Special Cement Grout

Special Cement Grout

BP550

Ready-to-use, powerful, non-shrink construction mortar

Suitable for base plate installation and stabilization

Special cement grout; the most critical and sensitive part of steel structures is the installation and stabilization of base plates on the foundation. The installation of base plates on the foundation must be done precisely, considering all related details. After the base plates are installed using anchor bolts, nuts are tightened, and the surface of the base plate is leveled, ensuring the plates are correctly positioned, the next crucial task is the grouting under the base plates to complete the installation process. The special cement-based grout, in addition to having high strength, also offers excellent flowability, which facilitates the grout flow under the bearing plates. Furthermore, the formulation of cement grouts includes materials that expand the mortar, compensating for the volume loss caused by cement hydration and preventing shrinkage and contraction after drying. These properties are highly important when installing and stabilizing bearing plates on the foundation. Using ordinary mortars or concretes is not ideal due to their insufficient strength and shrinkage during hydration, which can cause settling in the structure. To address this issue, non-shrink and powerful ready-mixed mortars have been formulated and produced. Special cement-based grouts are much stronger than ordinary construction mortars and provide specific properties that facilitate the installation of column plates. Powdered plasticizers in the formulation of special cement grouts reduce water content, enhancing the final compressive strength and other mechanical resistances. The grout’s flowability ensures excellent spreading to remote areas and facilitates filling sections with high rebar density without the need for vibration. Cement-based grout offers higher workability and performance compared to ordinary mortars and has better resistance to temperature fluctuations. Additionally, this product exhibits high resistance to freeze-thaw cycles.

In general, this product is a construction material used for filling and stabilizing empty spaces or cracks in concrete structures. It features high flowability, mechanical resistance, and reduced shrinkage. Due to its outstanding technical and mechanical properties, it is used in various construction and industrial projects. Ultimately, the use of this product increases the durability and stability of concrete structures, reducing maintenance and repair costs.

Mechanism of High-Strength Special Cement Grout

Special cement grout is based on cement and formulated using cement, graded aggregates, powdered plasticizers, polypropylene fibers, and expansion materials, each of which enhances the grout’s properties. Due to the inclusion of properly graded aggregates, the grout can be produced without any soil content. The powdered plasticizers in the formulation reduce the water requirement for mixing, resulting in improved workability and increased compressive strength. The polypropylene fibers increase wear resistance and improve mechanical properties. The expansion agents compensate for the volume loss during hydration, ensuring the grout remains non-shrinking.

Properties and Effects of High-Strength Special Cement Grout

• Reduced permeability and water absorption
• Achieves early setting strength without the need for accelerators
• Compressive strength of 60 MPa
• Prevents cracking due to shrinkage
• Protects reinforcing bars from corrosion
• Improved workability in plastic state
• Achieves high mechanical resistances
• High resistance to deformation under loads up to 200°C
• Can control plastic shrinkage through gas expansion
• High resistance to freeze-thaw cycles
• Faster utilization of the structure with controlled expansion (volume change)
• No cracking after hardening
• High resistance to weather conditions
• High static load resistance
• Prevents steel rust due to the absence of iron-based aggregates and chlorides
• Excellent pumpability and water flowability

Applications of High-Strength Special Cement Grout

• Grouting under conveyor rails in industrial factories
• Suitable for general and interior construction works
• Installation of industrial machinery such as generators, turbines, compressors, diesel engines, and vibrating machinery
• Suitable for anchor bolt installation and fence base fixing
• Installation and stabilization of column plates in steel frame buildings
• Filling gaps between column plates and foundations
• Ideal for grouting under bridge foundations and filling gaps between columns and bridges
• Suitable for grouting around water-passing pipes in concrete walls as a waterproof mortar
• Capable of anchoring reinforcement bars up to 8 cm in diameter
• Can be used as a repair mortar in deep injection sections under buildings and base plates

Physical and Chemical Properties of Special Cement Grout

• Form: Powder
• Color: Gray
• Bulk Density (in slurry form): 1.6 g/cm³
• Standard: ASTM C 1107
• Chloride Ion: None

Consumption Rate of High-Strength Special Cement Grout

The consumption rate of grout can be determined by evaluating the volume of the section and the specific gravity of the ready-to-use cement grout. Generally, the consumption rate is 2350 kg per cubic meter of space. A 25 kg bag of special cement grout occupies about 13 liters of space.

Method of Use for High-Strength Special Cement Grout

• Ensure the molds for grouting are 2 to 5 cm higher than the base plates.
• Verify the correct positioning of the base plates and, if necessary, use a level to check their alignment.
• To prepare grout, 3.5 liters of water are required for a creamy mortar and 4.5 liters for a flowable mortar.
• The surface to be grouted should be at least 7 days old.
• The gap between the underside of the plates and the concrete surface should be at least 1 cm.
• Ensure the surfaces in contact with the grout are free from contamination, oils, and dust.
• Adding additives, cement, or aggregates to the prepared grout mix is not allowed.
• Remove any loose or flaky material from the concrete surface using grinding, water jetting, or other methods.
• Ensure the molds are waterproof to prevent water leakage.
• To prevent air trapping, provide sufficient space under the base plates.
• Use a headbox for large grouting sections and a metal sheet for smaller sections to ensure consistent flow.
• Pre-wet the grouting surface with clean water to prevent grout from being absorbed too quickly and causing cracking.
• Use a suitable container to mix the grout powder with water, ensuring the mixture remains homogeneous.
• In hot weather, use cold water for mixing, and in cold weather, use warm water.
• Gradually add the grout powder to the water while mixing with an electric stirrer until a uniform mixture is achieved.
• Use the grout within 30 minutes of mixing.
• Grouting should be done from one side, ensuring continuous flow to other areas. For larger sections, divide the area into smaller sections using temporary molds.
• The temperature during grouting should be between 5°C and 30°C. Higher temperatures may accelerate setting, while lower temperatures may delay it.
• After grouting, cover the molds with a moist burlap to prevent water evaporation, and cover the burlap with plastic. Cure the surface for 7 days.

Safety of High-Strength Special Cement Grout

• This material is not toxic, flammable, or environmentally hazardous.
• In case of contact with skin or eyes, wash with clean water.
• Avoid inhaling the dust while mixing the grout.
• Always wear gloves, safety glasses, and a suitable mask when handling the grout.
• If swallowed accidentally, seek medical attention immediately.

Storage of High-Strength Special Cement Grout

• Shelf life: 1 year in its original packaging
• Storage conditions: Keep away from freezing, heat, and prolonged direct sunlight
• Optimal storage temperature: +10°C to +30°C

Packaging of High-Strength Special Cement Grout

• 25 kg bag