METHOD STATEMENT OF GROUTING FOR CASTING CAR RAILS SLAB IN AREA 3 CASTING AREA

NSH- ASP DOC-1093 METHOD STATEMENT OF GROUTING

FOR CASTING CAR RAILS SLAB IN AREA 3 CASTING AREA

JOB NO. 25457-4200-HC2-DB00-0001 (ANODE RODDING SHOP )

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INDEX

1. SCOPE

2. PURPOSE

3. REFERENCES

4. RESPONSIBILITIES

5. RESOURCE PLAN

6. EXECUTION PLAN

7. SAFETY PLAN

8. ATTACHMENT




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1. SCOPE This method statement covers the sequence of work activities required for

the grouting of Area 3 casting car rails slab in RAS AL KHAIR ALUMINUM

SMELTER PROJECT.

2. PURPOSE The purpose of this method statement is to ensure all the activities shall be

carried out in a neat, efficient manner, assuring satisfactory / proper operation and

to outline the critical items which require special attention of execution team while

carrying out all works with compliance to Project requirements.

3. REFERENCES The latest revision of the following Project Specification and documents shall

be used as references and is part of this Method Statement in the execution work.

25457-0000-3PS-DB00-0001 rev. 001 Concrete Work

25457-0000-3PS-DG01-0001 rev. 001 Reinforcing steel, embedded items and miscellaneous concrete accessories

Sikagrout 212 Material Technical Data Sheet and MSDS

KEMPE IFC Drawings

6684-522-04, 6684-522-04-001, 6684-522-06, 6684-181

Third Party Compressive Strength Result




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4. RESPONSIBILITIES

Project Manager shall be responsible for the overall implementation of the

company HSE & QA/QC plan and ensure effective execution of works in

accordance with Project Specifications.

QA/QC Manager shall oversee all the activities, to ensure all activities are in

conformance with the Quality plan and Project Specifications.

Construction Manager shall be responsible to give correct instructions to

supervisor for implementing the Project QA/QC Plan and HSE Plan.

Supervisor shall monitor the execution of all works and submit IRF in time 24

hours prior to inspection.

Foremen shall lead the work force and workmanship during the execution of the

works.

QA/QC Engineer shall ensure that all records pertaining to the particular works

shall be maintained.

QC Inspector shall ensure that all works are carried out as per IFC Drawing,

Project specifications and Standards.

Safety team shall ensure that all activities carried out as per Project HSE Plan

and Standards.




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5. RESOURCE PLAN

Manpower

NSH shall adequatly provide the resource for execution as follows:

Engineers, Foreman, Mason, Carpenter, Skilled Helpers, and Surveyor &

Assistant.The above workers are designated to every particular function they

have to act to.

Tools and Equipments

Required hand tools and other accessories which shall be put in place prior to

start the job.

6. EXECUTION PLAN

Chip / scabble the existing slab surface accurately to alignment, dimension and

depth required by the IFC drawings.

Scabbling shall be carried out by using Hilti chipping machine with great care.

Prior to grouting QC Inspector will inspect the proper surface preparation of

existing slab, isolation joints and expansion joints required by the drawings.

Pre soaking into the area to be grouted is required.

If the inspection is satisfactory proceed with the grouting.

Bulking of Sikagrout212 is possible by adding a dry single size and clean

aggregate. Sampling and compressive testing already conducted by third party.

(See attached third party compressive strenght test result)




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Mixing Ratio

Sikagrout212 10 mm size aggregate Water Consistency

25 kgs. 8 kgs. 3.5 liters Highly flowable

(maximum flow)

Placing, mixing & curing of grouting materials Sikagrout212 shall be carried out as

per the manufacturers instructions.

Trim and clean excess grouts.

Sampling by third party.

7. SAFETY PLAN

Safety of men and materials is a high priority for NSH. A brief note of the safety

strategy is given under:

All the activities will be envisaged a week in advance and job safety requirements

will be worked out by analyzing the likely hazards and resorting to preventive

measures. A Job Safety Analysis (JSA) is thus carried out.

At a micro level, an analysis of likely hazards will be done for everyday activities

and specific tasks will be assigned to the workers to ensure that the preventive

measures are taken. This is called Safety Task Analysis Risk Reduction Talk.

(STARRT).




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Proper housekeeping shall be maintained.

Proper Hard barricade and Sign boards shall be provided as required.

100 % tie off on the elevated areas.

Check list of equipments shall be maintained and monitored every day.

8. ATTACHMENT

Sikagrout 212 Technical Data Sheet and MSDS.

Compressive Strenght Test Result by Third Party.

******** End

Product Data Sheet Edition 1, 2007 Identification no. Provisional Sikagrout 212

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Sikagrout 2121

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Sikagrout 212 Cementitious, High Early Strength, Non-Shrink Precision Grout

Product Description

SikaGrout-212 is a pre-bagged, cementitious, precision grout that expands in twostages to sufficiently counteract the plastic shrinkage normally associated withcement grouts. Suitable for use in tropical and hot climatic conditions.

Uses SikaGrout-212 precision grout is used for grouting in the following: Machine foundations Columns in pre-cast construction Concrete anchors Cavities, gaps and recesses Base plates Structural concrete repairs

Advantages SikaGrout-212 is an easy to use grout requiring only the addition of water. It offersthe following beneficial properties:

Easy to mix Good flow characteristics High early strength Adjustable consistency High final strength Non shrink Non corrosive and Iron free

Standards ASTM C1107 and CRD- C 621-83

Product Data

Type Mixture of Portland Cement and graded aggregates

Form Grey Powder

Packaging 25 kg bag

Storage Condition Store in a dry area between 5C and 35C. Protect from direct sunlight

Shelf life 12 months minimum from production date if stored properly in original unopenedpackaging

Technical Data

Consistency Water per 25 kg bag Water/Powder Ratio

Plastic consistency 2.80 - 3.00 lt. 0.11 0.12

Flowable (max. strength) 3.00 3.25 lt. 0.12 0.13

Mixing Ratio

Highly flowable (max. flow) 3.25 3.50 lt. 0.13 0.14

Density ~2200 kg/m3 (fresh mortar)

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1 day 3 days 28 days

Compressive Strength (ASTM C109)

~ 30 N/mm ~ 40 N/mm ~ 60 N/mm

Flexural strength (BS4551) 8-10 N/mm

Mechanical Strengths (W/P=0.13), at 250C

Bond Strength (Pull off) ~ 2 N/mm

Thickness Minimum = 10 mm, Maximum = 75 mm per pour

E-Modul (static) ~ 37000 N/mm

Thermal Expansion Coefficient

Approximately 12x10-6 m/m per C

Expansion 0.025 - 0.10% (after 28 days) (CRD C 621)

Application Details

Consumption For 1 mm thickness per m2 : 2kg of powder

Substrate preparation Concrete surfaces should be clean, sound and free from oil, grease, cementlaitance and all loosely adhering particles. Absorbent surfaces should be saturatedthoroughly. Metal surfaces (iron and steel) should be free from scale, rust, oil andgrease.

Mixing Water is added to the pre-mixed powder to suit the consistency required, as per themixing ratio table above. Mix mechanically with a slow speed drill (max. 500 rpm)for at least 3 minutes and until a smooth even consistency is achieved.

Application Before pouring, however, let the mixed grout stand for approximately 5 minutes after mixing to allow entrapped air to escape. Pour the mixed grout intothe prepared area such that the grout has the shortest distance to travel. Ensurethat air displaced by the grout is allowed to escape. When carrying out base plategrouting, ensure sufficient head of pressure is maintained to keep mortar flowing. Exposed areas of the mortar surface should be kept as small as possible.

Curing Treat exposed surfaces with Antisol-E Curing Compound or use other approvedcuring methods.

Cleaning Clean equipment and mixer immediately after application with water. Hardenedmaterial can only be removed mechanically.

Remarks Use SikaGrout-212 for grouting only. Ensure formwork is secure and watertight to prevent movement and leaking duringplacing and curing. Where maximum thickness exceeds 75 mm, consider the use of Sikacrete 114. At high temperatures use chilled water for mixing to keep grout temperaturebelow 25C. In hot weather, base plates and foundations must be shaded from direct sunlight. Condition bags of grout prior to use At cooler temperatures use warm water for mixing to keep grout temperatureabove 25C. Depending on requirements and site conditions, the addition of up to 100% of, dry,single size and clean aggregates is possible. Trials are recommended to confirmthe suitability of aggregates to be employed. For additional information on SikaGrout-212 or other grouting materials contact ourTechnical Services Department.

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Safety

Precautions Accidental splashes to the skin must be washed off with water and soap. Accidental splashes to the eyes or mucous membrane must be rinsed with cleanwarm water. Seek medical attention without delay. Skin barrier cream, safety goggles and rubber gloves are recommended.

Ecology Do not dispose of into water or soil but according to local regulations.

Toxicity Non-toxic under the relevant Swiss health and safety codes.

Transportation Non-hazardous.

Legal notes The information, and, in particular, the recommendations relating to the applicationand end-use of Sika products, are given in good faith based on Sikas currentknowledge and experience of the products when properly stored, handled andapplied under normal conditions. In practice, the differences in materials,substratum and actual site conditions are such that no warranty in respect ofmerchantability or of fitness for a particular purpose, nor any liability arising out ofany legal relationship whatsoever, can be inferred either from this information, orfrom any written recommendations, or from any other advice offered. Theproprietary rights of third parties must be observed. All orders are accepted subjectto our current terms of sale and delivery. Users should always refer to the mostrecent issue of the Technical Data Sheet for the product concerned, copies of whichwill be supplied on request.

Sika Gulf B.S.C (c) Bldg.925, Road 115, Sitra Area 601. P.O.Box 15776 Adliya, Kingdom of Bahrain Tel: ++973 17 738188, Fax : ++973 17732 476 Email; [email protected] Web http // sika com bh

M A T E R I A L S A F E T Y D A T A S H E E T

Page 1 of 5

Sika Grout 212

HMIS

HEALTH *2

FLAMMABILITY 0

REACTIVITY 0

PERSONAL PROTECTION C

1. Product And Company IdentificationSupplier ManufacturerSika Corporation Sika Corporation201 Polito Ave 201 Polito AveLyndhurst, NJ 07071 Lyndhurst, NJ 07071

Company Contact: EHS Department Company Contact: EHS DepartmentTelephone Number: 201-933-8800 Telephone Number: 201-933-8800FAX Number: 201-933-9379 FAX Number: 201-933-9379Web Site: www.sikausa.com Web Site: www.sikausa.com

Supplier Emergency Contacts & Phone Number Manufacturer Emergency Contacts & Phone NumberCHEMTREC: 800-424-9300 CHEMTREC: 800-424-9300INTERNATIONAL: 703-527-3887 INTERNATIONAL: 703-527-3887

Issue Date: 05/12/2004

Product Name: Sika Grout 212CAS Number: Not EstablishedChemical Family: Cementitious GroutMSDS Number: 3178Product Code: 0525540

2. Composition/Information On Ingredients

Ingredient CAS Percent OfName Number Total Weight

CEMENT, PORTLAND 65997-15-1

SILICA, QUARTZ 14808-60-7

3. Hazards IdentificationEye Hazards

May cause eye irritation.

Skin HazardsProduct becomes alkaline when exposed to moisture. May cause a reversible inflammatory effect on skin ortissue at the site of contact.

Ingestion HazardsMay be harmful if swallowed.


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Sika Grout 212

3. Hazards Identification - Continued

Inhalation HazardsBreathing dust may cause nose, throat or lung irritation. Respirable crystalline silica can cause silicosis, a fibrosis(scarring) of the lungs. Silicosis may be progressive.

4. First Aid MeasuresEye

In case of contact, hold eyelids apart and immediately flush eyes with plenty of tepid water for at least 15 minutes.Get medical attention immediately if irritation develops and persists.

SkinIn case of contact, immediately flush skin with soap and plenty of tepid water for at least 15 minutes. Get medicalattention immediately if irritation (redness, rash, blistering) develops and persists.

IngestionIf swallowed, do not induce vomiting unless directed to do so by medical personnel. If victim is fully conscious,give one or two cups of water or milk to drink. Seek medical attention immediately.

InhalationRemove to fresh air. If not breathing, give artificial respiration, seek medical attention.

5. Fire Fighting MeasuresFlash Point: >200 FAutoignition Point: N/AV F

Fire And Explosion HazardsNone known

Extinguishing MediaIn case of fire, use water spray (fog) foam, dry chemical, or CO2.

Fire Fighting InstructionsIn the event of a fire, firefighters should wear full protective clothing and NIOSH-approved self-containedbreathing apparatus with a full facepiece operated in the pressure demand or other positive pressure mode.

6. Accidental Release MeasuresAvoid release to the environment. Use appropriate Personal Protective Equipment (PPE). Shovel or sweep up materialinto suitable containers, taking care to minimize dust. Dampen if necessary to control dust. Vacuum clean dust withequipment fitted with High Efficiency Particulate Air (HEPA) filters.

7. Handling And StorageHandling And Storage Precautions

Keep containers tightly closed.

Work/Hygienic PracticesWash thoroughly with soap and water after handling.

8. Exposure Controls/Personal ProtectionEngineering Controls

Use of a system of local and/or general exhaust is recommended to keep employee below applicable expsourelimits. Refer to the current edition of "Industrial Ventilation: A Manual of Recommended Practice" published bythe American Conference of Governmental Industrial Hygienists for information on the design, installation, use,and maintenance of exhaust systems.


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Sika Grout 212

8. Exposure Controls/Personal Protection - Continued

Eye/Face ProtectionSafety glasses with side shields or goggles.

Skin ProtectionLab coat or other work clothing to prevent skin exposure (Long sleeve shirt and long pants). Launder beforereuse.

Respiratory ProtectionA respirator protection program that meets 29 CFR 1910.134 requirement must be followed whenever workplaceconditions warrant a respirator's use. In areas where the Permissible Expsosure Limits are exceeded, use aproperly fitted NIOSH-approved respirator.

Ingredient(s) - Exposure LimitsCEMENT, PORTLAND ACGIH TLV-TWA - 10 mg/m3 OSHA PEL -TWA - 15 mg/m3 (total dust) OSHA PEL - TWA - 5 mg/m3 (respirable dust)SILICA, QUARTZ ACGIH TLV-TWA 0.05 mg/m3 OSHA PEL-TWA 30/%SiO2+2 mg/m3 OSHA PEL-TWA 10/%SiO2+2 mg/m3 OSHA PEL-TWA 250/%SiO+5 mppcf

9. Physical And Chemical PropertiesAppearance

Gray Powder

OdorOdorless

Chemical Type: MixturePhysical State: SolidMelting Point: N/AV FBoiling Point: N/AV FSpecific Gravity: 2.7-3.0Percent Volatiles: N/AVPercent VOCs: 0%Packing Density: N/AVVapor Pressure: N/AVVapor Density: N/AVS o l u b i l i t y : Negligible

10. Stability And ReactivityS t a b i l i t y : StableHazardous Polymerization: Will not occur

Conditions To Avoid (Stability)Contact of silica with powerful oxidizing agents such as fluorine, chlorine, trifluoride, manganese trixoide, oxygendifluoride, may cause fires. Upon direct contact with water, material will harden.

Incompatible MaterialsNone Known


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Sika Grout 212

10. Stability And Reactivity - Continued

Hazardous Decomposition ProductsSilica will dissolve in hydroflouric acid and produce a corrosive gas - silicon tetraflouride.

11. Toxicological InformationIngredient(s) - Carginogenicity

SILICA, QUARTZ NTP - Listed On The National Toxicology Program Listed In The IARC Monographs

12. Ecological InformationNo Data Available...

13. Disposal ConsiderationsDispose in accordance with applicable federal, state and local government regulations. Waste generators mustdetermine whether a discarded material is classified as a hazardous waste. USEPA guidelines for the classificationdetermination are listed in 40 CFR Parts 261.3. Additionally, waste generators must consult state and local hazardouswaste regulations to ensure complete and accurate classification.

14. Transport InformationProper Shipping Name

Not regulated by the USDOT.

15. Regulatory InformationU.S. Regulatory Information

All ingredients of this product are listed or are excluded from listing under the U.S. Toxic Substances Control Act(TSCA) Chemical Substance Inventory.

SARA Hazard ClassesAcute Health HazardChronic Health Hazard

SARA Section 313 NotificationThis product does not contain any ingredients regulated under Section 313 of the Emergency Planning andCommunity Right-To-Know Act of 1986 or 40 CFR 372.

State RegulationsWARNING: This product contains a chemical known to the State of California to cause cancer, birth defects, orother reproductive harm.

Ingredient(s) - State RegulationsSILICA, QUARTZ New Jersey - Workplace Hazard Pennsylvania - Workplace Hazard California - Proposition 65 Massachusetts - Hazardous Substance

16. Other InformationHMIS RatingH e a l t h : *2F i r e : 0R e a c t i v i t y : 0


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Sika Grout 212

16. Other Information - Continued

HMIS Rating - ContinuedP P E : C

Revision/Preparer InformationMSDS Preparer: EHS DepartmentMSDS Preparer Phone Number: 201-933-8800This MSDS Supercedes A Previous MSDS Dated: 05/12/2004

DisclaimerThe data in this Material Safety Data Sheet relates only to the specific material herein and does not relate to usein combination with any other material or in any process. The information set forth herein is based on technicaldata that Sika believes to be reliable as of the date hereof. Since conditions of use are outside our control, wemake no warranties, express or implied and assume no liability in connection with any use of this information.Nothing herein is to be taken as a license to operate under or a recommendation to infringe any patents.

SIKA CORPORATIONPrinted Using MSDS Generator 2000

C.. 1. E NTPROJECT

Standard ASTM C 109

MIs, NASSER S. AL HAJR CORPORATONPAZ AL ZAWR ALUMIMUM SMELTER MADEN

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METHOD STATEMENT OF GROUTING FOR CASTING CAR RAILS SLAB IN AREA 3 CASTING AREA