METHOD STATEMENT FOR

DUCT BUNK, CONCRETE CRADLE & REHABILITATION OF

EXISTING ASPHALT ROAD

Rev

00

TABLE OF CONTENTS

1.0 SCOPE ……………………………………………………………….. 3

 2.0 PURPOSE…………………………………………………………… 3

3.0 RESPONSIBILITY…………………………………………………… 3

4.0 REFERENCES……………………………………………………….. 3

5.0 MATERIALS………………………………………………………….. 3

6.0 PROCEDURES……………………………………………………….. 4

7.0 EQUIPMENT AND SPECIAL TOOLS………………………..…… 5

8.0 SAFETY...…………………………………………………………….. 5

9.0 ATTACHMENTS …………………………………………………….. 5

1.0 SCOPE:
This Method Statement outlines the methodology for grouting.

2.0 PURPOSE
The purpose of this method is to briefly outline some important steps in grouting
activities. This is intended as a guide for control of workmanship and ensures
compliance with the Project Specification

3.0 RESPONSIBILITY
The originator of this document is responsible for update and validity of contents herein.

4.0 REFERENCES
4.1 Saudi Aramco Construction Specifications
- Section 03600 – Grout
 - Section 02271 – Grouted Rip – Rap
- Section 04100 – Mortar & Masonry Grout

4.2 SATIP Cement Based Non-Shrink Grouting – SATIP-Q-010-01

Epoxy Grout for Machinery Support - SATIP-Q-011-01

SAIC
Cement Based Non-Shrink Grout
Compressive Strength Test Reports - SAIC-Q-1045

Cement Based Non-Shrink Grout

Material Components and Ingredients
Receiving Inspection - SAIC-Q-1046

Cement Based Non-Shrink Grout

Surface Preparation & Formwork
Inspection - SAIC-Q-1048

Cement Based Non-Shrink Grout

Mixing, Placement, Sampling, Testing,
Curing and Final Inspection - SAIC-Q-1049

Tensioning and Grouting Inspection for

Pre-Stressed/Post Tensioned Concrete - SAIC-Q-1026

Grout Mixing, Placement, Sampling &

Testing Inspection - SAIC-Q-1054

Foundation and Grout Curing/Protection

And Final Inspection - SAIC-Q-1055

Grout Materials Receiving and Storage

Inspection - SAIC-Q-1052

4.3 Cement Based, Non-Shrink Grout for Structural

And Equipment Grouting - SAES-Q-010

4.4 Epoxy Grout for Machinery Support - SAES-Q-011

4.5 Aggregate of Concrete - 09 SAMSS -088

4.6 Process Industry Practice (PIP)

PIP STS03600 Non-Shrink Cementitious Grout Specification

PIP STS03601 Epoxy Grout Specification

4.7 Industry Codes and Standards

ASTM C150 Standard Specification for Portland cement

ASTM C109M Standard Test Method for Compressive Strength of Hydraulic

Cement Mortars (using 50 mm cube specimens)

ASTM C579 Standard Test Method for Compressive Strength of Chemical-

Resistant mortars, grout, monolithic surfacing's and polymer
 Concretes

ASTM C1107 Standard Specification for Packaged Dry, Hydraulic-cement

Grout (Non-shrink)

ASTM C94 Standard Specification for Ready Mixed Concrete

ASTM C33 Standard Specification for Concrete Aggregates

ASTM C309 Standard Specification for Liquid Membrane-Forming Compounds

For Curing Concrete

PIP REIE686 Recommended Practice for Machinery Installation Design

5.0 MATERIALS

5.1 Cement and Pre-mixed grout must be stored in a watertight buildings or bins.
5.2
Class I – Pre-packaged, high fluidity, non shrink, non-catalyzed natural aggregate grout
& shall only require addition of water at the mixer. Master Builders MASTER FLOW 713
or equal. Class I grout shall attain minimum compressive strength of 34.5 MPa (5000
psi). @ 28 day Class I grout shall conform to YERP-SAES-Q-010.

Premixed Grouts (Class I) – Mix in accordance with manufacturer’s instructions.

Class II – Site mixed grouts, using locally available materials. Class II grout shall consist
of Portland cement Type V conforming to ASTM C150 and clean well graded fine
aggregate conforming to ASTM C33 and potable water. The material shall be no wetter
than necessary for satisfactory placement. Minimum compressive strength shall not be
less than 13.8 MPa (2000 psi).

Site Mixed Grout (Class II) – 1 part Portland cement, 1 part sand and the lease amount of
water to provide hydration and workability.

5.2 Sand Stockpile sand in manner to prevent contamination with other materials or with
other sizes of aggregate. Allow sand to drain until it has reached uniform moisture
content before it is used.

5.3 Epoxy Grout As per the approved manufacturer’s instruction.

Epoxy grout shall conform to YERP-SAES-Q-011. Mix epoxy grout as per manufacturer’s
instructions.

6.0 Procedures

6.1 Surface Preparation

6.2 Bearing surfaces to be grouted shall be roughened to provide key.

6.2 Cleaning

6.2.1 Prior to placing grout, remove all foreign matter from concrete bearing surfaces.

6.2.2 Pre-soak all surfaces to be grouted at least 24 hours prior to grouting with Portland
cement grout.
 6.3 Application

6.3.1 Class I Grout shall be used for precision, non-shrink grouting in the following applications:

1. All grouting of structural base plates and precast members.

2. Base plates for equipment wherever specified by Vendor.

6.3.2 Class II Grout shall be used for all non-precision grouting such as pipe sleeves and drains
and other applications (precast) where non shrink characteristics are not mandatory.

6.3.3 Class II grout will be packed in place to ensure the complete filling of the area to be
grouted.

6.3.4 Class I grout to be cured at manufacturer’s instructions. Class II grout to be kept damp
until it has cured but for not less than 72 hours, subject to modifications of YERP-SAES-
Q-010.

6.3.5 Epoxy grout shall be used for machinery supports as specified in YERP-SAES-Q-011 or if
specified by vendor. Installation shall be as per installation procedure in vendor manual.

6.4 Setting Base Plates and Bearing Plates

6.4.1 General: After being plumbed and properly positioned, column base plates, and
machinery
And equipment base plates shall be grouted, as required by SAES-Q-010 or SAES-Q-
011.
Plates shall be set and anchored to the proper line and elevation. Metal wedges, shims,
And/or setting nuts shall be used for leveling and plumbing structural members.
Concrete and metal surfaces in contact with grout shall be clean and free of oil and
grease.
Concrete surfaces shall be free of laitance and shall be dampened but not puddled.

6.4.2 Nonshrink grout: Literature and test data on the material shall be furnished confirming
that
a flow able mixture will give a hardened grout with a slight expansion and possessing the
Other properties needed for the application proposed. Mixing and placing shall conform
With the manufacturer’s written recommendations. Forms of wood or other suitable
Material shall be used to retain the grout. The grout shall be placed from one side only
Quickly and continuously, completely filling the space without segregation or bleeding of
The mix. Grout shall be cured as per SAES-Q-010.

6.4.3 Epoxy Grout: Literature & test data on the grout material shall be furnished. Application
Shall conform to the manufacturer’s recommendations. Epoxy grout shall be used for
Machinery support grouting for the situations described in SAES-Q-011.

7.0 EQUIPMENT AND SPECIAL TOOLS:

Approved Drawing
Low speed mixer
Tape measure
Thermometer (for water and premix)
 Grout machine where required
Suitable form work

8.0 SAFETY:

8.1 Personal Safety

Personnel shall be provided with the following safety equipment.
a. Safety Helmet
b. Coveralls
c. Safety shoes
d. Mask (as required in the MSDS)
e. Safety gloves (as required)

8.2 In case of insufficient ventilation, wear suitable respiratory equipment. Avoid skin and
Eye contact.
8.3 Wear rubber boots in addition to the recommended protective clothing.
8.4 For environmental protection, prevent mortar’s entry into drains, sewers and water
Courses.
8.5 Do not breathe dust.
8.6 Wear suitable protective clothing, gloves and eye/face protection.
8.7 In case of contact with eyes, rinse immediately with plenty of water and seek medical
advice.

9.0 ATTACHMENTS:

N/A

**********************************END OF THIS
DOCUMENT************************************