Five Star Special Grout 400 is a cement-based, nonmetallic, non-shrink fluid grout specifically formulated for grouting cables and tendons requiring corrosion protection. When tested in accordance with ASTM C 827, this precision-engineered grout demonstrates positive expansion characteristics while meeting the rigorous performance requirements of ASTM C 1107-02 Grades A, B and C, ASTM C 1107-07, CRD-C 621-93 specifications for non-shrink grout, and Post Tensioning Institute specifications for grouting post-tensioned structures.
This high-performance grout reaches 8,500 psi compressive strength at 28 days and provides extended working time of up to 2 hours at 90°F (32°C), making it ideal for complex cable grouting operations where precision and reliability are critical. Its advanced air release technology per ACI 351.1 R ensures complete void filling, while its non-bleeding, non-shrink properties provide permanent corrosion protection for bridge cables and post-tensioned structures. The fluid consistency allows for easy pumping through tight clearances while maintaining excellent flow characteristics for thorough tendon duct filling.
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Key Features of Five Star Special Grout 400
- Air Release Technology
Incorporates advanced air release technology per ACI 351.1 R for complete void elimination and optimal grout placement. - Extended Working Time
Provides up to 2 hours of working time at 90°F (32°C), allowing for complex grouting operations without rushing. - Pumpable Fluid Consistency
Engineered for very tight clearances with excellent flow characteristics through flow cone testing (9-20 seconds per ASTM C 939 modified to PTI requirements). - Non-Bleeding Formula
Zero bleeding at 4 hours per ASTM C 940 (Modified) ensures consistent grout density and performance. - Positive Expansion Properties
Shows positive expansion per ASTM C 827 while maintaining less than 0.2% hardened height change at 28 days. - High Compressive Strength
Achieves 3,500 psi at 1 day, 7,000 psi at 7 days, and 8,500 psi at 28 days for reliable structural performance. - Superior Corrosion Protection
Passes accelerated corrosion testing for over 2,500 hours with very low permeability (less than 1,000 coulombs). - Aluminum-Free Formulation
Does not contain aluminum powder, eliminating potential hydrogen gas generation concerns.
Recommended Applications for Five Star Special Grout 400
Five Star Special Grout 400 is specifically engineered for construction professionals working with post-tensioned concrete structures and bridge construction projects where cable and tendon protection is paramount. Its fluid characteristics and extended working time make it particularly suitable for complex grouting operations requiring precision placement and long-term corrosion protection.
Ideal Applications Include:
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- Corrosion protection of bridge cables and post-tensioned tendons
- Pressure placement into tendon ducts and cable stays
- Non-shrink grouting between precast panels, walls, and beams
- Grouting of post-tensioned concrete structures
- Permanent filling of voids in cable anchorage zones
- Bridge construction and rehabilitation projects
- Infrastructure projects requiring ASTM C 1107 compliance
Technical Specifications – Five Star Special Grout 400
Fluid precision non-shrink cable grout with comprehensive performance data for post-tensioned structures and cable protection.
8,500 PSI Ultimate Strength
2 Hour Working Time @ 90°F
ASTM C 1107 Grades A, B & C
0.0% Bleeding
ASTM C 1107 Grades A, B & C
Post Tensioning Institute Approved
Non-Shrink from Placement
Corrosion Protection
Extended Working Time
Pumpable Fluid Grout
Frequently Asked Questions
What is the recommended mixing ratio for Five Star Special Grout 400?
Mix with approximately 6 quarts of potable water per 49 lb bag. Do not exceed 6.5 quarts (13.5 lb) of water per bag. Mix to achieve a flow of 9-20 seconds through a flow cone per ASTM C 939 modified to PTI requirements.
What is the maximum injection pressure for tendon grouting?
Under normal grouting operations, pressure should not exceed 75 psi. Maximum allowable pressure is 150 psi. If pressure exceeds 150 psi, close the inlet and resume at the last intermediate vent where grout has been expelled.
How long is the working time at different temperatures?
Working time is approximately 2 hours at 90°F (32°C). For optimal performance, condition the grout between 40°F and 90°F (4°C and 32°C).
What standards does Five Star Special Grout 400 meet?
It meets ASTM C 1107-02 Grades A, B and C, ASTM C 1107-07, CRD-C 621-93 specifications for non-shrink grout, and Post Tensioning Institute specifications for grouting post-tensioned structures.
What is the shelf life and packaging?
One year in original unopened packaging when stored in dry conditions. Available in 49 lb (22.2 kg) bags yielding approximately 0.50 cubic feet (14.1 liters) of hardened material.
When can the structure be put back into service?
The grout should be protected from freezing until it reaches 1,000 psi (6.9 MPa). Post-placement procedures should be followed, including checking grout caps for voids after 24 hours and ensuring proper curing conditions.
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