SAUDI ARABIAN OIL COMPANY
NEAT KHUFF CONDENSATE FRACTIONATION PROJECT
METHOD STATEMENT
FOR
EPOXY GROUTING
SUB CONTRACT NO: 308200
DOCUMENT NO: 308200–MST–CI –021 Rev 00
Client : Project : Contractor : Date :
SAUDI ARAMCO NEAT KHUFF CONDENSATE DODSAL& CO. 26-02-2002
FRACTIONATION PROJECT
SNAMPROGETTI
DOC NO. 308200-MST-CI-021 Rev00
Date of Issue :26-02-2002 Page 1 of 10
METHOD STATEMENT
FOR
EPOXY GROUTING
REVISION CONTROL
Revision Date of Details of Prepared by Reviewed by Approved by Approved by
Status Issue Revision DODSAL DODSAL DODSAL SP
0 26-02-2002 Initial SKJ RON AB
DOC NO. 308200-MST-CI-021 Rev00
Date of Issue :26-02-2002 Page 2 of 10
METHOD STATEMENT
FOR
EPOXY GROUTING
INDEX
1.0 PURPOSE
2.0 SCOPE
3.0 REFERENCES
4.0 DEFINITIONS
5.0 PROCEDURE
6.0 DOCUMENTATION
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1.0 PURPOSE
The purpose of this Method Statement is to describe the steps to be taken for
achieving specified requirements for Epoxy Grouting for Neat Khuff Condensate
Fractionation Project ..
2.0 SCOPE
This method statement covers the selection of grouting material, supervision and
perform all operation necessary form work , proper mixing ,placing , finishing and
curing of Epoxy grout for the following for NEAT KHUFF CONDENSATE
FRACTIONATION PROJECT at J-64 Area at Ras Tanura Refinery
;
When type of grout is not specified by equipment manufacturer , epoxy grout shall be
used for any of the following;
Equipment with driver horsepower 500 (375 k W ) or greater
Equipment with speeds greater than 3600 RPM
Equipment that has a combined weight ( machine, driver,and base
plate) of greater than 2270 kg (5000 lbs)
All reciprocating machinery with driver horsepower greater than 50
( 37kW)
3.0 REFERENCE DOCUMENTS
SAUDI ARAMCO DOCUMENTS
Schedule – Q
Saudi Aramco Safety Manual
PP 276706 Rev A : Construction Specification For In- Kingdom Concrete
SAES-Q-001 : Criteria for Design and Construction of Concrete Structure
SAES-Q-011 : Epoxy grout for machinery support
RA- 277229 Sht 001 Rev. 00F1 : Drawing legend and abbreviation Concrete General
Note
SNAMPROJETTI DOCUMENTS
SPC –J 64 –ZA-E-09601 Rev D : Quality Plan for IK Activities
SPC –J 64 –ZA-E-09607 Rev A : General Requirement for Field Quality Control
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SPC –J 64 –ZA-E-09610 Rev C : Field Quality Control Plan for Civil Works
DODSALS PROCEDURE
308200-MST-CI-009 Rev 01 :Method statement for concrete works
308200-ITP-CI-009 Rev 01 :Inspection and Test Plan for concrete works
INDUSTRY CODES AND STANDARDS
Process Industry Practiccs PIPSTSO 3601: Epoxy grout specification
PIP REIE 686 : Recommended practices for machinery installation and installation
Design
ASTM C 313 :Standard test method for tensile strength of chemical resistant mortars,
grout and monolithic surfacing.
:
ASTM C 413 :Standard test method for absorption of chemical resistant mortars,
grouts and monolithic surfacing.
ASTM C 469 : Standard test method for static modulus of elasticity and Poisons ratio
of concrete in compression.
ASTM C 531 : Standard test method for linear shrinkage and coeff. Of thermal
expansion of chemical resistant mortars, grouts and monolithic surfacing.
ASTM C 579 : Standard test method for compressive strength of chemical resistant
mortars, grouts and monolithic surfacings and polymer concretes.
ASTM C 580 : Standard test method for flexural strength and modulus of elasticity of
chemical resistant mortars, grouts , monolithic surfacing and polymer concrete .
ASTM C 1181 : Standerd test method for compressive creep of chemical resistant
polymer machinery grouts.
4.0 DEFINITIONS:
MANUFACTURER
The party that produce and warrants the performance of the product..
5.0 PROCEDURE
5.1 RESPONSIBILITY
Area Engineer is responsible for all the activities along with the QC Inspectors.
Safety officer shall provide basic safety guidelines and it is the responsibility of Area
engineer to follow.
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5.2 SAFETY
Basic PPE shall be used. Manufacturers material handling data sheet shall be
followed for handling and storage purpose at site.
5.3 MATERIAL
All material shall be approved by Saudi Aramco. The grout shall meet the
physical requirement of SAES-Q-011 ,Table-1.
All materials shall be in original unopened packages and stored as per
manufacturers recommendation.
Resine component shall consists of a premeasured , prepackaged , solvent
free , liquid epoxy resine specifically formulated for the used grout system..
The hardner component shall consist of a premeasured , prepackaged
liquid specifically formulated to produce the specified final properties when
mixed with the other component. .
The aggregate shall be premeasured , prepackaged blend of inert ,
inorganic particulate filters, such as silica , designed specifically to provide
the proper flow , handling and physical properties required for the grout
product.
The ratio of aggregate to resin and hardner shall be per the manufacturer
recommendations. If aggregate ratio is adjusted for field conditions ,
physical properties shall be obtained at the recommended fill ratio .
The resin and catalyst components shall be free of hard sediments, show
no gelation in a freshly opened can , and shall be of proper consistency to
enable thorough mixing to a smooth homogenous state. The components
shall show no gelling when stored for the shelf life indicated on the data
sheets from the date of manufacture in unopened containers at
temperature of 32 C. Resin and catalyst container shall not leak when
subjected to normal shipping and storage. Packaging shall meet the
requirement of 09-SAMSS-060.
All components , resin , hardener and aggregate shall be properly labeled ,
including batch numbers, shelf life and storage requirements.
5.4 TOOLS
Grouting machine
Grout pump
Plastic and rubber bucket
Air compressor
Chisel and hammer
Wire brush
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5.5 SEQUENCE OF OPERATION
5.5.1 PRE-GROUTING ACTIVITIES
Concrete surface to receive epoxy grout shall be adequately roughened by
mechanical means , clean ,and free of dirt grease oil ,curing compounds,
paints, impregnations ,.laitance and loose material or foreign matter that
may affect the bond or performance of the epoxy grout.
The concrete substrate has reached the required design strength . Curing
of foundation shall be continued for 7 days or till the foundation attains 70%
of specified strength.
The areas of the steel plate or structural member in contact with the epoxy
grout shall be free from rust , oil , grease ,or other contaminants that may
likely affect the bond or performance of the epoxy grout installation.
The proper no. and size of air relief holes shall be installed.
The temporary shims , jack screws or wedges that are designated to be
removed after the epoxy grout has hardened are coated with a thin coat of
grease to facilitate removal.
Shims that are designated to remain in place after epoxy grout hardening
shall have a minimum distance from the edge of the finished epoxy grout
equal to the thickness of the epoxy grout pour and be coated as SAES-H-
101 ( APCS- 1C )..
All shims ( temporary or permanent ) shall be rounded with no sharp edges
or corners are properly set to prevent shifting during the epoxy grout
placement.
The formwork shall be constructed with adequate strength , rigidity and
dimension to permit epoxy grout placement.
A bond breaker consistent with the manufacturers recommendation shall be
applied to the surface of the formwork in contact with the epoxy grout.
Concrete surface in contact with epoxy grout shall be dry at time of
placement ..
Joints in epoxy grout shall be as per the construction drawing or as
recommended by the manufacturer.
The epoxy grout manufacturer recommendations on maximum depth of
pour and length to width ratio shall be followed .
If the grout pour is 100 mm or deeper , the grout manufacturer
recommendations for installing reinforcement rebar shall be followed.
5.5.2 INSTALLATION OF EPOXY GROUT
Epoxy grout shall be mixed, placed and cured in accordance with
manufacturers recommendation.
For epoxy grout installation on rotating equipment application, epoxy grout
shall be installed as per PIP REIE 686 , chapter on “Mounting Plate
Grouting.”.
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Epoxy grout shall be stored , mixed , placed and cured as per
manufacturer’s recommendation. Care shall be taken to prevent trapping
air .Epoxy grout shall be placed within the working time.
The final level of the epoxy grout shall be as installed with all chamfer
edges built into the formwork.
The corner of mounting plates shall be rounded.
5.5.3 SAMPLING AND TESTING
Sampling of grout shall be done at site for each day and tested for
compressive strength at the end of 1 day , 7 days and 28 days in
accordance with ASTM C 579.Nine number of 50 mm size sample shall
be cast per day. .
6.0 DOCUMENTATION
Form No. DOD / NEAT KHUFF / F-009 Rev 00 : Checklist for Epoxy grout
Installation..
Form No. DOD / NEAT KHUFF / F-008 Rev 00 : Compressive strength of grout
cubes .
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