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© 2019 Discovery Publication. All Rights Reserved. www.discoveryjournals.org OPEN ACCESS Page159 ARTICLE RESEARCH Testing for Cement Grouted Pavement – Low volume road Shrikant M Harle 1 , Prakash S Pajgade 2 1 Department of Civil Engineering, Professor Ram Meghe College of Engineering and Management, Badnera, India Email: [email protected] 2 Department of Civil Engineering, Professor Ram Meghe Institute of Technology and Research, Badnera, India Email: [email protected] Article History Received: 27 May 2019 Accepted: 16 July 2019 Published: August 2019 Citation Shrikant M Harle, Prakash S Pajgade. Testing for Cement Grouted Pavement – Low volume road. Science & Technology, 2019, 5, 159- 170 Publication License This work is licensed under a Creative Commons Attribution 4.0 International License. General Note Article is recommended to print as color digital version in recycled paper. ABSTRACT The low volume roads should be properly constructed so that the strength and durability will be achieved through economy. The research paper consists of rigorous testing for the cement grouted pavement as this comes in the category of low volume roads. The cement grouted pavement is constructed by just laying the aggregate in the formwork and then high strength grout is poured through gravity. The advantage of this construction is strength and durability achievement as compared to bituminous roads. This type of pavement considered in the category of semi-rigid pavement. The different types of grout are poured in the cubes and accordingly the tests are carried out. The partially filling and fully filling of the grout in the cubes is also carried out with trial and error, some ready mixed grouts are also tested. The developing countries like India will benefit from such research and development activities. Keywords: pavement, low volume, grout, semi-rigid and aggregates RESEARCH VOL. 5, 2019 ISSN 23943750 EISSN 23943769 SCIENCE TECHNOLOGY &

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Page 1: Testing for Cement Grouted Pavement Low volume road · Preparation of 150mmX150mm partially filled mould Take 6 moulds of size 150mmX150mm. Apply grease or oil on the inner surface

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ARTICLE RESEARCH

Testing for Cement Grouted Pavement – Low

volume road

Shrikant M Harle1, Prakash S Pajgade2

1Department of Civil Engineering, Professor Ram Meghe College of Engineering and Management, Badnera, India Email:

[email protected]

2Department of Civil Engineering, Professor Ram Meghe Institute of Technology and Research, Badnera, India Email:

[email protected]

Article History

Received: 27 May 2019

Accepted: 16 July 2019

Published: August 2019

Citation

Shrikant M Harle, Prakash S Pajgade. Testing for Cement Grouted Pavement – Low volume road. Science & Technology, 2019, 5, 159-

170

Publication License

This work is licensed under a Creative Commons Attribution 4.0 International License.

General Note

Article is recommended to print as color digital version in recycled paper.

ABSTRACT

The low volume roads should be properly constructed so that the strength and durability will be achieved through economy. The

research paper consists of rigorous testing for the cement grouted pavement as this comes in the category of low volume roads. The

cement grouted pavement is constructed by just laying the aggregate in the formwork and then high strength grout is poured

through gravity. The advantage of this construction is strength and durability achievement as compared to bituminous roads. This

type of pavement considered in the category of semi-rigid pavement. The different types of grout are poured in the cubes and

accordingly the tests are carried out. The partially filling and fully filling of the grout in the cubes is also carried out with trial and

error, some ready mixed grouts are also tested. The developing countries like India will benefit from such research and development

activities.

Keywords: pavement, low volume, grout, semi-rigid and aggregates

RESEARCH VOL. 5, 2019

ISSN 2394–3750

EISSN

2394–3769

SCIENCE TECHNOLOGY

&

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1. INTRODUCTION

General

Material used for filling the space or gap between the base or base plate of a column, trestle, machine etc. and the top surface of its

foundation is called grout and the process of filling grout is called grouting (Lin, et al., 2017, Schexnayder 2004). The grout must be

flowable and should have the enough strength. The main objectives of grouting is to maintain alignment of the erected structure or

equipment etc. accurately as well as to render the combination of it and its foundation monolithic (Sieglen and Langsdorff 2004, Ma,

Hou and Wu 2009). In case of structures like column, trestle and suchlike, this monolithic nature helps uniform transfer of load and

in case of a machine foundation it also imparts dynamic stability to the combination (Mampearachchi and Senadeera 2014, Rada, et

al., 1990). Various other kinds of grouts are also available in the market for various other purposes (Mahedi, Sahadat Hossain, et al.,

2017, Wu and Zhang, 2016). Grouts are integral elements of virtually all construction researches, especially industrial researches

(Teiborlang L. et al., 2005, Ni and Cheng, 2011). There are two most widely used grouts in such researches are:

a. Grouts prepared in-situ with Ordinary Portland Cement (OPC)

b. Ready to use or pre-mixed or pre-packed non-shrink grouts.

Few quite useful points about these two types of grouts are briefly discussed here.

a. Grouts prepared in-situ with Ordinary Portland cement (OPC)

Grout prepared in-situ is usually a simple mix of OPC & good quality, well graded sand. Sometimes, small sized stone chips i.e.

aggregates are also added in this type of grout. The ratio of cement to sand normally varies from 1:1 to 1:2 as per requirements.

These grouts are usually used in ordinary structures (Nehdi, et al., 2017). Water to cement (w/c) ratio for these grouts should be kept

as low as possible while ensuring the required workability too. In other words, w/c ratio should be just enough to render the mix

flowable which could be ascertained from trial mixes. Restricting this ratio is of almost importance from both strength & durability

point of views (Tan, et al., 2005). For gaps of thickness of 1″ and above, especially for large or heavy structures, it is appropriate to

use good quality stone chips of size 6mm & downgraded for better performance. The ratio of cement: sand: chips may be kept at

1:1:2

b) Ready to use or pre-mixed or pre-packed non-shrink grouts

For large machine/equipment foundations, tall or heavy structures etc., ready-to-use grouts, which come in many varieties with

diverse characteristics meant for diverse purpose, could be a much better choice from strength, durability or even workability point

of views. Non-shrink ready-to-use grouts are the ones tend to shrink in volume after hardening. Since, the extent of shrinkage is a

function of water content of the mix, it is quite necessary to maintain a low w/c ratio. W/c ratio usually needs to be increased as the

gap thickness increases (Zhang, et al., 2016).

Pre-packed, ready-to-use grouts have many advantages over ordinary grouts prepared in-situ with OPC. One need not worry

about procuring ingredients or mix proportion etc. as everything come ready in bags and it just needs to be mixed with water or the

prescribed fluid as per manufacturer’s literature. These grout are readily available with non-shrinking or free flowing characteristics,

eliminating issues like shrinkage of grout, workability etc. substantially (Yang and Weng 2015). Many of this grout is tailor-made for

specific purposes offering plenty of varieties to choose from for various purposes. Most of these compounds offer quite high

strength and could be chosen as per strength criteria as well (Cai, et al., 2017). As a simple rule of thumb for these grouts, when the

gap thickness is more than 1″ thick, the cement to sand ratio may be kept at 1:2 & maximum water to cement ratio restricted to

0.52. When the same is less than 1″ thick, the ratio may be adopted at 1:1 with the maximum and water to cement ratio restricted to

0.45.

How to perform mixing operation for grout

For mixing purpose, revolving type, tilting mixer of suitable capacity may be used. For preparing small quantity of grout,

large mixer drum is not suitable as proper mixing won’t take place. Mixing needs to be done for a minimum period of 3

minutes & mixing location should be as near as possible to the location of grouting (Pei et al., 2016).

Freshly mixed grout should be placed within 15 – 20 minutes of completion of mixing in order to maintain quality & the

quantity to be mixed may be estimated accordingly. Grouting operation should preferably be done from one direction only

in order to avoid air getting trapped within (Setyawan 2013). The grout needs to cover all shims to be retained and

completely fill the annular spaces of all anchor bolts.

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Once sufficiently set, the formwork is removed & excess grout, if any, is trimmed. Top surface of grout is float-finished

smooth and sloping mildly outwards. Curing for these grouts may commence immediately after a day of completion of

grouting and continue for a week (Oliveira, Thom and Zoorob 2008).

Regarding testing of cement-sand grouts prepared in-situ with OPC, cube compressive strength test is the usually adopted

one even though there are few other tests as well. No of cubes to be taken depends on quantity of mix and is usually

prescribed in relevant quality assurance documents.

The freshly filled cube moulds are kept undisturbed for 24 hours after which the grout cubes are removed from moulds and

submerged in water immediately. These are then taken out of water just prior to testing. Of the total number of cubes

taken, half may be tested for 3 days strength and the remaining half for 7 days

2. METHODOLOGY

The research describes the details of experimental programs for the research. All materials used, tests conducted, and the whole

process of preparation of the grout is discussed in this research.

Material used

For this research, various materials have been used, and all the materials have been tested. The entire tests conducted are briefly

discussed on all materials (table 1-6).

Cement: Ordinary Portland Cement (OPC) grade -53 with fineness of 4%, soundness of 2.5 mm, std. consistency of 37.5%,

initial setting time of 96 minutes and final setting time of 261 minutes.

Course aggregate

Sand

Fly-ash

Admixture

Water

Cement

Ordinary Portland Cement (OPC) of 53 grade is used in this research.

Table 1 Properties of cement used

Sr. No. Test performed Values

1. Standard Consistency 32.33 mm

2. Initial and final setting time 30 minutes & 600 Minutes

3. Soundness 3.5mm

Course aggregate

Table 2 Properties of coarse aggregate used

Sr. No.

Name of the tests

carried out on

coarse aggregate

Test result

found value

1. Specific Gravity 2.91

2. Impact value 13.84%

3. Abrasion test 6.8%

Sand

Locally available wardha sand is used for the preparation of grout. The tests performed on the sand is bulking of sand, when

measuring sand by volumes allowance should be kept for the fact that it can occupy a greater volume when it is wet. The extent of

bulking varies with the moisture content and coarseness of the sand.

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Table 3 Bulking of sand test result

Sr. No. % Water Height (h1) Height (h2) % Bulking

1. 4 12.9 13.9 7.75

2. 6 11.9 13.9 16.806

3. 10 11.7 13.9 18.803

Fly-ash

Fly ash available from Sofia Power plant is used in the preparation of grout.

Admixture

Mapie (M lab 50) and Mapefuild R 22 are used as an admixture in proper percentage for preparing proper grout with highest

strength.

This section presents the theoretical concept related to the subject of research as follows.

Aggregate Impact Value = (B/A) x 100%

Where,

A= 0.541 kg

B= 0.030 kg

Aggregate Impact Value = (0.030/0.541) x 100% = 5.54%

Los Angeles Abrasion Test

Abrasion value = (W2-W1)/W2 X 100

= 0.134/5 x 100

= 2.68%

Table 4 Initial and final setting time results

Sr. No. Time

(min)

Initial

Reading

Final

Reading

Settlement of

Needle

Penetration in

mm

1. 10 46 8 37

35 2. 20 46 10 36

3. 30 46 11 34

4. 40 46 12 33

Soundness

Table 5 Standard Consistency of Cement

Sr. No. % of water Initial

Reading

Final

Reading

Settlement of

plunger

Penetration

(mm)

1. 37 41 8 33

34.33

2. 34 43 8 35

3. 31 41 6 35

As per Indian standards, the penetration of the needle within paste should be 33 to 35 mm from the top of the mould.

Fineness of cement

Table 6 Fineness of cement

Sr. No. Weight of

sample (gram)

Weight of sample

retained on the

sieve (gram)

Fineness

in %

Average %

retained

1. 100 5.05 5.05

3.87 2. 100 4.87 4.87

3. 100 1.70 1.70

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Preparation of 150mmX150mm partially filled mould

Take 6 moulds of size 150mmX150mm.

Apply grease or oil on the inner surface of the moulds for the easy removal of the cubes after 24 hours.

Fill the aggregates in the empty moulds and then pour the prepared grout in the aggregate filled mould. While pouring the

prepared grout in the aggregate filled mould, vibration should be given to the mould to make the grout penetrated properly.

After this, keep the mould for 24 hours as it is for drying purpose and remove the cubes from the mould after 24 hours and put

them for curing.

Preparation of 150mmX150mm fully filled moulds

Take 6 moulds of size 150mmX150mm.

Apply grease or oil on the inner surface of the moulds for the easy removal of the cubes after 24 hours.

Fill the aggregates in the empty moulds in three layers and after each layer, pour the prepared grout in the aggregate filled

mould. While pouring the prepared grout in the aggregate filled mould, vibration should be given to the mould to make the

grout penetrated properly.

Repeat the same procedure for the remaining two layers of the aggregate.

After this, keep the mould for 24 hours as it is for drying purpose and remove the cubes from the mould after 24 hours and put

them for curing.

Preparation of 100mmX100mm fully filled moulds

Take 6 moulds of size 100mmX100mm.

Apply grease or oil on the inner surface of the moulds for the easy removal of the cubes after 24 hours.

Pour the prepared grout in the empty mould.

After this, keep the mould for 24 hours as it is for drying purpose and remove the cubes from the mould after 24 hours and put

them for curing.

Grout preparation

Self-made grout

The grout was prepared by referring the IS code 4031. Accordingly, the water to cement ratio taken was 0.22 and the percentage of

cement sand fly ash and water taken is as follows.

Cement = 42%

Crushed sand = 21%

Fly-ash = 22%

Admixture = 0.6%

Water = 15%

Total 18 cubes were prepared by using this grout, out of which, 6 cubes of size 150mmX150mm were filled partially (with

aggregate), 6 cubes of size 150mmX150mm were filled fully (with aggregate) and remaining 6 cubes of size 100mmX100mm were

filled with only grout (without using aggregate).

In addition to this, 3 beams were also casted using the same proportion and kept them for 3 days of its curing periods (figure 1).

Figure 1 Casting of self-made grout cubes filled with aggregates

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Mapefill 06 grout

Technical characteristics

Mapefill MC 06 is a ready-mixed powder composed of high strength cement, selected aggregates and special additives with an

expansive agent prepared according to a formula developed in MAPEI research laboratories. Mapefill MC 06, once mixed with water,

becomes a fluid mortar, suitable for pouring into formwork without separation of the aggregates even when forming great

thicknesses (figure 2).

Total 18 cubes were prepared by using this grout, out of which, 6 cubes of size 150mmX150mm were filled partially (with

aggregate), 6 cubes of size 150mmX150mm were filled fully (with aggregate) and remaining 6 cubes of size 100mmX100mm were

filled with only grout (without using aggregate).

Figure 2 Preparation of Mapefill-06 grout cubes filled with aggregates

Mapegrout T-40 grout

Total 18 cubes were prepared by using this grout, out of which, 6 cubes of size 150mmX150mm were filled partially (with

aggregate), 6 cubes of size 150mmX150mm were filled fully (with aggregate) and remaining 6 cubes of size 100mmX100mm were

filled with only grout (without using aggregate) (figure 3).

Figure 3 Cubes prepared for Mapegrout T-40

Mapegrout Sv grout

Mapegrout Sv is the grout which has fast setting and hardening time, compensated shrinkage, easy flow mortar, for repairing

concrete and for fixing drains, manhole covers and all types of urban fixtures and fittings.

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Total 18 cubes were prepared by using this grout, out of which, 6 cubes of size 150mmX150mm were filled partially (with

aggregate), 6 cubes of size 150mmX150mm were filled fully (with aggregate) and remaining 6 cubes of size 100mmX100mm were

filled with only grout (without using admixture) (figure 4).

Figure 4 Cubes filled with aggregates and Mapegrout-SV

Perma 60 Grout Grout

Quality of Perma 60

Water proofing system

Admixtures for concrete

Coating and protection system

Construction aids

Repair and bonding ages

Total 18 cubes were prepared by using this grout, out of which, 6 cubes of size 150mmX150mm were filled partially (with

aggregate), 6 cubes of size 150mmX150mm were filled fully (with aggregate) and remaining 6 cubes of size 100mmX100mm were

filled with only grout (Without using aggregate) (figure 5).

Figure 5 Cubes filled with aggregates and Perma-60 grout

Testing

Compressive strength test was performed in this study. The description of compressive strength test is as follows.

3. TESTING RESULTS

In this, compressive strength testing results of all the grout is mentioned as below.

Self-made grout

Testing result of self-made grout for 14 days and 28 days is given in the following table 7 and figure 6.

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Table 7 Compressive strength for cubes of self-made grout+aggregates

Sr. No. Name of Grout Size of moulds Cubes no. Compressive Strength in N/mm2

14 days curing Average 28 days curing Average

1.

Self Made Grout

150mmX150mm

(Fully filled)

1st 19.6

21.27

27.46

24.5 2nd 17.78 22.31

3rd 24.64 23.73

2. 150mmX150mm

(Partially Filled)

1st 21.33

22.07

24.88

24.69 2st 22.22 25.20

3rd 22.67 24.00

From the above test result, strength of fully filled self-made grout for 14 days and 28 days is 21.27 N/mm2 and 24.50 N/mm2

respectively, where as strength of partially filled self-made grout for 14 days and 28 days is 22.07 N/mm2 and 24.69 N/mm2

respectively.

Table 8 Compressive strength of self made grout

Sr. No. Name of

Grout Size of moulds

Cubes

no.

Compressive Strength in N/mm2

14 days curing Average 28 days

curing Average

1. Self Made

Grout 100mmX100mm

1st 15.8

20.5

28.2

29.33 2nd 23.0 38.2

3rd 22.7 21.3

From the above table 8, it is found that the strength of self-made grout (without aggregate) for 14 days and 28 days is 20.50

N/mm2 and 29.33 N/mm2 respectively.

Figure 6 After compressive strength of self made grout +aggregates cubes

Mapegrout T- 40 grout

Testing result of mapegrout T-40 grout for 14 days and 28 days is given in the following table 11 and figure 7.

Table 11 Compressive strength for cubes of Mapefill T-40 grout+aggregates

Sr. No. Name of Grout Size of moulds Cubes no. Compressive Strength in N/mm2

14 days curing Average 28 days curing Average

1.

Mapegrout

T-40

150mmX150mm

(Fully filled)

1st 13.88

10.07

11.52

10.66 2nd 11.24 9.23

3rd 5.11 12.25

2. 150mmX150mm

(Partially Filled)

1st 14.57

19.19

22.08

24.02 2st 21.68 24.80

3rd 21.33 25.20

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From the above test result, strength of fully filled mapegrout T-40 for 14 days and 28 days is 10.07 N/mm2 and 10.66 N/mm2

respectively, where as strength of partially filled mapegrout T-40 for 14 days and 28 days is 19.19 N/mm2 and 24.02 N/mm2

respectively.

Table 12 Compressive strength for cubes of Mapefill T-40 grout

Sr. No. Name of

Grout Size of moulds

Cubes

no.

Compressive Strength in N/mm2

14 days

curing Average

28 days

curing Average

1. Mapegrout

T-40 100mmX100mm

1st 29.60

29.83

35.7

35.40 2nd 32.50 34.2

3rd 27.40 36.3

From the above table 12, it is found that the strength of mapegrout T-40 (without aggregate) for 14 days and 28 days is 29.83

N/mm2 and 35.40 N/mm2 respectively.

Figure 7 After compressive strength of Mapefill T-60 grout+aggregates

Mapegrout Sv grout

Testing result of mapegrout SV grout for 14 days and 28 days is given in the following table 13.

Table 13 Compressive strength for cubes of Mapegrout-SV+aggregates

Sr. No. Name of Grout Size of moulds Cubes no. Compressive Strength in N/mm2

14 days curing Average 28 days curing Average

1.

Mapegrout

SV

150mmX150mm

(Fully filled)

1st 36.80

39.11

48.31

48.36 2nd 44.40 48.08

3rd 36.13 48.71

2. 150mmX150mm

(Partially Filled)

1st 35.24

39.52

36.29

39.97 2st 40.22 43.82

3rd 43.11 39.82

From the above test result, strength of fully filled mapegrout SV for 14 days and 28 days is 39.11 N/mm2 and 48.36 N/mm2

respectively, where as strength of partially filled mapegrout SV for 14 days and 28 days is 39.52 N/mm2 and 49.73 N/mm2

respectively.

Table 14 Compressive strength for cubes of Mapegrout-SV grout

Sr. No. Name of

Grout Size of moulds

Cubes

no.

Compressive Strength in N/mm2

14 days

curing Average

28 days

curing Average

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1. Mapegrout

SV 100mmX100mm

1st 16.2

18.03

21.10

26.10 2nd 22.5 27.70

3rd 15.4 29.50

From the above table 14, it is found that the strength of mapegrout SV (without aggregate) for 14 days and 28 days is 18.03

N/mm2 and 26.10 N/mm2 respectively.

Perma 60 grout

Testing result of perma 60 grout for 14 days and 28 days is given in the following table 15.

Table 15 Compressive strength for cubes of Perma-60 grout+aggregates

Sr. No. Name of Grout Size of moulds Cubes no. Compressive Strength in N/mm2

14 days curing Average 28 days curing Average

1.

Perma grout 60

150mmX150mm

(Fully filled)

1st 45.57

44.16

42.22

44.59 2nd 41.25 44.27

3rd 45.67 47.28

2. 150mmX150mm

(Partially Filled)

1st 46.57

45.40

45.23

45.65 2st 43.37 43.52

3rd 46.97 47.92

From the above test result, strength of fully filled perma 60 grout for 14 days and 28 days is 44.16 N/mm2 and N/mm2

respectively, where as strength of partially filled perma 60 grout for 14 days and 28 days is 45.65 N/mm2 and N/mm2 respectively.

Table 16 Compressive strength for cubes of Perma-60 grout

Sr. No. Name of

Grout Size of moulds

Cubes

no.

Compressive Strength in N/mm2

14 days

curing Average

28 days

curing Average

1.

Perma

grout

60

100mmX100mm

1st 32.80

26.56

27.30

29.16 2nd 22.20 29.50

3rd 24.7 30.70

From the above table 16, it is found that the strength of perma 60 grout (without aggregate) for 14 days and 28 days is 26.56

N/mm2 and 29.16 N/mm2 respectively.

Table 17 Testing results of grout prepared by diff. types of admixture

Sr. No. Name of Grout Cubes no. Compressive Strength in N/mm2

7 days curing Average 14 days curing Average

1. GROUT 1

(34% Fly-ash)

1st 19.20

20.44

29.66

31.82 2nd 19.73 32.54

3rd 22.40 33.25

2. GROUT 2

(30% Fly-ash)

1st 11.73

12.02

29.67

29.58 2nd 13.15 28.83

3rd 11.20 30.25

3. GROUT 3

(25%Fly-ash)

1st 11.70

10.95

28.70

27.70 2nd 9.95 27.30

3rd 11.2 27.11

4. GROUT 4

(SBR)

1st 23.467

23.64

32.825

34.79 2st 21.689 35.277

3rd 25.778 36.279

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The compressive strength obtained by the GROUT 1 , GROUT 2, GROUT 3 and GROUT 4 for 7 days of its curing period were

20.444N/mm2 , 12.02 N/mm2, 10.95 N/mm2, and 23.64 N/mm2 respectively. The compressive strength obtained by the GROUT 1 ,

GROUT 2, GROUT 3 and GROUT 4 for 14 days of its curing period were 31.82 N/mm2 , 29.58 N/mm2, 27.70 N/mm2, and 34.79

N/mm2 respectively (table 17).

4. CONCLUSION

Perma 60 grout, mapegrout SV and self-made grout gives the highest strength as compared to mapegrout T-40, whereas mapefill

06 is the failure grout. Mapegrout SV is most costly that the all among grouts, as the cost of one bag of mapegrout SV (50 kg grout)

is 2070/- hence it is not economical to use this grout. Considering the economy and strength factor, only two grouts i.e. perma 60

grout and self-made grout is the best as it gives more strength with economy. Hence it is better to use the perma 60 grout and self-

made grout. We can use these grout for repairing concrete floorings for industrial use, shopping centers and warehouses. These can

be used for repairing concrete floorings in airports, repairing pedestrian concrete pavements, fixing road signs, etc. Grouts can be

used for anchor or base plate grouting, under machineries, etc.

RREEFFEERREENNCCEE

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