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Project
Shell Project No: HP-3000-QAT
Project Document Number: T- 4.234.076
2MH127
Tag/Item Number(s):
N/A
Unit(s):
ASU
PCWBS:
LINDE ENGINEERING
Contractor Project No :
Project Rev.: C
Page 2 of 30
5887
01.12.08
SB
EO
AG
RFC
24.08.08
SB
EO
AG
ICC
09.01.08
IU
UA/IO
MC/ZG
RFC
01.10.07
MS
MC
ZG
ICC
MS
MC
ZG
IFR
MS
MC
ZG
IIR
GAMA
Rev.
No.
Project
Rev
No.
Date
Description
Status
Document Title:
Contractor
LOC470
GAM
MTS
CIV
GTL
010
Org.
Code
Doc.
Type
Disc.
Code
Geogr.
Area
Seq.
No
Rev.
No
Vendor Code
Rev No: C
Q A T A R
Doc. Title
GAM-MTS-CIV-GTL-010 Rev. F
Method Statement for Grouting
Date
01.12.2008
TABLE OF CONTENTS
1.
PURPOSE _____________________________________________________________________ 5
2.
SCOPE ________________________________________________________________________ 5
3.
HSSE _________________________________________________________________________ 5
4.
REFERENCES _________________________________________________________________ 6
5.
DEFINITIONS _________________________________________________________________ 6
6.
7.
8.
ATTACHMENTS ______________________________________________________________ 11
T-4.234.076 Rev. C
Page 4 of 30
Q A T A R
Doc. Title
GAM-MTS-CIV-GTL-010 Rev. F
Method Statement for Grouting
Date
01.12.2008
1. PURPOSE
This document describes the methods proposed to be used for the non-shrink grouting works that will be
carried out as part of ASU Construction Works of QSGTL Pearl Plant in Ras Laffan Industrial City of Qatar.
2. SCOPE
Grouting facilities will take place on the dedicated place(s) as per approved layout area. The construction &
erection activities will be carried out by Gama.
3. HSSE
All works will be in compliance with the State of Qatar laws and regulations, Ras Laffan Industrial City and
international standards/codes, and Company and Contractor requirements and instructions.
All personnel will go through Gama, Contractor and Company Safety Induction courses as well as other
trainings as identified by their supervisor. Please see Document Number GTL-GM-001-A-5635 for details.
A Job Safety Analysis (JSA) specific for this work including a Risk Assessment, is prepared as per Gama
procedure GTL-GM-001-A-5626 and is attached herein. Such JSA addresses the hazards associated with
each task within the scope of this Method Statement and introduces the controls that will be implemented to
reduce the associated risks to acceptable levels. The JSA will be used by the Site Supervisor as the basis of
his TSTI / TSTO and Toolbox Talks.
All personnel will have PPE required for their specific tasks in addition to the minimum PPE (coveralls, safety
goggles, safety shoes, high-visibility vests, gloves) at site at all times as required.
In the event of a release, fire or explosion, employees will secure their area and evacuate to the nearest
muster point. Once all employees are evacuated the supervisor will conduct a headcount to verify all
employees are out of harms way. The supervision will report this to Contractor. Emergency Contact numbers
for Company, Contractor and Gama will be posted onsite.
All vehicles and equipment used for the subject work will be inspected and certified as required.
Drivers and operators will be competent and will have attended all required trainings set forth in project
procedures and specifications.
T-4.234.076 Rev. C
Page 5 of 30
Q A T A R
Doc. Title
GAM-MTS-CIV-GTL-010 Rev. F
Method Statement for Grouting
Date
01.12.2008
4. REFERENCES
Qatar Construction Standard
DEP 34.19.20.31-Gen
T-13.376.358
ASTM C109
ASTM C156
ASTM C531
Linear Shrinkage and Coefficient of Thermal Expansion of ChemicalResistant Mortars and Monolithic
ASTM C579
ASTM C827
ASTM C1107
DEP 31.29.00.10
5. DEFINITIONS
Company
Contractor
: Linde Engineering AG
Subcontractor or Gama
Contract
QCR
QCP
QA/QC
ASTM
ACI
T-4.234.076 Rev. C
Page 6 of 30
Q A T A R
Doc. Title
GAM-MTS-CIV-GTL-010 Rev. F
Method Statement for Grouting
Date
01.12.2008
6. METHOD OF EXECUTION
6.1.
Equipment
-
: Manufactures Recommendation
: 1 (if needed)
: 4 (if needed)
Manpower
-
Civil Foreman
HSSE Officer
QA/QC Technician
Carpenter
Grouting Personnel
Helper
Operator
Truck Driver
6.2.
:1
:1
:1
:3
:4
:8
:1
:1
T-4.234.076 Rev. C
Page 7 of 30
Q A T A R
Doc. Title
GAM-MTS-CIV-GTL-010 Rev. F
Method Statement for Grouting
Date
01.12.2008
6.3.
Only materials approved by Contractor will be used. Fosroc - Conbextra BB 80 OR BASFMaster Flow 928 T)
6.3.1) FOSROC CONBEXTRA BB 80:
It is a non-shrink cementitious bearing grouting (dry powder) material will be used Flanged
Lighting Columns, Heavy stanchion bases and base plates for reciprocating pumps, anchor
bolts, Steel Structures etc
The grouting material is packed in 25 Kg air tight plastic bags used up to the section thickness
up to 100mm. For the thicker sections more than 100mm, the clean washed 5-10mm silt free
aggregate will be mixed (Max.Ratio1:1) with the grouting powder as per the manufacturer
recommendations.
Storage mixing & placing and curing shall be in accordance with the manufacturer
recommendations.
T-4.234.076 Rev. C
Page 8 of 30
Q A T A R
Doc. Title
GAM-MTS-CIV-GTL-010 Rev. F
Method Statement for Grouting
Date
01.12.2008
The grouting material will be mixed with a measured amount of clean water at WATER:
POWDER ratio of 0.15 at a maximum temperature of 250C.Water Temperature will be Monitor
by use of Thermometer.
The Compressive Strength of the grout must be 45 N/mm2 @ 24 Hours, 60 N/mm2 @ 3 days,
70N/mm2 @ 7 days and 85 N/mm2 @ 28 Days as per manufacturers data sheet
recommendations and as per BS 1881 Part 116 1983.
6.3.1.1)
PRE-SOAKING
Bolt holes and fixing pockets must be blown clean of any dirt or debris.
For a minimum of 24 hours prior to pouring, the area of cleaned substrate should be soaking
with wet Hessian with fresh water to minimize localized absorption and to assist in the free flow
of the grout.
Immediately before grouting, any free water should be removed. Particular care should be taken
to blow out all holes and pockets.
Forms will be waxed or use of Silica as necessary to prevent sticking and leak proof as
Conbextra BB 80 is a free flow grout. An intensive care will be paid to ensure that the grout
cannot squeeze out from below and around the forms during placing and setting.
Ensure the Form work is secure and watertight to prevent movement and the area should be
free from excessive vibration. Shut down all machineries until the grout has hardened.
6.3.1.2)
For the best result, the grouting material shall be mixed with mechanical mixer for larger
quantity. Dont use a colloidal impeller mixer for mixing.
To produce a fluid grout, add 3.75 Lit. of water (below 250C) will be to a 25Kg bag of Conbextra
BB 80.The water should be accurately measured into the mixer. Slowly add the total content of
the Conbextra BB 80 powder and mix continuously for 5 minutes on high shear / speed until the
smooth and even consistency is obtained.
Place the grout within 15 minutes of mixing to attain full strength.
Conbextra BB 80 can be placed in thickness up to 100 mm in a single pour.
Continuous grouting operation will be takes place until the process is finished.
The mixed grout shall be poured only from one side of the void to eliminate the entrapment of
air or surplus pre-soaking water.
6.3.1.3)
CURING
On completion of the grouting operation, exposed areas should be thoroughly cured. This should
be done by the use of continuous application of water with Hessian up to 7 days as per DEP
34.19.20.31 Gen Clause 10.3.2.
The Grouted area shall be covered with Wet Hessian with Polythene double Layer and/or as per
DEP 34.19.20.31(Gen) Amendments plus Manufacture recommendation.
T-4.234.076 Rev. C
Page 9 of 30
Q A T A R
Doc. Title
GAM-MTS-CIV-GTL-010 Rev. F
Method Statement for Grouting
Date
01.12.2008
1)
APPLICATION PROCEDURE :
Consistency
Flow Table
Water(Lit) / 25 Kg Bag
C
o
Min
Max
n
e
Grouting Machinery
Fluid
----
20 - 30
4.5
5.0
Grouting Machinery
Flowable
130
3.5
4.0
Plastic
60
3.0
3.5
Dry-pack
2.0
2.5
Bedding Pre-cast
Filling Tie-bar voids
Note: (1) If grout shoulders require finishing work, this should be carried out prior to application of
the curing membrane.
(2) Under no Circumstances should Master flow 928T be re-tempered by the later addition
of water.
(3) For the Compressive strength of Grout, the details in the Manufacture data sheet also
Followed.
T-4.234.076 Rev. C
Page 10 of 30
Q A T A R
Doc. Title
GAM-MTS-CIV-GTL-010 Rev. F
Method Statement for Grouting
Date
01.12.2008
7. QUALITY ASSURANCE
A Quality Assurance System will be operated conforming to related standards. Controls and checks will be
established and documented through relevant T- 4.234.545 (QCP), T- 4.234.576 (ITP) and QCR s.
8. ATTACHMENTS
8.1.
8.2.
T-4.234.076 Rev. C
Page 11 of 30
Q A T A R
Page No: 1 of 8
REVISED
Name
JSA Members:
Job Performers:
Signature
Date
Job Supervisor:
Additional Approvals (Determined by Job Supervisor in correlation with Linde HSSE Manager).
Name
Signature
Discipline Superindent (Linde)
Date
Approval required for hazardous work detailed in the Linde Work Permit Procedure.
Changing conditions and emergency procedures
Stop work. Switch off equipment.Supervisor directs personnel to nearest and safest muster point considering wind direction. Supervisor counts all employees. Missing
employees are reported to Linde HSSE Dept. When all clear is given, check with Linde HSSE before returning to work.
LINDE EMERGENCY TELEPHONE NO.
HSSE MANAGER:
Pearl HOT LINE :
Q A T A R
HAZARDS / POTENTIAL
ITEM
ACTIVITY
CONSEQUENCES
1
Unloading rebar from 1.1 Falling or dropped loads.
delivery truck with
crane to rebar stock
1.2 Overturning of machine.
area.
Initial Risk
RISK
P C
RANK
C
HIGH
MED
SCOPE :
GROUTING WORKS
Residual Risk
1.1.1
1.1.2
1.1.3
1.2.1
1.2.2
1.2.3
MAIN
CONTROLS
Third party crane inspections.
Daily crane checks.
Competent riggers.
SWL properly displayed.
Qualified and 3rd party certified
operators.
Set up crane on solid level ground
1.1.1.1
1.2.1.1
1.2.1.2
1.3
Improper rigging.
1.3.1
1.3.2
C
1.4
HIGH
Damaged, worn or
unusable rigging
equipment and/or gears.
1.3.3
1.4.1
1.4.2
C
HIGH
1.4.3
1.5
People struck by
suspended or swinging
load.
1.5.1
B
MED
Manual handling.
1.5.2
1.5.3
1.5.4
2.1.1
2.1.2
LOW
2.1.3
2.1.4
2.1.5
1.3.1.1
1.3.1.2
ADDITIONAL
CONTROLS
Supervisor/foreman shall ensure
that the TSTI is properly executed
at the work front and hazards
Supervisor/foreman shall ensure
that the TSTI is properly executed
at the work front and hazards
discussed.
Ensure daily check is performed
prior to each use.
Supervisor/foreman shall ensure
that the TSTI is properly executed
at the work front and hazards
discussed.
Rigging operations shall be
performed by competent and
qualified riggers.
Supervisor/foreman shall ensure
that the TSTI is properly executed
at the work front and hazards
discussed.
Ensure that all rigging gear are
has 3rd party certificates.
Supervisor/foreman shall ensure
that the TSTI is properly executed
at the work front and hazards
discussed.
LOW
LOW
LOW
LOW
LOW
LOW
Q A T A R
ITEM
ACTIVITY
Measuring and
cutting rebar to
length.
HAZARDS / POTENTIAL
CONSEQUENCES
2.2 Debris and materials
causing slip, trips and
falls.
3.1
Initial Risk
RISK
P C
RANK
LOW
2.2.3
3.1.1
LOW
3.2.1
B
3.3
3.2
Residual Risk
2.2.1
2.2.2
B
LOW
3.3.1
3.3.2
B
3.4
LOW
Defective equipment.
3.3.3
3.4.1
LOW
3.4.2
3.4.3
Transferring cut
rebars from cutting
machine to rebar
bending machine.
4.1
Manual handling.
4.1.1
4.1.2
C
4.2
LOW
LOW
SCOPE :
GROUTING WORKS
4.1.3
4.1.4
4.2.1
4.2.2
MAIN
CONTROLS
Adequate stacking of materials.
Regular housekeeping practices and
removal of trash and unnecessary
items.
Maintain access and walk paths.
Wear approved PPE, safety goggles,
safety helmet, safety shoes, gloves,
high-vis vests
Approved quality hand gloves,
available in a full range of sizes to
ensure proper fit to maintain
dexterity.
Competent operators, trained on the 3.3.1.1
machine they operate.
Ensure that the guards are properly
installed and are being used.
3.3.1.2
Post near machine the
manufacturers safe operating
procedures in different languages.
3.3.1.3
Daily inspection of equipment by
operator prior to use according to
manufacturers recommendations.
Current Contractor inspection
certificate.
Monthly equipment inspection and
color code.
Worker to wear appropriate gloves.
Break the load into manageable
portions.
Lift with your legs not your back.
Use the buddy system, Get help.
Adequate stacking of materials.
Regular housekeeping practices and
removal of trash and unnecessary
items.
3.4.1.1
4.1.1.1
ADDITIONAL
CONTROLS
LOW
LOW
LOW
LOW
LOW
LOW
LOW
Q A T A R
ITEM
5
ACTIVITY
Setting up rebar
bending machine to
perform desired
bend.
HAZARDS / POTENTIAL
CONSEQUENCES
5.1 Hand and finger injuries.
Initial Risk
RISK
P C
RANK
5.1.1
LOW
5.1.2
5.1.3
Measuring and
bending rebar.
6.1
6.1.1
6.1.2
6.1.3
D
MED
6.1.4
6.1.5
6.2
6.3
Unauthorized people in
rebar bending area or
radius.
6.2.1
D
MED
LOW
6.2.2
6.3.1
SCOPE :
GROUTING WORKS
MAIN
CONTROLS
Follow manufacturers
5.1.1.1
recommendations for properly and
safely setting up rebar bending
machine.
Control of hazardous energy, LO/TO. 5.1.1.2
de-energize equipment" before
making adjustments to moving parts. 5.1.1.3
Wear approved hand gloves for the
task.
Install stops on the edge of
workbench.
Approved hand gloves, available in a
full range of sizes to ensure proper fit
to maintain dexterity.
Follow manufacturers
recommendations for operating and
adjusting machine for rebar size.
Competent and properly trained
operator.
Keep away hand & finger from
moving parts.
6.1.1.1
6.1.1.2
6.1.1.3
6.1.1.4
6.1.1.5
Residual Risk
ADDITIONAL
P C
R
CONTROLS
Supervisor/foreman shall ensure
that the TSTI is properly executed
at the work front and hazards
discussed.
Minimize number of people at work
B 1
LOW
area of bending/cutting machine.
Mark the work area.
LOW
LOW
LOW
Q A T A R
ITEM
ACTIVITY
HAZARDS / POTENTIAL
CONSEQUENCES
6.4 Improper use of rebar
bending machine.
Initial Risk
RISK
P C
RANK
Residual Risk
6.4.1
6.4.2
B
Assembly of
reinforcement bars.
7.1
LOW
6.4.3
7.1.1
7.1.2
C
7.2
MED
7.1.3
7.1.4
7.2.1
7.2.2
C
SCOPE :
GROUTING WORKS
MAIN
CONTROLS
Competent and properly trained
operator.
Follow manufacturers
recommendations for operating and
adjusting machine for rebar size.
Post near machine the
manufacturers safe operating
procedures in the appropriate
languages
6.4.1.1
6.4.2.1
6.4.3.1
LOW
7.2.1.2
Surface preparation
for construction
joints.
8.1
8.1.1
8.1.2
B
LOW
8.1.3
8.2
8.2.1
LOW
8.2.2
8.2.3
ADDITIONAL
CONTROLS
Supervisor/foreman shall ensure
that the TSTI is properly executed
at the work front and hazards
discussed.
Ensure that equipment manual is
available near the machine.
Post names of authorized
operators near the machine.
LOW
LOW
LOW
LOW
LOW
Q A T A R
ITEM
ACTIVITY
HAZARDS / POTENTIAL
CONSEQUENCES
8.3 Sub-standard equipment.
Initial Risk
RISK
P C
RANK
8.3.1
B
Install formworks.
9.1
MED
8.3.2
9.1.1
9.2
LOW
9.2.1
9.2.2
B
9.3
9.4
LOW
LOW
9.3.3
9.4.1
Fall hazards.
9.2.3
9.2.4
9.2.5
9.3.1
9.3.2
10
LOW
9.4.2
HIGH
10.1.1
10.1.2
10.1.3
10.1.4
SCOPE :
GROUTING WORKS
MAIN
CONTROLS
Distribution panel inspected by
8.3.1.1
Contractor before being energized.
Inspection and color-coding of power
tools monthly with a visual inspection
prior to each use.
All work is to be completed with
approved PPE, including safety
glasses with side shields, safety
helmet, coveralls and steel toe
footwear and gloves.
9.1.1.1
9.1.1.2
Residual Risk
ADDITIONAL
P C
R
CONTROLS
Ensure all sub-standard equipment
should be remove from site and
tag as unsafe.
B 2
LOW
LOW
LOW
LOW
LOW
LOW
Q A T A R
ITEM
ACTIVITY
HAZARDS / POTENTIAL
CONSEQUENCES
10.2 Improper rigging.
Initial Risk
RISK
P C
RANK
HIGH
11
Pour concrete.
HIGH
MED
LOW
LOW
LOW
SCOPE :
GROUTING WORKS
Residual Risk
MAIN
CONTROLS
10.2.1 Competency check for all riggers.
10.2.2 Rigging supervisor to monitor rigger
performance.
10.2.3 Third party certified and competent
riggers.
10.2.1.1
10.2.1.2
ADDITIONAL
CONTROLS
Supervisor/foreman shall ensure
that the TSTI is properly executed
at the work front and hazards
discussed.
Rigging operations shall be
performed by competent and
qualified riggers.
Supervisor/foreman shall ensure
that the TSTI is properly executed
at the work front and hazards
discussed.
Ensure that all rigging gears are
has 3rd party certificates.
Supervisor/foreman shall ensure
that the TSTI is properly executed
at the work front and hazards
discussed.
LOW
LOW
LOW
LOW
LOW
LOW
Q A T A R
ITEM
ACTIVITY
HAZARDS / POTENTIAL
CONSEQUENCES
11.4 Sub-standard equipment.
Initial Risk
RISK
P C
RANK
MED
MED
LOW
LOW
LOW
LOW
SCOPE :
GROUTING WORKS
Residual Risk
MAIN
ADDITIONAL
P C
R
CONTROLS
CONTROLS
11.4.1 Distribution panel inspected by
11.4.1.1 Ensure all sub-standard equipment
Contractor before being energized.
is removed from site and tagged
11.4.2 Inspection and color-coding of power
as unsafe.
B 2
LOW
tools monthly with a visual inspection
prior to each use.
11.5.1 Contractor inspections.
11.5.1.1 Supervisor/foreman shall ensure
11.5.2 Daily operator inspection of vehicle
that the TSTI is properly executed
and associate pump equipment.
at the work front and hazards
11.5.3 Competent operator trained on the
discussed.
equipment in which he operates.
11.5.4 Visual inspection of boom prior to
each use.
11.5.5 Ensure whip check is nstalled.
11.6.1 Approved PPE( including face shield
by employees working is close
proximity of concrete pour).
11.6.2 Competent personnel.
11.6.3 Eye wash available.
11.7.1 Wearing of approved coveralls and
gloves, with the hose man wearing
additional non-permeable suit.
11.7.1 Appropriate footwear
11.8.1 Use of plastic, spread on the ground
to contain waste.
11.8.2 Operator to properly control pump
boom movement.
11.8.3 Workout set approved area.
LOW
LOW
LOW
LOW
LOW