Grouting, shimming, levelling procedures, and checks.
Grout is small in quantity but big in consequences. Select non-shrink types compatible with the foundation/socket (332), prepare bases, and plan flow/vent paths to avoid voids. Control pot life and curing in hot climates (337). Remove shims, complete QA tests, and document records (714). Typical defects and fixes are listed, with acceptance checks tied to height/level tolerances (312, 626). Include one-sentence context that naturally links upward to the parent hubs (this section and the chapter hub). Link installation pages only if helpful: What to Expect and Installation Guide.
Important: This is a general guide. For live projects we develop a tailored
Method Statement & Risk Assessment (MS/RA) and align with authority approvals (e.g., SIRA) where in scope.
625.1 Grout types & selection
Pick non-shrink grout compatible with base (332). Right grout supports crash rated bollard plates.
Choose a non-shrink cementitious grout formulated for baseplates and sockets, and ensure chemical compatibility with the foundation and any galvanizing around the socket. For crash-rated arrays, treat the grout as part of the tested system: changing type, water ratio, or aggregate can affect stiffness at the grout bed and the load path into the footing.
Match performance attributes: early strength for program pressure, flow/spread for tight gaps, and durability for hot, sandy environments. Confirm manufacturer limits for maximum pour thickness and embedment details from foundation design checks (333) and foundation types (332). Record the approved product and batch in the ITP (714).
| Aspect | What matters | Where to verify |
|---|---|---|
| Compatibility | Grout ↔ socket coating, footing concrete | Product datasheet · Design checks (333) |
| Flow & stability | No segregation/bleed; continuous fill | Method statement · Trial mock-up |
| Strength gain | Meets hold-down & bearing by required time | Cube tests · Manufacturer curves |
625.2 Base prep & cleanliness
Clean, saturated surface-dry per data sheet. Prep underpins HVM bollard bearing.
Preparation drives bond and bearing. Remove laitance, oil, paint, and dust. Roughen smooth concrete if specified. Achieve Saturated Surface-Dry (SSD) per the datasheet so the base concrete does not rob the grout of mix water. Dry runs for access, hose reach, and mix location reduce delays that shorten site pot life.
Check plate/sleeve gaps against the approved detail from Formwork & Cover (623) and confirm clearances for flow and headroom around services planned in Sleeves, Penetrations & Cable Glands (622).
625.3 Levelling techniques
Use shims/levelling nuts; remove after set. Techniques keep crash rated bollard plumb.
Two common approaches keep the baseplate level and the post plumb: (a) temporary shim packs positioned near corners and (b) levelling nuts beneath anchor nuts on studs. Both must place load paths where the finished grout will be; avoid large point loads that can crush grout or distort alignment. Set corner elevations using a datum & benchmarks stick and verify with calibrated levels.
Agree the removal method and timing in the RAMS: shims are pulled once grout has reached the manufacturer’s “safe removal” strength; levelling nuts are backed off to specified clearances after the final set. Cross-check plumb and height against Height setting (312) and close the loop later with Datum & Alignment Checks (626).
625.4 Flow/vent paths
Provide vents to avoid air traps. Paths ensure HVM bollard grout continuity.
Grout needs a low-resistance in path and a visible out path. Pre-plan pour holes (or skirt gaps) and vents at high points so trapped air and bleed water escape. For deep sockets, consider staged “gate pours” from one side while observing grout emergence from vents on the other. If drainage interfaces are close, coordinate with Drainage (334) to prevent grout blocking weep holes or sumps.
625.5 Pot life & curing
Respect pot life; protect from heat/wind (337). Curing preserves crash rated bollard bond.
In the UAE’s hot climate, pot life can halve on a sunny slab. Mix in the shade, use cooled water if allowed, and keep batches small so placement finishes before initial set. Apply curing measures (membranes or wet hessian, as approved) to prevent rapid moisture loss and micro-cracking. Cross-reference climate controls in Hot Climate Design (337) and record start/finish times and temperature in the pour log for later SAT/witness evidence (638).
625.6 Shim removal & final set
Remove shims; fill voids. Removal prevents HVM bollard point loading.
Once the grout reaches the manufacturer’s minimum strength for handling, remove temporary shims or back off levelling nuts to the specified clearance so the base bears on grout, not points. Immediately fill any voids with fresh grout or approved repair material. Re-check plumb, height, and level—record results and photos in the ITP (714) and tag them for the evidence capture standard (716).
625.7 QA tests & records
Flow/spread and compressive checks (714). QA validates crash rated bollard base.
Measure flow/spread (per datasheet) at the start of each batch; adjust water only within the approved range. Cast cubes or cylinders as required; record cure conditions and test ages so strength results are traceable to the installed bases. Keep a witness point log (714) and link product delivery notes and batch numbers to the location plan. Consolidate the set of records for the Handover Pack (736).
625.8 Typical defects & fixes
Address shrinkage, voids, high spots. Fixes sustain HVM bollard alignment.
Voids/air pockets: usually from no vent path or early set—drill/pressure-inject approved repair grout if the baseplate remains within tolerance. High spots/lipping: light grinding only if it won’t reduce bearing area below the accepted limit; otherwise re-grout. Shrinkage/edge cracking: often heat/wind related—improve curing regime and repair with compatible materials. Any defect threatening bearing, plumb, or acceptance criteria must trigger an NCR (719) and formal repair plan.
625.9 Acceptance checks
Verify level/flatness per 312, 626. Checks close crash rated bollard tolerance loop.
Prove the finished condition: plate flatness, grout flush/arrises sound, final plumb and height within the bands in Height setting (312). Run the full Datum & Alignment Checks (626) across the array and store geotagged photos and measurements with the submission pack (938). This closes the loop from product choice to installed performance.
Related
External resources
- ASTM F2656 — Crash testing overview
- NPSA — Hostile Vehicle Mitigation guidance
- FEMA 426 — Building security reference
625 Grout Beds & Levelling — FAQ
What grout should I use under a crash-rated bollard baseplate?
Use a non-shrink cementitious baseplate grout approved in the ITP. Match flow, early strength and thickness limits to the detail in 332/333, and record product and batch numbers in the QA pack.
Do shims stay in place after grouting?
No. Shims or levelling nuts are temporary. Remove or back them off after the grout reaches safe handling strength, then fill any voids to avoid point loading and distortion.
How do we prevent voids and air pockets?
Plan an “in” path and a vent “out” path at high points; place continuously from one side until grout emerges clean at vents. For deep sockets, use staged gate pours and observe emergence.
What acceptance checks close the task?
Verify level, flatness, height and plumb against 312. Run the array verification in 626 and file test results, photos and measurements with the submission pack for SAT/witness.