Project Name:

CONSTRUCTION OF OFF-SPEC CRUDE TANK AND REQUIRED ITEMS IN KARANJ/PARSI UNITS

Specification for Grouting Class: 2 Rev.: 00 Page: 1 (10)

National Iranian South Oilfields Co. (NISOC)

Doc. Name:

Company Doc. No.: Proj. Doc. No.:

90206-000-CV-SP-107

Specification for Grouting

B.R. PROJECT COMPANY LOCATION

: 53-73-90206 : CONSTRUCTION OF OFF-SPEC CRUDE TANK AND REQUIRED ITEMS IN KARANJ/PARSI UNITS : NATIONAL IRANIAN SOUTH OILFIELDS COMPANY (NISOC) : KARANJ/PARSI-KHUZESTAN-IRAN

00 REV.

21/01/2012 DATE

FOR TENDEING DESCRIPTION

I.R.M. ORIG.

I.R.M.

A.B.

A.A.L. APPD

PRPD

CHKD

Project Name:

CONSTRUCTION OF OFF-SPEC CRUDE TANK AND REQUIRED ITEMS IN KARANJ/PARSI UNITS

Specification for Grouting Class: 2 Rev.: 00 Page: 2 (10)

National Iranian South Oilfields Co. (NISOC)

Doc. Name:

Company Doc. No.: Proj. Doc. No.:

90206-000-CV-SP-107

TABULATION OF REVISED PAGES

Page Rev. 0 Rev. 01 Rev. 02 Rev. 03
1 2 3 4 5 6 7 8 9 10

Rev. 04

Page Rev. 0 Rev. 01 Rev. 02 Rev. 03 Rev. 04

Project Name:

CONSTRUCTION OF OFF-SPEC CRUDE TANK AND REQUIRED ITEMS IN KARANJ/PARSI UNITS

Specification for Grouting Class: 2 Rev.: 00 Page: 3 (10)

National Iranian South Oilfields Co. (NISOC)

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Company Doc. No.: Proj. Doc. No.:

90206-000-CV-SP-107

Contents:
1.0 General Statement 1.1 1.2 2.0 3.0 4.0 5.0 Scope Definition

APPLICABLE DOCUMENTS TYPES OF GROUT USES OF GROUT GROUT MATERIALS 5.1 5.2 5.3 5.4 General Type G1 - Cement-Sand Grout Type G2 - Cement - Base Non shrink Grout Type G3 - Epoxy Grout

6.0 7.0 8.0 9.0

SURFACE PREPARATION FORMWORK PLACING, FINISHING AND CURING TESTING

Project Name:

CONSTRUCTION OF OFF-SPEC CRUDE TANK AND REQUIRED ITEMS IN KARANJ/PARSI UNITS

Specification for Grouting Class: 2 Rev.: 00 Page: 4 (10)

National Iranian South Oilfields Co. (NISOC)

Doc. Name:

Company Doc. No.: Proj. Doc. No.:

90206-000-CV-SP-107

1- General Statement
1.1- Scope
This project Specification defines the requirements for materials and methods for the grouting of machines, equipment and structural steel works in CONSTRUCTION OF OFF-SPEC CRUDE TANK AND REQUIRED ITEMS IN KARANJ/PARSI UNITS

Project. 1.2- Definition Owner: National Iranian South Oil-Fields Company (NISOC).

2- Applicable Documents
American Standards ASTM C33 ASTM C109 ASTM C150 ASTM C191 ASTM C531 Standard Specification for Concrete Aggregates. Standard Test Method for Compressive Strength of Hydraulic Cement Mortars. Standard Specification for Portland Cement. Time of setting of Hydraulic Cement by Vicat Needle Test Method. Standard Test Method for Linear Shrinkage and Coefficient for thermal Expansion of chemical-Resistant Mortars, Grouts and Monolithic Surfacing. ASTM C579 ASTM C827 Standard Test Method for Compressive Strength of Chemical Resistant Mortar, Grouts and Monolithic Surface. Standard Test Method for Change in Height at Early Ages of Cylindrical Specimens for Cementations Mixtures.

Project Name:

CONSTRUCTION OF OFF-SPEC CRUDE TANK AND REQUIRED ITEMS IN KARANJ/PARSI UNITS

Specification for Grouting Class: 2 Rev.: 00 Page: 5 (10)

National Iranian South Oilfields Co. (NISOC)

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Company Doc. No.: Proj. Doc. No.:

90206-000-CV-SP-107

3- Types of Grout
Grouts specified are of two types: Type G1 Type G2 Type G3 : : : Sand-Cement Grout A Sand -cement grout prepared from basic material on site. Cement-Base Non shrink Grout. A factory prepared shrink controlled grout. Epoxy Grout. Notwithstanding the requirements of this specification, Type G2 shall be stored and used fully in accordance with the manufacturers instructions.

4- Uses of Grout
4.1- The various types of grout shall be used as described below. However, the type, location and extent of any grouting will be defined by the Engineering contractor on the construction drawings associated with a particular section of work the minimum thickness shall be 25mm and maximum thickness of grout under the highest point of machinery base shall be 50mm. Type G1: Under small pumps and other light equipment. Its use shall be limited for grouting minor steel structure not assuming structural function subject to the approval of the owner. Type G2: Under all reciprocating pumps, Under all plant air compressors, Under all centrifugal compressors and other machinery, and machinery of sole plates where specified by manufacturer, Under all equipment, regardless of size and weight, which, in the opinion of the Engineer will produce static or dynamic stresses in excess of those allowable for Cementations grout, unless epoxy grout (type G3) is specified on drawings. Under Pipe rack and steel structure column base plates.

Project Name:

CONSTRUCTION OF OFF-SPEC CRUDE TANK AND REQUIRED ITEMS IN KARANJ/PARSI UNITS

Specification for Grouting Class: 2 Rev.: 00 Page: 6 (10)

National Iranian South Oilfields Co. (NISOC)

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90206-000-CV-SP-107

Type G3: Shall be applied for grouting of compressors or heavy equipments subject to vibration and elsewhere if specified on the drawings. 4.2- All types of grout shall be placed as soon as possible after the erection of the item of structure, plant or equipment.

5- Grout Materials
5.1- General All materials shall be approved by the Engineer or Owners Representative. All Non shrink grout constituents except water shall consist of pre-measured, prepackaged materials supplied by the manufacturer. All grouts shall be non-corrosive, non-staining and resistant to the effects of moisture. Project authorization shall not absolve the subcontractor from any responsibilities whatsoever in respect of the work to be carried out. Cement aggregate shall be delivered to the site in complete and dry bags. The subcontractor shall be responsible for storing materials for making grout in a dry, weatherproof area on pallets and within the temperature ranges specified by their manufacturers. 5.2- Type G1 - Cement-Sand Grout Cement shall be Portland cement in accordance with ASTM C150. Sand shall meet all the requirements for fine aggregate as specified in ASTM C33. In addition, the aggregate grain size shall be between 0.08 and 2.0 mm and thoroughly washed. 5.2.1- Mix Design The mix proportions shall be checked on site by trial mixes. The grout shall be adequately mixed in a paddle-type mortar mixer or by other suitable mechanical means. The water-cement ratio shall be the minimum required for adequate flow properties. The sand-cement mix shall be such that the compressive strength of the grout at 7 days shall not be less than 28 N/mm2, as determined by tests on 50 mm cubes in accordance with ASTM C109. Neat cement grout shall

Project Name:

CONSTRUCTION OF OFF-SPEC CRUDE TANK AND REQUIRED ITEMS IN KARANJ/PARSI UNITS

Specification for Grouting Class: 2 Rev.: 00 Page: 7 (10)

National Iranian South Oilfields Co. (NISOC)

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90206-000-CV-SP-107

not be used. Mix shall be 1:1 for bedding thickness not greater than 25 mm and 1:2 for bedding thickness not greater than 50 mm. Where bedding thickness is greater, the mix shall be in accordance with the Engineers instructions. Other special grout, e.g. rapid hardening or quick setting, shall only be used with prior written agreement from the Engineer. 5.3- Type G2 - Cement - Base non Shrink Grout The grout mix shall have a compressive strength not less than 40 N/mm2 at 7 days as determined by tests on 50 mm cubes in accordance with ASTM C109. Other requirements shall be as follows: Plastic volume Change No shrinkage (0%) and a maximum of 4.0% expansion at any time before initial set when tested in accordance with ASTM C827. Hardened Volume Changes No shrinkage (0%) and a maximum of 0.2% expansion in the hardened state. Initial Set Time Not less than 45 minutes when tested according to ASTM C191. Soundness The grout shall contain no substances, aluminum powder, fluidizers, super plasticizers, or other materials known to increase drying shrinkage or compromise durability. 5.4- Type G3 - Epoxy Grout Minimum compressive strength shall be 80 N/mm2 at 7 days as determined by test in accordance with ASTM C579. Epoxy product shall be submitted for prior approval of the owner and applied in close accordance with manufacturer's instructions.

Project Name:

CONSTRUCTION OF OFF-SPEC CRUDE TANK AND REQUIRED ITEMS IN KARANJ/PARSI UNITS

Specification for Grouting Class: 2 Rev.: 00 Page: 8 (10)

National Iranian South Oilfields Co. (NISOC)

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90206-000-CV-SP-107

6- Surface Preparation
The following surface preparation shall be applied for all grouts: Concrete foundation shall be at least 7 days old before surface preparation. All laitance shall be removed down to sound concrete. Surface to receive grout shall be rough and reasonably level. Surfaces shall have been wet-cured or if not, curing compounds shall be removed by roughening the surface. The surfaces of concrete, underside of base plate, bolt holes and bolts shall be clean and free from oil, grease, chemicals, dirt and other harmful matter and thoroughly blown clean of dust and small particles by compressed, oil-free air prior to grouting. When cement based grout is used the concrete surface including bolt holes shall be saturated with clean water prior to grouting. All excess water shall be removed from the concrete and bolt holes before grouting, leaving only a damp film.

7- Formwork
Formwork shall be provided for grout and shall be compatible with the method of placing grout specified herein. Forms shall be designed for rapid, continuous and complete filling of space to be grouted. Forms shall be of adequate strength to withstand the horizontal forces of the fluid grout, and shall be caulked or sealed with tape to provide a watertight seal. The forms shall be coated with form oil heavy wax to prevent grout adherence and absorption. The forms shall extend a minimum of 25 mm above the underside of the base plate being grouted and a minimum of 13 mm in plan shall be left between the form and the edge of the base plate. On the pouring side, the forms shall be located a

Project Name:

CONSTRUCTION OF OFF-SPEC CRUDE TANK AND REQUIRED ITEMS IN KARANJ/PARSI UNITS

Specification for Grouting Class: 2 Rev.: 00 Page: 9 (10)

National Iranian South Oilfields Co. (NISOC)

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Company Doc. No.: Proj. Doc. No.:

90206-000-CV-SP-107

minimum of 50 mm away from the edge of the base plate. The top of the forms on the pouring side shall be sufficiently high, but no less than 150 mm.

8- Placing, Finishing & Curing

Grouting shall only commence once the base is leveled and written authorization given by the Engineer. Placing of grout, base plate and grout material for foundations shall be at an ambient temperature between 10-24C. This temperature shall be maintained within this range for 48 hours following installation and thereafter above 40C until strength exceeds 28 N/mm2. Cold water shall be used to extend working time in hot water. Care shall be taken to ensure that the pocket or base area is completely filled with grout which must be thoroughly compacted, free from air pockets and in full contact with the concrete surfaces. All trapped pockets shall be vented to allow full penetration of the grouting material. Where vent holes have been provided in base plates these shall be used, during the pouring of grout and then the holes must be filled with the grout material to the top level of the base plate or hole surroundings. Place grout rapidly and continuously to avoid cold joints under the base plate. Grout from one side to the other in 1 direction. Tamp or rod grout to eliminate voids. Be careful not to over tamp or rod such that air is taken into the grout. Grout placed by gravity flow shall be applied continuously under a head of not less than 30 mm and worked until the space is completely filled. The grout shall not be overworked. Sufficient quantities shall be mixed to ensure complete use within 1 hour. All bolt holes and sleeves shall be adequately filled and pressure grouting used where directed by the Engineer. Vibration shall not be used to ensure filling. Shade the foundation from direct sunlight for at least 24 hours before and 48 hours after grouting. Where a field service is offered by the manufacturer it shall be utilized. The manufacturers guarantees may be dependent on such involvement. Cement-based grout is to be trimmed back, after the initial set, to the level shown on the drawings with surfaces sloped away from the base plate neatly pointed and trawled

Project Name:

CONSTRUCTION OF OFF-SPEC CRUDE TANK AND REQUIRED ITEMS IN KARANJ/PARSI UNITS

Specification for Grouting Class: 2 Rev.: 00 Page: 10 (10)

National Iranian South Oilfields Co. (NISOC)

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Company Doc. No.: Proj. Doc. No.:

90206-000-CV-SP-107

off the left in a workmanlike manner. Chamfers 25 mm wide with the side inclined at 45C must be formed along the whole edge of the base. Exposed edges shall be protected against damage during the curing period.

Where shims are to be removed, or if wedges were used, they shall be removed after 3 days. On removal of the shims or wedges, the resultant spaces shall be filled with similar grout. Foundations bolts should then be adjusted for tightness. All curing compounds and method for application shall be approved by the Engineer before application may commence.

9- Testing
9.1- Test samples for sand-cement grout shall be taken at least once per day or once every 1.0 m3, whichever is greater. Compressive strength tests on cubes shall comply with ASTM C109. 9.2- Non shrink cement-base grout shall be tested at least once per day in accordance with ASTM C109. 9.3- Prepare the following number of cubes for each type of grout and test after the following periods for required compressive strength according to the schedule: Grout Type Sand Cement Grout Non shrink Cement Grout 24 Hrs. 3 2 Days 2 7 Days 2 3 28 Days 2 3

9.4- If the results of tests indicate that the grout is below the required specification, the whole of the material shall be removed after the placing of shims, and the base plate regrouted.