CIV-SU-985-F

CEMENTITIOUS GROUT

APPLICATION: ONSHORE

This document is the confidential property of Chevron U.S.A. Inc. Neither

the whole nor any part of this document may be disclosed to any third
party without the prior written consent of Chevron U.S.A. Inc. Neither the
whole nor any part of this document may be reproduced, stored in any
retrieval system or transmitted in any form or by any means (electronic,
mechanical, reprographic, recording or otherwise) without the prior
written consent of Chevron U.S.A. Inc.

Rev Date Description Author Sponsor

E 05/04 Revision MULI MULI
F 11/09 Revision. Some content is reproduced and used EMGL MULI
under PIP’s Membership Agreement.

November 2009 © 2004–2009 Chevron U.S.A. Inc. All rights reserved. 1 of 10

Cementitious Grout CIV-SU-985-F

CONTENTS

1.0 Scope ..........................................................................................................................3

2.0 References ..................................................................................................................3
2.1 ......Purchaser Documents ......................................................................................3
2.2 ......Industry Codes and Standards .........................................................................3
3.0 Definitions ...................................................................................................................4
4.0 Requirements .............................................................................................................4
4.1 ......Field Quality Control of Grout ...........................................................................4
4.2 ......Testing ..............................................................................................................5
4.3 ......Submittals .........................................................................................................6
4.4 ......Safety ...............................................................................................................6
4.5 ......Materials ...........................................................................................................6
4.6 ......Preparation for Grouting ...................................................................................7
4.7 ......Installation of Grout ..........................................................................................9
4.8 ......Curing .............................................................................................................10

November 2009 © 2004–2009 Chevron U.S.A. Inc. All rights reserved. 2 of 10

Cementitious Grout CIV-SU-985-F

1.0 SCOPE
1. This specification provides requirements for supplying, testing, and installing “nonshrink”
cementitious grout materials for equipment and structural base plates at Owner facilities.
2. CIV-DR-985 provides documentation requirements.
3. CIV-IT-985 provides inspection and testing requirements.
4. Some content of this specification is reproduced and used under PIP’s Membership
Agreement.

2.0 REFERENCES
1. The following documents are referenced herein and are considered part of this specification.
2. Use the latest edition of each document referenced below unless otherwise specified.
3. Any conflicts or inconsistencies between this specification, design drawings, grout
manufacturer’s specifications and recommendations, and other contract documents shall be
brought to the attention of Purchaser for resolution before the work begins.

2.1 Purchaser Documents

CIV-DR-985 Installation of Cementitious Grout–Documentation Requirements
CIV-IT-985 Installation of Cementitious Grout–Inspection and Testing Requirements
MAC-SU-3907 Grouting of Machinery

2.2 Industry Codes and Standards

American Petroleum Institute (API)
RP 686 Recommended Practices for Machinery Installation and Installation Design
ASTM Society for Testing and Materials (ASTM)
C109/C109M Standard Test Method for Compressive Strength of Hydraulic Cement
Mortars (Using 2-in. or [50-mm] Cube Specimens)
C230 Standard Specification for Flow Table for Use in Tests of Hydraulic Cement
C827 Standard Test Method for Change in Height at Early Ages of Cylindrical
Specimens of Cementitious Mixtures
C939 Standard Test Method for Flow of Grout for Preplaced-Aggregate Concrete
(Flow Cone Method)
C940 Standard Test Method for Expansion and Bleeding of Freshly Mixed Grouts
for Preplaced-Aggregate Concrete in the Laboratory
C953 Standard Test Method for Time of Setting of Grouts for Preplaced-
Aggregate Concrete in the Laboratory
C1090 Standard Test Method for Measuring Changes in Height of Cylindrical
Specimens of Hydraulic-Cement Grout
C1107/C1107M Standard Specification for Packaged Dry, Hydraulic-Cement Grout
(Nonshrink)

November 2009 © 2004–2009 Chevron U.S.A. Inc. All rights reserved. 3 of 10

Cementitious Grout CIV-SU-985-F

U.S. Army Corps of Engineers (COE)

CRD-C 621 Handbook for Concrete and Cement Standard Specification for Packaged,
Dry, Hydraulic-Cement Grout (Nonshrink)
U.S. Occupational Safety and Health Administration (OSHA)
Federal standards and instructions of OSHA, including additional requirements by state or local
agencies having jurisdiction over the grout installation, shall apply, including the following:
Part 1910 Occupational Safety and Health Standards

3.0 DEFINITIONS
Contract documents—Documents including codes, studies, design drawings, specifications,
sketches, practices, and data sheets that Purchaser has transmitted or otherwise communicated,
either by incorporation or reference, and made part of the legal contract agreement or purchase
order between Purchaser and Supplier.
Grout manufacturer—Party that produces and warrants performance of grout provided in
accordance with contract documents. The grout is manufactured in a controlled process using
standard codes, specifications, and tests, and possibly includes shop drawings to assist in
application, installation, or use. Unless otherwise noted, the term “grout manufacturer” shall apply
also to grout manufacturer’s Sub-Suppliers.

4.0 REQUIREMENTS
1. Supplier shall furnish equipment, materials, labor, and supervision, and shall perform
operations necessary for formwork, mixing, placing, finishing, and curing of “nonshrink”
cementitious grout, hereafter referred to as grout, where indicated by contract documents.
2. Grout shall also be used for rotating equipment that satisfies MAC-SC-3907, section 3.2.
3. For rotating equipment, Supplier shall follow recommended practices for machinery
installation and installation design as per API RP 686.

4.1 Field Quality Control of Grout

1. Supplier shall be responsible for quality control of Supplier-provided materials, installations,
and workmanship, including those items or installations provided by Sub-Suppliers.
2. Supplier shall not use additive to meet compressive strength result (see Section 4.2.2 item 3)
without Owner acceptance.
3. Notwithstanding Supplier’s responsibility for quality, grout manufacturer shall provide a
technical representative who shall be on site to review grouting set-up procedures and grout
manufacturer’s instructions with those who will perform the work.
a. Technical representative shall remain at grouting site as long and as often as required to
ensure that the grout manufacturer’s installation instructions are being followed.
b. This requirement may be waived by Purchaser or as otherwise specified in contract
documents.
4. Purchaser reserves the right to make inspections at any time during mixing of materials and
during execution of grout work.

November 2009 © 2004–2009 Chevron U.S.A. Inc. All rights reserved. 4 of 10

Cementitious Grout CIV-SU-985-F

4.2 Testing

4.2.1 Testing of Trial Mix

1. Supplier shall conduct the following tests on the trial mix, and submit test results to
Owner for acceptance:
a. Flowability in accordance with ASTM C939.
b. Shrinkage measurement in accordance with ASTM C827.
c. Grout strength for compression in accordance with ASTM C109.
d. Bleeding test in accordance with ASTM C940.
e. Setting time test in accordance with ASTM C953.
2. Results of compression strength tests obtained at 7 days and 28 days shall be
submitted to Owner for acceptance. If the 7-day results exceed minimum requirements
in accordance with ASTM C109/C109M, then Owner may choose to begin grouting
activities without waiting for the 28-day results.
3. Determine minimum linear expansion after set in accordance with CRD-C 621; test
results shall comply with MAC-SC-3907 Table 1, “Properties of Non-Shrinking
Grout.”

4.2.2 Testing of Injected Grout

1. Tests for injected grout shall be as follows:
a. Three test sets, each set consisting of 3 cubes, shall be made in the field each day
that grout is mixed and placed.
b. Test cubes shall be in accordance with ASTM C109/C109M.
c. One set of test cubes shall be transported to the testing laboratory after the initial
setting time and tested at 24 hours.
d. The two sets of test cubes that remain at the site shall be cured in the field for
3 days in the same way the placed grout is cured.
e. Cubes shall be transported to the laboratory for compressive strength testing after
the third day.
1) One cube set shall be tested at 7 days from the mixing date.
2) The other cube set shall be tested at 28 days from the mixing date.
2. Compressive strength of cubes shall be tested in accordance with
ASTM C109/C109M and shall meet the requirements of ASTM C1107/C1107M.
3. Nonshrink cement-based grout shall develop a minimum 7-day compressive strength
of 3,500 psi and a minimum 28-day strength of 5,000 psi when tested according to
ASTM C109/C109M.

November 2009 © 2004–2009 Chevron U.S.A. Inc. All rights reserved. 5 of 10

Cementitious Grout CIV-SU-985-F

4.3 Submittals
1. When no specific manufacturer and type of grout are specified in contract documents, or if an
alternate cementitious grout is proposed prior to installation, Supplier shall submit
manufacturer’s literature and certified test data for the cementitious grout, indicating the
product’s compressive strength, adhesive properties, dimensional stability, flowable or fluid
consistency, and other requirements of this specification.
2. A minimum of 15 days before installation, a written quality control program shall be
submitted to Purchaser for review and acceptance.
a. Program shall describe in detail how compliance with this specification is ensured.
b. Program shall include procedures for forming, handling, mixing, placing, locating joints
(including joint details), curing, testing, and inspection.
3. If testing is required by contract documents, Supplier shall submit to Purchaser copies of
inspection and test reports. Reports shall contain the following information:
a. Date of grout placement
b. Grout type
c. Identification of foundation of grout placement
d. Design compressive strength
e. Air temperature at time of grout placement
f. Foundation temperature at time of grout placement
g. Compressive break strengths

4.4 Safety
1. Supplier shall be responsible for compliance with safety requirements as specified in the
following:
a. Contract documents
b. OSHA Part 1910
c. Grout manufacturer requirements
2. Grout Material Safety Data Sheets (MSDSs) shall be available, and associated hazards shall be
reviewed with grouting personnel.
3. Goggles or face shields, protective gloves, and aprons shall be worn by personnel who mix
and place grout.
4. Dust masks or respirators (in accordance with MSDS requirements) shall be worn by
personnel exposed to grout or aggregate prior to mixing.
5. Soap and water shall be available for periodic hand cleaning as needed.

4.5 Materials
1. Materials shall be provided in accordance with contract documents and this specification.
2. Any cementitious material that becomes damp or otherwise defective shall be immediately
removed from the site.
a. Cement that has become damp takes longer to set.
b. Cement that has become damp often has reduced strength.

November 2009 © 2004–2009 Chevron U.S.A. Inc. All rights reserved. 6 of 10

Cementitious Grout CIV-SU-985-F

4.5.1 Grout Materials

1. Grout materials shall be proportioned products, in accordance with
ASTM C1107/C1107M.
2. Grout materials shall be packaged in accordance with ASTM C1107/C1107M.
3. Grout materials shall require only the addition of potable water, and shall not contain
metallic substances, aluminum powder, measurable amounts of water soluble
chlorides, or other substances that may be potentially harmful to concrete or steel
reinforcement.
4. Compressive strength shall be in accordance with ASTM C1107/C1107M (minimum
28-day compressive strength, 5000 psi (34 Mpa).
5. Grout shall be capable of maintaining flowable consistency for a minimum of 45
minutes at 70°F (21°C), measured under ASTM C230, using 5 drops in 3 seconds,
unless otherwise specified by manufacturer.
6. Cementitious grouts shall not shrink.
7. Cementitious grout expansion shall not exceed the following:
a. No more than 4 percent when tested in accordance with ASTM C827 (before set).
b. No more than 0.3 percent when tested in accordance with ASTM C1090
(after set).
8. Grout shall comply with dimensional stability requirements of ASTM C1107, Grade
C, if prepared in accordance with manufacturer’s instructions and tested at 40°F (4°C)
and 90°F (32°C).
9. Manufactured grout materials shall be delivered to the job site in original unopened
packages and shall be stored in accordance with grout manufacturer’s
recommendations.
10. Materials and tools shall be stored in a clean, dry, and organized manner.
11. Unless specified in contract documents, admixtures shall not be added to grout
without acceptance by Purchaser and grout manufacturer.

4.5.2 Mixing Water

Mixing water shall be potable and free of oils, acids, alkalines, organics, and other
deleterious materials.

4.6 Preparation for Grouting

4.6.1 Foundation
1. Foundation preparation shall be in accordance with grout manufacturer’s written
instructions and the following. If conflict arises between manufacturer’s instructions
and the following, manufacturer’s instructions shall take precedence.
a. New concrete foundations shall be cured for 7 days (minimum) before surface
preparation, unless otherwise accepted by Purchaser.
b. Before grouting, leveling and alignment of machinery and equipment shall be
performed according to project specifications.

November 2009 © 2004–2009 Chevron U.S.A. Inc. All rights reserved. 7 of 10

Cementitious Grout CIV-SU-985-F

c. In areas to be covered by grout, the foundation shall be prepared by chipping

away laitance (poor quality concrete) and oil-soaked or damaged concrete to
exposed fractured coarse aggregate.
1) Concrete shall be removed by chipping to a depth that permits 1 inch (25 mm)
grout (minimum) between the concrete and the bottom of base or sole plate.
2) Scarifying the surface with a needle gun or bushing tool, or sandblasting to
remove laitance from the foundation shall not be unacceptable.
3) Chipping and removal shall not be performed with heavy tools such as
jackhammers, which could damage the structural integrity of the foundation.
4) A chipping hammer with chisel bit is the preferred tool for concrete removal.
2. Grout thickness for column base plates and equipment supports shall be as specified in
contract documents.
3. If grout thickness is not provided in contract documents, the following requirements
shall be followed:
a. For base plates up to 3 feet (0.9 m) wide, grout thickness shall be a minimum of
1 inch (25 mm) and maximum of 2 inches (50 mm), with an additional 1 inch
(25 mm) of grout for each additional 3 feet (0.9 m) in width.
b. For clearances greater than 3 inches, a procedure shall be developed and
submitted to Owner for acceptance.
4. The grout type, consistency, placement method, and formwork for base plates of
various sizes shall be selected in accordance with Table 1 of this specification.
Table 1: Grouting of Structural Bases

Size of Base Placement

Obstructions Grout Type Consistency Formwork
Plate Method

Small None or Sand-cement Stiff Dry Pack Pack against

(< 2 ft. × 2 ft.) shear keys dry pack a back form
Large (least None or Non-shrink Fluid Pour Watertight
dimension shear keys cement-based
Flowable Pump Watertight
>2 ft.)
Large or small Severe or tight Non-shrink Fluid Pour Watertight
clearances cement-based

5. When surface chipping is complete, foundation shall be thoroughly swept and air-
blown free of dust with clean, dry, oil-free air.
6. Foundation shall be kept free of contamination by oil, dirt, water, etc., after
preparation for grouting.
7. Protective sheeting (such as sheets of clean polyethylene) shall be used to cover
prepared surfaces when work is not in progress.
8. Concrete surface shall not be too dry or too wet.
a. If surface is too dry, water from grout mix is absorbed, which can cause shrinkage
cracks to develop in grout.
b. If surface is too wet, water-cement ratio of grout increases, which can reduce
grout strength.

November 2009 © 2004–2009 Chevron U.S.A. Inc. All rights reserved. 8 of 10

Cementitious Grout CIV-SU-985-F

4.6.2 Grout Forms

1. Grout forms shall be built of materials of adequate strength and shall be securely
anchored and sealed to withstand the liquid head and forces developed by grout during
placement.
a. Formwork shall be constructed with adequate strength, rigidity, watertightness,
and dimension to permit cementitious grout placement.
b. Forms shall not be attached to foundation using power nailing.
c. Forms shall be sealed to prevent grout leakage. (Bitumastic or room temperature
vulcanizable [RTV] silicone rubber can be used for this purpose.)
d. Unless otherwise shown in contract documents, grout forms shall have minimum
3/4-inch (19-mm), 45-degree chamfer strips at exposed grout corners.
2. Metal surfaces of base plates and equipment bases to be in direct contact with grout
shall be free of oil, grease, and other foreign substances.
3. A bond breaker in accordance with grout manufacturer’s recommendations shall be
applied to the surface of the formwork in contact with grout.
4. Joints in grout shall be located in accordance with contract documents or as
recommended by grout manufacturer.
a. Unless otherwise shown in contract documents, expansion joints shall be made
from 1-inch-thick (25-mm) closed-cell neoprene foam rubber (polystyrene may
also be used).
b. These shall be glued in position prior to grout placement with RTV silicone rubber
or elastic epoxy seam sealant (liquid rubber).

4.7 Installation of Grout

1. Grout shall be stored, mixed, placed, and cured in accordance with manufacturer’s written
requirements and at temperature ranges consistent with manufacturer’s recommendations.
a. Grouting shall be performed with ambient temperatures and mix temperatures between
40°F (4°C) and 90°F (32°C) unless otherwise permitted by manufacturer.
b. Manufacturer’s recommendations shall be followed for grouting performed outside the
above temperature range.
2. Supplier shall be responsible for reading, understanding, and complying with grout
manufacturer’s instructions.
3. Grout shall be dry packed, flowed, or pumped into place in accordance with manufacturer’s
written instructions.
a. Dry packing shall be used only where accessibility is adequate.
b. For some grouts, particular installation methods are restricted or prohibited by the
manufacturer.
4. Concrete surfaces in contact with grout shall be saturated surface dry (saturated with clean
water before grout placement, with the concrete surface damp but free from standing water).
5. Grout shall be placed in only one direction to prevent trapping air.
6. Grout surfaces shall be sloped and finished to prevent accumulation of moisture next to base
plates and anchor bolts, and corrosion of base plates and anchor bolts.

November 2009 © 2004–2009 Chevron U.S.A. Inc. All rights reserved. 9 of 10

Cementitious Grout CIV-SU-985-F

7. Care shall be taken to avoid excess grout outside the plate.

a. This condition can cause an eventual crack if overbuilt to a level higher than the level of
grout under the base plate.
b. The crack is caused by differential thermal expansion between the steel and the grout,
differential strain of grout under the plate, and excess grout outside the plate.
8. Grout shall be applied in the thickness specified in contract documents.
9. Grouting shall be quick and continuous to avoid segregation, bleeding, or premature initial set.
10. Retempering of grout by adding water after stiffening shall not be permitted.
11. Where forms are not used, grout shall be cut back to the lower edge of base plate after it has
reached its initial set. Cutback shall be at a 45-degree angle unless otherwise indicated in
contract documents.
12. Grout placed through grout holes shall be placed into one hole continuously until it has passed
a second hole.
a. A liquid head pressure shall be maintained at the first access hole until a head pressure has
been established at the next hole.
b. Grout placement shall continue from the next hole in a similar fashion.
13. Voids in anchor bolt sleeves (except for rotating equipment) shall be cleared of foreign
material and completely filled with grout, unless shown otherwise on drawings.
14. Anchor bolt sleeves for rotating equipment or other equipment shown on drawings shall be
filled with a non-bonding moldable material prior to grout placement.
15. Grout placed around sliding surfaces (e.g., reactor skirts or exchanger supports) shall be
placed so that it does not inhibit movement between sliding surfaces.
16. Voids that remain after removal of temporary shims shall be filled with the same grout
material.

4.8 Curing
These procedures shall be followed unless grout manufacturer specifies otherwise:
1. Forms shall remain in place for 24 hours (minimum) after completion of grouting.
2. Moisture loss shall be prevented by keeping exposed surfaces wet for 7 days (minimum) or by
applying a curing compound.
3. Moist curing can be achieved by applying wet rags or burlap to exposed surfaces.
a. Wet rags or burlap shall be covered with plastic to prevent excessive evaporation.
b. Wet rags or burlap shall be re-wetted as necessary to maintain moistness.
4. Temperature of grouted base and concrete foundation shall be maintained between 40°F (4°C)
and 90°F (32°C) for 3 days (minimum) after initial set.
5. Equipment shall not be placed in service before the grout has attained 80 percent of specified
28-day design compressive strength.

November 2009 © 2004–2009 Chevron U.S.A. Inc. All rights reserved. 10 of 10