010-MS For Grouting PDF

Pearl GTL
Project
Shell Project No: HP-3000-QAT
Project Document Number: T- 4.234.076
Purchase Order Number:
2MH127
Tag/Item Number(s):
N/A
Unit(s):
ASU
PCWBS:
LINDE ENGINEERING
Contractor Project No :
Project Rev.: C
Page 2 of 30
5887
QATAR SHELL GTL PROJECT (PEARL)

C2 AIR SEPARATION UNITS CONSTRUCTION
01.12.08
Ready For construction
SB
EO
AG
RFC
24.08.08
Issued for Company Comments
SB
EO
AG
ICC
09.01.08
Ready For construction
IU
UA/IO
MC/ZG
RFC
01.10.07
Issued for Company Comments
MS
MC
ZG
ICC
Issued for Review
MS
MC
ZG
IFR
Issued for Internal Review
MS
MC
ZG
IIR
GAMA
Rev.
No.
Project
Rev
No.
Date
Prepared Checked Approved

By
By
By
ORIGINATOR
Description
Status
Document Title:
METHOD STATEMENT FOR GROUTING

LINDE ENGINEERING AG
Document No.
Contractor
Gama Qatar Co. W. L. L.
LOC470
GAM
MTS
CIV
GTL
010
Org.
Code
Doc.
Type
Disc.
Code
Geogr.
Area
Seq.
No
Rev.
No
Project Document Number: T-4.234.076
Vendor Code
Rev No: C
Q A T A R
Doc. Title
GAM-MTS-CIV-GTL-010 Rev. F
Method Statement for Grouting
Date
01.12.2008
TABLE OF CONTENTS
1.
PURPOSE _____________________________________________________________________ 5
2.
SCOPE ________________________________________________________________________ 5
3.
HSSE _________________________________________________________________________ 5
4.
REFERENCES _________________________________________________________________ 6
5.
DEFINITIONS _________________________________________________________________ 6
6.
METHOD OF EXECUTION _____________________________________________________ 7
7.
QUALITY ASSURANCE _______________________________________________________ 11
8.
ATTACHMENTS ______________________________________________________________ 11
T-4.234.076 Rev. C
Page 4 of 30
Q A T A R
Doc. Title
Date
01.12.2008
1. PURPOSE
This document describes the methods proposed to be used for the non-shrink grouting works that will be
carried out as part of ASU Construction Works of QSGTL Pearl Plant in Ras Laffan Industrial City of Qatar.
2. SCOPE
Grouting facilities will take place on the dedicated place(s) as per approved layout area. The construction &
erection activities will be carried out by Gama.
3. HSSE
All works will be in compliance with the State of Qatar laws and regulations, Ras Laffan Industrial City and
international standards/codes, and Company and Contractor requirements and instructions.
All personnel will go through Gama, Contractor and Company Safety Induction courses as well as other
trainings as identified by their supervisor. Please see Document Number GTL-GM-001-A-5635 for details.
A Job Safety Analysis (JSA) specific for this work including a Risk Assessment, is prepared as per Gama
procedure GTL-GM-001-A-5626 and is attached herein. Such JSA addresses the hazards associated with
each task within the scope of this Method Statement and introduces the controls that will be implemented to
reduce the associated risks to acceptable levels. The JSA will be used by the Site Supervisor as the basis of
his TSTI / TSTO and Toolbox Talks.
All personnel will have PPE required for their specific tasks in addition to the minimum PPE (coveralls, safety
goggles, safety shoes, high-visibility vests, gloves) at site at all times as required.
In the event of a release, fire or explosion, employees will secure their area and evacuate to the nearest
muster point. Once all employees are evacuated the supervisor will conduct a headcount to verify all
employees are out of harms way. The supervision will report this to Contractor. Emergency Contact numbers
for Company, Contractor and Gama will be posted onsite.
All vehicles and equipment used for the subject work will be inspected and certified as required.
Drivers and operators will be competent and will have attended all required trainings set forth in project
procedures and specifications.
T-4.234.076 Rev. C
Page 5 of 30
Q A T A R
Doc. Title
Date
01.12.2008
4. REFERENCES
Qatar Construction Standard
DEP 34.19.20.31-Gen
Reinforced Concrete Foundations and Structures
T-13.376.358
Amendments and/or Supplements to Reinforced Concrete Foundations and

Structures
ASTM C109
Compressive Strength of Hydraulic-Cement Mortars
ASTM C156
Test Methods for Water Retention by Concrete curing Material
ASTM C531
Linear Shrinkage and Coefficient of Thermal Expansion of ChemicalResistant Mortars and Monolithic
ASTM C579
Compressive Strength of Chemical-Resistant Mortars, Grout, and Monolithic

Surfacing
ASTM C827
Change in Height of Early Ages of Cylindrical specimens from Cementations

Mixtures
ASTM C1107
Standard Specification for Packaged Dry Hydraulic Cement Grout (Nonshrink)
DEP 31.29.00.10
Installation of Rotating Equipment (Amendments Supplements to API

RP 686
BS 1881 Part 116 1983 Standard for Grout Compressive Strength.
5. DEFINITIONS
Company
: QSGTL and/or its PMC
Contractor
: Linde Engineering AG
Subcontractor or Gama
: Gama Qatar Company Co. W. L. L.
Contract
: QSGTL Pearl Plant C2 ASU Construction Works
QCR
: Quality Control Record
QCP
: Quality Control Procedure
QA/QC
: Quality Assurance / Quality Control
ASTM
: American Society for Testing and Materials
ACI
: American Concrete Institute
T-4.234.076 Rev. C
Page 6 of 30
Q A T A R
Doc. Title
Date
01.12.2008
6. METHOD OF EXECUTION
6.1.
EQUIPMENT AND MANPOWER
Equipment
-
Low speed hand Mixer

Water Tanker (10 Tons)
Grout Mixer for manual Mixing
: Manufactures Recommendation
: 1 (if needed)
: 4 (if needed)
Manpower
-
Civil Foreman
HSSE Officer
QA/QC Technician
Carpenter
Grouting Personnel
Helper
Operator
Truck Driver
6.2.
:1
:1
:1
:3
:4
:8
:1
:1
GENERAL SURFACE PREPARATION & APPLICATION
Foundations for Rotating / Reciprocating Equipment:

Surface preparation of foundations for rotating/reciprocating equipment will be done as per
paragraph 4 of DEP 31.29.00.10-Gen., Installation of Rotating Equipment.
Special attention will be paid to the extent of the grouting. As mentioned in DEP 31.29.00.10Gen., the foundation will be sized so that grouting can be extended to 50 mm beyond the
base/sole plate or the shims.
If the size of concrete foundation is greater than the base/sole plate, formwork will be used to
match the 50 mm.
Foundations for Steel Structures and Stationary Equipment:
The surface of the foundation under the base plate of the object to be grouted will be chipped
and brushed to remove the weak upper layer of the concrete, damaged concrete and any oilsoaked concrete areas. Prior to grouting, loose concrete or dust will be removed, preferably by
compressed air.
Before grouting commences the concrete surfaces will be soaked with clean water for 24 hours,
unless the grout Manufacturer specifies otherwise.
T-4.234.076 Rev. C
Page 7 of 30
Q A T A R
Doc. Title
Date
01.12.2008
Grouting of Steel Structures and Stationary Equipment:

The installation of the grout will be carefully supervised.
Special attention will be paid to prevent distortion of the item being grouted.
The placing of sand-cement grout mortar will commence not later than 15 minutes after
completion of the mixing. No grout mortar will be used that has not been placed after 30 minutes
from completion of mixing.
Under no circumstances will re-mixing or knocking up be allowed.
Proprietary grouts will be mixed, placed and cured in strict accordance with the grout
Manufacturer's instructions.
Vent holes should be drilled in base plates to avoid air pockets.
The grout will fill all voids between the base plate or sole plate and the foundation, and will have
full surface contact.
Cement-based grout will be kept moist during the first 7 days after placing and will be protected
from sunshine and drying out by protective covering as per DEP 34.19.20.31 Clause 10.3.2.
After hardening, wedges will be removed and the resulting voids filled with grout.
The grout thickness will be minimum 25 mm but will not exceed 50 mm.
Grouting will be extended 50 mm beyond the base/ sole plate if the concrete foundation is
greater than the base/sole plate. Form work will be used to match the 50 mm.
The edge of the grout will be provided with a chamfer of approximately 25 mm.
The Gout is regarded as Non- shrink if its volume is not less than the Initial Volume, after
Hardening for 28 days. During this period the test specimens shall have been completely
protected against drying, evaporating, Carbonation and exposure to temperatures outside the
range 230 C 30 C as per the DEP 34.19.20.31 Clause 10.1.2.
6.3.
MATERIALS AND USAGE
Only materials approved by Contractor will be used. Fosroc - Conbextra BB 80 OR BASFMaster Flow 928 T)
6.3.1) FOSROC CONBEXTRA BB 80:
It is a non-shrink cementitious bearing grouting (dry powder) material will be used Flanged
Lighting Columns, Heavy stanchion bases and base plates for reciprocating pumps, anchor
bolts, Steel Structures etc
The grouting material is packed in 25 Kg air tight plastic bags used up to the section thickness
up to 100mm. For the thicker sections more than 100mm, the clean washed 5-10mm silt free
aggregate will be mixed (Max.Ratio1:1) with the grouting powder as per the manufacturer
recommendations.
Storage mixing & placing and curing shall be in accordance with the manufacturer
recommendations.
T-4.234.076 Rev. C
Page 8 of 30
Q A T A R
Doc. Title
Date
01.12.2008
The grouting material will be mixed with a measured amount of clean water at WATER:
POWDER ratio of 0.15 at a maximum temperature of 250C.Water Temperature will be Monitor
by use of Thermometer.
The Compressive Strength of the grout must be 45 N/mm2 @ 24 Hours, 60 N/mm2 @ 3 days,
70N/mm2 @ 7 days and 85 N/mm2 @ 28 Days as per manufacturers data sheet
recommendations and as per BS 1881 Part 116 1983.
6.3.1.1)
PRE-SOAKING
Bolt holes and fixing pockets must be blown clean of any dirt or debris.
For a minimum of 24 hours prior to pouring, the area of cleaned substrate should be soaking
with wet Hessian with fresh water to minimize localized absorption and to assist in the free flow
of the grout.
Immediately before grouting, any free water should be removed. Particular care should be taken
to blow out all holes and pockets.
Forms will be waxed or use of Silica as necessary to prevent sticking and leak proof as
Conbextra BB 80 is a free flow grout. An intensive care will be paid to ensure that the grout
cannot squeeze out from below and around the forms during placing and setting.
Ensure the Form work is secure and watertight to prevent movement and the area should be
free from excessive vibration. Shut down all machineries until the grout has hardened.
6.3.1.2)
MIXING & PLACING
For the best result, the grouting material shall be mixed with mechanical mixer for larger
quantity. Dont use a colloidal impeller mixer for mixing.
To produce a fluid grout, add 3.75 Lit. of water (below 250C) will be to a 25Kg bag of Conbextra
BB 80.The water should be accurately measured into the mixer. Slowly add the total content of
the Conbextra BB 80 powder and mix continuously for 5 minutes on high shear / speed until the
smooth and even consistency is obtained.
Place the grout within 15 minutes of mixing to attain full strength.
Conbextra BB 80 can be placed in thickness up to 100 mm in a single pour.
Continuous grouting operation will be takes place until the process is finished.
The mixed grout shall be poured only from one side of the void to eliminate the entrapment of
air or surplus pre-soaking water.
6.3.1.3)
CURING
On completion of the grouting operation, exposed areas should be thoroughly cured. This should
be done by the use of continuous application of water with Hessian up to 7 days as per DEP
34.19.20.31 Gen Clause 10.3.2.
The Grouted area shall be covered with Wet Hessian with Polythene double Layer and/or as per
DEP 34.19.20.31(Gen) Amendments plus Manufacture recommendation.
T-4.234.076 Rev. C
Page 9 of 30
Q A T A R
Doc. Title
Date
01.12.2008
6.3.2) BASF - MASTER FLOW 928T
1)
APPLICATION PROCEDURE :
a) All procedure is same as above mentioned in Conbextra BB 80.

b) The area shall be maintained as damp without water before grouting.
2)
MIXING, PLACING & CURING

a) Same as above mentioned in the Conbextra BB 80.
b) The mixing and placing process will be done at less than 300C. In cold weather, the
temperature will be minimum 100C maintained as per manufacturers recommendations.
c) Immediately after Master Flow 928T grout is placed, cover all exposed grout with clean
damp Hessian, and keep moist until grout is firm enough to accept a curing membrane.
d) Curing will be done as per DEP 34.19.20.31- Clause 10.3.2, for 7 days with wet Hessian
Covered with double layer polythene sheet.
For mixing of grouting material, follow the manufacturers recommended table:

Flow
Application
Consistency
Flow Table
Water(Lit) / 25 Kg Bag
C
o
Min
Max
n
e
Grouting Machinery
Fluid
----
20 - 30
4.5
5.0
Grouting Machinery
Flowable
130
3.5
4.0
Plastic
60
3.0
3.5
Dry-pack
2.0
2.5
Bedding Pre-cast
Filling Tie-bar voids
Note: (1) If grout shoulders require finishing work, this should be carried out prior to application of
the curing membrane.
(2) Under no Circumstances should Master flow 928T be re-tempered by the later addition
of water.
(3) For the Compressive strength of Grout, the details in the Manufacture data sheet also
Followed.
T-4.234.076 Rev. C
Page 10 of 30
Q A T A R
Doc. Title
Date
01.12.2008
7. QUALITY ASSURANCE
A Quality Assurance System will be operated conforming to related standards. Controls and checks will be
established and documented through relevant T- 4.234.545 (QCP), T- 4.234.576 (ITP) and QCR s.
8. ATTACHMENTS
8.1.
JOB SAFETY ANALYSIS
8.2.
MATERIAL DATA SHEET FOR MASTER FLOW
928 T & CONBEXTRA BB 80
8.3. DEP 34.19.20.31 GEN PAGE NO : 20 , 21( GROUTING)
T-4.234.076 Rev. C
Page 11 of 30
Q A T A R
JOB SAFETY ANALYSIS FORM
JSA For: T-4.234.076

NEW
Job being analysed: Grouting
Department/Section doing JSA: HSSE & Construction
Normal Approvals:
JSA by:
Page No: 1 of 8
REVISED
Name
JSA Members:
Job Performers:
Signature
Date
Job Supervisor:
Additional Approvals (Determined by Job Supervisor in correlation with Linde HSSE Manager).
Name
Signature
Discipline Superindent (Linde)
Date
General job requirements / Common Personal

Protective Equipment.
1. The following Personal Protective
Equipment shall be worn:
Approved coveralls, safety goggles, safety
helmet, safety shoes and gloves.
HSSE Representative (Linde)

2.Permit To Work.
OTHERS (List Below):
Approval required for hazardous work detailed in the Linde Work Permit Procedure.
Changing conditions and emergency procedures
Stop work. Switch off equipment.Supervisor directs personnel to nearest and safest muster point considering wind direction. Supervisor counts all employees. Missing
employees are reported to Linde HSSE Dept. When all clear is given, check with Linde HSSE before returning to work.
LINDE EMERGENCY TELEPHONE NO.
HSSE MANAGER:
Pearl HOT LINE :
JOB SAFETY ANALYSIS / RISK ASSESSMENT

FOR T-4.234.076
Q A T A R
HAZARDS / POTENTIAL
ITEM
ACTIVITY
CONSEQUENCES
1
Unloading rebar from 1.1 Falling or dropped loads.
delivery truck with
crane to rebar stock
1.2 Overturning of machine.
area.
Initial Risk
RISK
P C
RANK
C
HIGH
MED
SCOPE :
GROUTING WORKS
Residual Risk
1.1.1
1.1.2
1.1.3
1.2.1
1.2.2
1.2.3
MAIN
CONTROLS
Third party crane inspections.
Daily crane checks.
Competent riggers.
SWL properly displayed.
Qualified and 3rd party certified
operators.
Set up crane on solid level ground
1.1.1.1
1.2.1.1
1.2.1.2
1.3
Improper rigging.
1.3.1
1.3.2
C
1.4
HIGH
Damaged, worn or
unusable rigging
equipment and/or gears.
1.3.3
1.4.1
1.4.2
C
HIGH
1.4.3
1.5
Manually transferring 2.1

of stock rebars, to
rebar cutting
machine.
People struck by
suspended or swinging
load.
1.5.1
B
MED
Manual handling.
1.5.2
1.5.3
1.5.4
2.1.1
2.1.2
LOW
2.1.3
2.1.4
2.1.5
Competency check for all riggers.

Rigging supervisor to monitor rigger
performance.
Ensure that the riggers are
competent and Third Party certified.
1.3.1.1
1.3.1.2
Quarterly inspection of lifting gear by 1.4.1.1

Third party and color coded.
Removal and isolation of all worn or
damaged lifting equipment.
Rigging gear shall be color coded as 1.4.1.2
per Contractor procedure.
Barricade and secured area and
1.5.1.1
install safety sign boards.
Use tag lines to control load.
DO NOT lift load over people.
Do not allow people to walk under the
load.
Worker to wear appropriate gloves. 2.1.1.1
Break the load into manageable
portions.
Lift with your legs not your back.
Use the buddy system, Get help.
Provide pictorial sign boards with
correct lifting position.
ADDITIONAL
CONTROLS
Supervisor/foreman shall ensure
that the TSTI is properly executed
at the work front and hazards
discussed.
Ensure daily check is performed
prior to each use.
discussed.
Rigging operations shall be
performed by competent and
qualified riggers.
discussed.
Ensure that all rigging gear are
has 3rd party certificates.
discussed.
LOW
LOW
LOW
LOW
LOW
LOW
Provision for lifting aids when

practical.

FOR T-4.234.076
Q A T A R
ITEM
ACTIVITY
Measuring and
cutting rebar to
length.
HAZARDS / POTENTIAL
CONSEQUENCES
2.2 Debris and materials
causing slip, trips and
falls.
3.1
Initial Risk
RISK
P C
RANK
LOW
2.2.3
3.1.1
LOW
Manual handling of rebar.
3.2.1
B
3.3
Hand and finger injuries.

B
3.2
Residual Risk
2.2.1
2.2.2
B
LOW
Rebar cutting machine.
3.3.1
3.3.2
B
3.4
LOW
Defective equipment.
3.3.3
3.4.1
LOW
3.4.2
3.4.3
Transferring cut
rebars from cutting
machine to rebar
bending machine.
4.1
Manual handling.
4.1.1
4.1.2
C
4.2
Debris causing slip trips

and falls.
LOW
LOW
SCOPE :
GROUTING WORKS
4.1.3
4.1.4
4.2.1
4.2.2
MAIN
CONTROLS
Adequate stacking of materials.
Regular housekeeping practices and
removal of trash and unnecessary
items.
Maintain access and walk paths.
Wear approved PPE, safety goggles,
safety helmet, safety shoes, gloves,
high-vis vests
Approved quality hand gloves,
available in a full range of sizes to
ensure proper fit to maintain
dexterity.
Competent operators, trained on the 3.3.1.1
machine they operate.
Ensure that the guards are properly
installed and are being used.
3.3.1.2
Post near machine the
manufacturers safe operating
procedures in different languages.
3.3.1.3
Daily inspection of equipment by
operator prior to use according to
manufacturers recommendations.
Current Contractor inspection
certificate.
Monthly equipment inspection and
color code.
Worker to wear appropriate gloves.
portions.
items.
3.4.1.1
4.1.1.1
ADDITIONAL
CONTROLS
Post the manufacturer safe

operating manual near the
machine and HSSE office.
discussed.
Minimum 4 persons-Team leader
with 3 helpers.
Proper maintenance performed by
maintenance department
according to manufacturers
recommendations.
LOW
LOW
LOW
LOW
LOW
LOW
LOW

practical.

FOR T-4.234.076
Q A T A R
ITEM
5
ACTIVITY
Setting up rebar
bending machine to
perform desired
bend.
HAZARDS / POTENTIAL
CONSEQUENCES
5.1 Hand and finger injuries.
Initial Risk
RISK
P C
RANK
5.1.1
LOW
5.1.2
5.1.3
Measuring and
bending rebar.
6.1
Hand, finger and foot

injuries.
6.1.1
6.1.2
6.1.3
D
MED
6.1.4
6.1.5
6.2
6.3
Dropped rebar from

height.
Unauthorized people in
rebar bending area or
radius.
6.2.1
D
MED
LOW
6.2.2
6.3.1
SCOPE :
GROUTING WORKS
MAIN
CONTROLS
Follow manufacturers
5.1.1.1
recommendations for properly and
safely setting up rebar bending
machine.
Control of hazardous energy, LO/TO. 5.1.1.2
de-energize equipment" before
making adjustments to moving parts. 5.1.1.3
Wear approved hand gloves for the
task.
Install stops on the edge of
workbench.
Approved hand gloves, available in a
full range of sizes to ensure proper fit
to maintain dexterity.
recommendations for operating and
adjusting machine for rebar size.
Competent and properly trained
operator.
Keep away hand & finger from
moving parts.
6.1.1.1
6.1.1.2
6.1.1.3
6.1.1.4
6.1.1.5
Install appropriate stops on the edge 6.2.1.1

of workbench.
Ensure adequate number of workers
to control the operation.
Barricade and secure area and post
safety sign boards Authorized
Employees Only.
Residual Risk
ADDITIONAL
P C
R
CONTROLS
discussed.
Minimize number of people at work
B 1
LOW
area of bending/cutting machine.
Mark the work area.

discussed.
Ensure that equipment manual is
available near the machine.
Post names of authorized
operators near the machine.
Minimum 3 persons-Team leader
with 2 helpers.
Post the rebar bending machine
safe operating procedures and
safety precautions at the job site.
discussed.
LOW
LOW
LOW

FOR T-4.234.076
Q A T A R
ITEM
ACTIVITY
HAZARDS / POTENTIAL
CONSEQUENCES
6.4 Improper use of rebar
bending machine.
Initial Risk
RISK
P C
RANK
Residual Risk
6.4.1
6.4.2
B
Assembly of
reinforcement bars.
7.1
LOW
Use of tie-wire causing

hand, face or eye injury.
6.4.3
7.1.1
7.1.2
C
7.2
MED
Dropped or collapse of bar

structure or stand.
7.1.3
7.1.4
7.2.1
7.2.2
C
SCOPE :
GROUTING WORKS
MAIN
CONTROLS
Competent and properly trained
operator.
recommendations for operating and
adjusting machine for rebar size.
Post near machine the
manufacturers safe operating
procedures in the appropriate
languages
6.4.1.1
6.4.2.1
6.4.3.1
Use proper tie wire techniques.

7.1.1.1
Wear approved PPE, safety glasses,
safety helmet and safety foot wear.
Appropriate hand tools.
Appropriate hand gloves.
7.1.1.2
Use approved stands to support

7.2.1.1
rebar load.
Visually inspect daily support stands.
LOW
7.2.1.2
Surface preparation
for construction
joints.
8.1
8.1.1
Use of hand held power

tool, grinding buffing and
air compressor.
8.1.2
B
LOW
8.1.3
8.2
Electrocution and burns.
8.2.1
LOW
8.2.2
8.2.3
Ensure that guards are kept in place

and not removed.
Do not wear loose clothing or jewelry.
Long hair shall be pulled back and
kept from dangling.
PPE ( hearing protection as
appropriate).
GFCI and using the correct operating
voltage.
Competent personnel.
Equipment inspections performed by
competent personnel and has valid
inspection sticker with color coding.
ADDITIONAL
CONTROLS
discussed.
Ensure that equipment manual is
available near the machine.
Post names of authorized
operators near the machine.

discussed.
Ensure that workers carrying the
task is properly trained and
competent.
discussed.
Ensure that workers performing
the task is properly trained and
competent.
LOW
LOW
LOW
LOW
LOW

FOR T-4.234.076
Q A T A R
ITEM
ACTIVITY
HAZARDS / POTENTIAL
CONSEQUENCES
8.3 Sub-standard equipment.
Initial Risk
RISK
P C
RANK
8.3.1
B
Install formworks.
9.1
MED
Use of hand and power

tools.
8.3.2
9.1.1
9.2
LOW
Handling shutters (Back

injury).
9.2.1
9.2.2
B
9.3
9.4
Debris and materials

causing slip, trips and
falls.
LOW
LOW
9.3.3
9.4.1
Fall hazards.
Install rebar re10.1 Falling or dropped loads.

enforcement steel
into form works with
gantry crane.
9.2.3
9.2.4
9.2.5
9.3.1
9.3.2
10
LOW
9.4.2
HIGH
10.1.1
10.1.2
10.1.3
10.1.4
SCOPE :
GROUTING WORKS
MAIN
CONTROLS
Distribution panel inspected by
8.3.1.1
Contractor before being energized.
Inspection and color-coding of power
tools monthly with a visual inspection
prior to each use.
All work is to be completed with
approved PPE, including safety
glasses with side shields, safety
helmet, coveralls and steel toe
footwear and gloves.
9.1.1.1
9.1.1.2

9.2.1.1
practical.
portions.
Provide pictorial sign boards with
correct lifting position.
items.
Maintain access and walk paths.
Use approved ladder i.e. scaffold
9.4.1.1
material to gain height advantage.
Work from ground level or use
approved platform.
Third party crane inspections.

Daily crane checks.
Competent riggers.
Quarterly and Daily inspection of
rigging gear and equipment (color
coding).
10.1.5 Third party crane operator.
Residual Risk
ADDITIONAL
P C
R
CONTROLS
Ensure all sub-standard equipment
should be remove from site and
tag as unsafe.
B 2
LOW

discussed.
Post the table saw and
combination saw machine safe
operating procedures and safety
precautions at the job site.
discussed.
LOW
LOW
LOW
LOW
LOW
Ensure that all employees working

at height are properly trained.
10.1.1.1 Supervisor/foreman shall ensure

discussed.
10.1.1.2 Ensure the area is properly
barricaded and secured.

FOR T-4.234.076
Q A T A R
ITEM
ACTIVITY
HAZARDS / POTENTIAL
CONSEQUENCES
10.2 Improper rigging.
Initial Risk
RISK
P C
RANK
HIGH
10.3 Damaged, worn or

unusable rigging
equipment.
C
10.4 People struck by

suspended or swinging
load.
11
Pour concrete.
HIGH
MED
11.1 Fall hazards.

B
LOW
11.2 Use of hand held power

tools, vibrator.
B
LOW
LOW
11.3 Electrocution and burns.
SCOPE :
GROUTING WORKS
Residual Risk
MAIN
CONTROLS
10.2.1 Competency check for all riggers.
10.2.2 Rigging supervisor to monitor rigger
performance.
10.2.3 Third party certified and competent
riggers.
10.2.1.1
10.2.1.2
10.3.1 Quarterly inspection of lifting gear by 10.3.1.1

Third party and color coded.
10.3.2 Removal and isolation of all worn or
damaged lifting equipment.
10.3.3 Rigging gears shall be color coded as 10.3.1.2
per project procedure.
10.4.1 Barricade and secured area and
10.4.1.1
install safety sign boards.
10.4.2 Use tag lines to control load.
10.4.3 "DO NOT" lift load over people.
10.4.4 Do not allow people to walk under the
load.
11.1.1 Use approved ladder i.e. scaffold
11.1.1.2
material to gain height advantage.
11.1.2 Work from ground level or use
approved platform.
11.2.1 All work is to be completed with
11.2.1.1
approved PPE, including safety
glasses with side shields, safety
helmet, coveralls and steel toe
footwear and gloves.
11.3.1 GFCI and using the correct operating
voltage.
11.3.2 Competent personnel.
11.3.3 Dont touch electrically live parts with
skin or wet clothing.
11.3.4 Ensure good electrical connection.
ADDITIONAL
CONTROLS
discussed.
Rigging operations shall be
performed by competent and
qualified riggers.
discussed.
Ensure that all rigging gears are
has 3rd party certificates.
discussed.
Ensure that all employees working

at height are properly trained.
Ensure that all employees are

properly trained to use the
assigned tools.
LOW
LOW
LOW
LOW
LOW
LOW

FOR T-4.234.076
Q A T A R
ITEM
ACTIVITY
HAZARDS / POTENTIAL
CONSEQUENCES
11.4 Sub-standard equipment.
Initial Risk
RISK
P C
RANK
MED
11.5 Concrete pump truck

boom malfunctioning.
B
MED
LOW
LOW
LOW
11.6 Concrete splash. (Eye

injury).
11.7 Skin injury.
11.7 Foot injury.

11.8 Concrete waste.
LOW
SCOPE :
GROUTING WORKS
Residual Risk
MAIN
ADDITIONAL
P C
R
CONTROLS
CONTROLS
11.4.1 Distribution panel inspected by
11.4.1.1 Ensure all sub-standard equipment
Contractor before being energized.
is removed from site and tagged
11.4.2 Inspection and color-coding of power
as unsafe.
B 2
LOW
tools monthly with a visual inspection
prior to each use.
11.5.1 Contractor inspections.
11.5.1.1 Supervisor/foreman shall ensure
11.5.2 Daily operator inspection of vehicle
and associate pump equipment.
11.5.3 Competent operator trained on the
discussed.
equipment in which he operates.
11.5.4 Visual inspection of boom prior to
each use.
11.5.5 Ensure whip check is nstalled.
11.6.1 Approved PPE( including face shield
by employees working is close
proximity of concrete pour).
11.6.2 Competent personnel.
11.6.3 Eye wash available.
11.7.1 Wearing of approved coveralls and
gloves, with the hose man wearing
additional non-permeable suit.
11.7.1 Appropriate footwear
11.8.1 Use of plastic, spread on the ground
to contain waste.
11.8.2 Operator to properly control pump
boom movement.
11.8.3 Workout set approved area.
LOW
LOW
LOW
LOW
LOW

010-MS For Grouting PDF

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Pearl GTL

Purchase Order Number:

QATAR SHELL GTL PROJECT (PEARL)

Ready For construction

Issued for Company Comments

Ready For construction

Issued for Company Comments

Issued for Review

Issued for Internal Review

Prepared Checked Approved

METHOD STATEMENT FOR GROUTING

Gama Qatar Co. W. L. L.

Project Document Number: T-4.234.076

METHOD OF EXECUTION _____________________________________________________ 7

QUALITY ASSURANCE _______________________________________________________ 11

Reinforced Concrete Foundations and Structures

Amendments and/or Supplements to Reinforced Concrete Foundations and

Compressive Strength of Hydraulic-Cement Mortars

Test Methods for Water Retention by Concrete curing Material

Compressive Strength of Chemical-Resistant Mortars, Grout, and Monolithic

Change in Height of Early Ages of Cylindrical specimens from Cementations

Standard Specification for Packaged Dry Hydraulic Cement Grout (Nonshrink)

Installation of Rotating Equipment (Amendments Supplements to API

BS 1881 Part 116 1983 Standard for Grout Compressive Strength.

: QSGTL and/or its PMC

: Gama Qatar Company Co. W. L. L.

: QSGTL Pearl Plant C2 ASU Construction Works

: Quality Control Record

: Quality Control Procedure

: Quality Assurance / Quality Control

: American Society for Testing and Materials

: American Concrete Institute

EQUIPMENT AND MANPOWER

Low speed hand Mixer

GENERAL SURFACE PREPARATION & APPLICATION

Foundations for Rotating / Reciprocating Equipment:

Grouting of Steel Structures and Stationary Equipment:

MATERIALS AND USAGE

MIXING & PLACING

6.3.2) BASF - MASTER FLOW 928T

a) All procedure is same as above mentioned in Conbextra BB 80.

MIXING, PLACING & CURING

For mixing of grouting material, follow the manufacturers recommended table:

JOB SAFETY ANALYSIS

MATERIAL DATA SHEET FOR MASTER FLOW

928 T & CONBEXTRA BB 80

8.3. DEP 34.19.20.31 GEN PAGE NO : 20 , 21( GROUTING)

JOB SAFETY ANALYSIS FORM

JSA For: T-4.234.076

General job requirements / Common Personal

HSSE Representative (Linde)

OTHERS (List Below):

JOB SAFETY ANALYSIS / RISK ASSESSMENT

Manually transferring 2.1

Competency check for all riggers.

Quarterly inspection of lifting gear by 1.4.1.1

Provision for lifting aids when

JOB SAFETY ANALYSIS / RISK ASSESSMENT

Manual handling of rebar.

Hand and finger injuries.

Rebar cutting machine.

Debris causing slip trips