PepsiCo-Green Field Project

Construction Methodology- Grouting Work

Revision No. : 00 Issue Date :23.11.2024

Method statement for Grouting Work

CONTENTS

Sr. No. TITLE PAGE NO.

1 Introduction 2
2 Scope of work 2
3 Reference and standard 2
4 Work programmed 2
5 Equipment and material 2
6 Methodology 2-5
7 HSE - Health, Safety and Environment 5-7

Vendor PMC Client

Sign

Name

Date

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 PepsiCo-Green Field Project

Construction Methodology- Grouting Work

Revision No. : 00 Issue Date :23.11.2024

1. INTRODUCTION :
The method statement describes work procedure to be followed for Grouting Work to be
executed at PepsiCo green Field project by Semac Consultants Ltd.

2. SCOPE OF WORK COVERS REQUIREMENT OF MATERIAL AND GROUTING WORK FOR

WATER RETAINING STRUCTURE AND SPECIAL STRUCTURE :
1. Drawing Confirmation
2. Material Confirmation
3. Method of work
4. Inspection of work
5. Documents and approval
3. REFERENCE AND STANDARD:
1. GFC Drawing
2. (BS 1881-Part 116: 1983), (BS 4551,1998)
3. Specification
4. WORK PROGRAMME:
The grouting work shall be carried out in accordance with the approved work schedule.

EQUIPMENTS& MATERIAL:
Below mentioned is the list of Equipment and Material used for work:
1. Vessel for mixing
2. A heavy duty slow speed drill.
3. Formwork material
4. Foam rubber strip or mastic sealant.
6. METHODOLOGY:
6.1 Drawing confirmation:
1) Study the specification required for grouting work purpose which are approved from
client.
6.2 Material Confirmation:
6.2.1 Grouting Material:

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 PepsiCo-Green Field Project

Construction Methodology- Grouting Work

Revision No. : 00 Issue Date :23.11.2024

1) Before use of grouting material, it should be confirm that material is approved from
client.
2) Before use of material, it should be in dry state.
6.2.2 Mixing water:
1) Water should be clean & from a good source as suggested in IS 456/2000.
6.3 Method of work:
6.3.1 Preparation:
6.3.1.1 Foundation surface:
1) The substrate surface must be free from oil, grease or any loosely adherent material.
2) If the concrete surface is defective or has laitance, it must be cut back to a sound base.
3) Bolt holes and fixing pockets must be blown clean of any dirt or debris.
6.3.1.2 Pre-Soaking:
1) Several hours prior to placing, the concrete substrates should be saturated with fresh
water.
2) Immediately before grouting takes place any free water should be removed with
particular care being taken to blow out all bolt holes and pockets.
6.3.1.3 Base Plate:
1) It is essential that this is clean and free from oil, grease or scale. Air pressure relief holes
should be provided to allow venting of any isolated high spots.
6.3.1.4 Formwork:
1) The formwork should be constructed to be leak-proof. This can be achieved by using
foam rubber strip or mastic sealant beneath the constructed formwork and between
joints.
6.3.1.5 Unrestrained surface area.
1) Generally the gap width between the perimeter formwork and the plate edge should not
exceed 150mm on the pouring side and 50mm on the opposite side. It is advisable,
where practical, to have no gap at the flank sides.

6.3.2 Mixing and Placing:

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 PepsiCo-Green Field Project

Construction Methodology- Grouting Work

Revision No. : 00 Issue Date :23.11.2024

a) Mixing:
1) For best results a mechanically powered grout mixer should be used. When quantities
up to 50 kg are used, a heavy duty slow speed drill (400-500 rpm) fitted with a paddle
is suitable. Larger quantities will require a heavy duty mixer.
2) To enable the grouting operation to be carried out continuously, it is essential that
sufficient mixing capacity and labor are available. The use of a grout holding tank with
provision to gently agitate the grout maybe required.
b) Consistency of grout mix.
1) The quantity of clean water required to be added to a 25kg bag to achieve the desired
consistency is given below:
Pourable: 4.125 liters
Flowable: 4.500 liters
2) The selected water content should be accurately measured into the mixer.
3) The total content of the Conbextra GP2 (T) bag should be slowly added and continuous
mixing should take place for 5 minutes.
4) This will ensure that the grout has a smooth even consistency.
c) Placing:
1) At 30°C place the grout within 20 minutes of mixing to gain full benefit of the
expansion process.
2) Conbextra GP2(T) can be placed in thicknesses up to 100mm in a single pour when
used as an under plate grout.
3) For thicker sections it is necessary to fill out Conbextra GP2 (T) with well graded silt
free aggregate to minimize heat buildup. Typically a 10mm aggregate is suitable. 50-
100% aggregate weight of Conbextra GP2 (T) can be added.
4) Any bolt pockets must be grouted must be grouted prior to grouting between the
substrate and the base plate.
5) Continuous grout flow is essential. Sufficient grout must be prepared before starting.
The time taken to pour a batch must be regulated to be time to prepare the next one.

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 PepsiCo-Green Field Project

Construction Methodology- Grouting Work

Revision No. : 00 Issue Date :23.11.2024

6.3.3 Curing:
On completion of the grouting operation, exposed areas should be thoroughly cured. This
should be done by the use of concure WB curing membrane, continuous application of
water and/or wet hessian.
6.4 Inspection of grouting work:
6.4.1 Inspection during preparation:
1. Inspection to be executed by KIPL.
2. The substrate surface must be free from oil, grease or any loosely adherent material.
3. Bolts holes and fixing pockets should be blown clean of any dirt or debris.
4. Several hours prior to placing, the concrete substrates should be saturated with fresh
water, Immediately before grouting takes place any free water should be removed with
particular care being taken to blow out all bolt holes and pockets.
5. The formwork should be constructed to be leak-proof. And joints should be closed by
using foam rubber strip or mastic sealant.
6.4.2 Inspection during mixing:
1. Mixing of water should be accurately measured into the mixer.
2. Quantity of water in mixture should be maintain as given below:
Pourable: 4.125 liters / 25 kgs of GP2
Flowable: 4.500 liters / 25 kgs of GP2
3. The total content of the Conbextra GP2 (T) bag should be slowly added and continuous
mixing should be done for 5 minutes.
6.4.3 Inspection during placing:
1. Place the grout within 20 minutes of minutes of mixing.
2. It can placed in thicknesses up to 100 mm in a single pour when used as an under plate
grout.
3. For thicker sections, typically a 10mm aggregate is suitable with 50-100% of weight of
Conbextra GP2 (T) can be added.
4. Continues grout flow is essential.

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 PepsiCo-Green Field Project

Construction Methodology- Grouting Work

Revision No. : 00 Issue Date :23.11.2024

6.4.4 Inspection of Curing:

1. After grouting, exposed area should be cured with continuous application of water
and/or wet hessian.
6.5 Documents and Approval:
1. RFI - Request for Inspection
2. Marking Plan
3. Work Checklist
7.0 HSE – HEALTH, SAFETY AND ENVIRONMENT:
All necessary precautions shall be taken in accordance with HSE Plan (IS- 3764).
7.1 Risk Identification:
During the whole process of work the following risks are foreseen:
1. The risk of accidents caused by machinery and equipment.
2. The risk of traffic accidents during mobilization and demobilization of equipment and
material.
3. The risk of accident between Grading and dump truck delivering road work material
and public vehicle or persons.
4. The risk of accident caused by improper arrangement of road sign.
7.2 Risk Management:
ASEPLShall comply with all the necessary mitigation measure as stated in job safety analysis.
The risk management can be separated into general safety consideration and those that are
particularly applicable to the actual work at site

A. General safety considerations:

The Following safety precautions shall be followed during construction.
1. All the workers shall wear proper personal protective equipment.
2. All the workers shall be trained and safety induction shall be imparted to them
before the commencement of work at site.
3. Daily tool box talk shall be carried out for mutual understanding of work.

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 PepsiCo-Green Field Project

Construction Methodology- Grouting Work

Revision No. : 00 Issue Date :23.11.2024

4. Regular or daily check of equipment prior to use shall be carried out.

5. A competent site supervisor shall be present at all time during work.
6. A first aid person shall be present at site with first aid kit.
7. All record of operator and plant certificate shall be kept on site at all the times.
8. Emergency call number shall be posted on site for contact in emergency.
9. Proper illumination provide on working area.
B. Particular safety consideration:
The following safety precautions shall be taken in particular to filling work.
1. Accidents Caused By Machinery
1. Workers shall not be allowed to enter working radius of operating of heavy
vehicles such as excavator, JCB etc.
2. Incoming and outgoing traffic shall be directed and managed by appointed
signalman.
3. Spillage from truck shall be controlled by prevention of overloading.
2. Hazards by Other means:
1. IS marked approved respirators should be used when necessary.
2. Impervious gloves should be worn to prevent contact with the skin. In wet and
muddy conditions, the gloves may need to be tapped to prevent any moisture
from getting in the top of the gloves. In some wet and muddy conditions, gloves
with long gauntlets may be needed to protect the forearm and clothing.
3. Tight fitting goggles should be worn to protect form dusts and liquids, when it is
necessary to work in conditions where employees can be exposed to dust.