1 PURPOSE.
2 SCOPE.
3 APPLICABLE DOCUMENTS.
4 MANPOWER.
5 TOOLS AND EQUIPMENT.
6 GENERAL REQUIREMENTS.
7 METHODS/PROCEDURES.
8 QUALITY CONTROL.
9 SAFETY ACTION PLAN.
10 ATTACHMENT.
EPOXY GROUTING APPLICATION WORK PROCEDURE | METHOD STATEMENT
1.0 PURPOSE
1. This method statement shall provide ARCC of minimum guidelines to carry out epoxy grouting application works for JAZAN REFINERY and TERMINAL PROJECT Package 12-Naptha and Aromatics.
2.0 SCOPE
2.1 This method statement covers the epoxy grouting application for J10-K-0701 & JlO K-0703.
2.2 Grouting application shall be in accordance with Standard Drawing, vendors recommendation, clients procedure and Saudi Aramco Standard.
3.0 APPLICABLE DOCUMENTS
3.1 Reference Documents
3.1.1 PIP STS0360 I
3.1.2 PIP REJE686
3.1.3 Epoxy Grout Specification
3.1.4 Recommended Practices for Machinery Installation and Installation Design
Construction Safety Manual
Latest Approved For Construction Drawings
3.2 ARAMCO Specification and Standard
3.2.1 SAEP-302 Instruction for Obtaining a Waiver of a Mandatory Saudi ARAMCO Engineering Requirement
3.2.2 SAES-Q-011 Epoxy Grout for Machinery Support
3.2.3 SATIP-Q-011-01 Epoxy Grout For Machinery Support
3.2.4 SAIC-Q-1053 Epoxy Grout Pre-Installation Inspection
3.2.5 SAIC-Q-1054 Epoxy Grout Mixing, Placement, Sampling & Testing Inspection
3.2.6 SAIC-Q-1055 Foundation and Epoxy Grout Curing/Protection and Final Inspection
3.2.7 STS03601 Epoxy Grout Specification
3.2.8 SCHEDULE Q Saudi ARAMCO Project Quality Requirements
3.2.9 Saudi Aramco Construction Safety Manual.
4.0 MANPOWER
4.1 Construction Manager shall implement all HSE requirements and ensure the implementation of this method statement.
4.2 Civil/Mechanical Supervisor shall be responsible for implementation at site. Civil Foreman with qualified crews and personnel will be responsible for the direct supervision and implementation of this method statement. Basic manpower to be mobilize for site application shall include but not limited to:
4.2.1 Carpenter
4.2.2 Mason
4.2.3 Helper
4.2.4 Surveyor
4.2.5 Rodman / Chainman
4.3 HSE Officer/Supervisor
4 .4 QC Inspector
5.0 TOOLS AND EQUIPMENT
5.1 Tools and equipment should be in good condition and must be checked by Safety Officer/ Mechanical Supervisor prior to use in the construction area. These includes but not limited to the following:
5.1.1 Resin mixer drill and/or Spiral Paint Mixer
5.1.2 Bagger mixer (depends on quantity required)
5.1.3 Grout mixers with container suitable for quantity required
5.1.4 Drill mixer
5.1.5 Mixing paddle
5.1.6 Pan mixers or rectangular container
5.1.7 Pushing tools (use to assist the grout to fill for far location)
5.1.8 Caulking guns
5.1.9 Finishing trowel
5.1.10 Wheel-borrow, bucket
5.1.11 Survey instrument
5.1.12 Starret level
5.1.13 Air compressor
5.1.14 Fonnworks with releasing oil
5.1.15 Vacuum cleaner
5.1.16 Power stiff bristle brushes
5.1.17 Hand tools
5.1.18 Electric/Manual saw
5.1.19 Expansion joint
6.0 GENERAL REQUIREMENTS
6.1 Material Receipt and Preservation
6.1.1 Grouting materials shall be in accordance with the project specification. Only approved grout products shall be used. Refer to PIP STS03601 for epoxy grout requirements.
6.1.2 All materials shall be delivered to job site in original unopened packages and shall be stored in accordance with the manufacturer’s recommendation.
6.1.3 Grouting materials shall be stored out of direct sunlight, clear of the ground on pallets protected from rainfall. Avoid excessive compaction.
6.1.4 The grout shall be stored, mixed, placed at temperatures recommended by manufacturer.
6.2 Preparatory Works
6.2.1 Confirm that equipment foundations released for grouting has reached the required strength or has cured the length of time as per project specification.
6.2.2 Secure valid Work Transfer Sheet from civil sub-contractor / mechanical group signed by respective department confirming that the equipment is ready for grouting.
6.2.3 Secure a valid work permit before starting any grouting works.
6.2.4 Contact surfaces of grout shall be chipped/rough to remove all laitance and weak surface materials. A sound and clean substrate shall reveal.
6.2.5 Concrete chipping and removal must not be performed with heavy tools such as jackhammers as they could damage the structural integrity of the foundation. A chipping hammer with a chisel bit is the preferred tool for this purpose.
6.2.6 When surface preparation is completed, remove all debris from bolt pockets by vacuuming. For foundation’s top surface area, use power wire brushing to remove loose contaminants followed by blowing of oil free air using air compressor. All surfaces should be thoroughly cleaned to ensure a strong bond develops between interfaces.
6.2. 7 The underside of base frame equipment shall be clean, dry and unpainted to allow grout to bond.
6.2.8 A minimum of 25mm of concrete must be removed for damaged concrete down to exposed fractured coarse aggregate.
6.2.9 Anchor bolts are protected by sleeves and exposed threads are wrapped with tape or other suitable means to keep them clean to prevent adherence of the epoxy grout
6.2.10 Anchor bolts are not tilted or bolt bound and shall be perpendicular with respect to the bottom of the base plate/soleplate (PIP REIE 686 Sec 3.5.2).
6.2.11 Ensure the base frame or skid is properly positioned and leveled.
6.2.12 Formworks shall be built of materials of sufficient strength and securely anchored and sealed to withstand the I iquid head and forces developed by grout during placement.
6.2.13 Grout forms shall have chamfer strips at all vertical corners and at the horizontal surface of grout.
6.2.14 Confirm that proper number and size of air relief holes in base plates were provided to prevent voids.
6.2.15 Cover grouting work area on floor with plastic to protect the floor.
6.2.16 Area for grouting (Anchor, Hole, & foundation base) shall be surface dry prior to placement.
6.2.17 Insert filler packing around the jack bolt so that the jack bolt can be turned even after the grouting has become hardened.
7.0 METHODS/ PROCEDURES
7.1 Placement of Grout
7.1.1 Placement of grout shall be as per manufacturer’s recommendations on mixing temperature.
7.1.1.1 The following methods below must be satisfied prior to Epoxy Grout application
7.1.1.1.1 Epoxy grout shall have the properties as per Saudi Aramco Standard or Specifications.
7.1.1.1.2 Laitance and oil-soaked or damaged concrete are removed with chipping hammer to sound fractured aggregate, or to a minimum of the top 1 inch (25 mm) of concrete.
7.1.1.1.3 The minimum grout thickness under any portion of the base plate/soleplate shall be 25mm.
7.1.1.1.4 Concrete in contact with the epoxy grout shall be clean, dry and oil free.
7.1.1.1.5 Formwork must be constructed liquid tight with adequate strength, rigidity and dimensions to permit epoxy grout placement.
7.1.1.1.6 Maximum depth of pour and length to width ratio shall be as per manufacture’s recommendations.
7.1.1.1. 7 Ensure elevation of the form works, the top surface of the grout shall match the elevation shown on the construction drawings.
7.1.1.1.8 Suitable shelter or enclosures shall be provided to protect the foundation and base plate from direct sunlight, dew, rain or other inclement weather. During cold weather, adequate enclosure and heating shall be provided to maintain foundation and base plate temperature with acceptable range specified by the grout manufacturer.
7.1.1.1.9 Expansion joints in epoxy grout shall be spaced at a maximum of 48 inches (1.4 m) unless otherwise specified in the drawing.
7.1.1.1.10 Expansion joints shall be made from closed-cell neoprene or polyethylene foam board, having a minimum thickness of 1 inch (25 mm) unless otherwise noted in the contract documents.
7.1.1.1.11 Expansion joints shall be fixed into position to prevent movement and shall be sealed at formwork and at the concrete base to prevent epoxy grout from passing around or underneath the joint during placement. (PIP STS03601, Sec. 6.2.5.2)
7.1.1. 1.12 All mounting plate/soleplate outside corners shall have a minimum of 50mm radius to prevent cracking of the foundation grout due to stress concentration at the corners.
7. I .1.1.13 Anchor bolts hole shall have a minimum of 3mm annular clearance to allow for field alignment of mounting plates.
7.1.1.1.14 All pump and other small baseplate shall be provided with leveling screws. Shims and wedges are not to be used.
7.1.1.1.15 Baseplate leveling jack screws shall be provided with stainless steel leveling pads.
7.l.1.1.16 Mounting plate jackscrews shall be liberally coated with paste wax or grease to prevent grout adherence.
7 .1.1.1.17 The resin and hardener shall be mix at 200-250 rpm per the grout manufacturer’s specified time period prior to introducing the aggregate. There should be no entrained air in the resin/hardener mixture.
7 .1.1.1.18 Full bags of aggregate shall be slowly added to the blended resin/hardener liquid and sufficiently mixed to completely wet-out the aggregate.
7.1.1.1.19 Grout shall be mixed in a clean, slow speed (15-20rpm) portable mixer but not a concrete mixer. (PIP REIE, Sec. 3.13.4).
7.1.1.1.20 Epoxy grout shall be mixed with the manufacturer’s written requirements including temperature restrictions.
7.1.1.1.21 An adequate quantity of grout ingredients shall be on hand before starting to mix and place the grout. No partial units of epoxy, resins, hardener, or aggregate shall be used. Ratios of components shall not be varied, and solvents shall not be added to change the grout consistency.
7.1.1.1.22 Adequate enclosures or shelter shall be provided for weather protection to maintain foundation and baseplate temperature within the acceptable range specified by the grout manufacturer.
7.1.1.1.23 Grout shall be applied only when surrounding temperatures are between I 5°C and 32°C (60°F and 90°F) unless otherwise specified in the manufacturer’s data sheets.
7 .1.1.1.24 Grout placements shall be started at one end of forms, and the cavity shall be filled completely while advancing toward the other end to prevent air entrapment. Refer to
attachment 2 of this method statement for sequence of pouring.
7.1.1.1.25 During pouring of grout, vibration or other forms of dynamic distribution shall not be permitted.
7.1.1.1.26 All leaks shall be sealed to prevent voids from forming in the grout.
7.1.1.1.27 Suitable shelter or enclosures shall be provided to protect the grouted foundations from direct sunlight and weather.
7 .1.1.1.28 Foundation and baseplate temperature are within the acceptable range specified by the grout manufacturer until the grout has cured.
7.1.1.1.29 The grout shall be checked for voids after the grout has cured. Any voids shall be filled according to epoxy grout manufacturer’s recommendations.
7.1.1.1.30 After the void grout has cured, the baseplate shall be recheck to ensure that all voids are filled with grout. Any voids still exist shall be rectified.
7 .1.1.1.31 Exposed expansion joints shall be sealed with the epoxy grout manufacturer’s recommended sealant.
7.1.1.1.32 The final level of the epoxy grout is flush with the top horizontal chamfer edges built into the formwork.
7. I. I. 1.3 3 Formworks can be removed after 24 hours or as per manufacturer’s recommendation. Removal of formworks shall be properly done to avoid surface damage.
7.2 Testing
7.2.1 Epoxy Grout Sampling and Testing
7.2.1.1 Sampling and testing shall be performed by a Saudi Aramco approved independent testing laboratory.
7.2.1.2 Third Party Agency’s Quality personnel assigned to the Work must be technically competent to perform their duties.
7.2.1.3 Grout samples for compressive test shall be taken as per ASTM C579, Method B Modified
7.2.1.4 Minimum compressive strength shall be 80 MPa (12,000psi) at 7days.(PIP STS03601, Sec. 5.1.1.1).
7.3 Curing
7.3.1 Cure the grouted area as per manufacturer recommendation, or to provide protection from direct sunlight/ heat cover/ shade.
7.4 Finishing and Clean-up
7.4.1 The grout is of self-leveling consistency; however a steel trowel damped into solvent might be needed lo finish the grout surface.
7.4.2 Remove excess grout or drops; the leftover grout materials shall be made into solid waste for proper disposal as per DEC/JGC. Clean transport buckets and other equipment for next application jobs.
7.4.3 Good housekeeping shall be maintained after completion of application.
7.5 Repair/replace of Cracked Portion
7.5.1 Cracked/damaged portion shall be manually chipped and removed, the chipped surfaces should be thoroughly cleaned by air and washed with water to ensure a strong bond between surfaces; then apply grouting materials.
7.5.2 Testing and Curing in accordance with sections 7.2 & 7.3.
8.0 QUALITY CONTROL
8.1 ARCC Quality Control Inspector shall carry out necessary inspections and witness tests in various stages of grout casting in accordance with approved ITP. He shall coordinate with DEC/JGC QC Inspector to conduct inspection as required in approved ITP.
8.2 All documents attesting to the acceptability of the work will be produced by ARCC QC Inspector and submit to DEC/JGC for review and approval.
9.0 SAFETY ACTION PLAN
9.1 Approved work permit should be obtained prior to commence any application of grouting works.
9.2 Work execution shall be carried out in accordance with the method statement.
9.3 Safety Officers shall monitor compliance of the entire working crew to safety procedures until the work is fully completed.
9.4 The installation crew must carry out a safety risk assessment prior to the start of any new activities. Attached Job Hazard Analysis shall be disseminated to workers prior to work execution.
9.5 Toolbox meeting shall be conducted daily.
9.6 Workers should be equipped with proper PPE’s needed for the work.
9.7 Good housekeeping must be maintained in the duration of works.
9.8 Material Data Sheet of grouting materials shall be made available from grout manufacturer/dealer.
9.9 Continuous monitoring and inspection shall be implemented to detect and correct unsafe practices while performing the work activities.
10.0 ATTACHMENT
10.1 Attachment 1 – Job Hazard and Risk Analysis.
10.2 Attachment 2 – Epoxy grouting sequence.
