Rapid Set® UltraFlow® 4000/8 — HOW TO (Application Guidelines)
Precision, Fluid , Non-Shrink Grout
Installation Procedures
IMPORTANT:
Experienced CTS Cement | Rapid Set® field representatives are available for jobsite service. Contact CTS Cement | Rapid Set® at 800-929-3030 if grout will be pumped, mixed in a ready-mix truck, used with pea gravel, used at temperature extremes, less than ½" thick, over 6" thick, or if there are any unusual jobsite conditions. Please read the following carefully and call CTS Cement | Rapid Set® with any questions. Deviating from these instructions may void the product warranty.
SURFACE PREPARATION:
Concrete shall be clean, sound, and have a rough texture that exposes coarse aggregate. Bolt holes shall be cleaned out and grouted in advance to prevent sagging of grout into the holes. All surfaces shall be free from oil, grease, dust, laitance, and other contaminants. Remove rust and scale from metal surfaces. Equipment must be secured in place to prevent movement during the grouting procedure. Saturate the concrete (preferably by ponding) for a minimum of 8 hours prior to placing grout. Concrete must be SSD (Saturated, Surface Dry). Prior to placing grout, standing water must be removed. Blowing the water from underneath using oil-free air and then wet vacuuming is effective. Protect baseplate and concrete base from temperature extremes, such as direct sunlight for 24 hours prior to and following grouting.
FORMS:
Forms must be watertight and nonabsorbent. Use polyurethane foam, putty, or caulk to seal the joints. Forms must be coated or waxed. Use headbox with 45o angle to facilitate placement for large pours. Build forms 1" higher than bottom of plate and leave 2" to 3" between side of plate and form.
MIXING:
Add potable water to a bucket, pump mixer, or paddle type mixer (start with 4.5-quarts per bag). Slowly add undamaged bags of UltraFlow® 4000/8. Never add cement, sand, or admixtures to UltraFlow® 4000/8. Mix thoroughly for 5 minutes to a uniform consistency using enough water to achieve a consistency not less than 24 seconds through a flow cone per ASTM C939 and CRD C621. Variables affecting the amount of water needed include temperatures, efficiency of mixing, and consistency desired. Never mix by hand. Adjust water temperature to maintain mixed grout temperature from 45 to 90F. Do NOT retemper, add water, or remix after the grout stiffens. Grout that stiffens before use must be discarded. For deep pours 3/8-in pea gravel may be added, but only after consulting with the RapidSet® representative at 800-929-3030 for instructions and limitations.
PLACEMENT:
Verify that concrete, plate, and ambient temperatures are from 45o to 90o F and will remain in that range until the grout has reached final set. Place grout continuously from one side across the shortest dimension or from the center outward by pouring or pumping. Pour the grout onto headbox 45o incline to minimize air entrapment. Use multiple mixers if required to ensure continuous placement. Once placement has begun and the grout is in contact with the plate, the grout must remain in contact with the plate. It is important for the grout to extend at least ½-in up the edges of the plate to provide a small head pressure that will keep the grout in contact with the plate bottom. Do NOT vibrate the grout, but steel straps may be inserted prior to placement on large pours and jiggled lightly if required. Immediately after placement, cover exposed grout surfaces with clean wet rags until it has reached final set or cut back and finishing is begun. Shoulders may be cut back when the grout is hard enough to keep its shape without sagging from the plate and hard enough that cutting back will not cause the grout to sag away from the plate bottom (approximately 2-hr after placement). Immediately after cut back and finishing, cover with clean wet rags until final set. Have all required tools, equipment and materials as close to the grouting area as possible.
CURING:
Apply wet rags until final set. Apply curing compound immediately after finishing or final set is reached at a rate that meets ASTM C309. Apply curing compound to all exposed grout after forms are removed.
IN-SERVICE:
Grouted equipment may be put into service as soon as desired grout strengths are achieved. Exposed shoulders, particularly if they are wide, may have some hairline cracks. These cracks Do NOT affect the structural integrity of the grout and they have no negative effect upon the load transfer ability of the grout under the baseplate.
SHELF LIFE:
When stored in a dry location in an undamaged package, UltraFlow® 4000/8 has a shelf life of 12 months.
CAUTION:
UltraFlow® 4000/8 contains cementitious materials and may cause irritation to the lungs, eyes and skin. Avoid contact with lungs, eyes and skin. Wet mixture may cause burns. Use only in adequate ventilation. Wear suitable eye protection and protective clothing. Do NOT breath dust. Wear suitable gloves. In case of skin contact, wash thoroughly with soap and water. In case of eye contact, flush immediately and repeatedly with large quantities of water and get prompt medical attention. In case of difficulty breathing, remove person to fresh air. If difficulty breathing persists, seek medical attention.
LIMITED WARRANTY:
CTS Cement Manufacturing Corporation (CTS) warrants its materials to be of good quality and, at its option, within one year from date of sale it will replace material proven defective or refund purchase price thereof, and such replacement or refund shall be the limit of CTS's responsibility. Except for the foregoing, all warranties, expressed or implied, including merchantability and fitness for a particular purpose, are excluded. CTS shall not be liable for any consequential, incidental, or special damages arising directly or indirectly from the use of the materials.
MINING APPLICATIONS with UltraFlow® 4000/8
BASE PLATE GROUTING with UltraFlow® 4000/8
EQUIPMENT GROUTING with UltraFlow® 4000/8
GROUTING, GENERAL with UltraFlow® 4000/8
GROUTING, NON_SHRINK with UltraFlow® 4000/8