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ISO – QMS 9001:2008

METHOD STATEMENT

METHOD STATEMENT FOR GROUTING APPLICATION

SOUTH BORDERS SECURITY HOUSING COMPOUND PROJECT

REVIEWED BY NOTED BY:

NAME Alfred Comendador
TITLE QA/QC Manager
DATE 28 Jan. 2018

SIGNATURE

QMS CODE NO.: EPCMS-5.1-17-19

REVISION: 01

1 Method Statement for Grout Application

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TABLE OF CONTENTS

1.0 Introduction

2.0 Scope

3.0 Equipment / Tools

4.0 Materials

5.0 Site Surface Preparation

6.0 Formwork and Shuttering

7.0 Mixing of Grouts

8.0 Grout Application Procedure

9.0 Inspection and Test Plan (ITP)

10.0 Checklist

11.0 Health, Safety and Environment

2 Method Statement for Grout Application

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1.0 Introduction
This document has been prepared by Eastern Precast Concrete to describe the methods and
procedures to be followed for the application of grout on concrete wall panel and other precast
concrete elements. This document shall be read together with the Method Statement for
Erection of various precast elements.
All grouting works application shall be conducted by EPC Erection Team according to the
procedures here to describe prior for project hand over.

2.0 Scope

This method statement details the various procedures and working phases required for the application
of grout on the wall panel and other precast connection using an approved grouting material.
Precast wall panel connection for grouting:
 Dowel and Bolt connection

3 Method Statement for Grout Application

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 Vertical Joint Connection

4 Method Statement for Grout Application

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5 Method Statement for Grout Application

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3.0 Equipment / Tools

 Manlift
 Ladder
 Grinder
 Paddle type mortar mixer
 Slow speed drill
 Formworks for Shuttering

4.0 Materials
All materials shall be supplied in a ready to use form requiring only mixing

 Approved Non-Shrink Grout

 Cementitious grout with 3/8’’ aggregates

Note: All materials shall be mixed and placed in accordance with the manufacturer’s
instructions

5.0 Site and Surface Preparation

Between surface preparation and placement of grout, the prepared area shall be
protected from contamination.
All defective concrete, laitance, dirt, oil grease, liquid and foreign substances shall be
removed by mechanical means prior to grouting. The surface shall be left clean, sound and
reasonably rough to ensure a good bond.
All grouting area shall be blown out with oil-free, dry compressed air to remove any
foreign materials
The concrete surface shall be saturated for a minimum of three (3) hours before
grouting. Just before grouting, all free water shall be removed, particularly from grout area and
block outs, by sponging or by blowing out with oil-free, dry compressed air
Care shall be taken wherever possible to ensure that no heavy equipment is operating
which will transmit vibration to the grout location and affect the normal set, final strength and
bond of the grouted location
Shading the work area

6.0 Formwork and Shuttering

Formwork may be used to facilitate rapid, continuous and complete filling of the space
to be grouted. It shall be substantial, secured, well braced and sealed to withstand grout
pressure under working conditions and to minimize or prevent leakage
Formwork shall be coated with a concrete release agent to facilitate easy removal
On the grout placement side a feed trough / hopper shall be provided. The grout head
shall be maintained at all times so that a continuous grout front is achieved.
Shuttering shall be steel for wide gap, Plywood for small gap and backing for 25mm
gap.

6 Method Statement for Grout Application

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7.0 Mixing Grouts

Mixing procedures shall be in accordance with the Manufacturer’s instructions for the
selected and approved grout
Materials shall be mixed as close as possible to locations to be grouted, using a paddle
type mortar mixer until a homogeneous, uniform mixture is obtained
Cementitious grouts shall only be mixed with clean, uncontaminated, cool and potable
water
The addition of more water than the maximum specified by the Manufacturer will
reduce the strength of this type of grout and cause shrinkage and consequently, shall not be
permitted
The mixed grout shall be transported to the specific grout location without delay
Grout shall not be re-tempered or worked after the initial set has taken place

8.0 Grouting Procedures

Grouting shall not commence until the surface preparation of both steel and concrete
have been inspected and approved by the client.
Grout shall be placed in accordance with the manufacturer’s recommendations for
the selected grout and as per the following guidelines:
a) For Dowels and Bolt Grouting (Bolt Hole and Corrugated Pipe Sleeve)
- Non-Shrink Grout shall be used
- The grout shall be placed rapidly and continuously until grouting at
the location is complete to avoid overworking which may result in
segregation, bleeding or breaking down of initial set
- The grout shall completely fill the hole to be grouted and be free of
air pockets, cold joints and shall make full contact over the area to be
supported

7 Method Statement for Grout Application

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- The grout shall be placed / pour into the pipe or bolt grout hole inlet
provided and a grout head shall be maintained at all times to avoid air
entrapment

Grouting Details for pipe sleeve and bolt hole

b) Horizontal Gap Dry Packing of Ground Floor Panel

- Check that the gap between the bottom of the panel and top footing
or slab is with the design allowance before grouting
- Prepare and apply the non-shrink grout mortar to seal the gap along
the bottom edge of the inner side of the panel
- Check all horizontal joint are properly sealed

Dry Packing Horizontal Gap

c) Vertical Joint Grouting

- Cementitious grouting materials with 3/8’’ aggregates shall be used
- Ensure that the joint rebar or the extended U-Bar shall be in proper
position as per drawing or design specification prior for shuttering

8 Method Statement for Grout Application

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- Additional 16mm diameter vertical rebar shall be provided and insert

in between the overlapping joint U-Bar.

- Set-up form or shuttering. Ensure that it will be properly secured and

tight during the casting operation of joint.

9 Method Statement for Grout Application

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- Carry out grouting application. Grouting should be carried out as soon

as possible after installation of units. Where grouting is delayed, steps
should be taken to prevent accidental displacement of units from their
bearings.
- The grout shall be placed rapidly and continuously until grouting at
the location is complete to avoid overworking which may result in
segregation, bleeding or breaking down of initial set
- The grout shall completely fill the space to be grouted and be free of
air pockets, cold joints and shall make full contact over the area to be
supported.
- Wherever possible the grout shall be placed from one side only and a
grout head shall be maintained at all times to avoid air entrapment.
Gentle tapping from one side only is permissible and may assist
difficult placement. Grout shall NOT be vibrated into position
- Upon completion of grouting, the grout shall be damp-cured with wet
hessian or an approved membrane curing compound applied in
accordance with the manufacturer’s instructions
-Non shrink grout shall be cured as per grouting materials
manufactures recommendation.
- Smooth finishing shall be as per parent precast element appearance

9.0 Inspection and Test Plan (ITP)

10 Method Statement for Grout Application

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SOUTH BORDERS ITP Reference: EPC-QP. 4.2.2-12 rev 00

INSPECTION AND TEST PLAN
SECURITY HOUSING
COMPOUND PROJECT FOR GROUTING APPLICATION WORK BY: Eastern Precast Concrete
ACTIVITY: TEST AND INSPECTION CONTROL POINT CODES:
S = Surveillance – Random Physical Check Record, Activities and Process
GROUTING APPLICATION WORKS R = In-process Inspection – Work Continues – After Ensuring the Review and
Obtain Approval of Applicable Documents or Personnel Qualification by
Authority
W = Witness Inspection – Work Continues – After Notifying the Client
LOCATION: Engineer
H = Hold Point – Ensure Item/Activity ID Inspection by (Representative) prior
to raising IR. Work succeeding cannot proceed unless current activity has been
SOUTH BORDERS SECURITY HOUSING COMPOUND PROJECT SITE inspected and accepted by Client Engineer.
A = Approval (Work Content Only)
Person CONTROL
Verification Responsible POINTS
Frequency of
# Activity Description Activity Acceptance Criteria for Testing/ Ar RECORDS
Inspection/ Test ABV
and Documentation Inspection/ EPC che
Rock n
Verification
1 DOCUMENTS REQUIRING APPROVAL

In compliance with the Technical/ Design

project specifications, Team Engineer’s
Approval of Method Statement International standards One time prior to
1.1 Approval Code A or Code B QA/QC Department H H R Approval
and Saudi MOT commencement
specifications EPC QAQC on MS
Manager/Engineer

2 MATERIALS APPROVAL

Ensure the submittal &

approval of concrete Mix Material Engineer
Design after having Approved
3rd-Party Laboratory Trial Mix
2.1 Cementitious grout with 3/8 Mix Design examined all materials Approval Code- A Prior to work commencement H H R
EPC QC Documents
characteristics, quality, Manager/Laboratory
conditions & test results

11 Method Statement for Grout Application

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Manufacturer and supplier Approval Code A or Code B

Technical/ Design MTC /
Company profile
Team Delivery
Verify the materials data One time prior to Notes/
2.2 Non-Shrink Grout Materials sheet, Supplier EPC QA/QC
commencement
H H R
Department Lab Test
qualifications, availability Reports
Client Representative
and Schedule of Delivery
of materials

- Delivery Note -Client

Manufacturer’s Technical
Representative Materials
- Manufacture Test Certificate
2.3 Materials Receiving Datasheet/ MTC Each Delivery H S R Receiving
- Materials Approval Code A - EPC Quality Inspection Log
or B with Comments Engineer

3 GROUTING WORKS APPLICATION

Method Statement for

grout application Item 6.0
3.1 Pre-Grouting Works Site and Surface
Preparation
Approved Grouting Materials -Client Grouting
Each for grouting connection
MS Approval Code A or Representative H S R Inspection
of precast elements
Code B with comments -EPC QC Inspector Checklist

Method Statement for

Approved Grouting Materials -Client Grouting
grout application Item 7.0 Each for grouting connection
3.2 Formwork and Shuttering Formworks and MS Approval Code A or Representative H S R Inspection
of precast elements
Shuttering Code B with comments -EPC QC Inspector Checklist

Approved Grouting Materials -Client Grouting

Method Statement for
3.3 Mixing of Grouts
grout application Item 8.0
Grout Mixing
Each for grouting connection
MS Approval Code A or Representative H S R Inspection
of precast elements
Code B with comments -EPC QC Inspector Checklist

3.4 Method Statement for -Client Each for grouting connection H S R

Grouting Application grout application Item 9.0 Approved Grouting Materials Representative of precast elements Grouting
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Grouting Application MS Approval Code A or Inspection

Procedure -EPC QC Inspector
Code B with comments Checklist

4 RECORD AND DOCUMENTATION

Method Statement for

Grouting Works Passed and signed by EPC -Client Grouting
Each for grouting connection
4.1 Grouting Inspection Checklist Application QA Engineer and Client Representative H H R Inspection
of precast elements
-Materials Approval Representative -EPC QC Inspector Checklist
-Pre-Grouting Application
-Grouting Application
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10.0 Checklist

14 Method Statement for Grout Application

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Installation of Precast Concrete Elements

Project:
Location:
QR 7.5.2/5

Inspection
Checklist Remarks
Date Result Inspector Signature

INSTALLATION

1. Setting - out and Position of Elements

• Verticality
• Alignment
• Level
2. Adequacy of Temporary Supports and
Erection Equipment
3. Grouting Works
• Horizontal and Vertical Joints
• Dowel Connection
4. Joint and Connection Accessories Details
• Dowel Connections
• Socket and Angle Plate Weld Connection
• Cast in-situ joint connection

FINAL INSPECTION

5. Applied Horizontal and Vertical Sealant

6. Corrected Groove, Recess and Opening
6. Repaired cracks or damaged on Panel
7. Repaired damaged Color and Texture on Panel
8. Clean-up

Prepared By: Approved By:

EPC ERECTION IN-CHARGE CLIENT INSPECTOR / ENGINEER

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Grouting Inspection Checklist

Project:
Location:
QR 7.5.2/6

Inspection
Checklist Remarks
Date Result Inspector Signature

Pre-Grouting Works

Orientation , Level and Alignment of Precast

Elements
Precast Concrete Surface Prepared and Cleaned
Formworks (Placing and Fixing of Shutter)

Materials and Procedure

Materials Approval
Grouting Procedure Approval
(by grouting materials manufacturer)
Test Cube Sampling

Grouting Works

Mixing
Casting
Test Results
Curing and Drying
Anchor Bolts and any Connection Fixing
Final Inspection

Prepared By: Inspected and Approved By:

EPC ERECTION IN-CHARGE CLIENT QC INSPECTOR / ENGINEER

11.0 Health, Safety and Environment

a. Environment, Health and Safety Requirement

 Personal Protective Equipment shall be considered only as “last resort of defense” against
potential risk and hazards. All workers shall be provided with job specific Personal
Protective Equipment.
 EPC shall ensure that adequate stock of Personal Protective Equipment is readily either
available on site or issued to personnel. PPE shall be considered as consumable items.
 All PPE utilized shall be manufactured to a recognized international acceptablestandard.
 EPC is required to comply all requirements stated EPC Construction Safety Manual.
 Safety officer or safety coordinator shall be present full time on site during the
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 Execution of works and shall implement the safety rules and regulation at working area all
the time.
 Favoring strategies and methods to reduce/minimize excessive dust emission and
occupational noise levels.

b. Protective & Safety Equipment

 The following are the list of Personal Protective Equipment:

 Hard hat
 Safety shoes
 Dust Mask
 Safety goggles
 Rubber gloves
 Safety Vest
 Safety built Ladder

c. Contractual Requirements

The works described in this Method Statement must be executed in compliance with the Health & Safety
Requirements. In addition, the works described in this method statement must be executed in full
compliance with company and client Occupational Health and Safety and other Health & Safety
Requirement.

d. Handling of Hazardous Materials and Substances

 Read labels and the material safety data sheet (MSDS) before using any material to make
sure you understand hazards and precautions.
 Always use required PPE; replace worn out or damaged PPE as it won’t provide adequate
protection.
 Make sure that all materials are properly labeled and contained.
 Store all materials properly, separate incompatibles, and store in ventilated, dry, cool
areas.
 Materials Safety Data Sheet (MSDS) shall be available and display at storage area

e. Risk Assessment and Safety Measures for Grouting Application Works

Hazard Risks Control Measures

 Working in partial  Injury to worker  Allow for appropriate lighting
or full absence of facility when natural light is
light. not available.
 Working in hot  Provide adequate site water
environment and isotonic drinks supplies
causing and carry out regular health
dehydration of checks on site personnel etc.
site personnel.  Ensure Site emergency
 Inadequate vehicle/ambulance available
training. all time at site
 Contact with dust  Maintain emergency contact.
during sanding  Safety and work related
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 Presence of other training to personnel.

activities.  Minimize dust from dust
 Non-availability of creating activities; for example
toilets and cutting of holes through floor
washing facilities for plumbing etc.
in working areas.  Workers must wear safety
glasses and dust mask in order
to avoid contact with dust.
 Work program will be
submitted to the site
responsible.
 All activities will be
coordinated in order to avoid
interferences.
 Provide site vehicles to allow
movement of personnel to the
closest toilet / washing facility
available.
 Personnel to be made aware
of the facilities at site.
 Handling  Injury to worker  Always use required PPE;
Hazardous replace worn out or damaged
Materials PPE as it won’t provide
 (Repair Materials) adequate protection.
 Make sure that all materials
are properly labeled and
contained.
 Store all materials properly,
separate incompatibles, and
store in ventilated, dry, cool
areas.
 Read labels and the material
safety data sheet (MSDS)
before using any material to
make sure you understand
hazards and precautions.
 Personnel to keep themselves
and the work area clean. After
handling any material, wash
thoroughly with soap and
water
 Movement of  Injury to personnel  All machinery will operate
vehicles and third party inside the fenced site area.
 Simultaneous  Dust can cause  Simultaneous work activities
activity causing Occupational and site logistics to be planned
mutual respiratory disease in advance.
interferences  Dust can Irritate to  Only qualified plant operators
 Collision between eyes, nose, throat to be deployed.
moving and skin  Equipment on site to reverse
equipment under the control of a trained
 Loose clothing and designated banksmen.
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becoming  Ensure the reverse alarm

entangled in properly working on all
moving parts. plant/vehicle.
 Excessive emission  Signal / Eye contact with the
of dust operator while passing near
the mobile plant.
 Enforce speed limit on site
10km/hr to 20km/hr.
 Personnel to wear high visible
vest at all times when working
on site.
 Provide safe ty path/access
 Workers is required to always
use dust mask and protective
eye glasses
 Dust suppresion by water
sprays before all operation
starts at daily bases
 Concrete Grinding  Risk of having tinnitus  Workers must use ear
using grinding or Noise induced muffs/ear plugs when
Machine hearing loss when concrete consolidation is at
exposed continuously operation
to excessive noise  Do not expose continuously in
level. 8hrs above 85 to 90 dBa sound
level
 Working at  Staff could suffer  Use of ladders to climb at
height severe or even fatal high part of the stacking
injuries if they fell  Supervisor should always be
whilst climbing for present on loading and
stacking stacking to control workers
activities.
 Working under  Workers risk  Workers provided with
extreme discomfort and suitable PPE including
weather possible ill health warm, waterproof clothing
from exposure to for cold, wet weather
weather extremes
 Uniform requirements to be
relaxed during hot weather,
no jacket required
 Staff workers should be
aware of risks of sunburn
 Work arrangements allow
staffs and workers to take
regular breaks, at places
where they can sit down in
a sheltered safe area.
 Dusts  Breathing dust may  Spray water to dust before
result to diseases. It commencement of work in
may damage the daily basis.
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lung airways and  Cleaning workplace after

get harder to everyday work.
breathe  Respiratory protective
equipment can be used to
prevent workers to inhale
dust at work
 Noise  Risk of having  Workers must use ear
tinnitus or Noise muffs/ear plugs when when
induced hearing expose to excessive noise
loss when exposed  Do not expose continuously
continuously to in 8hrs above 85 to 90 dba
excessive noise sound level
level.