KOC_C_023 R1

7/17/2019 KOC_C_023 R1

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KUW IT

OIL

COMPANY K.S.C.)

STANDARDS

PU

BLlCATlON

KOC STANDARD

FOR

GROUTING

FOR

BASES

MATERIALS

ND WORKM NSHIP

ST ND RDS TE M I

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KU W AIT OIL CO MPAN Y K.S.C.)

ST ND RDS PUBLlC TlON

KOC STANDARD

FOR

G RO UT ING FOR BASES

MATERIALS A N D WO RKM ANSH IP

ST ND RDS TE M

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DOC. NO .

KOC C 023

KOC

STANDARD

FOR

GROUTING

FOR

BASES

MATERIALS A ND W ORKM ANSHIP

ISSUIN

AUTHORITY:

ST ND RDS TE M

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DOC. NO. KOC-C-023 REV 1

TABLE OF CONTENTS

FOREWORD

SCOPE

APPLICATION

TERMINOLOGY

3.1

Definitions

3.2 Abbreviations

REFERENCE STANDARDS CODES AND SPECIFICATIONS

4.1

Conflicts

4.2

List of Standards and Codes

ENVIRONMENTAL CONDITIONS

HEALTY SAFETY AND ENVIRONMENT

TECHNICAL REQUIREMENTS

7.1

General Conditions

MATERIAL REQUIREMENTS

8.1 Types Generally Used

8.2 Non-shrink Cementitious Grout

8.3 Epoxy Based Grout

8.4

Storage

CONSTRUCTION REQUIREMENTS

9.1 General

9.2

Specific

WORKMANSHIP

10.1

Von-shrink Cementitious Grout

10.2 Epoxy Based Grout

10.3

Base Setting

TESTS AND REPORTS

11.1 General

11.2 Test Reports

Page No.

5

6

6

6

6

7

7

7

7

9

9

10

10

10

10

10

11

12

12

12

12

13

13

15

15

16

16

16

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DOC.

NO

KOC C 0

Page

4 of 20

[ REV.1

12.0 QUALITY CONTROL

12 1 Qua lity Plan

13 0 QUALITY ASSURANCE

14.0 D O C U M E N T A T I O N

14.1 General

14.2

Deliverables

A C K N O W L E D G E M E N T

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I DOC.NO.K O

Page

f

2

R E V . l

F OREWORD

This documenl KOC Standa rd for Grout ing for Bases Mate r ia ls and

Wo rkman sh i p KOC-C-023) is intended to cover the minimum requirements of

installation of structural framework and equipment to the concrete foundations for

KOC Plants and Facilities Onshore).

This Standard has been approved by Standards Team in consultation with the

Standards Technical Committee for use throughout the corporate engineering and

operational funct ions of Kuwait Oil Company K.S.C).

This Standard sets out to achieve the following objectives:

a. To cover ths basic requirements of grouting wi th a view to provide reliable and

good perfo.-ming materials to cater for the specific installation needs of

equipment s) and structural framework to concrete bases.

b. To provide t.he specific technical inputs in order to develop the intended grouting

specification for the construction.

c. To set out minimum technical requirements to monitor compliance of material,

constructior. and workmanship w ith a contract.

Feedback as well as any comments or suggestions from the application of this

Standard derived at any stage of engineering, construction, testing, monitoring and

maintenance are encouraged and should be directed to:

The Team Leadsr Standards

Chairman, Standards Technical Committee)

Industrial Services Group, KOC

P.O. Box 9758, Ahmadi 61 008

State of Kuwait

Task Force Responsible for this S tandard

The preparation of this Standard has been entrusted by the Standards Technical

Committee STC) to the Task Force No. TF-C/07) comprising of the following

members:

Mr. S. Kumar

Standards Team

-TF Leader/Author Tel. No. 61407

Mr. Mohd. Javaid

Design Team Member

Tel. No. 61 32 2

Mr. Ahmed At-Fenaini

Export Fac. Proj. Member

Tel. No. 66987

Mr . Hussain Al-Jazzaf

Gen. Projects Member

Tel. No. 63226

Mr. Maged Madi

Projects Design Member

Tel. No. 66389

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SCOPE

T h i s S tandard p rov i des t he m i n i mum techn i ca l r equ i rements o f m a te ri a ls

and workma nsh i p f o r t he base se t t i ng g rou t s i n KOC cons t ruc t i on Onshore )

w i t h i n K u w a i t .

T h i s S t m d a r d c o v e r s o n l y t h e b a s ic r e q u i re m e n t s o grou t i ng t o bases and

s lid e p a t e s o f e q u i p m e n t an d s tr u c tu r a l f ra m e w o r k / m e m b e r s t o t h e

conc re te bases and f ounda t i ons .

T h i s S tandard does n o t cover t he o the r types o f g rou t i ng t o be used f o r

spec i f i c purposes, such as compact ion grouts i n sof t so i l s for dens i f i ca t ion,

and sea l ing o r p l ugg i ng g rou t s i n c racks and f issu res i n con c re te w ork as

we l l as i n aboveground and be l owground l iqu i d r e ta in i ng s t r uc tu res .

he cor t t en t o f t h i s S tandard i s i n tended t o b e adop ted as a gu i de t o m ee t

t he m i n i mum KOC requ i rements ; and shou l d f o rm the bas i s o f a de ta i l ed

des ign spec i f i ca t ion.

T he mate r i a l s , cons t ruc t i on , and workmansh i p o f g rou t i ng f o r bases sha l l

con fo r r? t o t he requ i rements o f t h i s S tandard and t he re fe rence s tandards

and codes me n t i oned here i n .

An y exc ep t i ons o r dev ia t ions f r om th i s S tandard , a l ong w i t h t he i r mer i t s

and jus t i fi ca t ions , sha ll be b rough t t o t h e a t t en t i on o f KOC Con t ro ll i ng T eam

for t he i r r ev i ew , cons ide ra ti on , and am endm ent by S tandards T eam i f

requi red) .

Comp li. 2nce w i t h t h i s S tandard does no t o f i t se l f con fe r i m mu n i t y f r om l ega l

or s ta tu tory ob l i gat ions .

T E R M I N O L O G Y

F or t he pu rposes o f t h i s S tandard , t h e f o l l ow i ng de f i n i ti ons a pp l y .

B leeding

Separa ti on o f w a te r f r om g rou t s as t i me passes ,

Con t rac to r

A n y a p p r o v e d f i r m o r c o m p a n y c o n t r a c t e d b y K O C , w h o a r e u n d e r t a k i n g

t h e e x e c u t i o n o f t h e c i v i l a n d s tr u c tu r a l w o r k a t t h e K O C F a c i li ty .

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Cons i s t ency

Degree o f t h i ckness o r smoothness o f g rou t s t a te , exp ressed by an

i nc reas i ng o rder i .e . by i ndex t o s ho w i t s wo rkab i l i t y .

G rou t i ng

In jec t ing or p lac ing appropr ia te b lend o f mater ia l s under pressure or grav i t y

in to spaces for f i l l i ng and therefore , sea l ing vo ids and o ther cav i t i es for

proper i ns ta l l a t i on o f bases o f equ ipment l s ) and s t ruc tura l f rames and

m e m b e r s

in

order t o f ac i l it a t e smoo th and un i f o rm t rans fe r o f l oads s ta t i c

o r v i b r ~ t o r y )o t he conc re te bases and o r f ounda t i ons .

Groutab i l i t y

I t r e f lez t s t h e va r i ous p rac t ica l cond i ti ons o f g rou t s such as v iscos i t y ,

f Iowa b i l it y , non-b leed ing, ear ly s t rength , tem pera ture under w hic h a

par ti cu la r g ro u t w i l l be expe c ted t o pe r f o rm sa t i s f ac to r i l y i n t he f ie l d by

penet ra t ing in to the des i red p laces and sea l ing a l l vo ids and cav i t i es be low

th e bases; and ac h iev ing the des i red s t rengths a t the spec i f i ed days .

Abbreviat ions

l ~

M i n i m u m C o m p r e ss iv e S t r e n g t h o f G r o u t

HSE Hea l th , Sa fe t y and Env i r onment

KOC Ku wa i t O i l Comp any K .S .C )

Q A I Q C

Qua l i t y Assurance ua l i t y Con t ro l

REFERENCE STANDARD S CODES AN D SPECIF ICATIONS

I n t h e e v e n t o f c o n f li c t s b e t w e e n t h i s S t a n d a rd a n d t h e st an d a rd s o d e s

referen2ed here in , or o ther cont rac tua l requ i rements , the most s t r i ngent

requ i rem ent sha l l app ly . In case fur ther c lar i f ica t ions are requ i red, th e

sub j ec t sha ll be b rou gh t t o t h e a t t en t i on o f KOC Con t ro l li ng T eam.

List of Stand ards an d Cod es

T h e l a t zs t ed i t ion o f t h e f o l l ow i ng s tandards , codes and spec i f ica t i ons sha ll

app ly :

Nat iona l 1 In ternat iona l S tandards

A A S H T O

T 6

S t a n d a rd M e t h o d o f T e s t f o r Q u a l i t y o f W a t e r t o b e u s e d

i n Conc re te

A S T M C 3 3

Spec i f i ca ti on f o r Conc re te Aggrega tes

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A S T M

C1 9

A S T M

C136

A S T M

21 5

A S T M PI91

A S T M 123 5

Standa rd Tes t Me thod fo r Compress i ve S t reng th o f

Hydrau li c Cem ent Mo r ta rs Us ing 2- in o r

5

m m C u b e

Spec imens)

Standard Tes t Me tho d fo r S ieve Ana lys is o f F ine and

Coarse Aggregates

Spec i f i ca t ion fo r Por t land Cem ent

S tanda rd Tes t Me thod fo r T ime o f Se t t i ng o f Hyd rau l i c

Cem ent By V ica t Need le

Prac t i ce fo r Mechan ica l M ix ing o f Hydrau l i c Cement

Pas tes and M or ta rs o f P las t ic Cons is tency

A S T M

2494

A S T M 3531

A S T M

C579

A S T M

C827

A S T M C 1 9

A S T M C 1 f 7

A S T M

D 5 12

A S T M

D 5

16

BS 12

BS EN 1262

BS 1881

BS 455

BS EN 2 6 7

Spec i f i ca t ion fo r Chemica l Admix tures fo r Concre te

Tes t M eth od fo r L inear Shr inkage and Coef f i c ien t o f

Thermal Expans ion o f Chemica l -Res is tan t Mor ta rs ,

Grouts , Mo no l i th ic Sur fac ing and Po lymer Concre te

Tes t Method fo r Compress ive St rength o f Chemica l

Res is tan t Mor ta rs , Grouts , Mono l i th ic Sur fac ing and

Polymer Concre te

Standard Tes t Me thod fo r Change in He igh t in Ear ly Ages

of Cy l indr ica l Spec imens fo rm Cem ent i t i ous Mix tu res

Standa rd Tes t Me th od fo r Measu r i ng Change i n He igh t o f

Cy l indr ica l Spec imens fo r Hydrau l i c -Cement Gro ut

Packaged Dry , hydrau li c -Cement Gro ut Non-shr ink )

S tanda rd Tes t Me thods fo r Ch lor ide Ion i n Wa te r

S tanda rd Tes t M e thod fo r S u l f a te I on i n Wa te r

Spec i f i ca t ion fo r Por t land Cem ent

Spec i f i ca t ion fo r Aggregates fo r Concre te

Me thods o f Tes t i ng Conc re te

M e t h o d o f T e s ti n g C e m e n t

Concre te Par t

:

Speci f icat ion, Performance, Product ion,

and Con fo rm i t y

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BS 8 1

10

4 2 2

KOC S tandards

Adm i x tu res f o r Conc re te , Mor ta r , and Gro u t Part 2:

Con crete Ad mix tures Def in i ti ons . Requi rements ,

Con fo rm i t y , M ark i ng and Labe l ing

S t ruc tu ra l Use o f Conc re te Part 1

:

Code o f P rac t i ce f o r

Des i gn and C ons t ruc ti on

KOC Standard for Bas ic C iv i l Eng ineering Des ign D ata

KOC Recommended Prac t i ce for Engineer ing Des ign

Bas is o f C i v il and S t ruc tu ra l Wo rk

KOC S tandard f o r Conc re te W ork Mate r i a l s and

C o n s t r u c t i o n

KOC S tandard f o r S t ruc tu ra l S tee l Work - Mater ia ls ,

Fabr i cat ion and Erec t ion

KOC Standard for Bas ic Des ign Data

KOC F i re Sa fe ty Regula tions

ENVIRONMENTAL CONDITIONS

T he env i r onmenta l cond i t i ons i n Kuwa i t a re severe . Due regard shou l d be

g i ven t o t he cons i s t en t l y h i gh l eve ls o f so la r r ad i a t i on exper i enced i n Kuw a i t

w h i c h m a y d e v e l o p s u r fa c e te m p e r a tu r e s o f o v e r 8 0 °C ( 176°F) in e xpos ed

meta l s .

Gro u t wo rk sha l l be du rab le a t a deser t l oca t i on under h i gh tempera tu res

and humi d i t y . T he a tmosphere a t t he S i t e i s genera l l y dus t y and co r ros i ve ;

a n d m a y c o n t a i n t r a c e s o f h y d r o ge n s u l ph i de .

Re fe r t o KO C S tandard f o r Basi c Des i gn Da ta (KOC-G-007) , wh i ch

prov i des t he de ta il ed des i gn i n f o rmat i on regard ing t h e env i r onmenta l , s i t e

and u t i l i t y supp l y cond i t i ons p reva i li ng t h rougho u t t h e KOC fac i li t ies .

HEALTH SAFETY AND ENVIRONMENT

T he eng i neer ing cons t ruc t i on shou l d mee t a ll t he app l i cab le Ku wa i t i EPA

Regu l a li ons and shou l d con fo rm to t h e KOC H ea l t h and E nv i r onment (H&E)

g u i d e l i r e s w i t h a v i ew t o p ro tec t i ng i t s pe rsonne l and su r round i ng

e n v i r o n m e n t .

A l l re levant sa fe ty requ i rements o f KOC F ire Safe ty Regula t ions and KOC

Hea l th , Sa fe t y and Env i r onment Managem ent Sy s tem (HSEMS) sha ll be

adhered t o , by t he Con t rac to r , wh i l e app l y i ng t he g rou t i ng t o t he bases o f

equ i pment ( s ) and s t r uc tu ra l f r amew ork me mb ers w i t h i n KOC areas .

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T ECHNICAL REQUIREMENT S

G e n e r a l C o n s i d e r a t i o n s

Genera ll y , grou t ing sha l l be used for severa l purposes in const ruc t ion, to

t r ans fe r t he s t a t i c a nd

/

or v ib ra to r y l oads in a smo oth and even m anner t o

t he conc re te bases

/

f ounda t i ons . T he loads ma y be f r om ro ta t i ng

eq u i pm en tk ) suc h as pumps , compressors , t u rb ines e t c . as we l l as fr om

stat i c equ ipm ent s ) such as heat exchangers , f la res s tacks , co lumns,

e l eva ted p i pe - racks and f r om va ri ous u t i l i ty bu i ld i ngs ma de o f s t ee l

f ram ew ork in p lants and fac i li ti es .

G rou t i r g m ay a l so be app li ed fo r o the r spec i f ic pu rposes i n cons t ruc t i on

such as f o r dens i f i ca t i on o r compac t i on o f so f t so i l s by f i l l i ng p re -bored

holes in spec i f i ed gr id pat terns and by f i l l i ng vo ids , f i ssures in rocks or by

sea li ng c racks i n co nc re te s t r uc tu res such as pavem ents , f ounda t i ons ,

bases, co lumns or i n p lugg ing ho les or cav i t i es in aboveground or

be l ow ground l i qu id r e ta i n ing s t r uc tu res .

Grout i r i g o f th i s spec i f i c nature be longs to a spec ia l ca tegory and sha l l be

se l ec ted on a case by case bas i s as appropr i a t e ; and i s exc l uded i n

a c c o rd a n c e w i t h c l a us e 1 3 o f t h i s S tandard .

Grout ing app l i cab le for c lause

7 1 1

above , sha ll b e com pose d o f ma i n l y

p re -b l ended mate r i a l s o f g raded s i zes w i t h spec i f i c i ng red i en t s t o ach i eve

the g rou tab i l i ty and m i n i m um charac te r is t i cs as desc ri bed b e l ow .

M A T E R I A L R E Q U I R E M E N T S

T v ~ e s e n e r a l l v U s e d

T he t ypes o f g rou t genera ll y used f or t h e i ns ta l la t i on o f equ i pment s ) and

s t ruc tu ra l f r am ew ork mem bers t o t he bases o f conc re te f ounda t i ons sha ll

b e as f i l o w s :

a . Non -shr ink Cem ent i t i ous Grout

b. Epclxy based Gr ou t

N o n - s h r i n k C e m e n t i t i o u s G r o u t

Genera l Requi rements

T h i s t ype o f g rou t ma te r i a l sha l l be non-meta l l i c , and p re -m i xed , f ac to r y -

packed as man u fac tu red by M as te r s Bu il de rs , F i ve S ta r , F os roc or approved

equa l; and sha ll me e t t he f o l l ow i ng requ i rements :

a . I t sha l l rema in fl u id , pumpa ble or pourab le ; and sha l l no t segregate

h a v i n g e x t e n d e d w o r k a b i l it y .

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DOC. N O . KOC C 023

b. It s : d l n o t e x h i b i t an y v i s ib le b l e e di n g t w o ( 2 ) h o u r s a f t e r p la c in g .

c .

I t s ~ a l l h o w n o s hr in ka ge a nd a m a x i m u m o f

4 0

percen t expans i on a t

any t i m e be fo re i n i ti a l se t, wh en t es ted

in

a c c or da n c e w i t h A S T M

C 8 2 7 .

d.

It

sha l l show no sh r i nkage and a max i mum o f 0 .2 pe rcen t expans i on i n

t h e h a rd e ne d s ta te , w h e n t e st e d i n a cc o rd a n ce w i t h A S T M C 1 1 0 7 .

e.

I t s ii a ll s h o w i n it ia l s e t t i m e o f n o t le ss t h a n 6 0 m i n u t e s ( 1 h o u r ), w h e n

t e s t e d i n a c c o rd a n c e w i t h A S T M ( 2 1 91 .

f It shal l be i ron- f ree and ch lor ide- f ree and sha l l conta in no meta l l i c

substances, water- reducing agents, accelerators, super plast ic izers, or

o ther mater ia l s .

g W ater sha l l be c lean and f ree f rom in jur ious amo unts o f o il , ac ids ,

a lka li s, and o the r de l e te r ious mate r ia l s i n accordance w i t h AAS HT O

T 2 6 , A S T M D 5 1 2 a nd A S T M D 5 1 6 .

2 . 2 mini mu^ C o m p r e s s iv e S t r e n g t h ( f c ' )

T he compress i ve s t r eng th o f non-sh r i nk cement i t i ous g rou t sha l l comp l y

w i t h t h e m i n i m u m s t r e n g t h s i n a c c o r d a n c e w i t h A S T M C 1 0 9 m o d i f i e d a s

b e l o w :

a.

f c ' a t 1 d a y ( 2 4 h o urs ) 1 4 N / m m 2 ( 2 0 0 0 p si)

b

f c ' a t

7

d a ys 3 5 N / m m 2 ( 5 0 0 0 p si)

c . f c ' a t 2 8 d a ys 4 9 N / m m 2 ( 7 0 0 0 p si)

8 3

E a w y

ased rout

8.3.1 Genera l Requi rements

T h i s t ype o f g rou t ma te r i a l sha l l be p re -m i xed w i t h epoxy based mate r i a l s ,

and f ac to r y -pack ed as man u fac tu red by Ma s te r s Bu il ders, F i ve S ta r, F os roc

or approved equa l; and sha ll me e t t he f o l l ow i ng requ i rements :

a . I t sha ll be f l owab l e , and sha ll compr i se o f 1 0 0 pe rcen t so li ds sys tem.

b . It s h a l l s h o w n o s h r i n k a g e a n d a m a x i m u m o f 4 . 0 p e r c e n t e x p a n s i o n

w h m t e s te d i n a cc o rd a nc e w i t h A S T M C 5 7 9 a t ta i ni ng t h e m i n im u m

st reng th as pe r c lause 8 .3 .2 o f t h i s S tandard .

c . T h e p e a k e x o t h e r m i c t e m p e ra t u re o f a c y li n d e r o f g r ou t , 5 0 m m

d i a m e te r x 1 0 0 m m h ig h , s ha ll n o t e x c e e d 3 5 C , w h e n t e s t e d a t 2 4 °C

ma ter ia l and a i r temperature .

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d. It shall not exceed a coefficient of thermal expansion of 5 5 x f 0-6mm

mm C, when tested in accordance with ASTM C531.

Minimum Compressive Strength (fc')

The compressive strength of epoxy based grout shall comply with the

minimum strengths in accordance with ASTM C579 as below:

a. fc ' at 1 day

(24

hours) 3 5 N l m m ~ 5 0 0 0si)

b. fc ' at 2 days 5 6 Nlmmj' (8 00 0 psi)

c. fc' at 7 days 77 Nl rn my f 1,000 psi)

Storage

Grout components shall be delivered to the Site in moisture proof sealed

bags. Fags shall be stored in a dry weatherproof cool area, out of direct sun

light and shall be kept w ith in the temperature range of 4°C to 32°C.

Material, which becomes damp or defective shall never be used; and shall

immediately be removed from the Site.

Normally storage time of grout mix should

be limited to 1 0 months; and

shall preferably be used within the time as specified in the written

instructions of the Manufacturer.

ONSTR U T ION REQUIREMENTS

Genera l

Light equipment, pipe supports, and structure bases, wh ich are not subject

to vibratory loads, shall be grouted with a non-shrink cementitious grout.

Grouting under machine base frame(s) shall be done in compliance with the

Machire manufacturer's recommendations; or epoxy based grout shall be

used for vibratory and or heavier loads.

Specific

Grout thickness shall be provided under bedplates and steel-bearing plates

as specified in the KOC approved construction drawings, but the minimum

shall not be less than 5 mm

Grouts (non-shrink type) shall be composed of generally hydraulic cement,

graded fine aggregates, and other ingredients, and shall require only the

addition of mixing water for use.

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DOC. NO . KOC C 023

P a g e 3

of 20 R E V . l

T h e a m o u n t o f w a t e r ( m i n im u m or m a x i m u m ) a s r e c om m e n d e d b y t h e

Manu fac tu re r sha l l be used f o r con fo rmance t o de te rm i ne t he des i r ed f l ow

(cons i s t ency ) and go od w orkab i l i t y .

H o w e v e r , c o n s i s t e n c y t e s ts s h a ll b e c o n d u c t e d t o a n a c c u r a c y o f

5

t o

d e t e r m i n e t h e a m o u n t o f w a t e r t o b e a d d e d f o r t e s t i n g a n d t h e w e i g h t o f

wa te r sha l l be expressed as a ra t i o o f w a te r t o d r y g ro u t m a te r ia l b y we i gh t .

N o n - s h r i n k C e m e n t i t io u s G r o u t

Sur face Preparat ion

a.

A l l con c re te su r f aces t o be g rou ted sha l l be c l eaned b y remov i ng d i r t ,

o i l , g rease, l a i tance, and any o ther fore ign substances. Bo l t ho les and

poc ke t s sha ll b e c l eaned o f f any d i r t and debr is . Sandb l as t and so l ven t

w a s h s h a ll b e d o n e a s r e c o m m e n d e d by t h e m a n u f a c t u r e r .

b . Con c re te su r f aces sha l l be roughened by ch i pp i ng o r b y na il rak i ng wh en

conc re te i s i n p l as t ic s t a te i n o rde r t o ensure a good bond o f g rou t t o

ex i s t ing co nc re te .

c . T he roughened su rf aces sha ll be c l eaned w i t h wa te r and shal l be soaked

for 4 hours p r i o r t o p l ac ing g rou t . C l ean su rf aces sha l l be covered w i t h

p l as t i c shee t s un t i l g rou t i s r eady f o r p l ac i ng . A l l f r ee wa te r shou l d be

remo ved i m med i a te l y p r i o r t o p l ac ing g rou t .

F o rms

a . F o r n s f or f l u i d g r o u t sh a ll b e o f m a t e ri a ls w i t h a d e q u a t e s t re n g t h t o

w i t i s t a n d t h e p la c e m e nt o f g r o u t.

b . F o rms f o r non-sh r i nk cement i ti ous g ro u t sha ll b e t i gh t aga i ns t a ll

sur faces and jo in ts sha l l be sealed w i t h tape. Form o i l sha ll be used for

easy release.

c . F o r rns f o r g rou t sha l l be wa te r t i gh t w i t h chamfe r s t r i ps i n p l ace .

Cau lk ing sha l l be use d on a l l j o in ts .

d . F orm s sh al l b e 1 0 0 m m t o 1 5 0 m m h ig he r t h a n th e b a se p la te w h e n

us ing hyd rau l i c he ad pressure for p lac ing.

e . A i r p ressure re li e f ho l es w i t h a m i n i m um o f 6 .5 -m m d i amete r sha ll be

prov i ded a t eve ry r ecessed base p l a te co rner and t o a l l ow ven t i ng f o r

any i so l a ted h i gh spo t s .

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DOC.

NO. KOC C 023

1 0 . 1 . 3 M i x i n g

a . G r o u t s h a ll b e m i x e d i n a c c o rd a n c e w i t h m a n u f a c t u r e r s

recomm enda t i ons . T h is sha ll be genera l ly b y add i ng g rou t t o t he w a te r

(no*; v i ce -ve rsa ) and m i x i ng f o r b e tw een t h ree (3 ) and f i ve

5)

m i n u te s t o

ob ta i n t he des i red cons i s t ency .

b . Mecha n i ca l ly po wered g rou t m i xe r ( no t conc re te m i xe r ) sha ll be used f o r

me chan ica l mix ing o f grout . For l a rge qua nt i t i es o f grou t ing mater ia ls

g rea te r t han 4 kg t o be m i xed , h i gh shear vane m i xe r sho u l d be used.

c . The mi xe r sha l l be c lean, pre-wet , and dra ined, and essent ia l ly sha ll be

f ree o f ha rdened m or ta r and o the r f o re ign m ate r ia l t ha t can be remove d

w i t h a t r o w e l o r b y r e as o n ab ly s tr ik i n g w i t h a h a m m e r .

d . Re -n i x i ng o f g rou t by add i ng mo re wa te r or r e -m i x i ng o f s t i ff en i ng g rou t

i s no t pe rm i t t ed .

e . I f nscessary t o enab l e g rou t i ng opera ti on t o be ca rr ied ou t con ti nuous l y ,

t he Con t rac to r sha l l make ava i l ab l e su f f i c i en t m i x i ng capac i t y and

l a b o u r . G r o u t h o l d i n g t a n k w i t h p r o v i s i o n t o g e n t l y a g i t a t e t h e g r o u t

shou l d be p rov i ded .

f . T he Con t rac to r sha ll be respons ib l e t o ove rsee t ha t any equ i pment i n

use sha ll n o t b e hazardous i n a phys i ca l o r me chan i ca l wa y t o opera to rs

and o the r pe rsonne l , and t ha t sa fe wo rk p rac t ices sha l l be ca r ri ed ou t a t

a l l t ime s.

10 . 1 . 4 P l a c e m e n t

Grou t i ng sha ll on l y b e ca r ri ed ou t whe n t he s tee l wo rk has been l eve led

and p l umbed , t he base p l a te be i ng suppor t ed by sh i ms a t t he cen te r .

S h i n s s h a ll b e t h e s a m e m a t er ia l as t h e b a s e p la t e .

Grw t sha l l be rap id l y p l aced con t i nuous l y f r om o ne s i de o f base p l a te

on l y i n one d i r ec t i on t o e l im i na te t he en t rapm ent o f a i r.

Anch or bo l t s l eeves o r pocke t s sha ll be g rou ted co mp l e te l y f i rs t ; and

the n grout in g under base p la te sha ll be done to f i ll a ll spaces. Sh ims

used for tem pora ry leve l i ng sha ll be le f t i n p lace.

I f sh i ms sha ll b e rem oved a f t e r t h e g rou t has ha rdened , t he y shou l d be

t rea ted w i t h a l aye r o f g rease f o r ease o f r emova l .

Hydrau l i c head g rou t i ng p ressure sha ll b e ma i n ta i ned b y keep i ng t h e l eve l

o f g r o u t i n t h e h e a d b o x a b o v e t h e b o t t o m o f t h e b a s e p la te . H e a d b o x

s h all b e f i ll e d t o a m a x i m u m l e ve l a n d g r o u t s ha ll b e w o r k e d d o w n t o t o p

o f base p l a te .

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DOC. NO . KOC C 02 REV.1

Finishirg

After grout has reached final set,

t

shall be trimmed back to the required

level.

Curing

a. All exposed areas shall be cured using continuous application of water

or ' ~ i t h et hessian or shall be done as specified by manufacturer's

recommendations.

b. Forms shall remain in place for 2 4 hours.

c. Necessary measures shall be taken to mainta in temperature of base

plate and supporting concrete between 4°C and 32°C during grouting;

and for a minimum of 12 hours after placing.

Limitations

a. A t ambient temperatures above 35 C, the mixed grout shall be placed

immediately af ter mixing. Water wi th a temperature less than 20°C

should be used for mixing.

b. Grouts should not be placed in any non-restrained situat ion i.e. base

plale plinth etc. Failure to comply may lead to crack development in the

grout.

c. Placing of grout shall be avoided when the ambient temperature exceeds

43°C.

Epoxv Based G rout

Epoxy based grout shall be prepared and installed in compliance with the

manufacturer's recommendations as specified in the catalogues and

instructions.

Base Set t ing

Base sstting shall be carried out in sequence after aligning the structures

and equipment prior to grouting the anchor bolts, sleeves or pockets and

bearing and sliding plates as below.

Anchor Bolts

Anchor bolts for fixed ends of horizontal vessels and exchangers shall be

tightened down; and nuts on sliding supports shall only be finger tightened

before backing of f by 1/3 turn. Locking nuts shall be used to hold in this

position to allow for free sliding.

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Stee l 8ea r ing and S l id ing P lates

A t s l ide p l a te l oca t i ons , ca re sha ll be t aken i n pa r t icu l a r no t t o f o r ce g rou t

under any p ressure ben ea th t he p l a te so as t o cau se de fo rm at i on o f t he

p la te .

Vesse l s w i t ho u t s l i de p l a tes

For smal l vesse ls and exchangers not requ i r i ng s l i de p la tes , bot tom of bases

sha ll be g reased t o p reven t adhes ion o f g rou t so t h a t vesse l can be removed

eas i ly i n fu ture .

TESTS ,AN D REPORTS

G e n e r a l

The Cont rac tor sha l l be respons ib le for prepar ing, s tor ing, cur ing and

t ranspor t i ng t he t e s t samp l es t o t he l abora to ry f o r t es t i ng .

Grou t sha ll deve l op i t s r equ ired compress i ve s t r eng th i n accordance w i t h

A S T M 121

09

mo d i f i ed fo r packaged g rou t s o f non-sh ri nk t ype .

Three 3) t es t cubes sha l l be made f o r each day f o r g rou t i ng . T es t s sha ll be

m a d e o f o n e 1 ) c u b e a t t h e i n te r v a ls o f

24

hours , 7 d a y s a n d 8 days.

T e s t R e p o r t s

A l l l abc f ra tory tes ts sha l l be furn ished w i th in

7

hours a f t e r t he t es t s be i ng

cond uc ted f r o m th e repu ted t es t i ng l abora to r y , approved by KOC.

Q U A L I T Y C O N T R O L

ualitv

lan

T he Con t rac to r sha l l pe r f o rm a t d i f f e ren t s t ages o f t he Work , a l l t he

respons ib i l i t i es and dut ies o f qua l i t y cont ro l by ver i f y ing, i nspect ing and

t e s t in g t h r o u g h h i s d e di ca te d q u a l i ty c o n t r o l s y s t e m i n c o n f o r m i t y w i t h

c l ause 13 .0 o f t h i s S tandard , and sha l l me e t f u l ly t h e qua l i ty con t ro l

r equ i rements o f t h i s w ork as desc ri bed i n t h i s S tandard .

The Contractor shal l prepare and submi t a detai led qual i ty p lan for KOC

approva l pr ior to implementat ion. The qua l i t y p lan sha l l cons is t o f the

fo l l ow i ng :

a.

insp ect io n and Tes t P lan ITP)

The ITP shal l l i s t the sequence of a l l ver i f i cat ion, inspect ion and test ing

ac t i v it i es f o r t he W ork .

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Tbe p lan sha ll deta i l submi t ta l s o f a ll the te s t cer t i f i ca tes for each

cons ignment o f mater ia l s as requ i red for records and approva l pr ior to

c ~ m m e n c i n gh e w o r k .

The plan shal l a lso inc lude inspect ion of s torage faci l i t ies, formwork,

c w e c t pos i t ion i ng and p lacement o f g rou t ing as we l l as tes t i ng o f a ll

samples in a sequent ia l order , showing the f requency o f cont ro l tes ts ,

th 4 accep tance cr i te ria , the govern ing s tandards

/

codes and whether

a

dc cu m en t or repor t is produced for each ac t i v i t y .

b. Prs- inspe ct ion Me et ing (PIM)

PIW sha l l be he ld by the Cont rac tor w i th KOC before commenc ing the

work . Dur ing the P IM the Cont rac tor and KOC wi l l rev iew and f i na l i ze

tho mark-up o f the ITP, conf i rm the requ i rements for w i tness ing

W),

surve il lance (S), moni tor ing ( M ) , rev iew ing (R), i n t he p l an . T he

approved qua l i t y p lan sha l l be s t r i c t l y adhered to throughout the ent i re

w w k , i nspect ion, and tes t ing per iod.

QU LITY

SSUR NCE

T he C on t rac to r sha ll opera te a qua l i t y sys tem p re fe rab ly based on SO

9000 seri es o f s t andards t o sa t i s fy t h e requ i rements o f t h i s S tandard . T he

Cont rac to r sha l l demons t ra te comp l i ance by p rov i d i ng a copy o f t he

accred i ted cer t i f i ca te or i t s qua l i t y manual . Ver i f i ca t ion o f the Cont rac tor

qua l i t y sys tem i s normal l y par t o f the pre-qua l i f i ca t ion procedure and i s ,

t he re fo re , no t de ta i l ed i n t he co re t e x t o f t h i s S tandard .

DOCUMENT TION

Al l cor respondence, i ns t ruc t ions , data sheets , draw ings or any o ther wr i t ten

in format ion sha l l be in Engl i sh language.

In case o f dua l l anguages, one

language shal l be Engl ish.

A l l d imens ions , un i t s o f mea surement , phy s ica l con stan ts e tc . sha ll be in

SI

un i t s un l ess o th e rw i se spec if ied .

(Nomina l bore p ipe s i zes to be genera l l y

m e n t i o a e d i n i n c h e s ) .

A l l docu me nts ( t ex t , da ta shee t s, spec i f ica t i ons e tc . ) sha ll be p rov i ded w i t h

e l ec tron ic f i les i n t he approved and w i de l y used so f tw are (M S Word , Excel,

Au to Cad e t c. ). A l l ca l cu l a t ions sha lt be sub mi t t ed i n approved and w i de l y

used so f tw are (s ) ag reed upon b y KOC.

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DOC.

NO

KOC C 023 Page 18of 20 REV l

14 2 Deliverables

The Contractor shall submit the necessary documents as a minimum to

KO

for review and acceptance as given below, but is not limited to the

following only:

a. Ma ufac ture r s catalogues

b Ma1:erial Samples

c .

Test Results

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Page 19 of

20

REV.1

ACKN OWLEDGEME NT

This Standard has been approved by th e Standards Techn ica l C omm i t tee (STC)

cons ist ing o f tk e fo l lowing :

M r. A/Redha A -Haddad Standards Tea m

M r . M o h a m m a d E m a m

Insp. Corr. Team (S EK)

M r . S. Kum ar Standards Team

Mr. Henry S. Hi l l

Opns. Tech. Svcs Team (SK)

Mr . Kha l id A l -Ahmad

Gen. Proj . Team

Mr s. Amina Rajab Design Team

Mr. Kha la f Hamada Des ign Team

M r. N. Ram anathan Ma jor Projects-EFP

M r. Daniel Pino Uti l i t ies Tea m

M r. Al i Hassan Al -Fai lakawi HSES Team

Dr. Mod is taba Aragh i Insp . Corr Team (N WK )

Mr . Abdul Az iz Akbar Proj. M g m t. Team (NK)

Mr . Moataz Kha la f In fo rmat ion Sys tem Team

Chai rman

Deputy Cha irman

Secretary / Member

Member

M e m b e r

Member

Member

Member

Member

Member

Member

Member

Member

The draf t of th is Standard has been c i rculated to the KOC User Teams for thei r

rev iew; and responses we re rece ived f rom the fo l lowing : -

ENGINEERING GR OU P AHMA DI SERVICES GROUP

Team Leader Cm s t ruc t i on

Team Leader General Projects

MAJO R PROJECTS GRO UP

Tea m Leader Project Design

Team Leader Uti l i t ies

HSE GROUP

Team Leader Project Suppo rt

Team Leader Safe ty

INDUSTRIAL SERVICES GR OUP

OPERATIONS GROU P SK)

Team Leader Insp. Corr . (S E K)

Tea m Leader Opns. Tech. Svcs

Team Leader Insp. Corr. (N W K)

Tea m Leader Gas Opns.

OPERATIONS GROUP WK)

DIV IDED ZONE G ROUP

Team Leader Maintenance

Te am Leader Proj. Engg. Faci li ties

OPERATIONS -GROUP NKJ

OPERATIONS GROUP EK)

Team Leader Frod. Op ns.

Team Leader 0pns .Tech. Svcs .

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Task orce Responsible for this tandard

The prepara t ion o f th is Standard has been ent rus ted by the Standards Techn ica l

Com mi t tee STC) to t he Task Fo rce No . TF-C/07 ) compr i s i ng o f t he fo l l ow ing

members :

Mr . S. Kumar Standards Team

TF Leader

/

Autho r Te l. No . 67 4 0 7

Mr . Mo hd . Java id Des ign Team Mem ber

Te l . No. 613 2 2

Mr . Ahm ed A l -Fana in i

Ex po rt Fac. Proj. Me mb er

T e l . N o . 6 6 9 8 7

M r . H u ss a in A L a z z a f G e n. P r oje c ts M e m b e r T el. N o . 6 3 2 2 6

M r . Maged Ma d- P ro jec ts Des ign

M e m b e r T el. N o . 6 6 3 8 9

KOC_C_023 R1

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