Grout Mortar Guideline

Production and use of cement-bound grouting concrete and grouting mortar (DAfStb guideline)

Declaration of Conformity Certificate

As a manufacturer of products subject to building regulations, PAGEL® Spezial-Beton GmbH & Co. KG is obliged under state building regulations to declare that our grouting mortars and concretes comply with the technical building regulations and have been certified for use by the building authorities. This is done by labelling them with the Ü mark. Formally correct labelling is crucial for the user, as construction products may only be used if they meet the building regulations.

This requires factory production control to ensure compliance with the relevant technical rules. At PAGEL®, this production control is monitored by the Quality Association of German Construction Chemistry (Qualitätsgemeinschaft Deutsche Bauchemie e.V.) as a recognised certification body in accordance with the DIBt's PÜZ directory.

The design of the Ü mark is specified in the MÜZVO: It contains the letter ‘Ü’ as well as the name and manufacturing plant of the manufacturer, the basis for the confirmation of conformity (for grouting mortar/concrete, the DAfStb guideline VeBMR, July 2019 edition), the essential characteristics for the intended use and the mark or designation of the certification body (QDB). This information must be clearly legible within the area enclosed by the ‘Ü’.

More information

The template for certificates of conformity also requires a clear designation of the construction product; each line refers to a specific product with its characteristics, technical rules and associated proofs of usability.

Foreword to the VeBMR

The production and application of grouting concrete and grouting mortar for load-bearing components requires in-depth knowledge and practical experience in handling these building materials.

The guideline refers to grouting concrete and grouting mortar that are usually processed in a flowable consistency. Mortars intended for other consistency ranges can be evaluated accordingly in accordance with the specifications of this guideline.

The provisions of the dry concrete guideline that deviate from DIN EN 206-1/DIN 1045-2 have been taken into account and integrated accordingly in this guideline.

The requirements of DIN EN 1992-1-1 in conjunction with DIN EN 1992-1-1/NA apply to the design values of the deformation properties and strengths. In certain cases, for example when grouting highly stressed machine foundations, it may be necessary to determine deformation and strength characteristics separately (e.g. modulus of elasticity, creep coefficient, thermal expansion coefficient, flexural strength, fatigue strength).

Grouting concrete and grouting mortar

Grouting concrete and grouting mortar consist of cement, mineral aggregate, concrete admixtures and, if necessary, concrete additives. They are produced as dry mixes at our PAGEL Spezial-Beton plant and processed at the installation site in a flowable consistency in accordance with our work instructions. Grouting concrete is defined by aggregate with a maximum grain size > 4 mm, grouting mortar by aggregate with a maximum grain size ≤ 4 mm.

Monitoring in the manufacturing plant

General information

Monitoring at our manufacturing plant includes in-house production control, external monitoring of this production control and certification of grouting concrete and grouting mortar.

In-house production control

We check and monitor the properties of the raw materials and the grouting concrete or grouting mortar until handover (in accordance with DIN EN 206-1 and DIN 1045-2).
The test results are documented and statistically evaluated.

Certification and regulatory monitoring

The certification and regulatory monitoring of our products is carried out by recognised bodies. The scope and frequency of regulatory monitoring are specified at regular intervals.

Delivery and storage

We fill casting concrete and casting mortar into containers (sacks or big bags) and prepare them for transport. After delivery, the recipient must store the material in a cool, frost-free and dry place in its original sealed container. This storage is important to ensure a shelf life of 12 months (from production).

Technical features

Flow classes / flow consistency classes (consistency classes)

By definition, grouting is a flowable mortar/concrete. In order to classify the flowability of the individual products, they are divided into consistency classes. Grouting concrete is classified into flow classes from a1 to a3 and grouting mortar into flow classes from f1 to f3.

Test procedure:

Grouting concrete – flow classes (a1–a3) (tested 5 minutes after production, based on DIN EN 12350-5)
Grouting mortar – flow classes (f1–f3) (flow channel as reference; alternatively, spreadability can be tested on site)

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	Product	Flow rate classes	1	2	3
Standard grout	V80 C45	a		•
	V160 C45	a		•
	V1®/10	f		•
	V1®/50	a			•
	V1®/80	a		•
	V1®/160	a		•
High-strength grout	V1®/30HF	f	•
	V1®/50HF	a		•
	V1®/60HF	a		•
	HF10	f			•
	HF50	a		•
Quick setting grout	V2/20	f		•
	V2/50	a			•
	V2/160	a		•

Early strength classes

The early strength class describes how quickly the grout becomes load-bearing or load-resistant after installation. Compressive strength is measured after 24 ± 0.5 hours. (DIN EN 12390-3, testing of hardened concrete)

Test specimens:

Concrete cube (150 mm × 150 mm × 150 mm)
Mortar prism (40 mm × 40 mm × 160 mm)

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	Product	Early strength class	A	B	C
Standard grout	V80 C45	Concrete			•
	V160 C45	Concrete			•
	V1®/10	Mortar	•
	V1®/50	Concrete	•
	V1®/80	Concrete	•
	V1®/160	Concrete	•
High-strength grout	V1®/30HF	Mortar	•
	V1®/50HF	Concrete	•
	V1®/60HF	Concrete	•
	HF10	Mortar	•
	HF50	Concrete	•
Quick setting grout	V2/20	Mortar	•
	V2/50	Concrete	•
	V2/160	Concrete	•

Compressive strength classes
Compressive strength is the key indicator for load-bearing capacity in the final state. The guideline requires that the required compressive strength in accordance with DIN EN 13670 in conjunction with DIN 1045-3 be maintained.

This guideline applies to grouting concrete and grouting mortar with high early strength and a compressive strength class of at least C50/60. The strengths are determined after 28 days.

Cylinder (150 mm Ø, 300 mm height) 50 N/mm² → C50/60 ← Cube (150 mm edge length) 60 N/mm²

	Product	Compressive strength class (N/mm² after 28 days)
Standard grout	V80 C45		C50/60
	V160 C45		C50/60
	V1®/10		C55/67
	V1®/50		C60/75
	V1®/80		C60/75
	V1®/160		C60/75
High-strength grout	V1®/30HF		C100/115
	V1®/50HF		C90/105
	V1®/60HF		C100/115
	HF10		C100/115
	HF50		C100/115
Quick-setting grout	V2/20		C60/75
	V2/50		C70/85
	V2/160		C70/85

Shrinkage classes

Shrinkage is the reduction in length/volume during drying and hardening. Excessive shrinkage can lead to cracks, joint breakage or loss of strength, which is particularly critical in undercuts and grouting joints. For this reason, we at PAGEL do not use shrinkage classes SKVB II and SKVM III in our grouting compounds in order to actively prevent these problems.

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	Product	Shrinkage class	0	I	II	III
Standard grout	V80 C45	SKVB	•
	V160 C45	SKVB	•
	V1®/10	SKVM			•
	V1®/50	SKVB		•
	V1®/80	SKVB	•
	V1®/160	SKVB		•
High-strength grout	V1®/30HF	SKVM	•
	V1®/50HF	SKVB	•
	V1®/60HF	SKVB	•
	HF10	SKVM		•
	HF50	SKVB	•
Quick setting grout	V2/20	SKVM	•
	V2/50	SKVB	•
	V2/160	SKVB	•

Our building materials laboratory

The PAGEL building materials laboratory

PAGEL has a modern, state-of-the-art building materials laboratory. In addition to mechanical test processes we can also measure the swelling and shrinkage deformation of materials, and much more besides. This considerably aids us in our product development.
Our products are tested for their practical suitability in a climate chamber and in climate cabinets in temperature ranges between -20 °C and +60 °C (-4°F and 140°F resp.).

Test presses

Compression load: 5.000 kN
Compressive strength on prism, cube and cylinde
Flexural strength on prism and bar
Splitting tensile strength on cylinder
Static Young's modulus

Temperature tests
- Climate chamber for sample preparation and fresh concrete testing between -10 °C and +50 °C (14°F and 122°F)
- Climate cabinets for sample storage at temperatures between -20°C and +60°C (-4°F and 140°F) and air humidity between 0% and 100%
- Storage of test specimens in water between 5°C and 35°C (41°F and 95°F)
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Measurement of deformations

Schleibinger shrinkage-cone at temperatures between +5°C and +35°C (41°F and 95°F) for testing the contraction and expansion behaviour.

Complementary tests

Automatic Blaine value Determination
Sieve analysis
Vicat test: initial and final setting time
Pull-off strength test
Böhme's abrasion resistance test
Acoustic analysis of the resonance frequency for non-aggressive testing of the dynamic and static Young's modulus
Characteristics of newly poured mortar in accordance to DIN EN 12350, directive VeBMR and ASTM

Schleibinger shrinkage cone for testing the early shrinkage and swelling behavior