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DOC. NO. KOC-C-023






DOC. NO. KOC-C-023 REV.1


Page No.




3.1 Definitions 6
3.2 Abbreviations 7


4.1 Conflicts 7
4.2 List of Standards and Codes 7



7.1 General Conditions 10

8.1 Types Generally Used 10
8.2 Non-shrink Cementitious Grout 10
8.3 Epoxy Based Grout 11
8.4 Storage 12

9.1 General 12
9.2 Specific 12

10.1 Von-shrink Cementitious Grout 13
10.2 Epoxy Based Grout 15
10.3 Base Setting 15


11.1 General 16
11.2 Test Reports 16
-- Page 4 of 20 I
-- -
12.1 Quality Plan


14.1 General
14.2 Deliverables

Page 5 of 20 REV.l F

This documenl "KOC Standard for Grouting for Bases - Materials and
Workmanship" (KOC-C-023) is intended to cover the minimum requirements of
installation of structural framework and equipment to the concrete foundations for
KOC Plants and Facilities (Onshore).

This Standard has been approved by Standards Team in consultation with the
Standards Technical Committee for use throughout the corporate engineering and
operational functions of Kuwait Oil Company (K.S.C).

This Standard sets out t o achieve the following objectives:

a. To cover ths basic requirements of grouting with a view t o provide reliable and
good perfo.-ming materials to cater for the specific installation needs of
equipment(s) and structural framework to concrete bases.

b. To provide t.he specific technical inputs in order t o develop the intended grouting
specification for the construction.

c. To set out minimum technical requirements t o monitor compliance of material,

constructior. and workmanship with a contract.

Feedback as well as any comments or suggestions from the application of this

Standard derived at any stage of engineering, construction, testing, monitoring and
maintenance are encouraged and should be directed to:

The Team Leadsr Standards

(Chairman, Standards Technical Committee)
Industrial Services Group, KOC
P.O. Box - 9758, Ahmadi 61 0 0 8
State of Kuwait

Task Force Responsible for this Standard

The preparation of this Standard has been entrusted by the Standards Technical
Committee (STC) to the Task Force No. (TF-C/07) comprising of the following

Mr. S. Kumar Standards Team -TF Leader/Author Tel. No. 61407

Mr. Mohd. Javaid Design Team - Member Tel. No. 61 322
Mr. Ahmed At-Fenaini Export Fac. Proj. - Member Tel. No. 66987
Mr. Hussain Al-Jazzaf Gen. Projects - Member Tel. No. 63226
Mr. Maged Madi Projects Design - Member Tel. No. 66389

This Standard provides the minimum technical requirements of materials

and workmanship for the base setting grouts in KOC construction (Onshore)
within Kuwait.

This S t m d a r d covers only the basic requirements of grouting t o bases and

slide p a t e s o f equipment and structural framework / members t o the
concrete bases and foundations.

This Standard does not cover the other types of grouting t o be used for
specific purposes, such as compaction grouts in soft soils for densification,
and sealing or plugging grouts in cracks and fissures in concrete work as
well as in aboveground and belowground liquid retaining structures.

The corttent of this Standard is intended t o be adopted as a guide t o meet

the minimum KOC requirements; and should form t h e basis of a detailed
design specification.

The materials, construction, and workmanship o f grouting for bases shall

conforr? t o the requirements o f this Standard and the reference standards
and codes mentioned herein.

Any exceptions or deviations from this Standard, along w i t h their merits

and justifications, shall be brought t o the attention of KOC Controlling Team
for their review, consideration, and amendment b y Standards Team (if

Compli.2nce w i t h this Standard does not of itself confer immunity from legal
or statutory obligations.


For the purposes o f this Standard, the following definitions apply.


Separation of water from grouts as time passes,


Any approved firm or company contracted by KOC, who are undertaking

the execution of the civil and structural work at the KOC Facility.

Degree of thickness or smoothness of grout state, expressed by an

increasing order i.e. by index t o show its workability.


Injecting or placing appropriate blend of materials under pressure or gravity

into spaces for filling and therefore, sealing voids and other cavities for
proper installation of bases of equipmentls) and structural frames and
members in order t o facilitate smooth and uniform transfer of loads (static
or v i b r ~ t o r y t) o the concrete bases and or foundations.


I t reflezts the various practical conditions of grouts such as viscosity,

f Iowa bility, non-bleeding, early strength, temperature under which a
particular grout will be expected t o perform satisfactorily in the field by
penetrating into the desired places and sealing all voids and cavities below
the bases; and achieving the desired strengths at the specified days.


f l ~ Minimum Compressive Strength of Grout

HSE Health, Safety and Environment
KOC Kuwait Oil Company (K.S.C)
QAIQC Quality Assurance IQuality Control


In the event of conflicts between this Standard and the standards I codes
referen2ed herein, or other contractual requirements, the most stringent
requirement shall apply. In case further clarifications are required, the
subject shall be brought t o the attention of KOC Controlling Team.

List of Standards and Codes

The latzst edition of the following standards, codes and specifications shall

National 1 International Standards

AASHTO T26 Standard Method of Test for Quality of Water t o be used

in Concrete

ASTM C33 Specification for Concrete Aggregates

ASTM C109 Standard Test Method for Compressive Strength of
Hydraulic Cement Mortars (Using 2-in or 50 m m Cube

ASTM C136 Standard Test Method for Sieve Analysis of Fine and
Coarse Aggregates

ASTM 21 50 Specification for Portland Cement

ASTM PI91 Standard Test Method for Time o f Setting o f Hydraulic

Cement By Vicat Needle

ASTM 12305 Practice for Mechanical Mixing of Hydraulic Cement

Pastes and Mortars o f Plastic Consistency

ASTM 2494 Specification for Chemical Admixtures for Concrete

ASTM 3531 Test Method for Linear Shrinkage and Coefficient of

Thermal Expansion o f Chemical-Resistant Mortars,
Grouts, Monolithic Surfacing and Polymer Concrete

ASTM C579 Test Method for Compressive Strength of Chemical -

Resistant Mortars, Grouts, Monolithic Surfacing and
Polymer Concrete

ASTM C827 Standard Test Method for Change in Height in Early Ages
of Cylindrical Specimens form Cementitious Mixtures

ASTM C 1090 Standard Test Method for Measuring Change in Height of

Cylindrical Specimens for Hydraulic-Cement Grout

ASTM C1 f 07 Packaged Dry, hydraulic-Cement Grout (Non-shrink)

ASTM D5 12 Standard Test Methods for Chloride Ion in Water

ASTM D5 16 Standard Test Method for Sulfate Ion in Water

BS 12 Specification for Portland Cement

BS EN 12620 Specification for Aggregates for Concrete

BS 1881 Methods of Testing Concrete

BS 4550 Method of Testing Cement

BS EN 206 - 7 Concrete - Part 1 : Specification, Performance, Production,

and Conformity
Admixtures for Concrete, Mortar, and Grout - Part 2:
Concrete Admixtures - Definitions. Requirements,
Conformity, Marking and Labeling

BS 8 1 10 Structural Use o f Concrete Part 1 : Code of Practice for

Design and Construction

4.2.2 KOC Standards

KOC Standard for Basic Civil Engineering Design Data

KOC Recommended Practice for Engineering Design

Basis o f Civil and Structural Work

KOC Standard for Concrete Work - Materials and


KOC Standard for Structural Steel Work - Materials,

Fabrication and Erection

KOC Standard for Basic Design Data

KOC Fire & Safety Regulations


The environmental conditions in Kuwait are severe. Due regard should be

given t o the consistently high levels of solar radiation experienced in Kuwait
which may develop surface temperatures o f over 80°C ( 176°F) in exposed

Grout work shall be durable at a desert location under high temperatures

and humidity. The atmosphere at the Site is generally dusty and corrosive;
and may contain traces o f hydrogen sulphide.

Refer to KOC Standard for "Basic Design Data" (KOC-G-007), which

provides the detailed design information regarding t h e environmental, site
and utility supply conditions prevailing throughout the KOC facilities.


The engineering construction should meet all the applicable Kuwaiti EPA
Regulalions and should conform t o the KOC Health and Environment (H&E)
guidelires w i t h a view t o protecting its personnel and surrounding

All relevant safety requirements of KOC Fire & Safety Regulations and KOC
Health, Safety and Environment Management System (HSEMS) shall be
adhered to, by the Contractor, while applying the grouting t o the bases of
equipment(s) and structural framework i members within KOC areas.

General Considerations

Generally, grouting shall be used for several purposes in construction, t o

transfer the static and / or vibratory loads in a smooth and even manner t o
the concrete bases / foundations. The loads may be from rotating
equipmentk) such as pumps, compressors, turbines etc. as well as from
static equipment(s) such as heat exchangers, flares i stacks, columns,
elevated pipe-racks and from various utility buildings made of steel
framework in plants and facilities.

Groutirg may also be applied for other specific purposes in construction

such as for densification or compaction of soft soils by filling pre-bored
holes in specified grid patterns and by filling voids, fissures in rocks or by
sealing cracks in concrete structures such as pavements, foundations,
bases, columns or in plugging holes or cavities in aboveground or
belowground liquid retaining structures.

Groutirig o f this specific nature belongs to a special category and shall be

selected o n a case by case basis as appropriate; and is excluded in
accordance w i t h clause 1.3 of this Standard.

Grouting applicable for clause 7.1.1 above, shall be composed of mainly

pre-blended materials o f graded sizes w i t h specific ingredients t o achieve
the groutability and minimum characteristics as described below.


T v ~ e Generallv
s Used

The types o f grout generally used for the installation of equipment(s) and
structural framework 1 members to the bases of concrete foundations shall
be as f i l o w s :

a. Non-shrink Cementitious Grout

b. Epclxy based Grout

Non-shrink Cementitious Grout

General Requirements

This type of grout material shall be non-metallic, and pre-mixed, factory-

packed as manufactured by Masters Builders, Five Star, Fosroc or approved
equal; and shall meet the following requirements:

a. It shall remain fluid, pumpable or pourable; and shall not segregate

having extended workability.
DOC. N O . KOC-C-023

b. It s : d l not exhibit any visible bleeding t w o (2) hours after placing.

c. It s ~ a l show
l no shrinkage and a maximum of 4.0 percent expansion at
any time before initial set, when tested in accordance w i t h ASTM

d. It shall show no shrinkage and a maximum of 0.2 percent expansion in

the hardened state, when tested in accordance w i t h ASTM C1107.

e. It siiall show initial set time of not less than 6 0 minutes (1 hour), when
tested in accordance w i t h ASTM (2191.

f. It shall be iron-free and chloride-free and shall contain no metallic

substances, water-reducing agents, accelerators, super plasticizers, or
other materials.

g. Water shall be clean and free from injurious amounts of oil, acids,
alkalis, and other deleterious materials in accordance w i t h AASHTO
T26, ASTM D 5 1 2 and ASTM D516.

2.2 mini mu^ Compressive Strength (fc')

The compressive strength of non-shrink cementitious grout shall comply

w i t h the minimum strengths in accordance w i t h ASTM C 1 0 9 modified as

a. f c ' at 1 day ( 2 4 hours) = 1 4 N/mm2 ( 2 0 0 0 psi)

b. f c ' at 7 days = 3 5 N/mm2 ( 5 0 0 0 psi)

c. f c ' at 2 8 days = 4 9 N/mm2 ( 7 0 0 0 psi)

8.3 E a w y Based Grout

8.3.1 General Requirements

This t y p e of grout material shall be pre-mixed w i t h epoxy based materials,

and factory-packed as manufactured by Masters Builders, Five Star, Fosroc
or approved equal; and shall meet the following requirements:

a. I t shall b e flowable, and shall comprise of 1 0 0 percent solids system.

b. It shall show no shrinkage and a maximum of 4 . 0 percent expansion

w h m tested in accordance w i t h ASTM C 5 7 9 attaining the minimum
strength as per clause 8.3.2 o f this Standard.

c . The peak exothermic temperature of a cylinder o f grout, 5 0 m m

diameter x 1 0 0 m m high, shall not exceed 35"C, when tested a t 24°C
material and air temperature.
d. It shall not exceed a coefficient of thermal expansion of 5 5 x f 0-6m m /
m m I "C, when tested in accordance with ASTM C531.

Minimum Compressive Strength (fc')

The compressive strength of epoxy based grout shall comply with the
minimum strengths in accordance with ASTM C579 as below:

a. fc' at 1 day (24 hours) = 35 N l m m ~ 5 0 0 0psi)

b. fc' at 2 days = 5 6 Nlmmj' ( 8 0 0 0 psi)

c. fc' at 7 days = 7 7 N l r n m y f 1,000 psi)


Grout components shall be delivered t o the Site in moisture proof sealed

bags. Fags shall be stored in a dry weatherproof cool area, out of direct sun
light and shall be kept within the temperature range of 4°C to 32°C.

Material, which becomes damp or defective shall never be used; and shall
immediately be removed from the Site.

Normally storage time of grout mix should be limited t o 1 0 months; and

shall preferably be used within the time as specified in the written
instructions of the Manufacturer.



Light equipment, pipe supports, and structure bases, which are not subject
to vibratory loads, shall be grouted with a non-shrink cementitious grout.

Grouting under machine base frame(s) shall be done in compliance with the
Machire manufacturer's recommendations; or epoxy based grout shall be
used for vibratory and I or heavier loads.


Grout thickness shall be provided under bedplates and steel-bearing plates

as specified in the KOC approved construction drawings, but the minimum
shall not be less than 25 m m .

Grouts (non-shrink type) shall be composed of generally hydraulic cement,

graded fine aggregates, and other ingredients, and shall require only the
addition of mixing water for use.
DOC. NO. KOC-C-023 Page 13 of 20 REV.l

The amount of water (minimum or maximum) as recommended by the

Manufacturer shall be used for conformance t o determine the desired flow
(consistency) and good workability.

However, consistency tests shall be conducted t o an accuracy of f 5 % t o

determine the amount of water t o be added for testing and the weight of
water shall be expressed as a ratio of water t o dry grout material b y weight.

Non-shrink Cementitious Grout

Surface Preparation

a. All concrete surfaces t o be grouted shall be cleaned b y removing dirt,

oil, grease, laitance, and any other foreign substances. Bolt holes and
pockets shall be cleaned off any dirt and debris. Sandblast and solvent
wash shall be done as recommended by the manufacturer.

b. Concrete surfaces shall be roughened by chipping or by nail raking when

concrete is i n plastic state in order t o ensure a good bond of grout to
existing concrete.

c. The roughened surfaces shall be cleaned w i t h water and shall be soaked

for 24 hours prior t o placing grout. Clean surfaces shall be covered w i t h
plastic sheets until grout is ready for placing. All free water should be
removed immediately prior t o placing grout.


a. F o r n s for fluid grout shall be of materials w i t h adequate strength t o

w i t i s t a n d the placement o f grout.

b. Forms for non-shrink cementitious grout shall be tight against all

surfaces and joints shall be sealed w i t h tape. Form oil shall be used for
easy release.

c. Forrns for grout shall be watertight w i t h chamfer strips in place.

Caulking shall be used on all joints.

d. Forms shall be 1 0 0 m m t o 1 5 0 m m higher than the base plate when

using hydraulic head pressure for placing.

e. Air pressure relief holes with a minimum of 6.5-mm diameter shall be

provided at every recessed base plate corner and t o allow venting for
any isolated high spots.
DOC. NO. KOC-C-023

10.1.3 Mixing

a. Grout shall be mixed in accordance with manufacturer's

recommendations. This shall be generally by adding grout t o the water
(no*; vice-versa) and mixing for between three (3) and five (5) minutes t o
obtain the desired consistency.

b. Mechanically powered grout mixer (not concrete mixer) shall be used for
mechanical mixing of grout. For large quantities of grouting materials
greater than 40 kg t o be mixed, high shear vane mixer should be used.

c. The mixer shall be clean, pre-wet, and drained, and essentially shall be
free of hardened mortar and other foreign material that can be removed
w i t h a trowel or by reasonably striking w i t h a hammer.

d. Re-nixing o f grout by adding more water or re-mixing of stiffening grout

is not permitted.

e. If nscessary t o enable grouting operation t o be carried out continuously,

the Contractor shall make available sufficient mixing capacity and
labour. Grout holding tank w i t h provision t o gently agitate the grout
should be provided.

f. The Contractor shall be responsible t o oversee that any equipment in

use shall not be hazardous in a physical or mechanical w a y t o operators
and other personnel, and that safe work practices shall be carried out at
all times.

10.1.4 Placement

Grouting shall only be carried out when the steelwork has been leveled
and plumbed, the base plate being supported by shims at the center.
S h i n s shall be the same material as the base plate.

Grwt shall be rapidly placed continuously from one side of base plate
only in one direction t o eliminate the entrapment o f air.

Anchor bolt sleeves or pockets shall be grouted completely first; and

then grouting under base plate shall be done t o fill all spaces. Shims
used for temporary leveling shall be left in place.

If shims shall be removed after the grout has hardened, they should be
treated w i t h a layer o f grease for ease of removal.

Hydraulic head grouting pressure shall be maintained by keeping the level

of grout i n the head box above the bottom of t h e base plate. Head box
shall be filled t o a maximum level and grout shall be worked d o w n t o top
o f base plate.
- -


After grout has reached final set, it shall be trimmed back t o the required


a. All exposed areas shall be cured using continuous application of water

or ' ~ i t hwet hessian or shall be done as specified by manufacturer's

b. Forms shall remain in place for 2 4 hours.

c. Necessary measures shall be taken to maintain temperature of base

plate and supporting concrete between 4°C and 32°C during grouting;
and for a minimum of 1 2 hours after placing.


a. A t ambient temperatures above 35"C, the mixed grout shall be placed

immediately after mixing. Water with a temperature less than 20°C
should be used for mixing.

b. Grouts should not be placed in any non-restrained situation i.e. base

plale plinth etc. Failure to comply may lead to crack development in the

c. Placing of grout shall be avoided when the ambient temperature exceeds


Epoxv Based Grout

Epoxy based grout shall be prepared and installed in compliance with the
manufacturer's recommendations as specified in the catalogues and

Base Setting

Base sstting shall be carried out in sequence after aligning the structures
and equipment prior to grouting the anchor bolts, sleeves or pockets and
bearing and sliding plates as below.

Anchor Bolts

Anchor bolts for fixed ends of horizontal vessels and exchangers shall be
tightened down; and nuts on sliding supports shall only be finger tightened
before backing off by 1/3 turn. Locking nuts shall be used to hold in this
position t o allow for free sliding.
Steel 8earing and Sliding Plates

A t slide plate locations, care shall be taken in particular not t o force grout
under any pressure beneath the plate so as t o cause deformation of the

Vessels without slide plates

For small vessels and exchangers not requiring slide plates, bottom of bases
shall be greased t o prevent adhesion of grout so that vessel can be removed
easily in future.



The Contractor shall be responsible for preparing, storing, curing and

transporting the test samples t o the laboratory for testing.

Grout shall develop its required compressive strength i n accordance w i t h

ASTM 12109 modified for packaged grouts o f non-shrink type.

Three (3) test cubes shall be made for each day for grouting. Tests shall be
made of one ( 1 ) cube at the intervals of 24 hours, 7 days and 28 days.

Test Reports

All labcfratory tests shall be furnished within 7 2 hours after the tests being
conducted from the reputed testing laboratory, approved by KOC.


Qualitv Plan

The Contractor shall perform at different stages of the Work, all the
responsibilities and duties of quality control by verifying, inspecting and
testing through his dedicated quality control system in conformity w i t h
clause 13.0 of this Standard, and shall meet fully the quality control
requirements of this work as described in this Standard.

The Contractor shall prepare and submit a detailed quality plan for KOC
approval prior t o implementation. The quality plan shall consist of the

a. inspection and Test Plan (ITP)

The ITP shall list the sequence of all verification, inspection and testing
activities for the Work.
Tbe plan shall detail submittals of all the test certificates for each
consignment of materials as required for records and approval prior t o
c ~ m m e n c i n gthe work.

The plan shall also include inspection of storage facilities, formwork,

c w e c t positioning and placement of grouting as well as testing of all
samples in a sequential order, showing the frequency of control tests,
th4 acceptance criteria, the governing standards / codes and whether a
dccument or report is produced for each activity.

b. Prs-inspection Meeting (PIM)

PIW shall be held by the Contractor with KOC before commencing the
work. During the PIM the Contractor and KOC will review and finalize
tho mark-up of the ITP, confirm the requirements for witnessing (W),
surveillance (S), monitoring (M), reviewing (R), in the plan. The
approved quality plan shall be strictly adhered t o throughout the entire
w w k , inspection, and testing period.


The Contractor shall operate a quality system preferably based on !SO

9000 series of standards t o satisfy the requirements of this Standard. The
Contractor shall demonstrate compliance by providing a copy of the
accredited certificate or its quality manual. Verification of the Contractor
quality system is normally part of the pre-qualification procedure and is,
therefore, not detailed i n the core t e x t of this Standard.


All correspondence, instructions, data sheets, drawings or any other written

information shall be in English language. In case o f dual languages, one
language shall be English.

All dimensions, units of measurement, physical constants etc. shall be in SI

units unless otherwise specified. (Nominal bore pipe sizes t o be generally
mentioaed in inches).

All documents (text, data sheets, specifications etc.) shall be provided w i t h

electronic files in the approved and widely used software (MS Word, Excel,
Auto Cad etc.). All calculations shalt be submitted in approved and widely
used software(s) agreed upon by KOC.
DOC. NO. KOC-C-023 Page 18 of 20 REV.l

14.2 Deliverables

The Contractor shall submit the necessary documents as a minimum to

KOC for review and acceptance as given below, but is not limited to the
following only:

a. Ma iufacturer's catalogues

b. Ma1:erial Samples

c . Test Results
Page 19 of 20 REV.1


This Standard has been approved by the Standards Technical Committee (STC)
consisting of t k e following:

Mr. A/Redha A -Haddad Standards Team Chairman

Mr. Mohammad Emam Insp.& Corr. Team (S&EK) Deputy Chairman
Mr. S. Kumar Standards Team Secretary/ Member
Mr. Henry S. Hill Opns. Tech. Svcs Team (SK) Member
Mr. Khalid Al-Ahmad Gen. Proj. Team Member
Mrs. Amina Rajab Design Team Member
Mr. Khalaf Hamada Design Team Member
Mr. N. Ramanathan Major Projects-EFP Member
Mr. Daniel Pino Utilities Team Member
Mr. Ali Hassan Al-Failakawi HSES Team Member
Dr. Modistaba Araghi Insp. & Corr Team (N&WK) Member
Mr. Abdul Aziz Akbar Proj. Mgmt. Team (NK) Member
Mr. Moataz Khalaf Information System Team Member

The draft of this Standard has been circulated to the KOC User Teams for their
review; and responses were received from the following: -


Team Leader Cmstruction Team Leader Project Design

Team Leader General Projects Team Leader Utilities


Team Leader Project Support Team Leader Safety


Team Leader Insp. & Corr. (S&EK) Team Leader Opns. Tech. Svcs
Team Leader Insp. & Corr. (N&WK) Team Leader Gas Opns.


Team Leader Maintenance Team Leader Proj. Engg.& Facilities


Team Leader Frod. Opns. Team Leader 0pns.Tech. Svcs.

Task Force Responsible for this Standard

The preparation of this Standard has been entrusted by the Standards Technical
Committee (STC) t o the Task Force No. (TF-C/07) comprising of the following

Mr. S. Kumar Standards Team TF Leader / Author Tel. No. 67 4 0 7

Mr. Mohd. Javaid Design Team Member Tel. No. 613 2 2
Mr. Ahmed Al-Fanaini Export Fac. Proj. Member Tel. No. 66987
Mr. Hussain A L a z z a f Gen. Projects Member Tel. No. 63226
Mr. Maged Mad- Projects Design Member Tel. No. 66389