Grouting Project-Formwork Grouting

Formwork Grouting with an IMER Step 120 Concrete Pump

Formwork grouting with the IMER STEP 120 concrete pump is a key step in many construction projects, including the formation of concrete walls, columns, and other structural elements. Formwork grouting is typically used to fill voids, gaps, and cavities in the formwork system, ensuring that the concrete is properly consolidated and fully fills the mold. The IMER STEP 120 is well-suited for this purpose due to its power, precision, and ability to handle large volumes of grout efficiently.

Here’s a step-by-step guide to formwork grouting using the IMER STEP 120 concrete pump:

Steps for Formwork Grouting Using the IMER STEP 120

1. Preparation of Materials and Equipment

Select the Right Grout: Choose the appropriate grout mix based on the project requirements (e.g., cement-based grout, non-shrink grout, or epoxy grout). If you're filling gaps in formwork before pouring concrete, ensure that the grout is compatible with the type of concrete being used.
Prepare the Grout: Mix the grout according to the manufacturer's specifications. The grout should have a smooth, pourable consistency that allows it to flow easily into the formwork without creating air pockets. For cement-based grout, use a mechanical mixer to ensure thorough mixing.
Inspect the IMER STEP 120: Check the grout pump and associated hoses, nozzles, and fittings for any damage or wear. Ensure everything is clean and ready to use.
Position the Equipment: Place the IMER STEP 120 grout pump near the formwork, ensuring that hoses can reach all the areas where grout will be applied. Set up the suction hose to draw grout from the mixing container, and the discharge hose to reach the formwork or the placement point.

2. Set Up the IMER STEP 120 Grout Pump

Prime the Pump: Before starting, prime the pump to ensure smooth operation. Run the pump without pressure to expel air from the system and ensure grout flows consistently. Once grout starts flowing through the discharge hose, the pump is primed.
Check Water Supply: If the grout mix requires water, make sure that the water supply is properly connected and that the pump is capable of mixing and pumping the grout evenly.

3. Start the Grouting Process

Begin Grouting: Start the grouting process by applying grout into the formwork from the bottom up, if possible. This will help to reduce the chance of air pockets forming and ensures the grout fills all gaps evenly.
Monitor Grout Flow: Use the IMER STEP 120’s adjustable pressure settings to control the grout flow. Start at a low speed and gradually increase the flow as necessary. The grout should flow evenly into the formwork and fill all voids.
Ensure Even Distribution: Work your way along the formwork, ensuring that the grout fills the spaces completely. Keep an eye on the grout as it enters the formwork, making sure there are no areas left unfilled. If necessary, adjust the nozzle or grout placement to ensure the grout fills evenly.
Avoid Over-Pressurizing: While it’s important to apply enough pressure to fill the formwork, avoid over-pressurizing the pump. Too much pressure can cause grout to leak out from the formwork or result in uneven filling.

4. Preventing Air Pockets and Voids

Vibration and Tapping: As you apply grout to the formwork, use vibration tools or gently tap the formwork with a hammer to help the grout settle into place and eliminate air pockets. This is especially important in larger voids or complex formwork shapes.
Check for Gaps: Monitor the grout closely as it fills the formwork. If you notice any areas where the grout isn’t filling properly, pause the pumping process and address the issue before continuing. Sometimes, repositioning the hose or nozzle can help improve grout flow into difficult-to-reach spots.
Work in Layers: If you're grouting a large formwork area, consider grouting in multiple layers. This ensures that each layer is filled properly and gives the grout time to settle before adding more.

5. Complete the Grouting

Stop Pumping: Once the formwork is completely filled with grout and there are no visible gaps, stop the IMER STEP 120 pump. If you're working with a large formwork area, you may need to check periodically to ensure that grout hasn't settled and created new voids.
Smooth the Grout: After the formwork is filled, use a trowel or smoothing tool to level out the surface if needed. This is important if the grout will be exposed after the formwork is removed.
Remove Excess Grout: If there is any excess grout spilling over or leaking from the formwork, clean it up immediately to avoid curing problems or surface irregularities.

6. Post-Grouting Care

Allow the Grout to Settle: Allow the grout to set in the formwork. The curing time will depend on the type of grout used, but typically, grout should be allowed to cure for several hours or days, depending on environmental conditions.
Inspect the Formwork: Once the grout has fully set and cured, inspect the formwork and the grouted areas. Look for any imperfections, leaks, or voids that may need to be addressed. If necessary, apply more grout to fill any areas that were missed during the initial grouting.
Remove the Formwork: Once the grout has fully cured, carefully remove the formwork. If the grout has been placed properly, you should have a solid, uniform structure inside the formwork.

7. Clean the Equipment

Clean the IMER STEP 120: After grouting, thoroughly clean the grout pump and all associated components, including hoses and nozzles. This is essential to prevent grout from hardening inside the system and causing blockages. Flush the pump with water or a suitable cleaning agent and ensure all grout is removed.
Inspect the Equipment: Before storing the equipment, check it for any signs of wear or damage. Replace any worn-out parts to keep the pump in good working order for future projects.

Additional Tips for Successful Formwork Grouting:

Use Proper Grout Consistency: Make sure the grout has the right consistency for easy flow into the formwork. Too thick a mix may not flow properly, while too thin a mix may weaken the structure.
Ensure Proper Ventilation: If grouting large areas, ensure that the grout is properly ventilated to prevent air pockets and pressure build-up. Use vibration tools or tapping to release air as the grout is applied.
Monitor for Settling: Keep an eye on the formwork as the grout cures, especially if it's a large or deep formwork. If any areas settle or shrink, consider topping them off with additional grout.

Benefits of Using the IMER STEP 120 for Formwork Grouting:

High Output: The IMER STEP 120 can handle large volumes of grout, making it ideal for larger formwork areas.
Precise Pressure Control: The pump allows for precise control over grout flow, ensuring consistent application and preventing over-filling or leakage.
Efficient and Fast: The IMER STEP 120 is designed for efficiency, allowing you to grout large areas quickly and effectively without sacrificing quality.
Durable and Reliable: The sturdy design ensures the pump can handle the demands of rigorous grouting tasks, providing reliability on construction sites.

Using the IMER STEP 120 grout pump for formwork grouting ensures efficient and high-quality results. By following the outlined steps and tips, you’ll achieve a smooth, solid, and fully grouted formwork for your concrete structures. Let me know if you need any further assistance or clarification on the process!