Sika Ag · SIX:SIKA
Sika — Technical Presentation
71 slides from Sika's technical presentation
Slide 1: Principles of Grouting Critical Equipment
PRINCIPLES OF GROUTING CRITICAL EQUIPMENT CHRIS HARDY DISTRICT MANAGER
Slide 2: Introduction
INTRODUCTION ▪ 20 years of industrial and commercial concrete experience ▪ Concentration in civil construction, grouting, and infrastructure repair/restoration
Slide 3: Sika Grout History & Commitment
SIKA GROUT HISTORY & COMMITMENT ▪ Over 100 years of experience, innovation, & expertise ▪ A dedicated team supporting a full range of solutions to the Power and Industrial Sector ▪ Inventor of non-shrink cementitious grout and epoxy grout ▪ Developed first non-shrink, cement grout in the 1920’s ▪ In
Slide 4: Sika contacts
Jay Patel Business Development Manager Chris Hardy patel.jay@us.sika.com District Manager 952-212-4475 hardy.chris@us.sika.com 985-320-8930 Chris Hardy District Manager hardy.chris@us.sika.com 985-320-8930 Jon Leavell Territory Manager leavell.jonathan@us.sika.com 216-990-5143 Chris Hardy District M
Slide 5: Discussion Topics / Agenda
DISCUSSION TOPICS / AGENDA What is Grout? onsectetur adipiscing elit Why is Grout Used? onsectetur adipiscing elit Types of Grouts onsectetur adipiscing elit The Equipment Foundation System (the elements and how they work together) onsectetur adipiscing elit Grout Selection & Properties onsectetur a
Slide 6: What Is Grout?
WHAT IS GROUT? ▪ Grout (governed by ASTM C1107) is defined as a material composed of hydraulic cement, fine aggregate, and other ingredients intended to be used under an applied load where changes in height below the initial placement height are to be avoided.
Slide 7: Why Is Grout Used?
WHY IS GROUT USED? Why not drill and fix plates directly to concrete foundations? Base plate ▪ Uniformly transfer load to foundation ▪ Resist applied forces ▪ Irregularities between foundation and plate ▪ Fill voids, keep them full, remain durable Concrete Foundation Uneven concrete foundation leads
Slide 8: Causes of Excessive Vibration in Equipment
CAUSES OF EXCESSIVE VIBRATION IN EQUIPMENT Misalignment and induced vibration: ▪ Poor alignment during install ▪ Misalignment from wear and excess vibration of internal components (unbalanced/high pulsation) ▪ Grout (or lack thereof) induced misalignment Types: ▪ Parallel ▪ Angular ▪ Axial
Slide 9: Excess Vibration
EXCESS VIBRATION Full-format picture
Slide 10: Excess Vibration
EXCESS VIBRATION
Slide 11: Excess Vibration
EXCESS VIBRATION 2 BUILDING TRUST yi
Slide 12: Why Is Vibration Important to an Owner?
WHY IS VIBRATION IMPORTANT TO AN OWNER? ▪ Excess vibration can cause premature wearing of critical components and reduce MTBF ▪ Safety ▪ Facility Maintenance strategies ▪ Set up based on two types of costs: ▪ Repair costs ▪ Production downtime costs
Slide 13: Types of Grout
TYPES OF GROUT ▪ Precision Non-Shrink Grout Grouts ▪ Cement based grout, volume change well Construction defined, versatile Use Precision Grouts Grouts Polymer ▪ Metallic Aggregate Grouts Cement Based Based Cement Based ▪ Cement based grout, impact resistant, high Mineral Metallic temps, steel mills
Slide 14: Equipment Foundation System
EQUIPMENT FOUNDATION SYSTEM Transfer static/dynamic loads, vibration, impact and rotational torque from equipment, through the grout and into the foundation to maintain alignment and limit wear and tear on machinery parts ▪ Equipment ▪ Shims / Dampening ▪ Baseplate / Soleplate ▪ Grout ▪ Jack bolts ▪
Slide 15: The Foundation
THE FOUNDATION ▪ Reinforced Concrete Foundation Block ▪ Concrete Footing / Piles / Mat ▪ Soil
Slide 16: Anchor Bolt Purpose
ANCHOR BOLT PURPOSE ▪ Attach equipment firmly to the foundation ▪ Stretched elastically like a spring ▪ Transmit loads from equipment to the foundation ▪ Just as important as grout ▪ Grout – prevents downward movement ▪ Bolt – prevents upward movement ▪ Resist horizontal forces ▪ Must be placed unde
Slide 17: The Vital Link
THE VITAL LINK “Bridging Structural Engineering with Mechanical Engineering” ▪ Equipment (Mechanical Engineering) ▪ Grout (The Vital Link) ▪ Foundation (Structural Engineering)
Slide 18: Grout Purpose
GROUT PURPOSE ▪ Fills space between equipment and concrete foundation ▪ Fills irregularities / voids between concrete and plate ▪ Maintains proper original alignment over life of machine (20+ years) ▪ Contains or absorbs unbalanced forces into foundation without excessive equipment movement ▪ Concre
Slide 19: Grout Selection – Balance of Properties
GROUT SELECTION – BALANCE OF PROPERTIES
Slide 20: Compressive Strength Comparisons
COMPRESSIVE STRENGTH COMPARISONS Good ductility = good cube shape under testing; doesn’t shatter or fracture; not too brittle
Slide 21: High Modulus / Low Modulus
HIGH MODULUS / LOW MODULUS ▪ ASTM C 580 ▪ Measures the ability of the grout to resist deflection under load ▪ Lower modulus than concrete ▪ Ability to withstand dynamic loads ▪ Too low of a modulus can result in a higher potential for creep
Slide 22: Creep
CREEP ▪ ASTM C1181 ▪ Measure the total compressive deflection under a sustained load ▪ Creep is defined as a permanent deformation occurring at a stress less than the yield stress. ▪ Comparisons can only be made under same load and temperature conditions ▪ Specifications should include both ▪ Critic
Slide 23: Flowability, Bearing Area
FLOWABILITY, BEARING AREA ▪ ASTM C1339 (flow box testing) - Flowability and Bearing Area ▪ Measures flow time and ability to flow under and across full dimension of equipment ▪ Using aggregate content specified by manufacturer per test results ▪ Note: Bearing area is compromised when contractors rem
Slide 24: Grout Box Flow Test Video
GROUT BOX FLOW TEST VIDEO 00:00:00 2 BUILDING TRUST yi
Slide 25: Flow Box Video – Grout Comparisons
FLOW BOX VIDEO – GROUT COMPARISONS
Slide 26: Bearing Area – Grout Comparisons
BEARING AREA – GROUT COMPARISONS ▪ Visual bearing area after 16 hours in mold after flow test – shows what is hidden in the field under steel!
Slide 27: Bearing Area – Quantifiable Test Method
BEARING AREA – QUANTIFIABLE TEST METHOD ▪ Remove plexiglass plate ▪ Wire brush grout sample ▪ Dust surface with white talc powder ▪ Photograph and scan ▪ Computerized histogram ▪ Covert scan to black and white ▪ Calculate percentage of light vs. dark areas ▪ MasterFlow 648 > 95% contact (best perfor
Slide 28: Bearing Area Issues
BEARING ARE ISSUES ▪ Large aggregate at top of grout cap can serve as barrier between epoxy and steel ▪ Causing poor bonding ▪ Voids can be caused by material, mixing, placement, excessive flow ▪ Outgassing evident in red photo ▪ Air migrates to grout surface ▪ A highly flowable grout may have highe
Slide 29: Coefficient of Thermal Expansion
COEFFICIENT OF THERMAL EXPANSION ▪ ASTM C 531 ▪ Standard Test Method for Linear Shrinkage and CTE of Polymer Grouts ▪ Measures the volume change of a material ▪ Shrinkage or expansion after hardening or as in-service temperatures increase and decrease ▪ Grout, baseplate, and concrete have different
Slide 30: Peak Exothermic Reaction
PEAK EXOTHERMIC REACTION ▪ Maximum temperature that grout reaches during cure ▪ Differences between peak exotherm and foundation, ambient temperatures: ▪ Localized stress at bolts and bond lines, causing cracks ▪ High and fast reaching peak exotherm of material can lead to brittle material and stres
Slide 31: Proper Mixing, Installation, & Testing
PROPER MIXING, INSTALLATION, & TESTING ▪ Temperature Conditioning ▪ Material, foundation, and equipment ideally at 60°F to 80°F for 48 hours prior to and after grouting (per API 686) ▪ Too cool - affects grout flowability, strength gain ▪ Too hot – increases cure, material working time ▪ Protective
Slide 32: Foundation Preparation for Grout
FOUNDATION PREPARATION FOR GROUT ▪ Clean, non-contaminated surface ▪ Surface profile per API guidelines ▪ Exposed, fractured coarse aggregate ▪ Removed oil-soaked, damaged concrete ▪ Preferred chipping tools ▪ Unlike concrete, epoxy won’t bond well to a wet surface ▪ Chamfered perimeter of concrete
Slide 33: Edge of Slab Detail
EDGE OF SLAB DETAIL ▪ Avoid placing grout to edge of slab when possible ▪ Limit shoulder to 2” width and apply protective coating per API 686 Chapter 5, Section 3.15.6 ▪ If grout shoulder extends at or beyond the top mat of the horizontal and vertical rebar of the foundation: ▪ Chamfer the edge of t
Slide 34: Concrete Surface Profile – ICRI
CONCRETE SURFACE PROFILE – INTERNATIONAL CONCRETE REPAIR INSTITUTE (ICRI)
Slide 35: Foundation – API 686 Surface Prep
FOUNDATION – API 686 SURFACE PREP ▪ Clean, dry, sound ▪ 1” (25mm) CSP ▪ No bush hammers
Slide 36: Liquid Surface Etchant
LIQUID SURFACE ETCHANT 2 BUILDING TRUST yi
Slide 37: Liquid Surface Etchant
LIQUID SURFACE ETCHANT BUILDING TRUST VN
Slide 38: Grout Termination Details
GROUT TERMINATION DETAILS Large Shoulders Small Shoulders ▪ Large shoulder width pinning or use of ▪ Dimension X less than Y, shoulder width wickets to secure epoxy grout less than epoxy grout depth
Slide 39: Baseplate & Soleplate Preparation
BASEPLATE & SOLEPLATE PREPARATION ▪ Proper radius on outside corners ▪ Prevent cracking due to stress concentration ▪ Machined top surfaces ▪ Sandblasted bottom surface if exposure time to elements is short ▪ Otherwise, epoxy primer approved by grout manufacturer can be used, but surface should be r
Slide 40: Equipment Bases – API 610
EQUIPMENT BASES – API 610 ▪ Equipment shall be designed and constructed for a minimum service life of 20 years and at least 3 years of uninterrupted operation ▪ Excluding normal wear parts, i.e. wear rings, shaft sleeve, gaskets ▪ Single-piece drain-rim or drain-pan shall be furnished for all horizo
Slide 41: Equipment Bases – API 610
EQUIPMENT BASES – API 610 ▪ All baseplates shall be provided with at least one grout hole having: ▪ Clearing area of 125 cm²(19 in²) ▪ No dimension less than 75 mm (3 in) in each bulkhead section ▪ Grout holes shall be located to permit filling entire cavity under the baseplate without creating air
Slide 42: Equipment Bases – API 610
EQUIPMENT BASES – API 610 ▪ Vendor shall commercially sand-blast all grout contact surfaces of the baseplate, and coat those with a primer compatible with the grout ▪ Inorganic zinc coatings are at times applied too thick, which can make them brittle and leads to chipping, scuffing and separation ▪
Slide 43: Anchoring
ANCHORING ▪ Anchor bolt sleeves are clean, dry, fill with nonbonding material ▪ Anchor bolt threads should be covered to: ▪ Keep them clean ▪ Prevent damage ▪ Prevent grout from adhering ▪ Assure anchors are aligned with bolt pattern ▪ Lateral movement for alignment purposes shall next exceed ¼” ▪ S
Slide 44: Expansion Joints
EXPANSION JOINTS ▪ Incorporated into large epoxy grout pours to reduce the potential of cracking ▪ Reduce epoxy grout volume which reduces exothermic reaction temperature ▪ Breaks up the epoxy grout pour into smaller pours: ▪ Reduce epoxy grout volume which reduces exothermic reaction temperature ▪
Slide 45: Expansion Joints
EXPANSION JOINTS ▪ Closed-cell neoprene foam ½” (13mm) to 1” (25mm) wide ▪ Placed every 4’ (1.2 meters) to 6’ (1.8 meters) intervals ▪ Placed ½ (13mm)” to 1” (25mm) to either side of the cross members ▪ Away from anchor bolts ▪ Glued into position with epoxy adhesive or RTV silicone ▪ Sealed after g
Slide 46: Expansion Joints
EXPANSION JOINTS BUILDING TRUST
Slide 47: Grout Placement Formwork
GROUT PLACEMENT FORMWORK ▪ Sturdy and suitable materials ▪ Well braced to resist grout pressure ▪ Accessible, watertight, non-absorptive ▪ Sufficient clearance (2’’-3’’) from baseplate ▪ For grout placement, air escape ▪ Bond breaker for epoxy grouts ▪ To prevent grout bonding to forms ▪ Sealed to p
Slide 48: Grout Placement Preparation
GROUT PLACEMENT PREPARATION ▪ Proper equipment and sequence of operations is critical to success ▪ Mixing equipment / time ▪ Transportation and filling methods ▪ Movement tools ▪ Avoidance of air bubbles ▪ Flow direction / rate, head pressure ▪ Pour from one side to other, or from middle in both dir
Slide 49: Mixing – API 686
MIXING – API 686 ▪ No partial units of epoxy, resin, hardener, OR aggregate are to be used ▪ Fully loaded aggregate grout systems only ▪ Resin and hardener are to be mixed with a jiffy mixer ▪ Mortar mixer used to blend epoxy and full bags of aggregate ▪ Aggregate must be mixed until completely wet-
Slide 50: Grout Mixing
GROUT MIXING >>
Slide 51: Installation
INSTALLATION ▪ Place from one side or from the middle out ▪ Maintain continuous head pressure ▪ Do not pour around the perimeter of the mounting plate
Slide 52: Pumping Precision Grouts
PUMPING PRECISION GROUTS ▪ Equipment: ▪ Piston ▪ Rotor Stator ▪ Peristaltic
Slide 53: Pumping MasterFlow Grouts
PUMPING MASTERFLOW GROUTS
Slide 54: Pumping MasterFlow Grouts
PUMPING MASTERFLOW GROUTS BUILDING TRUST yi
Slide 55: Large Skid Grouting with Deep Cavities
LARGE SKID GROUTING WITH DEEP CAVITIES ▪ Lock-in skid to the foundation with initial pour ▪ Subsequent lifts can be placed after grout has reached peak exothermic reaction ▪ Overfill skid to account for any settlement
Slide 56: Large Skid Grouting with Deep Cavities
LARGE SKID GROUTING WITH DEEP CAVITIES
Slide 57: Compressive Strength Testing
COMPRESSIVE STRENGTH TESTING ▪ ASTM C 579, Method B, Load Rate II ▪ 2” Cubes ▪ Brass Molds or Steel Molds ▪ Ductility = measure of material’s ability to undergo appreciable plastic deformation before fracture ▪ MF648 – high early and ultimate compressive strengths for early commissioning ▪ Ductile,
Slide 58: Compressive Strength – Casting of Grout Cubes
COMPRESSIVE STRENGTH – CASTING OF GROUT CUBES
Slide 59: Sample Fabrication – ASTM C-109 Tamper Pattern
SAMPLE FABRICATION – ASTM C-109 TAMPER PATTERN Tamping pattern repeated for each of two lifts 1 5 7 5 6 8 2 6 3 7 3 1 2 4 4 8
Slide 60: Load Cubes in Test Machine
LOAD CUBES IN TEST MACHINE ▪ Verify that: ▪ Spherical seat moves freely ▪ Cube will be loaded on two parallel molded faces (not the rough top surface) ▪ Upper & Lower loading platens are clean, and perfectly aligned ▪ Test machine has capacity to break at expected strengths ▪ ASTM C579 Method B, loa
Slide 61: Break Cubes & Record Data
BREAK CUBES & RECORD DATA ▪ Cube is set with cast top surface on side ▪ Load at a constant rate between 200 - 400 lbs/sec for cementitious grouts ▪ Crosshead speed of 0.20 – 0.25 in/min for epoxy grouts (2” cubes) ▪ Load rate will drop as cube begins to yield near failure; do not adjust it ▪ Continu
Slide 62: What Can Contribute to Low Strengths?
WHAT CAN CONTRIBUTE TO LOW STRENGTHS? Identifying the likely causes for low compressive strength test results Prep Mix Mold Cure Break
Slide 63: Post Grouting Coating API 686
POST GROUTING COATING API 686 ▪ Entire top surface of machinery foundation shall be painted with grout- compatible non-skid protective coating ▪ Protect foundation cap from oil and weathering ▪ Coating shall extend down from the top of the foundation at least 18”
Slide 64: Filling of Grout Voids – API 686
FILLING OF GROUT VOIDS – API 686 ▪ After grout has cured, check for voids by sounding the top deck ▪ Grout voids should not be accepted as “normal” ▪ Mark the void areas ▪ Void areas are to be filled by drilling NPT 1/8” holes in opposite corners of each void area ▪ One hole in each void is to be ta
Slide 65: Filling of Grout Voids
FILLING OF GROUT VOIDS
Slide 66: Methanol Plant in Gulf Coast
METHANOL PLANT IN GULF COAST Included 6 Flowserve compressors grouted with MasterFlow 678
Slide 67: MasterFlow 678 Low Dust Aggregate Comparison
MASTERFLOW 678 LOW DUST AGGREGATE COMPARISON
Slide 68: Petrochemical Plant Expansion – Gulf Coast
PETROCHEMICAL PLANT EXPANSION – GULF COAST
Slide 69: MasterFlow 648 Low Dust Competitive Flow Box Video
MASTERFLOW 648 LOW DUST COMPETITIVE FLOW BOX VIDEO
Slide 70: MasterFlow 648 Low Dust & Competitor Aggregate Comparison
MASTERFLOW 648 LOW DUST & COMPETITOR AGGREGATE COMPARISON
Slide 71: Chris Hardy
CHRIS HARDY 985-320-8930 HARDY.CHRIS@US.SIKA.COM