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STEAM TURBINE

500 MW
GROUTING PROCEDURES
ERECTION

Grouting of turbine base plates, bearing pedestals, foundation frame with shrink-free
grouting compound is intended to ensure uniform transmission of the force and
vibration of the TG unit to the foundation.

Caution:
Preparations for grouting, and grouting must be carried out with great care as it is no
longer possible to check and rectify the parts once they have been grouted.
CONBEXTRA GP-II or equivalent should be used as grouting compound.

Further

details on the grouting depths, mixing time, quantity of water to be mixed, should be
refereed from the manufacturers brochures.

PROCEDURE
The foundation should be thoroughly cleaned. All foundation bolt holes should be filled
with pea-gravels and covered at the top to avoid entry and

sticking of grouting

materials with the bolts.

NOTE:- Remove all rust preventive paints, grease etc. from surfaces by wire brushes
to ensure proper adhesion of the grouting compound.

SETTING UP OF SHUTTERING
Set up shuttering from suitable material in box like manner around the foundation
plates and secure it firmly.

NOTE:- Shuttering must be sealed well to prevent the liquid grouting compound from
running out. This can be done by using paste of grout materials and allowing it sets.

Bharat Heavy Electricals Limited


Rev 00,
2-97

T1-08-0505G
Page No. 4 of 4

STEAM TURBINE
500 MW
GROUTING PROCEDURES
ERECTION
As the grouting compound remains workable for a limited time, to prevent air bubbles, it
must be poured from one side only. For this, a large size filling heaped should be
used.

PREPARATION OF GROUT MIX


Following measure must be taken before commencing mixing and grouting due to
limited time that the grouting compound remains workable.
Keep the foundation moist for at least 6 hours before the grouting.
-Set up mixers in the immediate vicinity of the foundation plates. The capacity of the
mixers, should be adequate to cope with the quantity of mixed cement required at a
time. Two or more mixers are required for grouting of bearing pedestal foundation
frame.
-Store the grouting compound next to mixer.
- Ensure that the compound is well within its expiry date.
-Provide the water hose and measuring pans near the mixers.
-Ensure uninterrupted power supply to the mixers and EOT Crane for handling the
ready mix.
-Provide adequate workmen for grouting.
-Ensure six empty cubes for filling the grout for strength testing. This is to be done as
per recommended FQP

Bharat Heavy Electricals Limited


Rev 00,
2-97

T1-08-0505G
Page No. 4 of 4

STEAM TURBINE
500 MW
GROUTING PROCEDURES
ERECTION
-Take 80 % of the required water quantity first in the mixture. Then add gradually the
grout, ensuring that no lumps are found. It is desirable to add five or six large sizes
stones to break any lumps. Finally add the balance quantity of water and mix for atleast another five minutes
This mixture is then taken into through heaped mesh. The hopper must be big enough
to make the full quantity of grout.
Than pour the grout with a hose through the filling hopper until the desired height is
achieved on the opposite side. (Flow may be accelerated by moving the grout in the
filling nozzles underneath the plates with chains or material strips.) This should be
done only if it is permitted by the grout supplier.
CAUTIONS
1. Do not use concrete vibrator.
2. Pour grout from one side only so that no air bubbles remains entrapped in the
grouting compound.
3. Due to short workability times, never mix more grouting compound at one time than
is required for one plate or volume to be grouted.
4. Pour in one continuous operation, without interruption.
5. Do not install any woven steel fabric reinforcing mats beneath the foundation plates.
6. It is desirable that in hot weather the grouting is done in the evening so that ambient
temperature is low during the initial setting time.
7. Water should be clean and free from dissolved chlorides, as these weaken the
grout.
8. In case during the grouting operations heavy leakage is observed from the
shuttering that cannot be plugged during the grouting operation, and the level of
grout has fallen below the base plate level, it is desirable to wash out the complete
grout. The operation should be repeated after the shuttering has been rectified.

Bharat Heavy Electricals Limited


Rev 00,
2-97

T1-08-0505G
Page No. 4 of 4

STEAM TURBINE
500 MW
GROUTING PROCEDURES
ERECTION

NOTE:- After at-least 72 hours setting time, work may be commenced on pretensioning of the foundation both.

After the grouting compound has set (approximately. 24 hours after grouting), remove
all shuttering and smooth off the excess grout. The grouting compound is subjected to
compressive forces only. Resultant hair cracks are insignificant with regard to TG
stability. These can be avoided by covering the exposed areas of grout by polythene
sheets to avoid excess loss of moisture during initial setting.

Bharat Heavy Electricals Limited


Rev 00,
2-97

T1-08-0505G
Page No. 4 of 4