing.
c) Leaking of Grout
Arrest the leakages using the grout pow
der.
d) Cracks on shoulders
This is common in cementitious grouts. It is
only due to unrestrained expansion and dry
ing. This can be taken care of by sprinkling
some clean washed aggregates (5-12mm)
on the exposed shoulders. Also the shoul
ders width is to be restricted to 50mm on all
sides and 100-150mm on the puring side.
FOSROC GROUTS
Fosrocs Range of Grouts:
01 Grouting Additives
a) Conbex 100
b) Conbex FCC422
02 Cementitious Grouts
a) Conbextra GPI
b) Conbextra GP2
c) Conbextra Special
d) Conbextra HF
e) Conbextra HR
03 Epoxy Grouts
a) Conbextra EP10
b) Conbextra EP65
c) Conbextra EP120
04 Grout Anchors
a) Lokset S
b) Lokset L
c) Lokset P
Note: The technical details of these products shall
be explained in theory and are available in the
product datasheets.
Application areas of grouts
A huge potential for grout exists in all the major indus-
trial sectors and some of the common equipments
that need to be grouted are presented herein.
01 Power Sector
a) Turbines
b) Generators
c) Compressors
d) Condenser pumps
e) Boiler feed pumps
f) Boilers
g) Coal pulverising mills
h) Fans
g) Coal crushers
h) Coal conveyors
i) Stackers/Reclaimers
j) HD Motors
k) Pipe Hanger Supports
l) Transmission Tower
m) Scrubbers
n) Structural Columns
o) Rock Anchors
02 Cement Plants
a) Crushers
b) Conveyors
c) Generators
d) Motors
e) Separators
f) Coal Mills
g) Raw Mills
h) Ball Mills
f) Cement Mill Pinions
g) Kilns
h) Structural columns
03 Petrochemical And Chemical Industries
a) Compressors
b) Turbines
c) Tank Supports
d) Pipe Supports
e) Structural columns
f) Chemical pumps
g) Clarifiers
h) Engines
i) FRP Tanks
j) Processing machinery
k) Pressure vessels
l) Catalytic cracking units
m) Valve supports
n) Refrigeration units
04 Steel Plants
a) Continuous casting equipment
b) Crushers
c) Boilers
d) Clarifiers
e) Engines (Diesel, Steam & Gas)
f) Expanders
g) FRP Tanks
h) Fan Housings
i) Forges
j) Gantry Cranes Rail Beds
k) Gear Boxes
l) Large Lathes
m) Large DC motors
n) Main Mill Housings
o) Manipulators rail beds and raceways
p) Manipulators
q) Milling machines
r) Steel making vessels
s) Stamping machines
t) Structural support plates
u) Shearing equipments
v) Transfer car rail beds
w) Rolling mills
x) Hot strip mills
y) Furnaces and allied equipments
05 Pulp And Paper Industry
a) Paper Machines
b) Power Plants
c) Auxiliary Equipment
d) Pumps
e) Barkers
f) Boilers
g) Calenders
h) Chippers
i) Compressors
j) Driers
k) Hoods
l) Turbines
m) Fourdrinier Sections
n) Winders
o) Patching
p) Clarifiers
q) FRP Tanks
r) Fan Housings
06 Metals Industry
a) Acid Pumps
b) Ball Mills
c) Car Scales
d) Clarifiers
e) Boilers
f) Continuous Casting Equipment
g) Crushers
h) Descaling Pumps
i) Engines (Steam, Gas, Diesel)
j) Expanders (i.e., Pipe Mill)
k) FRP Tanks
l) Fan Housings
m) Forges
n) Gantry Cranes rail Beds
o) Gear Boxes
p) Large lathes
q) Large D.C.Motors
r) Main Mill Housings
s) Milling Machines
t) Shearing Equipment
u) Stamping Machines
v) Structural Support Plates
07 Mining Industry
a) Compressors
b) Engines
c) Pumps
d) Motors
e) Kilns
f) Gear Boxes
g) Fan Housings
h) Centrifuges
i) Rod & Ball Mills
j) Conveyor Supports
k) Crane Race Ways
l) Crushers and Vibrators
m) Starter Bolts
08 Granite Industry
a) Gang Saw Machines
b) Fly Wheels
c) Steel Stanchions
d) Pumps & Motors
e) Generators
ESTIMATION
Estimating the quantity of grout material required is a
very important aspect because if the quantity is un-
derestimated, there may be shortfall while grouting or
if it is overestimated then there may be a substantial
amount of material remaining. Both these have to be
avoided and for this a thorough knowledge of estima-
tion is necessary.
Yield Of Grouts:
Product Yield
01 Conbextra GPI 13.7 ltrs/25 kg of grout
02 Conbextra GP2 13.3 ltrs/25 kg of grout
03 Conbextra Spl 12.5 ltrs/25 kg of grout
04 Conbextra HF 13.5 ltrs/25kg of grout @
fluid consistency
05 Conbextra EP101.5 ltrs / pack
06 Conbextra EP658 ltrs/pack
07 Conbextra EP120 8 ltrs/pack
08 Lokset Use table given in datasheet
In case aggregates are added to grouts then the
following method may be used to estimate the quan-
tity of material.
Example:
Volume of grouting :100 litres
S.G of aggregates :2.60
% of aggregates :1) 50%
2) 100%
Grout used :Conbextra GPI
Solution:
Yield per bag of 25 kg =13.7 litres
S.G of aggregate to be used = 2.60
i.e. Density = 2600 kg/m
3
i.e. for filling 1m
3
of volume 2600 kg of aggregate are
needed (Theoretically)
1 kg will fill 1/2600 m
3
=1/2600x1000 ltrs
1 kg of grout powder will yield 13.7/25 ltrs
Case (i) 50% Aggregates
1 kg of grout + 1/2 kg of aggregates will yield
=0.5 x 1000 + 13.7 =0.19+ 0.548
2600 25
=
0.740
For 100 ltrs, quantity of grout required =100/0.740
=135 kgs
Quantity of aggregate needed = 135/2 = 67.5 kgs
Case (ii) 100% Aggregates
1kg of grout + 1 kg of aggregates will yield
=1 x 1000 +13.7 =0.385 + 0.548
2600 25
= 0.933 ltrs
For 100 ltrs,
Quantity of grout needed=100/0.933 =107 kgs
Quantity of aggregates needed = 107 kgs
Similarly it can be calculated for Conbextra GP2 or
Conbextra Spl.
Note : For simple calculations the yield on adding
aggregates can be calculated as follows -
Quantity of aggregates added
Yield = Yield/bag of grout +S.G of aggregates
Eg : If 100% aggregates are added to Conbextra
GP2 and SG of aggregates is 2.7
25
Yield = 13.3 + = 13.3 + 9.25 = 22.55 ltrs
2.7
So 1 bag of Conbextra GP2 on addition of 100% ag-
gregates by weight will yield 22.5 ltrs of grout or say
22 ltrs of grout.
The quantity of material required depends on the
specific gravity of aggregates.
The method suggested here is theoretical.
There may be a slight deviation from actual results.
Take 5-10% extra to compensate for wastage.
Estimation Example:
Estimate the quantity of material needed to grout the
machine base plate and bolt pockets. The data is given
below.
01 Type of grout : Conbextra GP2
02 Type of aggregate : Cr us hed
granite
03 Specific gravity :2.60
100% aggregates for bolt pockets 1,3, 4 and 6 .
50% aggregates for pockets 2 & 5.
Neat grout for base plate.
Shoulders - 50mm on all sides.
Pouring side - 150mm
Level of grouting to be done - 1/2 thickness of base
plate
COMMON TECHNICAL
QUESTIONS /
OBJECTIONS RAISED :
Many a time it so happens that we may have to an-
swer a volley of questions put forth by the consultants
or customers or site engineers. Some of the questions
Ans. No. Please do not recommend any addition
of materials like sand, fibres, etc., to the
grout.
Q.7. Does quality or type of aggregates have any
affect on strength of grout?
Ans. Yes, The SG of aggregates affects the strength
of the grout. Please avoid using low SG ag-
gregates.
Q.8 Can the grout be mixed by hand for
small applications.
Ans. No. Hand mixing should never be al
lowed under any circumstances.
Q.9 Can aggregates be used with epoxy grouts.
Ans. Aggregates are not generally recommended
for use with epoxy grouts.
Q.10 Does rate of loading have any effect on
compressive strength of grout?
Ans. Yes with increase in rate of loading, there will
be a slight increase in strength.
Q.11 What is the rate of loading to be selected while
testing grouts and as per what standards.
Ans BS 4550 : Part 3 : Section 3.4 : 1978, Clause
2.7 specifies that rate of loading shall be 35
N/mm
2
per minute. Our grouts are treated
as hydrulic cement mortars and tested as per
IS:4031 ( Part 6) - 1988.
may look simple but it has been found that our
Engineers are not in a position to tackle them to the
satisfaction of the customer. In this section some of
the common questions asked by customers and an-
swers to the questions are presented.
Q.1 Can grouting be done in 2 or more stages? If
done will it not form a cold joint and affect the
performance.
Ans. Yes grouting can be done in 2 or more stages.
The joint formed will be in a horizontal plane
and will not affect the performance of the ma-
chine. Only if very high shear forces are acting
between the two layers, then there is a
possibility of the performance being affected.
Q.2 When the concrete for foundation is about
M25 or M30 why go for GP2 in case of DG
sets, TG sets etc.
Ans. Grout layer does not contain any reinforce-
ment unlike concrete in foundation. Hence this
layer has to be sufficiently strong to take care
of flexural, bond and tensile stresses acting. A
very high compressive strength is essential as
flexural, tensile and bond strength are directly
proportional to compressive strength and are
functions of it.
Q.3 Can 150mm size cube be used for testing
compressive strength of grouts.
Ans. No. For plain grout (without aggregates) it is
preferable to use 70.7mm size cubes or even
50mm cubes as per international standards.
Our neat grouts are tested equivalent to hy-
draulic cement mortars and they are tested in
70.7mm size cubes as per IS:4031. Incase 5-
12mm aggregates are used then either 70.7mm
size cubes or 100mm cubes may be used.
Q.4. Are your grouts heat resistant?
Ans. Our Conbextra grouts can withstand upto 200
deg.c. Never recommend Conbextra grouts
for Chimney linings and other areas where
temperatures are likely to cross 200 deg.C.
Q.5 When aggregates are added to grout, will it
not reduce the compressive strength of grout?
Ans. No. In fact addition of 50-100% aggregates
improves the strength by 5-10%.
Q.6. Can fibres like steel or vegetable fibres be
added to grout mix to improve its proper-
ties?