METHOD OF STATEMENT

FOR GROUTIING WORK

G GTPP
Job Title : Closed Relief System & Flare Gas Recovery System Project at QCPF
JO No. : MS – GW - 001 Client : Saudi Aramco/Arabian Bemco Contracting Co, Contract No: 6600036803

Procedure Number : BI: Rev: 00, Date: 28 JULY 2016

Doc. Doc. Number: GTPP - 001
BI-10-01802 –PCW-002-000 10-01802

Method Of Statement
For
Grouting Works

Reviewed By –
Revision Prepared By – Site
Rev Site Reviewed By – QA/QC Insp. Approved By - PM DATE
Description Engineer
Superintendent

ISSUED FOR
00 MR. MURALI KASI MR. SAKTHI VEL MR. ELIAS OMAR ADAM MR. AMADO DELA CRUZ 28/07/16
APPROVAL

Page 1 of 13
 METHOD OF STATEMENT
FOR GROUTIING WORK
GTPP
Job Title : Closed Relief System & Flare Gas Recovery System Project at QCPF
JO No. : MS – EW - 001 Client : Saudi Aramco/Arabian Bemco Contracting Co, Contract No: 6600036803
Procedure Number : BI: Rev: 00, Date: 28 JUNE 2016
Doc. Doc. Number: GTPP - 001
BI-10-01802 –PCW-002-000 10-01802

TABLE OF CONTENTS

ITEM NO. DESCRIPTION PAGE NO.

1.0 OBJECTIVE 3
2.0 SCOPE 3
3.0 DEFINITIONS 3
4.0 APPLICABLE REFERENCES 4
5.0 PROCEDURES 5
5.1 RESPONSIBILITIES 6
5.2 CEMENT BASED NON-SHRINK GROUT 8-11
5.3 EPOXY BASED NON-SHRINK GROUT 12
6.0 DOCUMENTATION 13

Page 2
 METHOD OF STATEMENT
FOR GROUTIING WORK
G GTPP
Job Title : Closed Relief System & Flare Gas Recovery System Project at QCPF
JO No. : MS – GW - 001 Client : Saudi Aramco/Arabian Bemco Contracting Co, Contract No: 6600036803

Procedure Number : BI: Rev: 00, Date: 28 JULY 2016

Doc. Doc. Number: GTPP - 001
BI-10-01802 –PCW-002-000 10-01802

1.0 OBJECTIVE

To ensure that all Non-shrink grouting works are done in a way that is in compliance to
Saudi Aramco Standards and to the recommendations of the Manufacturer of the
Equipment and structures it supports.

2.0 SCOPE

This procedure includes the minimum requirements and guidelines in dealing with and
placing of non-shrink grouts on concrete structures supporting heavy equipment’s and
machineries.

3.0 DEFINITIONS

3.1 SAES - Saudi Aramco Engineering Standards

3.2 SAMSS - Saudi Aramco Materials System Specification
3.3 SAIC - Saudi Aramco Inspection Checklist
3.4 IFC - Issued For Construction
3.5 PPE - Personnel Protective Equipment
3.6 RFI - Request for Inspection
3.7 PIP - Process Industry Practice
3.8 ITL - Independent Testing Laboratory
3.9 TDS - Total Dissolved Solids
3.10 PPM - Parts per Million

Page 3 of 13
 METHOD OF STATEMENT
FOR GROUTIING WORK
GTPP
Job Title : Closed Relief System & Flare Gas Recovery System Project at QCPF
JO No. : MS – EW - 001 Client : Saudi Aramco/Arabian Bemco Contracting Co, Contract No: 6600036803
Procedure Number : BI: Rev: 00, Date: 28 JUNE 2016
Doc. Doc. Number: GTPP - 001
BI-10-01802 –PCW-002-000 10-01802

4.0 APPLICABLE REFERENCES

4.1 IFC Drawings

4.2 Saudi Aramco References:

Saudi Aramco Engineering Standards

SAES - Q-005 Concrete Foundations

SAES - Q-007 Foundations and Supporting Structures for Heavy Machineries
SAES - Q-010 Cement Based, Non-Shrink Grout for Structural Grouting
SAES - Q-011 Epoxy Grout for Machinery Support

Saudi Aramco Material System Specification

09-SAMSS - 060 Packaging Requirements for Coating

09-SAMSS - 092 Cement Base, Non-Shrink Grout
09-SAMMS-104 Epoxy Grout for Structural and Machinery Support

4.3 Industry Codes and Standards

Process Industry Practice

PIP STS03600 Non-Shrink Cementitious Grout Specification

PIP STS03601 Epoxy Grout Specification

Page 4
 METHOD OF STATEMENT
FOR GROUTIING WORK
G GTPP
Job Title : Closed Relief System & Flare Gas Recovery System Project at QCPF
JO No. : MS – GW - 001 Client : Saudi Aramco/Arabian Bemco Contracting Co, Contract No: 6600036803

Procedure Number : BI: Rev: 00, Date: 28 JULY 2016

Doc. Doc. Number: GTPP - 001
BI-10-01802 –PCW-002-000 10-01802

5.0 PROCEDURES

This procedure describes the actual steps to be undertaken and list of activities required to
perform the work.

5.1 RESPONSIBILITIES

The following comprises the minimum responsibilities from each designated personnel:

A. PROJECT MANAGER:

The Project Manager oversees and is the overall-in- charge of the Work Production units in this
particular project.

He monitors compliance by all personnel, Sub-Contractors and all parties to the governing
procedures, standards and specifications, the Project Quality Manual, the QC Inspection Plan,
IFC Drawings, Project Safety Plan, Relevant Saudi Aramco Specifications and Industry Codes
as the project requires.

He communicates with the different departments (Procurement, Planning, Construction,

Vendors, etc.) for concerns on their specific functions, and to Saudi Aramco for work progress,
inquiries and other concerns that need to be communicated for a continuous flow of work.

B. SITE SUPERINTENDENT;

The Site Superintendent, oversees and is in-charge of the Production work at the site. He
monitors the activities and undertakings at the site with reference to the planned schedule
and imposes compliance by all Site disciplines to the Quality Procedures and Inspection
Plans, the IFC drawings, the Project Safety Plan and To relevant Saudi Aramco Specifications
and Industry Codes as the project requires. He facilitates the coordination between the
different Departments and Disciplines to maintain a continuous flow of work.

The Site Superintendent, who is in charge of the Civil Work Production units of this
Page 5 of 13
 METHOD OF STATEMENT
FOR GROUTIING WORK
GTPP
Job Title : Closed Relief System & Flare Gas Recovery System Project at QCPF
JO No. : MS – EW - 001 Client : Saudi Aramco/Arabian Bemco Contracting Co, Contract No: 6600036803
Procedure Number : BI: Rev: 00, Date: 28 JUNE 2016
Doc. Doc. Number: GTPP - 001
BI-10-01802 –PCW-002-000 10-01802

project shall monitor and ensure compliance by his Site personnel, sub-contractors and
other Civil work associated parties to the Project Scope and to the governing Procedures,
Standards and Specifications, the Project Quality Manual, the QC Inspection Plan, IFC
Drawings, Project Safety Plan,

Relevant Saudi Aramco Specifications and Industry Codes as the project requires. He
communicates with the Site Supervisors for any work concerns, and to collect daily
Progress of Work Reports.

 He directly reports to the Proj Manager for Work Progress update and other work
concerns.

 He coordinates with other Departments (Quality, Procurement, Store Planning, etc.) for
project requirements and schedule and to Saudi Aramco Representative for the work
progress update, technical inquiries and other concerns that need to be communicated
with the support for a continuous flow of work.

C. SITE ENGINEER;

His responsibilities include but not limited to the following:

 Directly supervises by leading team of Foremen on the execution and conformance of this
activity to this procedure.

 Ensure that all site workers are achieved in a timely manner, on schedule and in
compliance to the approved procedure, specifications, drawings and all relevant
documents.
 Coordinates and reports to the Civil Construction Manager the work progress and
problems that may arise prior and during the execution of this activity.
 Compiles daily progress reports during the execution of this construction activity.

Page 6
 METHOD OF STATEMENT
FOR GROUTIING WORK
G GTPP
Job Title : Closed Relief System & Flare Gas Recovery System Project at QCPF
JO No. : MS – GW - 001 Client : Saudi Aramco/Arabian Bemco Contracting Co, Contract No: 6600036803

Procedure Number : BI: Rev: 00, Date: 28 JULY 2016

Doc. Doc. Number: GTPP - 001
BI-10-01802 –PCW-002-000 10-01802

D. QA/QC Inspector;

The Quality Control Inspector, oversees the activities of the Quality Control works.

 Complies Quality reports for submittal to BEMCO/ Saudi Aramco.

Make recommendations to the Civil Construction Manager in the case of Quality issues
encountered during the execution of this activity and the project as a whole.

 Implements and ensures compliance by all site personnel to this Procedure, to the Project
Specifications, the Project Quality Plan and the IFC Drawings.

 Supervises and monitors the QC Inspectors and their daily activities.

 Facilitates, reviews and is in-charge of disposition of any generated Non-Conformances at
his level.
 Verifies validity of Mill Certificates and Material Test Reports provided for the materials
supplied or required for this work prior to utilization.
 Facilitates Quality document submittals to the QA/QC Manager.
 Compiles all QA/QC documents (daily reports, test results, vendor certificates and NCRs)
for permanent project records.

E. QUALITY CONTROL INSPECTOR

The QC inspector shall be responsible for the site implementation of this Quality procedure for
this particular activity. His responsibilities include but are not limited to the following:

 Monitors daily activities, checks and assures that construction activities are in compliance
with the design drawings, standards and specifications.
 Initiates RFI after verification of the activities to be offered for inspection.
 Notifies the Field Supervisor and QA/QC Supervisor any observed deviation from the
specification so that corrective actions can be initiated.
 Maintains in his possession copies of Mill Certificates and Material Test Reports
corresponding to the materials to be utilized or required in this work.
 Coordinates with the ITL for the required testing on this work activity.
 Responsible for the preparation and submittal of the required Quality Control
documentations generated during the execution of this activity.

Page 7 of 13
 METHOD OF STATEMENT
FOR GROUTIING WORK
GTPP
Job Title : Closed Relief System & Flare Gas Recovery System Project at QCPF
JO No. : MS – EW - 001 Client : Saudi Aramco/Arabian Bemco Contracting Co, Contract No: 6600036803
Procedure Number : BI: Rev: 00, Date: 28 JUNE 2016
Doc. Doc. Number: GTPP - 001
BI-10-01802 –PCW-002-000 10-01802

F. Third (3rd ) Party Lab Test Agency;

 Responsible for all laboratory and field quality test works required in this Project.
 Provides technical laboratory test results to be Field inspectors monitoring the quality of
work at site.
 Submits the soonest time possible all test result and laboratory findings to the QA/QC , in
which, shall also be submitted to SA for review.

G. SAFETY ENGINEERR;

The SAFETY ENGINEER, checks, ensures and maintains compliance of all personnel and
activities to all safety requirements, such as the wearing of Personnel Protective Equipment
(PPE). Installation of site safety tools and abiding to the governing Safety procedures.

He checks the work areas for possible unsafe conditions.

He coordinates with the Site Superintendent and Supervisors in ensuring that work is carried
out in compliance to the Project Safety Plan.

5.2 CEMENT NON-SHRINK GROUT

Manufacturer’s Representative should come at site to demonstrate, mixing, placement etc prior to
start Grout activity.

Cement based non-shrink grout are to be used on equipment with driver HP of less than 500
(373 KW), on equipment with speeds 3600 RPM or less, on equipment that has a total weight of
up to 2,270 kg (5000 lbs) or as specified and recommended by the equipment manufacturer.
It shall also be used for grouting of structural base plates, anchor bolts and dowels as specified
on the drawing plans and specifications of this project.

MATERIAL SPECIFICATION:

The grout shall be factory pre-packed cement based non-catalyzed, non-metallic aggregate grout
ready for use with the addition of water at the jobsite and shall be free of hydrogen producing,
oxidizing catalysts and inorganic accelerating agents.

Water to be used for mixing shall not exceed 500Ppm of total dissolved solids and shall be free
of oil and other deleterious materials contamination.

Page 8
 METHOD OF STATEMENT
FOR GROUTIING WORK
G GTPP
Job Title : Closed Relief System & Flare Gas Recovery System Project at QCPF
JO No. : MS – GW - 001 Client : Saudi Aramco/Arabian Bemco Contracting Co, Contract No: 6600036803

Procedure Number : BI: Rev: 00, Date: 28 JULY 2016

Doc. Doc. Number: GTPP - 001
BI-10-01802 –PCW-002-000 10-01802

Requirements:

The Pre-packaged cement based grout shall have a minimum compressive strength of 3500psi
(28Mpa) at 7 days and 5000psi (35Mpa) at 28 days.
Actual compressive strength shall be obtained thru laboratory testing (by a Saudi Aramco
approved ITL) in which test samples are taken in the field at 2 sets of 3 cubes each day where
grout is mixed placed.

The test cubes shall be provided with the same curing treatment as with the placed grouts to
obtain uniformity of strength attained.
Water curing shall be continuous.

Application, Placement and Curing:

In this grouting procedure, the manufacturer’s written instructions shall be strictly followed;
from stocking, mixing through to application and curing.

5.2.1 Grout mixing procedure and quantity of water to be added shall be in accordance to the

Manufacturer’s recommendation and instructions. Refer to the instructions stated in the

package label and/or brochures.

5.2.2 Prepare the foundation or pedestal prior to placement.

 Concrete foundation and surface preparations shall be in accordance with the grout
Manufacturer’s written instructions, if provided.
The concrete shall already be cured for a minimum of seven (7) days before surface
preparation for grouting.
 Remove laitance, oil-soaked or damaged surfaces down to sound concrete by chipping to the
level of sound fractured aggregate or to a minimum of the top 25 mm. of the concrete.
 As possible, removal of dust and loose particles shall be by clean, dry, oil-free compressed air.
 Where required grout formwork shall be constructed with adequate strength, rigidity and
required dimensions to permit grout placement and avoid leakage.
A bond breaker shall be applied to the formwork that will be in contact with the grout.
 The concrete surfaces in contact with the grout shall be saturated with clean water and shall be
damp but free from standing water before grout placement.

Page 9 of 13
 METHOD OF STATEMENT
FOR GROUTIING WORK
GTPP
Job Title : Closed Relief System & Flare Gas Recovery System Project at QCPF
JO No. : MS – EW - 001 Client : Saudi Aramco/Arabian Bemco Contracting Co, Contract No: 6600036803
Procedure Number : BI: Rev: 00, Date: 28 JUNE 2016
Doc. Doc. Number: GTPP - 001
BI-10-01802 –PCW-002-000 10-01802

5.2.3 The grout shall be dry packed, flowed or pumped into place per the manufacturer’s
written instructions. Grouting shall be quick and continuous to avoid segregation,
bleeding or premature initial setting, and placement shall be in only one direction to
prevent air trapping.

5.2.4 The minimum thickness of grout layer shall be 25mm as specified in the drawing plans,
and shall also be the space between the bottom of base plate and the top of the concrete
foundation.

5.2.5 Wherever required, joints in grout shall be located as shown on the IFC Drawing or as
recommended by the grout manufacturer.

5.2.6 For each day grout is mixed and placed in the field, two sets of 3 grout test cubes shall be
cure in the same method as the field grouts.

Testing the comprehensive strength shall be at seven (7) and twenty eight (28) days of age.

5.2.7 When the water/cement ratio 0.4 or less, the grout shall be continuously water cured for a
minimum of seven days. Curing compounds, if used, shall be in accordance with ASTM C309.

5.3 Epoxy Based Non-shrink grout

Epoxy based non-shrink grout are to be used on equipment with drive HP of 500 (373 kW), on
equipment with speeds greater than 3600 rpm, on equipment that has a total weight greater than
2,270 kg (5000 lbs), on all reciprocating machinery with driver of greater than 50 HP (37 KW),
or as specified and recommended by the equipment manufacturer.

Material Specification:

Resin component of the epoxy grout materials shall consist of a pre-measured, pre-packaged,
solvent free, liquid epoxy resin specifically formulated for this grout system

The hardener component shall consist of a pre measured, pre-packaged, liquid specifically
formulated to produce the specified final properties when mixed with the other component.

The aggregate shall be a pre-measured, pre-packaged blend of inert, inorganic particulate fillers,
such as silica, designed specifically to provide the proper flow, handling and physical properties
required for the grout product.

Page 10
 METHOD OF STATEMENT
FOR GROUTIING WORK
G GTPP
Job Title : Closed Relief System & Flare Gas Recovery System Project at QCPF
JO No. : MS – GW - 001 Client : Saudi Aramco/Arabian Bemco Contracting Co, Contract No: 6600036803

Procedure Number : BI: Rev: 00, Date: 28 JULY 2016

Doc. Doc. Number: GTPP - 001
BI-10-01802 –PCW-002-000 10-01802

The resin and catalyst components shall be free of hard sediment, showing no gelling in a
freshly opened can and shall be of proper consistency to enable through mixing to a smooth
homogenous state.

The components shall show no gelling when stored for the shelf life indicated in unopened
containers at temperatures of 32oC.

REQUIREMENTS:

All the material/components (resin, hardener and aggregates) when delivered to the site shall be
in original unopened packages and properly labelled, including the batch number, shelf life and
storage requirements.
Storing shall be in accordance to the manufacturer’s recommendations.

The resin and catalyst to be received art the site shall not show any signs of leakage incurred
during shipping and storage. The packaging shall meet the requirements of 09-SAMSS-060.

The grout when mixed shall meet the physical requirements shown in the table below

Physical Properties Test Method Limits

Compressive Strength ASTM C579, Method B 95Mpa (14,000psi)@ 7 days
Min.
Tensile Strength ASTM C307 10.5 Mpa (1,500 psi) Min
Flexural Modulus of ASTM C580 10.3x 106 kpa (1.5x106psi) Min
Elasticity
Compressive Modulus of ASTM C469 13.8x 106kpa (2.0x106psi) Min
Elasticity
Creep ASTM C1181 5.0x 10-3 in/in (@400psi and
1400 F) Max
Coef. Of Thermal Expansion ASTM C531 45x10-6/oC (25x10-6/oF) Max.
Water Absorption ASTM C413 0.14% Maximum
Working Time 50 minutes at 320 C (900 F) Min

Preparation , Placement and Curing:

5.3.1 Surface of foundation under the mounting plate shall be chipped.

Ensure concrete surfaces to be in contact with the epoxy grout are free of dirt, dust, oil and
grease prior to application.

Page 11 of 13
 METHOD OF STATEMENT
FOR GROUTIING WORK
GTPP
Job Title : Closed Relief System & Flare Gas Recovery System Project at QCPF
JO No. : MS – EW - 001 Client : Saudi Aramco/Arabian Bemco Contracting Co, Contract No: 6600036803
Procedure Number : BI: Rev: 00, Date: 28 JUNE 2016
Doc. Doc. Number: GTPP - 001
BI-10-01802 –PCW-002-000 10-01802

5.3.2 Comply with every grout-manufacturers recommendations:

On the grout components mixed procedure, including tools to be used.

On the maximum depth of pour and the length to depth ratio.

On the temperature range to be maintained by the foundation or base plate until the grout has
cured or as recommended.

On procedure of preventing grout & formwork bonding.

On the patching/filling if grout voids.

On the type of sealants to be used on exposed expansion joints.

5.3.3 Protest anchor bolts with sleeves and wrap exposed threads with ducts tape to prevent
adherences of the epoxy grout.

5.3.4 Where required, Formworks shall be constructed to be liquid tight with adequate strength,
rigidity and dimensions permitting good grout placement.

Chamfer strips with of 25mm width, with 450 angles shall be installed at each vertical corner
and at the horizontal surfaces of the grout formwork and then apply to the inside surface three
coats of paste wax , or other procedure as recommended by the manufacturer, t prevent bonding
of the epoxy grout to the form works.

5.2.5 Ensure an adequate quality of grout ingredients shall be on hand mixing and placing.

No partial units or variations in mixing ratios of components shall be used.

Maintain consistency of the grout mixture and flow the manufacturer’s recommendations and
mixing instructions.

No solvents shall be added to change to grout consistency.

5.3.6 Group placement shall start at one end of the form.

Fill the cavity completely while advancing towards the other end.

Application shall be in one direction to prevent air entrapment.

Page 12
 METHOD OF STATEMENT
FOR GROUTIING WORK
G GTPP
Job Title : Closed Relief System & Flare Gas Recovery System Project at QCPF
JO No. : MS – GW - 001 Client : Saudi Aramco/Arabian Bemco Contracting Co, Contract No: 6600036803

Procedure Number : BI: Rev: 00, Date: 28 JULY 2016

Doc. Doc. Number: GTPP - 001
BI-10-01802 –PCW-002-000 10-01802

Grout placement shall be within the 50 minutes minimum working time after mixing at 32oC
maintained temperature.

5.3.7 After final placement, provide suitable shelter or enclosure to protect the grouted
foundations from direct sunlight and weather.

It shall be checked for voids after the grout has cured.

Any voids shall be filled according to the manufacturer’s recommendations.

5.3.8 Where applicable in the case of exposed expansion joints, it shall be sealed with the epoxy
grout manufacturers recommended sealant.

6.0 Documentation

This document will be distributed by the site technical office to all the site functions involved.

All records generated from this activity, including the corresponding inspection document, shall
be filed and maintained as defined in the quality records.

Quality Inspection Documents:

SAIC-Q-1045 Cement based non-shrink grout compressive strength test report.

SAIC-Q-1046 Cement based non-shrink grout material components and ingredients receiving inspection.

SAIC-Q-1048 Cement based non-shrink grout surface preparation & Formwork inspection.

SAIC-Q-1049 Cement based non-shrink grout mixing, Placement, Sampling and testing inspection.

SAIC-Q-1052 Grout material receiving and storage inspection

SAIC-Q-1053 Surface preparation & Formwork inspection.

SAIC-Q-1054 Grout mixing, Placement, sampling & Testing inspection.

SAIC-Q-1055 Foundation and grout curing/Protection and Final Inspection

……………………….END………………………….

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