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MS-C-0014 REV.

00

METHOD STATEMENT

FOR

APPLICATION OF NON- SHRINK CEMENTITIOUS GROUT

WASIT GAS PLANT SAUDI ARABIA


INDUSTRIAL SUPPORT FACILITIES (ISF)

KHURSANIYAH KINGDOM OF SAUDI ARABIA

Signature
00 08/06/2011 Print A. Langcay A. dela Cruz R. A. Dimatatac
Rev. DATE Name
Prepared By Checked By Approved By Approved by
MMG MMG MMG SKEC

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MS-C-0014 REV.00

1.0 PURPOSE
To develop guidelines for the placement of Non- shrink Cementitious Grout,
as required in AFC Drawings, particularly in Piperack base plates and other
applicable structures receiving grouts.
Ensure that application of non- shrink cementitious grout is carried out safely
in accordance with good working practice as per ARAMCO/ SKEC project
safety procedures & requirement.

2.0 SCOPE OF WORK


This Method Statement highlights MMGs work sequence intended for the
application of non- shrink cementitious grout on top of every pedestal and
equipment foundations as shown in the approved for construction drawing.
Execution of work shall be carried out in accordance with the relevant project
specifications. All other related work which requires application of non- shrink
grout shall commit to this Method Statement.

3.0 REFERENCES
Saudi Aramco Construction Safety Manual
SAES-Q-001 :Criteria for Design & Construction of Concrete Structures
SAES-Q-010 :Cement based,non-shrink grout for Structl.& Equipt. Grouting

4.0 REQUIRED EQUIPMENT, TOOLS & PERSONNEL


Equipment & Tools:
Chipping Gun or Chipping Hammer
Air Compressor
Wire Brush
Trowel or Spatula
Hand Brush, Roller & Steel Float
Scraper
Grout Mixer
Personnel:
Concrete Foreman
Mason/ Concrete Finisher
Helper

5.0 GROUT PRODUCTS (3 Options)


- Masterflow 524L Non- Shrink Cementitious Grout
- Cemtec NS Grrout Non-Shrink Cementitious Grout
- Conbextra 621 Non-Shrink Cementitious Grout

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MS-C-0014 REV.00

6.0 WORK PROCEDURE

Storage:
- Grout material shall be stored as per Manufacturers instruction to protect
from the sunlight, under the shade.
- Grout material shall be kept in a separate storage and avoid exposure to
environment.

Preparation:
- Preparation of the concrete surface to which the grout will bond should be
carried out before the base plate is installed.
- New concrete must be minimum of 28 days old.
- The concrete surface to receive grout must be clean and rough.
- All oil, dirt, debris, paint and unsound concrete must be removed.
- The surface must be prepared mechanically using a scrabbler,
bushhammer, shotblast or scarifier which will give a surface profile of a
minimum 3mm and expose the course aggregates of the concrete.
- Clean and chipped area by removing all laitance and loose particles, remove
dust by using compressed air.
- Preparation should cover the full extent of the surface which is intended to
be in contact with the grout.
- Where it is indicated that bolts are to be anchored within the grout, bolt
pocket formers should be shaped to form a cone, helping to ensure stresses
that build up when the bolts are tightened are transmitted to the foundation.
- Bolt pocket formers should be made from materials that are easy to remove,
but leave a rough concrete surface texture when stripped.
- All surface and bolt pockets to receive grout must be clean and free of oil,
dust, dirt, paint and residual curing compound.
- All base plates holding down bolts, etc., are to be free of rust, oil, dirt or
contaminants that could impair bond.
- Maintain good housekeeping at all times.

Formwork:
- Before fixing the formwork, ensure the foundation to receive non-shrink
grout and bolt holes to be filled with grout are clean.
- Provide formwork on the periphery of the area to be grouted. Formwork
should result in a grout edge having 50mm horizontal distance from the
edges of the base plate.
- Formwork should be as water tight as practical, to prevent grout leakage
and should be constructed in accordance with the shapes of the base
plates.
- The top of the formwork should be a minimum of 25mm above the underside
of the base plate or unless noted otherwise.

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MS-C-0014 REV.00

- For large base plate pours or when the gap between the base plate and
foundation concrete is less than 25mm in depth, the formwork should be
higher to allow a pressure head to build up.
- On the pouring side, which should be the shortest distance across the base
plate, a hopper should be constructed to allow a pressure head sufficient
to enable grout to flow to the full width of the pour.
- The forms should be fixed with the top sloping away from the base plate at a
45 angle to form a slope down which the grout can be poured.
- The formwork should be fixed to allow easy stripping without causing
damage or stress to the grout, if the formwork is to be removed when the
grout is still green.
- If grout is to be pumped under pressure, formwork should be constructed to
withstand the additional localised pressure.
- Provide 15mm X 15mm chamfer to result in grout section and dimension as
shown below:

CHAMFER BASE PLATE

NON- SHRINK GROUT

CONCRETE PEDESTAL

NOTE: Not drawn to scale

Pre- Grout Placement:


- Before grout placement, ensure that surfaces of the area to receive grout
shall be clean and free of oil, dust, paint and foreign materials.
- Saturate the concrete within the formwork with wet burlap for 24 hrs prior to
grout placement to ensure a saturated but surface wet condition at the time
of grouting. Standing water shall be removed.
- Ensure that sufficient grout is enough and available on hand to complete the
intended pour in a continuous process.
- Prior to grout placement, mixing equipment should demonstrate that it is
suitable and in good working condition.
- Ensure that potable water and ice supply is available for mixing and keeping
the required temperature of grout.
- If grouting is to take place in an open area (Hot weather grouting), store
bags of grout under shade. Shade the mixing area and the location to be

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MS-C-0014 REV.00

grouted and ensure that a supply of cool or chilled water is available to


produce a maximum mixed grout temperature of 32C, when placed.
- A thermometer should be available to monitor as mixed grout temperatures.
- (Cold weather grouting), if the temperature of the base concrete cannot be
maintained at 5C while the grout hydrates, delay grouting until this can be
achieved.
- Use warm water to bring the mixed temperature of the grout above 5C.
- If the ambient temperature will fall below 5C after placing the grout, make
sure materials are available to insulate the installation.
- Adjacent machinery should be shutdown if causing vibration that may impair
the on-going pour that may damage the integrity of the grout.

Grout Mixing:
- Prior to mixing applications, ensure that all standing water is removed from
bolt pockets and surrounding area.
- Grout ingredients shall be thoroughly mixed in quantities needed for
immediate use in accordance with the manufacturers instructions.
- Individual bags may be mixed with slow speed (300-500rpm), heavy duty
drill fitted with a suitable mixing paddle. Multiple bag mixes shall employ
dedicated grout mixers or modified drum mixers.
- A suitable mixing time of 3 minutes for drill and paddle and 4-5 minutes with
a drum mixer, depending on the type of mixing equipment.
- Place 90% of the mixing water required to achieve the desired consistency
into the pail or mixer before adding the bagged grout. Maintain water
addition within the range given in the appropriate Technical Data Sheet.
- When the mixed grout is lump free, add the remaining mix water to bring to
the desired consistency.
- The mixing set up must be able to produce a continuous supply of freshly
mixed grout once the pour starts.
- Grout, once mixed with water, shall not be tempered. Test cubes shall be
taken and tested as required .

Grout Placement:
- All bolt pockets must be filled with grout before pouring the rest of the under
plate grout, to avoid voids being formed.
- Start at one end of the base plate, pouring grout down the slope of the
formwork. When the grout reaches the far side formwork and rises above
the bottom of the base plate, move the pouring point slowly along the length
of the base plate, always ensuring that the grout has risen up on the
opposite side of the base plate before moving along.
- Pour the grout steady down the slope of the formwork to reduce the
possibility of entrapping air.

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- Do not pour from different sides of the base plate as this can cause voids,
which reduce the effective bearing area.
- Remove excess grouts as work progresses.
- The grouting of any section of pedestal/ base plate shall be completed in
one day with no interruptions.
- Grout shall be extended 50mm (min) beyond edge of the base plate
(General Note 8.2, Grouting)
- Care shall be taken so that the grout completely fills the void to be grouted
and is thoroughly compacted to ensure it is free from air pockets.
- Grouts may be placed by pouring, the perimeter edges shall be steel
trowelled to a neat 45 external chamfer.

Hot Weather Grouting:


- If grouting is to take place in an open area, store bags of grout under shade.
- The mixing area and location and location area to be grouted shall be
provided with temporary shade.
- Ensure that an ample supply of chilled water (or ice) is available to produce
a grout mixture with maximum of 23C (+-3C) temperature, when placed.
- Cure the grouted area immediately after setting with potable water during
the first three (3) days after placement but should be continued until the
required compressive strength is attained.

Grout Curing:
- Immediately after the grout is placed and completed, cover exposed edges
with wet burlap keeping them wet for seven (7) days. After seven (7) days,
stripping of forms may commence.

Quality Control & Testing:


All stages of the work shall be inspected in accordance with approved
Inspection & Test Plan (I.T.P).
- Make two (2) sets of three (3) test cubes in the field each day grout is mixed
and placed.
- A Saudi Aramco approved testing laboratory shall be utilized for taking the
test cubes and testing.
- The cubes shall be crushed and tested as follows to determine its respective
compressive strength:
o 3 days old cubes = 2 numbers
o 7 days old cubes = 2 numbers
o 28 days old cubes = 2 numbers
- Non-shrink grout cementitious grout shall comply with vendor and
manufacturers data sheets (see attached data sheets).
- Method for storage shall comply with manufacturers data sheet and
specifications.

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- Mixing and placement of grout shall conform with the manufacturers


recommendation and data sheets (attached herein).

6.0 SITE HEALTH & SAFETY


- The work shall be executed in accordance with the approved safety plan.
Work permit shall be obtained prior from the concerned Saudi Aramco
Department before starting any work.
- Tools and Equipment should be made operational and available for use.
- Continuous monitoring and inspection shall be implemented to detect and
correct unsafe practices while performing the work activities.
- Safety officers shall implement surveillance to help and to protect all
assigned workers against exposure to safety hazards.
- Barricades and sufficient signboards shall be provided.

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