Grouting of the structure with non-shrinking MAPEFILL material
Grouting of concrete structures is governed by standard ČSN EN 1504-6 (products and systems for the protection and repair of concrete structures). Grouting materials are designed to perfectly fill the space between the foundation concrete and the steel structure or another reinforced concrete structural element. Large technological units are also often grouted. Our company recommends using a self-levelling, non-shrinking MAPEFILL compound from the manufacturer Mapei for grouting steel columns.
Description of column installation on a base plate using threaded rods:
- The structure is anchored to the base plates using threaded rods, which are drilled and connected to the base plate using certified chemical mortar.
- The construction company installs waterproofing (geotextile and then a membrane or asphalt strip according to the project) on the threaded columns.
- Nuts are mounted on the bolts and, using a levelling instrument, the level of the entire structure is measured and the nuts are adjusted to the same height - level.
- The column is placed onto the threaded rods and the anchor plate is tightened from above with nuts.
- The vertical alignment of the columns is adjusted and the entire structure is braced using tie rods.
- The construction company creates frames around the columns from wood or sheet metal and fills any gaps with PU foam to prevent the self-levelling compound from leaking out of the frame.
- Finally, the construction company pours the space between the base plates with self-levelling, non-shrinking MAPEFILL compound.
Our company only performs column grouting if it is also the supplier of the substructure. The reason is that construction companies often have a height deviation greater than the standard of +/-1 cm, and the cost of one bag of MAPEFILL is around 600 CZK excluding VAT for a 25 kg bag, which is enough for about 0.0128 m3. Poor workmanship can thus result in additional costs of several thousand CZK, which must be borne by the construction company that installed the base plates. The grouting area must be at least 3 cm larger than the anchor plate of the steel column to allow the compound to be properly poured around the base plate.
Types of non-shrinking compounds:
- MAPEFILL (application 2-5 cm)
- MAPEFILL MF 610 (application 5-10 cm)
MAPEFILL Consumption Table under the Base Plate
| Column Base Dimension | Grouting Area Dimension | 3 cm* | Bases at 3 cm** | 4 cm* | Bases at 4 cm** | 5 cm* | Bases at 5 cm** |
| 0.12 x 0.25 m | 0.18 x 0.31 m | 0.0017 | 7.6 | 0.0022 | 5.7 | 0.0028 | 4.6 |
| 0.14 x 0.28 m | 0.20 x 0.34 m | 0.0020 | 6.2 | 0.0027 | 4.7 | 0.0034 | 3.8 |
| 0.15 x 0.31 m | 0.21 x 0.37 m | 0.0021 | 6.1 | 0.0028 | 4.6 | 0.0035 | 3.7 |
| 0.18 x 0.37 m | 0.24 x 0.43 m | 0.0031 | 4.1 | 0.0041 | 3.1 | 0.0051 | 2.5 |
| 0.20 x 0.41 m | 0.26 x 0.47 m | 0.0037 | 3.5 | 0.0049 | 2.6 | 0.0061 | 2.1 |
* Height of the column grout from the concrete base to the column base plate.
** Number of bases with a certain grout thickness (3-5 cm) that can be grouted from a 25 kg bag.
MAPEFILL
Fluid expansive grout for anchoring elements. Mapefill is used for grouting under columns of steel structures, as well as for filling rigid joints of individual building structures and grouting under foundation structures.
Mapefill is characterized by high mechanical strength even after a short curing time (24 hours) and high adhesion to steel and concrete.
Mapefill consists of cement binders, graded aggregates, and special additives.
Preparation
The mixture is prepared by mixing 25 kg of Mapefill (contents of 1 bag) with 3.0 – 3.75 liters of clean water (depending on the required consistency). The prepared grout is poured into the anchoring holes, which must be thoroughly saturated with water beforehand (any unabsorbed water must be removed); it is necessary to allow air to escape from the holes to prevent the formation of air pockets.
When filling larger spaces, it is recommended to add aggregate of suitable granulometry or Ghiaietto 6-10.
Mapefill meets the minimum requirements of EN 15004-6.
Technical data
Maximum aggregate size: 10 mm
Mixing ratio: 25 kg of Mapefill (contents of 1 bag) with 3.0 – 3.75 liters
Workability: approx. 2 hours (at +20°C)
Minimum application thickness: 2 cm
Maximum application thickness: 5 cm
Consumption
1.95 kg/dm3 of filled space.
Material data sheet for download here.
MAPEFILL MF 610
Expansive mortar for precision anchoring in greater thicknesses.
Technical data
Maximum aggregate size: 10 mm.
Mixing ratio: 100 parts MAPEFILL MF 610 with 9.5–10.5 parts water and 0.16–0.32% MAPECURE SRA.
Workability: approx. 2 hours (at +20 °C).
Minimum application thickness: 5 cm.
Maximum application thickness: 10 cm.
Packaging: 25 kg vacuum-packed polyethylene bags
Consumption
approx. 21 kg/m2 per cm of layer thickness