The Grouting Handbook: A Step-by-Step Guide to Heavy Equipment Grouting
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Table of contents
- Cover
- The Grouting Handbooki
- Copyright Pageii
- Contentsiii
- Prefaceix
- Chapter 1. The Foundation1
- The Initial Machinery Foundation Design1
- Reciprocating Compressor and Engine Foundations1
- Skid-Mounted Equipment Foundations3
- Foundations for Centrifugal Pumps3
- Foundation Mass to Equipment Weight Ratio for Pumps7
- Soil Conditions7
- Concrete for the Foundation9
- Adding Water to the Concrete Mix at the Job Site9
- The Concrete Mix11
- Placing Concrete in Hot Weather13
- Pouring Concrete in Cold Weather14
- Concrete Curing for Machinery Foundations15
- Methods for Curing Concrete15
- Types of Portland Cement16
- Contamination of the Foundation18
- Guidelines for Use of Epoxy Grout on Oil-Saturated Concrete18
- The Acceptable Moisture Content in Concrete, or How Soon Can We Pour the Epoxy Grout on the New Conc20
- Chapter 2. Anchor Bolts22
- The Basics of Anchor Bolts22
- Measuring Equipment Pull-Down at the Anchor Bolts25
- Determination of Anchor Bolt Pullout Strengths26
- Machinery Reliability Starts with the Anchor Bolts29
- How Anchor Bolts Behave29
- Conventional Procedures for Achieving Initial Anchor Bolt Tension35
- Types of Material Normally Used for Anchor Bolts of 1-11/2 in. in Diameter36
- Typical Ways of Applying, or Measuring, Anchor Bolt Preload or Tension36
- Seven Possible Causes of Loss of Preload in Anchor Bolts37
- Bolt Tensioning Devices Currently Available42
- The Easy Way To Observe and Monitor Anchor Bolt Preload, Both Initial and Residual45
- Load-Generating Washers48
- Ultimate Systems50
- Conclusion50
- Proper Anchor Bolt Tensioning51
- The Following Are Rules of Thumb for Anchor Bolt Tensioning52
- "Is It Safer to Over-Tighten an Anchor Bolt Than To Under-Tighten It?"53
- Chapter 3. Cement Grout54
- A Comparison between Epoxy and Cement Grouts, or Which Product Should We Use?54
- Conclusion59
- Merits of Epoxy Grouts versus Cement Grouts59
- Cementious Grouts: Cement Grouting in Real Life60
- Concrete Surface Preparation60
- Temperature61
- Mixing Cement Grout62
- Placing and Curing63
- Cement Grouting in Hot Weather63
- Recommended Temperature Guidelines for Hot Weather64
- When Cooling Cannot Be Accomplished65
- Cement Grouting in Cold Weather66
- Recommended Temperature Guidelines for Cold Weather66
- Chapter 4. Epoxy Grout69
- An Introduction to Epoxies69
- The Chemistry of Epoxy Grout70
- General Characteristics of Epoxy Grouts71
- Terminology73
- ASTM C 1181 Calls for77
- Conclusion79
- General Installation Procedures for Epoxy Grout80
- Concrete Temperature80
- Ambient Temperature and Its Effect on Epoxy Grout81
- Epoxy Grouting in Cold Weather81
- Epoxy Grouting in Hot Weather82
- Epoxy Grout Flow versus Clearance83
- Chapter 5. Selecting an Epoxy Grout85
- Chapter 6. The Use of Rebar and Expansion Joints in Epoxy Grout89
- Edgelifting: Cause and Cure92
- Why and When To Use Expansion Joints in Epoxy Grout94
- Suggested Expansion Joint Locations and Basic Construction Material95
- The Secondary Seal97
- The Primary Seal97
- Mixing Elastomeric Epoxy Expansion Joint Compound and Sand98
- Other Methods for Expansion Joint Design98
- Chapter 7. Cracking in Epoxy Grout100
- Thermal Stress Cracks100
- Mechanical Stress Cracks100
- Vertical Cracks101
- Horizontal Cracks102
- Chapter 8. Making Deep Pours with Epoxy Grout104
- Grout and Concrete Removal105
- Grout Placement105
- What Is the Possibility of Cracking?106
- Is Making Deep Pours with Epoxy Grout Too Costly?106
- Chapter 9. Surface Preparation of Concrete and Steel107
- Surface Preparation of Concrete for Grouting107
- The Preparation of a Steel Surface110
- How Well Is the Primer Bonded to the Steel Plate or Machine Base?110
- How Clean Does the Primer Surface Need To Be When the Grout Is Poured Against It?110
- Chapter 10. Pressure Grouting112
- Pressure Grouting Machinery Base Plates To Eliminate Voids112
- Chapter 11. Pump Grouting116
- The Different Ways of Grouting API and ANSI Pump Bases116
- Conventional Epoxy Grouting of Pump Baseplates121
- Pregrouting of API- and ANSI-Style Pump Baseplates126
- Chapter 12. Skid Grouting130
- Conventional Grouting of Skid-Mounted Equipment130
- Is the Epoxy Grout Compatible with the Paint on the Skid?134
- Manpower Requirements for Mixing and Pouring Epoxy Grout134
- Pour the Grout and Set the Skid135
- Skid Chocking136
- Chapter 13. Epoxy Chocking137
- Epoxy Chocking137
- Epoxy Chock Configuration145
- Chapter 14. Grouting Specifications146
- Machinery Grout Specifications146
- The OEM Grouting Specifications147
- The E&C Firm Specifications148
- End User Specifications148
- Material Specifications and Procedures for Epoxy Grouting or Chocking of Reciprocating Engines and C148
- Material Specifications and Procedures for Epoxy Grouting of API and ANSI Pump Baseplates154
- Material Specifications and Procedures for Epoxy Grouting of Baseplates, Rails, or Soleplates160
- Material Specifications and Procedures for Full Bed Epoxy Grouting for the Skid Section of Mechanica166
- General Specifications for Epoxy Injection of Grouted Baseplates173
- References176
- Index177
- About the Author181
Based on twenty years of research and field experience, this book collects a vast amount of information into a handy reference for mechanical and civil engineers. It focuses on four basic elements of grouting: load carrying capability of the foundation soil; mass design, concrete mix and installation, and curing procedures of the foundation; anchor bolts; and the grout. From the ground up, this book takes you step by step through the grouting process. Clear, straightforward directions give you details on preparing the foundation and surface, and selecting the best material and method. Comprehensive yet concise, this is a convenient handbook for veteran and rookie engineers alike.