Method Statement for Application of ISOLA N-S Grout Material

CONTENTS

1. Purpose

• Scope of Work

• Definitions

• References

• Materials

• Tools, Plant  & Equipment

• Safety

• Prior Activities

• Procedure

1. Responsibilities

1. Attachments

1. Purpose

1.1       To ensure that the application of ISOLA N-S Grout Material is executed safely and in accordance with the contract requirements and that all quality assurance/ control activities are conducted in a systematic manner, works are inspected and conformance is verified and documented.

• Scope of Work

• This procedure is applicable to the following works associated with the Project titled, “New 2K Runway – Main Runway Works” – Contract Number NRTW-1008-CN.

• This method statement outlines the procedures to be followed in the application of ISOLA N-S Grout Material for grouting around the storm water pipes, connecting to cast-in-situ and/or precast manholes, and under precast cover slabs or at any other locations shown on the contract drawings and as directed by the Engineer.

• Definitions

• CM                  Construction Manager
  • SE                   Site Engineer
  • CS                   Chief Surveyor
  • ME                   Material Engineer
  • ESHO              Environmental, Safety, and Health Officer
  • ITP                  Inspection and Testing Plan
  • AHA                 Activity Hazard Analysis
  • JHA                 Job Hazard Analysis

• References

• Specifications:             Volume 3 – Section 9 – Part A – General, Civil and Mechanical Infrastructure

• Drawings:                    Volume 2 – Section 8 – Part B – Civil, Mechanical and Navaids

• BOQ:                           Bill No. 7

• Materials       

• ISOLA N-S Grout Material (Non-Shrink, Non-Metallic)
  • ISOREX UMO Oil Based Form Release Agent
  • ISOCURE WB Curing Compound
  • Joint Sealant
  • Water (complying to Clause 200.12A of contract specifications)
  • Formwork/Shuttering
  • Foam Rods (if required)
  • Hessian Cloth
  • Polythene Sheet
  • Warning Tapes
  • Safety Barrier
  • Traffic Cones

• Tools, Plant & Equipments:

• Surveying Instruments
  • Ladders
  • Light Towers (if required)
  • Electrical Grinder / Saw
  • Generator
  • Air Compressor
  • Hand Tamping Tools(for cleaning and surface preparation)
  • Mechanical Mixer (Mortar Mixer with Moving Blades)
  • Trowel
  • Hopper
  • Water Measuring Jar
  • Personal Protective Equipment

• Safety

• Prior to the commencement of any activities, the workforce will receive an induction talk on the project site safety requirements. This induction talk will include both activity safety issues, as well as general safety requirements.

• Front line supervisor will ensure that Personal Protective Equipment is worn by site personnel at all times during construction activities.

• Heat Stress Training will be provided.

• Adequate cool drinking water, shade, and salt water tablets will be in place.

• Plant and Equipment will be provided with back-up alarms, lights, and all other applicable safety devices.

• For AOA work, safety requirements as defined per Section 107 will be implemented. Specific safety training will be provided to personnel for AOA work.

• Prior Activities

• Prior to grouting, it will be ensured that all necessary equipment and tools are available.

• All loose dust and dirt from the concrete substrate will be removed using an air compressor.  The surfaces will be roughened by chipping or other mechanical means to assure bond of the grout to existing concrete.

• It will be ensured that the surfaces to be grouted shall be clean, dry and free from dust, grease, oil, dirt laitance and other contaminants.

• The substrate will be saturated with water for at least two hours before placing grout, but ensuring that there is no free standing water just before placing grout.

• All of the necessary shuttering/formwork will be prepared and made ready.  Forms will be treated with ISOREX UMO form release agent.

• Consideration will be given to carry the grouting operations during the early morning or late in the afternoon when ambient temperature is decreasing.

• Procedure

• Grouting Around Drainage Pipes

• Construct and install a temporary shutter with a hole in the middle to allow the pipe to pass through both on the placing and opposite side.  On the placing side, allow an opening of 50mm at the top from which the grout can be poured into.

• Seal any gap between the pipe periphery and shutter with joint sealant.  Also, seal the edges of the shutter with joint sealant to ensure that grout will not leak.  Ensure that the shutters are strong, braced and absolutely leak-proof.
  • Calculate the total volume of grout that will be required to fill the hole.  Put the required amount of water into the mixer, then slowly add grout while mixing. The range of mixing water can be varied between 3.40 to 4.50 litres per 25 kg bag of grout.  As a general rule, always start with the minimum water and add additional water to obtain the desired consistency.  The mixing water should be accurately gauged.  Mix for 3 to 5 minutes until mixture is smooth and homogeneous.  Ideally, the grout should be poured in one continuous operation.  If this is not practical, ensure that the mixing and pouring sequence in between batches is within 15-20 minutes.

• Immediately pour the grout through the headboard allowing the grout to flow into the hole.  Final grout level should be at least 20mm above the top of the hole.

• Allow the grout to harden slightly than cut-off the excess portion with a trowel (depending on ambient conditions, grout can be cut-off within 4-5 hours).  Finish the grout flush with the pit concrete surface.

• Cover the exposed section with a wet Hessian cloth and polythene sheet.

• Shutters can be removed after 24 hours and exposed grout cured with ISOCURE WB curing compound.

• After the above works are completed and approved by the Engineer, waterproofing and backfilling operations will commence in accordance with the approved method statements for these activities.

• Grouting Under Precast Cover Slabs

• Place shims, of appropriate height, on top of the precast bottom panel.  Place the top precast cover slab on top of the shims.  Ensure that the four pins, protruding from the bottom of the precast cover slab, fit in to the sleeve sockets on top of the precast bottom panel.

• Construct and install a temporary shutter both on the placing and opposite side.  Alternatively, foam backing rods may be used on the inside for gaps less than 30mm.  On the placing side, allow an opening of 50mm at the top from which the grout can be poured into.

• Seal the edges of the shutter with joint sealant to ensure that grout will not leak.  Ensure that the shutters are strong, braced and absolutely leak-proof.

• Calculate the total volume of grout that will be required to fill the hole.  Put the required amount of water into the mixer, then slowly add grout while mixing. The range of mixing water can be varied between 3.40 to 4.50 litres per 25 kg bag of grout.  As a general rule, always start with the minimum water and add additional water to obtain the desired consistency.  The mixing water should be accurately gauged.  Mix for 3 to 5 minutes until mixture is smooth and homogeneous.  Ideally, the grout should be poured in one continuous operation.  If this is not practical, ensure that the mixing and pouring sequence in between batches is within 15-20 minutes.

• Immediately pour the grout through the headboard allowing the grout to flow into the hole.  Final grout level should be at least 20mm above the top of the hole.  This will ensure that all of the gaps, including the sleeve sockets, are completely filled with the grout.

• Allow the grout to harden slightly than cut-off the excess portion with a trowel (depending on ambient conditions, grout can be cut-off within 4-5 hours).  Finish the grout flush with the pit concrete surface.

• Cover the exposed section with a wet Hessian cloth and polythene sheet.

• Shutters can be removed after 24 hours and exposed grout cured with ISOCURE WB curing compound.

• After the above works are completed and approved by the Engineer, waterproofing and backfilling operations will commence in accordance with the approved method statements for these activities.

1. Responsibilities

1. The CM will coordinate with SE and ensure that all necessary resources to implement the approved method statement, JHA, and AHA have been allocated to the task.

1. The SE will ensure that the site preparation activities are conducted according to the approved method statement, JHA and AHA.  The SE will also ensure that all in-situ tests, as required by the ITP, are implemented.

1. The ME will ensure that the materials being used are in accordance with the project specifications and the approved material submittals.

1. It is the site supervisor’s responsibility to organize the work in a safe manner to ensure that safety and protective equipment are being properly utilized.  He must also ensure that the AHA and JHA are implemented and the approved method statement procedure is followed and the ITP is applied.