Grouts and Grout tests for NOVA The NOVA extrusions, when filled, will exert an average pressure of 19 psi (2736 psf) on the floor. The pressure is not uniform: 10/10/2015Grout test study results Hans Jostlein1

Floor pressure It is actually more complicated; there is partial force transmission through the webs, Except for the middle channel in the end cap. 10/10/2015Grout test study results Hans Jostlein2

There are two locations where grout can even out the pressure on the Extrusions: Between the block and the pallet (applies to IPND as well) Between the pallet and the hall floor (Applies to far detector only) 10/10/2015Grout test study results Hans Jostlein3

Why do we need grout ? The PVC block is stiff We always assumed a full support area There are several sources of imperfect alignment of the block components versus the pallet- or floor shape: 10/10/2015Grout test study results Hans Jostlein4

Geometrical Imperfections Non-square module bottoms (X and Y) Module bottoms misaligned (X and Y) Pallet construction tolerances Concrete floor not a perfect plane Cumulative error: Somewhere between 1/16” and 1/8” (my own wild guess) Risk: High Stress Points on the bottom glue joint may cause glue joint failure 10/10/2015Grout test study results Hans Jostlein5

Grout Requirements Long Service Life (no deterioration with time or oil soaking) No Creep (to avoid stresses during partial oil filling) Stiff (same reason) Easy to install Must flow easily Must provide very long pot life (Days ?) Must bear loads quickly (an hour or less ?) Does not require a tight seal to prevent leak-out Inexpensive (if possible) 10/10/2015Grout test study results Hans Jostlein6

Liquid Organic Grouts Commonly used for machinery Require leak-tight form Not easily used on far detector floor Load bearing setup time is much longer than the pot life Costly 10/10/2015Grout test study results Hans Jostlein7

Cement based grouts See DocDB # 581 (January 2006) for measurements Last for decades (centuries ?) Do not require leak tight forms Have the marvelous property of being Tixotropic: Behave like liquids when shaken or stirred Behave like solids when at rest 10/10/2015Grout test study results Hans Jostlein8

Typical mix Use “play-sand” as filler, add cement, mix Or, use premix, add water, and mix Fill into the gap “vibrate” with a long board until settled It can now bear the full load instantly Let cure (curing can be as short as 30 minutes, and can be tuned with additive for a “pot life” as long as 3 days) 10/10/2015Grout test study results Hans Jostlein9

Test assembly 10/10/2015Grout test study results Hans Jostlein10

Purpose of the Test Find out how hard or easy it is to fill the mortar in a tall gap with realistic block shape Check on resulting completeness and distribution of fill We covered the plywood wall with plastic foil to separate it from the mortar 10/10/2015Grout test study results Hans Jostlein11

Test Progress Everything worked pretty well on first try, Except we tried to vibrate the mortar with a ¼” stick, which was too wimpy On second try, used a 4” x 1/8” x 4 ft G10 strip, Which made the mortar flow perfectly 10/10/2015Grout test study results Hans Jostlein12

10/10/2015Grout test study results Hans Jostlein13

10/10/2015Grout test study results Hans Jostlein14

10/10/2015Grout test study results Hans Jostlein15 First try– not quite perfect

10/10/2015Grout test study results Hans Jostlein16 Second try—perfect matching to the plywood/ foil wall

Floor Grouting (Far Detector only) Place mortar on floor over the whole contact area Use a rake-type (maybe vibrating) tool to groove it deeply Set the block down with the block raiser During block alignment there is enough motion to re-liquefy the grout If not, just make a very small motion with the block raiser and set the block down Grout will set to full load bearing strength as soon as the motion stops 10/10/2015Grout test study results Hans Jostlein17

Floor Grout Test In Lab F (thanks, John Voirin !) we set a stack of three steel blocks on a grout bed The three blocks exerts the same floor pressure as the far detector We tested freshly mixed grout and day-old grout with Eucerin retarder mixed in We covered floor and top of mortar with a PE sheet for easy inspection and clean-up We installed 4 dial gauges to measure distance from floor to check for sagging 10/10/2015Grout test study results Hans Jostlein18

10/10/2015Grout test study results Hans Jostlein19 Sand mortar grout, shaped with a trowel

10/10/2015Grout test study results Hans Jostlein20 First block loaded onto grout bed, and equipped with dial gauges

10/10/2015Grout test study results Hans Jostlein21 Three blocks loaded. Droop motion is less than 10 mil

10/10/2015Grout test study results Hans Jostlein22 Grout after 3-day loading ; Middle is raised, matching bottom profile of the steel block

10/10/2015Grout test study results Hans Jostlein23 Grout with retarder, before loading

10/10/2015Grout test study results Hans Jostlein24 Grout after 3 days

Future Would like to use it on the mechanical prototype of the INPD Would like to use it on the FHEP (to test floor grouting, mostly) 10/10/2015Grout test study results Hans Jostlein25

Reference For earlier detailed emasurements on grout compressibility and load behavior see: NOVA Document 581-v1 10/10/2015Grout test study results Hans Jostlein26