EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
STEEAMS TO 61/ETV Program Water Quality Protection Center
TEST PLAN FOR VERIFICATION OF SSCI GROUT
FOR INFR^TRUCTURl REHABUJTATION
Original signed by Chuck Slack
Mr. Chuck Slack
Separation Systems Consultants, Inc.
Primary Contact
Phone:281-797-2713
Fax: 281-486-7415
Original signed by C. Vipulanandan
Dr. C, Vipulanandan /
University of Houston^- CIOMAT
Project Manager
Phone: 713-743-4278
Fax; 713-743-4260
Original signed by Thomas Stevens ^
Thomas Stevcnrf
NSF International
Project Manager, WQPC Center
Phone: 734-769-5347
Fax: 734-769-5195
Original signed by Raymond Frederick
Raymonjf Frederick
U.S. EPA
Pmject Officer, WQPC Center
Phone: 732-321-6627
Fax: 732-321-6640
Original signed by Richard Marinsha*
kichafd Marinshaw
RTI International
Project Manager,
Phone: 919-316-3735
Fax: 919-316-3420
SSCI Grout Test Plan - v3.2
9/14/2009
Page 1 of41
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
TEST PLAN FOR VERIFICATION OF SSCI GROUT
FOR INFRASTRUCTURE REHABILITATION
Prepared for:
RTI International
P.O. Box 12194
Research Triangle Park, NC 27709-2194
and
NSF International
P.O. box 130140
Ann Arbor, MI 48113-0140
With support from the
U.S. Environmental Protection Agency
Prepared by:
C. Vipulanandan, Ph.D., P.E.
Center for Innovative Grouting Materials and Technology (CIGMAT)
University of Houston
Houston, TX 77204-4003
713-743-4278
SSCI Grout Test Plan - v3.2 Page 2 of 41
9/14/2009
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
Foreword
Starting in Fiscal Year 2007, the U.S. Environmental Protection Agency's (EPA) Office of
Research and Development (ORD) has been supporting a new research program to generate the
science and engineering to improve and evaluate promising innovative technologies and
techniques to reduce the cost and improve the effectiveness of operation, maintenance, and
replacement of aging and failing drinking water and wastewater treatment and conveyance
systems. This research program directly supports the Agency's Sustainable Water Infrastructure
Initiative (www.epa.gov/waterinfrastructure).
The outputs from this program will assist EPA's program and regional offices, states and tribes
to meet their programmatic requirements and utilities to more effectively implement
comprehensive asset management, provide reliable service to their customers, and meet their
Clean Water Act and Safe Drinking Water Act requirements.
The plan proposes, in part, work relating to demonstration and verification of condition
assessment, system rehabilitation, advanced concepts and innovative treatment technologies.
Proposed activities to be conducted as part of this task order address the field verification of
condition assessment and rehabilitation technologies for drinking water distribution systems and
wastewater collection systems.
Condition assessment encompasses the collection of data and information through direct
inspection, observation and investigation and in-direct monitoring and reporting (soil conditions
and historical data), and the analysis of the data and information to make a determination of the
structural, operational and performance status of capital infrastructure assets. Research issues in
this area relate to the collection of reliable data and information and the ability of utilities to
make technically sound judgments as to the condition of their assets. Condition assessment also
includes the practice of failure analysis which seeks to determine the causes of infrastructure
failures in order to prevent future failures.
System rehabilitation is the application of infrastructure repair, renewal and replacement
technologies in an effort to return functionality to a drinking water or wastewater system or sub-
system. The decision-making process for determining the proper balance of repair, renewal and
replacement is a function of the condition assessment, the life-cycle cost of the various
rehabilitation options, and the related risk reductions.
SSCI Grout Test Plan - v3.2 Page 3 of 41
9/14/2009
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
Acknowledgements
EPA and NSF International acknowledge those persons who participated in the preparation,
review and approval of the protocol that provided the basis for this Test Plan. Without their hard
work and dedication to the project, this document would not have been approved through the
process that has been set forth for this ETV project.
Author:
Dr. C. Vipulanandan, Director of CIGMAT - Center for Innovative Grouting Materials and
Technology, University of Houston
Technical Panel Reviewers:
J. Jeffery Fordice, P.E.
Assistant City Engineer
City of Saline, Michigan
Ahmad Habibian, Ph.D., P.E.
Black & Veatch
Phil Hannan, P.E.
Black & Veatch
Steve Henning
Avanti International
SSCI Grout Test Plan - v3.2 Page 4 of 41
9/14/2009
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
Table of Contents
Foreword 3
Table of Contents 5
Acronyms 8
Glossary of Terms 9
1.1 Background (University of Houston Study) 11
1.2 Technical Approach 11
1.3 Test Plan Schedule and Milestones 11
1.4 Roles and Responsibilities 12
1.4.1 Verification Organization (VO - RTI International and NSF International) 12
1.4.2 U.S. Environmental Protection Agency (EPA) 12
1.4.3 Technology Panel 13
1.4.4 Testing Organization (TO - CIGMAT Laboratories at UH) 13
1.4.5 Vendor (Separation Systems Consultants, Inc.) 14
2 Test Facility 15
3 Experimental Design 16
3.1 Grout Evaluation 16
3.1.1 Grout Specimen Preparation 19
3.1.1.1 Grout Specimens 19
3.1.2 Grout Curing Properties 20
3.1.2.1 Viscosity 20
3.1.2.2 Setting (Gel) Time 20
3.1.3 Physical and Mechanical Properties 20
3.1.3.1 Unit Weight (Density) 20
3.1.3.2 Water Absorption 20
3.1.3.3 Shrinkage 21
3.1.3.4 Permeability 21
3.1.3.5 Unconfmed Compressive Strength and Stress/Strain Relationship 21
3.1.3.6 Tension Tests 22
3.1.4 Durability Properties 22
3.1.4.1 Wet/Dry Cycle 22
3.1.4.2 Chemical Resistance 22
3.1.5 Environmental Properties—Leaching Test 23
3.2 Grout-Substrate Bonding Strength 23
3.2.1 Cylinder Bonding (CIGMAT GR 5-00) 24
3.2.2 Concrete Prism Bonding (CIGMAT CT 3-00) 24
3.2.3 Wet/Dry Cycle 24
3.3 Model Tests 24
3.3.1 Model Test 4: Concrete Leak Repair 24
3.3.2 Model Test Procedures 26
4 Sampling and Analytical Procedures 27
5 Quality Assurance Plan 28
5.1 Quality Assurance Responsibilities 28
5.2 Data Quality Indicators 28
5.2.1 Representativeness 28
SSCI Grout Test Plan - v3.2 Page 5 of 41
9/14/2009
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
5.2.2 Completeness 29
5.2.3 Precision 29
5.2.4 Accuracy 30
5.2.5 Measurements 31
5.2.6 Analytical Quality Control 31
6 Data Reporting, Data Reduction, and Data Validation 32
6.1 Data Documentation 32
6.2 Data Reduction 32
6.3 Data Validation 32
6.4 Verification Report 33
7 Assessments 34
7.1 Audit Reports 34
7.2 Corrective Action Plan 34
8 Safety Considerations 35
9 References 36
SSCI Grout Test Plan - v3.2 Page 6 of 41
9/14/2009
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
Figures
Figure 3-1. Typical molds used for preparing grout specimens 19
Figure 3-2. Model configuration for testing concrete leak repair (Model Test 4) 25
Tables
Table 3-1. Grout Tests for Concrete Repair for Leak Control 17
Table 3-2. Grout-Substrate Interaction Tests 18
Table 3-3. Shrinkage Test Conditions 21
Table 4-1. Handling Methods and Analyses for Collected Samples 27
Table 4-2. Scheduled Instrument QC Checks and Corrective Actions for Analytical Methods .. 27
Table 5-1. Summary of Analytical Accuracy and Precision Limits 31
SSCI Grout Test Plan - v3.2 Page 7 of 41
9/14/2009
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
ASTM
CIGMAT
EPA
ETV
NSF
ORD
QA
T/QAP
QC
RTI
TO
UH
VO
WQPC
Acronyms
ASTM International
Center for Innovative Grouting Materials and Technology
United States Environmental Protection Agency
Environmental Technology Verification
NSF International
Office of Research and Development
quality assurance
Test/quality assurance plan
quality control
RTI International
Testing organization
University of Houston
Verification organization
Water Quality Protection Center
SSCI Grout Test Plan - v3.2
9/14/2009
Page 8 of41
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
Glossary of Terms
Accuracy—A measure of the closeness of an individual measurement or the average of a
number of measurements to the true value and includes random error and systematic error.
Batch—The number of samples analyzed during a period in which an instrument was operated
continuously.
Bias—The systematic or persistent distortion of a measurement process that causes errors in one
direction.
Comparability—A qualitative term that expresses confidence that two data sets can contribute
to a common analysis and interpolation.
Completeness—A qualitative term that expresses confidence that all necessary data have been
included.
Precision—A measure of the agreement between replicate measurements of the same property
made under similar conditions.
Representativeness—A measure of the degree to which data accurately and precisely reflect a
characteristic of a population parameter at a sampling point, or for a process or environmental
condition.
Room Temperature—23°C ±2°C and relative humidity of 50% ±5%. This definition of room
temperature shall be used for all testing even if a referenced SOP or standard defines the term
differently.
Standard Operating Procedure—A written document containing specific procedures and
protocols to ensure that quality assurance requirements are maintained.
STREAMS - The Scientific, Technical, Research, Engineering and Modeling Support
(STREAMS) contract by the U.S. Environmental Protection Agency's Office of Research and
Development (ORD).
Technology Panel—A group of individuals with expertise and knowledge in grouts.
Test Plan—A written document that describes the procedures for conducting an evaluation for
the application of a grout material; the quality assurance project plan is an important part of the
test plan.
Test/Quality Assurance Plan—A written document that describes the implementation of
quality assurance and quality control activities during the life cycle of the project.
Verification—To establish the evidence on the performance of grouts under specific conditions,
following a predetermined test plan.
SSCI Grout Test Plan - v3.2 Page 9 of 41
9/14/2009
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
Verification Report—A written document containing all raw and analyzed data, all QA/QC
data sheets, descriptions of all collected data, a detailed description of all procedures and
methods used in the verification testing, and all QA/QC results. The test plan shall be included as
part of this document.
Verification Statement—A document that summarizes the verification report reviewed and
approve by the Verification Organization and EPA.
SSCI Grout Test Plan - v3.2 Page 10 of 41
9/14/2009
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
1 INTRODUCTION
1.1 Background (University of Houston Study)
University of Houston (UH)/CIGMAT researchers have been investigating the performance of
various grouts for use in wastewater facilities for over two decades. Grouts can be used for
controlling leaks in the wastewater facilities and repairing the cracked concrete. The CIGMAT
studies have been focused on (1) testing and characterizing the flow properties and setting time
of cement and polymer grouts, (2) behavior under various chemical exposure, and (3) bonding
strength of concrete repairing grout materials.
1.2 Technical Approach
The overall objective of this test plan is to develop a testing program to systematically evaluate
grouts for controlling infiltration to wastewater systems and leaks in concrete structures. Specific
test plan objectives are to:
• Evaluate properties (working, physical, mechanical, durability, and leaching) of grouts;
• Characterize the bonding properties of the grout-substrate interaction; and
• Verify the performance of grouted joints and repaired concrete cracks under hydrostatic
pressure up to 5 psi (about 10 feet of water) and wet/dry cycles over a period of one
month.
Testing will use relevant ASTM and CIGMAT standards. A total of 10 different tests will
characterize the grouts (Table 3-1), and several additional tests will evaluate grout-substrate
interaction (Table 3-2). Model test will be used to evaluate grout effectiveness for concrete repair
for leak control. All CIGMAT standard methods referenced herein are included in Appendix A.
1.3 Test Plan Schedule and Milestones
The tests described herein will be completed within six months from the start date. The data will
be compiled and summarized in a report to RTI International within two months of the
conclusion of testing.
CIGMAT will meet the following approximate schedule:
Activity
Months after Project Initiation
Submit draft test plans to RTI and NSF
Approve test plans
Initiate testing
Complete testing
Submit draft report, with data to RTI and
NSF
Address comments, complete final report
1
2
3
9
11
13
SSCI Grout Test Plan - v3.2
9/14/2009
Page 11 of 41
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
1.4 Roles and Responsibilities
This section defines the participants in this technology verification and their roles and
responsibilities.
1.4.1 Verification Organization (VO - RTI International and NSF International)
• Coordinate with CIGMAT, the Testing Organization (TO), and the Vendor to prepare and
approve a product-specific test plan;
• Coordinate with the ETV Grouting Technical Panel, as needed, to review the product-
specific test plan prior to the initiation of verification testing;
• Coordinate with the EPA Water Quality Protection Center (WQPC) Project Officer to
approve the product-specific test plan prior to the initiation of verification testing;
• Review the quality systems of the TO and qualify the TO to complete the testing;
• Oversee the grouts evaluations and associated laboratory testing;
• Review data generated during verification testing;
• Oversee the development of a verification report and verification statement;
• Print and distribute the verification report and verification statement; and
• Provide quality assurance oversight at all stages of the verification process.
Primary contacts: Mr. Richard Marinshaw
RTI International
3040 Cornwallis Road
Research Triangle Park, NC 27709
Phone: 919-316-3735
Email: rjmarinshaw@rti.org
Mr. Thomas Stevens
NSF International
789 North Dixboro Road
Ann Arbor, MI 48105
Phone: 734-769-5347
Email: stevenst@nsf.org
1.4.2 U.S. Environmental Protection Agency (EPA)
This test plan has been developed with financial and quality assurance assistance from the US
EPA through a STREAMS contract, and through the ETV and WQPC Programs, all of which are
overseen by the EPA's Office of Research and Development (ORD), National Risk Management
Research Laboratory - Urban Watershed Management Branch (NRMRL-UWMB) in Edison, NJ.
The NRMRL-UWMB Quality Assurance Manager and the EPASTREAMS/WQPC Project
Officer will provide administrative, technical, and quality assurance guidance and oversight on
all STREAMS and ETV WQPC activities, and will review and approve each phase of the
verification project. The primary responsibilities of EPA personnel are to:
SSCI Grout Test Plan - v3.2 Page 12 of 41
9/14/2009
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
• Review and approve test plans;
• Sign the test plan signoff sheet;
• Review and approve the verification report and verification statement; and
• Post the verification report and verification statement on the EPA ETV website.
Primary contact: Mr. Ray Frederick
U.S. Environmental Protection Agency, NRMRL
Project Officer, Water Quality Protection Center
2890 Woodbridge Ave. (MS-104)
Edison, New Jersey 08837
Phone: 732-321-6627
Email: frederick.ray@epamail.epa.gov
1.4.3 Technology Panel
A Technology Panel was formed to assist with the review of the grouting test plan. Input from
the panel ensures that data generated during verification testing are relevant and that the method
of evaluating different technologies is fair and consistent. All product-specific grout test plans
may be subject to review by representatives of the Technology Panel.
1.4.4 Testing Organization (TO - CIGMAT Laboratories at UH)
The TO for verifications conducted under this test plan is CIGMAT Laboratories at the
University of Houston. The primary responsibilities of the TO are:
• Coordinate with the VO and Vendor relative to preparing and finalizing the test plan;
• Sign the test plan signoff sheet;
• Conduct the technology verification in accordance with the test plan, with oversight by
the VO;
• Analyze all samples collected during the technology verification process, in accordance
with the procedures outlined in the test plan and referenced SOPs;
• Coordinate with and report to the VO during the technology verification process;
• Provide analytical results of the technology verification to the VO; and
• If necessary, document changes in plans for testing and analysis, and notify the VO of
any and all such changes before changes are executed.
CIGMAT supports faculty, research fellows, research assistants and technicians. The CIGMAT
personnel will work in groups to complete the tests described in this test plan. All the personnel
report to the Group Leader and the CIGMAT Director. The CIGMAT Director is responsible for
appointing Group Leaders, who, with his approval, are responsible for drawing up the schedule
for testing. Additionally, a Quality Assurance (QA) Engineer, who is independent of the testing
program, will be responsible for internal audits.
Primary contact: Dr. C. Vipulanandan
University of Houston, CIGMAT
4800 Calhoun
SSCI Grout Test Plan - v3.2 Page 13 of 41
9/14/2009
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
Houston, Texas 77204-4003
Phone: 713-743-4278
Email: cvipulanandan@uh.edu
1.4.5 Vendor (Separation Systems Consultants, Inc.)
• Provide the TO with pre-grout samples for verification;
• Complete a product data sheet prior to testing (refer to Appendix B);
• Apply grout, as described in this test plan, for the model tests; and
• Provide technical assistance to the TO during verification testing period as requested.
Primary contact: Mr. Chuck Slack
Separation Systems Consultants, Inc.
17041 El Camino Real, Suite 200
Houston, TX 77058
Phone: 281-797-2713
Email: cslack@sscienvironmental.com
SSCI Grout Test Plan - v3.2 Page 14 of 41
9/14/2009
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
2 TEST FACILITY
The testing will be performed in the CIGMAT Laboratories at the University of Houston,
Houston, Texas. The CIGMAT Laboratories are located in the Central Campus of UH at 4800
Calhoun Road (off interstate highway 1-45 South toward Galveston).
The CIGMAT laboratories and affiliated facilities are equipped with devices that can perform all
of the grouting tests in this test plan. Molds are available to prepare the specimens for testing,
and all the grout and grout-substrate interaction test procedures are documented in standard
operating procedures.
SSCI Grout Test Plan - v3.2 Page 15 of 41
9/14/2009
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
3 EXPERIMENTAL DESIGN
This testing program for grouting materials will evaluate the performance and characteristics of
grouts in three different testing phases:
• The physical properties of the grout will be tested by utilizing test specimens created by
the TO;
• The interaction of the grout and substrate will be tested by TO application of the grout to
test substrate material (concrete) and completion of a series of performance tests; and
• Model tests, where grout applied by the Vendor to a laboratory-simulated concrete crack
and tests are conducted to evaluate the grout for leak control.
Testing details are provided in the following sections.
3.1 Grout Evaluation
Properties of the neat resin (unsolidified grout) and grout specimen samples to be tested can be
grouped as:
• Working properties (resin/grout mix);
• Physical and mechanical properties (grout specimens);
• Durability properties (grout specimens); and
• Leachability (grout specimens).
The properties to be tested are summarized in Tables 3-1 and 3-2. The physical property
evaluation tests consist of making grout specimens, subjecting the specimens to a particular test,
and measuring the results. For tests where the procedures have been developed by the American
Society of Testing and Materials (ASTM), the ASTM test procedure will be used. Where no
ASTM test procedures exist, CIGMAT has developed testing protocols that will be used. Where
applicable, the ASTM and CIGMAT testing procedures are referenced in the following sections.
The CIGMAT procedures are included in Appendix A of this protocol.
SSCI Grout Test Plan - v3.2 Page 16 of 41
9/14/2009
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
Table 3-1. Grout Tests for Concrete Repair for Leak Control
Properties Tests
Working
Properties
Physical and
Mechanical
Properties
Durability
Properties
Environmental
Properties
Viscosity
Setting (Gel) Time
Unit Weight
Water Absorption
Shrinkage
Permeability
Compressive Strength
Wet-Dry Cycle
Chemical
Resistance
Leaching
Conditions
Room temperature
Room temperature
Room temperature
Room temperature
23°C±2°C, 90%t5% RH
Water
3, 7, 28 days
Number of cycles
pH = 2, 7, 10
Water
Leak Control
Test Method to be Application
Used _ . _ .
Concrete Repair
CIGMAT GR 6-02
ASTM C 191-04 (cement-
based) or method defined
in 3. 1.2.1.2 (chem.)
CIGMAT GR 1-00
CIGMAT GR 3-00
Method defined in 3 . 1 .3 .3
CIGMAT GR 7-02
CIGMAT GR 2-02
CIGMAT GR 3-00
CIGMAT CH 2-01
Method defined in 3 . 1 .5
X
X
X
X
X
X
X
X
X
X
Number of
Specimens or Tests
o
J
6
3
3
o
J
3
9
3
9
3
SSCI Grout Test Plan - v3.2
9/14/2009
Page 17 of 41
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
Table 3-2. Grout-Substrate Interaction Tests
Materials
Tests
Conditions
Test Method to be Used
Leak Control Applications
Concrete Repair
Number of
Tests
GROUT-SUBSTRATE INTERACTION
Bonding
Strength
Wet condition
Wet-dry cycle
Concrete, cured under
water
Number of cycles CIGMAT GR 3 -00
CIGMAT GR 5-00 or CIGMAT CT 3-00
X
X
12
3
SSCI Grout Test Plan - v3.2
9/14/2009
Page 18 of 41
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
3.1.1 Grout Specimen Preparation
3.1.1.1 Grout Specimens
Figure 3-1 shows the molds that will be utilized to make the test specimens based on the type of
grout. After solidification, specimens shall be removed from the mold and stored in labeled,
sealed plastic bags for identification, protection, and to prevent moisture loss. Specimens to be
cured under water shall be completely submerged in a water bath of tap water at room
temperature. If the specimen floats, a small amount offeree will be applied to keep it submerged.
The specimens shall be stored in a temperature- and humidity-controlled room at 23 ± 2°C (room
temperature) and 50% ± 5% humidity.
PVC
Model
Rubber
Stopper
Grout
1.5 in.
4.5 in.
(a) Chemical/Cement Grouts
•Upper Plate
Load Cell
Upper Cap
Teflon Mold
Steel Sleeve
Cylinder
Thermocouple
Lower Cap
Lower Plate
(b) Polyurethane Grouts
Figure 3-1. Typical molds used for preparing grout specimens.
SSCI Grout Test Plan - v3.2
9/14/2009
Page 19 of 41
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
3.1.2 Grout Curing Properties
3.1.2.1 Viscosity
Grout viscosity will be evaluated using the procedures described in this section. Grout viscosity
will be evaluated using a procedure outlined in CIGMAT GR 6-02. Using a cylindrical spindle-
type viscometer (Brookfield Viscometer with 8 speeds, LVT model with four spindles or
equivalent), the initial viscosity and changes in viscosity during the gelling process shall be
measured at room temperature at selected strain rates (up to 180 sec"1). The specific strain rates
at which viscosity will be measured shall be determined in advance of testing by the TO, with the
consent of the vendor. Once the material performs consistently at different viscometer speeds,
the test shall be complete. A minimum of three replicate tests shall be conducted.
3.1.2.2 Setting (Gel) Time
Grout setting or gel time will be evaluated using the procedures described in this section. The
gel time for the grouts shall be determined by the elapsed time from grout preparation until the
grout no longer flows from a plastic cup or beaker inclined slowly (so that if the cup/beaker were
filled with liquid, the surface of the liquid would remain level) to 45°. Approximately 50 mL of
freshly prepared grout shall be poured into a container. The analyst shall tilt the cup to 45° to
horizontal and record the time for the grout to gel, as indicated by it no longer exhibiting liquid
flow properties and no longer flows from the container. A total of six replicates of each grout
shall be analyzed.
3.1.3 Physical and Mechanical Properties
To obtain initial characterization information on the grout specimens, all specimens shall be
weighed to 0.1 g using a calibrated digital balance and measured (diameter and height) using a
vernier caliper with a least count of 0.1 mm. Measurements shall be taken at the top, middle, and
bottom of the specimen, with two measurements taken at 90 degrees from each other at each
location to obtain consistent data.
3.1.3.1 Unit Weight (Density)
Solidified grout specimens shall be used to determine the unit weight (density) of the grout. The
determination shall be completed per CIGMAT GR 1-00 for both grout and grouted sand
specimens. Unit weight shall be calculated using the weight and volume of the specimens. A
minimum of three replicates will be evaluated for unit weight. Based on the unit weight, the
grout shall be reported as lighter or heavier than water.
3.1.3.2 Water Absorption
Water absorption characteristics shall be evaluated on grout specimens as outlined in standard
procedure CIGMAT 3-00. A minimum of three solidified grout specimens shall be immersed in
tap water (initial pH in the range of 7 to 8) and changes in weight and volume (determined by
SSCI Grout Test Plan - v3.2 Page 20 of 41
9/14/2009
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
measuring specimen diameter and height) of the specimens shall be recorded a minimum of once
every working day (Monday through Friday, excluding holidays) until the changes in weight and
volume become negligible (less than 0.5 percent of the previous weight and volume), or for one
week, whichever occurs first. The report for this testing shall include the time of immersion, the
initial characteristics of the specimens, the weight and volume change with time, water
absorption as a percentage of the initial weight, and volume of grout.
3.1.3.3 Shrinkage
The Vendor selected 23°C for this test to be completed, representing a climate between the
extremes indicated in the Protocol (10°C and 27°C). At the onset of the test, specimens shall be
prepared in a mold with inner dimensions of 1.5 in. (38 mm) in diameter and 3.5 in. (90 mm) in
length. Three specimens shall be tested under the selected test conditions. The specimens shall be
placed in zip lock bags and kept at conditions indicated in Table 3-3. Humidity will be measured
using a digital humidity meter. The weight and dimensions of the specimens shall be reported
before and after 28 days of conditioning.
Table 3-3. Shrinkage Test Conditions
Parts Temperature, Duration, and Storage Condition
Part C 23°C ± 2°C for 28 days in zip lock bags (RH = 90%+ 5%)
3.1.3.4 Permeability
Solidified grout specimens shall be used to determine their permeability. Specimens shall be
prepared in 1.5-in. diameter Plexiglas/glass cylinders and permeated with water under a
hydraulic gradient of 100, per CIGMAT GR 7-02. Testing shall be completed at room
temperature and humidity. A minimum of three replicate tests shall be run on the grout
specimens. The report for this testing shall include the temperature and humidity at which testing
was completed, any changes in the specimens during the testing, and the permeability obtained
during the testing.
3.1.3.5 Unconfined Compressive Strength and Stress/Strain Relationship
CIGMAT GR 2-02 has been developed for testing grouts in compression under monotonically
increasing load (load increasing linearly). Compression tests shall be performed using screw-type
machines with capacities up to 5,000 Ibs. Specimens shall be loaded at specified rates based on
the type of grout and the loading rate may be determined based on trial tests conducted outside of
this testing. Specimens shall be tested in duplicates at intervals of 3 and 28 days following
specimen preparation, as described in CIGMAT GR 2-02. The reported data shall include
compressive strength, modulus and failure strain, where the modulus is determined from the
initial slope of the stress/strain relationship and the failure strain is the maximum loading point
before the specimen fails.
SSCI Grout Test Plan - v3.2 Page 21 of 41
9/14/2009
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
3.1.3.6 Tension Tests
The tension test indicated in the Protocol will not be completed during this verification, as the
bonding test (described in Section 3.2) will provide the information regarding the grout's ability
to withstand tensile loading. The key performance indicator for the grout material under tension
is to show it does not fail before the bond with the substrate, which will be determined during the
bonding test.
3.1.4 Durability Properties
3.1.4.1 Wet/Dry Cycle
During its service life, the grout could be subjected to a number of wet/dry cycles. This test is
designed to determine the impact of repeated wetting and drying on the performance of grouts. A
minimum of three replicate specimens shall be used for this test. The specimens shall be
subjected to 10 wet/dry cycles for a total test time of 140 days, or until failure (unconsolidation).
One wet/dry cycle shall be 14 days in duration, consisting of 7 days of water exposure followed
by 7 days of dry conditions at room temperature and humidity (23 + 2°C and 50% + 5% RH).
The water exposures shall be completed as described in Section 11 of CIGMAT GR 3-00, using
tap water having a pH between 7 and 8. Changes in length, diameter, weight, and volume of the
specimens shall be measured daily per Sections 9 and 11 of CIGMAT GR 3-00. At the end of the
10-wet/dry cycles, specimens shall be tested to determine the compressive strengths of the grout,
as described in sections 3.1.3.5. The reported data shall include weight and dimension data
collected for the specimens, as well as the data to be reported described in sections 3.1.3.5.
3.1.4.2 Chemical Resistance
This test will evaluate the resistance of grouts when exposed to chemical conditions representing
various sand and groundwater environments. The test results will help when selecting suitable
grouts for use in various chemical environments. Cylindrical grout specimens shall be prepared
as described in Section 3.1.1.1, and the initial weight, dimensions, color, and surface appearance
of the specimens shall be recorded. Three specimens at each pH shall be fully immersed in
solutions with pH 2, 7, and 10 maintained at room temperature (23 + 2°C) for the entire exposure
period. The solutions shall consist of tap water with hydrochloric acid or sodium hydroxide
added to achieve the pH required for the tests. The weight, volume, color, and surface
appearance of the specimens shall be determined and recorded for three specimens at each pH
after 30, 90, and 180 days, as described in Section 7.3 in CIGMAT CH 2-01. The pH, clarity,
and color of the exposure solution shall also be recorded at each evaluation time. During the
evaluation, if the pH changes by more than ± 2 units, additional hydrochloric acid or sodium
hydroxide shall be added to the solution to return it to its original pH. The analyst shall note in
the project logbook the quantity of chemical and revised pH during each adjustment. After each
evaluation, compression testing shall be completed for the specimens in accordance with Section
7.4 of CIGMAT CH 2-01. All data and observations shall be reported, along with the
calculations described in sections 8.1, 8.3, and 8.4 of CIGMAT CH 2-01. The appearance of
specimens and immersion solutions shall be reported as described in sections 9.2 and 9.3 of
CIGMAT CH 2-01.
SSCI Grout Test Plan - v3.2 Page 22 of 41
9/14/2009
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
3.1.5 Environmental Properties—Leaching Test
Potential contaminant leaching from solidified grout shall be determined by analyzing water
exposed to the grout. The protocol calls for analysis of the exposure water for total organic
carbon (TOC) and lead. Lead is an issue only with inorganic materials, which is not the case with
the polyurethane grout in this test. Subsequently, the exposure water will be evaluated only for
TOC. A minimum of three test replicates, using cylindrical grout specimens, will be prepared as
described in Section 3.1.1.1. The specimens will be immersed in three individual exposure jars,
each containing tap water (pH = 8 ± 0.5; TOC < 1 mg/L). One blank container containing only
the exposure water shall be prepared and held under the same conditions as the specimen
exposure jars. The exposure jars and blank jar will be held at room temperature for seven days.
The test shall be conducted with grout specimens and water volume so that there is an adequate
volume of exposure water to conduct the required analyses. A liquid-to-solid ratio of 1:1 (by
volume) will be used./ If a different liquid-to-solid ratio is used, it shall be reported in the
verification report.
At the beginning and end of the exposure period, samples of the exposure water will be analyzed
to determine the presence of organic compounds that have leached from the grout. The samples
will be analyzed for TOC.
The water in the blank container shall be sampled at the beginning and end of the exposure
period, and analyzed for the same constituents as the grout specimen exposure water. This will
provide a baseline concentration of constituents in the tap water.
Details of the analytical methods, required sample volumes, and sample holding are provided in
Section 4.
3.2 Grout-Substrate Bonding Strength
Interaction between the grout and a concrete substrate shall be evaluated by testing the bonding
strength and type of failure (bonding failure, substrate failure, or a combination) under different
service conditions, as specified in sections 3.2.1 through 3.2.3. Testing of wet grout/concrete
substrate specimens shall be conducted over a period of six months in accordance with CIGMAT
GR 5-00 (where two cylinders are bonded with grout) or CIGMAT CT 3-00 (where the area
between concrete prisms is grouted), as selected by the vendor prior to the ETV verification. In
addition, bonded configurations prepared according to either CIGMAT GR 5-00 or CIGMAT CT
3-00 shall be subjected to wet/dry cycle testing, as described in Section 3.1.4.1.
SSCI Grout Test Plan - v3.2 Page 23 of 41
9/14/2009
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
3.2.1 Cylinder Bonding (CIGMAT GR 5-00)
This test configuration may be used to determine the bonding strength of various grout materials
(15,23). The test consists of sandwiching a layer of grout between flat surfaces of concrete (the
ends of concrete cylinders) and then loading the test specimen in tension. Details of specimen
preparation are in CIGMAT GR 5-00. The Grout-Rock Test outlined in Section 7.2 of CIGMAT
GR 5-00 will not be conducted as part of this testing. The reported data shall include all collected
data, the bonding strength, and the type of bonding failure.
3.2.2 Concrete Prism Bonding (CIGMAT CT 3-00)
Although CIGMAT CT 3-00 was developed for coating materials, it may be adopted for grouts.
As described in CIGMAT CT 3-00, the grout shall be sandwiched between a pair of rectangular
concrete prism specimens and then tested for bonding strength and type of failure. Even though
CIGMAT CT 3-00 specifies the use of dry prisms, for the purposes of ETV testing, wet
specimens shall be used to simulate extreme grouting conditions. The bonded wet specimens
shall be immersed in water until testing begins. The reported data shall include the number of
specimens tested, age of specimen at time of test, average bond strength, standard deviation and
type of failure.
3.2.3 Wet/Dry Cycle
During its service life, a grouted concrete joint could be subjected to a number of wet/dry cycles.
Hence, each bonded configuration will be tested for performance by subjecting it to 10 wet and
dry cycles, where one wet/dry cycle takes 14 days, for a total test time of 140 days, or until
failure. Following the wet/dry cycles, a minimum of three test specimens shall be retested to
determine the bonding strength, following methods in Section 3.2.2.
3.3 Model Tests
The model test is to simulate field conditions. Vendor has selected Model Test 4 for Concrete
Repair for this verification.
3.3.1 Model Test 4: Concrete Leak Repair
In order to simulate a leak in a concrete structure, this model test (Figure 3-2) shall use 10 in (25
cm) diameter circular concrete disks with 6 in (15 cm) openings at the center (so that each disk is
donut shaped). As a default, the two disks shall be placed 1 inch apart and grouted by the vendor.
The vendor may, however, select the opening size. The grouted joint shall be subjected to
hydrostatic pressure testing to determine the leak rate, as detailed in 3.3.5.
Procedure for preparing the concrete leak repair joint for Model Test 4:
• The gap between the concrete rings on the testing rig shall be one inch.
• The vendor shall apply the grout in the gap in accordance with the vendor's standard
procedures.
SSCI Grout Test Plan - v3.2 Page 24 of 41
9/14/2009
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
After the grout has cured, testing will commence using the procedures outlined in Section
Supporter
i
Concrete Ring steel Pipe
1"
a) Elevation View
Grout
10'
b) Plan View
Figure 3-2. Model configuration for testing concrete leak repair (Model Test 4).
SSCI Grout Test Plan - v3.2
9/14/2009
Page 25 of 41
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
3.3.2 Model Test Procedures
The testing procedure will be conducted in duplicate. The grout shall be applied by the vendor.
CIGMAT personnel shall supervise the grouting procedures and pictures shall be taken of the
joint/concrete disks prior to and after grouting. The time elapsed and volume of grout used
during the grouting process shall be recorded. During the grouting of the simulated crack, at least
ten grout samples shall be collected to test the setting time (Section 3.1.2.2), unit weight (Section
3.1.3.1), and compressive properties (Section 3.1.3.5) of the grouts. These analyses are in
addition to those specified in Section 3.1.
Once the grouted crack is cured per the manufacturer's instructions, they shall be subjected to the
following regimen:
1. Apply hydrostatic pressure of 3 psi and hold for 5 minutes; then measure the leak rate
using a graduated cylinder and a stopwatch.
2. Repeat Step 1 at a hydrostatic pressure of 4 psi.
3. Repeat Step 1 at a hydrostatic pressure of 5 psi.
4. Maintain saturated conditions for a period of one week. In model test 4, soak the joint
with water for a week.
5. Drain all water from the test chambers and allow them to stand for one week.
6. Repeat Step 4.
7. Repeat Step 5.
8. Determine leak rates as described in steps 1 through 3 after a month of test.
SSCI Grout Test Plan - v3.2 Page 26 of 41
9/14/2009
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
4 SAMPLING AND ANALYTICAL PROCEDURES
Verification of grouts under ETV primarily consists of physical tests performed on prepared
specimens as described in Chapter 3, "Experimental Design." The outlined procedures identify
the sampling locations and frequency required for each test.
Further sample preparation and analysis is required only for the leaching test, which is outlined
in Section 3.1.5. Exposure water samples will be collected and analyzed for TOC. Other analyses
may be conducted based on the chemical composition of the tested grout. The exposure water
samples shall be representative grab samples collected from the exposure jar.
The sample handling, analysis and reporting shall be as outlined in Table 4-1.
Table 4-1. Handling Methods and Analyses for Collected Samples
Analysis Method l Bottle Type and Size
Preservation,
Holding Time
Reporting
Detection Limit
TOC
SM5310
(B or C)
Glass, two 40-mL
bottles
Cool to 4°C, pH<2
s, six months
1 mg/L
1 Standard Methods for the Examination of Water and Wastewater, 20th Edition.
Samples shall be delivered to the analytical laboratory following appropriate chain of custody
procedures, including use of chain of custody forms. Samples shall be logged in and refrigerated
by the laboratory, as described in Table 4-1.
Table 4-2 describes the specific QC checks required for the analytical methods for TOC used in
this project. These checks shall determine when corrective action is needed.
Table 4-2. Scheduled Instrument QC Checks and Corrective Actions for Analytical
Methods
QC Procedure
Frequency
Acceptance Criteria
Corrective Action
Calibration curve Every batch
Analyze standard Every batch
Matrix spike
Analyze blank
(deionized water)
Every batch
Every batch
±10% of known sample
±10% of known sample
80-120% recovery of spike
Not to exceed detection
level.
Find cause, repair, rerun before
sample analysis
Find cause, repair, rerun before
sample analysis
Find cause, repair, rerun previous
samples
Find cause, repair, rerun before
sample analysis
SSCI Grout Test Plan - v3.2
9/14/2009
Page 27 of 41
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
5 QUALITY ASSURANCE PLAN
This section specifies procedures that shall be used to ensure data quality and integrity arising
from the testing. Careful adherence to these procedures will ensure that the data generated from
the testing will provide sound analytical results that will indicate the true performance of the
grout, and form the basis for the report on the testing.
5.1 Quality Assurance Responsibilities
The TO, in preparing the test plan, shall be responsible for ensuring that the test plan and the
QAPP properly implement the requirements of this test plan. The VO is responsible for review of
the test plan to assure that all elements required by this test plan are properly addressed.
During testing, the TO shall be responsible for assuring that the elements contained in the test
plan are complied with. Written or electronic records shall be maintained for calibrations, sample
collection, and data manipulation. In grout testing, sources of error may include instrumentation
drift or miscalibration; variations in the grout, sand, and/or substrate; systematic bias of
measurements; and/or intrinsically inaccurate instruments. The quality of reference
measurements is ensured by frequent instrumentation calibration in accordance with the
manufacturer's instructions. The TO shall maintain documentation of instrument calibration.
5.2 Data Quality Indicators
The data obtained during verification testing must be sound for accurate conclusions to be
drawn. For all measurement and monitoring activities conducted for grout verification, the VO
and EPA require that the data quality parameters be established based on the proposed end-users
of the data. Data quality parameters include four indicators of data quality: representativeness,
completeness, precision, and accuracy.
5.2.1 Representativeness
Representativeness refers to the degree to which data accurately and precisely reflect the
conditions or characteristics of the parameters and will be ensured by consistent data acquisition
and sample collection (including sample numbering, timing of sample collection, sampling
procedures, sample preservation, sample packaging, and sample shipping). Using each method at
its optimal capability to provide the most accurate and precise measurements possible will also
ensure representativeness. Representativeness also implies collecting sufficient data during each
operation to be able to detect changes in operation. The following actions will be taken to
achieve this:
Test Materials:
• Test Concrete: The test concrete batch shall be rejected if the unit weight and/or water
absorption properties exceed ±20% of the mean values.
SSCI Grout Test Plan - v3.2 Page 28 of 41
9/14/2009
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
Laboratory Conditions:
• Temperature and Humidity: For those tests where temperature and humidity
requirements are specified, temperature and humidity readings shall be recorded daily to
ensure that laboratory conditions have not changed.
Equipment:
• Proper operation: This shall be verified every morning of active testing.
5.2.2 Completeness
Completeness refers to the amount of data collected from a measurement process compared to
the expected amount to be obtained. For this test plan, completeness refers to the proportion of
valid, acceptable data generated using each method. The completeness objective for data
generated following this test plan is 85%, as calculated by Equation 5-1.
(n \
Completeness = vaM and acceptMe x 100 (5-1)
I "total )
5.2.3 Precision
Precision refers to the degree of mutual agreement among individual measurements and provides
an estimate of random error. Analytical precision is a measurement of how far an individual
measurement may deviate from a mean of replicate measurements. Precision is evaluated from
analysis of field and laboratory duplicates and spiked duplicates. Duplicates will be collected at a
frequency of one duplicate for every ten samples collected for the laboratory analyses discussed
in Chapter 4. The laboratory will run duplicate samples as part of its QA program. The data
quality objective for precision is based on the type of analysis performed.
The standard deviation (SD), relative standard deviation (RSD), and/or relative percent
difference (RPD) recorded from sample analyses are ways to quantify precision. SD is calculated
by:
Standard Deviation = ,
Where:
x = sample mean
x; = /'th data point
n = number of data points
SSCI Grout Test Plan - v3.2 Page 29 of 41
9/14/2009
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
Relative percent difference (RPD) is calculated by:
C -C
*~i *-:
RPD =
=-^- x 100% (5-3)
C
\ /
Where:
Cv = Concentration of the compound or element in the sample
C2 = Concentration of the compound or element in the duplicate
C = Arithmetic mean of the sample and the duplicate
As specified in Standard Methods (Method 1030-C), precision is specified by the standard
deviation of the results of replicate analyses. For the various tests to be conducted by CIGMAT
at its testing facility, precision will be measured by performing duplicate tests and evaluating the
resultant data by calculating the SD, RSD, and RPD. Tables 3-1, 3-2 and 4-1 provide the
required number of duplicate tests for the various testing methods.
In situations where the testing procedures specify precision objectives (such as ASTM or
Standard Methods), the specific precision objectives must be achieved in order for the test to be
considered valid. For other situations where specific precision objectives are not required, the
precision values shall be reported in the verification report.
5.2.4 Accuracy
For measurements that will be recorded as part of this study, accuracy refers to the difference
between the measured reading and an established reference. In order to report accuracy, the
instruments used during testing shall be calibrated as required by the analytical method, and the
calibration records, which are maintained as a hard copy maintained in the laboratory, shall be
made available.
Spiking a sample matrix with a known amount of a constituent and measuring the recovery
obtained in the analysis is a method of determining accuracy. Using laboratory performance
samples with a known concentration in a specific matrix can also monitor the accuracy of an
analytical method for measuring a constituent in a given matrix. Accuracy is usually expressed
as the percent recovery of a compound from a sample. The following equation will be used to
calculate percent recovery:
Percent Recovery = [(AT-A; ) / As ] x 100 (5-4)
Where:
AT = Total amount measured in the spiked sample
A; = Amount measured in the un-spiked sample
As = Spiked amount added to the sample
SSCI Grout Test Plan - v3.2 Page 30 of 41
9/14/2009
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
During verification testing, the laboratory will run matrix spike samples at a frequency of one
spiked sample for every 10 samples analyzed. The laboratory will also analyze liquid and solid
samples of known concentration as lab control samples.
5.2.5 Measurements
Leaks in the model tests will be measured accurate to ± 2 mL. The weight and dimension during
the grout tests will be measured to an accuracy of 0.1 g and 0.1 mm, respectively. The unit
weight and strength will be measured to an accuracy of 0.5 Ib/ft3 and 2 psi, respectively.
5.2.6 Analytical Quality Control
The quality control procedures for blanks, spikes, duplicates, calibration of equipment, standards,
reference check samples and other quality control measurements will follow the guidance of
EPA methods and CIGMAT SOPs. Table 5-1 shows the quality control limits that will be used
by the laboratory for these analyses to ensure compliance with the data quality indicators for
accuracy and precision. Field and laboratory duplicate analyses will be performed at a frequency
of one duplicate per ten samples collected. Samples will be spiked for accuracy determination at
a frequency of one per 10 samples analyzed by the laboratory. Accuracy and precision will be
calculated for all data using the equations presented in sections 5.2.2 and 5.2.3.
Table 5-1. Summary of Analytical Accuracy and Precision Limits
Analysis Accuracy (% recovery) Precision (RPD)
TOC 80-120 0-20
Note: If additional analytical parameters are added to the testing procedures, accuracy
and precision limits shall be specified in the test plan.
RPD: Relative percent difference
SSCI Grout Test Plan - v3.2 Page 31 of 41
9/14/2009
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
6 DATA REPORTING, DATA REDUCTION, AND DATA VALIDATION
The TO (CIGMAT) is responsible for managing all the data and information generated during
the testing program. To maintain quality data, specific procedures shall be followed during data
reporting, reduction, and validation. These procedures are discussed below.
6.1 Data Documentation
All field and laboratory activities shall be thoroughly documented by the use of field logbooks,
project approval/chain of custody sheets, laboratory notebooks and bench sheets, and instrument
records.
A field logbook shall be maintained at the test facility. Daily activity entries shall be made in the
logbook documenting operating conditions, observations, and maintenance activities, if any.
Each sample collected shall be noted in the logbook and any other pertinent information shall be
recorded. Completed pages in the logbook shall be signed and dated.
Original project approval and chain of custody forms shall accompany all samples sent to the
analytical laboratory and will be maintained by the TO. The laboratory shall produce a final data
report that includes all chemical test results, physical measurements, QA/QC data for blanks,
accuracy (recovery), precision (percent difference), and lab control or matrix check samples.
Any deviation from standard protocol shall be discussed in a narrative and any data that does not
meet the QA/QC requirements shall be flagged. A narrative shall be prepared discussing the
findings of any corrective action.
The laboratory shall maintain all logbooks, bench sheets, instrument printouts, and similar
materials. The TO shall make these records available for inspection by the VO or EPA upon
request.
6.2 Data Reduction
Data reduction refers to the process of converting raw test results into useful data for selecting
grout material for wastewater system maintenance and concrete repair. Data shall be obtained
from logbooks, data sheets, and computer outputs. While reduced data will be officially reported
to the VO upon completion of each evaluation, all raw data shall also be made available to the
VO for the QA review of the project and for record keeping.
6.3 Data Validation
The person performing each test shall verify the completeness of the appropriate data forms. The
TO Director shall review laboratory logbooks and data sheets on a regular basis to verify
completeness. The TO technical staff shall regularly inspect testing equipment and keep it in
working order.
SSCI Grout Test Plan - v3.2 Page 32 of 41
9/14/2009
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
6.4 Verification Report
All the data collected during the testing shall be reported as indicated in Chapter 3, processed
and analyzed as outlined in Chapter 5, and summarized in a verification report and verification
statement following ETV Water Quality Protection Center guidelines.
The verification report shall thoroughly present and discuss the findings of the verification test. It
shall contain all raw and analyzed data, all QA/QC data sheets, a description of all types of data
collected, a detailed description of the testing procedure and methods, results and QA/QC results.
The verification statement shall present a condensed summary of the testing procedure and
findings. It is expected that the verification report will contain the following main sections.
• Verification Statement
• Notice
• Forward
• Contents
• Abbreviations and Acronyms
• Introduction and Background
• Testing Procedures and Methods
• Testing Results
• Quality Assurance/Quality Control Summary
• Glossary
• References
• Appendices
o Raw Data and Testing Logs
o Laboratory Standard Operating Procedures
o Test Plan
o Vendor Data Sheet
SSCI Grout Test Plan - v3.2 Page 33 of 41
9/14/2009
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
7 ASSESSMENTS
7.1 Audit Reports
The TO Director or designee shall perform at least one QA inspection of the test facility
laboratories during the evaluation of the grout and shall document any and all findings in an
audit report, which will be submitted to the VO representatives for review. The VO Program
Managers may provide the report to the EPA Project Officer. At least one audit of CIGMAT
will be performed by the VO (RTI or NSF Manager, RTI or NSF QA/QC staff or a designee)
during the test to observe, where possible, sample preparation and storage, and to confirm proper
analytical methods, QA/QC procedures and calibrations are being used. A written report will be
prepared by the auditor and submitted to the RTI and NSF QA/QC Officers, who may provide
the report to the EPA Project Officer.
7.2 Corrective Action Plan
Corrective actions will be taken whenever:
• There is a non-conformance with sample preparation procedures;
• An analyst observes abnormal conditions in sample preparation, measurements or storage
conditions;
• The QA/QC data indicates any analysis is out of the established control limits;
• Audit findings indicate a problem has occurred; or
• Data reporting or calculations are determined to be incorrect.
All corrective actions will be reported to the VO representatives. The VO will review the cause
of the problem and the corrective action taken by the TO. The review will include consideration
of the impact of the problem on the integrity of the test, and a determination will be made if the
test can continue or if additional action is needed. Additional action could include adding
additional days to the test period, re-starting the test at day one, or other appropriate action as
determined by the VO. The VO will respond to any notification of corrective action within
twenty-four hours of being notified of the problem. This response can be to continue the testing,
cease testing until further notice, or other appropriate communication regarding the problem. The
response by the VO will be in writing by email, fax, or letter.
SSCI Grout Test Plan - v3.2 Page 34 of 41
9/14/2009
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
8 SAFETY CONSIDERATIONS
Grouting the joints for the model tests shall be done at the covered test facility at the University
of Houston, which has adequate ventilation. Grout specimens for testing shall also be prepared in
CIGMAT laboratories. The research personnel and technicians on-site will take all necessary
precautions to ensure safety and compliance with local and federal regulations.
CIGMAT maintains a health and safety plan, which shall be made available to personnel
involved in this project. Adherence to the health and safety plan shall be ensured throughout the
duration of the project.
SSCI Grout Test Plan - v3.2 Page 35 of 41
9/14/2009
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
REFERENCES
(1) American Water Works Association (1998), Standard Methods for the Examination of
Water and Wastewater, 20th Edition, American Public Health Association, Washington,
D.C.
(2) Annual Book of ASTM Standards (1999), Section 4 (Construction) and Section 8
(Plastics), ASTM, Philadelphia, PA.
(3) Ata, A. and Vipulanandan, C. (1999), "Factors Affecting Mechanical And Creep
Properties of Silicate-Grouted," Journal of Geotechnical and Geoenvironmental
Engineering, ASCE, Vol. 125, No. 10, pp. 868-876.
(4) Ata, A. and Vipulanandan, C. (1998), "Cohesive and Adhesive Properties of Silicate
Grout on the Grouted Sand Behavior," Journal of Geotechnical and Geoenvironmental
Engineering, ASCE, Vol. 124, No. 1, pp. 38-44.
(5) Bodocsi, A. and Bowers, M. T. (1991), "Permeability and Acrylate, Urethane and Silicate
Grouted Sands with Chemicals, Journal of Geotechnical Engineering, Vol. 117, No. 8,
pp. 1227-1244.
(6) CIGMAT News and Literature Review, Vol. 1, No. 3 (1995), Center for Innovative
Grouting Materials and Technology (CIGMAT), University of Houston, November 1995.
(http://geml .uh.cive.edu)
(7) Concrete Construction (Oct. 1998), "Repair, Protection and Rehabilitation, pp. 898-890.
(8) EPA (1986), Test Methods for Evaluating Solid Waste (SW 846): Physical/Chemical
Methods, Washington, D.C.
(9) Henn, R. W. (1996) Practical Guide to Grouting of Underground Structures, ASCE Press,
New York, NY, 191 p.
(10) Karol, R. H. (1990), Chemical Grouting, Marcel Dekker Inc., New York, NY, 465 p.
(11) Krizek, R. J. and Vipulanandan, C. (1985), "Evaluation of Adhesion in
Chemically Grouted Geomaterials," Geotechnical Testing Journal, American
Society for Testing Materials, Vol. 8, No. 4, pp. 184-190.
(12) Lowther, J. and Gabr, M. A. (1997), "Permeability and Strength Characteristic of
Urethane-Grouted Sand," Proceedings, Grouting, Geotechnical Special Publication No.
66, ASCE, pp. 197-211.
(13) Tonyan, T. D., and Gibson, L.J. (1992), "Structure and Mechanics of Cement Foams, "
Journal of Materials Science, Vol. 27, pp. 6272- 6378.
SSCI Grout Test Plan - v3.2 Page 36 of 41
9/14/2009
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
(14) Vipulanandan, C. and Krizek, R. J. (1986), "Mechanical Behavior of
Chemically Grouted Sand," Journal of Geotechnical Engineering, American Society of
Civil Engineers, Vol. 112, No. 9, pp. 869-887.
(15) Vipulanandan, C. and Shenoy, S. (1992)" Properties of Cement Grouts and Grouted
Sands with Additives," Proceedings, Grouting, Soil Improvement and Geosynthetics,
ASCE, pp. 500-511.
(16) Vipulanandan, C., Jasti, V., Magill, D. and Mack, D. (1996a), "Shrinkage Control in
Acrylamide Grouts and Grouted Sands," Proceedings, Materials for the New
Millennium, ASCE, Washington D.C., pp.840-850.
(17) Vipulanandan, C. and Jasti, V. (1996b) "Development and Characterization of Cellular
Grouts for Sliplining," Proceedings, Materials for New Millennium, ASCE, pp. 829-
839.
(18) Vipulanandan, C. and Jasti, V. (1996c), Behavior of Acrylamide and N-
methylolacrylamide (NMA) Grouts and Grouted Sands, Research Report No.
CIGMAT/UH 96-2, University of Houston, Houston, Texas.
(19) Vipulanandan, C. and Jasti, V. (1996d), Characterization of Polymer and Cellular
Cement Grouts for Sewer Rehabilitation, Research Report No. CIGMAT/UH 96-3,
University of Houston, Houston, Texas.
(20) Vipulanandan, C. and Jasti, V. (1997) "Behavior of Lightweight Cementitious Cellular
Grouts," Proceedings, Grouting, Geotechnical Special Publication No. 66, ASCE, pp.
197-211.
(21) Vipulanandan, C. and Neelam Kumar, M. (2000), "Properties of Fly Ash-Cement
Cellular Grouts for Sliplining and Backfilling Applications," Proceedings, Advances in
Grouting and Ground Modification, ASCE, GSP 104, Denver, CO, pp. 200-214.
(22) Vipulanandan, C., O'Neill, M. W. and Weng, Y (2000) "Mechanical Properties and
Chemical Resistance of Auger Grouts," Proceedings, Advances in Foundation
Technologies, ASCE, GSP 100, Denver, CO, pp. 433-446.
(23) Vipulanandan, C. Mattey, Y., Magill, D. and Mack, D. (2000) "Characterizing the
Behavior of Hydrophilic Polyurethane Grout," Proceedings, Advances in Grouting
Technologies ASCE, GSP 104, Denver, CO, pp. 234-245.
(24) Weaver, K. (1991), Dam Foundation Grouting, ASCE Press, New York, NY, 178 p.
SSCI Grout Test Plan - v3.2 Page 37 of 41
9/14/2009
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
APPENDIX A
CIGMAT Test Methods
CIGMATCH2-01
CIGMAT CT 3-00
CIGMAT GR 1-00
CIGMAT GR 2-02
CIGMAT GR 3-00
CIGMAT GR 4-00
CIGMAT GR 5-00
CIGMAT GR 6-02
CIGMAT GR 7-02
CIGMAT GS 1-02
CIGMAT PC 2-99
(Questions about CIGMAT procedures may be directed to CIGMAT at the University of
Houston)
SSCI Grout Test Plan - v3.2 Page 38 of 41
9/14/2009
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
APPENDIX B
Separation Systems Consultants, Inc.
Vendor Data Sheet
SSCI Grout Test Plan - v3.2 Page 39 of 41
9/14/2009
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
GROUT VENDOR DATA SHEET
Grout Product Name:
GST #3
Grout Product Manufacturer Name and Address: SSCI Environmental, Inc.
17041 El Camino Real. Ste. 200: Houston. TX 77058
Grout Type: Polvurethane
Chemical Formula:
Dioocyanate, oligomers of diiocyanate
TESTING METHOD
Type of Resin, Initiator and/or Promotor
Grout Mix (by weigh or volume)
Resin Viscosity (ASTM )
Flash Point (ASTM D 937 )
Tensile Adhesion to Concrete and Clay Brick
(ASTM )
Chemical Resistance (ASTM )
(NaOH, 3% H2SO4 or others)
Volatile Organic Compounds - VOCs
(ASTM )
MANUFACTURER'S RESULTS
Strong flexible foam, grey color
Water / various ratios
2200 - 2500 cps
200° F
~ 20 psi
Bases = Nominal impact;
Sulfuric acid = Mild discoloration
Does not apply
WORKER SAFETY
Flammability Rating
Known Carcinogenic Content
Other Hazards (Corrosive)
MSDS Sheet Availability
RESULT/REQUIREMENT
Not
Applicable
TDI
None
Yes
ENVIRONMENTAL
CHARACTERISTICS
Heavy Metal Content (w/w)
Leaching from Cured Grouts
Disposal of Cured Grouts
RESULT/REQUIREMENT
None
None
Cured material is non-hazardous
SSCI Grout Test Plan - v3.2
9/14/2009
Page 40 of 41
-------
EPA STREAMS 61/ETV WATER QUALITY PROTECTION CENTER VERIFICATION
DATA SHEET ON PROPERTIES OF GROUT (Continued)
APPLICATION CHARACTERISTICS
Minimum Application Temperature
Maximum Application Temperature
Minimum Cure Time before Immersion into
Service
Type of Preparation Before Grouting
Grouting Pressure
RESULT/REQUIREMENTS
40° F
120°F
Water is catalyst
Clean surface before application
Not applicable
VENDOR EXPERIENCE
Length of Time the Grout in Use
Applicator Training and Qualification Program
QA/QC Program for Grouts in the Field
COMMENTS
20+ years
Field and classroom training
Verify product being used
ADDITIONAL COMMENTS (Including Case Studies on Performance)
SSCI Grout Test Plan - v3.2
9/14/2009
Page 41 of 41
------- |