Stadium 974

A key structural challenge was anchoring the massive steel roof to the reinforced concrete foundation using large base plates and dense bolt configurations. This required a deep-pour grout solution that could flow through tight spaces, remain dimensionally stable under extreme loads, and control heat generation to prevent thermal cracking.

This task demanded a precision-engineered, deep-pour grout capable of:

• Flowing through narrow, congested bolt configurations
• Achieving monolithic bonding in deep layers (600 mm)
• Maintaining dimensional stability under high structural load
• Controlling heat during curing to avoid thermal cracking 

The grouting operation was on the critical path, as the steel roof erection depended on the successful, time-bound curing of grout in the shear key zones.

DCP recommended Flo-Grout BP800, a specialized high-performance, non-shrink precision grout engineered specifically for heavy-duty and deep-pour structural applications. The grout was selected due to its proven capability to meet stringent technical and environmental requirements.

Flo-Grout BP800 offered exceptional flowability and structural performance, making it ideal for applications involving deep pours, high bolt densities, and significant structural loads.

System and Execution Approach:

1. Mock-up Trials
   Before site implementation, mock-up trials were conducted to accurately assess grout behaviour, thermal characteristics, bonding integrity, and setting times under simulated conditions.
2. Controlled Layered Pouring
   The application involved carefully staged pours in three distinct layers, each with a 90-minute interval to manage heat buildup effectively. This allowed partial thermal dissipation and ensured a monolithic bond across layers, crucial for structural integrity.
3. No Aggregate Use
   To maintain consistent flowability through narrow and densely packed anchor bolt configurations, the grout mix excluded aggregates. This choice, though challenging due to thermal management, was essential for ensuring thorough encapsulation of complex reinforcement arrangements.
4. Continuous Quality Control
   Throughout the grouting operations, rigorous on-site monitoring ensured precise placement, consistent flow, complete encapsulation, and defect-free curing, critical to the structural integrity and long-term performance.

Technical Challenges Addressed

• Significant Grout Depth: Achieved successful application at depths of 600 mm without using aggregates, exceeding standard practice limitations.
• Complex Anchor Bolt Configurations: Successfully navigated through densely arranged bolt patterns (up to 14 bolts × 40 mm per plate).
• Structural Load Demands: Ensured grout stability under vertical, shear, and bending forces from the stadium’s steel roof.
• Thermal Stability: Managed curing heat effectively, preventing thermal cracking despite large-volume pours .

The careful selection of Flo-Grout BP800 and a meticulously planned phased application resulted in a highly effective grout solution that fulfilled the project’s stringent structural and timing requirements. The grout achieved:

• Monolithic, high-strength encapsulation of all base plates and anchor bolts.
• Exceptional load transfer performance, essential for the stadium’s structural integrity.
• Zero instances of thermal cracking or dimensional instability.

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