A Professional’s

Handbook on
Grouting and
Concrete Repair

FIVE STAR PRODUCTS, INC.

60 Parrott Drive
Shelton, CT 06484
Support: (800) 243.2206
FiveStarProducts.com
 A Professional’s Guide
to
Grouting and Concrete Repair
for:

Architects
Contractors
Engineers
Specifiers
Owners

Five Star Products Inc.

60 Parrott Drive, Shelton CT 06484
FiveStarProducts.com
© Copyright 2007-2019 Five Star Products, Inc.
Copyright© 1981, 1983, 1985, 1988, 1989, 1991, 1995, 2005, 2007, 2008, 2012, 2019
by FIVE STAR PRODUCTS, INC.
All rights reserved. No part of this book may be reproduced in any form without
written permission of the publisher,

FIVE STAR PRODUCTS, INC.

60 Parrott Drive
Shelton, CT 06484

Five Star®, Five Star Structural Concrete®, Five Star® Foundation System, Summerset®,
and the Five Star logo are registered trademarks of FIVE STAR PRODUCTS, INC.

Design-A-Spec™ is a trademark of FIVE STAR PRODUCTS, INC. Other trademarks

are the property of their respective owners.

NOTICE AND DISCLAIMER

The tables, data, and other information in this book have been obtained from many
sources, including professional architects, engineers, contractors, subcontractors,
manufacturers, government organizations, trade associations, and suppliers of building
materials. The publisher has made every reasonable effort to make this book accurate
and authoritative, but does not warrant, and assumes no liability for, the accuracy or
completeness of the text or its fitness for any particular purpose. It is the responsibility of
the users to apply their professional knowledge in the use of the information contained
in this book, to consult the original source, publisher, or manufacturer for additional
information when appropriate, and if they themselves are not professional experts in the
field, to consult with FIVE STAR PRODUCTS, INC. when appropriate.

Specifications subject to change. Refer to fivestarproducts.com for current technical

data.

(800) 243-2206 • fivestarproducts.com

A Professional’s Guide on Grouting and Concrete Repair

FIVE STAR PRODUCTS, INC.
ENGINEERING & TECHNICAL CENTER

FIVE STAR PRODUCTS, INC. MAINTAINS THE INDUSTRY’S FOREMOST

ENGINEERING AND TECHNICAL CENTER STAFFED WITH ENGINEERS,
AVAILABLE FOR CONSULTATION AND ON-SITE TECHNICAL SERVICE
WORLDWIDE.
PHONE: 203.336.7900 • FAX: 203.336.7913
 PAGE

TABLE OF CONTENTS 4

PREFACE 5

GROUTING INTRODUCTION 6

CHAPTER 1 SELECTING A CEMENTITIOUS NONSHRINK GROUT 9

CHAPTER 2 KEY PERFORMANCE PROPERTIES AND TEST METHODS 13

CHAPTER 3 MANUFACTURER’S QUALITY ASSURANCE PROGRAM 20

CHAPTER 4 ESTIMATING, PURCHASING, DELIVERY, AND STORING GROUT 21

CHAPTER 5 GROUT PLACEMENT PROCEDURES 25

CHAPTER 6 TYPICAL CEMENTITIOUS GROUTING APPLICATIONS 47

CHAPTER 7 TYPICAL INSTALLATIONS BY INDUSTRY 53

CHAPTER 8 GROUT SPECIFICATIONS 55

CHAPTER 9 SHORT FORM SPECIFICATIONS 59

CHAPTER 10 CONCRETE REPAIR INTRODUCTION 64

CHAPTER 11 SELECTING A REPAIR MATERIAL 67

CHAPTER 12 PERFORMANCE PROPERTIES AND TESTS 68

CHAPTER 13 MANUFACTURER’S QUALITY ASSURANCE PROGRAM 72

CHAPTER 14 ESTIMATING, PURCHASING, DELIVERING, AND STORING

73
CONCRETE REPAIR MATERIALS

CHAPTER 15 PERMANENT CONCRETE REPAIRS 74

CHAPTER 16 CONCRETE PAVEMENT REPAIRS 79

CHAPTER 17 TYPICAL CONCRETE REPAIR APPLICATIONS 82

CHAPTER 18 SPECIALTY CONCRETE REPAIRS 83

CHAPTER 19 CONCRETE REPAIR SPECIFICATIONS 85

CHAPTER 20 INDUSTRIAL CONCRETE REPAIR SPECIFICATIONS 87

CHAPTER 21 INFRASTRUCTURE CONCRETE REPAIR SPECIFICATIONS 90

CHAPTER 22 FOUNDATION SYSTEMS 93

APPENDIX A ANCHOR BOLT GROUTING 104

APPENDIX B GLOSSARY 113

APPENDIX C COMMON CONVERSION FACTORS 114

APPENDIX D RECOMMENDATIONS FOR BULK MIXING 115

APPENDIX E MIX WATER REQUIREMENTS 116

NOTES 118

4 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

PREFACE
This handbook, the first of its kind in the industry, was originally published by FIVE
STAR PRODUCTS, INC. in 1981 as an aid to owners, engineers, architects, specifiers
and contractors involved in the selection, specification and use of nonshrink grouts and
concrete repair materials. This latest version is the result of significant industry changes
that have occurred since its last publication.

The American Society for Testing and Materials (ASTM), the Corp of Engineers
and the American Concrete Institute (ACI), are key organizations responsible for
establishing standards and specifications for nonshrink grout and concrete repair.
The beneficial work of these organizations is important to industry. Reports, such as
“Grouting between Foundations for the Support of Equipment and Machinery” (ACI
351.1R-99), provide an excellent overview for evaluating and selecting nonshrink grouts
based on the different expansion mechanisms used by grout manufacturers. Because
some of these expansion mechanisms have a significant effect on the successful use of
grout products in the field, ACI 351.1R-99 is an important tool for owners, engineers,
architects, specifiers and contractors.

However, the nature of some committees within industry organizations is to generate

standards and practices around consensus. This is particularly evident with respect to
nonshrink grout. Because of this, the term “nonshrink” is one that has often been used
loosely and not clearly defined – certain “nonshrink” grouts available in the marketplace
actually do exhibit shrinkage when tested by ASTM test methods. Because of this,
engineers, architects, specifiers and owners must specify exact performance properties
with respect to vertical height change characteristics of grouts, and contractors should
understand the importance of the standards and specifications they are given. A
successful grout job is the joint responsibility of the engineer, the contractor, and the
manufacturer. The generic use of the term nonshrink in standards and specifications
is insufficient. This handbook, in conjunction with ACI and ASTM standards, can
guide the strengthening and use of product specifications to ensure proper selection,
specification, and use of precision nonshrink grouts and concrete repair materials.

We wish to acknowledge the assistance of all the owners, engineers, architects and
contractors who were of major assistance to us in the development of this Handbook,
along with the very knowledgeable and competent engineering and field personnel of
Five Star Products, Inc.

(800) 243-2206 • fivestarproducts.com 5

 A Professional’s Guide on Grouting and Concrete Repair

GROUTING
INTRODUCTION

A. This section deals with precision nonshrink grout. A precision nonshrink grout
does not exhibit any plastic or hardened vertical shrinkage at any time. Precision
nonshrink cementitious grouts are designed for static or light dynamic loading, or
for high temperature exposure. Precision nonshrink epoxy grouts are designed for
heavy dynamic loading from vibration or impact or for applications requiring good
chemical resistance.

B. The proper selection and specification of precision nonshrink grout is extremely

important. Changes in equipment and machinery packaging, along with the advent
of tighter alignment tolerances, have made grout selection a critical issue. Grout
cost is incidental when compared to equipment and machinery costs. Developing
strong specifications and enforcing them, helps to ensure initial, and long term
success in the field.

C. PRECISION NONSHRINK CEMENTITIOUS GROUT

1. According to the American Concrete Institute: “The most important requirement
for a grout that is intended to transfer loads to a foundation is that it have
volume change characteristics that result in complete and permanent filling of
the space.” Complete and permanent filling of a space is achieved through the
proper selection and specification of a precision nonshrink grout. This can
be accomplished through the use of ASTM standards developed for evaluating
height change characteristics of precision nonshrink cementitious grout:
a. ASTM C 827 – Standard Test Method for Change in Height at Early
Ages of Cylindrical Specimens from Cementitious Mixtures
b. ASTM C 1090 – Test Method for Measuring Change in Height of
Cylindrical Specimens for Hydraulic-Cement Grout
c. ASTM C 1107 – Standard Specification for
Packaged Dry, Hydraulic-
Cement Grout (Nonshrink)
2. ASTM C 827 is a test method that evaluates the
vertical height change characteristics of nonshrink
grout in the plastic state (prior to hardening) where
up to 90% of shrinkage can occur. Because of this,
ASTM C 827 has been widely and successfully
used throughout the industry and should be the
starting point for any precision nonshrink grout
specification.

6 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

3. In 2005, ASTM C 1107 was revised to where specific grades of nonshrink grout
(Grades A,B and C) are no longer specified within the standard. Due to this
revision, a precision nonshrink grout can no longer be specified using this test
method. While ASTM C 1107 does set maximum height change requirements
in the plastic state when tested in accordance with ASTM C 827 (4.0%), the
standard no longer sets a minimum requirement for height change in the
plastic state. Therefore, a grout can now exhibit shrinkage in the plastic state
and still meet the requirements of ASTM C 1107.
Due to this revision, the use of ASTM C 827 in any nonshrink grout
specification is critical. The specifier must not only reference ASTM C 827, but
also set minimum and maximum height change values. Typical values range
from 1% (minimum) to 4% (maximum).
4. All Five Star Precision Nonshrink Cementitious Grouts exhibit no
shrinkage at any time (0.0%) when tested in accordance with ASTM C 827
and meet the current version of ASTM C 1107.
5. Once the issue of height change has been addressed and clarified, other physical
properties including flow, working time, versatility, and strength development
should be considered. Other special requirements for some projects may
include issues pertaining to cement chemistry, such as sulfate resistance,
very high temperature resistance (up to 2400°F), or cold weather strength
development. No single type of grout can address every requirement. Five
Star Products, Inc. manufactures several different precision nonshrink
cementitious grouts for both normal and highly specialized applications.
6. Air Release
1. Cementitious grouts usually contain hydraulic cement, sand (aggregate) and
other additives to adjust rheology, working time, strength, and compensate
for shrinkage. Additives to compensate for shrinkage include oxidizing
iron aggregate, metallic powders (aluminum), along with various types of
expansive cements. In the 1960s, U.S. Grout Corp., now known as Five
Star Products, Inc. developed and introduced an Air Release System – a
major breakthrough in grouting technology. Air Release grouts exhibit
controlled expansion prior to hardening and are dimensionally stable in the
hardened state.
2. The Air Release mechanism offers distinct advantages over other expansion
mechanisms and results in a consistent high performance grout regardless
of job site conditions. It provides the same height change characteristics
at 40°F as it does at­ 90°F, something aluminum powder-based
grouts cannot achieve. Its volume change is independent of­ moisture
availability, something the expansive cement-based and metallic
grouts cannot achieve.

(800) 243-2206 • fivestarproducts.com 7

 A Professional’s Guide on Grouting and Concrete Repair
D. PRECISION NONSHRINK EPOXY GROUT
1. Since their inception, epoxy grouts have been promoted as “nonshrink”
or evidencing “negligible” shrinkage. Test methods supposedly verifying
nonshrink performance date back to the early 1960s, but it is now apparent
that these methods are inadequate for epoxy grouts because they do not
measure vertical height change. A modification of ASTM C 827 (Standard
Test Method for Change in Height at Early Ages of Cylindrical Specimens
from Cementitious Mixtures), which has proven so successful for evaluating
nonshrink cementitious grouts, is now being used for epoxy grouts. It shows
that most epoxy grouts can exhibit even greater vertical shrinkage than
the nonprecision cement-based grouts. Loss of Effective Bearing Area (EBA)
and failures of epoxy grouts can be directly correlated with plastic shrinkage
(vertical height change).
2. Five Star Products, Inc. was the first manufacturer to use ASTM C 827 to
demonstrate positive expansion in precision nonshrink epoxy grout. Since no
other standards are available for measuring the vertical shrinkage of epoxy
grout, specifiers should use ASTM C 827 (modified) in evaluating the
nonshrink properties of any epoxy grout.
3. Epoxy grouts must be prepackaged, premeasured systems in order to avoid
costly failures. Each epoxy system has a unique viscosity requiring a blended
aggregate tailored to that system. Using an aggregate that has not been carefully
selected invites segregation, poor flow, foaming or frothing, which leads to poor
EBA. Field purchasing of aggregates should be avoided since it is impossible to
properly match aggregates to the epoxy system without experienced formulators
and specialized laboratory facilities. In a field-proportioned system, attempts at
measuring may result in improper ratios of all the epoxy components. This can
result in a spongy resinous system that will be unable to support the design load.
4. Compared to precision nonshrink cementitious grouts, precision nonshrink
epoxy grouts are higher priced, but they have superior properties. When one or
more of the following properties are required, use a precision nonshrink epoxy
grout.

a. Proper Support of Equipment

b. Better Chemical Resistance
c. Better Dynamic Load Resistance
d. Higher Compressive Strength
e. Higher Flexural Strength
f. Higher Tensile Strength
­g. Higher Bond Strength

8 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

CHAPTER 1
SELECTING A CEMENTITIOUS NONSHRINK GROUT
A precision nonshrink grout does not shrink in the plastic state or hardened state.
Manufacturers incorporate various additives, including aluminum powders, expansive
cements, and other materials, into grout products in an attempt to achieve this.
Aluminum powder-based grout is a common type of cementitious grout. Aluminum
powders are often found in “construction grade” grouts. According to ACI in their
Committee 351.1R-99 Report; “Grouting Between Foundations for Support of
Equipment and Machinery”, aluminum powder reacts chemically with the soluble
alkalis in the cement to form hydrogen gas. The release of this gas provides expansion
of the grout in the plastic state. However, according to ACI, and as is well known in
the industry, this expansion is difficult to control because only a very small amount of
aluminum powder is used, and expansion depends on the job site temperature as well
as on the chemical reaction between the aluminum powder and soluble alkalis. Colder
temperatures may slow or stop the reaction, resulting in minimal or no expansion and
loss of EBA. Higher temperatures may cause the reaction to occur too quickly, and not
allow the grout to settle into place properly before expansion occurs, again, resulting in
loss of EBA.
The difficulty for the engineer or specifier is that grout manufacturers using metallic
or aluminum powder in their products do not openly acknowledge or publish that
information, so it becomes the responsibility of the engineer or specifier to prevent the
use of these products in inappropriate applications by:
1. Including statements in specifications disallowing aluminum powder-based grouts.
2. Requiring contractors or grout manufacturers to certify in writing that the grout
submitted does not contain aluminum powder or other metals.
Expansive cement grouts rely on the formation and growth of ettringite crystals
during the hardened state. Because ettringite occupies a greater volume than the
reacting sulfates and aluminates that cause its formation, the grout expands in volume.
The formation of ettringite depends on the availability of water/moisture. In the absence
of moisture, ettringite formation and growth
ceases. Expansive cement grouts require both
presaturation of the concrete substrate and a
source of moisture to ensure the continued
presence of moisture, ettringite growth, and
expansion.

Air Release Grouts provide expansion

based upon controlled release of air from
the additive within the grout. This additive
is blended in much larger quantities than
aluminum powder and does not rely on a
chemical reaction. Rather, the water used

(800) 243-2206 • fivestarproducts.com 9

 A Professional’s Guide on Grouting and Concrete Repair

for mixing displaces entrapped air in microscopic air pockets in the additive, causing
release of air and expansion. The Air Release mechanism has proven to be the most
reliable expansion mechanism in use and is found in all FIVE STAR PRECISION
NONSHRINK CEMENTITIOUS GROUTS.
Other categories of grouts include field-proportioned grouts and oxidizing iron
aggregate grouts. These materials cannot provide controlled expansion, so they are in
very limited use today.
In selecting and specifying cementitious grouts, among the many factors that must be
considered are working time, placement requirements, strength development, product
field support and proper alignment of equipment.
SELECTING A NONSHRINK EPOXY GROUT
The information that follows provides guidance to architects, engineers, contractors,
specifiers and owners on the appropriate application and installation of epoxy grouts.
If any one of the following conditions will exist, an epoxy grout should be used.
1. Impact/Dynamic Loading
2. Vibration
3. Chemical Attack
However, additional factors should be considered in choosing which epoxy grout to use.
No single epoxy grout will meet all of the various requirements which will exist for a
given application. Major considerations include:
1. Nonshrink Properties
2. Proper Alignment of Equipment
3. Operating Temperatures
4. Creep Resistance
5. Strengths
a. Compressive Strength
b. Bond Strength
c. Flexural Strength
d. Tensile Strength
6. Thermal Coefficient of Expansion
7. Dimensions of Grout Placement (in particular, thickness)
8. Exotherm
9. Working Time
Regardless of the type of epoxy grout selected, it should be nonshrink when tested by
the appropriate ASTM methods. Vertical Height Change should be the ultimate
criterion for acceptance.
The Grout Selection Charts on the following pages are a good starting point. Contact
Five Star Products, Inc. by email at info@fivestarproducts.com or call FIVE STAR’S
ENGINEERING AND TECHNICAL CENTER at 800-243-2206 for more specific
assistance. Additional information can also be found in Five Star Products’ DESIGN-
A-SPEC documents found on fivestarproducts.com.

10 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

(800) 243-2206 • fivestarproducts.com 11

 A Professional’s Guide on Grouting and Concrete Repair

12 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

CHAPTER 2
KEY PERFORMANCE PROPERTIES AND TEST METHODS

1. CEMENTITIOUS GROUTS
The performance requirements of ASTM C 1107, Standard Specification for Packaged
Dry, Hydraulic Cement Grout (Nonshrink), include height change and compressive
strength characteristics but no longer sets a minimum requirement for plastic height
change. Due to this change in ASTM C 1107, a specifier must include minimum
and maximum height change requirements under ASTM C 827 to ensure a precision
nonshrink grout is specified.

To build a complete specification, height change and compressive strength requirements

should be considered along with other key properties that will impact the successful use
of a precision nonshrink grout.

The key performance properties and corresponding test methods for a precision nonshrink
cementitious grout include:
A. Vertical Height Change / Shrinkage – ASTM C 827, ASTM C 1090, ASTM C 1107
B. Flowability / Consistency / Working Time – ASTM C 1437 (flowable grout), ASTM
C 939 (fluid grout)
C. Compressive Strength – ASTM C 109, modified per ASTM C 1107 or ASTM C 942
This portion of the Handbook reviews these properties and test methods in detail, along with
their significance in evaluating and specifying precision nonshrink cementitious grout.

A. VERTICAL HEIGHT CHANGE

Vertical Height Change is the most critical property with respect to precision
nonshrink cementitious grout. A grout that exhibits no shrinkage in the plastic state
and is dimensionally stable in the hardened state will permanently and completely
fill a space, in accordance with ACI’s definition. In accomplishing this, the grout
will provide a high Effective Bearing Area (EBA), permanently maintain alignment
of equipment or machinery, and provide proper load transfer to the foundation.

The two current ASTM test methods referred by ASTM C 1107 for height change
are ASTM C 827 and ASTM C 1090.

ASTM C 827 measures plastic height change and is required by ASTM C 1107. With
a light source behind a cylinder of grout and a focusing lens in front, the change in
height is magnified by projection on a screen. Measured over an appropriate period
of time, results are reported as a percentage. This test method will often identify
where 80% to 90% of shrinkage occurs in cementitious grouts.

(800) 243-2206 • fivestarproducts.com 13

 A Professional’s Guide on Grouting and Concrete Repair

ASTM C 827 Test Setup
ASTM C 1090 measures hardened height change. It involves the use of a fixed 3
x 6 inch cylinder of the grout to be tested, a micrometer bridge, and a restraining
plate. Measurements are taken with a depth micrometer. This test method, when
used in conjunction with ASTM C 827, can ensure proper evaluation of a precision
nonshrink cementitious grout. As previously
stated, minimum and maximum height change
values must be included by the specifier in both
ASTM C 827 and ASTM C 1090.

ASTM C 1090
TEST SETUP

B. FLOWABILITY/CONSISTENCY/
WORKING TIME
The flowability / consistency of a grout and its working time are of significant
importance to a successful grout installation. Many grout manufacturers offer both
flowable and fluid consistency cementitious grouts.

Working time, or the time within which a grout product remains flowable or fluid,
is a key indicator of whether a grout can be successfully placed in a particular
application. Grouts with working times of 15 to 20 minutes may be acceptable for
small footprint, non-critical applications, but may not provide sufficient working
time for larger footprint machinery applications without the potential for cold joint
development.

Grouts that provide working times of 30 to 45 minutes will provide sufficient

working time for most applications and allow a margin of error for any job site

14 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

difficulties that delay placement.

The consistency of a grout determines its ability to flow into a confined space or
clearance. Most determinations of consistency done in accordance with ASTM C
1437 (Flowable Grouts) or ASTM C 939 (Fluid Grouts), report results immediately
after mixing. However, grouts rarely are placed completely and immediately after
mixing on job sites. For this reason, it is important to have information on grout
consistency not just after mixing (initial test value) but after a specified period of
time (delayed test value).

NEVER exceed the maximum water content of cementitious grout to increase

flow or retemper the grout. Such a practice is called “overwatering”.
Overwatering grout will increase shrinkage, reduce strengths, and increase
the potential for segregation and cracking. Overwatering is the primary cause
for strength reduction issues encountered on job sites.

Placement versatility is another factor in determining the selection or specification

of a cementitious grout. Job site applications often vary – a versatile product that
has the ability to be poured or pumped into place offers distinct advantages. This
versatility allows a contractor to keep just one product on site that can address both
placement requirements.

C. COMPRESSIVE STRENGTH
The compressive strength of cementitious grouts is a property that is well defined
and understood. ASTM C 1107 specifies strength gain requirements under restraint
using applicable portions of ASTM C 109 – Standard Test Method for Compressive
Strength of Hydraulic Cement Mortars.
1. ASTM C 942 - the Standard Test Method
of Grouts for Preplaced Aggregate Concrete
in the Laboratory similarly describes casting
retained cubes.
Under ASTM C 109, 2 x 2 inch cube
specimens are taken of the mixed grout
and cured according to the manufacturer’s
instructions or other contract requirements.
2. The figure to the right shows cube molds
used to cast grout specimens either restrained
or unrestrained, along with some cast cubes.
Compressive strength readings are taken at
predetermined intervals, usually 1, 7, and
28 days.
Compressive strength requirements will
vary from project to project. However, compressive strengths should not be the sole
determining factor in selecting or specifying one grout over another. Many assume
a cementitious grout with very high compressive strengths to be the best product.
This is simply not accurate.
(800) 243-2206 • fivestarproducts.com 15
 A Professional’s Guide on Grouting and Concrete Repair

In summary, successful grout selection is the result of two key factors:

1. Proper material specification (precision nonshrink vs. nonshrink)
2. Proper consideration of grout consistency, working time, and versatility.
EXAMPLE:
Contractor X has been given the choice in a specification to use a flowable or fluid
grout, and has chosen Grout A, a fluid consistency grout, because it is deemed easier
to place than Grout B, a flowable consistency grout.
Grout A has a fluid consistency initially, but after 15 minutes, it loses its fluidity,
and at 20 minutes it loses the ability to be placed properly. The potential result can
be cold joints or entrapped air under the baseplate, reducing the EBA and leading
to future problems such as misalignment or even grout failure.
On the other hand, Grout B, a flowable grout, remains placeable for 45 minutes
and retains the ability to be placed for that entire time period. Using Grout B,
the contractor has sufficient time to place the grout continuously without the
development of cold joints or loss of EBA.
Five Star Products, Inc. manufactures precision nonshrink cementitious
grouts in flowable, fluid, and dry-pack consistencies that can be poured, pumped
or hand-applied. FIVE STAR PRECISION NONSHRINK CEMENTITIOUS
GROUTS have long working times and retain their consistency for extended
periods, thus ensuring proper and successful field installation. For special
applications, including very tight clearances (less than 1/2 inch), high sulfate or
high temperature exposure or long distance pumping, Five Star Products, Inc.
can provide a successful, time tested solution.

D. OTHER FACTORS AND ISSUES

Segregation is the separation of cement and aggregates within a grout mix. The
primary cause for segregation in grout mixes is overwatering. Segregation is evident
visually by excessive bubbling or frothing as the aggregate or sand component
separates within the grout mix and drops to the bottom.
Segregation can also be observed visually in hardened samples of grout. Cores taken
on in-place samples of grout and tested in accordance with ASTM C 39 for purposes
of evaluating compressive strength may show
a heavy concentration of aggregate in the
lower portion of a broken core compared to
the top portion. This usually indicates a degree
of segregation. Segregation affects every key
grout performance property, including loss of
compressive strength, increased shrinkage,
and potential grout failure.
Quality of a cementitious grout refers to its
ability to perform consistently, regardless of where the product is obtained. This is of
particular importance on capital projects that utilize large quantities of cementitious
16 (800) 243-2206 • fivestarproducts.com
 A Professional’s Guide on Grouting and Concrete Repair

grout. Quality comes from the manufacturer’s ability to control the blending and
production of the grout, and from the degree of rigor by which manufacturers test
their grout prior to shipment. Manufacturer’s that have a strict quality assurance
program, such as one meeting ISO 9001-2002, can ensure the quality of their
products bag to bag and lot to lot. Quality also comes from products with a proven
history of use in the particular industry or application under consideration.

Durability refers to the long term performance of a cementitious grout. For instance,
a normal Portland cement based grout may perform well at exposure temperatures
of 400°F, but will not at 1000°F. Also, cementitious grouts that contain gypsum or
expansive cements will not be durable in continuously wet environments, and may
actually fail. This failure can be extremely costly, particularly when critical plant
equipment has to be shut down for regrouting.

To ensure short term and long term success, engineers and specifiers should
carefully evaluate and consider all the necessary factors required for a given
application. When in doubt, contact FIVE STAR PRODUCTS ENGINEERING
AND TECHNICAL CENTER for product application assistance.

2. EPOXY GROUTS
Although there is no standard specification for an acceptable Nonshrink Epoxy Grout as
there is for the cement based grouts discussed above, there are several essential physical
and performance properties of Nonshrink Epoxy Grout that are, or should be, of interest
to owners, architects, engineers, and contractors. In order of importance, they are:
• Proper Support of Equipment
• Vertical Height Change / EBA
• Compressive Strength
• Creep
• Workability
• Quality
• Durability
This portion discusses these properties together with available test methods, their
applicability, and their usefulness in evaluating grout performance.
A. VERTICAL HEIGHT CHANGE / EBA
1. Vertical height change is a vital performance property of NONSHRINK epoxy
grouts because it is the major factor in determining the EBA. A grout that has
positive vertical height change in the plastic state will have a high EBA. But
unlike cement grout, there is no standard test for measuring vertical height
change in epoxy grout.
2. Five Star Products, Inc. adapted the cement grout test (ASTM C 827-Standard
Test Method for Change in Height at Early Ages of Cylindrical Specimens
from Cementitious Mixtures) to measure vertical height change in epoxy
grout. Over many years of experience, this test has demonstrated its value
in verifying the vertical height change and resulting EBA of epoxy grouts.
Among the advantages of using the method of ASTM C 827 to measure vertical
(800) 243-2206 • fivestarproducts.com 17
 A Professional’s Guide on Grouting and Concrete Repair

height change is that the results are statistically valid. They can be reproduced
consistently, thus assuring a sound basis for making judgments about the
material’s quality.

ASTM C 827 Test Setup

3. Horizontal length change is of little interest in grouting, except for extremely
long pours where expansion and contraction joints are needed.
4. To be considered a PRECISION NONSHRINK Grout, the vertical height must
NEVER go below the original placement height.
B. COMPRESSIVE STRENGTH
1. The value of an epoxy grout’s compressive strength is highly dependent on
the details of the test method used to measure it. ASTM C 579 (Compressive
Strength of Chemical-Resistant Mortars and Monolithic Surfacings) specifies
three different test methods, depending on the maximum aggregate size, and
allows two different loading rates. A note in the specification warns that the two
loading rates do not give the same values for the compressive strength.
2. In determining whether the compressive strength of an epoxy grout meets its
specified requirement, it is of paramount importance that the test method used
be the same as that called for in the specification. In comparing the compressive
strengths of two epoxy grouts, it is important to be sure that both are measured
by the same method. The difference between them when tested by different
methods allowed by ASTM C 579 can be as much as 2000 psi (13.8 MPa).
C. CREEP
1. Creep is the deformation of a material under a constant load applied over an
extended interval of time. Creep increases with temperature. Because creep acts
to reduce the stress in epoxy grout material, it can result in lower anchor bolt
torque and consequently cause equipment misalignment and eventual wear in
shafts and bearings.
2. Engineers, designers, and other specifiers should know the creep characteristic
of any epoxy grout they may be considering for use. Beware of extrapolations
from short term tests of only a few days duration. Reliable creep data are based
on tests using the method of ASTM C 1181 at a temperature at or above the
operating temperature of the grout in service.

18 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair
3. To be sure that epoxy grout will not creep beyond an acceptable level,
a. Select an epoxy grout for which long term creep data at or above the
operating temperature of the grout in service are available.
b. Design the installation so that the sum of the compression stresses in the
epoxy grout from the weight of the equipment plus that from the anchor
bolt torque is not more than 500 psi (3.45 MPa).

D. WORKABILITY
1. Epoxy grouts should be formulated for a flowable or pumpable consistency so
as to facilitate placement under all types of baseplates. This is the most versatile
consistency and is appropriate for almost all placements.
2. The consistency of epoxy grouts cannot be altered at the job site except by
adjusting the amount of aggregate added to the epoxy mix. The manufacturer’s
limits on the minimum aggregate content must be strictly observed. Failure to
do so can cause excessive heat buildup, foam, and segregation leading to loss
of EBA and grout failure.
3. To comply with safety and environmental regulations, both the specifier and the
field supervisor should prohibit the use of epoxy grouts that are not 100% solids.
E. QUALITY AND DURABILITY
1. Quality is the ability of a material to behave in a predictable manner during
placement, and is a critical characteristic of a good epoxy grout. To realize this,
epoxy grout must be prepackaged in premeasured units. Field proportioning of
partial units of epoxy grout is rarely accurate enough to realize the full potential
properties of epoxy grout.
2. Quality of an epoxy grout depends on the manufacturer’s ability to control
the quality of materials used in the grout, the manufacturing and blending
procedures, and the packaging, storage, handling, and shipping. To provide the
necessary assurance, the grout manufacturer should have in place a currently
certified quality control system conforming to ISO 9001-2000.
3. Durability of epoxy grout can be compromised by too great a difference in
the thermal expansion and contraction of epoxy and concrete with changes in
temperature. The coefficient of thermal expansion of unfilled epoxy is about
10 times that of concrete, but it can be reduced substantially by the grout
manufacturer’s design of a proper aggregate blend, another reason for strictly
observing the manufacturer’s
mixing directions. The sketch
to the right illustrates what can
happen as a result of differential
shrinkage. The effect can be
minimized by chamfering the
epoxy grout, and in extreme
instances, chamfering the concrete
as well.

(800) 243-2206 • fivestarproducts.com 19

 A Professional’s Guide on Grouting and Concrete Repair

CHAPTER 3
MANUFACTURER’S QUALITY ASSURANCE PROGRAM
Written Quality Assurance programs should be required of all manufacturers of approved
grouts. The minimum requirements for a manufacturer’s Quality Assurance System
should be:
• To maintain records of all the cements, sands, aggregates, resins, hardeners, and
other chemicals used in each manufacturing lot of cementitious and epoxy grout.
• To identify all containers of raw materials, intermediates, and finished products
with their sources and batch markings, so that all materials can be traced to their
sources and verified as meeting the manufacturer’s standards.
• To calibrate, at regular intervals, but at least annually, scales used at the manu-
facturing plant to weigh grout components and packaged products.
• To take regular samples from the manufacturing plant and to verify that they meet
their performance requirements, including their nonshrink requirements.
• To maintain test records and to retain them for at least one year beyond the shelf
life expiration date; test records for all shipments should be available.
CAUTION: The value obtained in a compressive strength test depends on the
sampling and testing procedure used. Differences in specimen size and shape,
conditioning, or loading rate can produce significantly different test results.
• To print instructions for normal mixing and placement conditions, including
the minimum and maximum mixing water limits for cementitious grout, on the
outside of the bag, pail, or other packaging.
• To post grout manufacturing instructions at the manufacturing plant in a manner
available to production operators.
• To provide access to manufacturing sites, upon receipt of adequate notice, by
the project engineer or his representative to audit the Quality Assurance System.
Manufacturers who cannot comply with this requirement should not be approved
as grout sources.
The manufacturer’s Quality Assurance System should also ensure that cement based
products stored beyond one year in bags (or two years in plastic pails) and epoxy
products stored beyond two years are not shipped unless the manufacturer can certify,
by retest that the products still meet their applicable performance requirements.
The manufacturer should furnish signed, written certification, when requested, that
the product meets its applicable performance requirements, is in accordance with
the manufacturer’s specifications, conforms to the terms of sale, or meets the project
specifications, as applicable. When appropriate, the manufacturer should furnish actual
test data. The manufacturer’s Quality Assurance System should be audited at regular
intervals by an independent auditor and should meet the requirements of ISO 9001-2000.

20 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

CHAPTER 4
ESTIMATING, PURCHASING, DELIVERY, AND STORING GROUT
A. ESTIMATING
1. To estimate the quantity of grout required for a job, calculate the volume of the
cavity to be filled in cubic feet. Divide the calculated volume by the yield in
cubic feet of one unit of grout to calculate how many units will be needed. Add
5% to 10% for waste and spillage, more for smaller jobs, and less for larger ones.
2. The most common shapes of cavities encountered in grouting operations are
rectangular solids (for example, the space under a rectangular base plate),
solid right cylinders (such as the space under a round, flat-bottomed tank), and
hollow right cylinders (like the space between an anchor bolt and its hole).
Many other cavity shapes can be divided into some combination of the common
shapes for estimating purposes.
3. To find the volume V of a rectangular solid in cubic feet, multiply the length L
in feet times the width W in feet times the thickness T in feet.
V = LWT
4. To find the volume V of a right cylinder in cubic feet, multiply the square of the
diameter D in feet times π/4 times the height H in feet.
V = 0.785 D2H
5. To find the volume V of a hollow right cylinder in cubic feet, subtract the
square of the inside diameter d in feet from the square of the outside diameter
D in feet and multiply that difference times π/4 times the height H in feet.
V = 0.785 (D2- d2)H
6. If all dimensions in these equations are in inches, the calculated volume will be
in cubic inches. To convert cubic inches to cubic feet, divide by 1728.
B. PURCHASING
1. To compare the cost of grout needed for a job, determine the cost per cubic
foot for each grout under consideration. To ensure that all prices are directly
comparable, requests for quotation should be made in cubic foot units. All cost
comparisons must be made on the basis of delivered cost per cubic foot to be
meaningful. Grouts must not be compared, bid, or purchased on a weight basis
because there is not a constant relationship between weight and volume. The
customary unit of volume is the cubic foot, so requesting quotations in cubic
foot units allows direct price comparisons.
2. In estimating the quantity of grout that is sold in units other than one cubic
foot, divide the manufacturer’s yield into the number 1 to determine the actual
number of units required for one cubic foot. For example, if a manufacturer’s
55-pound unit has a yield of .42 cubic feet, 1 cubic foot /.42 = 2.38 units (bags
or pails) per cubic foot.

(800) 243-2206 • fivestarproducts.com 21

 A Professional’s Guide on Grouting and Concrete Repair

C. DELIVERY
1. Nonshrink cement-based grout should be delivered palletized and shrink-
wrapped, and delivered to the job site in sound, dry packages.
2. Epoxy resin and hardener should be delivered, premeasured, in sealed
containers, palletized and shrink-wrapped to prevent shipping damage. Epoxy
grout aggregate, delivered as a separate component, should be premeasured,
packaged in sealed, dry bags, also palletized and shrink-wrapped to prevent
shipping damage.

D. STORAGE
1. Nonshrink cement-based grout should be stored in a dry area in accordance
with ACI instructions. The ideal storage temperature is 70°F. Avoid storing
cementitious grout below 40°F or above 90°F.
2. Preferably, epoxy grout components should be stored at a temperature between
70°F and 80°F, but never below 60°F nor above 90°F.
E. STORAGE DAMAGE
Immediately remove from the job site any cement-based grout material which
becomes damp or otherwise defective. Epoxy grout aggregate that becomes damp
or otherwise defective should not be used and should be removed from the job site.
Liquid components that are found to be defective should also be removed from the
job site.

22 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

NONSHRINK GROUT ESTIMATING SHEET

From Premeasured Units

PRODUCT
FIVE STAR “X”
A. Cost per Bag
Or Unit __________ __________

B. Yield per Bag

Or Unit
(Cubic feet/bag
or unit) __________ __________

C. Cost per
Cubic Foot
(A divided by B) __________ __________

D. Total Cubic
Feet Required
(From field
estimates) __________ __________

E. Total Material
Cost (C x D) __________ __________

To determine material prices in your area, contact your local Five Star Product’s sales
representative. (For your representative’s name and phone number, call FIVE STAR
PRODUCTS, INC. Customer Service at 203-336-7900.)

(800) 243-2206 • fivestarproducts.com 23

 A Professional’s Guide on Grouting and Concrete Repair
NONSHRINK GROUT COST PER CUBIC FOOT

Instructions:
1. Determine the delivered cost of grout per 100 lbs. (Not all grouts are supplied in 100
lb. bags.)
2. Determine cubic foot yield per 100 lbs.
3. Read the cost per cubic foot of grout in the body of the table. For values not
tabulated, use linear interpolation.

COST CUBIC FOOT YIELD PER 100 LB

PER
100 LB 0.70 0.75 0.78 0.80 0.85 0.90 0.95 0.97 1.00
$20.00 $28.57 $26.67 $25.64 $25.00 $23.53 $22.22 $21.05 $20.62 $20.00
$22.00 $31.43 $29.33 $28.21 $27.50 $25.88 $24.44 $23.16 $22.68 $22.00
$24.00 $34.29 $32.00 $30.77 $30.00 $28.24 $26.67 $25.26 $24.74 $24.00
$26.00 $37.14 $34.67 $33.33 $32.50 $30.59 $28.89 $27.37 $26.80 $26.00
$28.00 $40.00 $37.33 $35.90 $35.00 $32.94 $31.11 $29.47 $28.87 $28.00
$30.00 $42.86 $40.00 $38.46 $37.50 $35.29 $33.33 $31.58 $30.93 $30.00
$32.00 $45.71 $42.67 $41.03 $40.00 $37.65 $35.56 $33.68 $32.99 $32.00
$34.00 $48.57 $45.33 $43.59 $42.50 $40.00 $37.78 $35.79 $35.05 $34.00
$36.00 $51.43 $48.00 $46.15 $45.00 $42.35 $40.00 $37.89 $37.11 $36.00
$38.00 $54.29 $50.67 $48.72 $47.50 $44.71 $42.22 $40.00 $39.18 $38.00
$40.00 $57.14 $53.33 $51.28 $50.00 $47.06 $44.44 $42.11 $41.24 $40.00
$42.00 $60.00 $56.00 $53.85 $52.50 $49.41 $46.67 $44.21 $43.30 $42.00
$44.00 $62.86 $58.67 $56.41 $55.00 $51.76 $48.89 $46.32 $45.36 $44.00
$46.00 $65.71 $61.33 $58.97 $57.50 $54.12 $51.11 $48.42 $47.42 $46.00
$48.00 $68.57 $64.00 $61.54 $60.00 $56.47 $53.33 $50.53 $49.48 $48.00
$50.00 $71.43 $66.67 $64.10 $62.50 $58.82 $55.56 $52.63 $51.55 $50.00
$52.00 $74.29 $69.33 $66.67 $65.00 $61.18 $57.78 $54.74 $53.61 $52.00
$54.00 $77.14 $72.00 $69.23 $67.50 $63.53 $60.00 $56.84 $55.67 $54.00
$56.00 $80.00 $74.67 $71.79 $70.00 $65.88 $62.22 $58.95 $57.73 $56.00
$58.00 $82.86 $77.33 $74.36 $72.50 $68.24 $64.44 $61.05 $59.79 $58.00
$60.00 $85.71 $80.00 $76.92 $75.00 $70.59 $66.67 $63.16 $61.86 $60.00

24 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

CHAPTER 5
CEMENTITIOUS GROUT PLACEMENT PROCEDURES

INTRODUCTION
Cementitious grout placement involves proper mixing, placing, finishing, and curing, all
of which are critical components of a successful grout installation. Improperly placed
grout will often not perform as designed and can lead to potential problems such as grout
cracking, equipment misalignment, and even grout failure.
Selecting the type of cementitious grout, pumpable, flowable, fluid, or other, is
important and involves a detailed understanding of the application for which the
grout is to be used and of which material will provide the best results.

FLUID GROUTS
The industry definition of a fluid grout is one that will pass a specified volume of material
through a flow cone in accordance with ASTM C 939 in 30 seconds or less. Fluid grouts
are typically easier to place than flowable grouts and can therefore be expected to flow
longer distances at normal clearances or to get into tighter clearances. Fluid Grouts must
be mixed to a specified consistency, which requires having a flow cone on the jobsite.
Without a flow cone available, it is difficult to determine if the grout is mixed with the
appropriate amount of water.

FLOWABLE GROUTS
Flowable grout provides sufficient flow to properly grout a majority of applications.
Flowable grouts are defined as those having a flow of 125 to 145 when tested on a flow
table in accordance with ASTM C 1437- (Standard Test Method for Flow of Hydraulic
Cement Mortar). Flowable grouts are typically very versatile. Properly formulated
flowable grouts will provide long working times (30 to 45 minutes), can often be
extended with coarse aggregate in the field for deep pours, and can be pumped. Some
well formulated flowable grouts, such as FIVE STAR GROUT, can be mixed in ready
mix trucks and pumped long distances. However, it is important to understand that NOT
ALL FLOWABLE GROUTS PERFORM EQUALLY. Some flowable grouts, such as
those based on aluminum powders, have short working times and, therefore, cannot be
mixed in ready mix trucks or pumped.

Flowable grouts are typically packaged in 50 lb or 100 lb bags, and have minimum
and maximum water requirements listed on the bag. NEVER EXCEED THE
MAXIMUM WATER REQUIREMENTS AS STATED ON THE PRODUCT
PACKAGING. OVERWATERING CAN LEAD TO SEGREGATION, STRENGTH
REDUCTION, AND INCREASED GROUT SHRINKAGE, JEOPARDIZING
LONG TERM SUCCESS.

(800) 243-2206 • fivestarproducts.com 25

 A Professional’s Guide on Grouting and Concrete Repair

Tight clearance applications (less than 1 inch clearance) or baseplates with shear keys
are two applications where
fluid grouts have advantages
over flowable grouts. When
placed properly, fluid grouts
will tend to entrap less air in
shear key applications, though
vent holes should be present
in the baseplate to allow the
venting of any entrapped air.

Sometimes, mixing to a fluid
consistency has been used as
a way to speed the placement of grouts with very short working times, which occa-
sionally has led to shrinkage, air entrapment, and segregation. FIVE STAR FLUID
GROUT 100 is a fluid grout whose unique formulation produces a grout with excellent
workability and without these problems. It can be used where clearances are very tight,
as well as for normal clearances.
CAUTION: Take special note that making a normally flowable grout fluid by
adding more water than the maximum amount specified can result in aggregate
segregating and lower strength from the increased water-cement ratio. There is
also a considerable risk that certain flow agents will cause bubbling at the surface,
significantly reducing EBA. NEVER add more water than the maximum amount
specified on the package.

PUMPABLE GROUTS
Pumpable grouts are either well
formulated flowable grouts that provide
good pumpability or very specialized
grouts that contain pumping aids.
Pumpable grouts should be able to
be pumped with typical grout pumps
or larger pumps, such as concrete
pumps. Pumping grouts may involve
the addition of coarse aggregate
at the jobsite, particularly on large
volume placements. Aggregates used
for extending cementitious grouts
should be clean, washed aggregates of
specified size and conform to ASTM C
33. Dirty aggregates or aggregates with
a large amount of fines will affect pumpability and strength development.

26 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

SAFETY

CAUTION: Cement based grout contains cementitious material and crystalline free
silica. The International Agency for Research on Cancer has determined that there
is sufficient evidence for the carcinogenicity of inhaled crystalline silica to humans.
Take appropriate measures to avoid breathing dust. Avoid contact with eyes and
contact with skin. In case of contact with eyes, immediately flush with plenty of
water for at least 15 minutes. Call a physician immediately. Wash skin thoroughly
after handling. Keep this product out of the reach of children. BEFORE USING,
REFER TO THE MATERIAL SAFETY DATA SHEETS, which are available for
all Five Star Products at fivestarproducts.com

Take these simple precautions to avoid skin contact with cement powder or freshly
mixed grout or mortar:
• Wear rubber boots high enough to keep out cement products. Top of boots should
be tight to protect feet.
• Wear rubber gloves to protect hands.
• Wear long pants tucked into boots to protect legs.
• Wear kneepads when finishing concrete to protect knees.
• Wear long-sleeved shirts buttoned at the wrists and neck to protect upper body
and arms.
• Wear tight-fitting goggles when handling cement products to protect eyes.
• Do not breathe in the fine dust. Wear a NIOSH approved respirator when opening
or dumping bags.

INSTALLATION
A. GENERAL
The general application procedures that follow are appropriate for use under normal
conditions:
1. Many grouts are not recommended for placement under a wide range
of temperatures. Consult the grout manufacturer’s written instructions for
placement temperature limitations. At temperatures below 70°F, grout tends to
set more slowly than reported on typical product data sheets. At temperatures
above 70°F, grout tends to set faster than reported. When grouting is to be
done when ambient and mix temperatures are not between the manufacturer’s
specified temperature range for the grout, usually 40°F to 90°F, follow the
additional recommendations in the Hot Weather Grouting and Cold Weather
Grouting parts of this section to help maintain the set times and strength gains
at or near the 70°F rate.
2. If there are other unusual or difficult conditions (chemical attack, high working
temperatures, low clearances, shear keys, etc.), the contractor should consult the
owner’s engineer and the grout manufacturer’s Technical Service Department.
3. All necessary tools and materials should be as close as possible to the area
being grouted. Mortar mixer (with rotating blades), wheelbarrow, shovel, water
measuring container, and grout should be within easy reach.

(800) 243-2206 • fivestarproducts.com 27

 A Professional’s Guide on Grouting and Concrete Repair
B. PLACEMENT
1. Placing NONSHRINK grout is not a difficult process if the engineer and the
contractor are aware of the variety of methods available to them. The grout
manufacturer can recommend the best grade of grout to use and how to place
it. The specifier can make the contractor’s job easier by specifying a grout that
provides flexibility in placement. Selecting a cement-based grout that can be
placed by only one method can increase the cost of grouting.
2. The placement procedures used for grouts are just as critical as selecting the
proper grout. The leading grout manufacturers maintain extensive technical
service staffs to assist in selecting the proper grout and the applicable placement
procedures.
3. This section describes the three most common methods, most other placement
techniques being simply variations of the basics. The advantages and
disadvantages of each are described to assist the engineer and contractor in
choosing the method best suited to their application.
a. Dry Packing
Dry packing requires a grout with a thick consistency. There should be only
enough water mixed into the grout so that when a ball of grout is squeezed
in a gloved hand, the glove is slightly dampened. Although only a well
braced backboard, a tamping rod, and a mallet are required for placement
by the dry pack method, and carpentry expense for building and stripping
forms is saved, dry packing is not recommended except for very small,
accessible placements. Dry packing is labor-intensive and requires a highly
skilled worker to ensure that the grout is uniformly compacted under the
entire baseplate without cold joints.
b. Pouring
Pouring requires a grout with a
flowable or fluid consistency. To
place a flowable grout, use forms
and a headbox. This method is
appropriate for most grouting
applications. During the mixing
process, a flowable grout, being
stiffer than a fluid grout, is less
likely to incorporate excess air
that later gets trapped under the
baseplate. Watertight forms are
required for flowable and fluid grout.
To increase the rate of flow from a headbox, manually apply pressure in
addition to the hydraulic head by using a plunger. A plunger is a tool,
usually fabricated on the job site, made from two pieces of wood nailed
together to form a T. The stem is the plunger handle and the crossbar, just
slightly smaller than the width of the headbox, applies the pressure.

28 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair
c. Pumping
Grout should be placed by pumping for large or multiple grout installations,
particularly when there are obstructions, or when grout must be transported
over great distances, or when venting air is not possible. Pumping cement-
based grout into place is fast, and can achieve good results. Although it
may take somewhat longer to set up the pump and its associated equipment,
once done, the pumping method usually produces successful installations.
A pumpable grout, needing less water than a fluid grout, contributes to
higher strength. Pumping results in fewer air bubbles, and considerably
more grout can be placed in a day by the same size crew. As grout installers
become more experienced with pumping, it will continue to increase in
popularity because of its superior performance characteristics.
PREPARATION
1. CONCRETE
a. The base concrete should have attained its design strength before grouting.
b. Concrete should be sound and all surfaces that will be in contact with the
grout should be entirely free of oil, grease, laitance, curing compounds,
and other deleterious substances that can prevent cementitious grout from
bonding to concrete.
c. Prepare the surfaces by chipping, sandblasting or other mechanical means
to ensure a roughened profile. Particular care should be given to the quality
of the concrete foundation.
d. Efflorescence may occur on the surface of foundations containing limestone
aggregate.
2. BASEPLATES
a. All metal surfaces of equipment bases which are to be in direct contact with
the grout should be thoroughly cleaned to bare metal immediately before
grouting. NONSHRINK cement-based grout will not bond to grease, oil,
paint, primers, or epoxy coatings that are sometimes found on the underside
– the contact surface – of the baseplate. These foreign materials should be
removed immediately before, or as close as possible to, grouting time.
b. Level and align baseplates according to the project specifications or to the
recommendations of the equipment manufacturer. Provide approximately
two inches of clearance under leveled baseplates for grouting. For large-
volume placements with clearances greater than three inches, grout should
be extended with clean, washed coarse aggregate that meets ASTM C 33.
Contact the grout manufacturer for the size and amount of coarse aggregate
to use for deep pours. The added coarse aggregate helps to manage the
heat generated by the hydrating cement and provides dimensional stability.
It acts as a heat sink and reduces the temperature rise, helping to reduce
the potential for cracking. Special grouts are available to meet the special
application requirements of shallow pours, deep pours, or certain problem
environments. For long and large volume pours, expansion joints may be
considered.

(800) 243-2206 • fivestarproducts.com 29

 A Professional’s Guide on Grouting and Concrete Repair

c. Shims, wedges, blocks, and leveling nuts (see the sketch above) are used
to support the equipment during alignment and grouting. They can be
removed after grouting if the engineer specifies, but they are often left
in place. If they are required to be removed, apply two generous coats of
paste wax to them, wrap them with polyethylene film, or use some other
bond breaker. Shims and wedges that are to remain in place should have
generously rounded corners to ensure that they do not act as points of stress
concentration. They should be set back from the edge of the baseplate by
two inches or more.
d. Before grouting, tighten anchor bolt nuts finger tight only or follow OEM
instructions.
3. ANCHOR BOLTS
a. Grout anchor bolts with cementitious grout when the design engineer or the
equipment manufacturer so specifies. Anchor bolt holes can be precored
when the foundation is poured, or carefully and accurately located and core
drilled before the equipment is installed. Anchor bolt holes should be at
least 2 inches in diameter for bolts up to 1 inch, and at least 2 inches greater
than the bolt for larger sizes. Very deep holes may need to be bigger than
this to allow grout to flow all the way to the bottom. Roughen the sides of
anchor bolt holes and thoroughly clean all hole and bolt surfaces of oil,
greases, loose cement, dust, and other bond-breaking substances. Soak the
hole to saturation (8 to 24 hours) with potable water, and remove all free
surface water from the holes with oil-free compressed air, sponges, or with
a wet/dry vacuum. Refer to Appendix A for more detail.
b. If part of the anchor bolt length is to remain unbonded, protect it with duct
tape or a plastic sleeve. Locate and support the anchor bolt in the hole.
Mix and pour grout into the hole. Rod the grout well to release any trapped
air. When the grout has set, finish the grout surface, and cure the exposed
surface as the manufacturer directs.
4. FORMING
a. Forms are required for all placement methods except dry packing, which
requires a well-braced backboard to pack the grout against.
b. Build all forms of sufficiently strong materials, securely anchored and shored

30 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair
to withstand the considerable pressure forces developed in placing grout.
c. Coat forms with two generous coats of paste wax, form oil, or other
approved release agents for easy form removal. Seal forms tightly against
existing concrete and vertical wood surfaces. To retain grout within the
formwork, seal joints with tape or sealant. Flowable grout can generally be
retained by taping, but fluid grout will usually require a water-tight seal.
d. Air vent holes are mandatory for some baseplate designs. Provide vent
holes (1/4 to 1/2 inch minimum
diameter) in each corner of
a baseplate with a perimeter
skirt. Baseplates or skids
divided into two or more
compartments by stiffening
cross members, require a vent
hole in each corner of every
compartment, as shown in the
sketch.

5. MIXING
a. FOLLOW DIRECTIONS
Always follow the grout manufacturer’s directions when mixing grout.
Carefully read all mixing information on the package and in the latest
literature. Whenever possible, cement-based grout, as with all mortars,
should be mixed in a mortar mixer (a stationary drum with rotating blades)
rather than in a concrete mixer (a rotating drum with attached fins) or
by hand. If you are in doubt about mixing procedures, consult the grout
manufacturer.
b. MIXER TYPE
All leading grout manufacturers recommend using a mortar mixer with
moving blades to mix grout. A mortar mixer produces a more thorough
and uniform blend of the mixing water into the dry grout mix. For thorough
mixing, the mortar mixer should be large enough that a batch of grout
occupies less than half the mixer’s capacity. Mixing by hand, including
the use of an electric drill with a
propeller blade, also produces a
less thorough blend, takes much
more time, and often results in
lower strength, lumps, segregation,
and less flowability. Hand mixing
should be used only when a very
small amount of grout is needed.
c. PREPARATION
Have available an adequate number
of mortar mixers to support
continuous grouting operations,
as well as the buckets, buggies,
(800) 243-2206 • fivestarproducts.com 31
 A Professional’s Guide on Grouting and Concrete Repair

wheelbarrows, pumps, trowels and other hand tools that will be needed for
the job. Locate the equipment and tools as close as possible to the grouting
site to take maximum advantage of the available working time.
d. MIXING AND CONSISTENCY
Clean the mortar mixer’s drum and blades thoroughly. Rinse the drum
and blades with potable water, run the mixer briefly, and empty all excess
water. Only then add the measured amount of potable mixing water into
the drum. Start with the minimum amount of mixing water specified
on the package and in the manufacturer’s literature. The consistency of
cement-based grout will vary with the amount of water added. Use this
flexibility. Always start with the minimum amount of potable water printed
on the manufacturer’s bag or label. Run the mixer until the surface water
has disappeared and a uniform consistency is reached. Mixing should
not be for less than three minutes nor for more than five. Only then, add
the least amount of additional potable water needed to obtain the desired
consistency, and remix. REMEMBER that as the amount of water in the
mix goes up, the strength of the grout goes down. NEVER exceed the
maximum amount of water specified by the grout manufacturer and printed
on the bag or label, and NEVER add an amount of water that will cause
segregation of the aggregate. Rarely, a “false set” may occur. Correct this
by remixing — without adding more water! NEVER retemper a mix (that
is, NEVER add more water after the initial stiffening).
e. CLEAN UP
Clean all equipment and tools with water. An abrasive material such as
sand added to the water is helpful in cleaning a mortar mixer.

6. PLACING GROUT
a. GENERAL
1. Check Temperature Conditions
With a thermometer, determine whether the temperatures of the
ambient air, the grout, the potable water for mixing, the concrete
foundation, and the steel baseplate will be within the manufacture’s
specified temperature range, commonly between 40°F and 90°F. If not,
special hot weather or cold weather procedures will be required.

Checking Temperatures
With a Thermometer
2. Working Time
For a given grade of cement-based
grout, the working time varies with
the temperature. Working time
grows shorter as the temperature
rises, and grows longer as the
temperature falls. Measure the

32 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

placement temperature to estimate the time available to place grout.

A simple way to determine the working time available under job site
conditions is to mix a small sample of grout to the desired consistency,
fill a styrofoam drinking cup, and time the interval between mixing and
loss of workability.
A liquid additive, SUMMERSET, that provides additional working
time for Five Star grouts is available from Five Star Products.

3. Transporting Grout
Use a pump, wheelbarrows, buggies, or buckets to transport grout to
the placement site.
4. Eliminating Voids
Place grout in a way that assures that all spaces are completely filled
and that the grout is in intimate contact with boundary surfaces. Be
sure to check whether air vent holes are needed.

5. Continuous Grouting
To avoid cold joints under the baseplate, grout placement should be
rapid and continuous. If at all possible, cement-based grouts should

not be placed in lifts or layers. All grouting should take place from one
side to the other to avoid trapping air. If grout must be placed through
grout holes in the baseplate, cut off the tip of a traffic cone, invert it,
and use it as a funnel and headbox. It is important, to avoid trapping
air, to place the grout continuously from one hole until full-depth grout
has passed the next hole. Only then may grouting continue through a
second funnel/headbox through the next grout hole. Leave the first
cone full of grout in place as a standpipe at the previous grout hole to
maintain contact between the grout and the bottom of the baseplate.
Pumping is the preferred placement procedure in this case.

(800) 243-2206 • fivestarproducts.com 33

 A Professional’s Guide on Grouting and Concrete Repair
b. DRY PACKING GROUT
Dry packing grout is the placing of zero-slump or near zero-slump grout by
ramming into a confined space. It is not recommended except for very small jobs
with easy accessibility. Although dry packing avoids the need for formwork,
it requires considerable skill on the part of the worker to obtain a uniform
degree of grout compression,
and therefore, uniform strength
in the grout bed. To verify the
strength of dry packed grout,
test specimens must be packed
to the same extent, neither more
nor less, as the grout placed in
the job.

DRY PACKING
c. POURING GROUT
When a headbox is used and hydraulic head pressure is the means of flowing
grout into place, the minimum height of the headbox should be from 1/3 to 1/2
the distance that the grout must flow. Fill the head box to the maximum height
and allow the grout to flow down under the baseplate, but refill the headbox
before the level reaches the top of the baseplate. The level of grout in the head
box must never fall below the top of the baseplate to prevent trapping air under
the baseplate. This procedure is repeated until the grout moves completely
under the baseplate, pushing air out in front of it, and rising above the bottom
of the baseplate on the far side. When the baseplate is long and the headbox
is less than the full length of the baseplate, begin grouting at one end of the
long side. When the grout front reaches the far side, begin sliding the headbox
down the length of the baseplate — keeping pace with the advancing grout
front — until the baseplate is completely grouted. To increase the rate of flow
from a headbox, manually apply pressure in addition to the hydraulic head by
using a plunger. A plunger is a tool, usually
fabricated on the job site, made from two
pieces of wood nailed together to form a
T. The stem is the plunger handle and the
crossbar, just slightly smaller than the width
of the headbox, applies the pressure.

PLUNGING TO ASSIST
GROUT FLOW

34 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair
d. PUMPING GROUT
Pumping is the preferred method for placing grout on all large or multiple
grouting installations, particularly when there are shear keys, fixators, or
other obstructions under the baseplate, or when grout must be placed over
great distances, or when it is not possible to vent trapped air. Selecting the
appropriate pump to move the grout properly into place is critical. Choose a
positive displacement pump, such as a
diaphragm or piston pump, rather than
a screw pump. The size of the job will
dictate the size of the pump required.
Pumps vary in size from small ones,
delivering 10 to 14 cubic feet per hour,
to large ones, compressor-driven,
delivering several hundred cubic feet
per hour. Rinse the pump, the hose,
and the nozzle with potable water.
Before grouting, wash a cleansing
plug (called a “pig”) through the line
to ensure that it is open and clear,
and follow the pig with a slurry of
grout. This will ensure that neither
water nor cement are removed from
the grout during pumping, and that
neither pump nor hose will clog. For
PUMPING CEMENTITIOUS GROUT large pumping placements, use the
grout manufacturer’s pumpable grout
formulation. Consult the pump manufacturer and the grout manufacturer
for specific recommendations. Do not begin placing grout until material of
uniform consistency begins flowing from the nozzle. When pumping grout into
place, start at the far end of the space to be grouted. As the grout is pumped
in, back the nozzle out slowly so that it always remains submerged within the
grout. This will prevent air entrapment. Notice that pumping grout into place
is the reverse of flowing it into place. When flowing grout through a headbox,
grouting begins at the grouter’s position and flows away pushing air ahead of
it; when pumping, grouting begins at the most distant point and flows toward
the grouter, pushing air ahead of it.
7. FINISHING SHOULDERS
When the grout has stiffened to the point that it will hold its shape when scored with
the point of a trowel, remove the forms and cut the shoulders back at a 45° angle
from the bottom edge of the baseplate to the foundation. Finish the grout shoulder
with a trowel, float, or brush finish, as desired. Do not allow grout to remain above
the bottom edge of the baseplate or in an unchamfered shoulder. In those locations,
grout is prone to cracking because of differential expansion when the temperature
changes. Sometimes, when anchor bolts are close to the edge of the baseplate, a
vertical crack may occur in the grout shoulder. Shoulder cracks rarely propagate

(800) 243-2206 • fivestarproducts.com 35

 A Professional’s Guide on Grouting and Concrete Repair

under the baseplate, and do not affect the vertical load-carrying capacity of the
grout. For a cosmetic repair, coat the crack with a paste made from the grout and a
little water.

GROUT SHOULDER CONFIGURATIONS

8. CURING
a. FOLLOW MANUFACTURER’S DIRECTIONS
Cure cement-based grout as directed by the grout manufacturer in its latest
product literature, specifications, and package instructions. For any unusual
conditions, consult the grout manufacturer for guidance.
b. WET CURING
In general, and in the absence of manufacturer’s directions, begin wet curing
immediately after hardening. To prevent rapid surface drying, protect the
grout from extreme drying conditions. Cover all exposed grout surfaces with
continuously wetted burlap or flannel rags or seal the surface with polyethylene
film for a minimum of three days. Special grouts may require more or less
wet curing.
c. CURING TEMPERATURE
Maintain the temperature of the baseplate, the concrete foundation, and the
grout between 40°F and 90°F during grouting, and for a minimum of 24 hours
afterward. Machinery and baseplates will cool faster than the grout at low
temperatures and heat up more rapidly than the grout at high temperatures or in
direct sunlight. Protect the grout from these conditions during the curing period.
d. CURING COMPOUNDS
As an alternate to the wet curing procedure in b., wet cure for only one day,
then immediately coat the exposed surfaces of the grout with curing compound.
Apply two coats of white pigmented, resin-based curing compound that meets
the requirements of ASTM C 309, Type 2, Class B.
36 (800) 243-2206 • fivestarproducts.com
 A Professional’s Guide on Grouting and Concrete Repair
e. ANCHOR BOLT TORQUE
After the grout has cured to its design strength, use a torque wrench to tighten
anchor bolt nuts only to the specified torque. NEVER exceed the specified
torque. Overtorquing can cause the bolts to stretch beyond their yield point and
result in bolt failure.

9. HOT WEATHER GROUTING

High temperatures accelerate the set, decrease working time, and accelerate the
strength gain of cement-based products. The procedures below may compensate for
these conditions. Refer also to ACI 305R-91 “Hot Weather Concreting”.

a. Materials shall be conditioned as necessary so that the mixed grout is between

60°F and 95°F (16°C and 35°C). Due to the mass of palletized material, up to
72 hours of conditioning may be required. [For fast setting grouts, condition to
between 60°F and 80°F (16°C and 27°C)].
b. When temperature of mixed grout exceeds 80°F (27°C), normal setting grouts
shall be placed within 30 minutes of mixing.
c. All surfaces in contact with grout must be preconditioned and maintained below
95°F (35°C) for a minimum of 24 hours. [90°F (32°C) for fast setting grouts].
d. Cooling of surfaces, materials and equipment can be accomplished by using
chilled water for mixing and presoaking concrete and metal surfaces. Shade
area from direct sunlight or pour grout when temperatures are decreasing.
e. Wind breaks shall be provided when necessary to prevent rapid evaporation.
f. Grout shall remain shaded, protected with damp rags prior to set, and a wet
cure continuously maintained for at least three days. Wet cure must be followed
immediately by an approved curing compound that meets the requirements of
ASTM C 309.

10. COLD WEATHER GROUTING

Low temperatures delay the set, increase working time and delay the strength
development of cement-based products. The procedures below may compensate for
these conditions. Refer also to ACI 306R-88, Cold Weather Concreting.
a. Materials shall be conditioned as necessary so that the mixed grout is between
40°F and 80°F (4°C and 27°C). Due to the mass of palletized material, up to 72
hours of conditioning may be required.
b. All surfaces in contact with grout must be preconditioned and maintained at a
temperature between 40°F and 90°F (4°C and 32°C) for at least 24 hours.

(800) 243-2206 • fivestarproducts.com 37

 A Professional’s Guide on Grouting and Concrete Repair

c. Heating shall be accomplished by indirect exposure. Heated enclosures must be

windproof and weatherproof. Combustion heaters must be vented and shall not
be permitted to heat and dry the concrete locally. Caution: Exhaust gases may
contaminate or cause carbonation within the enclosed environment.
d. The grout temperature shall be maintained above 40°F (4°C) until the grout
reaches 1000 psi (6.9 MPa), typically 24 hours, or until it reaches the required
strength.
e. Gradually reduce the grout temperature to ambient temperature to avoid
thermal shock. [For low temperature conditions to 35°F (2°C), consider the use
of FIVE STAR INSTANT GROUT, which must be kept above 35°F until it
reaches 1000 psi (6.9 MPa), typically 6 hours, or until it reaches the required
strength.]

EPOXY GROUT PLACEMENT PROCEDURES

A. INTRODUCTION
1. The general application procedures outlined below are for use at ambient
temperature of 70°F. Temperatures below 70°F tend to slow the set and stiffen
the consistency of epoxy grout, and temperatures above 70°F tend to accelerate
the set and loosen the consistency of epoxy grout. If grouting is to be done when
ambient temperatures are not between 60°F and 90°F, follow the additional
recommendations given for Hot Weather Grouting and Cold Weather Grouting
for Epoxy Grouts. If other unusual or difficult conditions exist (low clearances,
shear keys, etc.), the contractor should consult the owner’s engineer and the
grout manufacturer’s Technical Service Department.
2. All necessary tools and materials should be as close as possible to the area
being grouted. Mortar box, mortar mixer (with moving blades), wheelbarrow,
hoe, shovels, trowels, and grout components should be within easy reach.
3. If it is desirable that the set times and strength gains are to be maintained at
the 70°F rate, the applicable hot weather or cold weather instructions should be
reviewed for guidance.
4. It is advised for health and safety reasons that all personnel handling epoxy

38 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

material be properly protected. Wearing protective clothing, eye protection

(goggles), a respirator, and chemically resistant gloves and boots is necessary.
Refer to the manufacturer’s Material Safety Data Sheet (MSDS).
B. SURFACE PREPARATION
1. CONCRETE
a. The base concrete should be dry and have attained its design strength
before grouting
b. DO NOT WET CONCRETE. All surfaces to be in contact with grout
should be dry and entirely free of oil, grease, laitance, curing compounds,
frost, and other potential bond-preventing substances.
c. Roughen the surfaces by chipping, sandblasting, or other mechanical
means to remove any laitance or weak surface layer.
2. BASEPLATES
a. All metal surfaces of equipment bases which are to be in contact with
the grout should be thoroughly cleaned. Sandblasting to an SSPC-SP6
commercial finish will ensure an optimal bond.
b. Level and align the baseplates according to the recommendation of
the equipment manufacturer and/or project specifications. For most
conventional epoxy grouts, a minimum 2 inch clearance should be provided
to facilitate placement. For baseplates wider than three feet, it is imperative
to provide an additional one-inch of clearance for each three feet of width.
Aggregate is the least costly of all the components of epoxy grout. Grout
pours deeper than four inches present the potential for cracking due to
excessive internal heat development and subsequent cooling. Deeper pours
can be accomplished by using a low exotherm epoxy grout, or pouring in
lifts. Embedded rebar acts as a heat sink for curing epoxy. Both methods
reduce temperature rise. For placements deeper than four inches, the grout
manufacturer should be contacted for detailed procedures.
c. Round shims, wedges, and blocks that are to be removed should be
covered with putty, grease, or similar non-bonding material to prevent the
grout from adhering. If shims, wedges, or blocks are to remain in place,
they should have generously rounded corners (to avoid potential crack
development) and be set back at least 2 inches from any plate edge.
3. ANCHOR BOLTS
a. Equipment manufacturers or design engineers often require anchor bolts
to be grouted. All surfaces should be thoroughly cleaned of oil, grease,
and other deleterious substances and must be dry. Holes must be dried
by evaporation, compressed air, or wicking with absorbent rags. Any
compressor used to blow out water or other substances from surfaces in
contact with the grout must be equipped with an oil trap in the air line to
prevent oil from being blown onto the contact surface and preventing the
grout from bonding. Refer to Appendix A for more information.
b. If equipment manufacturers or design engineers require anchor bolts to
remain isolated, sleeves should be used and filled with a pliable material
such as duct seal, putty, silicone rubber molding compound, or other
(800) 243-2206 • fivestarproducts.com 39
 A Professional’s Guide on Grouting and Concrete Repair

material specified by the equipment manufacturer. Wrapping bolts in duct

tape or foam insulation also works well.
4. SURFACE DRYNESS
All surfaces should be kept completely dry before grouting. Surface must NOT
be wet.
5. GROUT REMOVAL
Surfaces from which grout is to be removed after placing should be treated with
a paste wax or other release agent before placement.
C. FORMING
1. GENERAL
a. Forming or other leak proof containment is always required with epoxy
grout. The forms require careful attention to prevent any leakage. If forms
are not liquid tight, the grout will leak out and leave voids.
b. Forms must be designed to provide a hydraulic head. If additional hydraulic
head is required at the point of placement, headboxes may be used as
shown below. Typically, the headbox height should be 1/3 to 1/2 the distance
the poured grout must flow. If additional hydraulic head is required at the
point of placement, a plunger may be used as shown below.

c. All chamfer edges required in the grouts should be incorporated into the
forms because, after hardening, epoxy grout can only be cut or trimmed
by grinding.
2. FORM STRENGTH
All forms should be built of materials of adequate strength, securely anchored
and shored to withstand liquid head and the forces developed by plunging the
grout into place.
3. SEALING AND WAXING FORMS
Caulking, such as glazier’s putty, butyl rubber caulking, or duct seal should be
used to make all joints liquid tight. This particularly applies to the joint between
the form and the concrete. All forms may be lined with polyethylene film for
easy grout release. Carefully waxing forms with two coats of heavy floor or
paste wax, preferably colored, to ensure 100% waxed area is also acceptable.

40 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair
4. CONTROL OR ISOLATION JOINTS AND REINFORCEMENT
a. Depending upon the application, and as a general rule, control joints may be
placed on 4 to 6 foot centers. However, this spacing may (at the discretion
of the design engineer only) be increased as described in ACI 223-98
(Section 3.4.5). This section of the ACI Manual of Concrete Practice
contains control joint information for shrinkage compensating concrete
that can be used as a general guide to compensate for thermal expansion
differences using epoxy grouts. (There is no shrinkage compensating
standard for epoxy grouts as of this writing.) Control joints should extend
the full depth and full length from form to form.
b. Joint material can be closed cell styrofoam, thick rubber, thick sheet metal
covered with polyethylene, 1/4 inch thick steel or wood strips covered with
polyethylene tape. Any of these will make removal of the joints relatively
easy by preventing the epoxy grout from bonding to them.
c. For pours that are deep (more than 6 inches) or long (more than 6 feet)
and under extreme temperature conditions, reinforcing bars should be
placed in the grout. To distribute the stresses under these conditions, #6
reinforcing bars should be placed parallel to the equipment frame between
the control joints (see diagram below). If wide shoulders or extreme depths
are required, consult the grout manufacturer for direction.

Air relief holes

A A

TOP VIEW
5. AIR RELIEF HOLES
With some base plate designs, air relief holes are mandatory. Baseplates with a
skirt around the perimeter should have relief holes (minimum 1/4” diameter) in
each dead corner. If the plate is sectioned with stiffening members, then relief
holes should be provided at the intersections with the skirt (see diagram above
for minimum required air relief holes).

6. SHOULDERS
The difference in coefficient of thermal expansion between epoxy grout and
concrete induces stresses in shoulders. It is recommended that shoulders not
exceed a maximum of 2 to 3 inches. If wide shoulders are mandatory, special
anchoring must be provided as shown below and the manufacturer must be
contacted for specific instructions.
(800) 243-2206 • fivestarproducts.com 41
 A Professional’s Guide on Grouting and Concrete Repair

D. MIXING
1. FOLLOW DIRECTIONS
Grout should be mixed according to the procedures recommended by the
manufacturer. Carefully read all mixing information on the packages and the
latest literature. If in doubt about the mixing procedures, call the manufacturer.
2. MIXER TYPE
a. Mix in a mechanical mixer at a slow speed (15-20 rpm), using a portable
mortar mixer with moving blades (as shown in part three of this section)
inside the drum as opposed to a concrete mixer with fixed-in-place fins on
a rotating drum. A concrete mixer is not recommended as it will cause air
to be entrapped in the mix.
3. MIXING
a. Pour the hardener (Component B) into the epoxy resin (Component A)
container and stir by hand or with a variable speed (250 rpm max.) drill
and a paddle mixer for two to three minutes until all streaks are eliminated
and the mixture is clear. Mixing speed in excess of 250 rpm may entrain
air bubbles that reduce EBA.
b. Transfer the mixed liquids to a clean, dry mortar mixer and start it up. Add
the aggregate slowly and mix only until the aggregate is completely wetted
out. Overmixing results in excess entrapped air and may reduce working
time.
c. To maintain proper proportions of resin, hardener and aggregate, always
mix full units only. Under no circumstances should partial units be used.
For materials prepackaged in one container, such as FIVE STAR RAPID
EPOXY GROUT, follow the instructions on manufacturer’s label.

42 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

4. CONSISTENCY
a. Many years of experience have shown that epoxy grouts and aggregates
must be supplied in premeasured quantities to ensure a precision product.
Do not vary the ratio of components and never add solvent to change
the consistency. High temperatures will increase flowability and reduce
working time, while cold weather will decrease flowability and extend
working time. An ideal balance is developed at 75°F.
b. The only exception to this rule is for the first unit mixed. Because some of
the liquids will go to wetting the mixer, about half a 50 lb. bag of aggregate
should be withheld from the first batch only. All the following batches
should be mixed in accordance with the manufacturer’s recommendations
with no modifications.
5. CLEANING EQUIPMENT
Equipment and tools must be cleaned before epoxy grout hardens. Hardened
epoxy grout can be removed by soaking in appropriate solvent or by grinding.
After grouting is completed, or if delays occur, clean mixer, tub, wheelbarrows,
tools, etc. with a strong detergent (such as a laundry detergent or trisodium
phosphate) and water. Adding some ordinary sand will assist in cleaning a
mortar mixer. Organic solvents such as Solvesso, xylol, lacquer thinner, ketones,
or similar solvents, as specified by the manufacturer, can also be used for
cleaning, but FOR SAFETY REASONS, USE CAUTION WHEN CLEANING
POWERED EQUIPMENT WITH HIGHLY VOLATILE SOLVENTS, SUCH
AS LACQUER THINNER OR KETONES. KEEP SPARKS AWAY FROM
SOLVENTS AND WEAR APPROPRIATE RESPIRATORY PROTECTION.
E. PLACING
1. GENERAL
a. Check Temperature Conditions
Determine if ambient temperature will be between 60°F and 90°F at time
of grouting. If not, follow the compensating procedures found in Hot and
Cold Weather Epoxy Grouting in parts H and I of this section.

(800) 243-2206 • fivestarproducts.com 43

 A Professional’s Guide on Grouting and Concrete Repair
b. Working Time
Temperature affects the consistency of epoxy grout and therefore can affect
placement time. Check placement temperature of materials to estimate the
time available for placing grout.
c. Transporting Grout
Use power buggies, wheelbarrows, or buckets to transport grout to point
of placement.
d. Eliminating Voids
Grout placement should proceed in a manner that will assure that all
spaces are filled and that there is intimate contact between the grout and
the surfaces to be grouted. The placement should be rapid and continuous
to avoid cold joints and to keep voids from forming under the baseplate.
All grouting should take place from one side to avoid trapping air. When
grouting through grout holes or stand pipes, start placing grout into the next
grout hole or stand pipe only when grout from the first hole has reached
that next hole.
e. Check for Leaks
Forms must be checked constantly for leaks. All leaks must be sealed
immediately or voids will develop.
2. USING A HEADBOX
When hydraulic head pressure is used to flow grout in place, the level of
grout in the headbox must never fall below the top of the baseplate, because
then air will be trapped. The
headbox should be filled to
the maximum height (usually
/ to 1/2 the pour width) and
1 3

worked (plunged) down to

the top of the baseplate. This
procedure is repeated until the
grout moves completely under
the baseplate, pushing air out
in front of it, and rising to the
top of the chamfer strip on the
far side of the pour.

44 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair
F. FINISHING
Epoxy grout cannot be trimmed after set. It must be left at final placement level,
with all chamfer strips built into forms. To provide a smooth surface, puddle
the grout so all aggregate is covered. After initial stiffening, finish with a trowel
moistened with low volatility solvent such as diesel oil. All further finishing will
require grinding after the grout is completely cured.
G. CURING
1. FOLLOW INSTRUCTIONS
Grout should be cured in accordance with the manufacturer’s specifications and
recommendations. Read and follow the directions printed on the packaging or
on the manufacturer’s associated printed material.
2. FORMS
All forms should remain in place until the minimum required strengths are
attained.
3. TEMPERATURE
The temperature of the baseplate, supporting concrete foundation and grout
should be maintained between a minimum of 60°F and a maximum of 90°F
during grouting and for at least 24 hours afterward. See grout manufacturer’s
literature for curing schedules.
4. MOIST CURING
Water interferes with proper curing of epoxy grouts. DO NOT MOIST CURE
EPOXY GROUT!
H. HOT WEATHER GROUTING INSTRUCTIONS FOR EPOXY GROUT
1. PRECONDITIONING TEMPERATURE
All epoxy grout components should be stored in a dry, weatherproof area
until all epoxy grout components reach a temperature between 65°F and 80°F.
Since aggregate is the major portion of the mix, its temperature will be the
most critical in determining final mix
temperature.
2. COOLING AND SHADING
Shading or other methods should be
used to cool baseplates to below 90°F,
Extreme caution should be used because
all surfaces in contact with epoxy grout
must be completely dry before grouting.
Concrete, steel, and forms should be
shaded from direct sunlight beginning
24 hours prior to placing grout and
kept shaded until at least one day after
placement.
3. MIXING PRECAUTIONS
Do not allow mixed resin and hardener
to remain without aggregate for more than 3 minutes.

(800) 243-2206 • fivestarproducts.com 45

 A Professional’s Guide on Grouting and Concrete Repair
4. TIME OF PLACEMENT
Place the grout in the evening or later when the temperature is dropping. This
allows the heat developed during the curing phase to take place during the
coolest part of the day.
I. COLD WEATHER GROUTING INSTRUCTIONS FOR EPOXY GROUT
1. PRECONDITIONING TEMPERATURE
All epoxy grout components should be stored in a dry, weatherproof area until
all epoxy grout components reach a temperature between 70°F and 80°F. Since
aggregate is the major portion of the mix, its temperature will be the most
critical in determining final mix temperature.
2. SURFACE CONDITIONS
All surfaces in contact with grout must be maintained at a temperature of
at least 60°F for at least 24 hours prior to and at least 48 hours subsequent
to grouting. It is economically advantageous to pour and cure the epoxy at
temperatures between 65°F and 75°F. Doing so quickens the pace of placement
and subsequent curing, thus enabling the equipment to start up sooner. It is
important to prevent frost formation on these surfaces.

TENTED, HEATED ENCLOSURE FOR COLD WEATHER GROUTING

3. METHODS
There are many methods of maintaining proper preconditioning, preparation,
and curing temperatures. Consult the grout manufacturer for advice on
techniques best suited to each application.

46 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

CHAPTER 6
TYPICAL CEMENTITIOUS GROUTING APPLICATIONS
The advantages and disadvantages of different placement methods are reviewed for
several typical grouting applications:
• A 2 ft x 2 ft baseplate
• A 6 ft x 10 ft baseplate with shear keys
• A waffle baseplate
• Embedded anchors and tie rods
• Precast, pre-stressed applications

The following basic rules are applied in each of the examples:

1. Use the minimum water possible to achieve the required consistency in all
placements and do not exceed manufacturer’s recommended maximum.
2. Use flowable or fluid grouts and their required watertight formwork where
required.
3. If, when using any placement method, the grout extends up the side of the
baseplate, cut it back at a 45° angle from the bottom of the baseplate to the
foundation. This will avoid cracking of the grout due to possible movement of
the baseplate caused by temperature changes, vibration, or other causes.
4. When grout is placed in depths over three inches, consider extending the grout
with a course aggregate such as clean, washed 3/8 inch pea gravel that meets the
requirements of ASTM C 33. Conditions may vary. Contact the manufacturer
for further information.
5. Use grout holes and air relief holes where appropriate.
6. Keep equipment anchors a reasonable distance from the edge of the plate to
avoid vertical cracking on the grout.
7. Improper curing, over-finishing, or over-troweling of the grout may result in
hairline cracking of the surface.
8. Consult the manufacturer for grouting situations that need clarification.

The typical applications are meant to be guidelines in selecting grouting procedures.

Every project, however, is subject to many variables which could require modifications
in the selected method. Consult the FIVE STAR PRODUCTS, INC. Engineering and
Technical Center for assistance and for any needed clarification.

(800) 243-2206 • fivestarproducts.com 47

 A Professional’s Guide on Grouting and Concrete Repair
TYPICAL GROUTING APPLICATIONS
NONSHRINK Cement-Based Grouts

2 ft x 2 ft BASEPLATE
A typical 2 ft x 2 ft baseplate is easily grouted with any one of the methods listed below.
PLACEMENT
METHOD ADVANTAGES DISADVANTAGES
DRY PACKING • No Forms • Highly Skilled Personnel
AND • High Strength Needed
TROWELABLE • Potential for Cold Joints
• Not economical for a Large
Number of Plates
POURING • Fast Placement • Watertight Forms Must Be
• Tight Clearances Built
• Consistent Placement • Potential Segregation
PUMPING • Faster Method • Watertight Forms Must Be
• Little Air Entrapment Built
• Considerable Economy • Equipment Rental
for a Large Number • Skilled Personnel Needed
of Plates • Potential Segregation
Dry packing is often used when a few small plain plates need to be grouted, but
ACI 351.1R cautions that “it is difficult…(and in many cases, impossible) to achieve
proper placement” by dry packing. In addition, some fluid grouts may exhibit high
drying shrinkage and segregation. If a large number of plates are involved, pumping the
grout should be considered because of economy and high performance.

STRUCTURAL COLUMNS, AND BEARING

PLATES, POLES AND ANCHORS.
FIVE STAR GROUT can be dry packed, rammed,
troweled, poured, or pumped, indoors or out.

48 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

TYPICAL GROUTING APPLICATIONS

NONSHRINK Cement-Based Grouts

6 ft x 10 ft BASEPLATE with SHEAR KEYS

Often a baseplate with obstructions is encountered. In this example, the obstructions are
three shear keys under a 6 ft x 10 ft baseplate.

PLACEMENT
METHOD ADVANTAGES DISADVANTAGES
DRY PACKING • NOT
AND RECOMMENDED
TROWELABLE
POURING • Fast Placement • Watertight Forms Must Be
• Consistent Placement Built
• Skill Required in Placement
• Potential Segregation
PUMPING • Faster Method • Watertight Forms Must Be
• Highest EBA Built
• Lowest Cost • Equipment Rental
• Skilled Personnel Needed
• Potential Segregation
Dry packing is neither an economical nor an effective procedure for this baseplate
configuration. It would be very difficult to obtain a high performance placement.
Pouring is worth considering under these conditions. Pumping, however, is the fastest,
best performing, and most economical method for grouting this type of plate.

Shear keys Air holes Air relief holes

A A

Baseplate with Shear Keys

Section A-A

(800) 243-2206 • fivestarproducts.com 49

 A Professional’s Guide on Grouting and Concrete Repair
TYPICAL GROUTING APPLICATIONS
NONSHRINK Cement-Based Grouts

WAFFLE BASEPLATE
A waffle plate, or a plate with a skirt around the perimeter, is often encountered in
grouting applications. Waffle plates are one of the most difficult types of plates to grout
successfully. Adequately sized and located vent holes in each compartment of the plate
are required, as are air relief holes in corners. For this configuration, and for those with
similar obstructions, close supervision is important to ensure that no air is entrapped.

PLACEMENT
METHOD ADVANTAGES DISADVANTAGES
DRY PACKING • NOT
AND RECOMMENDED
TROWELABLE
POURING • Fast Placement • Watertight Forms Must Be
• Consistent Placement Built
• Skill Required in Placement
• Potential Segregation
PUMPING • Faster Method • Watertight Forms Must Be
• Highest EBA Built
• Lowest Cost • Equipment Rental
• Skilled Personnel Needed
• Potential Segregation

Dry packing should not be used because of the high probability of entrapping air under
the plate. Pouring may be used provided great care is exercised in making sure the grout
rises through the air relief holes. The use of a vibrator is recommended. If fluid self-
leveling grout falls below any one of the many waffle areas, and loses contact with the
plate during the placement, it will entrap air and reduce the EBA.
Pumping through a nozzle (as shown below) is the fastest, best performing, and most
economical method for grouting under waffle plates.

Typical Pumping Application

50 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair
TYPICAL GROUTING APPLICATIONS
NONSHRINK Cement-Based Grouts

EMBEDDED ANCHORS AND BOLTS

In anchoring bolts or anchors in concrete, it is important to remember that a precision
NONSHRINK grout must be used to ensure adequate anchoring strength of the
embedded item. When the bolt diameter is one inch or less, the hole diameter should
be a minimum of two inches. When the bolt diameter is greater than one inch, the hole
diameter should be at least twice the bolt diameter. The anchor should be embedded
deeply enough so that it will fail before the grout does. Refer to Appendix A for more
information on anchor bolt grouting.
PLACEMENT
METHOD ADVANTAGES DISADVANTAGES
DRY PACKING • NOT
AND RECOMMENDED
TROWELABLE
POURING • Fast Placement • Cannot Be Used Horizontally
• Little Skill Required • Potential Segregation
• Good for Moderate
Embedments with
Adequate Clearance
(Flowable)
• Good for Tight
Clearances and Deep
Embedments (Fluid)
PUMPING • Good for a Large • Equipment Rental
Number of Anchors • Skilled Personnel Needed
• Horizontal Anchors • Potential Segregation
Anchors must be embedded using flowable or fluid grouts only. The grout can often be
placed in the hole before the anchor, and then the anchor inserted and rotated repeatedly
clockwise, then counterclockwise, or vibrated to ensure proper coverage. Flowable or
fluid grout is good for long, deep holes with adequate clearances.
Note that insufficient clearance between the anchor and the hole risks reduced strength
and failure to develop a good bond.Grout should be placed either by pouring or by pumping.
Special grouts are formulated for each of the previously discussed applications, including
cable grouting. Machinery anchor bolts can be placed before or after the grout is placed
in any of the above applications, provided the bolt hole is vibrated before the grout
sets. Machinery manufacturers, for various reasons, may have to change the anchoring
locations, and setting anchors accurately in the field prior to the arrival of machinery
is extremely expensive. When the machinery arrives, the anchor bolt locations can be
readily determined, the bolt holes quickly drilled, and a threaded, deformed, or plain
anchor, threaded to receive the locking nut, grouted into place.

(800) 243-2206 • fivestarproducts.com 51

 A Professional’s Guide on Grouting and Concrete Repair

TYPICAL GROUTING APPLICATIONS

NONSHRINK Cement-Based Grouts

PRECAST OR PRE-STRESSED WORK

Grouting horizontal and vertical joints between precast or pre-stressed panels may be
performed by one of the following methods:

PLACEMENT
METHOD ADVANTAGES DISADVANTAGES
DRY PACKING • No Forms • Potential for Cold Joints
AND • High Strength • Skill Required in Placement
TROWELABLE
POURING • Fast Placement • Watertight Forms Required
• Potential Segregation
PUMPING • Fastest Method for • Equipment Rental
Large Number of • Hand Pumps for Small Jobs
Joints or Bearing Pads • Mechanical Pumps for Large
Projects
• Potential Segregation
• Watertight Forms Required

52 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

CHAPTER 7
TYPICAL INSTALLATIONS BY INDUSTRY
CEMENTITIOUS GROUT
TYPICAL INSTALLATIONS BY INDUSTRY

CHEMICAL PROCESSING POWER

PULP AND PAPER

INFRASTRUCTURE REFINING

(800) 243-2206 • fivestarproducts.com 53

 A Professional’s Guide on Grouting and Concrete Repair

TYPICAL INSTALLATIONS BY INDUSTRY

EPOXY GROUT

POWER REFINING

PORTS (CRANE RAILS) PULP AND PAPER

INFRASTRUCTURE GAS TRANSMISSION

(WATER TREATMENT)

54 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

CHAPTER 8
SPECIFICATIONS

1. CEMENTITIOUS GROUT SPECIFICATIONS

The purpose of a specification is to ensure that the type and performance of materials,
techniques, and equipment used by a contractor meet the requirements established by the
designer and owner. The proper grout should be clearly specified for the particular application.

In specifying a NONSHRINK grout, the specifier faces a particularly difficult situation.

Manufacturers today are marketing products claiming they are NONSHRINK or
nonmetallic, and they may or may not meet either of these requirements or be
NONSHRINK when tested according to pre-approved national test standards such as
ASTM C 827 (Standard Test Method for Change in Height in Early Ages of Cylindrical
Specimens from Cementitious Mixtures) or ASTM C 1107 (Standard specification for
packaged dry hydraulic cement grout NONSHRINK). When a manufacturer has not had
a ten to twenty year history of satisfactory performance, the specifier should specifically
ask for or obtain independent verification that the products he desires to specify are
indeed precision NONSHRINK. These products should be supplied by companies
who have many years of experience and rigorous quality control specifications. The
manufacturer should mark packages and literature to warranty their products have been
tested under the appropriate ASTM standards.

The contractor is in a difficult position if the specifications do not name a grout, or

clearly state the type and performance of grout desired for a particular application.
Specifications must be clear, not vague, obsolete, or otherwise fail to define the level of
performance required.

The designers using ASTM and ACI Standards can ensure a precision NONSHRINK
grout is specified. It is important in the selection process for the designer to consult the
grout manufacturer on the grout type and performance that is required. The specification
writer should work closely with the project designer on each project to ensure both the
drawings and specifications clearly state where and what type of NONSHRINK grout
is to be used.

In selecting the grout, the specifier should carefully evaluate the performance stated in
published literature and should require a quality laboratory’s signed test results verifying
the NONSHRINK performance and other desired properties.

The cost of grouting is a small portion of the total expense of a construction project,
and the material cost of the grout is minor compared to the labor cost for installation.
The specifier should be aware that certain grouts, as with other construction products,
may have the lower initial cost, but not necessarily the lower lifetime cost. Therefore,
the specifier should be governed primarily by performance and history and not only by
material cost considerations.
It is essential that all grouts specified be manufactured by a company supported by a
technical service organization. It is also important when selecting a grout for the specifier
(800) 243-2206 • fivestarproducts.com 55
 A Professional’s Guide on Grouting and Concrete Repair

to give preference to the leading manufacturers who have distribution networks throughout
the country to ensure that the grout is readily available.
DESIGN-A-SPEC® (DAS)
Five Star Products, Inc. has developed a standard set of product selection and installation
instructions to help architects and engineers expeditiously choose the right Five Star
product or an equal for their design applications. The document is designed to enable
architects and engineers to follow a procedure that they can use to create a clear set of
installation instructions for contractors to follow.
Design-A-Spec®, available to specifiers upon request, provides performance specifications for
individual Five Star products. To obtain a copy, go to website at fivestarproducts.com, or
call Five Star Products, Inc. at 203-336-7900.
Specifiers who need assistance in selecting a grout can consult FIVE STAR PRODUCTS,
INC. Engineering and Technical Center for help with design or field application issues,
or contact a field representative.
TYPES OF SPECIFICATIONS
The specifier has four primary types of specifications to choose from in specifying grout.
They are, in order of preference:
1. Proprietary Specification: Name the specific grout to be used for each specific
application, such as “FIVE STAR FLUID GROUT 100 for machinery.” Also
give the company name and address such as “Manufactured by FIVE STAR
PRODUCTS, INC., Shelton, Connecticut.”
2. Or Approved Equal with Identical Properties: Name a proprietary product
with the clause “or approved equal with identical properties” after the name of
the product.
3. Performance Specification: Specific data and performance requirements are
listed.
4. Open Listing: Naming three or more competitive grouts.
PROPRIETARY SPECIFICATION
In a proprietary specification there is no question in the mind of the owner, designer, or
contractor as to the type and level of performance of the grout required. In addition, no
time is lost in the search for, submittal of, or approval of other materials.
OR APPROVED EQUAL WITH IDENTICAL PROPERTIES
When required by the owner or when the specifier thinks there may be a possibility of
additional products meeting the required standards, consideration should be given to
the use of a specification that reads, for example, “FIVE STAR GROUT or approved
equal with identical properties.” This has some of the advantages of the above, but it
involves the designer, specifier, and contractor in determining if another grout matches
the specified grout’s performance. It forces the specifier to spend considerable time
evaluating other grouts and rejecting those products that do not achieve the desired
performance. The “or approved equal” type of specification should be used if the
proprietary specification listed above cannot be accepted by the owners.

56 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair
PERFORMANCE SPECIFICATIONS
The specifier in using a performance type specification faces many issues. Clearly
delineating the performance requirements and test standards, such as ASTM C 827 and
ASTM C 1107 for NONSHRINK, strength tests, time of setting (initial and/or final),
and other desirable properties is required. The specifier should be aware this may mean
that many submissions might be received from various manufacturers. The specifier
must select from those products believed to meet the criteria established. This opens
the specifier and designer to potential liability unless they are experts in the grouting
field. The time consumed by the specifier, designer, and owner can be quite extensive.
OPEN LISTING
Naming three or more competitive products is most common in the industry. However,
it is essential that the selected competitors offer comparable performance properties.
Unless the specifier has taken the time to carefully research the listed grouts to determine
if their performance is satisfactory, the grout used will be selected on the basis of cost
rather than performance.
COMBINATION SPECIFICATION
Sometimes a specifier is required to use a specification which is a combination of two or
more types. When this happens, the specifier may limit liability by specifying a single
grout such as FIVE STAR GROUT in a proprietary specification, and then adding a
performance specification to eliminate grouts that exhibit shrinkage.
LONG FORM AND SHORT FORM SPECIFICATIONS
There are two forms of specifications: a long form and a short form. Although in many
cases, the short form is adequate, the long form may be more appropriate for projects with
special requirements. Long form specifications are complete specifications, including
sections on General Conditions, Material Specifications, Preparation, Application,
Finishing and Curing, and Extreme Weather Conditions. Short Form Specifications
are generally limited to a section on Material Specification, but may include such other
requirements as the specifier deems necessary.

2. EPOXY GROUT SPECIFICATIONS

Portions of the above discussion of specifications for cementitious grouts apply to
specifications for epoxy grout as well. Keep in mind when specifying an epoxy grout that
the purpose of the grout is to fill the space to be grouted completely and permanently,
and to transfer the load to concrete. Since their inception, epoxy grouts have been
promoted as “nonshrink” or as evidencing “negligible” shrinkage. Test methods
supposedly verifying nonshrink performance date back to the early 1960s, but it is now
clear that these methods are inadequate for epoxy grouts, because they do not measure
vertical height change. A modification of the ASTM C 827 test method shows that most
epoxy grouts exhibit even greater vertical shrinkage than the shrinking cement-based
grouts. Loss of EBA and failures of epoxy grout can be directly correlated with plastic
shrinkage (vertical height change).
Loss of Effective Bearing Area will decrease the area of baseplate actually in contact
with the grout, thus reducing the effectiveness of the grout and increases creep in an

(800) 243-2206 • fivestarproducts.com 57

 A Professional’s Guide on Grouting and Concrete Repair

epoxy grout. It is generally recommended that the total load on the epoxy grout (dead
load plus bolt tension) not exceed 500 psi (3.45 MPa). This design assumes 100%
EBA. At 50% EBA the load increases to 1,000 psi (6.9 MPa). Tests indicate that creep
increases in direct proportion to the increase in load. In the situation mentioned, creep
would approximately double! To prevent such an occurrence, a minimum of 95%
EBA should be specified. Because this is one of the most important requirements
in an epoxy grout specification, to be reasonably assured of obtaining a 95% EBA, a
“NONSHRINK” epoxy grout should be specified. Testing according to ASTM C 827
(Modified) should be an integral part of the specification.
Following are examples of NONSHRINK EPOXY GROUT specifications:
SHORT FORM PROPRIETARY SPECIFICATION
All grouting as called for on the drawings and/or in the specifications shall be
performed with FIVE STAR DP EPOXY GROUT as manufactured by Five Star
Products, Inc. of Shelton, Connecticut. No substitutions will be approved.
OR APPROVED EQUAL WITH IDENTICAL PROPERTIES SPECIFICATION
All grouting as called for on the drawings and/or in the specifications shall be
performed with FIVE STAR DP EPOXY GROUT as manufactured by Five
Star Products, Inc. of Shelton, Connecticut, or approved equal with identical
properties. The grout must show no shrinkage when tested according to ASTM
C 827 (Modified).
PERFORMANCE SPECIFICATION
All grouting as called for on the drawings and/or in the specifications shall be
performed with an epoxy grout meeting the performance requirements that follow:
1. Epoxy grout must have a minimum 10-year history of use and meet the
following performance requirements. It must be a 100% solids system.
2. Vertical Height Change
The grout shall show no shrinkage (0.0%) and a maximum 4.0% expansion
from time of placement when tested according to ASTM C 827 (Modified).
3. Compressive Strength
The grout shall (depending on product selection) show a 7-day compressive
strength of at least 13,000 psi (89.7 MPa) when tested according to ASTM C
579, Method B.
4. Thermal Expansion
The grout shall show a maximum coefficient of thermal expansion of
20 x 10-6in/in/°F (36 x 10-6mm/mm/°C) when tested according to ASTM C 531.
5. Creep Resistance
The grout shall show creep equal to or less than 4.5 x 10-3 in /in at 140°F (60°C) for
one year with a load of 400 psi (2.8 MPa) when tested according to ASTM C 1181.

58 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

CHAPTER 9
SHORT FORM SPECIFICATIONS

Five Star® Grout

Performance Specification
A. Nonshrink cementitious grout shall be a preproportioned, prepackaged, precision
cement based grout requiring only the addition of potable water. The grout shall
not contain metallic aggregate, expansive cement, or gas generating additives such
as aluminum powder. The grout shall contain an air release aggregate to generate
positive expansion.
B. The manufacturer shall be ISO 9001 certified.
C. Manufacturer shall have at least ten years experience in the manufacture of precision
cement-based grouts.
D. The grout material shall meet all the following typical performance criteria when
cured at 73°F (23°C): Note 1
1. Early Height Change, ASTM C 827 0.0 to 4.0%
2. Hardened Height Change, ASTM C 1090 0.0 to 0.3%
3. Effective Bearing Area 95%
4. Compressive Strength, ASTM C 942
28 Days 6500 psi (44.8 MPa)
5. Bond Strength, ASTM C 882
28 Days 2000 psi (13.8 MPa)
6. Application Temperature 40°F to 90°F (4°C to 32°C)
7. Material Temperature 40°F to 90°F (4°C to 32°C)
8. Meets performance requirements of
ASTM C 1107, Grades A, B and C.
9. Working Time 45 Minutes
E. The precision nonshrink cementitious grout meeting these criteria is:
Five Star® Grout
as manufactured by Five Star Products, Inc., Shelton, Connecticut 06484,
Direct: 203-336-7900.

Note 1 The data shown above reflect typical results based on laboratory testing under controlled

conditions. Reasonable variations from the data shown above may result. Test methods are
modified where applicable.

(800) 243-2206 • fivestarproducts.com 59

 A Professional’s Guide on Grouting and Concrete Repair

Five Star® Fluid Grout 100

Performance Specification
A. Nonshrink cementitious grout shall be a preproportioned, prepackaged, precision
cement-based grout requiring only the addition of potable water. The manufacturer
shall be ISO 9001 certified and have at least 10 years experience in the manufacture
of precision cement-based grouts. The manufacturer shall offer technical services
and provide a representative at the jobsite if requested.
B. The grout material shall meet all the following typical performance criteria when
cured at 73°F (23°C): Note 1
1. Grout shall not contain metallic aggregate, expansive cement, or gas
generating additives, such as aluminum powder.
2. Grout shall contain an air release aggregate to generate positive
expansion.
3. Early Height Change, ASTM C 827 0.0 to 4.0%
4. Hardened Height Change, ASTM C 1090 0.0 to 0.3%
5. Effective Bearing Area 95%
6. Compressive Strength, ASTM C 942
28 Days 8000 psi (55.2 MPa)
7. Bond Strength, ASTM C 882
28 Days 2000 psi (13.8 MPa)
8. Consistency, ASTM C 939 20 to 30 seconds
9. Working Time 30 minutes
10. Meets performance requirements of ASTM C 1107,
Grades A, B and C for 30 minutes at 40°F to 90°F (4°C to 32°C).

C. An acceptable product which meets these criteria is:

Five Star® Fluid Grout 100
as manufactured by Five Star Products, Inc., Shelton, CT [203-336-7900].

Note 1 The data shown above reflect typical results based on laboratory testing under controlled

conditions. Reasonable variations from the data shown above may result in the field. Test
methods are modified where applicable.

60 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

Five Star® DP Epoxy Grout

Performance Specification
A. Nonshrink epoxy grout shall be a 100% solids, premeasured, prepackaged system
containing thermosetting epoxy resins, expansive additives and inert fillers. The
manufacturer shall be ISO 9001 certified and have at least 10 years experience in
the manufacture of nonshrink epoxy grouts. The manufacturer shall offer technical
services and provide a representative at the jobsite upon request.
B. The grout material shall meet all the following typical performance criteria when
cured at 73°F (23°C): Note 1
Standard Mix High Flow Mix
Aggregate Content 5 Bags/Unit 4 Bags/Unit

1. Compressive Strength, ASTM C 579 B Note 2

Comp. Strength Comp. Modulus Comp. Strength Comp. Modulus
psi (MPa) psi (kPa) psi (MPa) psi (kPa)
1 Day 11000 (75.9) 1.5 x 106 (10.4) 9000 (62.1) 1.4 x 106 (9.7)
7 Days 14000 (96.6) 2.0 x 106 (13.8) 13000 (89.7) 1.9 x 106 (13.1)
Post cured @ 140°F (60°C)
6500 (113.8) 2.2 x 106 (15.2) 14500 (100.0) 2.0 x 106 (13.8)
2. Height Change, ASTM C 827, 90°F (32°C)
Positive Expansion Positive Expansion
3. Effective Bearing Area (EBA)
95% 95%
4. Tensile Strength, ASTM C 307, 90°F (32°C)
2100 psi (14.5 MPa) 2000 psi (13.8 MPa)
5. Creep, ASTM C 1181, 1 Year, 400 psi (2.8 MPa), 140°F (60°C)
3.2 x 10-3 in/in (mm/mm) 4.1 x 10-3 in/in (mm/mm)
6. Flexural Strength, ASTM C 580
3800 psi (26.2 MPa) 4000 psi (27.6 MPa)
7. Bond to Concrete, ASTM C 882
Concrete Failure Concrete Failure
8. Coefficient of Expansion, ASTM C 531
17 x 10-6 in/in/°F(30 x 10-6 mm/mm/°C) 18 x 10-6 in/in/°F
(32 x 10-6mm/mm/°C)
C. An acceptable product which meets these criteria is:
Five Star® DP Epoxy Grout
as manufactured by Five Star Products, Inc., Shelton, CT [203-336-7900].

Note 1 The data shown above reflect typical results based on laboratory testing under controlled

conditions. Reasonable variations from the data shown above may result in the field. Test
methods are modified where applicable
Note 2 Rate of loading 0.25 inches per minute.

(800) 243-2206 • fivestarproducts.com 61

 A Professional’s Guide on Grouting and Concrete Repair

Five Star® Pile Jacket Grout

Performance Specification
A. The epoxy grout shall be a 100% solids, premeasured, prepackaged, system
containing epoxy resin, hardener, and aggregate with inert filler and graded sand.
The manufacturer shall have at least 10 years experience in the manufacture
of nonshrink epoxy grouts. The manufacturer shall offer technical services and
provide a representative at the jobsite upon request.
B. The manufacturer shall have at least a five year history of ISO certification.
The grout shall be manufactured according to ISO 9001 certified procedures for
all manufacturing operations.
C. The grout material shall meet all the following typical performance criteria when
cured underwater at 73°F (23°C): Note 1
1. Compressive Strength, ASTM C 579 B Note 2
1 Day 3000 psi (20.7 MPa)
7 Days 7500 psi (51.7 MPa)
2. Tensile Strength, ASTM C 307
7 Days 2000 psi (13.8 MPa)
3. Bond to Concrete, ASTM C 882
7 Days 1500 psi (10.3 MPa)
4. Water Absorption, ASTM C 413 0.0%

D. An acceptable product which meets these criteria is:

Five Star® Pile Jacket Grout
as manufactured by Five Star Products, Inc., Shelton, CT [203-336-7900].

Note 1 The data shown above reflect typical results based on laboratory testing under controlled
conditions.

Reasonable variations from the data shown above may result. Test methods are modified where
applicable..
Note 2 Rate of loading 0.25 inches per minute.

62 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

Five Star® Elastomeric Grout

Performance Specification
A. The polyurethane grout shall be a 100% solids, premeasured, prepackaged, system
containing polymer, curative, and aggregate with inert filler and graded sand.
The manufacturer shall have at least 10 years experience in the manufacture of
nonshrink grouts. The manufacturer shall offer technical services and provide a
representative at the jobsite upon request.
B. The manufacturer shall have at least a five year history of ISO certification.
The grout shall be manufactured according to ISO 9001 certified procedures for all
manufacturing operations.
C. The grout material shall meet all the following typical performance criteria when
cured at 73°F (23°C): Note 1

1. Shore A Hardness, ASTM D 2240

Neat 70 ± 10
Filled 85 ± 10
2. Volume Resistivity, ASTM D 257 > 1012 Ohm-cm
3. Tensile Properties, ASTM D 638
Ultimate Tensile Strength 450 psi (3100 kPa)
Elongation 200%
4. Tear Resistance, ASTM D 1004 200 lb/in (35.7 kg/cm)
5. Slant Shear Bond Strength, ASTM C 882
Concrete (deflection to substrate) No failure
Steel (deflection to substrate) No failure
6. Compression Modulus, ASTM D 575B 1 to 12%
7. Compression Set, ASTM D 395
Incremental Set (third test) < 1%
8. Dynamic Deflection, ASTM D 2231 No failure
9. Fatigue Resistance, 5 to 250 psi (35 to 1720 kPa)
16 million cycles at 20 Hz < 10% deflection
10. Height Change, ASTM C 827 Positive

D. An acceptable product which meets these criteria is:

Five Star® Elastomeric Grout
as manufactured by Five Star Products, Inc., Shelton, CT [203-336-7900].

Note 1 The data shown above reflect typical results based on laboratory testing under controlled

conditions.

Reasonable variations from the data shown above may result. Test methods are modified
where applicable.

(800) 243-2206 • fivestarproducts.com 63

 A Professional’s Guide on Grouting and Concrete Repair

CHAPTER 10
CONCRETE REPAIR
INTRODUCTION
This section of the Handbook discusses materials available for concrete repairs, their
performance, use, and specifications.
Concrete can fail for any of several reasons, ranging from exposure conditions, wearing
conditions, and misuse of the structure, to poorly selected ingredients, inadequate mix
design and improper placement of mixes. Lack of attention to procedures, inadequate
training of skilled people, limited knowledge of materials, the improper selection of the
repairing material to be used, and environmental factors like carbonation or degradation
from chlorides, are other factors that can contribute to concrete failures.
Contractors often must repair spalled or honeycombed concrete. For large areas or
major repairs, various versions of FIVE STAR STRUCTURAL CONCRETE® should
be considered to select the proper repair product. All repair surfaces must be free of
all oil, grease, laitance, curing compounds, and other harmful substances. The surfaces
should be mechanically roughened to assure the bond of the repair material to the
existing concrete. Contact the repair material manufacturer for any unusual applications.
When repairing a damaged section of concrete, all these factors have to be taken into
account. Recently, manufacturers of concrete products and the Army Corps of Engineers
performed considerable research in this area and developed products specifically for
the repair of structural concrete. These products have taken into account critical factors
such as bonding capability, shrinkage, expansion, strength, thermal compatibility, ease
of application, waterproofing, freeze/thaw resistance, chloride ion permeability, and
abrasion resistance. FIVE STAR STRUCTURAL CONCRETE® was developed with
these criteria in mind.
Sand/cement mixes that have been used in the past should not be used as structural repair
products. Such mixes do not provide acceptable performance under the criteria listed.

64 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

CEMENTITIOUS CONCRETE REPAIRS

EXPLANATION OF PROPERTIES
Because materials will vary by manufacturer, care should be taken to ensure that similar
properties and related test methods are properly understood and compared before
choosing a product. Below are brief descriptions of the critical physical properties and
related test methods. These should be investigated by a Licensed Professional Engineer
before deciding upon a concrete repair material. Particular attention should be paid to
elevated structures and through deck repairs. It is recommended that a Licensed Professional
Engineer approve the application, design, reinforcement, repair procedures, etc.

Length Change - A repair material should not exhibit significant length change in the
hardened state. ASTM C 157 is one test method to measure length change. This test
should be modified to reflect the manufacturer’s curing procedures. Length change
should be less than 0.05% for wet expansion or dry shrinkage.

Compressive Strengths - Compressive strength is a basic structural property, and the

repair material should at least reach the compressive strength of the concrete being
repaired. ASTM C 109 is one test method used to measure compressive strength and
should be modified to reflect the manufacturer’s recommended curing procedures,
according to ASTM C 928 for rapid setting materials.

Bond Strength - Bond Strength is critical property for any structural application,
especially for elevated structures. Without adequate bond [2000 psi (13.8 MPa)
or greater] to concrete, a repair may break out prematurely and serve no structural
purpose. This may result in the failure of a structure. ASTM C 882 is used to test bond
strength provided the procedures are modified to the substrate preparation instructions
recommended by the manufacturer.

Thermal Coefficient of Expansion - A repair material should exhibit a thermal coefficient

of expansion similar to the substrate. The thermal coefficient of expansion of concrete
has been reported between 2 x 10-6 and 11 x 10-6 inch per inch per °F. ASTM C 531 is
the appropriate test method.

Permeability - The permeability of the repair material is critical because it is a measure

of durability. If a material is very permeable to water, then salts and other ingredients
will penetrate the repair material, ultimately leading to the deterioration of the repair and
surrounding concrete.

Set Time - Set time is a relative measure of and directly proportional to the material
working time. ASTM C 266 is the appropriate test for this property.

Yield - Yield (or volume) is a very important feature in purchasing material because
buying by the bag or pound can be costly since not all materials with the same bag
weight have the same yield.

(800) 243-2206 • fivestarproducts.com 65

 A Professional’s Guide on Grouting and Concrete Repair

CRACKING IN CONCRETE
Ever since the first discovery of cementitious mixtures by the Egyptians, there has
been cracking in concrete. Some of the world’s greatest concrete experts have written
volumes of information and given many lectures about the causes of concrete cracking.
There are many ways to describe the types of cracking. In the following, an attempt is
made to define most of the various causes of concrete cracking. It is not meant to be the
total explanation for any particular crack or the absolute answer to the exact cause, just
a series of potential possibilities.
Common types of cracking can be broken down into two force categories. External
Forces and Internal Forces:
External Forces:
Static load factors
Horizontal pressures (tension or compression)
Vertical forces causing deflection or positive bending
Excessive dynamic loads (impact or vibration)
Large ambient temperature gradients (changes) which cause shrinkage on cooling and
expansion on heating.
Internal Forces:
Plastic shrinkage
Hardened shrinkage
Hardened expansion
Rapid evaporation
Internal heat build-up (addition of coarse aggregate can alleviate this)
High ambient temperatures
Rapid or sudden ambient temperature changes (particularly downward)
High material temperatures
High water temperatures
Freezing
Use of chemical additives
Internal tensile and/or shear stresses
Improper formulation of cementitious mixture
Over watering
Segregation
Internal rebar corrosion
Length of pour
Depth of pour
Mass of pour
Inability of the concrete materials to keep a low heat of hydration
Inability of the concrete materials to dry out and cool off on an even basis
Excessive vibration (over-use of pencil vibrator) during pour
Lack of appropriately located expansion or isolation joints
Improper curing
Improper placement

66 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

CHAPTER 11
SELECTING A REPAIR MATERIAL
Repair materials may be classified into three general groups: Cementitious, Polymer and
Polymer modified. Cementitious materials are those materials which require the addition
only of potable water – they may also be termed “hydraulic materials”. Polymer materials
are modifying agents to increase flexural strength and other performance properties. Both
groups have advantages and disadvantages.
Cement-Based: These generally are prepackaged materials requiring only the addition of
potable water. Their physical properties are very similar to those of concrete. As opposed
to the polymer types, cementitious products are considered “user-friendly” and users have
had considerable experience with them.
The cementitious materials achieve strengths to or greater than the concrete being
repaired. Thermal coefficients of expansion are nearly identical to that of concrete. The
main disadvantage of most cementitious products is that they don’t develop adequate bond
strength. Sand/cement mixtures, with or without “bonding” admixtures, and gypsum-
based products, exhibit this disadvantage and are usually classified as temporary patches.
Of all the properties of cementitious repair materials, bond strength is one of the most
important requirements.
One product on the market was developed specifically to produce excellent bond strength
and the other desirable properties of an ideal repair material. It is called Five Star
Structural Concrete®.
Polymer Based: These include epoxies, polyesters, and acrylics and are most commonly
used where chemical resistance is required. Most of the polymer-based repair materials
achieve high strength and good bond to a properly prepared and dry substrate.
There are some disadvantages to these materials:
• They are generally more difficult to work with as compared to cement-based material.
• They exhibit varying degrees of toxicity and flammability and must be used with
caution.
• Proportioning the components and mixing are critical to proper curing.
Polymer-Modified: Dispersions of polymers in water have been in use for many years as
admixtures to portland cement mortar and concrete. The property improvements from this
family of admixtures includes increased bond strength, reduced permeability, increased
resistance to freezing and thawing, and increased flexural strength. The specific property
improvement to the modified mortar and concrete will vary with the type of latex used.
Applications of these materials include floor leveling, concrete patching, and bridge deck
overlays.
In addition, all of the polymer based repair materials are more expensive than cement-
based materials. Regardless of the type of repair material, an adequate inventory should be
kept in stock. Any repair material chosen to be kept in stock must have an adequate shelf
life. These materials may remain in inventory for months and must retain their efficacy. A
shelf life of a minimum of 6 months is highly recommended. There are some companies,
such as Five Star Products, Inc., who are constantly doing research and development
work in this field. Individuals working in this area should keep in touch with Five Star
Products, Inc. to stay current with the latest developments.

(800) 243-2206 • fivestarproducts.com 67

 A Professional’s Guide on Grouting and Concrete Repair

CHAPTER 12
CONCRETE REPAIRS
PERFORMANCE PROPERTIES AND TESTS
A. PROPERTIES
The important properties in considering a concrete repair material are
• Length Change
• Bond Strength
• Compressive Strength
• Consistency
• Working Time
• Thermal Coefficient of Expansion
• Durability
• Chloride ion permeability
B. LENGTH CHANGE
1. For concrete repair material, length change (linear shrinkage or expansion) is
a critical property. Excessive length change, by shrinkage or expansion, can
produce cracks during and after the curing period and result in failure. Cracks
also permit the entry of water and harmful substances — such as chlorides,
sulfates, oils, and others — that can cause the repair to fail.
2. Use the test method of ASTM C 157 (Standard Test Method for Length Change
of Hardened Cement Mortar and Concrete) — or ASTM C 928 for rapid setting
materials — to evaluate the length change property of a concrete repair material.
Two inch, three inch, or four inch square bars are the most common specimen
sizes because many concrete repair materials contain coarse aggregates. Test
bars should be cured according to the manufacturer’s recommendation. The
length change of an acceptable concrete repair material should be within
±0.05% to avoid cracks or excessive stress in the repair.
C. BOND STRENGTH
1. Bond strength is one of the most important — and yet the most under appreciated
property of a concrete repair material. By and large, concrete repairs do not fail
in compression. They fail because of inadequate bond strength and excessive
length change. The entire repair can
“pop out” if the bond strength is too
low.
2. Although there is no universally
recognized standard test for the bond
strength of a cementitious repair
material to a hardened concrete
substrate, a modified version of
ASTM C 882 (Standard Test Method
for Bond Strength of Epoxy-Resin
Systems Used With Concrete) has proven useful for this purpose and is widely
accepted by the construction industry and by many state highway departments.

68 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

3. The modified slant shear procedure of ASTM C 882 consists of casting the
concrete repair material directly against a properly prepared substrate without
a primer coat. The test specimen is then loaded in compression, producing a
shear load on the slanted interface. A minimum strength of 2500 psi (17.3 MPa)
in this test will, in most cases, compensate for the cold joint between the repair
and the substrate.
D. COMPRESSIVE STRENGTH
1. Except as a way to decide when a concrete repair can be returned to service,
compressive strength is a less significant property of a concrete repair material.
Bond strength and length change are better criteria for selecting a concrete
repair material. That said, most repair jobs require rapid compressive strength
development to minimize the time that the structure is out of service.
2. Test concrete repair materials according to ASTM C 109 (Standard Test Method
for Compressive Strength of Hydraulic Cement Mortars). The compressive
strength of an acceptable rapid setting repair material three hours after adding
the mixing water should be at least 2500 psi (17.2 MPa). After 24 hours, it
should be at least 4500 psi (31.0 MPa).
E. CONSISTENCY
1. Horizontal repairs can usually be made with repair material of flowable
consistency. Repairs to a slightly tilted surface such as a pedestrian ramp or
bridge deck will require a repair material of a somewhat thicker consistency
(low slump) to be able to maintain the slope without running down to level.
2. Repairs to vertical and overhead surfaces require a material of thick plastic
consistency to be capable of placement by troweling. Large repairs can be
formed and a flowable repair material poured or pumped into the repair.
There is no practical test method to determine the optimum consistency for a
specific repair job, but where a range of mixing water content is allowed by the
directions on the repair material package, experienced workers can generally
determine a suitable consistency in relatively short order. However, it is
probable that a single grade of concrete repair material will not cover the entire
range of consistencies that may be needed in practice.
F. WORKING TIME
1. Working time is the elapsed time beginning when the mixing water is added
to the concrete repair material and ending when the repair material stiffens to
the point that it can no longer be easily worked. Working time is shorter than
set time — the time when the repair material can no longer be penetrated by a
needle of a particular size and weight as specified in ASTM C 266.
2. There is no reliable field test to determine working time, but workers unfamiliar
with fast-setting repair materials should mix a small sample batch following
the manufacturer’s directions and determine the actual working time under the
prevailing environmental conditions.
G. THERMAL COEFFICIENT OF EXPANSION
1. A large difference in the coefficients of thermal expansion between the concrete
substrate and the repair material can result in the failure of the repair when it
(800) 243-2206 • fivestarproducts.com 69
 A Professional’s Guide on Grouting and Concrete Repair

is subjected to a large change in temperature. Some polymeric repair materials

whose coefficients of thermal expansion are greater than three to five times
that of the concrete
substrate, may
be susceptible to
such failures. The
repair, expanding three
to five times as much
as the substrate as the
temperature rises,
and contracting three
to five times as much
as the substrate as the
temperature falls creates
substantial stress in the
substrate and can lead
to tensile failure of the
concrete substrate.

2. The coefficient of thermal expansion for most cementitious repair materials

is close to that of the concrete substrate, so this failure mode is seldom
encountered.
3. The coefficient of thermal expansion can be measured by the test method of
ASTM C 531 (Standard Test Method for Linear Shrinkage and Coefficient of
Thermal Expansion of Chemical Resistant Mortars, Grouts, and Monolithic
Surfacings).
H. DURABILITY
1. Durability is the ability of a concrete repair material to remain in service and
protect the substrate over an extended length of time. Durability depends on
low absorption, low permeability, and good abrasion resistance in the repair
material.
2. A low absorption rate prevents damage to the repair and its deterioration
because of freeze/thaw cycling or salt and chemical attack.
3. A low permeability will prevent the transmission of salt and water through the
repair to the substrate where they can cause freeze/thaw damage and corrode
the reinforcing steel.
4. Good abrasion resistance is important in a repair subject to vehicular traffic to
prevent it from being worn away and exposing the substrate.
I. CONCRETE REPAIR MATERIAL SELECTION CHART
Use the Selection Chart on the next page to help select the appropriate concrete
repair material for a specific repair application. If your application is not included
in the chart, consult the Technical Service Department at Five Star Products, Inc.
at (800) 243-2206.

70 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

(800) 243-2206 • fivestarproducts.com 71

 A Professional’s Guide on Grouting and Concrete Repair

CHAPTER 13
CONCRETE REPAIRS
MANUFACTURER’S QUALITY ASSURANCE PROGRAM
A. Quality Assurance programs should be required of all manufacturers of approved
concrete repair materials. The minimum requirements for a manufacturer’s Quality
Assurance System are described in Chapter 3.
B. The manufacturer’s Quality Assurance System should also ensure that cement
based products stored beyond one year in bags (or two years in plastic pails) are
not shipped unless the manufacturer can certify by retest that the products still meet
their applicable performance requirements.
C. The manufacturer should furnish written certification, when requested, that the
product meets its applicable performance requirements, is in accordance with the
manufacturer’s specifications, conforms to the terms of sale, or meets the project
specifications, as applicable. When appropriate, the manufacturer should furnish
actual test data.
D. The manufacturer’s Quality Assurance System should be audited at regular intervals
by an independent auditor and should meet the requirements of ISO 9001-2000.

72 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

CHAPTER 14
CONCRETE REPAIRS
ESTIMATING, PURCHASING, DELIVERING, AND
STORING CONCRETE REPAIR MATERIALS
A. ESTIMATING
1. To estimate the quantity of concrete repair material required for a job, calculate
the volume of the cavity to be filled in cubic feet. Divide the calculated volume
by the yield in cubic feet of one unit of concrete repair material to calculate how
many units will be needed. Add 5% to 10% for waste and spillage, more for
smaller jobs and less for larger ones.
2. The most common cavity shape encountered in repair operations is a rectangular
solid. When the shape of the area to be repaired is irregular or uneven in depth,
the average length, width, and depth must be determined by measurement or
by estimate. But consider that an irregular shape should be squared off for a
durable repair.
3. To find the volume V of a rectangular solid in cubic feet (for example, a floor
overlay) multiply the length L in inches times the width W in inches times the
thickness T in inches.
V=LWT
The calculated volume will be in cubic inches. To convert cubic inches to cubic
feet, divide by 1728, the number of cubic inches in a cubic foot.
B. PURCHASING
To compare the cost of a concrete repair material needed for a job, determine the
cost per cubic foot for each material under consideration. Because concrete repair
materials are sold in units that may be of different sizes, and may yield different
volumes of concrete for a given weight.Note 1
C. DELIVERY
Concrete repair materials should be delivered, premeasured, and packaged in
sealed, dry bags, and on stretch-wrapped or shrink-wrapped pallets to prevent
shipping damage.
D. STORAGE
1. Concrete repair materials should be stored in a dry location at a temperature
near 70°F, but never below 40°F nor above 90°F.
2. Concrete repair materials that become damp or otherwise defective should not
be used and should be removed from the job site.
3. Concrete repair materials that are beyond the manufacturer’s expiration date
should not be used unless the manufacturer has requalified them by actual
laboratory retest.

NOTE 1: For Metric: Take U.S. measure in cubic feet and multiply by .03 to determine cubic meters.

(800) 243-2206 • fivestarproducts.com 73

 A Professional’s Guide on Grouting and Concrete Repair

CHAPTER 15
PERMANENT CONCRETE REPAIRS
General structural repairs include repairs to walls, piers, pilings, abutments, columns,
and industrial and commercial floors.
FIVE STAR STRUCTURAL CONCRETE® has been developed specifically for
structural repair of horizontal and formed vertical surfaces. FIVE STAR STRUCTURAL
CONCRETE® V/O is specially formulated for repair of vertical and overhead concrete.
They both develop excellent bonds and high strengths for tough problems. They also
have rapid strength gains so the repaired area can be reopened to use with a minimum
delay.
Most of the following procedure is derived from the “Industrial Concrete Repair”
section of Five Star Products, Inc. “Design-A-Spec” (DAS) document. It is shown here
to illustrate the content of that document. Architects, engineers, and specifiers are
encouraged to refer to the DAS when preparing material specifications for Five
Star Products, Inc.’s concrete repair materials.
A. VERTICAL AND OVERHEAD REPAIRS
The procedures outlined below will suffice for most applications. Snap tie holes
and the like are usually filled simply by troweling in a repair material such as FIVE
STAR STRUCTURAL CONCRETE or FIVE STAR STRUCTURAL CONCRETE
V/O and leveling with the surrounding concrete.
1. SURFACE PREPARATION
Surface preparation is extremely critical in all repair work. In all structural
repairs, it is essential to remove from the existing concrete all substances that
might prevent the repair from bonding to it. This includes, but is not limited
to, form oils, form coatings, curing agents, and similar products. Acid etchers,
concrete cleaners, and degreasers may be required to properly clean the surface.
All acid, chemical cleaners, and degreasers must be completely removed.
The surface to be repaired must not be smooth. It should be roughened by
mechanical means such as chipping or sandblasting. All loose and excess
material should be removed from the area to be repaired.

CAUTION: Some methods of roughening surfaces can bruise the concrete

substrate and cause microcracks under the prepared surface. This can signifi-
cantly reduce the tensile strength, resulting in failure beneath the bond line.
• Sandblasting, steel shot blasting, and high pressure and ultra high pressure
water jetting have a very low risk of generating microcracks.
• Scarifying, needle scaling, and flame blasting have a moderate risk of
generating microcracks.
• Scabbling and milling or rotomilling have a high risk of introducing
microcracks, and should not be used without the approval of the engineer
in charge.

74 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

On deep or large repairs, consider using forms, rib lathe, mesh, or reinforcing
bars, separately or in combination, depending on the circumstances. Because
surface preparation is critical when applying a repair product, it is essential that
the contractors and engineers carefully inspect the preparation to ensure that the
surfaces are truly cleaned and roughened.
Studies by the American Concrete Institute and the Portland Cement Association
show that concrete substrates should be presoaked with potable water to an
saturated surface dry (SSD) condition at the time cementitious repair materials
are placed. With a dry substrate in hot weather, the repair material may lose
water too rapidly for proper hydration to take place. On the other hand, if the
substrate is too wet, cement may be washed from the bonding surface.
Under unusual circumstances, the manufacturer of the repair material should be
contacted for guidance, but generally, the following procedure should be used:
a. Outline the areas to be repaired with chalk or crayon.
b. Saw cut 1/2 inch deep along the outline. Chip out the concrete within the saw
cut to a minimum depth of 1/2 inch. Keep all edges as vertical as possible.
Avoid feather edges – they tend to dry rapidly, debond, and break up.
c. Add rebar or mesh for deep or large repairs.
d. If rebar is exposed, chip to 3/4 inch (or 2 times the maximum aggregate size,
whichever is greater) below the rebar.
e. All exposed rebar showing any oxidation should be water or sandblasted.
f. Brush away any debris or dust in the chipped area.
g. Presoak the area to be repaired or use bonding adhesive where appropriate.
2. FORMS
a. Surface preparation should be as outlined above.
b. Forms should be lined with polyethylene or coated with paste wax or form
release agent for easy release.
3. MIXING
a. Mix the repair material in a mortar mixer to a trowelable consistency for
all applications except those to be poured in place. Mix only the amount
of material that can be placed within the working life of the material. For
small applications, use a paddle type mixer.
b. For formed areas to be poured, use the repair material mixed to a pourable
consistency. Do not exceed maximum water indicated on the packaging.
Tap the forms while placing and after placing to eliminate trapped air.
c. During hot weather, adjust set and working times with the admixture
provided by the manufacturer.
4. PLACING
a. TROWEL METHOD [For vertical and overhead repair areas with limited
reinforcement.]
1. Apply thin layer of repair material and work firmly into roughened
substrate filling all pores and voids. Allow material to begin to
stiffen. Follow with application of repair material.

(800) 243-2206 • fivestarproducts.com 75

 A Professional’s Guide on Grouting and Concrete Repair

2. Apply repair material in a thick layer, but short of the point of

sagging. Roughen each lift for mechanical bond and allow to stiffen
before applying next thin layer and subsequent lift. Work repair
material firmly into previous lift to ensure bond.
3. Place the repair continuously, repeating the thin layer/thick layer
sequence until the void is completely filled.

b. FORM AND POUR METHOD

Leave a small opening or slot at the top of the form to permit the material to
be poured into place. The material may be poured directly from the pail or
into a small chute inserted in the opening. Consolidate by lightly vibrating
the formwork to ensure good contact with the substrate and eliminate
bubbles and voids.
CAUTION: Always use care when vibrating. Excessive vibration can
cause segregation of the aggregate and spoil the job.

c. PNEUMATICALLY APPLIED REPAIRS

The pneumatically applied repair method (generally called Shotcrete or
Gunite) is not covered since the method requires an experienced shotcrete
contractor. It is an excellent method to use where very large total areas
or overhead installations are involved. It does, however, require an
experienced contractor with one or more highly skilled nozzle men. It is
an excellent, and the most economical, method to use for repairing very
large vertical, or overhead areas. It has the additional advantage of placing
a repair at the lowest possible water content (water/cement ratio), resulting
in a higher strength repair.

76 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair
5. CURING
Follow the manufacturer’s instructions.
6. FORM REMOVAL
If it was necessary to anchor the forms through the repair, form removal
should be delayed until an adequate bond of the repair to the old concrete has
developed.
B. HORIZONTAL REPAIRS
This category applies mainly to floors in plants, warehouses, and other industrial
and commercial structures.
1. SURFACE PREPARATION
Prepare the surface as previously described in the beginning of this section for
VERTICAL AND OVERHEAD REPAIRS.
2. WETTING
Presoak the area to be repaired, and remove any excess (standing) water before
placing the repair.
3. MIXING
a. Mix the repair material in a mortar mixer to a pourable consistency for
most applications. Mix only the amount of material that can be placed
within its working life. For small repairs, hand mix or use a paddle-type
mixer.
b. For deep or large repairs, most materials may be extended with coarse
aggregate, such as clean, damp pea gravel that meets the requirements
of ASTM C 33, to act as a heat sink, provide dimensional stability, and
lower the material cost. Consult the manufacturer for the amount of coarse
aggregate to add.
c. During hot weather, adjust set and working times with FIVE STAR®
SUMMERSET or FIVE STAR® SET EXTENDER, or use ice water to mix
the repair material.
4. PLACING
Place the repair material full depth from one side or end of the repair to the
other side or end. Puddle lightly to assure full contact with bottom and sides
of the repair. Screed the repair level with surrounding concrete and finish as
desired.
5. CURING
Follow the manufacturer’s recommendations for curing.
C. REPAIRING CONCRETE JOINT EDGES
Joints in concrete floors are often subjected to repeated heavy loads by steel-
wheeled or hard rubber-wheeled equipment. With time, the edge of the joint breaks
off and the process continues until a large gap or hole exists. These holes should
be immediately repaired to avoid hazardous conditions to people and equipment.
Repair material must be chosen to accommodate the type of traffic and loads
to which the joint will be exposed. Light impact loadings and pneumatic-tired
equipment often will not damage cementitious surfaces as severely as steel wheels.
(800) 243-2206 • fivestarproducts.com 77
 A Professional’s Guide on Grouting and Concrete Repair

For most applications, repairs may be made with Five Star Structural Concrete®. For
heavy impact loadings or steel wheeled equipment, use one of Five Star’s epoxy
grouts for the repair. The procedure is as follows:
1. SURFACE PREPARATION
Prepare the surface as previously described in the beginning of this chapter for
VERTICAL AND OVERHEAD REPAIRS, but outline the repair area with a
vertical saw cut at least 1 inch deep. Chip down so the depth of the repair is at
least 2 inches. If chipping exposes reinforcing, chip to a minimum of 3/4 inch
(or 2 times the maximum aggregate size, whichever is greater) below the steel.
If no reinforcing is present or if the repair will be deep or wide, the engineer
should design suitable reinforcement to be added before placement.
2. WETTING
If FIVE STAR STRUCTURAL CONCRETE® is being used, presoak the area
to be repaired. Remove any standing water before placing the repair. If an
epoxy grout is to be used, do not presoak and be sure the substrate is dry before
placing the repair.
3. FORMING
As the form, use a length of wood board or rigid plastic foam having a
thickness equal to the width of the joint. Wrap the form with polyethylene film
to serve as a form release. Do not use oil, grease, or other release agents that
will prevent the joint sealant (used to fill the joint after the repair is complete)
from bonding.
4. MIXING
Mix the selected repair material as indicated on the package.
5. PLACING
Place the material full depth from one end to the other end. Consolidate by
puddling. Screed off level with surrounding concrete. IMPORTANT: Do not
permit the repaired side of the joint to be higher or lower than the other side!
6. FINISHING
Finish FIVE STAR STRUCTURAL CONCRETE® with a steel trowel slightly
moistened with water (or with solvent or diesel oil if you are using one of the
FIVE STAR EPOXY GROUTS.)
7. CURING
As soon as FIVE STAR STRUCTURAL CONCRETE® has hardened, wet cure
all exposed surfaces for a minimum of 30 minutes.

78 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

CHAPTER 16
CONCRETE PAVEMENT REPAIRS
INTRODUCTION
Concrete pavement repairs include bridge decks, highways, dowel bar retrofits, roads,
parking garages, and similar applications. All of these require products having certain
properties.

The most important properties are drying shrinkage and bond strength. Excessive
length change (linear shrinkage or expansion) can cause a repair failure if the tensile
stress in the repair exceeds the tensile strength of the bond to the older material. More
repairs have failed because of inadequate bond than from all other causes combined.
Products which do not develop a 7-day minimum bond strength of 2,500 psi (17.3 MPa),
as measured by ASTM C 882, should be considered questionable for any permanent repair.

Excessive length change can also cause cracks in the repair material itself if the tensile
stress in the repair exceeds the materials tensile strength. Cracks permit entry of water
and harmful solutions that can lead to failure from freezing or corrosion.

Most repair materials do develop adequate strength. Strength gain should be rapid in
order to minimize shutdown time and the resulting inconvenience to the traveling public.

A versatile repair material is formulated to be capable of use at varying consistencies.

Flowable-only materials present problems at any areas that are not absolutely level.
Flowable repair materials tend to flow toward the low end and require constant
troweling to make them conform to the levels of the surrounding concrete. If they start
to set while being troweled, undesirable ripples may develop on the surface of the repair.

Most repairs are not done at carefully controlled temperatures. Hot weather presents
problems of too rapid set and too short working time. Preferably the repair material
manufacturer will have available admixtures to adjust set and working times. These
admixtures should be capable of being used in varying amounts and should also be able
to be used in the field to meet any job requirement. FIVE STAR PRODUCTS, INC.
offers products called SUMMERSET and SET EXTENDER, which will adjust the set
time and extend the working time of fast-setting repair materials.

FIVE STAR PRODUCTS, INC. recommends that all specifiers and users upgrade their
specifications and projects to permanent FIVE STAR HIGHWAY PATCH to take
full advantage of its far superior characteristics. Since all materials will vary by
manufacturer, the data shown is based on the typical performance of the top selling
brands of each type.

(800) 243-2206 • fivestarproducts.com 79

 A Professional’s Guide on Grouting and Concrete Repair
PLACEMENT PROCEDURES
A. EQUIPMENT
All tools, screeds, mixer, potable water, aggregate, and product should be at or near
the point of placement before starting to mix and place the repair.
B. SURFACE PREPARATION
1. Outline areas to be repaired with chalk or crayon.
2. Saw cut at least 1/2 inch deep at the outlines. This is to avoid feather edges and
their potential for failure. Feather edges dry out rapidly with resulting cracking
and debonding. They are also much more susceptible to breakout and abrasion.
3. Chip down at least one inch, but deeper if necessary to reach sound,
uncontaminated concrete. If chipping exposes reinforcing bar, chip at least
/ inch (or 2 times the maximum aggregate size, whichever is greater) below
3 4

the reinforcing bar. There may be insufficient reinforcing bar at headers. The
engineer should design reinforcing bar cages with top steel approximately (but
not less than) 1-1/2 inches below the surface.
4. Keep all outside edges as vertical as possible.
5. Remove all chipped debris and dust using shovels, brooms, oil-free compressed
air blowers, or a wet/dry shop vacuum.
C. SUBSTRATE PRESOAKING
Follow the manufacturer’s recommendations for presoaking the substrate.
Important: Some products require a wet substrate; others do not. After
presoaking a substrate, be sure that all standing water (puddles) is removed before
placing the repair.
D. MIXING
1. If mechanical mixing equipment is used, a mortar mixer (a stationary drum with
rotating blades) is recommended for all prepackaged FIVE STAR® products.
For larger batch sizes please consult Appendix D-Recommendations and
Procedures for Bulk Mixing at the end of this book.
2. Wet all tools and the inside of the mixer and pour out all excess water.
3. Measure out a quantity of potable water equal to the maximum called for on
the bag or pail times number of bags to be mixed at a time. Pour somewhat
less than 85% to 90% into the mixer. Start the mixer. If the product is being
extended with clean, washed pea gravel, add the pea gravel last. Aggregate
containing larger pieces (over 1/2 inch) should not be put into a mortar mixer.
Larger stones tend to wedge under the blades and stall the mixer.
4. If it is necessary to extend the set time or the working time, add SUMMERSET
to the water in the mixer before adding the dry repair material. (In many cases,
using ice cold water (35°F to 40°F) in the mixer may extend the working time
sufficiently).
5. Add the dry repair material into mixer and mix for time indicated on the product
bags.
6. After adding the coarse aggregate and mixing as required, add only enough of
the remaining 10% to 15% water to obtain desired mix consistency. You can
always add more water to a mix, but it can’t be removed. Never add more than
100% of the maximum water stated on the bag or pail. Too much water may
80 (800) 243-2206 • fivestarproducts.com
 A Professional’s Guide on Grouting and Concrete Repair

cause segregation while too little water may compromise the hydration process.
In either case, the product properties will be adversely affected.
E. PLACEMENT
1. Most repair products will be pourable and self-leveling at the maximum
recommended water and mixing time. Products should have the capability of
being mixed at varying water contents to produce consistencies appropriate to
the job requirements.
2. Pour the mix into the repair area from the low side and continue pouring across
the repair until it is filled. Do not place the repair in lifts. Most repair materials
will function best if placed in a single layer. When this is not practical, multiple
layers (lifts) can be placed by allowing the previous layer to stiffen somewhat
before placing additional lifts. Puddle or rod the first lift to ensure good contact
with the substrate.
3. Screed the repair level with surrounding concrete. Float, trowel, or broom to
desired finish. Be sure to trowel edges of the repair carefully to ensure that the
edges are sealed.
F. CURING
Follow the manufacturer’s recommended procedures for curing all repair materials.

CONCLUSION
All of the foregoing assumes that repairing and repair of surfaces in a horizontal
plane are the main and only problems associated with bridge decks, highways,
dowel bar retrofits, roads, and parking decks. Unprotected surfaces such as piers,
columns, and abutments, along with retaining walls, must be protected from
water and salt penetration to avoid deterioration. Such areas can be effectively
and economically protected by coating with FIVE STAR® WATERPROOFING
or FIVE STAR PILE JACKET GROUT. Information about these products is
available at fivestarproducts.com or from the FIVE STAR PRODUCTS, INC.
Engineering and Technical Center at 203-336-7900.

(800) 243-2206 • fivestarproducts.com 81

 A Professional’s Guide on Grouting and Concrete Repair

CHAPTER 17
TYPICAL CONCRETE REPAIR APPLICATIONS

WATER TREATMENT REFINING

HIGHWAYS AND AIRPORT INFRASTRUCTURE

POWER

82 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

CHAPTER 18
SPECIALTY CONCRETE REPAIRS
INTRODUCTION
Throughout its history, FIVE STAR PRODUCTS, INC. has prided itself on being
able to provide customers with custom designed concrete mixes. Specialty mixes
are created in the testing laboratory under the guidance of experienced and dedicated
technical personnel. These mixes address special applications going beyond the
normal, such as concrete repairs for high temperature processes. FIVE STAR
STRUCTURAL CONCRETE® HTR and FIVE STAR STRUCTURAL CONCRETE®
HTR SHOTCRETE are unique, high temperature resistant concrete repair materials that
gain strength quickly and can be exposed to high temperatures from 1000°F (538°C) to
2400°F (1316°C). Five Star Products, Inc. also custom manufactures salt water resistant
concrete repair materials for placement under water, FIVE STAR STRUCTURAL
CONCRETE® UNDERWATER HP, FIVE STAR STRUCTURAL CONCRETE®
UNDERWATER PG, and FIVE STAR® PILE JACKET GROUT. These products
are specifically designed to be placed under water with reduced washout. Each of these
products and their properties are explained more fully in the following paragraphs.
Specialty repair materials are made to order only. Minimum order sizes apply.

FIVE STAR STRUCTURAL CONCRETE® HTR (FSSC HTR) and FIVE STAR
STRUCTURAL CONCRETE® HTR SHOTCRETE are both suited for use in
high temperature environments where concrete exposure temperatures exceed 400°F
(204°C). These products can be exposed to 1000°F (538°C) in three hours and up to
2400°F (1316°C) after a seven-day curing procedure. FSSC HTR can be poured or
pumped. It has been applied on floors and walls of coker plants and steel mills, and
for repairing kilns and foundries. FSSC HTR SHOTCRETE is a dry process shotcrete
available for the same applications.

Typical Properties of FSSC HTR & FSSC HTR SHOTCRETE):

Compressive Strength, ASTM C 109
3 Hours 2500 psi (17.3 MPa)
1 Day 4500 psi (31.1 MPa)
28 Days 7000 psi (48.3 MPa)
Bond Strength, ASTM C 882
1 Day 1500 psi (10.4 MPa)
7 Days 2500 psi (17.3 MPa)
Thermal Coefficient of Expansion, ASTM C 531
5.0 x 10-6 in/in/°F (9.0 x 10-6 mm/mm/°C)
Set Time, ASTM C 266
FSSC HTR 45 minutes
FSSC HTR SHOTCRETE 20 minutes

(800) 243-2206 • fivestarproducts.com 83

 A Professional’s Guide on Grouting and Concrete Repair
FIVE STAR STRUCTURAL CONCRETE® UNDERWATER HP (FSSC UWHP)
and FIVE STAR STRUCTURAL CONCRETE® UNDERWATER PG (FSSC
UWPG) are designed for underwater placement to repair concrete in tidal zones and
marine environments. Concrete piles, piers, tanks, dams, seawalls, and other related
hydraulic structures are typical repair candidates. FSSC UWHP is a rapid setting, hand
pack consistency material suitable for small-volume repairs. It can be placed in as little
as 1/2 inch thickness and as much as several inches in a single application with reduced
washout. Saltwater, chloride, and sulfate resistant, this is a one-component material
designed for reliability and ease of use. FSSC UWPG is essentially the same product,
except in a longer working time, pumpable version for large volume placements.
Consult the FIVE STAR PRODUCTS, INC. Engineering and Technical Center (203-
336-7900) for more information.
Typical Properties of FSSC UWHP & FSSC UWPG SHOTCRETE):
FSSC UWHP FSSC UWPG

Compressive Strength, ASTM C 109

3 Hours 2000 psi (13.8 MPa) ——
6 Hours —— 2500 psi (17.3 MPa)
1 Day 3000 psi (20.7 MPa) 5000 psi (34.5 MPa)
7 Days 4000 psi (27.6 MPa) 6000 psi (41.4 MPa)
28 Days 5000 psi (34.5 MPa) 7500 psi (51.7 MPa)

Underwater Bond Strength, ASTM C 882

1 Day 950 psi (6.5 MPa) 1000 psi (6.9 MPa)
7 Days 1150 psi (7.9 MPa) 1500 psi (10.3 MPa)

Length Change, ASTM C 157

28 Days Wet +0.02% +0.02%

Thermal Coefficient of Expansion,

ASTM C 531 5.0 x 10-6 in/in/°F (9.0 x 10-6 mm/mm/°C)

84 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

CHAPTER 19
CONCRETE REPAIR SPECIFICATIONS
Repair materials should not be specified based only on requirements for compressive
strength and/or rate of strength gain. As mentioned earlier, these materials seldom,
if ever, fail as a result of insufficient compressive strength. They fail because of
inadequate bond strength and excessive length change.

Any specification that does not recognize this will not ensure the use of a product that
will give long-lived performance. A proprietary specification can assure the owner and
specifier that the desired performance will be achieved. Where a proprietary specification
is prohibited, for whatever reason, a performance specification should be written.

The performance specification should include requirements for bond strength, length
change, and compressive strength. In order to demonstrate the level of performance
expected, the specifier may add the name of a product and manufacturer that meets the
performance requirements required.

TYPES OF SHORT FORM SPECIFICATIONS

1. PROPRIETARY SPECIFICATION
All repairs called for in the drawings and specifications shall be made using
FIVE STAR STRUCTURAL CONCRETE® as manufactured by FIVE STAR
PRODUCTS, INC. of Shelton, Connecticut. No substitutions will be approved.
2. OR APPROVED EQUAL WITH IDENTICAL PROPERTIES
SPECIFICATION
All repairs called for in the drawings and specifications shall be made using
FIVE STAR STRUCTURAL CONCRETE® as manufactured by FIVE STAR
PRODUCTS, INC. of Shelton, Connecticut, or approved equal with identical
prop-erties. The repair material must exhibit a minimum bond strength of 2,500 psi
(17.3 MPa) in 7 days when tested according to ASTM C 882 (modified) and typical
length changes of +0.05% measured according to ASTM C 157.
3. PERFORMANCE SPECIFICATION
All repairs called for in the drawings and specifications shall be made using a cement
based concrete repair material that meets the following performance requirements.
[The specifier must then list the required properties together with acceptable values
and the test methods to be used. The names of one or more approved products can
also be included.]

(800) 243-2206 • fivestarproducts.com 85

 A Professional’s Guide on Grouting and Concrete Repair
AN EXAMPLE OF A SHORT FORM PERFORMANCE SPECIFICATION

1. All the concrete repair and repairing as called for in the drawings and specifications
shall be made using a material meeting the performance requirements that follow.
Permanent structural repair material must be a one component system that requires
only the addition of water. It must meet the following performance requirements at
maximum water content.
A. Bond Strength: 1 Day 2,000 psi (13.8 MPa) min.
ASTM C 882* 7 Days 2,500 psi (17.3 MPa) min.

B. Length Change: 28 Days Dry -0.05% (max.)
ASTM C 157* 28 Days Wet +0.03% (max.)

C. Compressive Strength: 3 Hours 2,500 psi (17.3 MPa) min.

ASTM C 109 1 Day 5,000 psi (39.5 MPa) min.
7 Days 7,000 psi (48.3 MPa) min.

D. Chloride Ion Permeability 28 Days Very Low

2. A concrete repair material meeting these criteria is

Five Star Structural Concrete®
as manufactured by Five Star Products, Inc., Shelton, Connecticut [203-336-7900].

*Modified: Contact FIVE STAR PRODUCTS, INC. for details

86 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

CHAPTER 20
INDUSTRIAL CONCRETE REPAIR SPECIFICATIONS
STANDARD PERFORMANCE SPECIFICATIONS

FIVE STAR STRUCTURAL CONCRETE®

For Permanent Structural Concrete Repair Materials

1.01 PART I – GENERAL

1.02 The work covered by this specification consists of furnishing all permanent
structural concrete repair material, equipment and labor required in performing
all operations required for the installation of permanent structural concrete
repair materials shown in the drawings and specifications. Permanent structural
concrete repair materials are used to replace defective or deteriorated concrete
and re-establishing the structural capabilities of the original structure.
1.03 REFERENCES
The following codes and standard specifications establish the minimum
requirements for concrete repair materials. Referenced test methods,
specifications and recommended practices are to be used to verify material
properties and identify acceptable practices applicable to permanent structural
concrete repair materials:
ASTM C 109 Standard Test Method for Compressive Strength of
Hydraulic Cement Mortars
ASTM C 157 Standard Test Method for the Length Change of Hardened
Cement Mortars and Concrete
ASTM C 531 Standard Test Method for Linear Shrinkage and Coefficient
of Thermal Expansion of Chemical-Resistant Mortars,
Grouts, and Monolithic Surfacing
ASTM C 882 Standard Test Method for Bond Strength of Epoxy-Resin
Systems using Concrete
ASTM C 928 Standard Specification for Packaged, Dry, Rapid-Hardening
Cementitious Materials for Concrete Repairs
1.04 SUBMITTALS
The Contractor must submit the manufacturer’s literature and certified test
data to the Engineer prior to installation. The Engineer may choose to buy any
submitted material in the open market at the Contractor’s expense, without the
Contractor or manufacturer’s knowledge, and test the material at an independent
laboratory to verify compliance with this specification.
1.05 DELIVERY, STORAGE, AND HANDLING
All materials shall be delivered to the jobsite in original, unopened packages,
clearly labeled with the manufacturer’s identification and printed instructions.
All cementitious materials shall be stored and handled in accordance with the
recommendations of the manufacturer and the American Concrete Institute.

(800) 243-2206 • fivestarproducts.com 87

 A Professional’s Guide on Grouting and Concrete Repair

1.06 PROJECT/SITE CONDITIONS

Refer to the manufacturer’s literature or contact the manufacturer directly for
any physical or environmental limitations required by the product:
PART II – PRODUCTS
2.01 MANUFACTURERS
The following manufacturers supply materials which meet this specification
and will provide field technical service upon request:
Manufacturer Products
Five Star Products, Inc. Five Star Structural Concrete®
Shelton, Connecticut 06484
203-336-7900
Other manufacturers may submit materials to the Design Engineer for approval
following the procedures outlined in Article 1.02
2.02 MATERIALS
Permanent structural concrete repair materials shall be preblended, prepackaged
materials requiring only the addition of water, meeting the following performance
criteria:
(a) Dimensional Stability – The typical length change after hardening shall be
less than +0.05% when tested according to ASTM C 157 as modified in
ASTM C 928.
(b) Bond Strength – The bond between repair materials and concrete shall be
at least 2,500 psi (17.2 MPa) in 7 days or the shear strength of the concrete,
whichever is less, when tested according to ASTM C 882 as modified in
ASTM C 928.
(c) Compressive Strength – The minimum compressive strengths when tested
according to ASTM C 109, as modified in ASTM C 928, shall be: 2500 psi
(17.3 MPa) at 3 hours, 4500 psi (31.0 MPa) at 24 hours and 6000 psi (41.4
MPa) at 7 days.
(d) Compatibility – The coefficient of thermal expansion shall be less than 6.0 x
10-6 in/in/°F (10.8 x 10-6 mm/mm/°C) when tested according to ASTM C 531.
PART III – EXECUTION
3.01 EXAMINATION
(a) Inspect concrete surfaces to receive concrete repair and verify they are free
of ice, frost, dirt, grease, oil, curing compounds, paints, impregnations, and
all loose material or foreign matter likely to affect the bond or performance
of the concrete repair material.
(b) Inspect all reinforcing steel for rust, oil, and other deleterious substances
that may affect the bond or performance of the repair material.
(c) Confirm that all surfaces are sufficiently rough to ensure good cement bond
and that the concrete is structurally sound.
3.02 PREPARATION
(a) Roughen all concrete surfaces requiring additional surface preparation by
sandblasting, chipping, or other mechanical means to assure bond. Loose
or broken concrete shall be removed.
88 (800) 243-2206 • fivestarproducts.com
 A Professional’s Guide on Grouting and Concrete Repair

(b) All grease, oil, dirt, rust, curing compounds, laitance, and other deleterious
materials that were identified in the inspection process shall be completely
removed from the concrete and/or reinforcing steel.
(c) Forms for repair material shall be built of material with adequate strength
to withstand the placement of the material if forms are required.
(d) All concrete surfaces shall be thoroughly saturated and free of standing
excess water immediately prior to applying the repair material.
3.03 INSTALLATION
(a) The repair material shall be added to a premeasured amount of water that
does not exceed the manufacturer’s maximum recommended water content.
Retempering the repair material by adding more water after stiffening is not
permitted.
(b) Mix and place the repair material according to the manufacturer’s specific
installation guidelines.
(c) The manufacturer should be contacted for aggregate extension guidelines
when applicable.
3.04 CURING
(a) Repair materials shall be cured in accordance with the manufacturer’s
specifications and recommendations. The method needed to protect the
repair material would depend upon temperature, humidity, and wind.
Wet burlap or ponding are the preferred curing methods. Consult the
manufacturer for appropriate curing schedule.
(b) Equipment and tools shall be cleaned as recommended by the manufacturer.

(800) 243-2206 • fivestarproducts.com 89

 A Professional’s Guide on Grouting and Concrete Repair

CHAPTER 21
INFRASTRUCTURE CONCRETE REPAIR SPECIFICATIONS
STANDARD PERFORMANCE SPECIFICATION

FIVE STAR® HIGHWAY PATCH

For Rapid Setting Cement Mortar

PART I – GENERAL
1.01 The work covered by this specification consists of furnishing all rapid setting
cement mortar, equipment and labor required in performing all operations
required for the installation of rapid setting cement mortar shown on drawings
or in the specifications. Rapid setting cement mortar is used to replace defective
or deteriorated concrete and re-establishing the structural integrity of the
original pavement.
1.02 REFERENCES
The following codes and standard specifications establish the minimum
requirements for rapid setting cement mortar. Referenced test methods,
specifications and recommended practices are to be used to verify material
properties and identify acceptable practices applicable to rapid setting cement
mortar:
ASTM C 109 Standard Test Method for Compressive Strength of
Hydraulic- Cement Mortars
ASTM C 157 Standard Test Method for the Length Change of Hardened
Cement Mortars and Concrete
ASTM C 531 Standard Test Method for Linear Shrinkage and Coefficient
of Thermal Expansion of Chemical-Resistant Mortars,
Grouts, and Monolithic Surfacing
ASTM C 882 Standard Test Method for Bond Strength of Epoxy-Resin
Systems using Concrete
ASTM C 928 Standard Specification for Packaged, Dry, Rapid-Hardening
Cementitious Materials for Concrete Repairs
1.03 SUBMITTALS
The Contractor must submit the manufacturer’s literature and certified test
data to the Engineer prior to installation. The Engineer may choose to buy any
submitted material in the open market at the Contractor’s expense, without the
Contractor or manufacturer’s knowledge, and test the material at an independent
laboratory to verify compliance with this specification.
1.04 DELIVERY, STORAGE, AND HANDLING
All materials shall be delivered to the jobsite in original, unopened packages,
clearly labeled with the manufacturer’s identification and printed instructions.
All cementitious materials shall be stored and handled in accordance with the
recommendations of the manufacturer and the American Concrete Institute.

90 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

1.05 PROJECT/SITE CONDITIONS

Refer to the manufacturer’s literature or contact the manufacturer directly for
any physical or environmental limitations required by the product:
PART II – PRODUCTS
2.01 MANUFACTURERS
The following manufacturers supply materials which meet this specification
and will provide field technical service upon request.
Manufacturer Products
Five Star Products, Inc. Five Star Highway Patch
Shelton, Connecticut 06484
203-336-7900
Other manufacturers may submit materials to the Design Engineer for approval
as allowed in Section 1.02.
2.02 MATERIALS
Rapid setting cement mortar shall be preblended, prepackaged materials
requiring only the addition of water, and meeting the following performance
criteria:
(a) Dimensional Stability – The typical length change after hardening shall be
less than +0.05% when tested according to ASTM C 157 as modified by
ASTM C 928.
(b) Bond Strength – The bond between repair materials and concrete shall be
at least 2,500 psi (17.2 MPa) in 7 days or the shear strength of the concrete,
whichever is less, when tested according to ASTM C 882 as modified in
ASTM C 928.
(c) Compressive Strength – The minimum compressive strengths when tested
according to ASTM C 109, as modified in ASTM C 928, shall be: 2000 psi
(13.8 MPa) at 2 hours, 4500 (31.0 MPa) at 24 hours.
(d) Compatibility – The coefficient of thermal expansion shall be less than 6.0 x
10-6 in/in/°F (10.8 x 10-5 mm/mm/°C) when tested according to ASTM C 531.
PART III – EXECUTION
3.01 EXAMINATION
(a) Inspect concrete surfaces to receive repair mortar and verify that they are
free of ice, frost, dirt grease, oil, curing compounds, paints, impregnations,
and all loose material or foreign matter likely to affect the bond or
performance of the repair material.
(b) Inspect all reinforcing steel for rust, oil, and other deleterious substances
that may affect the bond or performance of the repair material.
(c) Confirm that all surfaces are sufficiently rough to ensure good cement bond
that the concrete is structurally sound.
3.02 PREPARATION
(a) Roughen all concrete surfaces requiring additional surface preparation by
sandblasting, chipping, or other mechanical means to assure bond. Loose
or broken concrete shall be removed.

(800) 243-2206 • fivestarproducts.com 91

 A Professional’s Guide on Grouting and Concrete Repair

(b) All grease, oil, dirt, rust, curing compounds, laitance, and other deleterious
materials that were identified in the inspection process shall be completely
removed from the concrete and/or reinforcing steel.
(c) Forms for repair material shall be built of material with adequate strength
to withstand the placement of the material if forms are required.
(d) All concrete surfaces shall be thoroughly saturated and free of standing
excess water immediately prior to applying the repair material.
3.03 INSTALLATION
(a) The repair material shall be added to a premeasured amount of water that
does not exceed the manufacturer’s maximum recommended water content.
Retempering the repair material by adding more water after stiffening is not
permitted.
(b) Mix and place the repair material according to the manufacturer’s specific
installation guidelines.
(c) The manufacturer should be contacted for aggregate extension guidelines
when applicable.
3.04 CURING
(a) Protect repair material until initial set. Then immediately coat exposed
surfaces with an approved coating compound that meets the water retention
requirements of ASTM C 309. Alternatively, wet cure for a minimum of
three days.
(b) Equipment and tools shall be cleaned as recommended by the manufacturer.

92 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

CHAPTER 22
FIVE STAR FOUNDATION SYSTEMS®
INTRODUCTION
Building on currently existing, time tested products, FIVE STAR PRODUCTS, INC.
offers customers the materials either to create new equipment foundation systems
or to repair existing ones. Equipment installations for diesel or gas compressors,
HVAC equipment, turbines, generators, motor and pump assemblies, etc., are
generally placed on structural support foundations requiring precision alignment.
For this reason, the selection of the material to be used in the design of a strong and
sustainable foundation depends on the equipment operating parameters, including,
but not limited to, loading (static or dynamic), ambient operating temperature,
chemical environment, pour volume, and construction turnaround time.
SELECTING A FOUNDATION SYSTEM
To satisfy the requirements for rebuilding foundations for industrial machinery, and
for new installations, FIVE STAR PRODUCTS, INC. offers six different Foundation
Systems. Selecting an appropriate foundation system depends on the type of loading
(static: no movement, or dynamic: movement through impact loads or vibration)
and on the turnaround time available. Each foundation system is summarized in the
following pages, but architects and design engineers are invited to request a CD copy
of FIVE STAR PRODUCTS, INC.’s Design-A-Spec™ (DAS), a specification guide
that more fully describes them. DAS allows the architect, engineer or specifier to
edit each section as necessary and appropriate for an individual application.
MINIMUM DOWNTIME REGROUTING
FIVE STAR FOUNDATION SYSTEM 2 is a very successful method for regrouting
compressors and other vibrating equipment. Rather than waiting 7 to 10 days for
conventional materials to cure and gain strength, this system, using a high early
strength nonshrink epoxy grout, permits the equipment to be back in service within
10 hours at 73°F.
FIVE STAR FOUNDATION SYSTEM 2 can be used to rebuild existing bases or
to construct new ones whenever time is critical.

SELECTING A FOUNDATION SYSTEM

USING FIVE STAR® PRECISION NONSHRINK GROUTS
This table is a partial list of machinery and equipment types representing various load-
ing conditions, and the recommended grout component of the FIVE STAR PRODUCTS
Foundation Systems material directly under the machinery.  Depending on the operat-
ing parameters, multiple lift substrate foundation material can be either FIVE STAR
STRUCTURAL CONCRETE® ES or FIVE STAR® DP EPOXY GROUT.  Contact
FIVE STAR PRODUCTS, INC.’s Engineering and Technical Center at 203-336-7900
for assistance in selecting an appropriate Foundation System.

(800) 243-2206 • fivestarproducts.com 93

 A Professional’s Guide on Grouting and Concrete Repair

EQUIPMENT GROUT SELECTION CHART

  Nonshrink Nonshrink  
Type of Equipment Cement Grout Epoxy Grout Comments
Fast Turnaround:
Static Loads (4 hour start-up) A Five Star Instant Grout NR
Fast Turnaround:
Dynamic loads: (8 hr. start-up) A NR FS Rapid Epoxy
Pump Base Systems FSG or FSFG B FS DP Epoxy C Design Engineers Choice  
TMP & Pulp Refiners FSG or FSFG B FS DP Epoxy  Design Engineers Choice  
Reducers & Drivers NR FS DP Epoxy   
Steel Column Baseplates FSG or FSFG B Not Required  FSFG-100 required
for shear keys
Log Chippers NR FS DP Epoxy  
Paper Machine Track Baseplates FSG or FSFG B FS DP Epoxy Design Engineers Choice 
Stamping Process NR FS DP Epoxy
Forced or Induced Draft Fans NR FS DP Epoxy
Debarking Drums NR FS DP Epoxy
Bark Hogs NR FS DP Epoxy
Vibrating Screens NR FS DP Epoxy
Boiler Feedwater Pumps NR FS DP Epoxy
Thick Stock Pumps NR FS DP Epoxy
Lime Kiln FSG B NR  
Conveyors FSG or FSFG B Not Required 
Skid Mounted Equip. (static) FSG or FSFG B Not Required 
Skid Mounted Equip. (dynamic) NR FS DP Epoxy C
Reciprocating Compressors NR FS DP Epoxy C
Centrifugal Compressors FSG or FSFG B FS DP Epoxy Design Engineers
Choice  
Fan Blower Motors FSG or FSFG B FS DP Epoxy Design Engineers
Choice  
Brine Water Pump Five Star Special Grout 120 Not Required  
Temperatures ≥ 400˚F (200˚C):
Coke Drum Rings or Pit Five Star HTR Grout NR
Clinker Cooler Five Star HTR Grout NR
Absorber Vessel Five Star HTR Grout NR  
Turbine Generator FSG or FSFG B FS DP Epoxy  
Winder Baseplates NR FS DP Epoxy  
Steel Soleplates
(1) inch or greater clearance FSG   FS DP Epoxy Alternate is FS HP Epoxy  
1/2 inch or greater clearance FSFG B FS Rapid Epoxy Design Engineers
Choice  
Storage Tanks D FSG / FSFG B / FS DP or Rapid Consult with FS Technical
FSG HTR Grout Epoxy & Engineering Center
NR = Not Recommended
A. At 73°F (23°C).
B. FSG=Five Star Grout; FSFG=Five Star Fluid Grout 100.
C. Meets API 610 App. L.
D. Grout choice determined by storage material, storage temperature, storage environment, substrate material,
clearance to substrate, and pour volume.

94 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

FOUNDATION SYSTEM 1
SINGLE LIFT – CEMENTITIOUS

Key Application Features: New construction, static loads in a non-chemical

environment.

DESCRIPTION:
FIVE STAR FOUNDATION SYSTEM 1 consists of FIVE STAR GROUT, a non-
metallic, nonshrink grout extended with coarse aggregate up to 100% by weight. This
system is used to rebuild foundations and grout equipment in a single application,
enabling three day turnarounds. Large mass pours are facilitated by mixing bulk bags in
ready mix concrete trucks. The material may be poured or pumped into place.

TURNAROUND TIME: Three days.

EQUIPMENT BASEPLATE

FIVE STAR GROUT

EXISTING FOUNDATION

LIMITATIONS:
Not recommended for dynamic (impact/vibration) loads, chemical exposure, or high
temperature environments exceeding 400°F (204°C). There is no pour volume limit.

(800) 243-2206 • fivestarproducts.com 95

 A Professional’s Guide on Grouting and Concrete Repair

FOUNDATION SYSTEM 2
SINGLE LIFT – EPOXY

Key Application Features: New construction, dynamic loads in a chemical environment.

DESCRIPTION:
FIVE STAR FOUNDATION SYSTEM 2 consists of FIVE STAR DP EPOXY
GROUT, an expansive, nonshrink, low exotherm epoxy grout. This system achieves
both foundation repairs and equipment grouting in a single application. Its 90 minute
working time allows for deep pours to facilitate equipment rebuilds in 10 to 24 hours.
FIVE STAR FOUNDATION SYSTEM 2 is ideal for high impact or vibrating machinery
and for chemical environments.

TURNAROUND TIME: Ten hours when conditioned to between 75°F (24°C) and
85°F (29°C). Although FIVE STAR DP EPOXY GROUT Epoxy Grout can be poured
at temperatures as low as 50°F (10°C), flowability and strength gain are adversely
affected by temperatures below 65°F.

LIMITATIONS:
Not recommended for operating temperatures exceeding 180°F (82°C). Pour volume is
limited to five cubic yards.

96 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

FOUNDATION SYSTEM 3
MULTIPLE LIFT – CEMENTITIOUS

Key Application Features: Fast turnaround repair work, static loads in a non-chemical
environment.

DESCRIPTION:
Foundation System 3 consists of FIVE STAR STRUCTURAL CONCRETE ES
(Extended Set), concrete foundation repair material, capped with FIVE STAR
INSTANT GROUT, a nonshrink machinery grout for equipment support, to complete
a total equipment rebuild. FIVE STAR FOUNDATION SYSTEM 3 features one
component cementitious repair materials that are capable of aggregate extension up to
100% with adjustable working times. Ideal for small or large rebuilds requiring a fast
turnaround. For use with static, nonvibrating equipment.

TURNAROUND TIME: 12 to 36 hours depending on pour ambient temperature

conditions.

LIMITATIONS:
Not recommended for dynamic (impact/vibration) loads, chemical exposure, or high
temperature environments exceeding 400°F (204°C). Maximum pour volume is six
cubic yards.

(800) 243-2206 • fivestarproducts.com 97

 A Professional’s Guide on Grouting and Concrete Repair

FOUNDATION SYSTEM 4
MULTIPLE LIFT – EPOXY

Key Application Features: Fast turnaround rebuilds, dynamic loads in a chemical

environment

DESCRIPTION:
FIVE STAR FOUNDATION SYSTEM 4 consists of FIVE STAR DP EPOXY GROUT
as a foundation repair material capped with FIVE STAR RAPID EPOXY GROUT for
equipment support. FIVE STAR RAPID EPOXY GROUT, which achieves a 95%
Effective Bearing Area (EBA) may be used to maintain precision alignment of equipment
at elevated temperatures up to 250°F (121°C). FIVE STAR FOUNDATION SYSTEM
4 is ideal for high impact or vibrating equipment and in chemical environments.

TURNAROUND TIME: 12 hours at ambient temperatures between 65°F (18°C) and

75°F (24°C). Cooler temperatures, as low as 50°F (10°C), will reduce flowability and
strength gain while warmer temperatures, up to 90°F (32°C), will increase flowability
and strength gain.

LIMITATIONS:
Not recommended for operating temperatures exceeding 250°F (121°C) or in highly
corrosive chemical environments. Pour volume is limited to five cubic yards.

98 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

FOUNDATION SYSTEM 5
MULTIPLE LIFT – COMBINATION CEMENTITIOUS AND EPOXY

Key Application Features: High temperature environment, dynamic loads with

confined chemical exposure.

DESCRIPTION:
FIVE STAR FOUNDATION SYSTEM 5 consists of FIVE STAR STRUCTURAL
CONCRETE ES concrete repair material capped with FIVE STAR RAPID EPOXY
GROUT, a NONSHRINK epoxy machinery grout, for equipment support, to complete
a total equipment rebuild suitable for chemical environments and dynamic load
conditions. FIVE STAR FOUNDATION SYSTEM 5 features a one component
cement-based repair material capable of aggregate extension up to 100% with adjustable
working times. Capped with a nonshrink expansive epoxy grout, Five Star Foundation
System 5 is ideal for small or large foundation repairs and for dynamic loads and
vibrating equipment.

TURNAROUND TIME: 12 to 36 hours depending on pour ambient temperature

conditions.

LIMITATIONS:
Can be used in a chemical environment provided chemicals are contained or confined to
the epoxy grouted area. The maximum pour volume is six cubic yards.

(800) 243-2206 • fivestarproducts.com 99

 A Professional’s Guide on Grouting and Concrete Repair

FOUNDATION SYSTEM 6
MULTIPLE LIFT – COMBINATION CEMENTITIOUS AND EPOXY

Key Application Features: Large or small volume applications, dynamic loads with
confined chemical exposure, lowest material cost foundation system for dynamic load
conditions.

DESCRIPTION:
FIVE STAR FOUNDATION SYSTEM 6 consists of FIVE STAR STRUCTURAL
CONCRETE ES, concrete repair material, capped with FIVE STAR HP EPOXY
GROUT, a NONSHRINK, expansive epoxy grout for equipment support, to complete
a total equipment rebuild suitable for chemical environments and dynamic load
conditions. FIVE STAR FOUNDATION SYSTEM 6 features a one component cement
based repair material capable of 100% coarse aggregate extension with adjustable
working time. Capped with an expansive epoxy grout, FIVE STAR FOUNDATION
SYSTEM 6 is ideal for dynamic loads and vibrating equipment, and for small and large
foundation repairs.

TURNAROUND TIME: Up to three days depending on ambient cure temperature.

LIMITATIONS:
Not recommended for operating temperatures exceeding 180°F (82°C), or for chemical
environments, unless chemicals are contained or confined within the epoxy grouted area.
Maximum pour volume is six cubic yards.

100 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

TYPICAL INSTALLATION INSTRUCTIONS FOR 48 HOUR

TURNAROUND USING FOUNDATION SYSTEM 6
A. FOUNDATION - FIVE STAR STRUCTURAL CONCRETE® ES
1. SURFACE PREPARATION
a. Using mechanical roughening, remove all loose, unsound or cracked
concrete. Never use a jackhammer. Bush hammers are not recommended,
as they tend to loosen the aggregate in the concrete substrate, possibly
resulting in failure under the bond line.
b. Sandblast existing reinforcing bars in the chipped out area.
c. If the base or foundation does not contain reinforcing bars, a “cage” should
be assembled and put in place.
d. Wet the existing concrete with saturated rags or sponge foam while forms
are being constructed. This will save substrate preconditioning saturation
time.
2. FORMING
a. Construct all forms watertight. Wrap forms with polyethylene sheets or
treat form with a release agent for easy form removal.
b. Forms must be built and supported to withstand rodding and/or vibration of
the rapid setting cementitious material.
3. MIXING
a. A mortar mixer (with moving blades) is recommended for mixing.
b. The mixer should be thoroughly washed out with potable water and all
excess water drained out prior to mixing.
c. Water used to mix the FIVE STAR STRUCTURAL CONCRETE ES
must be potable. Always begin with the minimum amount of water printed
on the package. Add the measured amount of water into the mixer. If
additional water is required, do not exceed maximum amount on container.
d. Add ingredients to the mortar mixer in the following sequence:
• Potable water
• SUMMERSET, if used in hot weather (cold or ice water is an alternative)
• FIVE STAR STRUCTURAL CONCRETE ES
• Clean, washed coarse aggregate per ASTM C 33
e. Mix for a minimum of five minutes.
f. Add only enough of the remaining water to reach the desired consistency.
g. Do not add more than the maximum amount of water specified on the
package.
4. PLACEMENT
a. Placements up to 1 ft deep may require coarse aggregate extension of up to
80% by weight with 3/8 inch clean, washed coarse aggregate, depending
on the mass of the pour and on ambient temperature conditions.
b. Placements of 1 ft to 3 ft deep will require coarse aggregate extension of
up to 100% by weight of clean, washed coarse aggregate. Mix as directed

(800) 243-2206 • fivestarproducts.com 101

 A Professional’s Guide on Grouting and Concrete Repair

under “Mixing”, and place in a single lift. Rod or vibrate to ensure proper
consolidation and bond with the concrete base. Excessive vibration can
cause segregation. Since all pours are not alike, consult the manufacturer
for additional details.
c. When using FIVE STAR DP EPOXY GROUT as the grout cap, leave at
least 2 inches of clearance between the lift of FIVE STAR STRUCTURAL
CONCRETE ES and the baseplate for a pour of up to two feet wide.
Generally, 1/2 inch of additional clearance should be allowed for each
additional foot of flow distance up to 8 ft for temperatures between 69°F
(20.6°C) and 78°F (25.6°C). For temperatures between 55°F (12.8°C) and
68°F (20°C), increase the clearance by 3/4 inch. For temperatures between
79°F (26.1°C) and 90°F (32.2°C), the clearance should be increased by only
/ inch as the flowability at higher ambient temperatures is greater. Skid-
1 4

mounted equipment can be grouted with somewhat smaller clearances.

d. Moist cure FIVE STAR STRUCTURAL CONCRETE ES according to the
manufacturer’s recommendations to prevent rapid drying. Allow an unfin-
ished rough surface lift of FIVE STAR STRUCTURAL CONCRETE
ES to dry after moist curing before installing FIVE STAR DP EPOXY
GROUT.

B. GROUT CAP - FIVE STAR DP EPOXY GROUT

1. SURFACE PREPARATION
The lift surface of FIVE STAR STRUCTURAL CONCRETE ES must be clean
and dry before placing FIVE STAR DP EPOXY GROUT. If the FIVE STAR
STRUCTURAL CONCRETE ES surface was not rough raked after initial set,
it should be mechanically roughened and cleaned before receiving epoxy grout.
2. FORMING
If forms for FIVE STAR STRUCTURAL CONCRETE ES were not carried
high enough to permit the placement of FIVE STAR DP EPOXY GROUT,
erect a new form to contain the FIVE STAR DP EPOXY GROUT. It must be
liquid tight and have chamfer strips built in. Set the height of the chamfer strips
at the bottom (contact) surface of the plate or skid.
3. EPOXY CHOICE
a. FIVE STAR DP EPOXY GROUT
Provides an average compressive strength of 6,000 psi (41.4 MPa) in 16
hours, 11,000 psi (75.9 MPa) in 24 hours and increases to 14,000 psi (96.6
MPa) in 7 days.
b. FIVE STAR RAPID EPOXY GROUT – QUICK START UP GROUT:
For a shorter turnaround time, specify FIVE STAR RAPID EPOXY
GROUT. This epoxy system provides 8,000 psi (55.2 MPa) in only 8 hours
at 73°F (23°C) and increases to 15,000 psi (103.5 MPa) in 7 days.

102 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair
4. MIXING
a. FIVE STAR DP EPOXY GROUT:
Pour all of Component B (Hardener) into the pail containing Component A
(Resin). Mix slowly but thoroughly by hand or low speed mixer to avoid
air entrapment. Pour all of the mixed material into a mortar mixer. Add
Five Star Epoxy Aggregate one bag at a time. Start the first batch at 4
bags of aggregate instead of 5 bags to wet the mixer. Mix only until all
aggregate is wetted and no dry pockets remain. Follow printed instructions
ach package.
b. FIVE STAR RAPID EPOXY GROUT
This product is packaged in a seven-gallon pail that contains all three
components. Remove the containers of liquid and the bag of aggregate.
Pour the contents of liquid containers into the now empty seven-gallon
pail. Mix these liquids with a slow speed (maximum 250 rpm) electric
drill, fitted with a mixing paddle, until no streaks of unmixed liquids are
obvious. Empty the contents of the aggregate bag into the mixed liquids
and continue mixing until all aggregate is wetted and a smooth, pourable
grout is obtained. Do not over mix. FIVE STAR RAPID EPOXY GROUT
is a rapid setting material and must be mixed and placed within 30 minutes
at 73°F (23°C). Turn the mixer off before withdrawing the mixing blade to
avoid air entrapment.
5. PLACING
Immediately after mixing FIVE STAR DP EPOXY GROUT, place the grout
without delay from one side of the form to the other. Additional batches should
be mixed and placed quickly to avoid blockages and cold joints.
6. CURING
FIVE STAR DP EPOXY GROUT does not require any curing and will reach
6,000 psi (41.4 MPa) within 16 hours at 75°F (23°C). This is adequate to put
most equipment back in operation. Forms may be stripped as soon as FIVE
STAR DP EPOXY GROUT has stiffened enough to prevent sagging.

(800) 243-2206 • fivestarproducts.com 103

 A Professional’s Guide on Grouting and Concrete Repair

APPENDIX A
ANCHOR BOLT GROUTING - INTRODUCTION
Anchor bolt grouting accounts for a large number of applications relative to both the
construction and industrial machinery grouting industry and must be addressed, as it is
very important in connection with a successful installation. Precision grouting always
includes the need to ensure the installation is completely secured and stable. This is
of special concern when the equipment is subjected to dynamic (vibration or impact)
loads created during operation.
FIVE STAR PRODUCTS, INC. offers the following general application and
installation guidelines to help owners/developers, architects, engineers, specifiers, and
contractors engaged in this work to better understand the technical issues associated
with the equipment operating environment. These issues, if not properly addressed,
can make the difference between a successful or an unsuccessful installation.
FIVE STAR PRODUCTS, INC. highly recommends a visit to our website at
fivestarproducts.com to obtain current product information, newly available products,
and technical support.
Grout Selection Process
In working with architects, engineers and contractors on grouting applications, the
frequency of questions related to grouting generally follow a pattern as noted below
and which will be individually addressed in the sections to follow:
1. What type of anchoring grout should be used? Cementitious or epoxy based?
2. What product does Five Star recommend for the application at hand?
3. What size (diameter) should the grout hole be?
4. Is there information available on how to calculate embedded length requirements in
cementitious based grouts or alternatively, epoxy based grouts?
5. Are there guidelines available on how to install these grouts?
Product Recommendation
FIVE STAR PRODUCTS, INC. has several different grout products, each of which has
performance and placement characteristics suitable to the application. Because there
are many variables that would impact the appropriate selection, and in the interest of
helping ensure the correct selection, FIVE STAR PRODUCTS ENGINEERING AND
TECHNICAL CENTER (203-336-7900) is available to offer assistance. However, it is
the responsibility of the “Design or Project Engineer” on which product is ultimately
selected for any application. Product warranties are limited to those as stated on each
of FIVE STAR PRODUCTS, INC. product data sheets.
Helpful Information
A product selection chart and technical support information on anchoring placement
using cementitious or epoxy grout is provided on the following pages to help facilitate
the selection and installation process.

104 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

ANCHOR GROUTING WITH FIVE STAR® GROUT

TOTAL LOAD
Pounds at Pullout or Bar Failures
(Designers should allow a factor of safety.)

MODERATE STRENGTH STEEL – YIELD STRENGTH – 80,000 psi

Reinforcing Bar
Bar Diameter Plain Bar (Deformed) Threaded Bar

One Foot Embedment

1/4” 3,930 3,930 3,930
1/2” 15,700 15,700 15,700
3/4” 28,200 35,400 35,400
1” 37,700 56,500 62,900

Five Foot Embedment

1” 62,900 62,900 62,900
1-1/2” 141,500 141,500 141,500
2” 252,000 252,000 252,000
3” 565,000 565,000 565,000

Ten Foot Embedment

1” 62,900 62,900 62,900
2” 252,000 252,000 252,000
3” 565,000 565,000 565,000
4” 1,005,000 1,005,000 1,005,000

HIGH STRENGTH STEEL – YIELD STRENGTH – 135,000 psi

Ten Foot Embedment
2” 424,000 424,000 424,000
3” 955,000 955,000 955,000
4” 1,505,000 1,700,000 1,700,000
5” 1,880,000 2,650,000 2,650,000

(800) 243-2206 • fivestarproducts.com 105

 A Professional’s Guide on Grouting and Concrete Repair

106 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

ANCHOR BOLT GROUTING

CEMENT GROUT
Surface Preparation
Bolts: Free of oil, grease and rust. Preferably sandblasted to a “bright metal” Note 2
surface condition.
Holes: A. Dry drilled holes shall be cleaned of dust and debris.
B. Wet drilled holes shall be cleaned of drilling slurry.
C. Formed and/or core drilled holes shall be scarified to roughen anchor hole
surface.
D. Concrete shall be saturated with water for 24 hours prior to grouting.
E. Standing water shall be removed immediately prior to grouting.
Dimensions
The dimensions called for are designed to eliminate the possibility of a grout failure.
A concrete or steel failure is still possible. Therefore, if the concrete is designed to
withstand maximum steel tension, the bolt/bar will be the governing design factor.
(i.e., failure due to cone mechanism is eliminated due to reinforced concrete or
because of baseplate.)
L = Length of EmbedmentNote 1
D = Diameter of Hole
d = Diameter of Bolt/Bar
fy = Yield Strength of Bolt/Bar
C = Bolt/Bar Shape Factor

C = 1.0 for Smooth Bolt/Bar

C = 1.5 for Deformed Bolt/Bar
C = 2.0 for Threaded Bolt/Bar

NOTES:
1. The length of embedment “L” was developed with information provided through ACI 318-99 & ACI
349.2R-97 (design requirements for steel embedments); anchoring in concrete.
2.2. SSPC-SP6: Joint Surface Preparation Standard for Commercial Blast Cleaning; Document Number:
NACE No. 3 - per the NATIONAL ASSOCIATION OF CORROSION ENGINEERS, October 1994:
Commercial blast cleaned surface is defined as one in which all oil, grease, dirt, mill scale, rust and
old paint have been completely removed from the blast cleaned surface, except that slight streaks,
or discolorations caused by rust stain, mill scale oxides, or slight tightly adherent residues of paint or
coating may remain. If the surface is pitted, slight residues of rust or paint may remain in the bottom of
the pits. The slight discolorations mentioned above are limited to one-third of every square inch.

(800) 243-2206 • fivestarproducts.com 107

 A Professional’s Guide on Grouting and Concrete Repair

Length of Embedment

Based on shear/bond strength of 1000psi:

1000 psiNote 3 x C x πdL = 1/4 πd 2 fy

Solving for L: minimum L = fy d ÷ [4000 x C]

Therefore: With fy = 80,000 psi (moderate strength steel):

minimum L = 20d for Smooth Bolt/Bar

minimum L = 15d for Deformed Bolt/Bar
minimum L = 10d for Threaded Bolt/Bar

With fy = 135,000psi (high strength steel):

minimum L = 34d for Smooth Bolt/Bar

minimum L = 23d for Deformed Bolt/Bar
minimum L = 16d for Threaded Bolt/Bar

Hole Diameter

The diameters called for are minimum diameters. The requirements will ensure an
adequate size bonding surface between grout and concrete. Larger dimensions may
ease placement on top or awkward pours.

When bolt diameter d ≤ 1.0 in, then hole diameter shall be a minimum of 2 in.
When bolt diameter d > 1.0 in, then hole diameter shall be a minimum 2d.

NOTES:
3. The value 1000 psi is 1/2 the average bond strength of FIVE STAR PRODUCTS, INC. precision
nonshrink cementitious grouts per ASTM C 882 at 28 days and is adjusted upwards to the fully
available average bond strength (2000 psi) through “C” above based on anchor bolt surface roughness
to ensure concrete cone failure or bolt tension failure BEFORE grout failure occurs. In the application
as illustrated with an anchored base plate, only bolt tension failure can occur.

108 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

ANCHOR BOLT GROUTING

EPOXY GROUT
Surface Preparation
Bolts: Free of oil, grease and rust. Preferably sandblasted to a “bright metal” Note 2
surface condition.
Holes: A. Dry drilled holes shall be cleaned of dust and debris.
B. Wet drilled holes shall be cleaned of drilling slurry.
C. Formed and/or core drilled holes shall be scarified to roughen anchor hole
surface.
D. Standing water shall be removed and anchor hole surfaces completely dry.

Dimensions
The dimensions called for are designed to eliminate the possibility of a grout failure.
A concrete or steel failure is still possible. Therefore, if the concrete is designed to
withstand maximum steel tension, the bolt/bar will be the governing design factor.
(i.e., failure due to cone mechanism is eliminated due to reinforced concrete or
because of baseplate.)
L = Length of EmbedmentNote 1 [See diagram on next page]
D = Diameter of Hole
d = Diameter of Bolt/Bar
fy = Yield Strength of Bolt/Bar
C = Bolt/Bar Shape Factor
S = Factor of Safety [Epoxy grout bears a different
relationship to steel surfaces
C = 1.5 for Smooth Bolt/Bar than cement grout.]
C = 2.0 for Deformed Bolt/Bar
C = 2.5 for Threaded Bolt/Bar

Because of the unique nature of a properly prepared steel surface (in accordance with
SSPC-SP6, Steel Structure Painting Council:Note 2 to bond to epoxy grout in a much
stronger fashion than a similar bond to concrete, the value of “C” as shown above is
modified to reflect that uniqueness.
NOTES:
1. As the behavior of epoxy based grouts are similar to cementitious based grouts, the length of embedment “L”
was developed with information provided through ACI 318-99 & ACI 349.2R-97 (design requirements for steel
embedments); anchoring in concrete.
2. SSPC-SP6: Joint Surface Preparation Standard for Commercial Blast Cleaning; Document Number: NACE No.
3 - per the NATIONAL ASSOCIATION OF CORROSION ENGINEERS, October 1994:
Commercial blast cleaned surface is defined as one in which all oil, grease, dirt, mill scale, rust and old paint have
been completely removed from the blast cleaned surface, except that slight streaks, or discolorations caused by rust
stain, mill scale oxides, or slight tightly adherent residues of paint or coating may remain. If the surface is pitted,
slight residues of rust or paint may remain in the bottom of the pits. The slight discolorations mentioned above are
limited to one-third of every square inch.

(800) 243-2206 • fivestarproducts.com 109

 A Professional’s Guide on Grouting and Concrete Repair

Length of Embedment

Using:
1000 psiNote 1 x C x π d L = 1/4 π d 2 fy; where π = 3.1415

Solving for L: minimum L = f y d ÷ [4000 x C]

Therefore: With f y = 135,000 psi (high strength steel):

minimum L = 22.6d for Smooth Bolt/Bar

minimum L = 17.0d for Deformed Bolt/Bar
minimum L = 13.6d for Threaded Bolt/Bar

Hole Diameter

The diameters called for are minimum diameters. The requirements will ensure
an adequate size bonding surface between grout and concrete. Larger dimensions
may ease placement on deep or awkward pours.

When bolt diameter d ≤ 11/2 in, the minimum hole diameter shall be d + 11/2 in.
When bolt diameter d > 11/2 in, the minimum hole diameter shall be d + 2 in.

NOTES:
1. The value 1000 psi is 1/2 the average bond strength of FIVE STAR PRODUCTS, INC. precision
nonshrink cementitious grouts per ASTM C 882 at 28 days and is adjusted upwards to the fully
available average bond strength (2000 psi) through “C” above based on anchor bolt surface
roughness to ensure concrete cone failure or bolt tension failure BEFORE grout failure occurs. In
the application as illustrated with an anchored base plate, only bolt tension failure can occur.

110 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

INSTALLATION GUIDELINES
ANCHOR BOLT LOCATION
EDGE DISTANCE AND CENTER TO CENTER DISTANCE
Determining the location of the grout hole relative to the foundation edges is especially
important when larger bolts are employed for tensioning without a baseplate.
Assuming the appropriate embedment length has been established, to assure maximum
available resistance to tension loads and avoid concrete cone failure, a minimum of
twelve (12) bolt diameters from any edge and twenty four (24) bolt diameters between
bolt center lines is suggested. The design engineer has the final authority on this.

AVOIDING EDGE LIFTING

Because of the difference in the coefficients of thermal expansion (COTE) between
cementitious and epoxy based concrete, large transient temperature differences (as with
equipment operating outdoors during seasonal changes) can cause separation at the outer
edges of the bond line between a cementitious substrate and epoxy grout. Therefore,
during the equipment foundation design phase, it is recommended that the foundation
shoulder width (W) always be less than the proposed grout clearance depth (D).

Equipment
12 d
W

Baseplate

Epoxy Grout D

d = bolt diameter
Concrete Foundation

D>W

(800) 243-2206 • fivestarproducts.com 111

 A Professional’s Guide on Grouting and Concrete Repair

Please refer to FIVE STAR PRODUCTS, INC. product specific data sheets
(downloadable in Adobe Acrobat® PDF file format) for product information and
installation instructions and/or fill out a request form at fivestarproducts.com to
receive more detailed instructions available through our “Design-A-Spec®” (DAS)
document. The DAS is both a specification and detailed installation instruction
document, and is highly recommended for architects, engineers, specifiers, and
contractors to help ensure the design, development, and installation of a successful
project. Additional information or clarifications may be obtained by contacting the
FIVE STAR TECHNICAL AND ENGINEERING CENTER by e-mail through
info@fivestarproducts.com or by calling (203) 336-7900.

112 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

APPENDIX B
GLOSSARY
ACI American Concrete Institute
PO Box 9094, Farmington Hills MI 48333

ASTM American Society for Testing Materials

100 Barr Harbor Drive, West Conshohocken PA 19428

DIMENSIONAL STABILITY
Resistance to excessive shrinkage or expansion in the plastic
or hardened state.

EFFECTIVE BEARING AREA (EBA)

The portion, expressed as a percent, of the total area of a base plate
that is in actual physical contact with the grout beneath it and is
available to transfer compressive loads.
GROUT A mixture of cementitious material and water, with or without
aggregate, proportioned to produce a pourable consistency
without segregation of the constituents. Also, a mixture of other
composition but of similar consistency.
ICRI concrete industry association devoted to repair and restoration,
publishes a magazine and technical guidelines for concrete repair,
and co-sponsors the World of Concrete. Worldwide membership
include contractors, manufacturers, engineers, distributors, owners
and other professionals with a common goal: prolonging the useful
life of concrete through quality repair, restoration, and protection.

MACHINE-BASE GROUT
A grout used in the space between plates or between a machinery
base and the underlying foundation and which is expected to
maintain essentially complete contact with the base and to maintain
uniform support.

NONSHRINK GROUT
A hydraulic cement grout that includes a shrinkage-compensating
mechanism to produce a volume that, when hardened under
stipulated conditions, is greater than or equal to the original installed
volume.

PRECISION NONSHRINK GROUT

A grout whose vertical height change is never less than the vertical
height at the time of placement and no more than 4.0% in the plastic
state and no more than 0.3% in the hardened state. There is no
plastic or hardened vertical shrinkage at any time.

(800) 243-2206 • fivestarproducts.com 113

 A Professional’s Guide on Grouting and Concrete Repair

APPENDIX C
COMMON CONVERSION FACTORS

Multiply By To Get
inches [in] 2.54 centimeters [cm]
feet [ft] 0.3048 meters [m]
mils 1000 inches [in]
cubic inches [cu in] [in3] 16.39 cubic centimeters [cc] [cm3]
cubic inches [cu in] [in3] 16.39 millimeters [ml]
cubic feet [cu ft] [ft3] 28.31 liters [l]
liters [L] 33.81 fluid ounces [fl oz]
cubic feet [cu ft] [ft3] 7.48 gallons [gal]
cubic feet [cu ft] [ft3] 1728 cubic inches [cu in] [in3]
cubic meters [m3] 35.31 cubic feet [cu ft] [ft3]
cubic meters [m3] 1,308 cubic yards [cy] [yd3]
cubic yards [cy] [yd3] 27 cubic feet [cu ft] [ft3]
square feet [sq ft] [ft2] 144 square inches [sq in] [in2]
square inches [sq in] [in2] 6.452 square centimeters [sq cm] [cm2]
square yards [sq yd] [yd2] 9 square feet [sq ft] [ft2]
square meters [sq m] [m2] 1.196 square yards [sq yd] [yd2]
square meters [sq m] [m2] 10.76 square feet [sq ft] [ft2]
megapascals [MPa] 145.0 pounds/square inch [psi] [lb/in2]
kilograms/square centimeter 14.22 pounds/square inch [psi] [lb/in2]
kips/square inch [ksi] [kip/in2] 6.895 megapascals [MPa]
kips/square inch [ksi] [kip/in2] 1000 pounds/square inch [psi] [lb/in2]
pounds (force or weight) [lb] 4.448 newtons [N]
tons (metric tons) [t] 2205 pounds (force or weight) [lb]
ounces (force or weight) [oz] 28.35 grams [g]
degrees Centigrade [°C] 1.8 degrees Fahrenheit -32 [°F]
degrees Fahrenheit -32 [°F] 0.555 degrees Centigrade [°C]
quarts [qt] 0.9466 liters [l]
quarts [qt] 2 pints [pt]
gallons [gal] 4 quarts [qt]
cubic feet of water (at 4°C) 62.43 pounds [lb]
gallons of water 8.33 pounds [lb]

To Get By Divide

114 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

APPENDIX D
BULK SACK MIXING PROCEDURES
1. Ready-Mix Concrete Truck - Extended
A. Verify working time of grout and water requirements under job site conditions
before placement in concrete truck.
B. Mixing drum and mixing blades must be in good operating condition, pre-
dampened and excess water removed.
C. First add clean, damp, coarse aggregate meeting the requirements of ASTM C 33
to drum.
D. Add approximately 75% of premeasured potable water to mixing drum as pre-
determined by testing. Five gallons of this 75% shall be held back for hopper wash
down. Water addition must be adjusted if wet aggregate is used or water is present
in the drum.
E. Add grout, with drum turning at a slow speed. Do not exceed half the capacity
of drum or add more than 3 bulk bags per truck. Use the 5 gallons (19 liters) of
held back water to wash down hopper and drum after loading. Mix thoroughly for
approximately five minutes at slow speed to a uniform consistency.
F. Reverse drum to check consistency. Add remaining water as needed, then mix to
a uniform consistency. Do not exceed maximum allowable water content as stated
on product packaging or add an amount that will cause segregation. Small bags of
grout should be available to stiffen consistency if necessary.
G. Position truck as close as possible to pour and promptly discharge from truck.
When transporting mixed grout, take care not to allow grout to segregate.
2. Ready-Mix Concrete Truck - Neat
A. Verify working time of grout and water requirements under job site conditions
before placement into concrete truck.
B. Mixing drum and mixing blades must be in good operating condition, pre-
dampened and excess water removed.
C. Add approximately 75% of premeasured potable water to mixing drum as
predetermined by testing. Five gallons of this 75% shall be held back for hopper
wash down. Water addition must be adjusted if wet aggregate is used or water is
present in the drum.
D. Add grout with drum turning at slow speed. Do not exceed half the capacity of the
drum or add more than 3 bulk bags per truck. Use the 5 gallons (19 liters) of held
back water to wash down the hopper and drum after loading.
E. Continue mixing at slow speed for 70 – 100 revolutions.
F. Reverse drum to check consistency. Add remaining water as needed, then mix to
a uniform consistency. Do not exceed maximum allowable water content as stated
on product packaging or add an amount that will cause segregation. Small bags of
product should be available to stiffen consistency if necessary.
G. Position truck as close as possible to pour and promptly discharge from truck.
REFERENCES: ACI 351.1R-93 “Grouting for Support of Equipment and Machinery”
PCA 1990 “Cementitious Grouts and Grouting”

(800) 243-2206 • fivestarproducts.com 115

 A Professional’s Guide on Grouting and Concrete Repair

APPENDIX E: MIX WATER REQUIREMENTS, MEASURED IN QUARTS

+ Only add that amount of water necessary to achieve a 20-30 second flow / ASTM C 939

116 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

APPENDIX E: MIX WATER REQUIREMENTS, MEASURED IN QUARTS

(800) 243-2206 • fivestarproducts.com 117

 A Professional’s Guide on Grouting and Concrete Repair

NOTES:
Project Name:

Date:
Product:

Water/Aggregate:

Project Name:

Date:
Product:

Water/Aggregate:

Project Name:

Date:
Product:

Water/Aggregate:

Project Name:

Date:
Product:

Water/Aggregate:

Project Name:

Date:
Product:

Water/Aggregate:

118 (800) 243-2206 • fivestarproducts.com

 A Professional’s Guide on Grouting and Concrete Repair

NOTES:
Project Name:

Date:
Product:

Water/Aggregate:

Project Name:

Date:
Product:

Water/Aggregate:

Project Name:

Date:
Product:

Water/Aggregate:

Project Name:

Date:
Product:

Water/Aggregate:

Project Name:

Date:
Product:

Water/Aggregate:

(800) 243-2206 • fivestarproducts.com 119

 A Professional’s Guide on Grouting and Concrete Repair

NOTES:
Project Name:

Date:
Product:

Water/Aggregate:

Project Name:

Date:
Product:

Water/Aggregate:

Project Name:

Date:
Product:

Water/Aggregate:

Project Name:

Date:
Product:

Water/Aggregate:

Project Name:

Date:
Product:

Water/Aggregate:

120 (800) 243-2206 • fivestarproducts.com

Cement Grouts • Epoxy Grouts • Foundation Systems
Concrete Repair / Overlays • Coatings / Waterproofing
Adhesives
Engineered Products Distributed Worldwide

FIVE STAR PRODUCTS, INC.

60 Parrott Drive
Shelton, CT 06484
Support: (800) 243.2206
FiveStarProducts.com

© 2012-2019 Five Star Products, Inc. | 031612