10-22 Section 1003
1003 -1 DESCRIPTION This section addresses cement grout to be used for structures, foundations, retaining walls, concrete barriers, embankments, pavements and other applications in accordance with the contract. Produce non- metallic grout composed of Portland cement and water and at the Contractor’s option or as required, aggregate and supplementary cementitious materials . Include chemical admixtures as required or needed. Provide sand cement or neat cement grout as required. Define “neat cement grout” as grout without aggregate. The ty pes of grout with their typical uses are as shown below: Type 1 – A cement grout with only a 3 day strength requirement and a fluid consistency that is typically used for filling subsurface voids. Type 2 – A nonshrink grout with strength, height change and flow conforming to ASTM C1107 that is typically used for foundations and rock anchors. Type 3 – A nonshrink grout with high early strength and freeze -thaw durability requirements that is typically used in pile blockouts, grout pockets, shear keys, dowel holes and recesses for concrete barriers and structures. Type 4 – A neat cement grout with low strength, a fluid consistency and high fly ash content that is typically used for slab jacking. Type 5 – A neat cement grout that is typically used for soil nails and ground anchors. Type 6 – A low slump, low mobility cement grout with minimal strength that is typically used for compaction grouting. 1003 -2 MATERIALS Refer to Division 10. Item Section Chemical Admixtures 1024 -3 Fine Aggregate 1014 -1 Fly Ash 1024 -5 Ground Granulated Blast Furnace Slag 1024 -6 Portland Cement 1024 -1 Silica Fume 1024 -7 Water 1024 -4 Do not use grout that contains soluble chlorides or more than 1% soluble sulfate. At the Contractor ’s option, use an approved packaged grout instead of the materials above except for water. Use packaged grouts that are on the NCDOT APL . Use admixtures for grout that are on the NCDOT APL or other admixtures in accordance with Subarticle 1024 -3(E) except do not use concrete additives or unclassified or other admixtures in Type 4 or 6 grout. Use Class F fly ash for Type 4 grout and Type II Portland cement for Type 6 grout. Use well graded rounded aggregate with a gradation, liquid limit (LL) and plasticity index (PI) that meet Table 1003 -1 for Type 6 grout. Fly ash may be substituted for a portion of the fines in the aggregate. Do not use any other supplementary cementitio us materials in Type 6 grout.
10-23 Table 1003-
AGGREGATE REQUIREMENTS FOR TYPE 6 GROUT Gradation Maximum Liquid Limit Maximum Plasticity Index Sieve Designation per AASHTO M 92 Percentage Passing (% by weight) 3/8" 100 N/A N/A No. 4 70 – No. 8 50 – No. 16 30 – No. 30 25 – No. 50 20 – No. 100 15 – No. 200 10 – 30 25 1003 -3 COMPOSITION AND DESIGN When using approved packaged grout, a grout mix design submittal is not required. Otherwise, submit proposed grout mix designs for each grout mix to be used in the work, except for Type 5 grout, which has a prescribed mix design specified in Article 1003- 4. Mixes for all grout shall be designed by a Certified Concrete Mix Design Technician or an e ngineer licensed by the State of North Carolina. Mix proportions shall be determined by a testing laboratory approved by the Department. Base grout mix designs on laboratory trial batches that meet Table 1003- 2 and this section. With permission, the Contractor may use a quantity of chemical admixture within the range shown on the current list of approved admixtures maintained by the Materials and Tests Unit. Submi t grout mix designs in terms of saturated surface dry weights on Materials and Tests Form 312U at least 35 days before proposed use. Adjust batch proportions to compensate for surface moisture contained in the aggregates at the time of batching. Changes in the saturated surface dry mix proportions will not be permitted unless revised grout mix designs have been submitted to the Engineer and approved. Accompany Materials and Tests Form 312U with a listing of laboratory test results of compressive strength, density and flow or slump and if applicable, aggregate gradation, height change and durability from a certified laboratory . List the compressive strength of at least three 2 inch cubes at the age of 3 and 14 or 28 days per Table 1003- 2 for Type 1 through 4 grouts. List the compressive strength of at least three 6 inch x 12 inch cylinders at the age of 3 and 28 days for Type 6 grout. The Engineer will review the grout mix design for compliance with the contract and notify the Contractor as to its acceptability. Do not use a grout mix until written notice has been received. Acceptance of the grout mix design or use of approved packaged grouts does not relieve the Contractor of his responsibility to furnish a product that meets the contract .
10-24 Perform lab oratory tests in accordance with the following test procedures:
Property Test Method Aggregate GradationA AASHTO T Compressive Strength AASHTO T 106 Density (Unit Weight) AASHTO T 121 , AASHTO T 133B, ANSI/API RPC 13B-1B (Section 4, Mud Balance) Durability AASHTO T 161D Flow ASTM C939 (Flow Cone) Height Change ASTM C1090E Slump AASHTO T 1 19 (Except do not rod grout)
A.Applicable to grout with aggregate.
B.Applicable to Neat Cement Grout.
C.American National Standards Institute/American Petroleum Institute Recommended Practice.
D.Procedure A (Rapid Freezing and Thawing in Water) required
E.Moist room storage required. 1003 -4 GROUT REQUIREMENTS Provide grout types in accordance with the contract. Use grouts with properties that meet Table 9 1003 -2. For Type 1 through 5 grouts, t he compressive strength of the grout will be considered the average compressive strength test results of three 2 inch cubes at the oldest age per Table 11 1003 -2. Make cubes that meet AASHTO T 106 from the grout delivered for the work or mixed on-site. Make cubes at such frequencies as the Engineer may determine and cure them in accordance with AASHTO T 106. For Type 5 gr out, use neat cement grout that only contains cement and water with a water cement ratio of 0.4 to 0.5, which is approximately 5.5 gallons of water per 94 lbs. of Portland cement. For Type 6 grout, the compressive strength of the grout will be considered the average compressive strength test results of three 6 inch x 12 inch cylinders at the age of 28 days. Make cylinders in accordance with AASHTO R 100 except do not rod grout. Make cylinde rs at such frequencies as the Engineer may determine and cure them in accordance with AASHTO R 100.
10-25 Table 1003 -2
GROUT REQUIREMENTS Type of Grout Minimum Compressive Strength at Height Change at days FlowA/SlumpB Minimum Durability Factor 3 days 14 daysC 28 days 1 3,000 psi - - - 10 – 30 sec - 2 Table 1D Fluid ConsistencyD - 3 5,000 psiE 5,000 psi - 0 – 0.2% Per Accepted Grout Mix Design or Approved Packaged GroutF 4G 600 psi - 1,500 psi - 10 – 26 sec - 5 1,500 psi - 4,000 psi - Per Standard Mix Design specified in Article 1003 -4 - 6 100 psi - 250 psi - < 2" -
A.Applicable to Type 1 through 4 grouts.
B.Applicable to Type 6 grout.
C.Not applicable to Type 2 grout
D.ASTM C1107.
E.Minimum compressive strength at 3 days is only required to approve Type 3 grout mix designs or evaluate Type 3 packaged grouts for the NCDOT APL.
F.Add mixing water to Type 3 packaged grout at the manufacturer’s recommended rate to produce grout with the des igned consistency and required 3 day strength.
G.Use Type 4 grout with proportions by volume of 1 part cement and 3 parts fly ash. 1003 -5 TEMPERATURE REQUIREMENTS When using an approved packaged grout, follow the manufacturer’s instructions for grout and air temperature at the time of placement. Otherwise, the grout temperature at the time of placement shall be not less than 50 °F nor more than 90°F. Do not place grout when the air temperature measured at the location of the grouting operation in the shade away from artificial heat is below 40°F. 1003 -6 ELAPSED TIME FOR PLACING GROUT Agitate grout continuously before placement. Regulate the deli very so the maximum interval between the placing of batches at the work site does not exceed 20 minutes. Place grout before exceeding the times in Table 1003- 3. Measure the elapsed time as the time between adding the mixing water to the grout mix and pla cing the grout. TABLE 1003 -3 ELAPSED TIME FOR PLACING GROUT (with continuous agitation) Air or Grout Temperature, Whichever is Higher Maximum Elapsed Time No Retarding Admixture Used Retarding Admixture Used 90°F or above 30 minutes 1 hr. 15 minutes 80°F through 89 °F 45 minutes 1 hr. 30 minutes 79°F or below 60 minutes 1 hr. 45 minutes
Source: North Carolina Standard Specifications for Roads and Structures, 2024 Edition. Pages 438–441 of 857.