- PURPOSE
- SCOPE
- REFERENCE
- RESPONSIBILITIES
- PROCEDURE
- ATTACHMENT
1.0 PURPOSE
The purpose of this procedure is to provide the work methods, guidelines, and quality requirements for the application of grouting for all structural pipe racks foundation.
2.0 SCOPE
The scope of works covers under this procedure applies to all grouting application for all structural steel foundation covered.
3.0 REFERENCES
SATIP-M-001-01 Structural Steel Pipe Racks, Steel Supports & Miscellaneous *Steel Structures (Incl. Piping Supports per specification).
SAIC-M-2007 – Structural Alignment prior to grouting.
SATR-M-2001 – Structural Steel Alignment Report.
SAES-Q-007 – Foundation and Supporting Structures for Heavy Machinery.
SAES-Q-010 – Cement based, Non-shrink grout for Structural and Equipment Grouting.
SAES-Q-011 – Epoxy Grout for Machinery support.
SAIC-Q-1047 – Materials Components & Ingredients Receiving Inspection.
SAIC-Q-1048 – Cement Based Non-Shrink Grout Surface Preparation & Formwork Inspection.
SAIC-Q-1049 – Mixing, Placement Sampling, Testing Curing and Final Inspection.
PIP STS03600 – Process Industry Practices.
4.0 RESPONSIBILITIES
4.1 Site Manager shall be responsible in providing all necessary requirements at site such as implementing all HSE requirement, manpower, materials and equipment to carry out grouting activities as per schedule and as per project specification.
4.2 Quality Control Inspector shall be responsible to provide inspection documentation such as RFI Notification to Company. Ensure that grouting activities are being carried out in compliance with the quality requirements from materials to installation activities.
4.3 Construction Manager shall be responsible in carrying out safety measures such as preparation of barricades and warning signs, work permits, etc.
5.0 GROUTING (NON-SHRINK) PROCEDURE
General:
Non-Shrink Grout (CONBEXTRA HF) materials prior to use for the actual grouting application shall have available records of materials receiving inspection and accepted as per SATIP-Q-010 and SAIC-Q-1047
compliance.
All Installed Structural Steel Pipe Racks and Steel supports shall have records of inspection as per SATIP-M001-01 and SAIC-M-2007 with accepted SATR-M-2001 final alignment report prior to final grouting application.
Preparation of cement based non-shrink grout materials and formworks inspection shall be in line with SAIC-Q-1048 and in line with SAIC-Q-1049 for mixing, placement, sampling, testing, curing and final inspection. Process Industry Practices – PIP STS 03600 for Non-Shrink cementitious specification and application is part of Saudi Aramco practices to be considered should there be any relevant consideration.
The following step by step procedures is as per manufacturer’s recommendation and guidelines practices for the application of grouting:
5.1 Foundation Preparation:
5.1.1 Concrete surface to be grouted shall be prepared for chipping using chipping hammer, grit blasting or high pressure water jetting whichever is applicable in order to leave a rough textured and clean surface before installation of base plate. Use of bush hammering or any similar method that can fracture or damage the integrity of the surface and foundation is not permitted.
5.1.2 Chipping should cover the full extent of the surface intended to be in contact with grout. This will enable the grout to have a strong adhesion to the chipped surface of the concrete.
5.1.3 In case of bolt anchoring inclusion to the grout, a bolt pocket formers shall be shaped to form a cone, this will enable to help ensure stresses build up when the bolts are tightened and stress will be directly transmitted to the foundation.
5.1.4 Bolt pocket formers shall be made from materials that are easy to remove, but leave a rough concrete surface texture when stripped.
5.1.5 Surface of the chipped concrete, base plates and holding down bolts, etc. shall be cleaned and free from any oil, dust, dirt, paint and any residual curing compound that can cause bond impairment.
5.2 Formworks:
5.2.1 Surface foundation to be fitted with formworks shall be thoroughly cleaned including bolt holes.
5.2.2 Fitted formworks around the base plates where grout is to be contained shall be as water tight as possible to prevent loss of grout.
5.2.3 The top of the formwork shall have a height minimum of 25mm above the underside of the base plate. Base plates and foundation concrete gap of less than 25mm depth, the formwork shall be higher to allow a pressure head to build up when there are large base plate pours requirements.
5.2.4 Formworks shall be fixed and shall hold up additional localized pressure should pouring of grouting requires equipment such as pump under pressure, etc. Formworks shall be sealed using silicon adhesive that may adhere tightness of the form and shall be free from any water leakage during grouting.
5.3 Grouting Preparation
5.3.1 Before grouting pouring application starts, ensure that formwork and concrete surface shall be free from all kinds of dirt, dust, and debris and shall be vacuum clean and air blown.
5.3.2 Concrete surface within the formwork shall be saturated with water within 24 hours prior to grouting. Ensure that the surface is damp and in good and acceptable temperature condition
prior to grouting.
5.3.3 Mixing equipment shall demonstrate to be suitable and in good working condition and a backup mixing equipment shall be available in case of equipment breakdown to ensure a continuous grouting process.
5.3.4 Drum type mixers is permitted only if it is modified by a fixing wire mesh with size of 12-15mm over blades inside the drum to assist in breaking up balls of grout if it exist.
5.3.5 Ensure that adequate potable water is available for mixing and should meet the allowable acceptable temperature as prescribed in material specification.
5.3.6 Grouting during hot weather condition is not permissible if ambient temperature exceeds the allowable limit especially if grouting activities is to be carried out in an open area. Grouting is permissible only if area is shaded and material does not exceed the ambient storage limit and a mixture of grout not exceeds to it maximum mixed at 26° C when placed.
5.3.7 A calibrated thermometer gauge shall be available to monitor grout materials, water and ambient temperature to ensure compliance of grout mixture as per specification.
5.3.8 Any adjacent machinery in operation that may cause vibration to pour site shall be shutdown.
5.4 Grouting Mixing
5.4.1 Fitted formworks shall be checked for possible leakage after saturation compliance of 24 hours. Ensure that prior to grout mixing all standing water is removed including water from the bolt pockets and surrounding area. Concrete to be poured with grout shall be in damp condition.
5.4.2 Ensure that materials and water mixture is as per materials specification specified in materials technical data sheets and shall be in compliance with PIP STS 03600 and SAIC-Q-1049.
5.4.3 Mixture of grout in an individual bag shall have a slow speed of 300-500 RPM using a heavy duty drill fitted with a suitable paddle and a minimum of 3 minutes. For multiple bag mixes, a dedicated grout mixer shall be used to allow a consistency of mixtures and with a minimum allowable mixing time of 4-5 minutes meeting the acceptable and desired mixes prior to grout pouring.
5.4.4 When the mixture grout is lump free, add mix water to bring the mixture to the desired consistency.
5.4.5 Ensure cube samples of non- shrink grouting materials are taken for compression test, Two(2) sets of 50x50mm cubes per grouting operation.
5.4.6 Ensure copy of compression test results of grout cubes are forwarded to Saudi Aramco project inspection unit for their reference.
5.5 Grouting Placement
5.5.1 Pouring of grout shall start at one end of the base plate down to the slope of the formwork. When grout reaches at the far side of the formwork and rises above the bottom of the base plate, slowly moving the pouring point along the length of the base plate to secure a uniform and even pours within the formwork.
5.5.2 All bolt pockets shall be filled with grout and shall secure fullness of pouring grout to avoid and prevent voids to form within the formwork and below the base plates.
5.5.3 Allow at least a minimum of 3mm grout filling above the bottom of the base plate to secure a uniform and even filling and to avoid possible cracks during curing time.
5.5.4 Always pour at one side of the base plate steadily down to the slope of the formwork to reduce the possibility of air entrapment. Avoid pouring of grout at different sides to avoid voids which can cause the effectiveness of the bearing area.
5.6 Curing
5.6.1 After the grout is placed, a covering of the exposed edges with wet rags shall be placed to keep the grout wet for 24 hours A cloth retains moisture more effectively than hessian ( a wet burlap is recommended for use and a plastic covering to maintain its moisture). Refer to SAICQ-1049 and SAES-Q-010 for further compliance.
5.6.2 Formworks can be remove after 24 hours, but it is best to remove the formworks after minimum 7 days curing to allow a solid and effective bearing grout foundation. Curing by the use of potable water and wet burlap shall be continuous within 7 days.
Note: Strict monitoring of curing time shall be strictly implemented to secure a wet curing within 24 hours to avoid cracks and holes to form when curing is not complied. It is still best to follow manufacturer’s recommendation on curing as per materials technical data sheets.
6. Attachment:
6.1 CONBEXTRA Method Statement / Materials Specification / Material Safety Data Sheet
SAFETY DATA SHEET CONBEXTRA HF