ML20076N140

Rept of Overhead Fluid Grouting Test Program

ML20076N140
Person / Time
Site:	Midland
Issue date:	07/15/1983
From:	CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To:
Shared Package
ML20076N137	List: ML20076N133 ML20076N140
References
NUDOCS 8307210210
Download: ML20076N140 (47)

Text

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e REPORT of the OVERHEAD FLUID GROUTING TEST PROGRAM i

Located at Consumers Power Company Midland Nuclear Power Plant Midland Units 1 & 2 i

l July 15, 1983 8307210210 830715 PDR ADOCK 05000329 A

PDR

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TABLE OF CONTENTS I.

Executive Summary of Test Progran 1

A.

Purpose of test i

B.

Summary of test results 1

C.

Summary of conclusions 1

II.

Scope of Test Program 1

A.

Objectives 1

B.

Location 2

C.

Test Facilities 2

D.

Personnel 2

III. Test Procedures 2

A.

Layout of test plates 2

B.

Description of test plates, formwork 2

and surface preparation area C.

Description of grouting 3

D.

Post test observations 4

E.

Test results 5

IV.

Conclusions 6

V.

Recommendations 8

VI.

Exhibits Exhibit A - Grouting Plan Arrangement Exhibit B - field Evaluation of Void Areas Exhibit C - Laboratory Test Data Exhibit D - Photographics Exhibit E -. Procedures MCP-15.000 (Excerpt) a

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Page 1 OVERHEAD FLUID CROUTING TEST PROGRAM REMEDIAL UNDERPINNING MIDLAND UNITS 1 & 2 I.

EXECUTIVE

SUMMARY

OF TEST PROGRAM A.

Purpose of Test To insure proper pressure grout placement on the permanent j

underpinning piers, a series of tests simulating leveling plate installations has been performed using different concrete surface preparations, different methods for venting air, and different grouting techniques for the placement of grout.

B.

Summary of Test Results i

All pressure grouted test plates provided a fully satisfactory grout pad.. None of the special surface preparations appeared to have had any affect on reducing the amount of entrapped air. Multiple in-jection points seemed to induce more entrapped air than the single injection point. An expanded metal /leadwool forming system had more disadvantages than advantages. The performance of the Masterflow 4

1. 713 grout and the equipment used all proved to be more than adequate for these tests.

C.

Summary of Conclusions The pressure grouting with Masterflow #713 provided a quality product equal to or better than drypacking with Masterflow #713.

The overhead pressure grouting of steel plates can successfully be performed using conventional materials, equipment, and methodology already available and in use on the project. Successful pressure grouting can be accomplished using a single centrally located grout injection point-thru the steel plates and by bulkheading around the periphery of the plate with wooden forms.

II.

_ SCOPE OF TEST PROGRAM A.

Objectives 1.

To determine the quality of a grout pad that can be achieved by-overhead pressure grouting. Of particular concern was the minimizing of voids created by air being entrapped in the' grout' at the interface between the existing concrete surface and grout surface 2.

To determine the optimum methods of surface preparation,

'formwork and grout pincement.

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Page 2 II SCOPE OF TEST PROGRAM B.

Location Testing was performed in a portion of the. northeast corner of the Midland Jobsite Poseyville Laydown Area.

C.

Test Facilities 4

The simulation of actual conditions which exist under a structure being underpinned was accomplished by utilizing concrete blocks (crane counter weights) cribbed by other concrete blocks to create two test' bays. (See. Exhibit D - Photographs #1 and #5).

a D.

Personnel The Mergentime personnel during grouting consisted of four (4) craftsmen, a foreman, and a superintendent.

The drypack crew consisted of five (5) craf tsmen, a foreman, and a superintendent.

In addition to the Mergentime personnel, observers were present from L

Bechtel's FSO Field engineering and MPQAD for all of the grout placements. Part time observers included Hergentime Field Engineering, Stone & Webster Independent Assessment Team, U.S.

Testing (for testing) and Consumers Power Company.

III TEST PROCEDURES A.

Layout of Test Plates Eight (8) test plates were laid out four (4) in each of the~two

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simulation bays. The north simulation bay test plates were t

installed to test a multiple injection point system of grout-placement under varying bulkheading and concrete preparation l_

conditions.- The South simulation bay test. plates were installed L

to test the single grout injection point system with various' concrete surface preparations. One plate was formed on three sides and drypacked with Masterflow #713 as a comparison to the pressure grouting techniques. '(See Exhibit /A for. Grouting Plan Arrangement).

B. -Description of' Test Plates -Formwork, and Surface Preparation. Area *-

All' test plates were made of " x 3'5" x 5'8" steel plates and were held in position by eight ~(8) 3/4" diameter Hilti kwik bolt expansion anchors.

The plates were positioned 1 " beneath the concrete' slab.by means oflshort pieces of pipe sleeves'placed over the: anchor bolts. -The' sleeves also facilitated easier test plate removal. 'The steel test plates were sized to represent the maximum size' anticipated for actual conditions. -In addition, four plates were1 notched to represent the worst geometric conditions anticipated.. The concrete' underslab surface was lightly greased =

. *Also see. Exhibit-A'and Photographs #9 thru #'12 of Exhibit D s

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III. TEST PROCEDURES (Cont'd)

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with Union 76 - Multipurpose grease. This was used as a bond breaker. The grease was brushed on with a 2 " wide paint brush with Ik" bristles. The underslab concrete surfaces above each plate had a combination of surface preparations consisting of grooves cut in the concrete, forming either a figure X, H, or 3 parallel liues or no surface preparation at all. The cut grooves were installed as air venting systems with the grooves extending well beyond the forming at the edges of the steel plates.

Test plates #1 thru #4 had four grout injection points down the center of each plate. Plates #1 and #4 were formed on four sides (bulkheaded) with 2 x 4 lumber and were sealed to the underslab concrete using a silicone caulking. Plates #2 and #3 were bulk-headed using expanded metal backed with leadwool packing.

This system of bulkheading also required 2 x 4 framing to retain the expanded metal. In addition to these cut grooves, the 2 x 4 bulkheading had " square vents cut into its top surface. These vents were later plugged with wood plugs or leadwool. The backup framing for Plate #2 and #3 had long slots approximately 3/4" deep cut along its top edge to aid in the passage of air thru the lead-j wool packing.

Test plates #6-thru #8 had one grout injection point each. All were

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conventionally bulkheaded with 2 x 4 lumber and silicone caulking.

Test plate #6 had an injection point at its center and the underslab l

concrete was prepared by roughening it with a chisel bit tool to i'

simulate an irregular surface. Test plate #7 had an injection point at its center with a pipe extension which protruded up into a 1\\"

j diameter hole cored into the underslab concrete. This was done to provide a positive means of ILmiting grout loss to the area of the cored hole in the event leakage resulted from failure of the injec-tion shut-off valve.

In addition, ar. "X" groove pattern was cut 7

. across the hole extending to each corner. Test plate #8 had one i -

injection point located 3" in from the northwest corner.. The underslab concrete was left in its original condition.

Test plate #5 was drypacked utilizing hasterflow #713 grout. This test plate was bulkheaded on the north, south, and east sides with

-all drypacking being done from the west side.

In addition to test plate #5, two additional drypack test plates were prepared from this same location and they were numbered SA and.5B. Test plate #5A was made with Masterflow #713 grout mix while test plate #5B was made using a 1:1 ratio sand / cement drypack mix.

4

' C.

Description of Grouting The flowable grout used was Masterflow #713 mixed in accordance with Mergentime Grouting' Procedure MCP 15.000 (See Exhibit D - Photograph

1. 2 - and Exhibit E). Where multiple injection points were used,

- grouting progressed south to north.

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The grouting was accomplished using an Airplaco model #HC-5, hand operated grout pump, in a five gallon plastic pail. The grout pump was connected to the plate injection point by a flexible hose using Chicago type couplings. Attached to the steel test plate injection nipple was a shut-off valve and a Chicago type coupling.

(See Exhibit D - Photographs #4 and #7). Air vents were plugged only after a good flow of grout passed through them. After all vents were plugged the pump was used to apply and maintain a static pressure of 9 to 15 lbs. until the injection point valve was closed.

U.S. Testing was present at the start of grouting and drypacking each day and to take flow cone tests and to make strength cubes (see Exhibit D - Photograph #3) for verification of material character-istics (see Exhibit C).

It should be noted that no curing was performed on the grout test pads and that they were all stripped within approximately 20 hours2.314815e-4 days <br />0.00556 hours <br />3.306878e-5 weeks <br />7.61e-6 months <br /> of being placed.

D.

Post Test Observations All test plates were removed the day after placement. The grease bond breaker worked well, however, most ' test plate grout pads were cracked or otherwise broken during the process of removal.

The results of all test plates grouted with Masterflow #713 were satisfactory. The utilization of various patterns of specially cut 4

grooves in the underslab concrete appeared to have had no influence on relieving entrapped air.

In certain instances air bubbles were l

entrapped continuously across a cut groove.

The larger (over b" diameter and 1/8") air bubbles appeared almost exclusively on the plates with four (4) injection points. (See Exhibit D - Photograph

1. 27).

Since the first injection point generally filled the bulk of each test area it appears that these bubbles may be portions of a larger bubble that was formed when grout was placed from a previous injection point. There is no definite pattern on entrapped air bubbles other than they appear to be radially oriented about one or more of the three subsequent injection points.

Both the wood form and expanded metal /leadwool bulkhead methods effectively contained the grout and provided adequate avenues for escaping air. The wood forms left a neat uniform grouted edge while the Expanded metal /leadwool created a void area approximately 3/4" back from the test plate edge.

(See Exhibit D - Photograph #28);

The wood plug system used to plug the bulkhead air vents worked well at all locations where it was used. Although the leadwool plugs were satisfactory, in some locations they were pushed as im2ch as 3/4" to 1" into the-grout pad itself and thus leaving a void. Also leadwool was used at the only two vent areas that showed evidence of l

grout leakage after grout shut-off.

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Page 5 III TEST PROCEDURES (Cont'd)

Minor dripping of a clear amber fluid was noted from all pressure grouted test plates, starting at approximately half way thru the grouting time period and extending well beyond completion of grout-ing. This was apparently bleed water and a visual inspection of the pads could find no damage or voids as a result of the fluid.

E.

Test Results Plate Grouting Grouting Plate

% of Remarks Voids No.

Time Pressure Deflection Over k" 6 1

35 min.

13 psi 3/16 to 1/4 0.9 Many small surface bubbles noted 2

27 min.

12 psi 3/16 to 1/4 0.5 Contained large and deep trapped air pockets 3

39 min.

15 psi 1/4 to 3/8 0.7 Contained air bubbles apparently formed from subsequent injection points 4

40 min.

9 psi 0 to 1/8 1.2 Contained large shallow air pockets 5

1 to lh hr n/a None 14.0 Poor consolidation at east (DP) edge of pad SA Not Avail n/a 3/16 to 1/4 7.0 Poor consolidation at east (DP) edge of pad SB 2 to 2% Hr n/a 3/16 to 1/4 0.1 Actual Void Area is 2.5%

(DP)

When Lost Contact Arca is Included 6

25 min.

12 psi 1/16 to 1/8 0.8 Experienced No Problem Filling Irregularities Chipped Into Concrete Surfaces 7

20 min.

12 psi 1/8 to 3/16 0.5 Appears to have had plate movement during grouting 8

30 min.

10 psi 1/8 to 1/4 0.9 Poor consolidation appears to have resulted form exces-sive grout flow distance

• See Exhibits B and D for additional photographs and test results

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Page 6 III TEST PROCEDURES (Cont'd)

Dates of Testing:

o Plates 1 thru 5 were grouted on 6-28-83 and removed on 6-29-83 o Plates 5 thru 8 were grouted on 6-29-83 and removed on 6-30-83 o Plate 5A was drypacked on 6-30-83 and removed on 7-1-83 o Plate SB was drypacked on 7-6-83 and removed on 7-7-83 IV.

CONCLUSIONS All pressure grouted test plates provided a fully satisfactory grout pad for transfer of loading into or from an overhead concrete structure.

. Based upon the comparison of the seven (7) pressure grouted test plates, it appears that the single centrally located injection point type of test gives the best product.

j Test plate #7 had a special condition of a pipe extension of the injec-tion nipple up'into a 1 " drilled hole in the underslab concrete. No advantages to this system were noted in the resultant underslab/ grout contact surface to merit further consideration.

l Two drypack test. plates were made using Masterflow #713 for comparison purposes. Neither of these two test plates proved to be better than the pressure grouted test plates. Proper consolidation of the drypack on the far side of the test plate and behind anchor bolts appears to be the weak areas for these plates. A third drypack test plate was made using a 1 to 1 sand / cement ratio which proved to be the best test plate except for a loss of contact area in the northwest corner, apparently a result of the plate moving during final stages of drypacking.

One problem noted from the pressure grouting and from two of the three drypack test plates, was the elastic bowing of the " steel test plates resulting from the induced pressures. The least affected pressure grout test plate was #4, on which grouting was stopped with a static pressure, indicated at the grout pump, of approximately 8 to 10 psi. All other plates were stopped at static pressures of 12 psit. It should be noted 4

that only eight (8) expansion bolts were used to support the test plates and that no attempts were made to restrain or limit plate deflections (bowing).

It should also be noted that the static shut-off pressure was measured on a 0 to 60 psi pressure dial attached to the grout pump

-discharge.

(See Exhibit #D - Photograph #4). This static pressure includes approximately six (6)-feet of head between the gage and the overhead test plate. Consequently ten (10) pounds per square inch pressure at the gage should mean four (4) psi actual pressure within the grout bed itself. Thus it appears that minimal pressure (sufficient to force grout to flow out the bulkhead air vents) is all that is necessary to achieve grout placements.

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Page 7 IV CONCLUSIONS (Cont'd)

An observation noted was that the pressure gage attached to the grout pump indicated high pressure peaks during the initial stages of pumping.

This pressure could not have built up under the plates, since all the vents were open during this stage of pumping.

This " peaking" was due to a combination of rapid pumping and line losses during the initial filling. As the vents were closed and pumping slowed, the pressures stabilized in the line, reflecting pressures actually transferred to the grouted plates. (This " peaking" phenomena will be a consideration in gage range selection in permanent pier grouting.)

No advantages were noted by use of the expanded metal /leadwool system over the more conventional wooden bulkhead system. A major disadvantage was, however, noted in that there was a definite loss in available grout pad size in the leadwool system. Consequently production plates utiliz-ing this bulkhead system would require larger sized plates to makeup for the lost grout pad area.

The Union 76 multipurpose grease was used as a bondbreaker on the underslab concrete surface and performed its function.

The use of this grease as opposed to normal pre-soaking or the use of the weld crete could be expected to result in a larger amount of air entrapped in the grout concrete contact surface due to the grease being impervious and thus not allowing any air to be absorbed by the concrete.

On the whole the amount of small air pockets noted were about equivalent to what might be expected on a vertically formed surface poured with air entrained concrete. A quantitative value for percentage of lost contact surface, due to air or just no contact, was determined by physical measurements of the void areas larger than k" equivalent diameter. The results of these measurements for plates #1 thru #4 and #6 thru #8 show a range of from 0.5 percent to 1.2 percent loss.

Inclusion of all void areas less than 1/4" $ should not amount to any more than double the values calculated or in other words a maximum of 2.4 percent loss in total.

The hand pumping of the grout was a satisfactory method for placement of the grout.

It was an easy method to control the placing of grout as well as being mobile and requiring little in the way of support facilities or maintenance during placement.

The Masterflow #713 grout proved to be an acceptable mix in terms of its net physical characteristics as well as the finished product.

It should be noted that although the Mergentime Procedures for grouting (MCP 15.000) and drypacking (MCP14.000) were utilized as guidelines,' absolute adherence was not expected, nor was it guaranteed by quality control inspections.

In particular, no bonding to existing concrete was desired, no grout placement plan was utilized, and no attempts were made to properly cure the test plate grout pads.

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Page 8 IV CONCLUSIONS (Cont'd)

It should be noted also that the expansion anchor bolts were installed at varying depths and in several instances spacer washers had to be utilized in order to tighten the nut without bottoming out on the the threads.

The bowing or elastic bending of virtually all of the test plates was to be expected, but should not be a source of concern.

Bowing of the test plates showed up on both the pressure grouted plates as well as the dry-packed plates. To date, no problems have been noted in the Auxiliary Building Underpinning work with drypacked leveling plates.

Bowing of pressure grout plates will not be a problem either since the bowing can easily be eliminated by the installation of plate bracing before grout placement.

V.

RECOMMENDATIONS Utilization of leadwool as a form of bulkheading for pressure grouting should be kept as an option for areas where the more conventional wood bulkheading can not be utilized. There may be instances during grouting where the use of leadwool will provide the best and most reasonable means of stopping grout movement.

Care will still have to be exercised to ensure that use of leadwool does not reduce the required effective bearing area of the grout pad.

An option, although not tested, that should prove equally as good as the single injection point system would be a dual injection point system (At 1/3 points down the center of plate).

This system would use two grout pumps both of which are pumped either simultaneously in a manner so as not to form air pockets / bubbles as noted in Section III D of this report.

Grouting pressure should be kept near the minimal required to obtain grout flow through the air vents. To avoid possible plate bowing or excessive bracing of plates, slow stroking of the handpump to eliminate impulse loading should be utilized.

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4 OVERHEAD FLUID GROUTING TEST PROGRAM EXHIBIT A GROUTING PLAN ARRANGEMENT t

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OVERHEAD FLUID GROUTING TEST PROGRAM EXHIBIT B FIELD EVALUATION OF VOID AREAS e

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PLATE NO.

1 1.

Peripherial bubbles about nipples?

No (Peripheral bubbles

1. 1 (South) from #2 over hole) #3 No

1. 2 Yes - Towards 61

• 4 (North)

No 2.

Air noted in underslab notch grout projections?

Yes 3

Grout leakdown at air vent holes?

No. but lead wool hole ninen extending into grout slab 9/4" cast niate edea.

4.

Noticeable general air bubble pattern?

Yes Visual interpretacion sketch (no scale):

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areas (all plates)

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Calculated void area in excess of 1/4" 0 nominal sizing =

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percent of surface area.

6.

General quality evaluation of grout / concrete contact area.

North 1: Poor,6 satisfactory) good, excellent l

South i: Poor,(satisfactoryJ good, excellent

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7.

General evaluation of test plate: For some reason. this olate has a lot of little air bubbles and they form chains of flow lines.

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This is by far the worst of the plates (#2, #3, & #4) placed on same day as far as general arpearance and numbers of small bubbles are concerned.

The cut grooves appear to have had little, if any effect on the pattern of these bubbles.

This was the last plate done on this day.

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PLATE NO.

2 1.

Peripherial bubbles about nipples?

1. 1 (South) No

1. 3 No

1. 2 Yes, Sevaaral

1. 4 (North)

Yes, (two 1 " x 4 " &

(one 21" x 11")

31" x 1")

2.

Air noted in underslab notch grout projections?

Yes, Minor 3

Grout leakdown at air vent holes? n/a Leadwool/exp. metal bulkhead 4.

Noticeable general air bubble pattern?

Yes, minor

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..,',' f,[

Void areas 1/8" or less deep 5.

Calculated void area in excess of 1/4" 0 nominal sizing =

.05%

percent of surface area.

6.

General quality evaluation of grout / concrete contact area.

North i: Poor, satisfactory, good, excellent South 1: Poor, satisfactory, ood excellent 7

General evaluation of test plate: The grooved end seemed to have more small air bubbles than the non-grooved end.

Both ends had several large trapped air pockets.

In general, the non-grooved end looked better.

Steel plate size should be increased to account for approximately 3/4" to 1"t grout oad loss, 'due to lead-wool packing.

t

~

4 j

PLATE NO.

3 1.

Peripherial bubbles about nipples?

l

1. 1 (South) No

1. 3 Yes, 4 deep approx. 11" long j

1. 2 Yes, one (21" x 1)") #4 (North) Yes, shallow & minor 2.

Air noted in underslab notch grout projectionsi Yes, minor 3

Grout leakdown at air vent holes? n/a Lead wool /Exp. metal bulkhead 4.

Noticeable general air bubble pattern?

Yes. minor Visual interpretation sketch (no scale):

!.ECEND l

Mall contact surface 5

areas (all plates)

{ '. '. G G

G

'O'.

Areas or less than rull Contact.Containing small' air voids. l'he densities w;

P-j

-['.-

of the semil air voids

1. d.

are not indicated.

(Pressure grout plates only);

y:

l Porous and/or less than 7-

-4 full contact areas.

O O

O e

4 In.jection point nipples

",7

)

/

N Cat grove patterns l

/

1. p Anchor molt holes

~ 8 each per plate)

/

}

(

Noticeable air bubble chains

/

~.],

y - Void areas deeper than 1/8" g

g

[ ),*.

~

'[

Void areas 1/8" or less deep

.'.8, t

/

W 5.

calculated void area in excess of 1/4" 0 nominal sizing =

0.7%

-percent of surface area.

6.

General quality evaluation of grout / concrete contact area.

North }: Poor, satisfactory, excellent South ): Poor, satisfactory, excellent 7

General evaluation of test plate: Overall grout / cement contact surface is good; however, the leadwool packing bulkhead undercuts the grout pad so plate size would have to be increased.

No noticable difference between the cut groove catterns.

PLATE NO.

4 1.

Peripherial bubbles about nipples?

l

1. 1 (South)

No

1. 3 No

1. 2 No

1. 4 (North)

Yes, one 2.

Air noted in underslab notch grout projections? Yes 3

Grout leakdown at air vent holes? No, one wood plug too deeply I

inserted, though.

4.

Noticeable general air bubble pattern? Yes Visual interpretation sketch (no scale):

t.rcEwo y Full contact surface Iareas (all plates)

• * ' ' ' O u' '. 4. y g. '.,

'. '.. " O O

Areas of less than full

. *, a.

,q

- -g._ _

,5 a

contact containing small.

.r T

air voids. The densities

,I

.q u e.

of the==m11 air voids

'. 's are not indicated.

(Aweg,,

/, cia /'

- Y, (Pressure grout plates only) def@

'] [.

l Porous and/or less than s'.

--4 full contact areas.

O O

u w

g In,)ection point nipples I

N Cut grove patterns Ancace bolt holes

~ (8 each per plate)

" , f,,,,

• e.

p

,, Noticeable air bubble chains

,.s

f ",, ',.', ', O,'

N s,. ',*,, e y

Void areas deeper than 1/8"

• 0,4., *.

Void areas 1/8" or less deep r

\\

t 1

5.

Calculated void area in excess of 1/4" 0 nominal sizing =

1.2%

percent of surface area.

6.

General quality evaluation of grout / concrete contact area.

North }: Poor, satisfactory, oo excellent South i: Poor, satisfactory, oo excellent 7

General evaluation of test plate: The wooden bulkhead with wooden grout hole plugs seem to have worked quite well.

No maior advantages noted for grooved half.

J

l i

PLATE NO.

5 - Masterflow #713 Drypack 1.

Peripherial bubbles about nipples?

1. 1 (South) n/a

1. 3 n/a

1. 2 n/a

1. 4 (North) n/a 2.

Air noted in underslab notch grout projections?

n/a 3

Grout leakdown at air vent holes? n/a 4.

Noticeable general void pattern?

Yes Visual interpretation sketch (no scale):

y Full contact surface I areas (all plates)

Areas of less than full contact containing small air voids. The densities 3,

of the small air voids are not indicated.

g5CiF (Pressure grout plates ecly).

ed h"N o

g3 a s

lPerous and/or less than

-4 full contact areas.

e 3

Inj ection point nipples N %._ Qat grove patterns g~

e

, _ Anchor bolt holes ts;z:sr p

(8 each per plate)

Noticeable air bubble chains g

y Void areas deeper than 1/8" a

Void areas 1/8' or less deep u

b Mmen:o

.%a -rkus is De gi 5.

Calculated void area in excess of 1/4" 0 nominal sizing =

14.0%

percent of surface area.

6.

General quality evaluation of grout / concrete contact area.

North ):,b satisfactory, good, excellent South i: Poor, 6 tisfacto M good, excellent 7

General evaluation of test plate: General appearance of concrete /

grout contact surface is lesser than the worst fluid pumped grout test plate.

'X j

PLATE NO. 5A - Masterflow #713 Drypack i

1.

Peripherial bubbles about nipples?

1. 1 (South) n/a

1. 3 n /a

1. 2 n/a

1. 4 (North) n /a 2.

Air noted in underslab notch grout, projections?

n /a 3

Grout leakdown at air vent holes? n/a 4.

Noticeable general void pattern?

Yes Visual interpretation sketch (no scale):

Full contact surface

---

m areas (all plates)

Areas of 1ess than rull t

~ contact containing small air voids. The densities 3;

of the small air voids g

~e

'.'s-are not indicated.

(Pressure grout plates only)

[ Porous and/or less than

-4 full contact areas.

(

3 In.jection point nipples a

e,e N _. Qat grove patterns

_ Anchor bolt holes (8 each per plate) e Noticeable air bubble chains y

Void areas deeper than 1/8" Void areas 1/8" or less deep Al

^

DryPMrch chm M

.D as l

f' 5.

Calculated void area in excess of 1/4" 0 nominal sizing =

7.0%

percent of surface area.

j 6.

General quality evaluation of grout / concrete contact area.

North }: Poor, satisfactory, Q excellent South i: Poor,(satisfactoryl good, excellent 7

General evaluation of test plate: General accearance of contact surface is not as good as best pumped grout test plate, but I

as good as the worst.

PLATE NO. cB - Sand / Cement Drypack 1.

Peripherial bubbles about nipples?

l

1. 1 (South) n/a

1. 3 n/a

1. 2 n/a

1. 4 (North) n /a 2.

Air noted in underslab notch grout projections?

n /a 3

Grout leakdown at air vent holes?

n/a J

4.

Noticeable general void pattern? No Visual interpretation sketch (no scale):

t. scrap q Full contact surface iareas (all plates)

O g

Areas of less than full r

e contact containing small-air voids. 'Ihe densities

,g; of the small air voids

',z e.

are not indicated, d

(Pressure grout plates only)

Lo1S 0 b b ^'

C 44 p'e.e7 l Porous and/or less than

-4 full contact areas.

y m,s e

e InJ ection point nipples Q{((h Ns Cut grove patterns

_ Anchor bolt holes (8 each per plate)

,,- Noticeable air bubble chains y - Void areas deeper than 1/8" p,_voida,eas,,8or1.s.dee, A

a 3,4krD/C6*erparT~ Ddy9Mck 8Hoo farens %s $soan 5

Calculated void area in excess of 1/4" 0 nominal sizing =

2.49%

percent of surface area.

Neglecting lost contact area== 0.1%

6.

General quality evaluation of grout / concrete contact area.

North i: Poor, satisfactory,Q excellent auth i: Poor, satisfactory, good,(e'xcellentl 7

General evaluation of test plate: Good sound plate, most voids were in surface paste only.

Test plate was solid, however, it accears that some, if not all of the West side anchor bolts have slioned j

some in the final stages of packing.

Basic grout oad thickness is 1)", but West face is 1 3/4" at N&S ends and 2" at midpoint.

This is probably when large lost contact area was developed.

PLATE NO.

6 1.

Peripnertal bubbles about nipples?

1. 1 (South) n/a

1. 3 n/a i

1. 2 n/a 94 (North) n/a 2.

Air noted in underslab notch grout project'.ons?

n/a 3

Grout leakdown at air vent holes? Yes, at 2 locations, both are lead wool plugs (3" x 2") at North end east plug & 14 " x 1" at East side, north middle plug,, both are shallow depressions.

4.

Noticeable general air bubble pattern? Yes, minor Visual interpretation sketch (no scale):

tzerm a Full contact surface y

l areas (all plates)

Areas of less than full vhd*M' air d

r[s i s'

',i.

.e

,., 'w; M

of the small air voids t

4 i

are not indicated.

(Pressure grout plates only)

/1 y

l Porous and/or less than

~

--4 full cantact areas.

7.. ~.

,rJ' g

3 Inj ection point nipples

~, ;,

cO N% _ Cut grove patterns

^

, _ Anchor bolt holes b>.'*..

(8 each per plate)

/ _,

Noticeable air bubble chains

'

• s' e..

Void areas deeper than 1/8" j

O Void areas 1/8" or less deep e

W' 5

Calculated void area in excess of 1/4" 0 nominal sir.ing =

0.8%

percent of surface area.

6.

General quality evaluation of grout / concrete ecntact area.

North }: Poor, satisfactory, ood excellent South i: Poor, satisfactory, ood excellent 7.

General evaluation of test plate:

The scarrified contact surface is so irregular that it is hard to evaluate with grooved and non-grooved test plates.

Again, the lead wool grout olues nenetrate into grout slab at approximately 3/4".

Overall evaluation in that this appears to be one of the better lookin41ess flawed test plates.

)

- \\

t PLATE NO.

7 e

1.

Peripherial bubbles about nipples?

1. 1 (South) n/a

1. 3 n/a

1. 2 No

1. 4 (North) n/a 2.

Air noted in underslab notch grout projections?

Yes 3

Grout leakdown at air vent holes? No 4.

Noticeable general air bubble pattern?

Yes, minor Visual interpretation sketch (no scale):

t,geg,3 Full contact surface

/

lareas (all plates)

N Areas of less than full

• O contact containing small

',.'O,,

--G.

air voids. The densities

,,, of the small air voids are not indicated.

(Press'tre grout plates only) '

jPorous and/or less than

-. full contact areas.

/

I

)

g In,1ection point nipples N

,, Out grove patterns Anenor bolt holes

• - (8 each per plate)

Noticeable air Dubble chains p%-

j 3

y Void areas deeper than 1/8" 73 _ Void areas 1/8" or less deep

,g

._,e q~

, e e

.e.

v-

/

b 5.

Calculated void area in excess of 1/4" 0 nominal sizing =

0.5%

percent of surface area.

6.

General quality evaluation of grout / concrete contact area.

North }: Poor, satisfactory, ood excellent South i: Poor, satisfactory, good excellent 7

General evaluation of test plate: The expansion bolts on the East side appear to have pulled or never were snug at 1}".

Grout pad thickness increased up to 24" nominally.

Overall evaluation is as good as plate #6.

No advantage noted due to fountain or cut grooves.

s;

-.f. g e

g.'

PLATE NO.

8

~

1.

Peripherial bubbles about nipples?

1. 1 (South) n/a

1. 3 n /a

1. 2 n/a

1. 4 (North)

No, (in West corner) 2.

Air noted in underslab notch grout projections? n/a 3

Grout leakdown at air vent holes? No 4.

Noticeable general air bubble pattern? Yes Visual interpretation sketch (no scale):

3,3 1 areas (ntactsurfac,e Phil co all plates)

Areas of less than full O

• O contact containing small S

c' -

air voids. The densities

.. s of the small air voids

.s M '

~

'\\ g d are not indicated.

(Pressure grout plates only)

N'

• " m\\s

..N,.

j Porous and/or less than cs e full contact areas.

J,,,

g Ina action point nipples g! h

/ lb N s Cut grove patterns r' <

~ Anenor bolt holes (8 each per plate)

/

g 'd b'

Noticeable air bubble chains d.

~

y Void areas deeper than 1/8"

[

g-O*'*

[, _ Void areas 1/8" or less deap Q

- 'M' O

f e

e e

v 1

W' 5

Calculated void area in excess of 1/4" 0 nominal sizing =

0.9%

percent of surface area.

6.

General quality evaluation of grout / concrete contact area.

North i: Poor, satisfactory, Q excellent South i: Poor,(datisfactoryl good, excellent 7.

General evaluation of test plate: General condition evaluation is that this plate is no worse than plate #1.

One injection niople in the corner gives a lesser quality product than one in the l

middle of the plate.

l

v 1

e 7; 9 OVERHEAD FLUID GROUTING TEST PROGRAM EXHIBIT C LABORATORY TEST DATA m

e

e T..*

~

,l.,, L *..x BECHTEL POWER CORPORATION

)

MIDLAND NUCLEAR POWER PLANT JOE 7220 REPORT OF NON-SHRINK GROUT TESTS l

2. c a t e ~~

,., a....n t

..t.

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,gg.9,J ) J (,\\

Lot No B2(o&203 Exa. oate: 9-84

d. 83 gg, Q 3.Ptacement i.ncasson l

h0S 9 s! sHll*

l A.) De sJ d kALI L3A.

Source Grout Brand & Type

/7/146-14774 4..

//r.wppt)k 1k

/M % 6kb/ hts ff7Asrtre frob '7/3 AM badT

4. Mes

5. Gisee

6. 'Q' 4.Jat 7.Requiree Strengtn 7/J 6.J 6<t.cwr O vos S No

1. cco psi At 2.s Days

8. Test Data At:

9. Stopwelch CallDration Qate Ghsaow m 5 foswowe /x coad Ace,a.

W

//*3 M e

10. Flow Qata CRO 611-60 Time of Efflux (Sec)

11. Flowcone Cassaretion Date

• O 7' N

/N #

No.2 27 /

No.3 1/ #

4verage Sec i

N.1

12. Thermometer Castoration Date

13. Temp.: Grout

14. Temp.: Air

15. Initials 21I 9-s'-63

//

'r f27

• r 2x se v.ne.g.)

16.Inittas Curing Thermometer Casic. Date

17. Time of Testing

18. Time of Moleing 760 le-v.-s s

/333 I

/343 Mrs wra at sage

19. Initial Curing-heMb=4-44-ee # 4-as-83

20. Stripped ASTM-C109-75

21. Initaale 6-24-s3 issr 7/

77

.e A,

8,,

Sp i,.u-o,

..e ro COMPRESSIVE STRENGTH DATA ASTM-C-100-75 i

lCueeO 2

28.

22. Specimen 23*Date 24*Date 25.

26. Total Load g

cant Stron9th PSI Identification Molded Teated AG.

In Pounda C m Arese8reak-Fieldi Lac n 144 - 249 t 6-ts-o s 7-1-s *A 3

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2.11.

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2(o,300 2x2.-

4. 0 A

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b 6,578 smens==manmemime 4, '/ '7 0 6 /64.ers,.

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mm m

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32. Specimen Seze

37. Remarna I

3 2'x 2'Cune Q Other Y Nod -ileesp r ra Omf Checked ByF Reviewed tiy Q.Cl 35.

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(De M d ~M-$c o

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9 INT 83 t R SG 74.- M

38. Lacoratcry Supervisor Signature

39. Cate Ty*e of Breaka: A-Cone. Mortar Failure C-Shear. Mortar Failure E - Other QCF-P Mv.1 N

..~

~....

p-

--' UMTED-STATE 5 TESTING -COMPANY, INC.

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T/fft) A iAl&~ 3 Mfd-

i r'E!T 'f 0ATIC

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$ -J (- P 3 jl m urs < Bwous i

/-.CE !E!T IDE :TIFICAT!C ::

N d x) d' 7/fg//>/vG GROUT TYFE: 7 / 3 74 did G /9AT~

m rs re x,ri c a -

FLO*4 DATA CRD-C-611-80/ QCP-18 l

4 I

Test :u=ber #

1 2

3 4

[i Sat ::ucter i

~

Q[l,"l1.

c.,g, <.ll

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l

}

Ti=a a t Samp'1e 737g

,3 3 l Anbicnt Temperature ( ?)

g7 47 l

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. Grout Eag Temperature ( ?) l gg gg j

~*

da:cr Temperature ( ?)

l f4 yy

iz Te=pern: re ( ?)

73 l

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Stopwa:ch 615

// 8 3' Lot Number: 8J/,/m3 6 9 Expiration Date:

9-8 IR No.

A #

Struck off @

/43

_ Hrs. on h-28-?33, af ter initial set.

Workaba.11ty ended @

U/#

Hrs. on INf0RMAT10N

" ""'*"=

N o M - AC C E P TE D,, G R ou T TEST ONLY

• seae ue'v F

S MII 123W Date:

[-79 Y )

,.4 b 6-3-83 v.

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$(

y SECHTEL POWER CORPORATION M10 LAND NUCLEAR POWER PLANT JOB 7220 l

REPORT OF NON-SHRINK GROUT TESTS h.

A

[

t

2. Date Pieceo

=

1. Placement identsfication 4

O'8 4 29-[ 3 g g g*.. -7 & 7/jf/ g /,,

Let No.: 8045203 Exo. Date:

3. Placement Location p6ssv v t L LE Lav Do w a ArtA 13 A.

Source Grout Brend & Typer-PLANT DATA m ERGw f DmL HM D m et Gg ansTit Dwtoggs mpsidfA m 713 pm Gedu1*

4. Mas

5. Glass

6. 'Q' Last

7. Required Strengtn OE Daye l

?/3 nsw caar

_'ZE Ova B'No 4/do d PSI At

9. Stopwatctl Calibretton Date

8. Test Data At.

m dgGest am e #/I M D m a X4A, l

b0$

//. 3 # $ 3 A6S L Y H L L 4 U 4ms 4 MM

11. Flowcone Calderation Date

10. Flow Data CRO 511-60 Time of Efflux (Sec)

M Y" S Sec W P 7-O O "f 3 O93 Average

/ k' b N o. 2 M* 7 No.3 N c.1

12. Thermometer Gattoration Date

13. Temp.: Grout

14. T emp.: Air

15. Initiala y )l q 5-8 3

&3 4

'? %

9

.s!, ut s.2,-n 16.4nitta6 Curing Thermometer Catic. Date

17. Time of Testing

18. Time of Molding

/34o Nr.

/

sage 773

/a -/ 4 -f 3

/1o?

Nr..t

19. Initial Caring.".0T" C :: 00 (# 6.,29-P 3

20. Stripped ASTM-C109-75

21. Initlets y.To

'78 off

• d. - 3 o - 6 3 At

/C M Nr.

57 / -So-e_r N

COMPRESSIVE STRENGTH DATA ASTM-C-1C9-75 Total Load bl Actuoi Strength PSI E

22. Specimen 2 3.D a t e 2 4.D at e 25 R

identification Molded Tested 0e in Pounds n_,=Olm C e e Aree Break-FieldI Lac

$fa 4.0 A

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37. Remarna

32. Specimen Saze 2* a 2* Cune 0 Otheri Wro c a. jp ep ppt F D $ 9 0 a T" 35, 138.

checked By.aeviewed liy Q.C;]

33.^8*

34 Tested ay gg,,3 r4 %c 3

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38. Lacoratory Supervisor Signature

39. Cate b

Q Type of Breaks: A-Cons. Mortar Failure C-Shear. Mortar Failure E - Other QCF-74 Rev.1

.. ~

N_

UNITED STA i sa a c TING COMPANY, INC.

{

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hr:'*.*T T2:AT:C::: Pds&Vvitie t yom a aog try y

ACE S!T IDE:TIFICATIC::

0 o 0 'O' 7#/r/d/06 CROUT TYTE: _ ') /

/o G duf

1. N '"

FLOW DATA CR D-C-611 -8.0/ QCP-18 l

Test :u=ber #

1 2

3 4

1 Sct :: umber H G - I t, 6

-l Ti=n of Sample jg7 l

{

Ambient Temperature ( ?)

gg l

l Grou Eag Temperature ( ?) l gg Water Temperature ( F) l

{

.ir Tc=pern:Ure ( ?)

3 l

?10w 22:a

.l Fir : ( ::ec. )

l

/ g 6, l

l I Secen: ( ec.)

l g q, g l

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l Jhird (sec.)

l 7 9,3 _ l l

l

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l gy,2__ l l

l l

l l

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7. :: ::u:-b er Cal br :icn Ive E :e Il0* Cone 49g l

9 aJ-2 3 2

l l

g.s.r3

' The=cre:er l

g,j Stopwatch f, 9 f jf. 3, g y 6

Lot Number:#BJ /,/. 2 8 %

Expiration Date:

9-PN IR No. ___ M / A-

~

Struck off @

/ <./ 6 0 Hrs. on

/,- Q 9-83, af ter initial set.

Workability ended @

SIN Hrs on NfA I

Rsmarks:

-+ *9 o 9 - A c e rr g1E D" Gcour 4660 f31 e 2 g pgy 3 Q l 3.2 0 Checked by: Y m,23 maee.

&>w

,+ c

b.11., b l.5N G.

p.- ts.,;

h BECHTEL POWEA CORPORATION MIDLAND NUCLEAR POWER PLANT JOB 7220 REPORT OF NON-SHRINK GROUT TESTS

& W_ &

vb 1.Pleccment Identification

2. Date Placed UOO "O' - 7 /f,? /n in g Lot No !3 J 62 2 0 3 Exp. Date: 7-N 6

o7, 9 - f 3

3. Placement Location P6 S E >' st /L L E M V D6 tu eJ RR&A 13 A.

Source Grout Brand & Type PLANT DATA mMG tHTom t HAND (no t E D ines tra. BM ILD art b inA S Tt t04 0 LJ

~713 D f VPac k:

4. Mix

5. Cla ss

e. 'O' t.ast 7.Requireo Strengtn

?/3 DRVP4ex I

Yes

@o 4660 PSI At M__ _

Days

8. Test Data At: mtsce m a

9. Stopwatch Calleration Datt uo%o

" YN

" lA

'POS f 4 VILL 6 LAYOewa A R G it

10. Flow Data CRD 611-80 Time of Ettlux (Sec)

11. Flowcone Calibration Oste

^# b

1. b M/A No.2

1. E No.3 M4 Average

^> I A Sec No.1

12. Thermometer Calleration Date

13. Temp.: Grout

14. T emp.: Air

15. Initials

• *

• I nose s m e a t s as.t 3 y ll 9 ? *$

R 'l

• F P _2 I 11

• F SF,in

16. inital Curing Thermometer Caile. Date

17. Time of Testing

18. Time of Molding -

NY Hrs

'758 9 2 2-F 3

/4V2 Hrs at

/

Bacs

19. Initial Curing ASTM-C-31-6 9

20. Stripped A STM-C 10 9-7 5

21. Initials

• F To

• F At Hrs COMPRESSIVE STRENGTH DATA ASTM-C-109-75 fff p;p gjg., 7 p/

f-J. & 3

22. Soscimen 2 3.Da t e 2 4.D a t e 25.

26. Total Load 27.

28.

{9.,.30 Cure

' 3 1.-

Strength N Identification Molded Tested Age in Pounds Cut Dirn C ree Break Fletd Lab A

A $39

(,- J 9-7 '3 ') S 3 b

Y I5 0 3 Y)

4. O h

D 0

0,I O O c28 8/ O J /."1

//. b A

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%D6 h

.2541 3

%'50 g y2 4.o h

3 o

6,78s

[,.J 9 8 3

~7-2-73

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.84'l

'I 7 - /, -y 3 7

39900 Jt d V.0 c.

7 o

c.) $ Y b N.EO b\\)(1 Y.O D

' 0 a

l a 5W 7

37poo aya

v. o c.

7 o

9p5o 6 $-s3 ?$-r3 7 N5hhkhbh!$$Nk 9pSO

S'

32. Spocamen Size

37. Rema rk a Z

2' x 2* Cuce C Other

• ** uo e-p cy cpy g o G eo,. 7

. 3.

36.

33.^88 34 r ecked Byl. Reviewed liy Q.C, @

r l

Tested By l

(Days) p i

au s sm, t,- so.e 3 sprew,a p;evwp og ze < uad e ers

~~ b &

.3 AN $3 wth. umaeeinac.,

.As apturo siast. m o u;ut 1 'l-i~~

]

7 bD

@5p ?.7.g

38. Lacoratory Supervisor Signature

39. Date j

u - a, o y.s,,,,,,.,, y m,,,,,, p,

/ I

)

Type of Breaks: A-Con Mortar Failure C-Shear. Mortar Failure E-Other m

QCF-74 Re'/. 1

-. c.

0 'QC.;'ha.TmmigLN T

,uu a

BECHTEL POWER CORPORATION MIDLAND NUCLEAR POWER PLANT JOL 7220 W MTT V REPORT OF NON-SHRINK GROUT TESTS 0E UAR A

~

2. Date Placed l 1.Placsment icentification 0 0 AJ Q___tT /f,9 / D, a r.

Lot No 73 M'l Y 8 ? Exp. Date: I"SY

")- /- 7.3 3.Placsment Lccation l

PAS E V U/ LL E 1 A VDo w AJ A /7f R 13 A.

Source Grout Brand & Type.

PLANT DATA g,y y pgjg 3y m 4 7 g g,,, 4 y myyp;4 y s7,3 yypg

4. Mix

5. Class

6. ' Q

• 1.as t

7. Required Strength A7 Days 913 DRYPAeX A

O Y**

o 4AA0 pst At

9. Stopwatch Calibratio Date

8. Test Data At: g U

N 90 3 f Y t/ IL Lf L p ygm,J A fV/V id. Flow Data CRO 611-80 Time of Ettlux (sec)

11. Flowcone Calieration Date d/

d D /,4 No.3 0 /4 Nc.1 M /+

No.2 A'

Sec Average

12. Tnsrmometer Calioration Date

13. Temp.: Grout 14 Temg: Ajrp

15. Injt,1,apa c't l l q.f-73

~7 7

'F 7t> f "17

• F 3 f, e n

16. Instist Curing Thermometer CaliD. Date

17. Time of Testing

18. Time of Mciding

/

Bags

/ dS E Hrs

'7'79

/ d - O ff - P 3

/ dd O Hrs at

19. Initial Curing ACTM-C-31-69

20. Stripped ASTM-C109-7S

21. Initials

/44 1-Mrs

'l5 F 7-2 :a3 b'7

F To O/

• F 7'2-83 At 7j9j71//g,. 7 y/ [f.3/3 l

COMPRESSIVE STRENGTH DATA ASTM-C-109-75 Spacimen 2 3.D a t e 24.D a t e 25.

26. Total Load 27.

28.

f9, 3 0. C ur e

'3 1.

22.

AG' in Pounda C

Irn rea Breakl F1cid ! i.a c Strength PSI Idantification Molded Tested G.11lf 3

O' 25(,3 ')-I-2 3 9-4-83 3

bh?

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46 A

- + 6.86*

a an c/

k 3

66.9 5 Y

9.6 I&

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'). /. r 3 J.

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3 3.5Q an

v. d M

7 O

Y,37f J 54l, i

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• )

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1 0

2,3 7C I

(

mbt t

3 3,500 1a 40 A

9 0

8,395

~

f, Av rage 7./. g 3 g

K 380

32. Soscimen Size

37. Remarna

@ 2" x 2* Cube O Other 4 u o,,. e, c e g y r i G ec a-r-34 35.

36.

33.#88 Checked Byl Reviewed liy Q.C; Tested By (Days) l Y]-le&

l_

3 PB 4 9.s.e h

($ 712 8) j 7

gra ww

38. Lacoratory Supervisor Signature

33. Date J

Typ3 cf Sreeks: A-Cone. Mortar Failure C-Shear. Mortar Failure E -Other QCF-N Rev.1

~

~

EECHTEL POWER CORPORATION MIDLAND NUCLEAR ' POWER PLANT JOB 7220 bC REPORT OF NON-SHRINK GROUT TESTS fhf h{

2. Date Pieced i.eiscement la ntification N!r g en forne. 7Ycserir $

Lot No.:

AlA Exa. Dete:

A/A 9.g..g3 r

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Source Grout Bran 1 & Type '

~

PLANT DATA

jff, Q

gg 4 gg 7 gg g,yg

4. Msz

5. Ctaas

6. 'Q' List

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Cemenf/doad 6,dek E

O vos Do

1. coo psi A.

2#

D.y.

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9. Stopwatch Calibration Date fC$equsllc $CyClotan Area

/hs~be A/A

/VA

10. Flow Data CRD 611-80 Tame of Ef flux (Sec)

11. Flowcore Callaration Date 2!I N!

M M

No.3 Average See No.1 No.2

12. Thermometer Catterattor; Date

13. Temp.: Grout

14. T,e,mp.:

1,r 1

Initials OIl A.$'-23 90

• F

??

79

• F su 94-1.s

16. inattat curing Thermometer Calic. Date

17. Time of Testing

18. Time of Molding

/

Bagg

/83f '

Hrs 2f/r 9-2A-83

/83#

Hra at

19. Initl21 Curing ".0% O2-C ^. AJ7M-c J8-4 4

20. Stripped ASTM-C109-75

21. Initials ef,t ey 77'"

S3 op 9 '7-8 3 At 1/ 0 C Hra KA G& / 9 *?43

' ice.ga re 9*4I 6 ~s -83 l COMPRESSIVE STRENGTH DATA ASTM-C-109-75 w,f g,,,,

gyg, 4,,g,gy

,2 2*

Spscimen 2 3.D a t e 24.Date 25.

26. Total Load 27.

28.

{9, W Cure 31.

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ree Br ak Field' Lan Identification Molded Tested G-ItH F 3tA1 9 b-23

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35,3go' y,,1 4o p

3 9

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32. Spacimen Size

37. RomerKs 72* x 2* Cuce O Other 33 3

34 35.

36.

Tested By Checked B eviewed by Q.C.

(D3y3) 4*l l7.Y 3

kP

%wK l

l

38. Laboratory Supervisor Signature

39. Date l

l 1

i Ty::o af Breaks: A-Cone. Mortar Failure C-Sheer. Mortar Failure E - Other QCF 'Fi Rev.1 A

6' l

-s*

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OVERHEAD FLUID GROUTING TEST PROGRAM EXHIBIT E PROCEDURE #MCP-15.000 (EXCERPT) 6 i

[,I Rev. 8

[

. N' 10.1.1 Forms will be mortar tight and well braced.

.. 2

. 0.1. 2 Sufficient air relief holes of adequate size m,p will be provided to avoid entrapment of air WA' as determined by the MFE and concurred with by the RSG FE.

10.1.3 If required, forms will be caulked to prevent leakage of grout and loss of head.

P 10.2 When pouring grout in a form, the form will be extended high enough to facilita'te rapid, continuous and complete filling of the space to be grouted.

11.0 MIXING 11.1 The approximate amount of water / bag to be used for GAF mixing grout wt11 be as listed in Attachment a.

11.1.1 Graduated buckets or containers will be used for determining quantity of water.

11.2 The subcontractor will determine the amount of water to be used in the grout mix at the beginning of each days production, for each type of grout used, excluding Set

{

45, based on the flow cone tests performed by the contractor's approved testing agency.

Acceptance l

criteria for flow cone tests will be as shown in Attachment B.

The amount of water added to Set 45 will {

)

always be as listed in Attachment B.

11.3 Any time the amount of water to be used in the grout mix needs to be adjusted, the adjusted amount of water will be based on the results of a flow cone

• test performed by the contractor's approved te' sting agency.

l The subcontractor will notify the RSG FE when additional flow cone tests are required.

11.4 Discard any grout batched for flow cone tests that does not pass the test requirements given in Attachment B.

11.5 Compressive strength test cubes will be cast by the contractor's approved testing agency at the beginning of each days production for each type of grout used.

The subcontractor will notify the RSG FE when grout test cubes are required.

11.6 A paddle mixer, vertical shaft vane mixer,'or Jiffler-type mixer revolving at less than 300 rpm will be used i

for mixing grout.

In no case will the grout be mixed l

by-hand.

hM-C/9I* M Page 5 of 12

- c.

wy c

MCP 15.000 Il Rev. 8 0

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• 11,7 i,:ater to be used for mixing will be potable water-

[A[

(i.e.,

drinking water) having a temperature range ind cated in Attachment 3.

11.8 Grout as mixed will be between temperature ranges specified in Attachment B.

The use of ice water in hot weather and warm water in cold weather is recommended.

. 11.9 Place at least 90% of the water in the mixer first, then with the mixer operating, steadily add grout and water and mix for the ti'me period shown in Attachment B.

If lumps exist, mixing may be continued one additional minute beyond the times listed in Attachment B.

If lumps still exist, the grout will be filtered through a 1/8" mesh sieve or discarded.

11.10 Do not mix a grout quantity greater than what can be placed in approximately 15 minutes.

@4[

11.11 Grout will not be re-tempered.

Discard any material that becomes unworkable.

12.0 PLACING 12.1 The grouting sequence for structural plates will.De in gg accordance with approved grout placement plan (Attachment C).

G, rout placement operations will be observed by the RSG FE for compliance with the approved

)

plan.

12.2 Grout will be placed quickly and continuously to avoid segregation, bleeding, and change in the initial set.

gg 12.3 During the grout operation, the surfaces which are to come in contact with grout will have a temperature range as indicated in Attachment B.

12.4 Sufficient head will be maintained so that all the spaces become full with grout.

12.5 Subcontractor may drill additional holes in the form to

@/[

determine whether grout has filled all the spaces.

These holes shall be plugged by wood, eth.afoam or cork once the grout starts oozing out of these holes.

is being placed by means of tube, the tube 12.6 When grout will be withdrawn slowly in.such a manner that the end of the tube is always in grout.

Sufficient holes in the form will be provided to f acilitate in making this l

determination.

These holes shall be plugged by wood, ethafoa=,.or cork once the grout starts oozing out of these holes.

\\

F J)36-CI95-a8-Y Q Page 6 of 12

.d MCP 15.000 4

Rav. 8 O '/ ~ ',

e w

. 7p-12.9.4 For croutine soin lock rock bolts, a steel

($

plate with 'two' keyholes for inserting grout tube and de-air tube will be used.

The grout tube will be inserted to the top of the thrust ring.

Grout will then be pumped with a hand pump until grout starts oozing out of

~

the de-air tube.

The grout tube will be gradually removed once grout starts oozing from the de-air tube.

Discharge of grout in a steady strea.m from the de-air tube is positive proof that_the entire hole is filled and entire area of the bolt, including seams, is well grouted.

Plug the de-air tube and continue pumping briefly.

Then plug the grout hole.

12.9.5 For grouting hollow core spin lock rock bolts, a steel plate with one keyhole for inserting grout tube (for bciting to surface above) or de-air tube (for bolting to surface below) will be used.

The hollow tube in the rock bolt is the de-air tube (for bolting to surface above) or the grout tube (for bolting to surface below).

Grout will be purped with a hand pump until grout starts oozing from the de-air tube.

Discharge of grout in a steady stream from the de-air tube is positive proof that the entire hole is filled

)

and entira area of the bolt is well grouted.

d Plug the. de-air tube and continue pumping briefly.

Then plug the grout hole.

13.0 PRESSURE GROUTING 13.1 The grouting sequence for structural plates will be in g gI accordance with approved grout placement plan (Attachment C).

Grout placement operations will be observed by the RSG FE for compliance with the approved plan.

13.2 Pressure grouting will be used where necessary fand at the Subcontractor's option.

Pressure grouting will be necessary where. indicated on the approved grout

. placement plan (Attachment C) and at other locations determined by the M.FE and. concurred with.by the RSG FE.

4 such as 13.3 The pump must be a positive displacement. type, the piston, or a progressive cavity type.

13.4 The pump, the hose, and the nozzle will'first be. rinsed' with water.

V 72M <MS-38-7v)

Page-8 of 12

(

. ~. --.,

ig%y MCP 15.000 o

Rev. 8 Qn, i

i 0?

Fe 13.5 The grout to be used will be made into a slurry and f,o pumped through the line prior to pumping grout to uA ensure that neither water nor cement are removed from the grout during pumping, and that the pump and hose will not clog.

Slurry will be discarded.

13.6 If a nozzle is not used on a mechanically driven grout pump, first pump water through the line, followed by a pig, and immediately followed by a pump grade grout.

13.7 Grout pressure will b e' monitored when using mechanically driven pumps to place grout.

Maximum grout pumping pressure will be 40 psi or as noted on the approved grout placement plan (Attachment C).

13.7.1 Pressure gauges for monitoring grout pressures will be supplied and calibrated by the Contractor.

The range of the gauge will be between 0 and 100 psi (maximum).

13.8 On mechanically driven grout pumps, a pressure gauge will be installed on the pu=p discharge line, for indicating to the operator incipient line blockage or a plugged insert pipe.

13.9 When grout is pumped into place, grouting is started at the far end of the, space to be grouted or as shown on the approved grout placement plan (Attachment C).

)

13.10 As the grout is pumped in, the nozzle will be backed out slowly so that it always remains within the grout, preventing air entrapment.

14.0 CURING 14.1 After placement, the grout will be cured in accordance gf4 with the methods and temperatures listed in Attachment 3

B until the grout has attained its specified compressive strength.

F7ago-ci95-al8-1%

Page 9 of 12

__f._

Q n,o MCP 15.000 Rsv. S h

(

g.

ATTACHMDT 3 g

o To MCP 15.000

~

Embeco 636 Masterflow 713 Masterflow 814 Set 45 i

Cutntity of Water Per Bag 1.26 gals.*

1.32 gals.*

2.55 gals.*

0.5 gals.

Wstar Temperature 32'T to 80'T 32*F to 80*F 32'I to 80*F 32'F to 80' Crcut Te=perature 45'T to 70*F 45'T to 70*F 45'? to 75'T 50*F to 85*

Surftce Ie=perature 45'T to 85'F 55'F to 85'T 55'F to 85'T 50*F to 85" Curing Te=perature 45'T to 75'T 45'T to 85'F 45'F to 85'T SO'T to 85*

Curing Method Cover exposed grout Cover exposed greut Cover exposed grout Air dry.

with clean vet rags with clean wet rags with clean wet rags Do not use (not burlap) a mini =us (not burlap) a minimum ; (not burlap) a =ini=us curing of 3 days then apply of 3 days then apply of 3 days then apply ce= pound. 2 apprcpriate Centractor appropriate Contractor appropriate Contractor not wet cur approved and supplied approved and supplied approved and supplied curing ecepound.

curing cocpound.

curing compound.

how Cona values 25 25 Sec.

25 25 Sec.

l 25 25 Sec.

N/A Mixing Time 2-3 Min.

2-3 Min.

~

Until Uniform 3 Min. Max.

1-1 1/2 Mir

(

• These are recc= mended cuantities of water to be added and may be adjusted as specified in Section 11.2 and 11.3 of this procedure.

I ryno-ciet-a8-1(0-Page 11 of 12 S