HISTORIC FORT GAINES

Dauphin Island, Alabama

August 1, 2006

SECTION 03600
INJECTION GROUT
PART 1 GENERAL REQUIREMENTS
1.01 SUMMARY
A. Work of this Section will use injection
grouts to consolidate cracks and
voids resulting from fractures in storm
damaged cast-in-place concrete and
to consolidate voids within
deteriorated brick masonry
construction where indicated on the
Drawings, as specified herein and as
required for the complete and proper
repair of storm related damages.
B. Brick Masonry
1. Existing brick masonry
construction was installed circa
1854 thru 1860 under the
supervision of the US Army
Corps of Engineers under the
strict direction of Chief Engineer
Joseph Totten during which time
hard ironspot brick masonry was
installed in most locations using
natural cement (Rosendale);
other limited locations appear to
have utilized softer lime based
mortars.
2. Construction continued under the
Confederacy for the period of the
Civil War during which time
material and workmanship
suffered; work from this period
exhibits questionable detailing
and inferior materials. Lime
based mortars appear to contain
beach sand and exhibit evidence
of extensive salt contamination
and related deterioration.
C. Concrete
1. Existing cast-in-place concrete
construction was installed circa
1899 to 1901 and numerous
defects and weakened conditions
have developed in the interim
period.

COOPER WHITESIDE NORMAN, PC

SECTION 03600
INJECTION GROUT
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2. Exposed surfaces have provided

the opportunity for salt laden
moisture to seep into the
concrete mass, which in turn has
caused embedded ferrous metals
to corrode and expand.
3. Corroded metals have exerted
expansive pressures imposing
tensile forces from within the
concrete materials resulting in
weakened sections that are
susceptible to cracking, spalling,
and fractures where sections are
prone to shift away or separate
completely from their more stable
base construction.
D. Storm Damage Repair Summary
1. Brick Masonry
a.) Wind driven sand and rain
combined with agitated
flooding (waves) on the
interior of the fort resulted in
moderate to severe erosion
of brick masonry jointwork;
cracking, fracturing, and
limited collapse of brick
masonry assemblies; and
cracking, spalling, and loss of
individual brick units.
b.) Brick repairs consist of
pointing eroded jointwork;
repairing cracked and
fractured brick masonry
assemblies; grouting voids
within brick masonry
assemblies; reconstructing
collapsed sections, including
reestablishing brick header
tie courses into backup wall
assemblies; repairing or
replacing cracked, spalled,
and lost brick masonry units.
i.) Masonry joints exhibiting
-inch or deeper erosion
shall be repointed under
this program.
ii.) Brick masonry jointwork,
units, and assemblies not

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Dauphin Island, Alabama
August 1, 2006

exhibiting storm related

damages as defined
herein are not subject to
repair under this
program.

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INJECTION GROUT
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damages, they are not the

object of the current repair
program.

1.02 WORK INCLUDED

1. Prior repairs
exhibiting poor
workmanship or
inappropriate
materials but
otherwise do not
exhibit storm related
damages as defined
herein are not subject
to repair under this
program.

A. In consultation with the Architect and

Owner, survey selected installations
and identify specific damage
conditions that will be repaired under
the Work of this Section.
1. Cooperate with Architect to
establish accurate quantity of the
repairs made and to otherwise
facilitate the audit of the delivery
of this work.

2. Concrete
a.) Storm damage resulted in
separation and collapse of
some of these weakened
areas of concrete
construction and the areas
where damages were
worsened by the subject
storm event are the object of
current repairs.
i.) Subject areas are
evidenced by cracking at
their perimeters or have
separated either partially
or completely from the
more stable substrate.
ii.) Concrete repairs consist
of returning the damaged
building elements to their
original lines, planes,
profiles, and appearance
in a way that stabilizes
the construction and
minimizes future
damage.
b.) Some areas of concrete
deterioration are assumed to
remain in place and may be
identified by sounding the
surface of the concrete;
although these areas are in a
weakened condition and may
be subject to future storm

COOPER WHITESIDE NORMAN, PC

B. Coordinate the work of this section

with the preparation and repair of
deteriorated brick masonry under
Section 04900 Masonry
Restoration.
1. Clean organic and other
contaminants that may have been
deposited on working surfaces
prior to making repairs.
2. Prepare substrate by removing
loose or deteriorated mortar and
masonry unit materials.
C. Coordinate the work of this section
with the preparation and repair of
deteriorated horizontal and vertical
concrete surfaces under Section
03920 Concrete Restoration.
1. Clean organic and other
contaminants that may have been
deposited on working surfaces
prior to making repairs.
2. Prepare substrate by removing
loose or deteriorated concrete
materials and reinforcing.
D. Provide scaffolding required for
access to the Work of this Section.

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Dauphin Island, Alabama
August 1, 2006

1.03 RELATED REQUIREMENTS

A. Section 01210 - Unit prices
B. Section 01220 - Allowances
C. Section 01230 - Alternates
D. Section 01510 - Environmental
management during periods of
extreme heat and cold
E. Division 3 Concrete restoration
F. Division 4 Masonry restoration
G. Division 9 Painting and mineral
coatings

1.04 UNIT PRICES

A. Provide Unit Prices per Section
01210 for the following Work of this
Section:
1. Grouting Cracks and Fractures in
Concrete and Masonry Substrate
- cubic foot price for injection
grouting to consolidate cracks,
fractures, and voids in substrate
in preparation for concrete and
masonry restoration.

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INJECTION GROUT
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supervision of one with minimum five

(5) years experience successfully
executing work of this type.
1.06 SUBMITTALS
A. See Section 01300 General
Requirements, for submittal
procedures.
B. Submittals Required:
1. Samples of all specified
materials, product information
and data, and Material Safety
Data Sheets (MSDS).
2. Certificates of Compliance as
furnished by the Manufacturer,
stating that all supplied materials
are in conformance with the
Manufacturers published
literature, and will meet or exceed
the current specifications.
3. Written verification that all
specified materials will be used.
Provide purchase orders,
shipping tickets, receipts, etc. to
prove that the specified materials
were ordered and received.

1.07 DELIVERY, STORAGE, HANDLING

2. Grouting Masonry Voids on a
cubic foot basis for injection
grouting to consolidate voids in
masonry substrate when staged
with masonry restoration
operations.

1.05 QUALITY ASSURANCE

A. Use adequate numbers of skilled
workmen who are thoroughly trained
and experienced in the necessary
crafts and who are completely familiar
with the specified requirements and
the methods needed for proper
performance of the work of this
Section.
B. Work of this section shall be installed,
or installed under the direct

COOPER WHITESIDE NORMAN, PC

A. Deliver the product in original factory

packaging with product listing label
and manufacturing label.
B. Handle and store the product to
prevent damage and deterioration.
C. Handle all products with appropriate
precautions as outlined in the
Manufacturers product literature and
Material Safety Data Sheets (MSDS).
D. Organize material inventory storage
to clearly distinguish between
different material formulations and
area of intended application.
E. Comply with the Manufacturers
written specifications and
recommendations for mixing,

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Dauphin Island, Alabama
August 1, 2006

application, and curing of grouts.

1. Provide written certification that
work will be performed using
specified materials only.
a.) Provide copies of purchase
orders, shipping tickets,
receipts, materials tracking
cards, etc. as evidence that
the specified materials were
ordered, received, and stored
at the job site, and were
subsequently incorporated
into the work.
b.) False certification will be
interpreted as fraud and will
be prosecuted accordingly.

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INJECTION GROUT
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2.02 MATERIALS
A. Design Standards
1. Injection Adhesives
a.) Pre-mixed mineral based
adhesives suitable for
injection into micro cracks,
fissures, and voids in
masonry and concrete.
b.) Shall contain no corrosive
constituents.
c.) Shall exhibit extraordinary
flow capacity, high
penetration, and strong
adhesion.
2. Injection Grouts

PART 2 - PRODUCTS
2.01 ACCEPTABLE MANUFACTURERS
A. JAHN Mineral Based Injection Grouts
as manufactured by Cathedral Stone
Products, Inc.; 7266 Park Circle
Drive; Hanover, Maryland 21076
telephone 800-684-0901
B. Alternate manufacturers may be
acceptable, providing substituted
products meet or exceed stated
performance criteria of the design
standard, subject to review and
approval by Architect.
1. Proposed substitution shall be
subjected to independent
laboratory testing, paid for by
Contractor, and submitted per
requirements of Section 01600 Product Requirements to
establish composition and
performance relative to Design
Standard.
2. Architects determination will be
final.

COOPER WHITESIDE NORMAN, PC

a.) Pre-mixed mineral based

grout suitable for injection
into cracks, fissures, and
voids in masonry and
concrete.
b.) Shall contain no acrylic, latex,
or other synthetic polymer
bonding agents or additives.
c.) Field preparation consisting
of controlled mixture of dry
grout and water.
d.) Cured installation shall be
vapor permeable, frost and
salt resistant, shrink resistant,
and physically compatible
with substrate materials.
B. Grouts and Adhesive Products
1. Jahn M30 Micro Injection
Adhesive for injection into
hairline cracks up to 3/16 or 5.0
mm in width.
2. Jahn M40 Crack and Void
Injection Grout for injection into
cracks approximately 3/16 to
3/8 or 5.0 mm to 10.0 mm in
width.

HISTORIC FORT GAINES

Dauphin Island, Alabama
August 1, 2006

2.03

ACCESSORIES
A. Potable water for use with grouting
and adhesive materials.
B. Provide other equipment and
materials not specifically described
but required for a complete and
proper installation as selected by the
Contractor, subject to the approval of
the Architect.

PART 3 - EXECUTION
3.01 INSPECTION
A. Examine the areas and conditions
under which work of this Section will
be performed to establish extent of
work, access, and need for protection
of surrounding construction,
landscaping, etc.
1. If conditions are not as expected,
notify the Architect immediately
for direction.
2. Do not proceed with work until
unsatisfactory conditions are
corrected.
3. Grout workmanship shall comply
with all applicable
recommendations of the
Manufacturers written
specifications and requirements.
4. Do not add any bonding agents,
accelerators, or retarders to the
grout.
5. Discard all grout that has
hardened or exceeded its
allowable pot life after mixing.
a.) Provide separate, clearly
labeled containers for
discarded grout and remove
material from the staging
area as soon as practical.

COOPER WHITESIDE NORMAN, PC

SECTION 03600
INJECTION GROUT
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3.02 PREPARATION
A. Transverse Cracks
1. For cracks across the face of the
substrate, drill a series of
injection ports in the center of the
crack. These ports should be
drilled in a downward direction.
a.) Seal the crack between the
ports, with removable, nonstaining clay or repair
sections along the crack with
patching mortar, specified in
other Sections.
B. Lateral Cracks (Delaminating Layers)
or Voids
1. Drill a series of injection ports in a
square configuration (90 angles)
on the face of the substrate to
create a drill frame.
2. Ports should be drilled in a
downward direction.
C. Wash the surface and interior of the
crack using clean water to remove all
dust, loose or deleterious material,
which could prevent proper flow
and/or adhesion, compromising the
integrity of the cured injection grout.
D. Sound surface of concrete around
area of crack using small hammer to
locate any remaining hollow or
deteriorated sections of concrete
extending from area of patch.
1. Remove deteriorated materials to
establish sound substrate for full
area of repair.
2. If necessary, drill into detected
voids or cut away an additional
-inch of the substrate to ensure
the surface to be repaired is solid
and stable.

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Dauphin Island, Alabama
August 1, 2006

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INJECTION GROUT
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hours after installation of

grouts.

3.03 GROUTING
A. Material Modifications Prohibited

ii.) Hot Weather

Requirements: When
ambient air temperature
exceeds 90 F, provide
shaded working area,
wetting to cool substrate
surfaces, and other
measures to mitigate
effects of heat. Protect
grout installation from
direct sunlight and wind.

1. Do not substitute, supplement,

adulterate, or otherwise alter
factory produced grouting
materials specified for this work.
a.) Do not use any additives,
such as bonding agents,
accelerators, or retardants in
these grouts.
b.) Do not use bonding agents
as surface preparation
materials.

1. Do not mix or work

materials exceeding
90 Fahrenheit or
apply materials when
substrate exceeds
90 Fahrenheit.

c.) Do not add any other

components to the repair
system as specified without
written approval of Architect.
C. Mixing
B. Environmental Limitations
1. Do not apply patching materials
to a frozen or exceedingly hot
substrate, per repair material
manufacturers printed guidelines.
a.) The applied mortar must be
protected from extreme heat,
freezing, excessive wind,
direct sunlight, and rain.
b.) Normal working conditions
include ambient temperature
range between 40 F to 90 F
with low to average humidity.
i.) Cold Weather

Requirements: When
work will continue
through cold weather,
Contractor shall provide
heated enclosure and
other requirements of
Section 01510 Winter
Conditions, specifically
when temperatures fall
below 40 F, when the
substrate is colder than
40 F, or when the
temperature is expected
to fall below 40 F for 48

COOPER WHITESIDE NORMAN, PC

1. It is recommended that safety

goggles, gloves, and a dust mask
be worn for protection when
handling these products.
2. Do not mix more material than
can be used within 30 minutes.
a.) Discard any mixed material
that has been unused for 30
minutes or more.
D. Proportioning
1. Jahn M30: mixing ratio is
approximately two (2) to five (5)
parts powder to one (1) part
potable water by volume.
a.) Mix mechanically using a
high-speed drill (3,000 RPM
or higher) equipped with a
Jiffler type-mixing paddle.
b.) After mixing, the mortar
should be poured into
another clean container using
a sieve.
c.) Continued agitation is
necessary if the mortar will be

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Dauphin Island, Alabama
August 1, 2006

allowed to sit prior to use.

2. Jahn M40: mixing ratio is
approximately two-and-one-half
(2 ) parts powder to one (1) part
water by volume.
a.) Mix manually or
mechanically, using a slow
speed drill (400-600 RPM)
equipped with a Jiffler typemixing paddle.
b.) The material should be mixed
for a minimum of three
minutes, with continued
agitation if the mixture will be
allowed to sit prior to use.

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INJECTION GROUT
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inject the remainder of the grout

until port is full and grout flows
freely from other ports at the
same level.
3. Seal ports using non-staining
clay, sealant, or caulk.
4. Inject grout into lower right port
and proceed in identical fashion.
5. The order of injection is lower left,
lower right, upper left, then upper
right.
6. Clean up overflow immediately.

D. Grout Consolidation of Masonry

Substrate
3.04 INJECTION PROCEDURE
A. Wash the interior of the crack or void
immediately before injection by
flushing with clean water. If the crack
is allowed to dry out before grout is
injected, this step must be repeated.
B. Treatment of Transverse Cracks
1. Inject grout into lowest port and
continue until it flows freely from
this port and other ports at the
same level.
2. Seal ports using non-staining
clay, sealant, or caulk and
proceed in identical fashion until
the crack is filled.
3. Clean up overflow immediately.
C. Treatment of Lateral Cracks
(Delaminating Layers) or Voids:
1. Inject grout into lower left port
and proceed until it flows freely
from this port and other ports at
the same level.
2. Where necessary, insert threaded
stainless steel dowels after some
grout has been injected, agitate
or tap several times to remove
any voids or air pockets, and

COOPER WHITESIDE NORMAN, PC

1. Coordinate the installation of the

work of this section with masonry
restoration work specified in
Section 04900.
2. Where masonry construction has
suffered damages and
deterioration that extends beyond
the reach of manual repair
techniques, grout injections shall
be used to consolidate
construction assemblies and
stabilize substrata to which
surface repairs will be applied.
a.) Except where wall section is
scheduled for disassembly
and reconstruction,
consolidate and stabilize wall
sections where pointing and
patching operations are
performed by installing
injection grout into the inner
voids in backup masonry
construction.
b.) Install grout progressively in
lifts proceeding from the
bottom of the wall upward.
c.) Install mortar approximately
3-inches deep on face wythe
(proceeding progressively
upward on both sides of the

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Dauphin Island, Alabama
August 1, 2006

wall, where applicable) to

dam faces of wall.
i.) Inject grout into the voids
within wall construction
progressively installing
grout in 2-course to 3course lifts.
ii.) Select grout type to
match porosity and flow
characteristics required
by wall condition.
iii.) Clean up overflow
immediately.

3.05 FINISHING
A. Remove temporary plugs after 24 to
48 hours and repair the ports and the
crack surface, if not previously
performed, using specified patching
mortar to match color and type of
existing masonry per Section 04900.

3.06 CLEAN UP
A. Remove uncured mortar from
substrate before it dries using clean
water and a rubber sponge.
1. Cured mortar may only be
removed chemically or
mechanically.
B. Remove uncured mortar from tools
and equipment with water as soon as
possible.
1. Cured material may only be
removed chemically or
mechanically.

END OF SECTION

COOPER WHITESIDE NORMAN, PC

SECTION 03600
INJECTION GROUT
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