PROJECT PROCEDURE

Work Method Statement for

Mechanical and Steel Structure
Grouting
DOC. NO. : IONE- AA00-MS-MS-0004
KARBALA REFINERY PROJECT Rev.6 Page 1/14
Ref. FEED DOC. No. : N/A

WORK METHOD STATEMENT FOR

MECHANICAL & STEEL STRUCTURE
GROUTING
Carmelo De Dominicis
2018.02.03 16:18:20 +03'00'

PMC REVIEW STATUS CODE

PROJECT : KARBALA REFINERY PROJECT
CODE 1: REJECTED
LOCATION : KARBALA, IRAQ
CODE 2: REVIEWED WITH COMMENTS

CODE 3: NO COMMENTS
EMPLOYER : STATE COMPANY FOR OIL PROJECTS (SCOP)

Refer to: IONE-AA00-PE-PM-0005 for code

description

6 23 JAN 2018 Revised as Per Marked Y.S.KIM J.H.KIM Y.S.KIM B.S.SHIM H.S.HWANG

5 04 JAN 2018 Revised as Per Marked Y.S.KIM J.H.KIM Y.S.KIM B.S.SHIM H.S.HWANG

4 26 SEP 2017 Revised as Per Marked Y.S.KIM J.H.KIM Y.S.KIM B.S.SHIM H.S.HWANG

3 26 OCT 2016 Revised as Per Marked M.K.PARK M.K.PARK Y.S.KIM B.S.SHIM H.S.HWANG

2 26 SEP 2016 Revised as Per Marked M.K.PARK M.K.PARK Y.S.KIM B.S.SHIM H.S.HWANG

1 04 JUL 2016 Revised as Per Marked M.K.PARK S.J.BACK Y.S.KIM B.H.SHIM H.S.HWANG

0 22 DEC 2015 ISSUED FOR CONSTRUCTION M.K.PARK S.J.BACK Y.S.KIM B.H.SHIM H.S.HWANG

A 11 AUG 2015 ISSUED FOR REVIEW M.K.PARK S.J.BACK Y.S.KIM B.H.SHIM H.S.HWANG

CHKD APPRD CONFD

REV. DATE DESCRIPTION PRPD CHKD REVD (PM)
(PQM) (PD) (SCOP)
Joint Venture of Hyundai Engineering & Construction Co., Ltd., GS Engineering & Construction Co., Ltd., SK Engineering
& Construction Co., Ltd., and Hyundai Engineering Co., Ltd.,

Note :
a) Revision bar(vertical line) shall be placed in the right hand margin to indicate where the changes has been made
b) PRPD = Prepared by, CHKD = Checked by, REVD = Reviewed by, APPRD = Approved by, CONFD = Confirmed by

HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

 PROJECT PROCEDURE
Work Method Statement for
Mechanical and Steel Structure
Grouting
DOC. NO. : IONE- AA00-MS-MS-0004
KARBALA REFINERY PROJECT Rev.6 Page 2/14
Ref. FEED DOC. No. : N/A

REVISION HISTORY

Rev Date Description Page

A 11 AUG 2015 Initial Issue -

0 22 DEC 2015 JV Noted in Revision Updated document ALL

1 04 JUL 2016 Added reference documents in ‘ 2.0 References ‘ 4

1 ‘’ Added some wording in ‘ 5.4.1.1 ‘ 7

1 ‘’ Added ‘ 5.4.4 Test ‘ in ‘ 5.4 Pouring ‘ 8,9

2 26 SEP 2016 Issued for Construction All

3 26 OCT 2016 Issued for Construction All

4 26 SEP 2017 Issued for Construction All

5 04 JAN 2018 Issued for Construction All

6 23 JAN 2018 Issued for Construction All

HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

 PROJECT PROCEDURE
Work Method Statement for
Mechanical and Steel Structure
Grouting
DOC. NO. : IONE- AA00-MS-MS-0004
KARBALA REFINERY PROJECT Rev.6 Page 3/14
Ref. FEED DOC. No. : N/A

TABLE OF CONTENTS

Sl.No. CONTENTS PAGE

1.0 SCOPE 4

2.0 REFERENCE 4

3.0 GENERAL 4

4.0 TYPE OF GROUT 4

5.0 METHOD OF APPLICATION 5

6.0 CURING OF GROUT 10

7.0 HSE REQUIREMENTS 10

8.0 EQUIPMENTS & MANPOWER 11

9.0 GROUTING CHECKLIST 12

10.0 ATTACHMENTS 13

HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

 PROJECT PROCEDURE
Work Method Statement for
Mechanical and Steel Structure
Grouting
DOC. NO. : IONE- AA00-MS-MS-0004
KARBALA REFINERY PROJECT Rev.6 Page 4/14
Ref. FEED DOC. No. : N/A

1.0 SCOPE
1.1 This method statement covers the non-shrink cementitious and epoxy grout for steel
structure, static and rotating equipment.
1.2 This Method Statement is applied to final grouting work of mechanical and steel
structure.
1.3 Any deviation between this document and company standards shall be clarified by the
company representative prior to proceeding.

2.0 REFERENCES

2.1 Manufacture’s instruction Manual (Conbextra GP, Sika grout 212, Master Flow
928 ,Sikadur 42Grout-Pak, Conbextra EP65, Master Flow 648)
2.2 API 686 (Recommended practice for machinery installation and installation design)
2.3 SAES – Q – 010 &011 SCOP Engineering Standard
2.4 IONE-AA00-PE-QA-0001 (Project Quality Plan)
2.5 IONE-AA00-PE-QA-OO24 (Construction Quality Plan)
2.6 2342-AA00-JSM-501 (Quality Management Requirement for EPC Contractor)
2.7 IONE-AA00-ITP-MS-0001 (Inspection and Test Plan for Equipment)
2.8 IONE-AA00-ITP-CS-0005 (Inspection and Test Plan for Steel Structure Work)
2.9 IONE-AA00-PE-HS-0001 (Project HSE Plan)

3.0 GENERAL

3.1 Contractor, as a part of these activities, shall provide grout manufacturer’s technical
representative who will be on site to instruct the grouting set– up procedures prior
grouting installation.

3.2 Contractor or grout manufacturer’s technical representative will complete the grouting
checklists described in chapter 5, section 4, of API 686 and will submit to company
representative for acceptance before starting to place grout.

4.0 TYPES OF GROUT

Selection of type of grout shall be accordance with approved drawings specifications

HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

 PROJECT PROCEDURE
Work Method Statement for
Mechanical and Steel Structure
Grouting
DOC. NO. : IONE- AA00-MS-MS-0004
KARBALA REFINERY PROJECT Rev.6 Page 5/14
Ref. FEED DOC. No. : N/A

and equipment manufacturer recommendations. Grout application scheme will be

followed as

Grout Type Application Applicable Standard

Compression Strength (*1)

Cement based a) Structure Minimum compressive strength ASTM

Non shrink grout b) Anchor box filling shall be 28 N/mm2 at 7 days
C109
c) Rotary and static
equipment bases
Non shrink Epoxy As per material Minimum compressive strength ASTM
grout manufacturer shall be 70 N/mm2 at 7 days
C579
recommendation

*1: This strength is general value. Right strength value will be followed by selected vendor
requirement

5.0 METHOD OF APPLICATION

5.1 Projection of anchor bolt and location.

5.1.1 Projection of anchor bolt and location shall be confirmed in accordance with the
approved drawings.
5.1.2 The surface of anchor pocket shall be cleaned and dried before equipment
installation. If any, cleaning method (e.g. water jetting, air blowing, hand blushing,
etc.) should be used.
5.1.3 Before final grouting, anchor bolt shall be hand tightened only or follow vendor
instructions.

5.2 Surface preparation

5.2.1 The below surface preparation is general all surface preparation shall follow
Supplier instruction
5.2.2 Concrete foundation shall be cured for a minimum of 7 days before surface
preparation.

HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

 PROJECT PROCEDURE
Work Method Statement for
Mechanical and Steel Structure
Grouting
DOC. NO. : IONE- AA00-MS-MS-0004
KARBALA REFINERY PROJECT Rev.6 Page 6/14
Ref. FEED DOC. No. : N/A

5.2.3 Remove the concrete surface/bolt box with chipping hammer/machine to around
of the top 1 inch (25mm) of concrete. down to a depth to permit 25mm to 50mm
of clearance between the concrete of bottom of the mounding plate (Refer: API
686 3.6.2)
5.2.4 Remove all dust and loose particles (e.g. laitance, etc.) with clean, oil free air.
5.2.5 Concrete surfaces for non-shrink grout shall be saturated with clean water, and
the surfaces are to be tightly covered with suitable sheeting in order to protect
foreign material and contamination.
5.2.6 In case of epoxy grout, concrete surface shall be dry condition.

5.3 Form Work

5.3.1 Non – Shrink Grout

1) This WMS para 5.2 surface preparation is general , all surface preparation shall
follow supplier instruction
2) The form work shall be constructed with adequate strength to with stand the
horizontal forces of the fluid grout, and shall be caulked or sealed with tape to
provide water – tight seal.
3) The surface of the form work in contact with the grout shall be coated with form
oil or heavy wax to prevent adherence of non – shrink grout.
4) The forms shall extend a minimum 25 mm above the under of the base plate
being grouted.
5) The forms shall be left a minimum of 50 mm away from all around base plate
unless otherwise shown on the drawing.
6) The surface of the concrete shall be damp but free from standing water before
grout placement.
7) Grout shall be applied considering whole foundation chipped area and be
chamfered at 45 deg. of its edges.
8) Generally, wet hessian cloth or burlaps shall be used for pre-soacking. If grout
area is wide case, small hole can be made for easy drain the water of pre-
socking. The hole shall be sealed before grouting.

HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

 PROJECT PROCEDURE
Work Method Statement for
Mechanical and Steel Structure
Grouting
DOC. NO. : IONE- AA00-MS-MS-0004
KARBALA REFINERY PROJECT Rev.6 Page 7/14
Ref. FEED DOC. No. : N/A

5.3.2 Epoxy Grout

1) This WMS para 5.2 surface preparation is general all surface preparation
shall follow supplier instruction
2) The formwork shall be liquid – tight with adequate strength, rigidity, and
dimension to permit epoxy grout placement.
3) Attach grout forms to concrete with drilled anchors.
4) The surface of the form work in contact with the grout shall be coated with paste
wax or use other methods as recommended by the epoxy grout manufacturer
to prevent grout adherence.
5) Install 1 inch 45°chamfer strip at each vertical corner and at the horizontal
surface of the grout forms.
6) Expansion joints shall be spaced at a maximum of 48 inches (1.4 m) unless
otherwise specified on the drawing.
7) Anchor bolt shall be protected by sleeves, and exposed thread shall be
wrapped with duct tape to prevent adhere of epoxy grout.
8) Concrete surfaces in contact with the epoxy grout shall be clean and dry at
time of grout placement.

5.3.2.1 Expansion Joints

1) Expansion joint shall be incorporated in large epoxy grout pours to reduce the
possibility of cracking. Expansion joint shall be placed at approximately 1.4 to
2.8 meter (4 to 6 foot) intervals in the grout foundation.
2) Expansion joint shall be made from 12 to 25 millimeter (1/2 to 1 inch) thick
closed cell neoprene foam rubber. Polystyrene may also be used. Ensure that
the expansion joint material is compatible with the grout.
3) Expansion joint require sealing after the grout has cured with elastic epoxy
seam sealant (liquid rubber) or silicone rubber.

HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

 PROJECT PROCEDURE
Work Method Statement for
Mechanical and Steel Structure
Grouting
DOC. NO. : IONE- AA00-MS-MS-0004
KARBALA REFINERY PROJECT Rev.6 Page 8/14
Ref. FEED DOC. No. : N/A

5.4 POURING

5.4.1 Trial mix procedure for other approved grout materials

One grout manufacturer’s recommended trial procedure will not be applicable

to other grout manufacturers. If in case master flow grout is not available at site,
alternate grout material will be used as approved by SCOP (Letter: KRP-EH-
CH-2961 dated 11/11/2015) and trial mix procedure will be carried out
accordingly as per alternate vendor specifications.

Grout materials approved by SCOP (Letter: KRP-EH-CH-2961 dated 11/11/2015)

Non-Shrink Cement Grout

Conbextra GP
Sika 212
Master Flow 928

Epoxy Non-Shrink Grout

Conbextra EP 65
Sika 42
Master Flow 648

5.4.2 Non-Shrink Grout

1) This WMS para 5.2 surface preparation is general all surface preparation shall
follow supplier instruction
2) All grout shall be placed in only one direction to prevent trapping air.
3) Grout shall be stored, mixed, placed, and cured at temperature ranges in
accordance with manufacturer instruction.
4) If atmosphere temperature is more than 35, Non-shrink grout shall use cold
water (below 20 ).
5) Machine base plates and soleplates shall be prepared and installed according
to the requirements of PIP / API REIE 686.

HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

 PROJECT PROCEDURE
Work Method Statement for
Mechanical and Steel Structure
Grouting
DOC. NO. : IONE- AA00-MS-MS-0004
KARBALA REFINERY PROJECT Rev.6 Page 9/14
Ref. FEED DOC. No. : N/A

6) The grout shall fill all the voids between the base plate and foundation.
7) Grout shall be kept moist and cured for a minimum of 7 days after placement,
it shall be protected from sunshine and drying out covered by wet burlap and
0.5 mm polyethylene.
8) The cutback shall be at a 45° angle unless otherwise indicated on the drawing.

5.4.3 Epoxy Grout

1) This WMS para 5.2 surface preparation is general all surface preparation shall
follow supplier instruction.
2) Grout placement shall be started at one end of the forms, and the cavity shall
be filled completely while advancing toward the other end to prevent air
entrapment.
3) The forms shall be checked for grout leaks frequently, all leaks shall be sealed
to prevent voids from forming in the grout.
4) Exposed expansion joints shall be sealed with the epoxy grout manufacturer
recommended sealant.
5) The final level of the epoxy grout shall be flush with the top of horizontal
chamfer edges built into the formwork.
6) Also in case of 55 atmosphere temperature, epoxy grout under atmosphere
condition can use from 10mm to 150mm gap.
7) Grout for pocket design shall be filled without entrapping air. Since closed
design of pocket grout will not be impacted from curing, it can be carried out at
one time.

5.4.4 Test

The below mentioned test are recommended for grouting work:

Temperature
Bleeding
Compressive Strength
Fluidity (For epoxy grout only)
Volume Change

HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

 PROJECT PROCEDURE
Work Method Statement for
Mechanical and Steel Structure
Grouting
DOC. NO. : IONE- AA00-MS-MS-0004
KARBALA REFINERY PROJECT Rev.6 Page 10/14
Ref. FEED DOC. No. : N/A

The frequency of test should be recommended as below:

Grouting of Compressor and Pump foundations (One time at each day per sub-
contractors.
Other Foundations (Only one time for all of the foundations at beginning stage)

6.0 CURING OF GROUTS

6.1 Cement mortar & Non- shrink grout

1) This WMS para 5.2 Surface preparation is general all surface preparation shall
follow supplier instruction.
2) Non shrink cement grout/ sand cement mortar shall be kept moist and cured
for a minimum of 7 days after placement.
3) It shall be protected from sunshine and drying out by wet hessian which is
covered by polyethylene sheet.
4) If there is some special reason, curing compound should be used instead of
wet hessian.

6.2 Non shrink Epoxy grout

1) Epoxy grout should be kept dry for minimum 24 hours.

2) It shall be protected from direct sunshine by polyethylene sheet.

6.3 Summary of Grouting issues

Refer to Attachment 10-2 (Repair procedure for Cracked Non-shrinkage Grout)

7.0 HSE REQUIREMENTS

7.1 General

HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

 PROJECT PROCEDURE
Work Method Statement for
Mechanical and Steel Structure
Grouting
DOC. NO. : IONE- AA00-MS-MS-0004
KARBALA REFINERY PROJECT Rev.6 Page 11/14
Ref. FEED DOC. No. : N/A

1) Appropriate PPE (Personal protective equipment) must be worn during this

task.
2) Pre job talk must be conducted and all the persons assigned to perform this
task must understand the hazards associated with this job and necessary
control measures.
3) Noninvolved personnel will be kept away from the area of operation and
warning barricading will be provided
4) Safety tool box training will be conducted before each& every grouting
activates stags
5) Must be use special PPE (face shield, year protector ,hand gloves dust mask)
6) Working at height requires full body harness ,scaffolding, life line, area
barricade
7) All the electrical tools and equipment must be inspected and color code on a
monthly basis by authorized person

7.2 Hand tools and equipment

1) All tools and equipment will be in good condition and equipment will be
mechanically and electrically checked before entering the site.
2) Equipment operation will be done by trained, skilled personnel.
3) All people shall be trained
4) Hand tolls are hear for chipping, grouting and formwork

7.3 Environmental Issues

1) All machinery and equipment shall be kept well-maintained to reduce

emission.
2) Sand cement mortar and cement based non shrink grout after using will be
disposed with concrete wastes and epoxy after using will be disposed with
chemical waste.
3) Precautions will be taken to minimize the risk of fuel spillage. If there is any
spillage the material will be removed to safe, dry place.

HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

 PROJECT PROCEDURE
Work Method Statement for
Mechanical and Steel Structure
Grouting
DOC. NO. : IONE- AA00-MS-MS-0004
KARBALA REFINERY PROJECT Rev.6 Page 12/14
Ref. FEED DOC. No. : N/A

8.0 EQUIPMENT AND PERSONNEL

8.1 TOOLS
Mixing paddler
Electric generator (Before starting inspected by authorized qualified person)
Chipping machine
Air Compressor
Water basket (calibration cup)
Mixing bucket
Trowel
Scrapper
Chisel
Hammer
Wire brush

8.2 Manpower
Supervisor (Trained)
Carpenter (Trained)
Mason (Trained)
Helper (Trained)

9.0 GROUTING CHECK LIST

No Description Yes No Remarks

1 Anchor bolts are not tilted.

2 Foundation anchor bolt threads are undamaged.

3 All anchor locations and projections have been verified.

4 The minimum grout thickness under any portion of the Baseplate / soleplate
will be 25-50 millimeters (1-2 inches).

5 Foundation is free of structural cracks.

6 All baseplate elevation set in accordance with the construction Drawings.

7 A preliminary equipment alignment check has been made.

HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

 PROJECT PROCEDURE
Work Method Statement for
Mechanical and Steel Structure
Grouting
DOC. NO. : IONE- AA00-MS-MS-0004
KARBALA REFINERY PROJECT Rev.6 Page 13/14
Ref. FEED DOC. No. : N/A

10.0 ATTACHMENTS

10.1 Grouting Products

Master Flow 648 Manual
Master Flow 928 Manual
Conbextra EP 65
Conbextra GP
Sika 42
Sika 212
Renderoc HSXtra

10.2 Repair Procedure for Cracked Non-Shrinkage Grout

10.3 JSA

1 Grout Material Grouting Workers Use PPE Tool box meeting Foreman
handling(delivery, Material – bag
Storage) Broken Pay attention to Good
handle the grout supervision
material not to
tear the grout
material bag.
2 Mixer for grouting Grout material Workers Use PPE Regular Safety officer
scattered inspection and
Qualified maintenance of foreman
Damage eyes Worker to be tool
and other required.
body parts Tool box meeting
Inspect tool
prior to mixing
the grout
material

HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

 PROJECT PROCEDURE
Work Method Statement for
Mechanical and Steel Structure
Grouting
DOC. NO. : IONE- AA00-MS-MS-0004
KARBALA REFINERY PROJECT Rev.6 Page 14/14
Ref. FEED DOC. No. : N/A

3 Removal waste Damage to Workers Give specific Use PPE Safety officer
material body instruction the
use of grout Training and Supervisor
Occupational material to the orientation
health worker
problems Pre job talk

Discuss the
potential hazard
of the job

Enough
knowledge of
their job
4 Working at Falling from Workers Give specific Scaffolding Safety officer
heighted height instruction the around the
Property
working at working area Foreman

height elevation
5 Electrical tools and The Machine Worker No working is Control PTW Safety Officer
equipment running during Property permitted and
handling working without PTW Foreman

(Permit to Work) Skill worker

Give the specific

instruction the
use of
equipment to
the worker

HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea