Method Statement of Non Shrink Grouting Materials

1. PURPOSE
2. SCOPE
3. REFERENCE
4. RESPONSIBILITIES
5. QUALITY ASSURANCE
6. PROCEDURE
7. QUALITY CONTROL AND INSPECTION PLAN
8. SITE HEALTH & SAFETY
9. CONFLICTS AND DEVIATIONS
10. DOCUMENTATION
11. SKETCHES
12. RISK ASSESSMENT

Method Statement of Non Shrink Grouting Materials

1.0 PURPOSE

1.1 This Method Statement provides information concerning the materials, tools; manpower and method of application of none shrink grouting materials to ensure compliance with ARAMCO standard, contract requirements, drawings, technical specifications as well International standards ACI, ASTM, and quality control as per Schedule Q.

2.0 SCOPE

This Method Statement Covers the Application of Selected/Approved Grout Material CONBEXTRA EP150 from FOSROC/Fosam Co. Ltd, Non -Shrinkage epoxy resin grout for use in Block/Box outs for MEP and Embedded items of Walls of Buildings As per manufacturer recommendations.

3.0 REFERENCE

The selection of material, mix design and application/execution covered by the latest/applicable edition of standards and references listed below unless otherwise noted.

3.1 SAUDI ARAMCO ENGINEERING STANDARDS, REFERANCESS AND INTERNATIONAL STANDARDS.

 SAEP-302 Instructions of obtaining a waiver of a mandatory Saudi Aramco Engineering standards.
 SAES H 003 Protective Coating for Industrial Concrete Structure.
 SAES Q 009 Concrete Retaining Walls.
 SAES Q 001 Criteria and design of concrete structures.
 SAES Q 010 Cement Based, Non-Shrinkage Grout for Structural and Equipment Grouting.
 SAES M 100 Saudi Aramco Building Code.
 SCHEDULE Q Saudi Aramco Quality Requirements.
 ACI 309R Guide for Consolidation of Concrete.
 ASTM C 1107 Standard specification for Packaged Dry, Hydralic-Cement Grout (Nonshrink).
 ASTM C 150 Standard specification for Portland cement.
 ASTM C 309 Standard specification for liquid membrane forming compounds for curing Concrete.
3.2 Construction Drawings.

3.3 Contract Specifications.

3.4 SATIP-Q-001-04 Saudi Aramco Typical Inspection Test Plan for Cement Based Non-Shrink Grouting.
3.5 SAIC’s SAUDI ARAMCO INSPECTION CHECKLIST, SAIC-Q-1047, SAIC-Q1048 and SAIC-Q-1049.

4.0 RESPONSIBILITIES

4.1 Site Manager

The Site Manager arrange and ensures that the site QC Section provided the necessary information and cooperation from Civil Site Engineer, to enable satisfactory inspection andverification of activities performed by the site civil section, Civil Site Engineer, Supervisor and  site civil section responsible for implementing job with compliance of Quality and site manager  shall be fully responsible for implementation of all contractual requirements at the job site and shall visibly demonstrate the priority of safety in all activities, including setting a good personal example.

4.2 Safety Supervisor

The Safety supervisor ensures that all safety management will enforced in a ways to prevent injury to personnel, damage to Plants and/or equipment by Fires. He should provide written instruction to established work method, explain the sequence of operation, outline the potential hazards at each stage and indicate precaution to be adopted and the Safety supervisor shall Visibly demonstrate the priority of safety in all activities, including setting a good personal example. He is responsible and accountable for the proper performance of field and the competency of the safety officers under his authority. He can stop the work that deem to be unsafe and can take immediate corrective action as needed.

4.3 Civil Site Engineer/Supervisor

The Civil Site Engineer/Supervisor and/or Foreman are responsible for the application of Grouting works assuring all materials installed permanently and works being implemented are in conformance with standard specifications as well as manufacturer recommendation.

4.4 QC Manager

 QC manager shall be responsible for;
 Ensuring approved & latest revision of drawings is followed for the finishing schedule.
 Inspection of material and review of test plan.
 Inspection of material storage condition.
 Final inspection.
 Test execution and test record sorting / reporting according to inspection and test plan.

4.5 QC Civil Inspector

The QC Civil Inspector shall ensure that approved quality control procedure is being implemented throughout the grouting works. Inspection shall be done on materials or work, which will be incorporated to the permanent structure. He shall coordinate with client’s representative regarding inspection and test made shall also his responsibility.

5.0 QUALITY ASSURANCE

5.1 Saudi Aramco Engineering Standards

a) Comply with all applicable codes and standards particularly those listed in the above in Section 3 (Reference).

5.2 Grouters Qualification

a) Provide at least one person who shall be present at all times during the execution of the work, who shall be thoroughly familiar with the specified requirements and the materials and method needed for their execution, and who shall direct all works performed under this section.

b) Provide adequate numbers of workmen skilled in the necessary crafts and properly informed of the method and materials to be used.

5.3 Material Submittals

a) Product Data: Consisting of manufacturer specification and application instruction for each product, including certification to show compliance with the requirements of this specification.
b) Samples: Submit for approval to the Company Representative.
c) Approved Grouting Material: (CONBEXTRA EP150), Free Flow Epoxy Resin Grout.
Refer to: T-AL-DW-0237/AL-MAR-064.

5.4 Material Inspection

a) All material inspection shall be subjected to available SATIP and SAIC.

5.5 Product Delivery, Storage & Handling

a) Delivery: Deliver all materials to the project site in original, unopened containers bearing the manufacturers’ name and label showing the following information:

1. Name and Title of Material
2. Manufacturer’s Batch Number
3. Contents by volume of major constituents
4. Thinning Instruction
5. Application Instruction
6. Date of Manufacture

7. Warnings and Special Precaution.

b) Storage: Store all materials inside and under cover in a well-ventilated space and in accordance with manufacturer’s specification.

c) Handling: Use all means necessary to protect materials before, during and after execution and to protect the work and materials of other trades. In the event of damage, immediately make all repairs and replacements.

6.0 PROCEDURE FOR GROUTING WORKS

6.1.1 Surface Preparation Prior to Grouting Works

 The surface onto which the grout is to be applied should be scrabbled to remove laitance and expose aggregate.

 Do not use bush hammers or similar preparation equipment’s that can crush the aggregate but leave in place.

 The surface must be free of oil, dust, dirt, paint, curing compounds or other contaminants that could impair adhesion.

 Installation of Box outs of required steel sleeves, Steel boxes and Sub-frame of Doors using plywood sheets and therofome. (Please, refer to attached Sketches)

 Soak area to be grouted to minimize absorption.

 Ensure form work is secure and water tight to prevent movement and leaking during placing and curing of the grout.

6.1.2 Mixing:

Damp down the inside of the mixer with water prior to mixing the initial batch of grouting material. Ensure the damp but free of standing water. Slowly add grouting material. Mixing continuously. Mix for 3 to 5 minutes until a smooth, uniform, lamp free consistency is achieved and refer to MDS of CONBEXTRA EP150.

6.1.3 Placing:

Place immediately after mixing, into the prepared area in such a manner that the grout has shortest distance to flow. Pour the grout continuously maintaining a hydrostatic head wherever possible. Immediately after grout is placed, cover all exposed with clean wet hessian and keep moist grout surface is ready to be finished, or until final set.

7.0 QUALITY CONTROL AND INSPECTION PLAN

7.1 All materials, workmanship and inspection shall conform to all Saudi Aramco Typical Inspection Plan, Saudi Aramco Inspection Checklist, Construction Specification, Standard Drawings and IFC Drawings.

8.0 SITE HEALTH & SAFETY

8.1 The work shall be executed in accordance with the approved Safety Plan. Work permit shall be obtained prior to any commencement of the work when required.