Masonry Magazine September 2007 Page. 36
GROUT CONSOLIDATION
A panel is built and then tested. It is up to the architect/engineer and inspector to evaluate and enforce these codes on their projects, and all projects are different, requiring different methods to achieve success.
Further, Blohowiak noted that consolidation and reconsolidation become more critical as the lift heights increase and the amount of congestion increases in the masonry cores. And he said that if the construction is performed in hot weather, the grout has a higher propensity to rapidly loose moisture into the units as it is poured into the cavities, which leads to bridging and voids.
"A proper preconstruction evaluation of the grouting process, including analyzing the reinforcement in the cores, temperatures expected during construction, and proposed lift heights should be done as a precursor to all projects," he said. "If there is any question on how the grout will perform for the chosen method, a demonstration panel should be constructed and filled and deconstructive testing should be done to verify the success of the chosen method of grouting."
National building codes not withstanding, Blohowiak also stressed that local codes and contractor preferences for pouring methods also play vital roles in adding to the confusion and misconceptions for grouting and consolidating. But according to him, "There is no wrong way to grout in terms of lift height selection or placement method; the key to success is ensuring that quality materials go into the wall and that the cores are completely full without voids. This may require consolidation and reconsolidation if standard masonry grout is selected."
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There is no wrong way to grout in terms of lift height selection or placement method; the key to success is ensuring that quality materials go into the wall and that the cores are completely full without voids.
The Grout
THE GENERAL CONSENSUS within the industry is that the grouting process is the most critical facet of RMC, and consolidation is the most crucial aspect of grouting. The goals are to steer clear of voids in the grout space, to ensure proper curing, and to avoid excessive debris in the grout during placement. To accomplish this, one must be fully aware of the materials and equipment required for consolidating grouted masonry cells.
Basically, there are two types of grout (fine and coarse), both of which are specified under ASTM C 476. Generally, the grout chosen for a particular job is based on the grout space dimensions, with fine grout recommended where large amounts of reinforcing steel are installed or where conduits or piping are laid.
From there, your options boil down to personal preference and availability of materials when choosing a grout supplier.
According to Blohowiak, the SPEC MIX system allows the contractor to control the mixing of grout on site with speed that rivals ready-mixed supplied grouts. SPEC MIX grouts are available in either 80-pound bags or 3,000-pound bulk bags to be used in conjunction with one of the SPEC MIX silo delivery systems. The company offers silo delivery systems that hold between one and 10 bulk bags of material to handle the smallest and largest projects. This system is gaining in popularity because of its level of quality control, speed of mixing and versatility of the silo systems, he says. "It no longer matters where the project is because bulk bags can be delivered and stockpiled ahead of the grouting schedule, and as little as a pail or as much as 40-plus yards of grout can be efficiently mixed out of one SPEC MIX silo per day," Blohowiak said.
Leonard said there are two other advantages to using pre-blended grouts (including QUIKRETE's Core-Fill Grout) with a silo system. First, he said, the mix designs that are produced and sent to the job have prior testing and back up. "If a highly fluid grout - 11-inch slump let's say is placed in a cylinder