AtoxmillgroutingProcedure

forfoundationparts

Approved date: 21-Dec-2009

Created by: BGR
Approved by: RH

Doc. No. 749501-1.0

 Atox mill grouting procedure for foundation parts
749501-1.0

Atoxmillgroutingprocedureforfoundationparts:
The importance of establishing a good foundation for the mill cannot be over
stressed. Poor grouting will cause problems when the mill is operating. It is strongly
recommended that a representative from the grout manufacturer be present so as to
ensure the grout is correctly mixed and poured. The grouting procedure for the ATOX
Mill is of cementitious. The cementitious grout surrounds and fills the large areas in
the foundation.

WARNING
Failures of machine components have occurred because of improper grout
specification. Voids that occur due to shrinkage of grout or incorrect installation

techniques of grout will not adequately support the machine. The purpose of the

grout is to ensure that the machine and foundation concrete mass act together


as one mass in order to dampen vibrations. This can only be achieved if there
is intimate contact between the grout and the machine; as well as intimate
contact between the grout and the concrete. Master Builders or other
competent grout specialists must be hired to supervise the installation including
preparation of concrete; selection of grout material, tools and equipment;
mixing; placement; and curing. If grout installation is not proper, repairs to the
machine and to the grout will be absolutely necessary and will be very
expensive.

1.1Generalsequenceoffoundationwork

1. Preparation of concrete foundation and equipment.
2. Installation of equipment and anchor bolts.
3. Alignment of Gear & motor bases, hydraulic cylinder mounting brackets and mill
Housing, Make sure that the surfaces of the equipment are free from oil, grease,
paint etc.
4. Cementitious grout with non shrink for anchor bolts.
5. Time delay for grout cure.
6. Final alignment of all base frames and housing
7. Complete cementitious grout for all base frames and mill housing.
8. Time delay for grout cure.
9. Paint the grout and concrete.

1.2Concretepreparation:
Independent of the grouting method used, the base concrete should be poured with a
rough surface and water cured. Before placing the mill base frames in place, all
lattice and weak concrete must be removed. If the base concrete was cast smooth,
bush, hammer or chip the surface to leave a sound, clean rough surface. (A
continuously rough surface will develop the full shear strength of the concrete under
the grout). During the installation of the frame, care must be taken to avoid oil and
grease spillage.
The concrete surface must be re cleaned and saturated with water for 24 hours just
prior to pouring the grout material. Remove free water from the concrete just before
starting the grout pouring.

2/5 The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Atox mill grouting procedure for foundation parts
749501-1.0

1.3Pocketgroutingforanchorbolts:

The anchor bolts are grouted into pockets in the concrete. The bolts must be degreased and
be absolutely free from oil and paint. Place the mill housing and all base frames with anchor
bolts. The top of the anchor bolt must be extended a certain distance above the top of the
steel member being bolted down. This distance is specified on the drawings. Cover the
anchor bolt top portion, only as indicated on the installation drawings, with duct tape or
tubular urethane foam to prevent the anchor bolt from bonding to the cementitious grout.
The duct tape or tubular urethane foam, properly installed on the anchor bolt, will allow the
anchor bolt to stretch when tensioned. After all base frames and housing are aligned and
levelled in close proximity to the final position, then use non shrink cementitious grout to
grout all the anchor bolts of base frames and mill housing. Allow at least 7 days for the grout
to cure before tensioning all the anchor bolts.

Agitation straps should be used to level the grout as it is poured, and to remove air from
under the flanges.

1.4Foundationpreparationforfinalgrouting

Preparation of foundation:

Concrete support structure for ATOX Mill, main gear units, and other heavy machinery must
be executed with an appropriate surface reinforcement, however, as a minimum 7 kg/m2.

When determining the reinforcement, account must be taken of the influences from the
equipment, including temperature loads by connecting with frame and supporting beams by
means of a cross reinforcement.

The lateral face reinforcement of the concrete support must be carried to level where it
covers the construction joint between the first pour and grouting which is executed after the
equipment has been mounted

In order to grout the layer between the upper most beams of the frame, a wall (shuttering)
must be placed on either side of the centre section of the frame. This may e.g. take the form
of a 3 mm plate which is tack welded to the stiffening ribs of the beams, a plate which
remains inserted, or a wooden shuttering which leaves a smooth surface when it is
removed.

The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth. 3/5
 Atox mill grouting procedure for foundation parts
749501-1.0

1. Grout the holding down bolts here after coarse alignment of the equipment.
2. Do not forget wedges or shims on either side of the bolt.
3. Bend down the side face reinforcement.
4. Spot welding to all frames / housing.
5. Support height specified on drawings.

1.5Finalgrouting:

Having finally aligned the equipment and tightened up the anchor bolts to the
specified torque value and then grout or embed the equipment.

Concrete used for the execution of support structures must have a 3-day cube
Strength T 30 MN/m2, corresponding to 3-day cylinder strength of C 25
MN/m2. The compressive strength per ASTM C-109 must be around 7,000 psi, fluid
consistency.

When proportioning mortar and concrete, use correctly graduated additives having
an adequate maximum stone size to ensure good placement properties. It may be
required to use special grouting mortars for particular applications.

Prior to grouting or embedment of the equipment, the parts to be grouted and

embedded must be degreased and cleaned.

Remove (chip off) any oil spillage, grease stains and impurities on the concrete in
the construction joint.

Embed the support flange only if it is shown on the drawings or required in the
instruction manuals.

The lateral face reinforcement of the concrete support must be carried to level where
it covers the construction joint between the first pour and grouting which is executed
after the equipment has been mounted.

4/5 The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Atox mill grouting procedure for foundation parts
749501-1.0

The grout material should be poured outward from under the top plate of the bedplate for
gear. It is extremely important that no voids exist under or around the flanges. The outer
edge of grout will have to be troweled with a slope from bottom corner of the top plate to the
top of the concrete. The inner area of the gear frame should be filled with grout to within 15-
20 mm of the top of the plate. The grout should be covered with wet rags or burlap until
troweled smooth.

Finally after the completed installation of mill section paint the foundation with epoxy paint to
avoid oil seepage in to the foundation in case any oil spillage during maintenance.

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The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth. 5/5