epoxy grout specification

COMPLETE REVISIONOctober 2001

Process Industry PracticesStructural

PIP STS03601Epoxy Grout Specification

PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES

In an effort to minimize the cost of process industry facilities, this Practice hasbeen prepared from the technical requirements in the existing standards of majorindustrial users, contractors, or standards organizations. By harmonizing thesetechnical requirements into a single set of Practices, administrative, application, andengineering costs to both the purchaser and the manufacturer should be reduced. Whilethis Practice is expected to incorporate the majority of requirements of most users,individual applications may involve requirements that will be appended to and takeprecedence over this Practice. Determinations concerning fitness for purpose andparticular matters or application of the Practice to particular project or engineeringsituations should not be made solely on information contained in these materials. Theuse of trade names from time to time should not be viewed as an expression ofpreference but rather recognized as normal usage in the trade. Other brands having thesame specifications are equally correct and may be substituted for those named. AllPractices or guidelines are intended to be consistent with applicable laws andregulations including OSHA requirements. To the extent these Practices or guidelinesshould conflict with OSHA or other applicable laws or regulations, such laws orregulations must be followed. Consult an appropriate professional before applying oracting on any material contained in or suggested by the Practice.

This Practice is subject to revision at any time by the responsible Function Teamand will be reviewed every 5 years. This Practice will be revised, reaffirmed, orwithdrawn. Information on whether this Practice has been revised may be found atwww.pip.org.

© Process Industry Practices (PIP), Construction Industry Institute, TheUniversity of Texas at Austin, 3925 West Braker Lane (R4500), Austin,Texas 78759. PIP member companies and subscribers may copy this Practicefor their internal use. Changes, overlays, addenda, or modifications of anykind are not permitted within any PIP Practice without the express writtenauthorization of PIP.

PRINTING HISTORYNovember 1996 IssuedOctober 2001 Complete Revision

Not printed with State funds

COMPLETE REVISIONOctober 2001

Process Industry Practices Page 1 of 7

Process Industry PracticesStructural

PIP STS03601Epoxy Grout Specification

Table of Contents

1. Introduction..................................21.1 Purpose ............................................. 21.2 Scope................................................. 2

2. References ...................................22.1 Process Industry Practices ................ 22.2 Industrial Codes and Standards ........ 22.3 Government Regulations ................... 3

3. Definitions ....................................3

4. General .........................................34.1 Field Quality Control of

Epoxy Grout ....................................... 34.2 Testing ............................................... 44.3 Submittals .......................................... 44.4 Safety................................................. 4

5. Products .......................................45.1 Materials ............................................ 4

6. Execution......................................56.1 Application ......................................... 56.2 Preparation ........................................ 56.3 Installation of Epoxy Grout................. 66.4 Disposal ............................................. 7

PIP STS03601 COMPLETE REVISIONEpoxy Grout Specification October 2001

Page 2 of 7 Process Industry Practices

1. Introduction

1.1 Purpose

This Practice provides the contractor with a specification for supply and installationof epoxy grout for machine baseplates and soleplates.

1.2 Scope

The contractor shall furnish all equipment, materials, labor, and supervision andshall perform all operations necessary for the foundation surface preparation,formwork, proper mixing, placing, finishing, and curing of epoxy grout, whereindicated by the contract documents.

Any conflicts or inconsistencies between this Practice, the design drawings, theepoxy grout manufacturer’s specifications and recommendations, the machine orequipment manufacturer’s recommendations, or other contract documents shall bebrought to the attention of the buyer for resolution before the performance of work.

The following items are referenced within this Practice but are to be completed byothers:

• Installing and leveling equipment or machine soleplates and baseplates

• Aligning equipment and machinery

2. References

When adopted in this Practice or in the contract documents, the latest edition of thefollowing codes, standards, specifications, and references in effect on the date of contractaward shall be used, except as otherwise specified. Short titles will be used herein whenappropriate.

2.1 Process Industry Practices (PIP)

− PIP STS03001 - Plain and Reinforced Concrete

− PIP REIE686 - Recommended Practices for Machinery Installation andInstallation Design

2.2 Industrial Codes and Standards

• American Petroleum Institute

− API 610, Appendix L - Baseplate and Soleplate Grouting

• American Standard Testing Methods (ASTM)

− ASTM C531 - Standard Test Method for Linear Shrinkage and Coefficient ofThermal Expansion of Chemical-Resistant Mortars, Grouts, MonolithicSurfacings, and Polymer Concretes

− ASTM C579 - Standard Test Method for Compressive Strength of Chemical-Resistant Mortars, Grouts, Monolithic Surfacings and Polymer Concretes

COMPLETE REVISION PIP STS03601October 2001 Epoxy Grout Specification


− ASTM C882 - Standard Test Method for Bond Strength of Epoxy-ResinSystems Used with Concrete by Slant Shear

− ASTM C1181 - Standard Test Methods for Compressive Creep of Chemical-Resistant Polymer Machinery Grouts

2.3 Government Regulations

Federal Standards and Instructions of the Occupational Safety and HealthAdministration (OSHA), including any additional requirements by state or localagencies that have jurisdiction where the epoxy grout is to be installed, shall apply,including the following:

− Code of Federal Regulations, OSHA Part 1910 and Part 1926

3. Definitions

buyer: The party who awards the contract to the contractor. The buyer may be the owner orthe owner’s authorized agent.

buyer’s inspector: The authorized representative of the buyer with authority to act in theinterest of, and on behalf of, the buyer in all quality assurance matters

contractor: The party responsible for the supply and installation of the epoxy grout. Unlessotherwise noted, the term contractor shall apply also to the contractor’s subcontractor(s)and/or vendors.

contract documents: Any and all documents, including design drawings, that the buyer hastransmitted or otherwise communicated, either by incorporation or by reference, and madepart of the legal contract agreement or purchase order agreement between the buyer and thecontractor

manufacturer: The party that produces and warrants the performance of the product

4. General

4.1 Field Quality Control of Epoxy Grout

4.1.1 The contractor shall be solely responsible for the quality control of allcontractor-supplied materials, installations, and workmanship, includingthose items or installations supplied by any of the contractor’ssubcontractors or vendors.

4.1.2 Notwithstanding the contractor’s responsibility for quality, the epoxy groutmanufacturer shall provide a technical representative who will be on-site forat least the first day of epoxy grout placement to review the set-up and toensure that the epoxy grout manufacturer’s installation instructions arefollowed. This requirement may be waived by written notice from the buyeror as otherwise directed in the contract documents.

4.1.3 The contractor and epoxy grout manufacturer’s technical representative shallcomplete the appropriate Grouting Checklists found in Chapter 5, Section 4,



of PIP REIE686 and shall submit these to the owner’s representative beforestarting to place epoxy grout.

4.1.4 The buyer reserves the right to make inspections at any time during mixingof the materials and during execution of all epoxy grout work.

4.2 Testing

4.2.1 After initial prequalification, epoxy grout may be sampled and tested ifrequired by the contract documents.

4.2.1.1 Minimum sample frequency is one per shipment or permanufacturing lot of grout. Each sample shall consist of sufficientcubes to complete the required tests.

4.2.1.2 Test each sample for compressive strength and linear shrinkage. SeeSection 5.1.1 of this Practice.

4.3 Submittals

4.3.1 When required in the contract documents or if an alternate epoxy grout isproposed before installation, the contractor shall submit to the buyer themanufacturer’s literature and certified test data for the epoxy grout and shallindicate the product’s properties as required by this Practice.

4.3.2 Fifteen days before installation, the contractor shall submit to the buyer, forreview and acceptance, a written quality control program describing in detailhow compliance with this Practice will be ensured. The program shallinclude all forming, handling, mixing, placing, joint locations, joint details,curing, testing, and inspection procedures.

4.4 Safety

The contractor shall comply with the safety requirements specified in the contractdocuments.

5. Products

5.1 Materials

5.1.1 Epoxy grout for equipment or machine baseplates shall meet the followingphysical properties (see API 610 Appendix L):

5.1.1.1 Minimum compressive strength (ASTM C579, Method B modified):12,000 psi (80 MPa) at 7 days

5.1.1.2 Maximum linear shrinkage (ASTM C531): 0.080 percent

5.1.1.3 Maximum coefficient of thermal expansion (ASTM C531): 30 x 10-6

inch/inch/°F (54 x 10-6 mm/mm/°C)

5.1.1.4 Maximum creep (ASTM 1181): 0.005 inch/inch (5 x 10-6 mm/mm),tested at 70°F (20°C) and 140°F (60°C) with 400 psi (2.8 MPa)applied vertical load



5.1.1.5 Minimum bond strength of epoxy grout to concrete (ASTM C882):2000 psi (14 MPa)

5.1.2 All materials shall be delivered to the job site in original unopened packagesand shall be stored in accordance with the manufacturer’s recommendations.All materials and tools shall be stored in a clean and organized manner.

6. Execution

6.1 Application

6.1.1 Epoxy grout thickness shall be as indicated in the contract documents.

6.2 Preparation

6.2.1 Foundations shall be suitably prepared before installation of formwork forgrout.

6.2.1.1 Remove laitance and oil-soaked or damaged concrete with chippinghammer to sound fractured aggregate, or to a minimum of the top1 inch (25 mm) of concrete.

6.2.1.2 When surface chipping is complete, remove all dust and looseparticles with clean, dry, oil-free air.

6.2.1.3 After cleaning, protect the foundation surface from contamination byapplying protective sheeting.

6.2.2 Suitable shelter or enclosures shall be provided to protect the foundation andbaseplate from direct sunlight, dew, rain, or other inclement weather. Duringcold weather, adequate enclosures and heating shall be provided to maintainfoundation and baseplate temperature within the acceptable range specifiedby the grout manufacturer. This temperature shall be maintained until thegrout has cured or until directed by the grout manufacturer.

6.2.3 Formwork for epoxy grout shall be constructed to be liquid-tight withadequate strength, rigidity, and dimension to permit epoxy grout placement.

6.2.3.1 Attach grout forms to concrete with drilled anchors or other methodwhen approved by the buyer. Power nailing is not permitted.

6.2.3.2 Apply three coats of paste wax to the inside surface of forms or useother methods as recommended by the epoxy grout manufacturer toprevent grout adherence. Oil or liquid wax is not permitted.

6.2.3.3 Install 1-inch (25-mm) 45° chamfer strips at each vertical corner andat the horizontal surface of the grout forms.

6.2.3.4 Seal all form joints and interface between forms and concretefoundation using grout manufacturer’s recommended sealant.

6.2.4 Anchor bolts shall be protected by sleeves, and exposed threads shall bewrapped with duct tape to prevent adherence of epoxy grout. Anchor boltsleeves shall be extended to the underside of the mounting plate, or the area



from the top of the anchor bolt sleeves and the bottom of the mounting plateshall be sealed to exclude epoxy grout.

6.2.5 Expansion joints in epoxy grout shall be spaced at a maximum of 48 inches(1.4 m) unless otherwise specified in the contract documents.

6.2.5.1 Expansion joints shall be made from closed-cell neoprene orpolyethylene foam board, having a minimum thickness of 1 inch(25 mm) unless otherwise noted in the contract documents.

6.2.5.2 Expansion joints shall be fixed into position to prevent movementand shall be sealed at formwork and at the concrete base to preventepoxy grout from passing around or underneath the joint duringplacement.

6.2.6 Concrete surfaces in contact with the epoxy grout shall be clean and dry attime of placement. Air used for blowing shall be clean, dry, and oil-free.

6.2.7 Reinforcement shall be installed as indicated in the contract documents andin accordance with PIP STS03001.

6.3 Installation of Epoxy Grout

6.3.1 Equipment and machine baseplates and soleplates shall be prepared andinstalled according to the requirements of PIP REIE686 before grouting.

6.3.2 Epoxy grout shall be stored, mixed, placed, and cured in accordance withmanufacturer’s written requirements, including temperature restrictions.

6.3.3 Dust and dirt accumulation shall be removed with clean, dry, oil-free airfrom surfaces that are to receive grout.

6.3.4 An adequate quantity of grout shall be on hand before starting to mix andplace grout. No partial units of epoxy, resins, hardener, or aggregate shall beused. The ratio of components shall not be varied, and solvent shall not beadded to change the grout consistency.

6.3.5 Grout placements shall be started at one end of the forms, and the cavityshall be filled completely while advancing toward the other end to preventair entrapment.

6.3.6 To avoid separation of aggregate from resin binder, vibration or other formsof dynamic distribution are not permitted.

6.3.7 The forms shall be checked for grout leaks frequently. Leaks will not self-seal and may cause voids in the grout if not stopped. All leaks shall be sealedto prevent voids from forming in the grout.

6.3.8 The grout shall be checked for voids after the grout has cured. Any voidsshall be filled according to the epoxy grout manufacturer’s instructions.

6.3.9 Exposed expansion joints shall be sealed with the epoxy groutmanufacturer’s recommended sealant.



6.3.10 Epoxy grout cannot be cut back after cure. The final level of the epoxy groutshall be flush with the top of horizontal chamfer edges built into theformwork.

6.4 Disposal

All materials shall be converted to solid waste for proper disposal. The procedure formaking solid waste in any type of hardener container is as follows:

a. Mix the hardener with the resin. This mixture is considered inert.

b. Pour excess hardener/resin mixture into the hardener container.

c. Close container and shake until excess hardener mixes with excesshardener/resin mixture.

This final mixture in the hardener container is considered inert for proper solid wastedisposal.

epoxy grout specification

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