Attachment B - FRP Grout Kit Specifications.docx

ATTACHMENT B – FRP GROUT KIT SPECIFICATION

DATE: 18 JULY 2025

B1. SCOPE.

B1.1. Scope. This technical characteristic describes the requirements for procuring the required rapid setting grout material and the ISO container for the FRP grout kit.

B2. FRP RAPID SETTING SPALL REPAIR/GROUT MATERIAL REQUIREMENTS.

B2.1. Rapid Setting Spall Repair/Grout Material. The Engineering Research and Development Center (ERDC), Vicksburg, MS, is the Department of Defense’s lead pavement research facility for roadways, permanent airfields, contingency airfields, and railroads. ERDC is the approving agency for all Air Force ADR related repair materials. Due to the critical nature of performing emergency airfield repairs, presumably after an act of war, and the requirement to support heavy aircraft loads, materials must be pre-qualified for procurement and use.

B2.1.1. Approved Grout Material Information. Currently, nine products meet the grout performance specifications, and the products are listed on the Tri-Service Transportation Qualified Products List (QPL). Table B1, Approved Grout Material is the current table from the QPL. Verify currency per delivery order.

The QPL can be accessed at https://transportation.erdc.dren.mil/triservice/research.aspx; however, it requires a DoD Common Access Card. If unable to access via DoD Common Access Card, the AFCEC/CXXM can provide the list as needed if requested via email.

Table B1. Approved Grout Material

B2.1.2. Grout Material Recommendation. ERDC/AFCEC recommends using any of the approved material above (see Table B1) with aggregate being smaller than 3/8-inch minus, such as material #5 on the list (Rapid Set Mortar Mix by CTS Cement Corp); due to the nature of placing the mortar material for securing the tri-talon anchors.

B2.1.3. Grout Material Packing Requirements. The grout material must be packaged in 5-gallon buckets (50-lbs of dry material) with sealed lids. The bucket must allow for the addition of water and mixing operation.

B2.1.4. Grout Material Shelf-Life Requirements. The grout material must have a minimum shelf-life remaining of 36 months at the time of delivery.

B2.1.5. Grout Material Safety/Hazardous Chemical Issues. The material’s Safety Data Sheets (SDS) will be evaluated against that of standard cementitious material. If additional precautions are required, the effect to the tri-talon grouting process will be evaluated and if deemed unacceptable, the material will be rejected.

Table B2. Spall Repair and Grout Material Specifications

≥ 3,000 psi @ 2-hr

≥ 5,000 psi @ 1 day

≥ 5,000 psi @ 7 days

≥ 5,000 psi @ 28 days

≥ 350 psi @ 2-hr

≥ 600 psi @ 7 days

≥ 600 psi @ 28 days

2 ≤ x ≤ 6 Mpsi @ 2-hr

2 ≤ x ≤ 6 Mpsi @ 28 days

Initial Set: ≥ 15-min

Final Set: 25 – 35 -min

Stored in water

≤ 40 με @ 14 days

No cracking @ 28 days

B3. FRP GROUT KIT COMPONENTS REQUIREMENTS.

B3.1. Rapid Set Mortar Mix. 140 Rapid Set Mortar Mix buckets are required in the FRP Grout Kit. Rapid Set Mortar Mix buckets shall be equivalent to specifications in Section B2.1. thru B2.1.5. of this attachment.

B3.2. Bucket Lid Opener. Four (4) bucket lid openers, are required in the FRP Grout Kit. These bucket lid openers, are required open the buckets of Rapid Set Mortar Mix. The bucket lid opener, shall be equivalent to

· Construction Material: Durable Plastic

· For Use With: 5-gal buckets

B3.3. Wood Pallet, 48-in x 44-in,. Four (4) wood pallets, 48-in x 44-in, are required in the FRP Grout Kit. The wood pallet, 48-in x 44-in, shall be equivalent to

· Size: 48-in wide with forklift pocket opening x 44-in long (no forklift opening required on this side)

· Material: Wood, Heat Treated per ISPM 15

· The contractor shall place and secure two (2) 48-in wide x 44-in long x 3/8-in thick plywood to the top and bottom of each 48-in x 44-in wood pallet.

· Contractor shall provide ISPM 15 Certification with each/all wood pallets.

· A detailed drawing of the wood pallet, is shown in ATTACHMENT H – FRP DRAWING PACKAGE drawing number 6833284-02 page 3.

B4. FRP KIT ISO QUADRUPLE (QUADCON) REQUIREMENTS AND COMPENENTS.

B4.1. Quadruple Container (QUADCON). One (1) QuadCon, is required for the FRP Grout Kit. This QuadCon stores and secures all items within the FRP Grout Kit for shipment, long-term storage and for use during the installation of and/or maintenance of the installed FRP mat panel assembly. The QuadCon, shall be equivalent to

· QuadCon shall have corrugated steel sides, roof, and swing doors on both sides.

· QuadCon shall have a heavy-duty steel floor.

· QuadCon shall have four-way forklift pockets.

· QuadCon shall be in good condition.

· QuadCon shall be the following dimensions:

· Exterior Length – 4-ft, 9 3/8-in

· Exterior Width – 8-ft o Exterior Height – 8-ft

· Interior Length – 4-ft, 6-in

· Interior Width – 7-ft, 6-9/16-in

· Interior Height – 7-ft, 5-in

· Door Width – 4-ft, 5-1/2-in

· Door Height – 7-ft, 1-1/8-in

· QuadCons shall have dual swing doors on two opposite sides. Doors shall incorporate gaskets for a weatherproof seal when closed.

· QuadCons shall be Army green, tan, or brown in color, in priority order.

· The contractor shall mark each QuadCon according to the uniform procedures detailed in Defense Transportation Regulation (DTR) – Part VI, chapter 603 (paragraph 5).

· Serial numbers shall be displayed on all four sides and on top of the QuadCon.

· ISO containers shall be weatherproof.

· Maximum tare weight shall not exceed 2,120 lbs. and maximum payload capacity shall not exceed 9,040 lbs.

· QuadCon shall have vents, two (2) each in door panels.

· QuadCon shall have connecting couplers, three (3) per QuadCon.

· QuadCons shall be CSC certified and cargo worthy, Reference: MIL-HDBK-138B, Guide to Container Inspection for Commercial and Military Intermodal Containers, 01 Jan 2002

B4.2. Strap, Ratchet, Wide Handle. Two (2) ratchet straps, are required for the FRP Grout Kit. The ratchet straps shall be equivalent to

· Width min 2-in

· Length min 30-ft

· Flat nylon webbing

· Working load – 12,000-lbs

· Coated S-Hook

B4.3. Lock, Combination, Government. Two (2) locks, combination, government, are required for the FRP Grout Kit. These locks, combination, government, are used to secure both sets of doors on the QuadCon during shipment and long-term storage. The lock, combination, government, shall be equivalent to

· Size: 5/16-in diameter, 2-1/4-in high, 1-in wide shackle.

· 2-in wide laminated steel body padlock.

· Hardened steel shackle for extra cut resistance.

· Combination change instructions and change tool included.

· 4-digit dialing allows for thousands of possible combinations.

· Without chain.

· Spec Number (CID): ASTM F883 A-A-1928

B5. FRP GROUT KIT PACKAGING.

B5.1. Packaging

B5.2. FRP Grout Kit Packaging Requirements. The following list of packaging requirements are used to package each FRP grout kit for shipping.

B5.2.1. Metal Strapping (Banding) 1/2-in. Approximately 750-ft of metal strappings (banding) and 48 metal strapping seals can be expected to be used in the FRP Grout Kit. The metal strapping and seals are used to secure the Rapid Set Mortar Mix buckets together on each of the four (4) pallets. Metal strapping, shall be equivalent to

· Banding material: Low carbon cold-rolled steel

· Seal material: Rust resistant zinc coating

· Finish: Painted and waxed

· Banding width: min 1/2-in

· Banding thickness: min .020-in

· Banding breaking strength: min 1,200-lbs

· Includes enough seals to adequately secure the buckets

B5.2.2. Stretch Wrap, 80 GA. Approximately 1,250-ft of Stretch wrap, 80 GA, can be expected to be used in the FRP Grout Kit. This stretch wrap is used to secure the Rapid Set Mortar Mix buckets together on each of the four (4) wood pallets. The stretch wrap, shall be equivalent to

· Material: LLDPE (Liner Low Density Polyethylene)

· Features: Exterior surface treated to prevent slippage

B5.2.3. Corrugated Fanfold. Approximately 200-ft of corrugated fanfold can be expected to be used in the FRP Grout Kit. This corrugated fanfold, is used to secure the Rapid Set Mortar Mix buckets together on each of the four (4) wood pallets. The corrugated fanfold, 200-lb Test, shall be equivalent to

· Material: C flute

· Style: Corrugated sheets, corrugated runs widthwise

· Appearance: NOT pre-scored

· Test: 200#

B6. PACKAGING FRP GROUT KIT IN ISO QUADCON.

B6.1. Wood Pallet, 48-in x 44-in. Secure 42 buckets of Mortar Mix on two (2) of the wood pallet, and 28 buckets of Mortar Mix on two (2) of the wooden pallets per drawings/inventory on ATTACHMENT H – FRP DRAWING PACKAGE drawing number 6833284-02 pages 2 – 3.

B6.2. QuadCon. Package the one (1) QuadCon with the appropriate items per drawings/inventory on ATTACHMENT H – FRP DRAWING PACKAGE drawing number 6833284-02 pages 2 – 3.

B6.2.1. Safety Data Sheets & ISPM 15 Certification. The material’s SDS and ISPM 15 certifications will be secured in some kind of plastic document protector and placed inside the QuadCon or attached to the inside of one of the container doors.

B6.2.2. Container Labeling. The contractor shall stencil 1-in (minimum) high block characters on the outside of the left door of each container as follows: ‘ 3 of 5 ’

B6.2.3. Container Inventory & Packaging Diagram. The vendor shall provide a full container inventory listing and packaging diagram. The container inventory listing and packaging diagram will be permanently attached to the inside of the right-side door on opposite ends of the QuadCon. Inventory and packaging diagram will be imprinted on a stainless-steel board. Minimum size for inventory and packaging sheet is 12-in wide and 18-in tall.