PROJECT / UNIT

Khurais Area Facilities Expansion & Satellite JOB

GOSP Project 032184

PLANT LOCATION
Doc. No. 000-ZA-E-T09411
Khurais – SAUDI ARABIA
General Method Statement for Epoxy Grout Rev. A 13-FEB-18

GENERAL METHOD STATEMENT for

Epoxy Grout

CONTRACTOR review result 1: Approved

by 2: Approved with comments
3: Rejected

Department Date Name Sisgnature

Technical Discipline 1 2 3
Field Engineering Dept. 1 2 3
HSE Dept. 1 2 3
QA/QC Dept. 1 2 3

1: Approved
2: Approved with comments
CONTRACTOR review result 3: Rejected
by Date Name Signature
1 2 3

REV DATE Prepared Checked Checked Approved Approved

Jaycy Yutuc Readolf Fedelin Rubenel Javier Ahmad Shibi Abdullah Hani
A 13-Feb-18
QCDC HSE Mngr. QC Mngr Const.Mngr. Proj. Dir.

Page | 1
 PROJECT / UNIT
Khurais Area Facilities Expansion & Satellite JOB
GOSP Project 032184

PLANT LOCATION
Doc. No. 000-ZA-E-T09411
Khurais – SAUDI ARABIA
General Method Statement for Epoxy Grout Rev. A 13-FEB-18

General Method Statement for

Epoxy Grout

Issued for Jaycy Yutuc Readolf Fedelin Rubenel Javier Ahmad Shibi Abdullah Hani
A 13-Feb-18
Review QCDC HSE Mngr. QC Mngr Const.Mngr. Proj. Dir.
Rev Description Prepared Checked Checked Approved Approved Date

Page | 2
 PROJECT / UNIT
Khurais Area Facilities Expansion & Satellite JOB
GOSP Project 032184

PLANT LOCATION
Doc. No. 000-ZA-E-T09411
Khurais – SAUDI ARABIA
General Method Statement for Epoxy Grout Rev. A 13-FEB-18

Table of Contents

1. PURPOSE-------------------------------------------------------------------------------------------------- 4

2. SCOPE------------------------------------------------------------------------------------------------------ 4

3. DEFINITION & ABBREVIATION---------------------------------------------------------------------- 4

4. REFERENCES DOCUMENTS/DRAWINGS---------------------------------------------------------- 4

5. METHODOLOGY/ WORK EXECUTION PROCEDURE-------------------------------------------- 4

5.1 SURFACE PREPARATION------------------------------------------------------------------------- 5

5.2 FORM WORK----------------------------------------------------------------------------------------5
5.2.1 Expansion Joints (if applicable)-------------------------------------------------- 5
5.3 SAMPLING------------------------------------------------------------------------------------------- 6
5.4 MIXING----------------------------------------------------------------------------------------------- 6
5.5 PLACING----------------------------------------------------------------------------------------------7
5.6 CURING PROTECTION AND FINAL INSPECTION--------------------------------------------7

6. DUTIES AND RESPONSIBILITY------------------------------------------------------------------------ 7

7. LIST OF EQUIPMENTS--------------------------------------------------------------------------------- 8

8. GENERAL HSE/SAFETY REQUIREMENTS---------------------------------------------------------- 9

9. ATTACHMENTS------------------------------------------------------------------------------------------ 9

 JSA – Job Safety Analysis

 Approved IFC Plot Plans as Sub Contractor Gecat Scope of Works

Page | 3
 PROJECT / UNIT
Khurais Area Facilities Expansion & Satellite JOB
GOSP Project 032184

PLANT LOCATION
Doc. No. 000-ZA-E-T09411
Khurais – SAUDI ARABIA
General Method Statement for Epoxy Grout Rev. A 13-FEB-18

1. PURPOSE

The purpose of this method statement is to describe the Sub Contractor Gecat General
Methodology for EPOXY GROUT involved in Khurais Area Expansion & Satellite GOSP Project.

2. SCOPE

This method statement covers all EPOXY GROUT activities and details the activities involving
quality requirements, HSE requirements, methodology and inspection/ testing requirements.

3. DEFINITION & ABBREVIATION

COMPANY/OWNER – SAUDI ARABIAN OIL COMPANY (“SAUDI ARAMCO”),

CONTRACTOR: SAIPEM

SUBCONTRACTOR: Gecat Limited Co. [The party responsible for performing demolition
including work executed through the use of sub-contractors].

Method Statement: A written document that explains the procedure & execution of
work.

IFC - Issued For Construction drawings

PTS - Project technical specification

4. REFERENCE DOCUMENTS/DRAWINGS:

 GI 2.100, Work Permit System

 SAES-Q-011 Epoxy grout for machinery support
 PIP-3601
 ASTM C579 Standard Test Method for Compressive Strength of Chemical Resistant
Mortars, Grouts, Monolithic Surfacing and Polymer Concretes
 PIP STS 03601 Epoxy Grout Specification
 Approved Material Manufacturer’s Data Sheet

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 PROJECT / UNIT
Khurais Area Facilities Expansion & Satellite JOB
GOSP Project 032184

PLANT LOCATION
Doc. No. 000-ZA-E-T09411
Khurais – SAUDI ARABIA
General Method Statement for Epoxy Grout Rev. A 13-FEB-18

5. METHODOLOGY/ WORK EXECUTION PROCEDURE

Work permits shall be secured prior to commencement of EPOXY GROUTING activities

5.1 SURFACE PREPARATION

 Laitance and oil-soaked or damaged concrete are removed with chipping hammer to
sound fractured aggregate, or to a minimum of the top 1 inch (25 mm) of concrete.
(PIP STS03601, Sec. 6.2.1.1 and 6.2.1.2).
 Concrete chipping and removal shall not be performed with heavy tools such as
jackhammers as they could damage the structural integrity of the foundations. (PIP
REIE 686 Sec 3.6.2).
 The minimum grout thickness under any portion of the baseplate/ soleplate shall be
25mm (PIP REIE 686 686 Sec 3.6.2).
 Concrete in contact with the epoxy grout shall be clean, dry and oil free (PIP
STS03601, Sec. 6.2.6).
 Only Approved Epoxy Grouting Material shall be used for Epoxy Grouting activities.
 This Methology is applicable only for General Epoxy Grouting activities.

5.2 FORM WORK

 Formwork for epoxy grout are constructed to be liquid tight with adequate strength,
rigidity and dimensions to permit epoxy grout placement. (PIP STS03601, Sec.
6.2.3).
 The formwork should be constructed to be leak-proof to prevent Loss of grout once
the material is placed but not hardened, will result in incomplete filling of the gap.
 For free-flow grout conditions it is essential to provide a hydrostatic head of grout.
To achieve this a feeding hopper system should be used.
 Maximum depth of pour and length to width ratio shall be as per the pproved
manufacturer’s recommendations.
 Elevation of the formworks shall be check to ensure that the top surface of the
grout will match the elevation shown on the construction drawings. (PIP STS03601,
Sec. 3.12.4)

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 PROJECT / UNIT
Khurais Area Facilities Expansion & Satellite JOB
GOSP Project 032184

PLANT LOCATION
Doc. No. 000-ZA-E-T09411
Khurais – SAUDI ARABIA
General Method Statement for Epoxy Grout Rev. A 13-FEB-18

 Form Work shall be 75 higher than the Base plate height in the pouring side and
25mm higher than the Base plate at the open side.
 Appropriate formwork release agent shall be applied to the inside surface of forms
or other manufacturer recommended procedure for preventing bonding of the
epoxy grout to the formwork. (PIP STS03601, Sec/ 6.2.3.2).
 Suitable shelter or enclosures shall be provided to protect the foundation and base
plate from direct sunlight, dew, rain or other inclement weather. During cold
weather, adequate enclosure and heating shall be provided to maintain foundation
and base plate temperature with acceptable range specified by the grout
manufacturer. (PIP STS03601, Sec. 6.2.2).
 Chamfer shall install at final level edge built in the formwork as per PIP. 3601.

5.2.1 EXPANSION JOINTS (if applicable)

 Expansion joints shall be provided spaced at a maximum space of 48” (1.4 meter)
unless otherwise specified I the contract documents
 Expansion joints shall be made from closed – cell neoprene or polyethylene foam
board, having minimum thickness of 1 inch (25mm) unless otherwise noted in the
contract documents.
 Expansion joints shall be fixed into position to prevent movement and shall be
sealed at formwork and the concrete base to prevent epoxy grout from passing
around or underneath the joint during placement.
 Wherever the equipment in position on the foundations methology of the
expansion joints formworks/closed – cell neoprene or polyethylene foam board
installation shall be incorporated.

5.3 SAMPLING

 Sampling and testing shall be performed by a Saudi Aramco approved independent

testing laboratory.
 Third Party Agency’s Quality personnel assigned to the Work must be technically
competent to perform their duties.
 Grout samples for compressive test shall be taken as per ASTM C579, Method B
Modified.
 Minimum compressive strength shall be 80 MPa (12,000psi) at 7 days. (PIP
STS03601, Sec. 5.1.1)

5.4 MIXING

 Mixing procedures as per the Approved Manufacturer Instructions.

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 PROJECT / UNIT
Khurais Area Facilities Expansion & Satellite JOB
GOSP Project 032184

PLANT LOCATION
Doc. No. 000-ZA-E-T09411
Khurais – SAUDI ARABIA
General Method Statement for Epoxy Grout Rev. A 13-FEB-18

5.5 PLACING

 Methology for Epoxy Grout Mixing, Placing, Testing shall follow Manufacturer
Product Technical Data sheet and Aramco Standards.
 Adequate enclosures or shelter shall be provided for weather protection to maintain
foundation and baseplate temperature within the acceptable range specified by the
grout manufacturer. (PIP STS03601, Sec. 6.2.2)
 Grout placement shall be started at one end of forms, and the cavity shall be filled
completely while advancing toward the other end to prevent air entrapment. (PIP
STS03601, Sec. 6.3.5)
 Vibration or other forms of dynamic distribution shall not be permitted. (PIP
STS03601, Sec. 6.3.6)
 All leaks shall be sealed to prevent voids from forming in the grout. (PIP STS03601,
Sec. 6.3.7)
 Final checking of soleplate elevation and level shall be made before the grouts sets.
(PIP REIE 686 Sec. 3014.6)
 Any air bubbles rising to the surface of the epoxy grout shall be removed by lightly
spraying the bubble surface with the solvent approved by the manufacturer. (PIP
REIE 686 Sec. 3014.6)

5.6 CURING PROTECTION AND FINAL INSPECTION

 Suitable shelter or enclosure shall be provided to protect the grouted foundations

from direct sunlight and weather. (PIP STS03601, Sec. 6.2.2)
 Foundation and baseplate temperature are within the acceptable range specified by
the grout manufacturer until the grout has cured. (PIP STS03601, Sec. 6.3.8)
 After the void grout has cured, the baseplate shall be recheck to ensure that all
voids are filled with grout. Any voids still exist shall be rectified. (PIP REIE 686 Sec.
3.16.5)
 Exposed expansion joints shall be sealed with the epoxy grout manufacturer’s
recommended sealant. (PIP STS03601, Sec. 6.3.9)

6. DUTIES AND RESPONSIBILITY

It’s the responsibilities of Sub Contractor Gecat construction, Quality and Safety Teams to
ensure that all the relevant requirements, specifications and standards are followed during the
execution of the work

Project Manager

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 PROJECT / UNIT
Khurais Area Facilities Expansion & Satellite JOB
GOSP Project 032184

PLANT LOCATION
Doc. No. 000-ZA-E-T09411
Khurais – SAUDI ARABIA
General Method Statement for Epoxy Grout Rev. A 13-FEB-18

Project Manager will be responsible for the overall implementation and monitoring of all
activities in the method of statement for Epoxy Grout.

Site Manager

Site Manager will be responsible for the overall direction, monitoring coordination and control
of all the construction activities attached and related to the Epoxy Grout and overall health and
safety standards and procedures.

Site Engineer

Site Engineer will be responsible for the overall implementation and monitoring of all the
activities involve in Epoxy Grout including safety measures and mitigation from his work place.
Application for work permits if required prior to commence of any demolition.

Supervisor/Foremen

Supervisor/Foremen will be responsible:

 Having knowledge and direction of work’s activities and planning at site, and directly
imparted people to do what is the best way to achieve the assigned task
 Conduct safety briefing prior to commence daily activities and give information and
guidance to newly hired workers.
 Report any incident, accident, unsafe condition and defects in equipment to immediate
superiors.
 Provide correct action of safety among his people i.e horse play, bullying and other
unsafe acts.
 Incorporate safety procedures in routine tasks and see that they are obeyed.
 Set a personal example to his people

Surveyor

Shall be responsible for the benchmarks and setting of points, including the elevations in
accordance with approved drawing reference documents.

HSE Officer/ Supervisor

Safety Officer/ Supervisor will be responsible

 Review prior to the start of the work Safe Work Plan.

 To Implement daily and specific safety program at the work place and ensure all
working activities comply with the established safety rules, regulations and
procedures as safe working practices.

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 PROJECT / UNIT
Khurais Area Facilities Expansion & Satellite JOB
GOSP Project 032184

PLANT LOCATION
Doc. No. 000-ZA-E-T09411
Khurais – SAUDI ARABIA
General Method Statement for Epoxy Grout Rev. A 13-FEB-18

 To provide instructions on task and responsibility for safe and correct working
practices and tool box talk.
 Securing confined space requirement.
 Any near miss accidents or incidents should be immediately reported to the Site
Manager or Project Manager and submitting the report recommending actions to be
taken to prevent recurrence.

7. LIST OF EQUIPMENTS

 Air compressor
 Air blower
 Angle grinder ( with buffing wheel)
 Generator
 Electric drill with paddle mixer
 Roller Brush
 Wire Brush
 Measuring Jug
 Hand Application Trowel
 Scraper
 Filling Knife

8. GENERAL HSE/ SAFETY REQUIREMENTS

Safety measure during the execution of work shall be strictly implemented and observed. Gecat
Limited Co. safety department shall by then without excuses to implement the safety rules,
regulations and ensure that all personnel involve in the execution of work shall brief and explain
the implanting rules

 All personnel should wear proper PPE

 Area must be provided with barricade
 Install necessary signage and other precautionary measures
 Provide safety access at demolition & excavation areas
 Flagman must assign with all moving construction equipment’s
 Equipment should provide 3rd party certificate prior to operate
 Ensure permit has provided

9. ATTACHMENTS

 Job Safety Analysis

 Approved IFC Plot Plans as Sub Contractor Gecat Scope of Works

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