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1、ACI 351.1R-99 became effective June 2, 1999. This report supercedes ACI 351.1R-93. Copyright 1999, American Concrete Institute. All rights reserved including rights of reproduction and use in any form or by any means, including the making of copies by any photo process, or by electronic or mechanica
2、l device, printed, written, or oral, or recording for sound or visual reproduc- tion or for use in any knowledge or retrieval system or device, unless permission in writing is obtained from the copyright proprietors. 351.1R-1 ACI Committee Reports, Guides, Standard Practices, and Commentaries are in
3、tended for guidance in planning, designing, executing, and inspecting construction. This document is intended for the use of individuals who are competent to evaluate the significance and limitations of its content and recommendations and who will accept re- sponsibility for the application of the m
4、aterial it contains. The American Concrete Institute disclaims any and all re- sponsibility for the stated principles. The Institute shall not be liable for any loss or damage arising therefrom. Reference to this document shall not be made in con- tract documents. If items found in this document are
5、 de- sired by the Architect/Engineer to be a part of the contract documents, they shall be restated in mandatory language for incorporation by the Architect/Engineer. Grouting between Foundations and Bases for Support of Equipment and Machinery ACI 351.1R-99 Reported by ACI Committee 351 Hamid Abdov
6、eisJames P. LeeL. E. Schwietz Sam HarshFred G. LouisAnthony J. Smalley C. Raymond HaysJack MollPhilip A. Smith Edward P. HolubNavin PandyaW. Tod Sutton Charles S. HughesIra PearceRobert C. Vallance Larry KernJohn RichardsAlan Wiley Erick N. LarsonAndrew RossiMatthew W. Wrona This report provides an
7、overview of current practices of grouting for sup- port of equipment and machinery. Materials and installation methods are described for hydraulic cement and epoxy grouts used as the load-transfer material between equipment bases and their foundations. Characteristics of placed material, test method
8、s for forecasting long-term performance, qualification of grout materials, foundation design and detailing considerations, and installation procedures are described. A listing of standard test methods and specifications is also included. Keywords: bleeding (concrete); consistency tests; curing; dura
9、bility; epoxy grout; formwork (construction); foundations; grout; hydraulic cement grout; inspection; mixing; placing; specifications; stiffness; strength; tests; volume-change. CONTENTS Chapter 1Introduction, p. 351.1R-2 1.1General 1.2Definitions 1.3Grout requirements 1.4Evolution of materials Chap
10、ter 2Properties of grout, p. 351.1R-4 2.1General 2.2Hydraulic cement grouts 2.3Epoxy grouts Chapter 3Requirements of materials for grout, p. 351.1R-6 3.1General 3.2Hydraulic cement grouts 3.3Epoxy grouts Chapter 4Testing of grout, p. 351.1R-8 4.1General 4.2Hydraulic cement grouts 4.3Epoxy grouts 4.4
11、Performance evaluation test Chapter 5Grouting considerations for foundation design and detailing, p. 351.1R-12 5.1General 5.2Machine or equipment bases 5.3Concrete foundation 5.4Anchorage design 5.5Clearances William L. Bounds Chairman Robert L. Rowan, Jr. Secretary 351.1R-2ACI COMMITTEE REPORT Chap
12、ter 6Preparation for grouting, p. 351.1R-13 6.1General 6.2Anchor bolt 6.3Concrete surface preparation 6.4Metal surfaces 6.5Formwork 6.6Safety and handling of epoxies Chapter 7Grouting procedures, p. 351.1R-14 7.1Consistency 7.2Temperature 7.3Mixing 7.4Placing 7.5Removal of excess material Chapter 8C
13、uring and protection, p. 351.1R-16 8.1Hydraulic cement grouts 8.2Epoxy grouts Chapter 9Construction engineering and testing, p. 351.1R-17 9.1General 9.2Hydraulic cement grouts 9.3Epoxy grouts 9.4Documentation Chapter 10References, p. 351.1R-17 10.1Recommended references CHAPTER 1INTRODUCTION 1.1Gene
14、ral This report provides an overview of current practices for grouting to support equipment and machinery. Recommen- dations are provided for those portions of the grouting oper- ation where a consensus could be developed among knowledgeable manufacturers and users. For areas where opinions differ,
15、various approaches are outlined. Many state- ments and much information contained in this report are based on unpublished manufacturers data and observations by technical representatives and users. The committee has re- viewed this unpublished information and considers it suit- able for use in the d
16、ocument. This report describes materials and installation methods for grouts used as load-transfer ma- terial between machine or equipment bases and their founda- tions. Characteristics of the placed material, test methods for forecasting their long-term performance, and installation procedures are
17、included. The information may also be appro- priate for other types of applications where filling of the space between load-carrying members is required, such as under column baseplates or in precast concrete joints. Machinery and equipment that have precise tolerances for alignment or require unifo
18、rm support cannot be placed di- rectly on finished concrete surfaces. Both the concrete sur- face and the machine base have irregularities that result in alignment difficulties and bearing load concentrations. For this reason, machine bases or soleplates are aligned and lev- eled by shimming or othe
19、r means, and the resulting space be- tween the machine base and the foundation filled with a load-transfer material. The load-transfer materials most frequently used are hy- draulic cement grouts and epoxy grouts. 1.2Definitions The following definitions are common terminology for base- plate grouti
20、ng work under machinery and equipment bases. These definitions are based on the terminology in ACI 116R. GroutA mixture of cementitious materials and water, with or without aggregate, proportioned to produce a pour- able consistency without segregation of the constituents; also a mixture of other co
21、nstituents (such as polymers) with a similar consistency. Dry packConcrete or mortar mixtures deposited and consolidated by dry packing. Dry packingPlacing of zero or near zero slump concrete, mortar, or grout by ramming into a confined space. Machine-base groutA grout that is used in the space be-
22、tween plates or machinery and the underlying foundation that is expected to maintain sufficient contact with the base to maintain uniform support. Hydraulic cement groutA mixture of hydraulic cement, aggregate, water, and additives (except dry pack). Preblended groutA commercially available, factory
23、 blended mixture of hydraulic cement, oven-dried aggregate, and other ingredients that requires only the addition of water and mixing at the job site. Sometimes termed premixed grout. Field-proportioned groutA hydraulic cement grout that is batched at the job site using water and predetermined pro-
24、portions of portland cement, aggregate, and admixtures. Epoxy groutA mixture of commercially available ingre- dients consisting of an epoxy bonding system, aggregate or fillers, and possibly other proprietary materials. ConsistencyThe relative mobility or ability of freshly mixed concrete, mortar, o
25、r grout to flow; the usual measure- ments are slump for concrete, flow for mortar or grout, and penetration resistance for neat cement paste. FluidThe consistency at which the grout will form a nearly level surface without vibration or rodding; the consis- tency of a grout that has an efflux time of
26、 less than 30 sec from the ASTM C 939 flow cone. FlowableThe consistency at which the grout will form a level surface when lightly rodded; the consistency of a grout with a flow of at least 125% at 5 drops on the ASTM C 230 flow table and an efflux time through the ASTM C 939 flow cone of more than
27、30 sec. PlasticThe consistency at which the grout will form a nearly level surface only when rodded or vibrated with a pen- cil vibrator; the consistency of a grout with a flow between 100 and 125% at 5 drops on the ASTM C 230 flow table. Volume changeAn increase or decrease in volume due to any cau
28、se. Thermal volume-changeThe increase or decrease in vol- ume caused by changes in temperature. Settlement shrinkageA reduction in volume of concrete or grout prior to the final set of cementitious mixtures, caused by settling of the solids and by the decrease in volume due to the chemical combinati
29、on of water with cement. In the 351.1R-3GROUTING FOR SUPPORT OF EQUIPMENT AND MACHINERY case of epoxy grout, minor settlement shrinkage may occur if the formulation includes volatile components. Drying shrinkageShrinkage resulting from loss of moisture or a reduction in the volume of the cement comp
30、o- nent after hydration. BleedingThe autogenous flow of mixing water within, or its emergence from, newly placed concrete or mortar; caused by the settlement of the solid materials within the mass; also called water gain. CreepTime-dependent deformation due to sustained load. EttringiteA mineral, hi
31、gh-sulfate calcium sulfoalumi- nate (3 CaOAl2O33 CaSO4 30-32 H2O), also written as Ca6Al(OH)62 24 H2O(SO4)31-1/2 H2O; occurring in nature or formed by sulfate attack on mortar and concrete; the product of the principal expansion-producing reaction in expansive cements; designated as “cement bacillus
32、” in older literature. 1.3Grout requirements After placement and hardening in the space between a ma- chine or equipment base and the foundation, the grout is ex- pected to perform one of the following functions: 1. Permanently maintain the original level and alignment of the machinery or equipment
33、and transfer all loads to the foundation when shims and other temporary positioning de- vices are removed. 2. Participate with shims or other alignment devices in the transfer of loads to the foundation. 3. Provide only lateral support or corrosion protection for shims or other alignment devices tha
34、t are designed to trans- fer all loads to the foundation. The descriptions given in this report are for applications where the grout is intended to transfer loads and maintain a long-term, effective bearing area without load-bearing shims left in place. While it is recognized that certain equip- men
35、t and machinery, such as rock crushers used in the min- ing industry, have been grouted and the shims left in place, these applications are not covered in this document. When shims are left in place, the grouts described herein will, in most cases, participate with shims in the load transfer. The pr
36、oportion of the load carried by the grout, however, de- pends on many variables such as size, number and location of shims, and the volume-change characteristics of the grout. Therefore, the participation of the grout cannot be deter- mined accurately. The most important requirement for a grout that
37、 is intended to transfer loads to the foundation is that it has volume- change characteristics that result in complete and permanent filling of the space. Plain grouts consisting of cement, aggre- gate, and water do not have these characteristics. Several other properties of the grout, such as consi
38、stency, strength, chemical resistance, and compatibility with the operating environment, are also important. These properties, however, are obtained more easily than the necessary volume-change characteristics. For most applications, the space between the foundation and the machinery or equipment ba
39、se can best be filled by flowing a grout into the space. To maintain permanent contact with the plate, a grout must be formulated using special ad- ditives with cementitious or epoxy systems. A plain sand-ce- ment grout with this consistency could be placed in the space and may develop adequate stre
40、ngth. After placement, how- ever, the sand-cement grout will lose contact with the plate because of settlement shrinkage and bleeding or drying shrinkage. The result will be an incompletely filled space, leaving the equipment resting primarily or completely on the shims or other alignment device. 1.
41、4Evolution of materials 1.4.1 GeneralSince the need for a material that can be placed between a machine base and the foundation developed, several placement methods and materials have evolved in an at- tempt to achieve the necessary volume-change characteristics. 1.4.2 Dry-pack (damp-pack)One of the
42、 first methods for permanently filling a space was to ram or dry-pack a damp, noncohesive mixture of sand and cement into the space. The mixture contains only enough water for compaction and hy- dration but not enough to permit settlement of the grouts constituents. The grout mixture has the consist
43、ency of damp sand and is placed in lifts of approximately 3 to 5 in. in thick- ness. Each lift is rammed in place between the base plate and the substrate concrete using a flat-faced wooden or metal tool. The end of the tool not in contact with the grout may be struck with a hammer to increase compa
44、ction. If properly placed, dry-pack grout is acceptable. It is diffi- cult, however (and in many cases impossible), to achieve proper placement. Dry-packing requires an almost unob- structed space and must be installed by skilled workers under the review by the engineer. 1.4.3 Grouts with aluminum p
45、owderAnother early method for making grout was to add a small amount usually 3 to 5 g per 90 lb (44 kg) of cement of aluminum powder to a plastic or flowable grout. The aluminum powder reacts with the soluble alkalies in the cement to form hydrogen gas. The gas formation causes the grout to increase
46、 in volume only while it is in the plastic state. The expansion is difficult to control due to the difficulty of blending very small quan- tities of aluminum powder into the mixture and the sensitiv- ity of the chemical reaction to temperature and soluble alkalies in the mixture. Aluminum powder gro
47、uts are dis- cussed further in Section 2.2.3.2. 1.4.4 Grouts with oxidizing iron aggregateIn the 1930s, an admixture was introduced that contained a graded iron ag- gregate combined with a water-reducing retarder, an oxidant (or catalyst), and possibly other chemicals. When blended in the field with
48、 cement, fine aggregate, and water, oxidation of the metallic aggregate during the first few days after harden- ing causes sufficient volume increase to compensate for set- tlement shrinkage. Metal oxidizing grouts are discussed further in Section 2.2.3.4. 1.4.5 Air-release systemIn the late 1960s,
49、a grout was developed that used specially processed fine carbon. These carbon particles release adsorbed air upon contact with the mixing water and cause an increase in volume while the grout is in the plastic state. The material is less temperature- 351.1R-4ACI COMMITTEE REPORT sensitive than aluminum powder and insensitive to the alkali content of the cement used. The air-release system is dis- cussed further in Section 2.2.3.3. 1.4.6 Grouts with expansive cementsIn the late 1960s, grouts were devel