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SECTION 03600

GROUTS

** NOTE TO SPECIFIER ** ProSpec (formerly Bonsal) manufacturers of surface preparation products, setting materials, colored tile grouts and tile and stone care and maintenance products.

This section is based on the products of Bonsal / ProSpec, which is located at:
8201 Arrowridge Blvd.
Charlotte, NC 28273
Toll Free: (800)738-1621
Phone: (704)525-1621
Fax: (704)529-5261
E-mail: Send message to ProSpec (formerly Bonsal)

[ Click Here ] for additional [ Product Data ].

Bonsal American, one of the most trusted manufacturers in concrete and flooring products for both commercial and residential construction, is proud to announce the next evolution in the industry ProSpec, a Sakrete brand.

Bonsal American / Oldcastle acquired the Sakrete brand in 2006. Building on the strength of the Sakrete brand, all products are being transitioned under the Sakrete umbrella. ProSpec is the professionally-specified group of products formerly packaged under the Bonsal brand, which included Concrete Restoration and Repair and Tile Installation products.

ProSpec is built on the core values that you have come to know and trust with the Bonsal brand. The only difference you'll see is how much easier it is to get the products you need from one source, because the entire ProSpec and Sakrete lines are one simple call away. With ProSpec, you'll get the same level of quality and performance you expect from American products.

PART 1

GENERAL

1.1

SECTION INCLUDES

Cementitious grouts for the following applications:

** NOTE TO SPECIFIER ** ProSpec® F-77 Construction Grout is a high-strength, non-metallic, cementitious structural grout. Delete if not required.

Column and equipment bases, steel bearing and sole plates, rebar, crane rails, anchor bolts, tilt-up panels, structural columns, bug hole repair.

** NOTE TO SPECIFIER ** ProSpec® PRO-DOT Construction Grout is a high-strength, nonmetallic, cementitious structural grout. Delete if not required.

Bridge piers, steel bearing and sole plates, rebar, crane rails, anchor bolts, tilt-up panels.

** NOTE TO SPECIFIER ** ProSpec® High Strength Precision Grout is a specially-formulated, ready-to-use, high strength, flowable precision grout. Delete if not required.

Precision grouting of: machinery bases, sole plates, rolling mills, generators, anchor bolts, transfer lines, paper mills. Structural grouting of: precast columns, crane rails, bridge seats, dowels.

** NOTE TO SPECIFIER ** ProSpec® Precast Mortar Grout is a fast-setting, non-shrink, single component, cementitious construction grout formulated for precast repairs and erections. Delete if not required.

Patching mortar for use on vertical and overhead concrete and masonry surfaces, trowel or hand apply for structural repairs of interior or exterior and above or below grade areas, used as a bedding mortar joining vertical and horizontal precast members together and restoration of architectural details, bridges, parking structures, tunnels, precast concrete products, retaining walls, balconies, etc.

** NOTE TO SPECIFIER ** ProSpec® Slab Dowel Grout is a non-shrink, high compressive strength, non-metallic construction grout used for placing prefabricated concrete pavements. Formulated to meet the requirements of the Fort Miller Co. Inc. Super Slab System®. Delete if not required.

Specifically designed grout to compliment precast concrete slab placement and fill inverted dovetail slots in precast slabs.

** NOTE TO SPECIFIER ** ProSpec® Commercial Anchor Cement is a polymer-modified, Portland cement based anchoring grout. Delete if not required.

For anchoring: railings; bolts; parking meters; ornamental iron; metal fence posts; machinery; banisters; dowels; structural columns; metal signs.

1.2

RELATED SECTIONS

** NOTE TO SPECIFIER ** Delete any sections below not relevant to this project; add others as required.

Section 03300 - Cast-In-Place Concrete.

Section 05120- Structural Steel.

Section 05500 - Metal Fabrications.

1.3

REFERENCES

** NOTE TO SPECIFIER ** Delete references from the list below that are not actually required by the text of the edited section.

ASTM C 78 - Standard Test Method for Flexural Strength of Concrete (Using Simple Beam with Third-Point Loading).

ASTM C 109 - Standard Test Method for Compressive Strength of Hydraulic Cement Mortars (Using 2-inch (50-mm) Cube Specimens).

ASTM C 190 - Method of Test for Tensile Strength of Hydraulic Cement Mortars.

ASTM C 191 - Standard Test Method for Time of Setting of Hydraulic Cement by Vicat Needle.

ASTM C 469 - Standard Test Method for Static Modulus of Elasticity and Poisson's Ratio of Concrete in Compression.

ASTM C 496 - Standard Test Method for Splitting Tensile Strength of Cylindrical Concrete Specimens

ASTM C 580 - Standard Test Method for Flexural Strength and Modulus of Elasticity of Chemical-Resistant Mortars, Grouts, Monolithic Surfacings, and Polymer Concretes.

ASTM C 666 - Standard Test Method for Resistance of Concrete to Rapid Freezing and Thawing

ASTM C 827 - Standard Test Method for Change in Height at Early Ages of Cylindrical Specimens of Cementitious Mixtures

ASTM C 882 - Standard Test Method for Bond Strength of Epoxy-Resin Systems Used With Concrete By Slant Shear

ASTM C 928 - Standard Specification for Packaged, Dry, Rapid-Hardening Cementitious Materials for Concrete Repairs

ASTM C 939 - Standard Test Method for Flow of Grout for Preplaced-Aggregate Concrete (Flow Cone Method)

ASTM C 1090 - Standard Test Method for Measuring Changes in Height of Cylindrical Specimens from Hydraulic-Cement Grout

ASTM C 1107 - Standard Specification for Packaged Dry, Hydraulic-Cement Grout (Nonshrink)

ASTM C 1202 - Standard Test Method for Electrical Indication of Concrete's Ability to Resist Chloride Ion Penetration

ASTM E 488 - Standard Test Methods for Strength of Anchors in Concrete and Masonry Elements

1.4

SUBMITTALS

Submit under provisions of Section 01300.

Product Data: Manufacturer's data sheets on each product to be used, including:

Preparation instructions and recommendations.

Storage and handling requirements and recommendations.

Manufacturer's printed installation instructions for each product.

1.5

QUALITY ASSURANCE

Manufacturer Qualifications: Single manufacturer, with twenty years experience in the production of all products required by this section, shall provide all primary materials specified.

Installer Qualifications: Firm with minimum 5 years documented experience with projects of similar scope, design, and materials.

Mock-Up: Provide a mock-up of each type of installation for approval of quality of workmanship.

Pre-Installation Meeting: At least three weeks prior to commencing work conduct a meeting at the project site to discuss contract requirements and job conditions; require the attendance of installers, representative of installation materials manufacturer, and installers of related materials; notify Architect in advance of meeting.

1.6

DELIVERY, STORAGE, AND HANDLING

Deliver and store packaged materials in original containers with seals unbroken and labels intact until time of use. Prevent damage or contamination to materials by water, freezing, foreign matter or other causes.

Store materials subject to damage by freezing or overheating.

Deliver and store materials on site at least 24 hours before work begins.

1.7

PROJECT CONDITIONS

Maintain environmental conditions and protect work during and after installation to comply with referenced standards and manufacturer's printed recommendations.

Do not install products under environmental conditions outside manufacturer's recommended limits.

PART 2

PRODUCTS

2.1

MANUFACTURERS

Acceptable Manufacturer: ProSpec (formerly Bonsal branded products), which is located at: Bonsal American 8227-C Arrowridge Blvd. ; Charlotte, NC 28273; Toll Free Tel: 800-738-1621; Tel: 704-525-1621; Email: request info; Web: www.prospec.com

** NOTE TO SPECIFIER ** Delete one of the following two paragraphs; coordinate with requirements of Division 1 section on product options and substitutions.

Substitutions: Not permitted.

Requests for substitutions will be considered in accordance with provisions of Section 01600.

Obtain products from a single manufacturer.

2.2

GROUTS

** NOTE TO SPECIFIER ** ProSpec® F-77 Construction Grout is a high-strength, non-metallic, cementitious structural grout. Delete if not required.

Product: F-77 Construction Grout as manufactured by Bonsal / ProSpec.

Application: Column and equipment bases, steel bearing and sole plates, rebar, crane rails, anchor bolts, tilt-up panels, structural columns, and bug hole repair.

Meets ASTM C 1107 grades A, B & C.

Meets Corps of Engineers Specification CRD-C 621.

Set Time ASTM C 191 at 70 degrees F (21 degrees C):

Plastic: initial set - 4.5 to 5.5 hours, final set - 6.5 to 7.5 hours.

Flowable: initial set - 5.0 to 6.0 hours, final set flowable - 6.5 to 7.5 hours.

Consistency of Flow ASTM C 1107:

Plastic: 100 to 125 percent.

Flowable: 125 to 145 percent.

Compressive Strength ASTM C 109:

Plastic - 1 day - >2,500 psi (17.2 MPa), 3 days - 4,500 psi (31.0 MPa), 7 days - 6,500 psi (44.9 MPa), 28 days - 8,000 psi (55.2 MPa).

Flowable: 1 day - 2,200 psi (15.2 MPa), 3 days - 4,450 psi (30.7 MPa), 7 days - 5,700 psi (39.3 MPa), 28 days - 7,000 psi (48.3 MPa).

Volume Change, % Expansion ASTM C 827: At final set Plastic - +0.40, Flowable +0.20.

Expansion ASTM C 1090:

Plastic 3, 7, 14 and 28 days: +0.02

Flowable 3, 7, 14 and 28 days: +0.10

Slant Shear Bond ASTM C 882: 28 days Plastic >3,000 psi (20.7 MPa).

** NOTE TO SPECIFIER ** ProSpec® High Strength Precision Grout is a specially-formulated, ready-to-use, high strength, flowable precision grout. Delete if not required.

Product: High Strength Precision Grout as manufactured by Bonsal / ProSpec.

Application: Precision grouting of: Machinery bases, Sole plates, Rolling mills, Generators, Anchor bolts, Transfer lines, Paper mills. Structural grouting of: Precast columns, Crane rails, Bridge seats, Dowels.

Meets ASTM C 1107

Conforms to CRD-C621 Corps of Engineers Specification for Non-Shrink Grout.

Compressive Strength ASTM C 109: (plastic, flowable, fluid, requirement).

1 day 6,000 psi (41.4 MPa), 5,500 psi (38.0 MPa), 4,000 psi (27.6 MPa). 1,000 psi minimum

3 days 7,200 psi (49.7 MPa), 7,000 psi (48.2 MPa), 6,100 psi (42.1 MPa). 2,500 psi minimum.

7 days 8,500 psi (58.6 MPa), 7,500 psi (51.8 MPa), 8,000 psi (55.2 MPa). 3,500 minimum.

28 days 10,500 psi (72.5 MPa), 10,000 psi (69.0 MPa), 9,000 psi (62.1 MPa). 5,000 psi minimum.

Expansion - ASTM C 1090 Measuring Changes in Height of Cylindrical Specimens from Hydraulic - Cement Grout: (plastic, flowable, fluid, requirement).

1 Day Expansion: +0.04 percent, +0.01 percent, +0.00 percent, 0.02 to 0.3 percent.

3 Day Expansion: +0.04 percent, +0.02 percent, +0.00 percent, 0.02 to 0.3 percent.

28 Day Expansion: +0.06 percent, +0.03 percent, +0.00 percent, 0.02 to 0.3 percent.

ASTM C 827 Change in Height at Early Ages of Cylindrical Specimens from Cementitious Mixtures: Average Change in Height at Final Set: (plastic, flowable, fluid, requirement).

0.55 percent, 1.49 percent, 1.23 percent, 0 to 4.0 percent.

ASTM C 191 Time of Setting of Hydraulic Cement by Vicat Needle: (plastic, flowable, fluid).

Initial Set: 5 hrs., 6 hrs., 6.5 hrs.

Final Set: 5.75 hrs., 7 hrs., 7.5 hrs.

Flow of Grout ASTM C 939: plastic - 115 flowable - 135. Requirement: Plastic 100-125, Flowable 125-145, Fluid 10-30 sec.

Fluid at 5 min. 27 seconds.

Fluid at 30 min. 28 seconds.

Fluid at 60 min. 35 seconds.

Product: Precast Mortar Grout as manufactured by Bonsal / ProSpec.

Application: Patching mortar for use on vertical and overhead concrete and masonry surfaces, trowel or hand apply for structural repairs of interior or exterior and above or below grade areas, used as a bedding mortar joining vertical and horizontal precast members together and restoration of architectural details, bridges, parking structures, tunnels, precast concrete products, retaining walls, balconies, etc.

Curing Method: ASTM C1107.

Compressive Strength ASTM C 109: (dry-pack, mortar, plastic).

1 day: >4,000 psi (27.6 MPa), >3,500 psi (24.1 MPa), >2,700 psi (18.6 MPa).

7 days: >8,000 psi (55.2 MPa), >7,000 psi (48.3 MPa), >5,900 psi (40.7 MPa).

28 days: >9,500 psi (65.6 MPa), >8,000 psi (55.2 MPa), >7,250 psi (50.0 MPa).

Expansion - ASTM C 1090 Measuring Changes in Height of Cylindrical Specimens from Hydraulic - Cement Grout: (dry-pack, mortar, plastic).

3 Day Expansion: +0.03 percent, +0.02 percent, +0.00 percent.

14 Day Expansion: +0.03 percent, +0.02 percent, +0.01 percent.

28 Day Expansion: +0.03 percent, +0.02 percent, +0.01 percent.

ASTM C 827 Change in Height at Early Ages of Cylindrical Specimens from Cementitious Mixtures: Average Change in Height at Final Set: (dry-pack, mortar, plastic).

0.40 percent, 0.70 percent, 0.80 percent.

ASTM C 191 Time of Setting of Hydraulic Cement by Vicat Needle: (dry-pack, mortar, maximum allowed).

Initial Set: 2.5 to 3 hrs., 3 to 3.5 hrs., 3.5 to 4 hrs.

Final Set: 3 to 3.5 hrs., 3.5 to 4 hrs., 4 to 4.5 hrs.

Product: Slab Dowel Grout as manufactured by Bonsal / ProSpec.

Application: Specifically designed to compliment precast concrete slab placement and fill inverted dovetail slots in precast slabs.

Meets ASTM C 928, Standard Specification for Packaged, Dry, Very Rapid Hardening Cementitious Materials for Concrete Repair.

Working Time at 70 degree F (21 degree C): 30 minutes; pumpable for 20 minutes.

Set Time ASTM C 191 at 70 degree F (21 degree C): Initial set - Approx. 35 min., Final set - Approx. 40 min.

Compressive Strength ASTM C 109 at 75 degree F (24 degree C):

2 hours: 2,500 psi (17.2 MPa).

3 hours: 4,000 psi (27.5 MPa).

1 day: 5,200 psi (35.8 MPa).

7 days: 6,200 psi (42.7 MPa).

28 days: 7,500 psi (51.7 MPa).

Test Length Change of Hardened Cement Mortar and Concrete ASTM C 928

Change (28 days) / ASTM C 928 requirement:

Water storage / +0.04 percent (max. to 0.15 percent).

Air storage / -0.01 percent (max. to -0.15 percent).

Differential / 0.14 percent (max. 0.20 percent).

** NOTE TO SPECIFIER ** ProSpec® Commercial Anchor Cement is a polymer-modified, Portland cement based anchoring grout. Delete if not required.

Product: Commercial Anchor Cement as manufactured by Bonsal / ProSpec.

Application: For anchoring: Railings; Guard Rails; Bolts; Parking meters; Ornamental iron; Metal fence posts; Machinery; Banisters; Dowels; Reinforcing rods; Structural columns; Metal signs.

Set Time ASTM C 191: Initial set 20-25 minutes, Final set 30-40 minutes.

Compressive Strength ASTM C 109:

2 hours: >4,500 psi (31 MPa)

24 hours: >9,000 psi (62 MPa)

7 days: >10,000 psi (69 MPa)

28 days: >11,000 psi (75.8 MPa)

Expansion ASTM C 827: +0.10 percent.

Length Change at 28 Days ASTM C 157:

Air cured:-0.07 percent.

Moist cured: +0.00 percent.

Splitting Tensile Strength ASTM C 496:

7 days: >740 psi (5.1 MPa).

28 days: >785 psi (5.4 MPa).

Anchor Strength in Concrete ASTM E 488:

inch rod diameter: >12,000 lbs. (5,443 kg).

0.075 inch rod diameter: >22,000 lbs. (9,979 kg).

inch rod diameter: >60,000 lbs. (27,215 kg).

Flexural Strength ASTM C 78:

28 days air cured: >1,400 psi (9.7 MPa).

28 days moist cured: >1,700 psi (11.7 MPa).

Tensile Strength ASTM C 190: 24 hr - >485 psi (3.35 MPa).

10.

Modulus of Elasticity ASTM C 469: 28 days - 4.93 x 10(6).

11.

Chloride Permeability ASTM C 1202: 28 days - 418 very low

12.

Freeze/Thaw ASTM C 666: 100 percent.

PART 3

EXECUTION

3.1

EXAMINATION

Examine surfaces to receive grout and conditions under which grout will be installed.

Do not proceed with grout work until surfaces and conditions comply with requirements indicated in manufacturer's printed instructions.

3.2

PREPARATION

Clean area and remove all unsound concrete, grease, oil, paint and any other foreign materials that will inhibit performance.

** NOTE TO SPECIFIER ** Structural concrete repair preparation using ProSpec Precast Mortar Grout. Delete if not required.

Structural Concrete Repair: Completely expose and clean all reinforcing steel, ensuring a minimum clearance of 3/4 inch (19 mm) behind reinforcing steel. Perform reinforcing steel preparation in accordance with International Concrete Repair Institute Technical Guideline No. 03730. For best results patch area edges should be saw cut to a depth of 1/2 inch (13 mm). Abrade the concrete to obtain a good surface promoting adhesion. The use of a vigorously scrubbed in no slump bond coat of Precast Mortar Grout or a bonding agent similar to ProSpec 118 Primer is required. This shall be applied to all surfaces coming into contact with the patch. Do not allow bond coat to dry prior to the placement of Precast Mortar Grout.

Apply when air or substrate temperature is between 40 degrees F (4 degrees C) and 100 degrees F (38 degrees C).

Surface shall be saturated with water 4-24 hours prior to placement.

Surface shall be Saturated Surface Dry (SSD) with no ponding at time of placement.

Provide air relief holes in forms where necessary.

Release agents are recommended for pretreating wood surfaces that can absorb moisture.

3.3

INSTALLATION

Shut down nearby machinery prior to placement. Avoid vibration for 24 hours after placement.

Use a mixer large enough to permit continuous placement before any part of the grout has set.

Provide vent holes where necessary.

Pour and place grout from one side of form to eliminate air voids.

A rod, chain or trowel may be used to assist in compacting the grout and eliminating air voids.

Confine grout to ensure minimum surface exposure.

** NOTE TO SPECIFIER ** Delete if grout product selected can not be extended

For placements greater in depth than 4 inches (102 mm), pre blend 25 lb. (11.3 kg) of washed clean SSD (saturated surface dry) 0.37 inch (9 mm) graded aggregate per 50 lb. (22.7 kg) bag.

Forms may be removed after grout has hardened to an initial set.

ACI 351.R-99 Report on Grouting between Foundations and Bases for Support Equipment and Machinery.

** NOTE TO SPECIFIER ** Structural concrete repair using ProSpec Precast Mortar Grout. Delete if not required.

Structural Concrete Repair: Place grout in lifts up to 5 inches (127 mm) on vertical and overhead applications by compacting the mortar in place until initial set takes place. In applications where the thickness is greater than 3 inches (76 mm) up to 33 percent clean, washed and dried 3/8 inch (10 mm) pea gravel, based on the weight of the grout may be added. (15 lbs. (6.8 kg) pea gravel to 50 lbs. (22.7 kg) Precast Mortar Grout). When placing adjoining precast members use the mortar consistency water level 4.5 qts. (4.3 L) to 50 lb. (22.7 kg) bag. Place the mortar on the horizontal member and then place the vertical element. Let the mortar reach a shavable consistency and shape as outlined above. A joint striking tool will be helpful to insure a clean seam.

** NOTE TO SPECIFIER ** Follow installation instructions as outlined by the Fort Miller Co. 1nc. Super Slab System® pertaining to precast concrete placement slab installation (518.695.5000). Delete if not required.

Slab Dowel Grouting: Super-Slab System:

The grout shall completely fill the inverted dovetail slots.

Place immediately after mixing working the grout firmly into the sides and bottom of the cavity eliminating air pockets and insuring bond and coverage.

Pumping: Because of the early strength gain the grout shall be pumped rapidly to avoid having the grout set-up in the pump or hose. It is important to pre-test insuring that the technique and equipment is suitable for the task. Install the ProSpec Slab Dowel Grout by placing the hose nozzle in the back port of each slab until grout exceeds from the port near the joint. Continue pumping until the grout fills the joint as specified in the Fort Miller installation drawings. After several slots have been filled, monitor the grout level in previously grouted ports and add material as required.

Do not drive on any freshly grouted slab with any construction equipment or vehicle until the specified grout strength of 2,500 psi (17.2 MPa) has been reached. To do so may compromise future efficiency of load transfer between slabs.

3.4

CURING

Comply with ACI 308 Standard Practice for Curing Concrete.

Wet cure exposed surface for a minimum of 3 days or apply Bonsal / ProSpec Curing Compound on exposed surface after final set (6 to 7 hours).

END OF SECTION