Method Statement - Grouting of Segmental Lining Green Line

Document History
Rev. No. Description of Revision Date of Revision

0 First Issue 16.06.2014
1/2 Incorporated comments, additional chapter 28.07.2015
3 Incorporated comments, additional chapter 14.01.2016
4 Incorporated comments 01.03.2016
Total Number of Pages: 29 including this cover page and without Appendix
Method Statement for Grouting of Segmental Lining Rev 04

- Green Line Underground Project
2/29
TABLE OF CONTENTS
1. PURPOSE ........................................................................................................... 6
1.1 General issue...................................................................................................... 6
1.2 Purpose .............................................................................................................. 6
2 SCOPE ................................................................................................................ 6
2.1 Interdependence with Management Plans .......................................................... 7
2.2 Revisions of Method Statement Documents ....................................................... 8
3 ROLES AND RESPONSIBILITIES ..................................................................... 8
4 EQUIPMENT AND MATERIALS USED .............................................................. 8
4.1 Equipment used .................................................................................................. 9
4.2 Material used ...................................................................................................... 9
5 QUALITY ASSURANCE / QUALITY CONTROL ................................................ 9
5.1 Handling and Storing of Materials ....................................................................... 9
6 HEALTH, SAFETY, ENVIRONMENT .................................................................. 9
7 JOB HAZARD ANALYSIS ................................................................................ 10
8 METHODOLGY ................................................................................................. 10
8.1 Temporary Works ............................................................................................. 10
8.2 Operation .......................................................................................................... 10
8.2.1 Introduction .................................................................................................... 10
8.2.2 Bi-component grouting system ....................................................................... 11
8.2.3 Mix Design ..................................................................................................... 24
8.2.4 Maintenance table ......................................................................................... 25
8.2.5 Secondary grouting ........................................................................................ 26

3/29
LIST OF APPENDICES
Appendix 1 PMC Comments / Contractor Response Rev 2

Appendix 2 ITP - Inspection and Test Plan
Appendix 3 JHA - Job Hazard Analysis
Appendix 4 Risk Assessment Mobile Plant
Appendix 5 Data Sheets
Appendix 6 QA/QC sheets
HARDCOPY DISTRIBUTION LIST

This Document in printed form should be considered as a controlled version only when it is
identical with the file stored on the Project Servers valid Documents Folder.
Hardcopy Distribution List*
Copy No. Name Company Position Signature
001 Qatar Rail Project Owner
Employers
002 Qatar Rail
Personnel
003 PSH Project Director
Director Tunnel
004 PSH
Works
Project Manager
005 PSH
TBM
006 PSH QA / QC Manager
007 PSH HSE Manager
008
009
010
* The final distribution may be modified after consultation with Qatar Rail.
** It is the responsibility of the Construction Manager to provide this Method Statement

to the respective Project or Site Engineers and obtain sign off that they have received
and understood the document. Please refer to the communication protocol.

4/29
ABBREVIATIONS
ARCH Project Archive

DVE Design Verification Engineer
EPB Earth Pressure Balance
HSE Health, Safety and Environment
IT Information Technology
ITP Inspection and Test Plan
MS Method Statement
MSV Multi Service Vehicle
PD Project Director
PLC Programmable Logic Controller
PMC Project Management Consultant
PSH Joint Venture of PORR, Saudi Binladin Group and HBK (code)
QA/QC Quality Assurance / Quality Control
QCS Qatar Construction Specification
QMS Quality Management System
QS Qatar Standard
SONO Statement of No Objection
TBM Tunnel Boring Machine

5/29
1. PURPOSE
1.1 General issue
This document is to present and demonstrate the Method Statement (MS) for Grouting of
Segmental Lining required by the Contract Document, Design & Build Package 4 Green
Line Underground awarded to the Joint Venture of PORR GmbH, Saudi Binladin Group and
HBK Contracting WLL (PSH).
This document was composed exclusively for the Qatar Railway Green Line Project. All the
requirements listed in the above referred contract document were taken into account. All the
PSH JV companies have Quality Management System Certificate of ISO 9001: 2008,
Certificate of ISO 14001: 2004 of Environmental Management System. Furthermore all the
parties apply the BS OSHAS 18001: 2007 on Occupational Health and Safety Management
System.
1.2 Purpose
The purpose of this Method Statement is to demonstrate the approach and procedures to be
followed to execute Grouting works of Segmental Lining in a safe manner to an approved and
controlled methodology to demonstrate a thorough and considered understanding and
approach, all in accordance with applicable standards, codes of practice and project
specifications. It also highlights dependencies on other MSs before the Grouting of Segmental
Lining can be executed. The Job Hazard Analysis in Appendix 2 identifies the hazards and
the safe systems of work to be followed when conducting the activity
2 SCOPE
Scope of this MS is the execution of Grouting works of Segmental Lining at all tunnels. This
process follows those described in MS for Tunnel Excavation Methodology (TBM) and Fire
Hazard.
This document includes the following either in the main body or in the Appendices:
Methodology for execution of Grouting works of Segmental Lining

Equipment/Tools and Materials used
Inspection and Test Plans
Job Hazard Assessment
Applicable Drawings

6/29
2.1 Interdependence with Management Plans
The following documents are referred to either to support the implementation of the MS or are
a pre-requisite to its implementation:
Qatar Construction Specification 2010 (QCS 2010)

Construction Drawings. For details, please refer to Appendix 6.
Contract Specifications
Note: DVE verified Construction Drawings will be in place at the time of starting the works.
Method Statements for:
Title Code Status

Dewatering M008-PSH-DEW-MES-00002 D-NOWC
Soil Disposal M008-PSH-EAR-MES-00006 C-SONO
Instrumentation and Monitoring M008-PSH-STM-MES-00001 Resubmitted
Structural Survey M008-PSH-SUR-MES-00003 D-NOWC
Tunnel Survey (TBM & NATM) M008-PSH-TUN-MES-00004 C-SONO
TBM Excavation / Fire Haz. Analysis M008-PSH-TUN-MES-00012 C-SONO
Specifications:
Title Code Status
Concrete Mix Designs Grade C50 M008-PSH-PMT-MAR-00088 D (NOWC)
Annulus Grout M008-PSH-PMT-MAR-00362 C-SONO
Specification - Concrete Structures M008-PSH-STR-SPE-00001 Submitted
Materials and Workmanship M008-PSH-CIV-SPE-00001 D (NOWC)
Specifications - Civil
Materials and Workmanship M008-PSH-TUN-SPE-00001 D (NOWC)
Specifications - Tunnel
Procedure:
Title Code Status
Confined Space Procedure M008-PSH-HMS-PRO-00010 Submitted
Reports:
Title Code Status
Durability Report Stations, Shafts & M008-PSH-STR-RPT-00001 C-SONO
In-situ Tunnels
Plans:
Title Code Status
Project Management Plan M008-PSH-PRJ-PLN-00003 D (NOWC)
HSE Plan M008-PSH-HMS-PLN-00001 D (NOWC)
HSE Plan M008-PSH-HMS-PLN-00002 C (SONO)
Project Quality Plan M008-PSH-QMS-PLN-00002 D (NOWC)
Risk Management Plan M008-PSH-RSK-PLN-00002 Submitted
Traffic Management Plans M008-PSH-TTM-PLN-00001 Submitted
7/29
Emergency Response Plan M008-PSH-HMS-PLN-00003 D (NOWC)
Construction Environmental M008-PSH-EMS-PLN-00001 C (SONO)
Management Plan
2.2 Revisions of Method Statement Documents

The revision of Method Statement documents shall be done when:
New information becoming available;
Qatar Rail requires modifications;
The Project Director requires modifications of Method statement;
There is a significant change in the construction methodology
The revised MS shall be submitted to the Engineer for SONO.
3 ROLES AND RESPONSIBILITIES
The grouting works will be executed by the TBM team under supervision of the
superintendent.
The Material Engineer is part of the QA/QC team.
4 EQUIPMENT AND MATERIALS USED

The following equipment and material are to be utilised in carrying out of grouting activity
(changes in the materials and equipment type possible due to work purpose and actual
circumstances):

8/29
4.1 Equipment used
Herrenknecht EPB TBM with integrated bi-component grouting system
Mixing unit on the surface
Tunnel supply line
Holding tanks
Transfer pumps
Feed pumps
Pump station for Component A and B including flow meter
Pressure sensors
Control system (PLC)
High-pressure water cleaner
Wastewater tank
4.2 Material used

Water
Cement
Bentonite
Stabilizer (for Component A)
Accelerator (Component B)
5 QUALITY ASSURANCE / QUALITY CONTROL

The Inspection and Test Plan (ITP) for this Method Statement summarises various
characteristics to be checked. The concerned Site Engineer or General Foreman will be
responsible to ensure compliance for these operations and the site QA / QC Engineer will
carry out quality control checks and report the inspection results. The Inspection and Test Plan
(ITP) applicable to this work is attached in Appendix 1.
5.1 Handling and Storing of Materials

All materials shall be inspected at time of delivery for damage and for compliance with
specifications.
Any material that is found to be damaged or not in accordance with the specification
shall be immediately replaced.
All materials shall be handled and stored as recommended by the manufacturer to
prevent damage and deterioration.
During storage, handling and transporting, every precaution shall be taken to prevent
damage to material. On delivery at site, material will be checked for any damage
incurred during transport and offloading to Storage area. Storage will be done in
suitable and safe locations (e.g. store yard or near site work area).
6 HEALTH, SAFETY, ENVIRONMENT

The Health and Safety Plan will be strictly adhered to at all times.

9/29
All workers will receive a site induction and be issued with PPE including a helmet with a
PSH Inducted sticker.
Daily Tool Box talks are held and attendance logged.
The Emergency Response Plan is in place and will be strictly adhered to.
In the event of any accident the HSE Incident Escalation Matrix will be followed at all times.
Site nurse will be available across both shifts with the Green Line doctor available as
necessary.
Specific HSE Hazards are mitigated in the Job Hazard Analysis.
7 JOB HAZARD ANALYSIS

The Job Hazard Analysis for this work is attached in Appendix 2.
8 METHODOLGY
The preparation and safety review activities have been completed and all relevant Permits to
Work have been approved and issued by HSE.
8.1 Temporary Works

All required temporary works will be carried out in accordance with the PSH Temporary
Works Procedure (M008-PSH-ENG-PRO-00001).
8.2 Operation
8.2.1 Introduction
To eliminate or minimize the risk of settlement behind the shield, the annular gap between the
segmental lining and the actual excavated diameter has to be backfilled during TBM advance.
The major advance of the bi-component system is a rapid fixation of the ring.
The bi-component grout is injected under pressure through grout lines in the tail skin into the
annular gap limiting the redistribution of stress in the soil body as a result of the tunnel
excavation.
Component A is prepared on the surface, transported through the tunnel via a 3 steel pipe to
the holding tank on the TBM back-up with a capacity of 7 m. Component B is transferred from
the MSV to the holding tank by means of a transfer pump (see Figure 8.2-1). The PLC
controlled screw pumps feed the grout lines integrated in the tail skin. The PLC system adjusts
the flow rates of the pumps to keep the pressure in the annulus within pre-set limits.

10/29
Figure 8.2-1 Bi-component grouting system
8.2.2 Bi-component grouting system

The grouting of the annular gap directly affects both the surface settlement and the quality of
the ring build. The grout injected leads to an immediate bedding of the segment rings. The
injection pressure must be sufficient to guarantee complete filling of the annular gap but should
not exceed the static capabilities of the segment rings or lead to damage of the tail skin seal.
The Bi-component system's main advantage lies in rapidly fixing the ring and evenly
transferring the ground forces onto the segment. The support given to the TBM from the last
constructed ring during tunneling facilitates ring twisting and shifting. This is because the rings
must take up both the torque and tunneling forces. However, rapid setting of the bi-
components can considerably reduce the inclination of the rings to twist and shift. They, in
turn, can absorb tunneling forces and backup loads that much quicker.
Component A (mixture of water, cement, Bentonite and a stabilizer) is mixed with Component
B (accelerator) at the end of the injection lines and injected into the annular gap. The quality
of the backfill components used is significant in terms of eliminating ring movement and
distortion and in achieving complete filling of the annular gap.
Metallic tank with mixing apparatus is used for transfer storage of Component A
Component B is supplied in tanks by the MSVs to the TBM and is kept in plastic tanks
until use.
High-pressure water cleaner: is used to clean the grouting lines at the tail skin.
Pump station including flow- and pressure meter for each of the 6 grout lines in the tail
skin is supplied by one progressing cavity pump for the grout (component A) and one
progressing cavity pump for the accelerator (component B), resulting in excellent
control over the filling process. The advantage of the progressing cavity pumps over
piston pumps is their continuous supply of grout / accelerator.

11/29
Valves: The system is fitted out with different types of valves. The check valves and
backflow stoppers are provided for a one-way flow in the lines. They are a vital
component in ensuring operational reliability. These valves ensure that the accelerated
grout is not pressed back into the lines. The check valves are fitted out with a spring
to allow for active resetting.
Injection cap: the slurry (Component A) and the accelerator (Component B) are
pumped to the tail skin and mixed in the injection cap. The injection cap is the vital
component for mixing the accelerator with the grout slurry. It must ensure effective
mixing and be operationally reliable. It is bolted onto the injection bar of the tail skin in
which the grout slurry is conveyed. As it is the constructional element coming into direct
contact with the two components, it is essential that it is cleaned at the end of the
grouting procedure and that both components are again separated to prevent any
setting in the lines.
8.2.2.1 Injection material Component A

Component A is a type of grout mixture and consists of water, bentonite, cement and a
stabilizer. These materials have different properties and the mix determines the extent to
which they affect Component A material properties. It can be described as non-Newton fluid -
i.e. viscosity changes in response to bringing in shearing forces. Viscosity changes as a
function of the shearing forces brought about by the bentonite share.
Bentonite is a mixture of clay minerals and will absorb substantial amounts of water to swell.
The bentonite proportion ensures that Component A is thixotropic in nature. This means that
during the loading phase the mixtures structural strength is reduced and the material becomes
more fluid from the input of kinetic energy and the viscosity is getting lower. The effect of the
material stabilizing is for structure strength to rise as the viscosity is raised.
Cement is the binding agent for the slurry and largely determines the solidifying time and
hardening of the mixture. The water/cement figure w/z = represents the weight ratio of water
to cement and is an important factor in setting the required mixture properties. This figure for
Component A lies between 2 and 3. It has an impact on the flowability and also affects hold
time of the slurry.
The stabilizer is supplied in a liquid form. The liquid variant has the benefit of being easier to
dose and to mix.
The TBM operates on a periodic principle. This means Component A is not constantly used.
It has a stopping time which is dependent on the TBM drive. It must therefore have a certain
durability in which it does not set and can still be pumped. If this durability is exceeded, then
the slurry in the storage tanks and supply lines is to be disposed.
The mixture sequence and mixing times impact on the durability of Component A. The mixing
times are laid down by the manufacturer of the mixing units and must be adjusted during the
test phase. They are important for producing a homogeneous material mixture and they also
affect both the quality and durability of Component A.

12/29
8.2.2.2 Injection material Component B
Component B is a sodium silicate and is generally referred to as soluble glass. The quantity
of the accelerator has a crucial effect on the setting time and final strength of the grout. Sodium
silicate coming into contact with air starts to crystallize; solids are formed which could get into
the grouting system and eventually damage sensitive components.
The component B will be stored in 3 Silos on the surface (22,000 liters each) for 2 TBMs. Via
a pipe the IBCs, which are installed on the MSVs, will be filled and transported to the TBM.
8.2.2.3 System components batching plant

One batching plant (seeFigure 8.2-2) is designed to supply 2 TBMs with the required
quantity of grout. The calculated consumption per TBM and per meter is approximately
3,50m (2 TBMs: 7m). The colloidal mixer is designed for a quantity of 20m/h. So a safety
factor of 3 is set. The mixture will be transferred after the mixing to a 20m buffer tank. This
is installed as a backup, in case of changing ground conditions or carstic voids occurring.
If the 20 m buffer tank is on the minimum level the mixing unit will start to mix component A
until the maximum level is reached on the tank. Additionally an automatic mode is installed
to give a signal from the TBM that the transfer pump has to start, if the minimum level on the
Component A tank on the TBM is reached, until the tank is filled.
Figure 8.2-2 Layout of the Mixing Unit

13/29
8.2.2.3.1 Equipment Mixing Unit
Table 8.2-1 shows an overview of the equipment, which is installed on one batching plant.
Table 8.2-1 Required Equipment
Water Tank 3x 10,000 gal

Water chiller 1x with cooling capacity down to 15C
Mixing Unit 1x colloidal shear mixer
Silos with screw conveyors 1x 80 m Cement
1x 80 m Bentonite
Silo 1x 22m for Admixture (Stabilizer)
Buffer tank 1x 20m with agitators/ isolated
Transfer screw to TBM 2x with 20m/h
Steering Unit Manual/ TBM automatic
8.2.2.3.2 Function of the Mixing Unit

The water will be cooled by a water chiller/ cooling water combination.
Via a pump the water with a temperature between 15 C and 25 C will be pumped to
the water tank of the mixing container.
The share mixer (description see below) mixes the water with bentonite, cement and
stabilizer with the requested recipe.
The mixture will be transferred to a buffer tank (20 m).
The screw pump will start pumping- after receiving a signal from the TBM- the
component A to the buffer tank on the TBM (see Figure 8.2-3).
Figure 8.2-3 Principle of the Mixing Unit

14/29
8.2.2.3.3 Water chiller
The water chiller is a pre- assembled 40 ft. container, built on a combination of a cooling
tower/ water chiller.
Wet bulb temperature 30C

Cooling tower cooling capacity 1,090 kW
Water Inlet 45C
Water Outlet 33C
Chiller cooling capacity 420 kW
Water Inlet 33C
Water Outlet 15C
Quantity 20 m/h
8.2.2.3.4 Mixing Unit

The MTW2000 (see Figure 8.2-4) mixing tank has a max working capacity of 2.000 liters and
is endowed of an open impeller pump (max. mixing capacity: about 2.000 l/min.) driven by a
15 kW electric motor.
Figure 8.2-4 Colloidal mixer
The MTW2000 is a high-shear mixer dispersing one phase or ingredient (liquid, solid, gas)
into a main continuous phase (liquid), with which it would normally be immiscible. The impeller,
together with the stationary component (Scroll), known as a stator, is located on the bottom of
the mixing tank containing the solution to be mixed to create shear. The high-shear mixer can
be used to create emulsions and suspensions.
Fluid undergoes shear when one area of fluid travels with a different velocity relative to an
adjacent area. A high-shear mixer uses the rotating impeller powered by an electric motor, to
15/29
"work" the fluid, creating flow and shear. The tip velocity, or speed of the fluid at the outside
diameter of the rotor, will be higher than the velocity at the center of the rotor, and it is this
velocity difference that creates shear.
The stationary component (Scroll) is used in combination with the rotor, and is referred to as
the stator (see Figure 8.2-5). The stator creates a close-clearance gap between the rotor and
itself and forms an extremely high-shear zone for the material as it exits the rotor.
Figure 8.2-5 Particular of an open impeller pump
In the MTW2000 batch high-shear mixer, the components to be mixed (whether immiscible
liquids or powder in liquid) are fed from the top into the mixing tank containing the mixer on a
rotating shaft at the bottom of the tank. Such mixer is usually used where faster processing by
volume is the major requirement.
8.2.2.3.5 Buffer tank

The buffer tank (see Figure 8.2-6) has a capacity of 20 m and takes the suspension with
paddle mixer.
Figure 8.2-6 Buffer tank (capacity 20m)
Inside the tank, each shaft is equipped with two paddles (Figure 8.2-7). One is located half
way down the tank; the other is positioned at the bottom and is fitted with a scraping rubber
blade.

16/29
Figure 8.2-7 Agitation tank paddles [1]. Lower paddle with scraping rubber blade; [2]. Intermediate paddle
8.2.2.3.6 Screw pumps

The screw pumps will transfer the grout from the buffer tank, via 3 pipes, to the tank on the
TBM.
Table 8.2-2 Technical Data Screw pump
Volume 20m/h
Power 22 kW
Diameter Tunnel line 3
Pressure relieve valve 16 bar
8.2.2.4 System components on the TBM
8.2.2.4.1 Basic principle

There are two tanks on the gantry, one holding the prepared component A and the other the
component B. The excentric screw pumps, one for each line, convey both liquids to the
injection box in the tail skin. The pump motors are equipped with frequency converters allowing
the pumping volumes to be varied. Each grout line is equipped with a flow measuring device
and a pressure sensor.
The mixture flows a short distance to the end of the tail skin into the gap to be backfilled (see
Figure 8.2-8). The bi-component grout hardens and consolidates rapidly.
The basic principle of the Bi-component system is shown on the enclosed schematic.

17/29
Figure 8.2-8 principle of the Bi- component system at the tail shield
8.2.2.4.2 Position of grout and grease lines in the tail skin of the shield
The position of the grouting lines and the greasing lines are shown in Figure 8.2-9.
Figure 8.2-9 Position of the Grout- and Grease lines

18/29
Grease lines: 7 ports for front chamber
7 ports for rear chamber
Grout lines: 4 working ports

2 reserve ports
8.2.2.4.3 Main parts of the injection
Consumption:
Theoretical grout volume per ring: 5,75m

Factor advance: 20%
Reference volume incl. supplement: 6,90m
Max. required flow rate for 80mm/min: 20,7m/h (sum component A + component B)
(incl. 20% supplement) 18,6m/h comp. A (90% shared consumption)
2,1m/h comp. B (10% shared consumption)
8.2.2.4.4 Excentric screw pump

Component A: (see Figure 8.2-10 and Table 8.2-3)
Figure 8.2-10 Screw pump for A- component
Table 8.2-3 Technical data for screw pump A- component
Flow per pump: 115 l/min / 6,9m/h

Flow for 4 pumps 460 l/min / 27,6m/h
Pressure max.: 16 bar
Power (each): 7,5 kW
Number of pumps: 5 (1 pump for regrouting)
(Frequency controlled)
Component B: (see Figure 8.2-11 and Table 8.2-4)

19/29
Figure 8.2-11 Screw pump for B- component
Table 8.2-4 Technical data for screw pump B- component
Flow per pump: 17 l/min / 1,02m/h

Flow for 4 pumps 68 l/min / 4,08m/h
Pressure max.: 18 bar
Power (each): 1.5 kW
Number of pumps: 5 (1 pump for regrouting)
(Frequency controlled)
8.2.2.4.5 Tanks
Tank of Component A is shown in Figure 8.2-12; data shown in Table 8.2-5.
Figure 8.2-12 Tank for A- component on the TBM

20/29
Table 8.2-5 Technical data for Tank A- component
Volume: 7 m
Dimensions approx.: 7100mm x 800mm x 1400mm
Number of agitators: 5
Power (each): 2.2 kW
The tank (with agitation) made of steel is used to store component A until its usage.
Special shape to avoid ground scaling

4 openings for cleaning
4 level sensors
1 connection to transfer line
5 connections to pumps
Tank of Component B is shown in Figure 8.2-13. The capacity amounts to 2m
1 connection to transfer line

1 connection to pumps
1 connection to return line
3 level sensors
Figure 8.2-13 Tank for B- component on the TBM
8.2.2.4.6 Injection box grout line

Component A + B are pumped to the tail skin and mixed in the injection box (see Figure
8.2-14). The injection box is the key element when it comes to the injection of the accelerator
into the grout.

21/29
Figure 8.2-14 Injection box at the end of the tail shield
The injection box is bolted to the injection line in which the suspension is conveyed. Because
of its contact with both components it is important to clean it at the end of the injection with
pressure water (flushing).
8.2.2.4.7 Non return valves in component B and flushing lines

The bi-component system is equipped with different valves. Non-return valves are installed
to enable flow in only one direction. The valves have to prohibit that the accelerated grout is
pressed back into the lines.
Feed pumps: are installed outside the mixing unit and forward the Component A
mixture through the tunnel supply line to the TBM.
8.2.2.4.8 Description of the individual modes

Notice:
The flow rate of component A should be at least 20 l/min each line. The flow rate depends
on the advance rate of the TBM. When the advance rate is not enough to reach 20 l/min the
two top lines should be used only.
Manual Mode:
Mode changed by selector switch.

In manual mode, the pumps for component A are started individually from the control
panel and the volumes are set. The pumps for component B are set as a percentage
on the display. The pumps are started from the control panel.
For safety reasons, manual mode includes an automatic pressure switch-off.
Semi- automatic mode:

Semi-automatic mode and manual mode differ only in the percentage admixture of
component B which has to be entered on the display (percentage of component B to
component A = max. 15 %). An automatic pressure switch-off (max. pressure in
component A) as well as a pressure for the advance stop function also has to be
entered via the display.
Otherwise the same procedures as Manual mode apply.
Automatic mode:

22/29
In automatic mode, the backfilling process must take place within a specific pressure
range (see Figure 8.2-15).
System stop
max pressure
regulation
Pressure
active
min pressure
regulation
active
advance stop
Time
Figure 8.2-15 Pressure range for automatic mode
The individual grout lines are preselected on the display. One or more lines may be
selected. The flow rate, calculated from the advance rate, is distributed to the
selected grout lines:
e.g. Line 1: 50%

Line 2: 50%
An automatic pressure switch-off (pressure in component A), maximum pressure

level, minimum pressure level, advance stop are entered.
The pumps are volume-controlled as long as the pressure remains within the
maximum and minimum pressure range. The normal pump speed is calculated and
controlled from the advance rate and the annular gap to be filled. If the maximum or
minimum pressure level is reached, the pump speed is respectively decreased or
increased in accordance with a defined algorithm.
When the defined advance stroke is reached, the pump for component B is shut
down, while component A continues to be pumped. A flushing cycle with high-
pressure water now follows for 10 seconds.
When the advance is stopped, a message is shown on the touch panel display.
However, the backfilling process continues.
8.2.2.5 Control system (PLC) and reports

The 2-component grouting system can be used in manual, semi-automatic and automatic
modes controlled from the local control station with automatic mode being the preferred mode
of operation. With the mixing ratio pre-set in the system the injection rates are controlled by
the advance speed of the TBM. All relevant parameters for the grout injection system can be
set via the dedicated parameter screens and the readings from all sensors in the system are
recorded in the TBM data logging system.

23/29
The PLC of the 2-component grouting system communicates with the TBM main PLC to
retrieve information on TBM advance. Data is used to control drives of the progressing cavity
pumps as well as for generation of warnings on the touch panel display. This data will be
recorded and can be used for reports.
Pressure and flow in all active lines is monitored by means of pressure transducers and flow-
meters.
The pressure will be not greater than one bar above the prevailing hydrostatic pressure at the
location of grouting.
The theoretical grout injection rate is derived from the TBM advance speed, cut diameter and
outside diameter of the segmental lining. In praxis more grout than the theoretical volume of
the annular gap has to be injected to account for grout volume reduction as a result of bleeding
caused by consolidation. The system is designed to cope with injection rates up to 40% higher
than theoretically required. A correction factor can be set by the operator.
8.2.3 Mix Design

The final mix design (see M008-PSH-PMT-MAR-00362) is submitted by the Material
Approval Request. To fulfill the requirements of the aggressive ground conditions the sulfate
resistance cement is chosen. The stabilizer and the accelerator were tested in the laboratory
of the supplier as well to reach the required targets.
Following Mix Design will be used, see also ITP and Material Approval Request.
Component A
Water 875 kg
Bentonite 42 kg
SRC 42.5 316 kg
Pozzolith 55R 5 kg
Component B
Roc SA 430 7%

24/29
8.2.4 Maintenance table
Table 8.2-6 Maintenance table
8.2.4.1 Cleaning
Experience has shown that it is useful to clean the grout lines periodically. Therefore tools
such as a cutter of the company Rothenberger or a flushing device (see Table 8.2-7and
Figure 8.2-16) with high pressure water will be used.
Table 8.2-7 Technical data High Pressure cleaner
Flow rate 23 l/min

Pressure 160 bar
Power 6,5 kW

25/29
Figure 8.2-16 Illustration of flushing device
8.2.4.2 Flushing function

Notice: the high pressure cleaner has to be switched on always during the advance
(pressure 160 bar)
8.2.4.2.1 Manual flushing

The flushing function can be used in any mode. Flushing must be enabled in manual mode.
All lines can be selected individually. The standard setting is flushing with 3-5 liters. This
takes 5-20 seconds each line.
8.2.4.2.2 Automatic flushing

This function is run automatically in every mode. In a mode change or in case of a shutdown,
around 1 liter high-pressure water is added when flushing with component A.
Figure 8.2-17 Bi- component flushing concept
8.2.5 Secondary grouting

The secondary grouting will be executed every 5th ring continuously from the gantry. For the
secondary grouting the same material as for the primary grouting will be used.

26/29
Figure 8.2-18 Embedded item for secondary grouting
8.2.5.1 Operating process for the secondary grouting

Usually, the proof grouting takes place on the top of the ring.
The process of the proof grouting is the following:
When the hole for proof grouting is accessible from the platform, drilling the segment
preformed hole in accordance with predefined drilling pattern. The length will be
adapted to each case (see Figure 8.2-18, Figure 8.2-19).
Positioning of the injection insert at the boring end.
Check the relief valve functioning and adjust the pressure according to the usual
pressure and the line loss. The head loss in the line is determined by a no load test
before the injection.
Inject the grout.
Stop the injection when the max pressure of 4 bar, is accomplished. Close the valve.
Cleaning and inner wall washing to avoid grout trace before hardening.
Take off the injection inserts about 24h after the injection.
A resurfacing takes place in the borehole.

27/29
Figure 8.2-19 Drill and grouting device
8.2.5.2 Operating process for the secondary grouting TBM 848 / 849
For the secondary grouting of the first 70 m of TBM 848 / 849 the secondary grouting will be
executed from the Doka scaffold.
For this grouting a cement suspension will be used.
Usually, the proof grouting takes place on the top of the ring.
The process of the proof grouting is the following:
When the hole for proof grouting is accessible from the platform, drilling the segment
preformed hole in accordance with predefined drilling pattern. The length will be
adapted to each case (see Figure 8.2-18, Figure 8.2-19).
Positioning of the injection insert at the boring end.
Check the relief valve functioning and adjust the pressure according to the usual
pressure and the line loss. The head loss in the line is determined by a no load test
before the injection.
Inject the grout.
Stop the injection when the max pressure fixed is accomplished. Close the valve.
Cleaning and inner wall washing to avoid grout trace before hardening.
Take off the injection inserts about 24h after the injection.
A resurfacing takes place in the borehole.
8.2.5.2.1 Working platform

The repair works will be executed from a separate Scaffolding.
It is the same as for the repair works of segments, described also in M008-PSH-TUN-MES-
00020.

28/29
29/29
Appendix 1
Green Line Underground Project
Method Statement for Grouting of Segmental Lining Rev 04 30/82

Qatar Rail
Document Review Sheet (Engineer)
Company Management System
PROJECT: Green Line Underground PROJECT NO.: M008
DRS NUMBER: M008-HIL-CON-DRS-00156 REV.: 3 TRANSMITTAL NO / DATE: 14-02-16
ORIGINATOR: PORR SBG HBK JV TRANSMITTAL NO / DATE: 18-01-16
DOCUMENT NO.: M008-PSH-TUN-MES-00031 REV.: 3 DISCIPLINE: TUNNELING WORKS
DOCUMENT TITLE: METHOD STATEMENT FOR GROUTING OF SEGMENTAL LINING DOCUMENT TYPE: METHOD STATEMENT
Comment Code Legend (for individual comments): Reply Code Legend

i=incorporated, ii= evaluated and not incorporated for reason
1 = Action required for this issue 2 = advisory comment Open/Closed
stated
Comment Reply
No. Initial Page/Section Reviewers Comments (PMC/CPO, CTO) D&B Contractor/Other Party Reply Reply Status by Reviewer
Code Code
Comments on Rev.0
GeneralIssues
Section1.1
1 2 Changereferencefrom"TenderDocument.."to"Contract i SeeAppendix1forContractor'sreply. Closed
page6/33
Document."(Volume7Section13.4)
RolesandResponsibilities
ThisMSwillbereaddirectlywithvarioushigherleveltunnellingMS's,
Section4 thereforepleaselimitthereferencedpersonneltotheindividualswithdirect
2 1 ii SeeAppendix1forContractor'sreply. Closed
page8/33 responsibilityforthegroutingoperations.(Volume7Section13.4)
ShouldaMaterialsEngineerbeconsidered.
SurveyControl
Section6 Thewordingshouldreflectthatthegroutingoperationlimitsanypotential
3 1 i SeeAppendix1forContractor'sreply. Closed
page10/33 groundsettlementandshouldrefertotheMonitoringandInstrumentation
MSfortunnellingoperations.Volume7Section13.4
Access/Egress
Section8.1.4
4 1 Thissectionshouldbelimitedtotunnellingoperations.Referencecanbe i SeeAppendix1forContractor'sreply. Closed
page12/33
madetogeneralsiteaccessdocument.(Volume7Section13.4)
PlantOperations
Section8.1.6
5 1 Thissectionneedstoberevisedtoreflectthespecificwork i SeeAppendix1forContractor'sreply. Closed
page13/33
operation.(Volume7Section13.4)
Method Statement for Grouting of Segmental Lining Rev 04 31/82 Page1of3

DescriptionofWorks
Pleaseprovideinformationonthefollowing
expectedpressurerangeofgroutingoperation,
groutmixdetails,
detailsofstabilizer,
whatistheexpectedlifeofAComponentontheTBM,providedetailsfor
disposalofunusedgroutandconsideranyenvironmentalimpactofthe
same,
whataretheprecautionsagainstspillageofBComponentduringtransfer
fromthesitestoragesilos,
howmanygroutlinespertunnelwillbeinstalled,howwilltheybe
Section8.2 maintained,
6 1 ii SeeAppendix1forContractor'sreply. Closed
page14/33 isthereanyconditionwhichwillresultinthereserveportsalsobeing
used,
whatconditionswilldeterminewhichmodeisusedforgrouting,who
controlthisdecisionmaking,
whatcontingencyisinplaceforopenfractures/voidsintherockmass,
howwillthevolumebecontrolled,
whatwilldeterminetheannularspacingisfilled,
whenissecondarygroutingcarriedout,whereontheTBMwillthis
operationbecarriedout,underwhatcircumstancesisitexpected,who
makesthefinaldecision,pleaseexpandthissection,
GroutresistancetestsneedstobeinsertedasaHOLDPOINTintheITP
(Volume7Section13.4)
ITP
1.3IStheoperationofgroutingtobesubcontracted,ifsofullapproval
fromEmployerisrequired.
Appendix1 1.6MixissubjecttoSONO.
7 1 i SeeAppendix1forContractor'sreply. Closed
ITP 2.6pleaseconfirmwherethesesampleswillbetaken,
3.0wherewillthesesamplesbetaken.
(Volume7Section13.4)
Comments on Rev.2
Sections6&10 Health,SafetyandEnvironment
8 ST 1 i SeeAppendix1forContractor'sreply. Closed
page(s)8&28/29 Thissectionisrepeated.Pleasemergeallinformationinonesinglesection.
SecondaryGrouting
Thegroutingmixforsecondarygroutingisthesameasfor Open.
Pleaseconfirmifgroutingmixwillbethesameasforprimarygrouting.
Pleaseconfirmifgroutingmixwillbe
Pleaseoutlinespecificprocedureforchoiceofsegmentsandinjection primarygrouting
thesameasforprimarygrouting.
Section8.2.5 locationforsecondarygroutingandpersonresponsibleforfinaldecision. Thesecondarygroutimgwillbeexecutedpermanently
9 ST 1 Pleaseoutlinespecificprocedurefor
page25/29 Sections8.2.5.1and8.2.5.2containsimilarinformation.Pleasemergeinto each5thring choiceofsegmentsandinjection
onesection. Themaximumpressureforthesecondarygroutingis4bar locationforsecondarygroutingand
Pleaseconfirmifthesecondarygrouting,Section8.2.5.2,describedfor SeealsoMassBalanceReport personresponsible.
tunnels848&849willbeapplicabletoalltunnels.
Section8.2.3 MixDesign
MixDesign. IsthemixdesignprovidedthefinalMixDesign?
10 JG Page23/29and 1 ComponentAisgiveninKG.ComponentBisgivenin%.Ifpossiblekindly i SeeAppendix1forContractor'sreply. Closed
Appendix1ITPItem provideconsistentunits.
1.5. TheMaterialsApprovalRegisterdated5Augustdoesnotprovidethelatest
finalmixdesign.
Appendix1ITPItem Grouting
11 JG 2 i SeeAppendix6 Open.
2.6 KindlyprovideanexampleoftheGroutingInspectionForm.

Testing
Kindlyplacethetestmethodunderthe"Test"columnandnotthe
Appendix1ITPItem "Acceptance"column.
12 JG 2 i SeeAppendix1forContractor'sreply. Closed
3.13.5 WilltestsbeconductedbyExovaQCEngineersorPSHEngineers?Kindly
declare.
Kindlyattachtestproformas.
JHARepeatedinMS
ThereisasignedandunsignedcopyofthesameJHAinthisMS.
13 KJS JHA 2 i SeeAppendix1forContractor'sreply. Closed
MergethecopiessothatthereaderonlyhasonecopyofJHAtorefertoin
thisMS.
HighPressureFlushingEquipment
Thehazardsidentifieddonotincludeworkersbeingstruckbyhighpressure
JHA
14 KJS 1 flushingliquid. i SeeAppendix1forContractor'sreply. Closed
item#16
Includeaitemidentifyingthishazardandassociatedcontroltominimize
workerexposureintheJHA.
LackofConfinedSpacesControls
Thecontrolsdonotincludetheconfinedspacepermitsystemwhenentering
JHA
15 KJS 1 thetanktocleanit. i SeeAppendix1forContractor'sreply. Closed
item#22
IncludetheHSEMS"confinedspaceentrypermitsysteminthisitemofthe
JHA.
WorkingatHeight
ThecontrolsidentifytrainedMachineOperatorsabletousethemachinesas
JHA
16 KJS 1 acontrolforworkingatheight?Why? i SeeAppendix1forContractor'sreply. Closed
item#25
Thecontrolsshouldbeforeveryonewhoisworkingatheighttobetrained
fortheworkinthisMS.
UseofSDS'sasControlMeasure
TherearenumerousitemsintheJHAwhereworkersinteractwiththe Open.
JHA componentA&Bgrout.Whereworkerscancontactthegroutcomponents SDSoutlineshazardsandcontrol
17 KJS 1 i SeeJHA2730
General referencetotheSDS'sshouldbestatedasacontrolmeasureintherelated methods.Itshouldbereferencedin
itemsintheJHA. JHA.
IncludethereferencetotheSDS'sintheappropriateitemsintheJHA.
A. Approved C. SONO E. Fail/Not approved

Document Review Status Code: D
B. Approved with comments D. NOWC: No Objection with comments F. Responded/Reviewed/Actioned
PMC/CPO Comments/Reply Status Chief Technical Office (CTO) Engineer/Delegated Party D&B Contractor
COMMENTS/STATUS
Reviewers Name Position COMMENTS/STATUS RECOMMENDED BY CTO NO OBJECTION BY (Where necessary) REPLY APPROVED BY
RECOMMENDED BY PMC
Construction
Daniel Dowling Name: John Swann Name: Name: Name:
Manager
Position: Engineer's Assistant Position: Position: Position:
Signature: Signature: Signature: Signature:
Date: Date: Date: Date:

Appendix 2

page 1 of 3
ITP- INSPECTION & TEST PLAN

Ref. Vol 4 - Employer's Requirements - General, Sec. 2.4
TITLE / NAME: Grouting of Segmental METHOD STATEMENT REF. No.: M008-PSH-TUN-MES-00013 ITP No.: M008-PSH-QMS-ITP-00100 Rev.2
(refer to latest revision)
Lining DATE: 13-Jan-16
Inspection Parties / Type of

Test or Inspection
Item
Activity description Reference documents inspection Acceptance Criteria Frequency Records
action
No.
method PSH PSH RESPONSIBLE
SITE QA/QC
1 Documentation
Volume 7 Clause 5.1.3 Project Manager
Relevant permits and licenses shall be Granted
1.1 Permits to work QCS Section 1 Clause 19.1.3 submittal Prior to commencing the works H W Tunnel/HSS/Quality
acquired permits/licenses
MS Clause 8.1.1 Manager
Volume 4 Clause 16.2 Project Manager

Obtain a statement of no objection of the
1.2 Method Statement M008-PSH-TUN-MES-00013 submittal Prior to commencing the works SONO H H Tunnel/Quality
Engineer
QCS Section 1 Clause 8.2.4 Manager
Volume 4 Clause 12.3 & 12.13

Obtain a statement of no objection of the Project Manager
1.3 Design documents and DVE Design Verification Volume 3 Clause 5.1.2 (k) submittal Prior to commencing the works SONO H H
Engineer to the Design Documents Tunnel / Site Engineer
MS Clause 4.10
Project Manager
Obtain a statement of no objection of the
1.4 Materials & Workmanship Specifications Volume 7 Clause 1.1.3 submittal Prior to commencing the works SONO H H Tunnel / Site Engineer
Engineer
/ QC Engineer
Component A:
Water (potable ) = 875 kg
Bentonite = 42 kg Project Manager
Volume 7 Clause 13.4.2.1
1.5 Grout Mix Design submittal SRC 42.5 = 316 kg Prior to commencing the works Mix design records H H Tunnel/ Site Engineer /
MS Clause 8.3.2
Pozzolith 55R = 5 kg QC Engineer
Component B:
Roc SA430 = 7% (Nominal )
Any work item that does not meet the acceptance criteria shall be reworked and reinspected; failure to satisfactorily rework deficient items shall result in the raising of NCR.
Method Statement
PSH-QMS-ITP-Q-27 for Grouting of Segmental Lining Rev 04 35/82
Rev.02, 14May2014
page 2 of 3
ITP- INSPECTION & TEST PLAN

Ref. Vol 4 - Employer's Requirements - General, Sec. 2.4
TITLE / NAME: Grouting of Segmental METHOD STATEMENT REF. No.: M008-PSH-TUN-MES-00013 ITP No.: M008-PSH-QMS-ITP-00100 Rev.2
(refer to latest revision)
Lining DATE: 13-Jan-16
Inspection Parties / Type of

Test or Inspection
Item
Activity description Reference documents inspection Acceptance Criteria Frequency Records
action
No.
method PSH PSH RESPONSIBLE
SITE QA/QC
2 Site Works
Volume 4 Clause 20.7.4 Safety induction and training is provided to Induction attendance HSE Manager / Site
2.1 Safety Induction Not Applicable Prior to commencing the works W H
QCS Section 11 Clause 1.1.5 personnel records Engineer
Volume 4 Section 2.8 Induction attendance

Quality induction and training is provided to Construction
2.2 Quality induction Not Applicable Prior to commencing the works records, MS briefing W H
personnel Department/QA QC
MS Clause 8.1.2 sheets
QCS Section 1 Clause 8.3.8
2.3 Tool Box Talk Not Applicable Briefing for daily tasks Prior to commencing the works Tool box records H R Site Engineer
MS Clause 8.1.2
No damage and compliance with
specifications at time of delivery (and on
MS Clause 8.1.7 Site Engineer/QC
2.4 Handling and storage of materials inspection delivery at site), otherwise replaced Each section Inspection records H H
Handled and stored as recommended by the Engineer
QCS Section 5 Clause 14.1.6 manufacturer
Materials assessed and approved

Materials are logged on the relevant register Each material and before delivery to Site Engineer/QC
2.5 Materials assessment MS Clause 5.2 inspection Inspection records H H
the site Engineer
The annulus must be regularly and

completely filled
Grout pressure is to be measured at the
nozzle with a suitable gauge
Pressure not greater than one (1) bar above
the prevailing hydrostatic pressure at the
location of grouting. Inspection records,
Site Engineer/QC
2.6 Grouting Volume 7 Clause 13.4.3 inspection Grout doesn't excape between the tail and the Each section Grouting consumption H H
Engineer
excavation profile records
Check of the complete filling of the
gap particularly over the crown of the
segment lining
Injection cap is clean and in good contition
Parameters for the grout injection are

recorded in the TBM data logging system Site Engineer/QC
2.7 Control system MS Clause 8.2.2.5 inspection (e.g. Pressure, flow, theoretical and actual Inspection records H H
Engineer
grout volume)
Any work item that does not meet the acceptance criteria shall be reworked and reinspected; failure to satisfactorily rework deficient items shall result in the raising of NCR.
Method Statement
PSH-QMS-ITP-Q-27 for Grouting of Segmental Lining Rev 04 36/82
Rev.02, 14May2014
Appendix 3

Appendix 2 Approved By: Signature:
Job Hazard Analysis John Wheadon
Grouting of segmental lining Rev 4 Sean Field
JHA Execution
Task Steps Hazard Impact (likelihood) Controls
Step What could hurt me / others or Responsibility
What am I going to do? What harm could occur? What must be in place to prevent harm? (include specific responsibilities where applicable)
impact on the environment
Only authorized persons allowed on site. Operation team to control access to site at all times. Stop work and
Potential of injury or accident or vandalism Site Engineer /
pit lowering, station construction, report to supervisor in case of unauthorized person accessing site.
1 Access and egress Runover by vehicle Foreman / HSE
stock pile, vehicle contact Maintained clear and visible fencing, hoarding and edge barriers and signage.
Risk of falling in open excavation Engineer
Construction Manager
/ Project Engineer /
Respiratory Problems / Harming / Breathing /
2 General Tunnel Works Working Environment All personel must have a full medical test to proof of physical items Site Engineer / QA and
General Items
HSE Engineer / Plant
Operator
Site Engineer /
Hearing loss Use the proper and the minimum requirement of PPEs.
Foreman / HSE
3 Operate plant Excessive noise and vibration Hand and arm vibration syndrome (HAVS) Monitor noise and vibration. Do not exceed the daily exposure level.
Engineer / Surveyor /
Disturb nearby residents Review methology if problems occur.
Plant operator
Site Engineer / HSE
Silica lung disease Use the proper and the minimum requirement of PPEs.
Dust generated during plant Engineer /
4 Operate plant Breathing problems, Use proper ventilation and dust exhaust system, spray water on affected areas.
operation Environment Manger /
Environmental hazard Monitor air samples.
Plant Operator
Site Engineer / HSE
Equipment on fire Burning Every equipment must be equipped with fire extinguisher. Engineer /
5 Operate plant
Emission of toxic gases Respiaratory problems Deployment of proper ventilation system. Frequent checking of air quality of the working area. Environment Manger /
Plant Operator
Site Engineer /
Protection of cables and using low-voltage equipment. Before commencing any maintance works, all electrical
6 Using electrical equipment Electician system Electric shock Foreman / HSE
equipment must be isolated from the main. Proper and frequent maintanincing of the equipment.
Engineer
Site Engineer /
Hearing loss Use the proper and the minimum requirement of PPEs, ear muffs / plugs@80db(A)-85.
7 Using of manual equipment Noise and vibration Foreman / HSE
Hand arm vibration syndrome Monitor noise and vibration. Review methology if problems occur. Use the vibrating equipment in short terms.
Engineer
Site Engineer /
Working in harsh environment Drink plenty of water, cover exposed body parts, wear proper PPEs and sun protection, apply sun screen. Shaded
8 Heat Stress and dehydration Heat Stroke, Dehydration Foreman / HSE
(high temperature and humidity) areas will be provided.
Engineer
Site Engineer /
Working in harsh environment
9 Sand, dust Eye injury / breathing issues Proper eye protection must be worn at all times. Wear proper dust mask if necessary. Foreman / HSE
(wind blow/dust)
Engineer
Ensuring a clean and tidy workplace (housekeeping) to prevent trips, and slips. Do proper housekeeping. Site Engineer /
Working in harsh environment
10 Slips, trips and falls Slips, trips and falls Establishing emergency planning procedures, including first aid. Provide good quality of lighting, spillages of liquid Foreman / HSE
(on work sites)
being cleaned promptly. Engineer
Site Engineer /
Use the proper and minimum PPEs all time (eye, breath, hand protection). Good maintenance.
11 Concrete pumping Burst hose / fitting Concrete works - skin / eye injury Foreman / HSE
Regular inspection of equipment.
Engineer
Site Engineer /
Injury caused by using inappropriate Risk should be eliminated or reduced through the use of lifting aids, reducing the load, dividing or sharing the load,
12 Manual handling Back injury Foreman / HSE
lifting methods. provide training in ergonomic lifting techniques
Engineer
Site Engineer /
Entrapment hazard, shock, damage Proper eye protection must be worn at all times. Wear proper dust mask if necessary. Control of the pumps are
13 Working with static pumps Cuts, eye injury, loss of limbs Foreman / HSE
to the eyes. disconnected before open its.
Engineer
Site Engineer /
14 Component A - Mixture process Mixture spraying on workers Harmful to skin Foreman / HSE
Engineer
Site Engineer /
During disposal, slurry spilling on Environmental Use the proper and minimum PPEs all time (eye, breath, hand protection). Good maintenance.
15 Storage tank of Component B Foreman / HSE
workers When in contact with workers, harmful to body Regular inspection of equipment.
Engineer
Site Engineer /
Use the proper and minimum PPEs all time (eye, breath, hand protection).
16 High pressure water cleaner Flying pieces/chips on workers Cuts, bruises Foreman / HSE
Be aware to other workers in surrounding
Engineer
Site Engineer /
Leakage in transit and storage Environmental Use the proper and minimum PPEs all time (eye, breath, hand protection). Good maintenance.
17 Stabilizer supplied in liquid form Foreman / HSE
Sillage during handling Skin irritation, other harmful effects to skin Regular inspection of equipment.
Engineer

1/2
Appendix 2 Approved By: Signature:
Job Hazard Analysis John Wheadon
Grouting of segmental lining Rev 4 Sean Field
JHA Execution
Task Steps Hazard Impact (likelihood) Controls
Step What could hurt me / others or Responsibility
What am I going to do? What harm could occur? What must be in place to prevent harm? (include specific responsibilities where applicable)
impact on the environment
Component A - Slurry stored in Site Engineer /
During disposal, slurry spilling on
18 tanks, to be disposed when Harmful effects to skin Use the proper and minimum PPEs all time (eye, breath, hand protection). Foreman / HSE
workers
passed durability date Engineer
Site Engineer /
During disposal, slurry spilling on
19 Filling of Component B Harmful effects to skin Use the proper and minimum PPEs all time (eye, breath, hand protection). Foreman / HSE
workers
Engineer
Site Engineer /
Equipment suddenly stops Workers manually trying to fix Use the proper and minimum PPEs all time (eye, breath, hand protection).
20 Hands / limbs / clothing getting jammed in equipment Foreman / HSE
working equipment, unsupervised Stop power / electricity before repairing
Engineer
Site Engineer /
21 Buffer tank Electrocution Electrocution, injuries Foreman / HSE
Engineer
Use the proper and minimum PPEs all time (eye, breath, hand protection). Site Engineer /
Cleaning of storage tanks for
22 Four openings for cleaning Spraying on skin, eyes Open all openings during cleaning. Always one worker being outside to secure Foreman / HSE
Component A
Following Confined Space Procedure Engineer
Site Engineer /
Contact with excess grout in grout Harmful reaction to skin Use the proper and minimum PPEs all time (eye, breath, hand protection). Good maintenance.
23 Manuel cleaning of equipment Foreman / HSE
tank Injury to eyes Regular inspection of equipment.
Engineer
Site Engineer /
24 Drilling the segment Drilling, flying pieces Injury, cuts, bruises Foreman / HSE
Be aware to other workers in surrounding
Engineer
Site Engineer /
Eliminate the hazard by of falling by using the proper PPEs (e.g. helmet, safety shoes, harness).
25 Working at heights Falling from height Potential of serious injury or accident Foreman / HSE
Workers must be fully trained and qualified and can use machines only.
Engineer
Working scaffold to be fixed properly in accordance with shop drawings and manufacturer's instructions
Falling from the working scaffold
Inspect working scaffold prior to use and regularly during usage Site Engineer I
Collapse of working scaffold
26 Working on scaffold Injury, fatality Maintain working scaffold clean at all times General Foreman I
Tripping (congested, limited working
Do not store material and tools on the working scaffold HSE
area at the working scaffold)
Wear appropriate PPE
Site Engineer /
27 Using Grouting mixture Inhalation aerosol Injury, fatality Foreman / HSE
In case of inhalation remove to fresh air and seek medical attention.
Engineer
Site Engineer /
28 Using Grouting mixture Skin contact Injury, fatality Foreman / HSE
In case of contact wash immediatly with plenty of water and soap.
Engineer
Site Engineer /
29 Using Grouting mixture Contact with eyes Injury, fatality Foreman / HSE
Wash affected eyes for at least 15 minutes under running water with eyelids held open, consult an eye specialist
Engineer
Site Engineer /
30 Using Grouting mixture Ingestion Injury, fatality Foreman / HSE
In case of ingestion rinse mouth immediately and then drink plenty of water, seek medical attention.
Engineer
Use the proper and minimum PPEs all time (eye, breath, hand protection). Site Engineer /
31 High pressure water cleaner Struck person Injury, fatality Be aware to other workers in surrounding Foreman / HSE
Dont pointing the beam at other people Engineer

2/2
Appendix 4

Green Line Underground
Risk Assesment - Generic Mobile Plant
MOBILE PLANT RISK

REGISTER
REVISION G
BASE RL
Environmental
Health Safety
IDENTIFIED RISK EVENT
ID
EXISTING CONTROL P
HAZARD FAULT CONSEQUENCE C R C R
TRUCK
a Designated roads
A General site Injury C 3 H
b Speed limits
1 movement of Collision between Trucks
c Trucks Licenced operators
B Fatality E 4 M
d
a Designated roads
A General site Injury C 3 H
b Speed limits
2 movement of Collision with light vehicle
B Fatality E 4 M
d
a Designated roads
A General site Injury D 3 M
b Speed limits
3 movement of Roll over / tipping over
c Licenced operators
B Trucks Fatality E 4 M
d
a Water tankers on site
A General site Exceeds dust limits B 2 H
b Traffic movements creates
4 movement of
c Trucks excessive dust / noise
B Exceeds noise limits D 2 L
d
a Designated roads
A Excavated Accident - fatality E 4 M
b Overdriving heap or deep Speed limits
5 material heap /
c Excavation excavation edge Licenced operators
B Accident - injury D 3 M
d Berms / barriers
A Exceeds dust limits B 2 H
b Loading and
6 Creates excessive dust / noise.
c unloading trucks
B Exceeds noise limits D 2 L
d
a Designated roads
A Failure to adequately designate Accident - injury D 2 L
b Roads and Speed limits
7 (incl signage etc) areas - roads,
c designated areas walkways etc leads to accident Accident - fatality Licenced operators
B E 4 M
d
a Designated areas for refuel
8 A Refuelling on site Spill in uncontained area Environmental issue C 2 M
b
EXCAVATOR
a Designated roads
A Surface Mobile Injury D 3 M
b Speed limits
47 Equipment (SME) Collision between SME's
c / Excavator Licenced operators
B Fatality E 4 M
d
a Designated roads
b Speed limits
48 Equipment (SME) Collision with light vehicle
B Fatality E 4 M
d

BASE RL
Environmental
Health Safety
ID
EXISTING CONTROL P
a Designated roads
b Speed limits
49 Equipment (SME) Roll over / tipping over
B Fatality E 4 M
d
A Surface Mobile Exceeds dust limits C 2 M
b Traffic movements creates Plant moves very slowly
50 Equipment (SME)
c / Excavator excessive dust / noise
B Exceeds noise limits E 2 L
d
b Distance to boundary
51 Loading trucks Creates excessive dust / noise.
c
B Exceeds noise limits C 2 M
d
a
52 A Hydraulic lines Burst line Environmental issue C 2 M
b
b
a Restricted areas
A Unauthorised personal entry in Injury D 3 M
b
54 Boom area of swinging boom - person
c hit by boom / bucket
B Fatality E 4 M
d
A Exceeds dust limits C 2 M
b Use of excavator Creates excessive dust / noise Distance to boundary
55
c as rock breaker (vibration). Exceeds noise / vibration
B C 2 M
d limits
a Restricted areas
A Results in fly rock - fragment of Injury D 2 L
b Use of excavator Inside excavation
56 rock that flies off and impacts
c as rock breaker PPE / glasses
B person in area Fatality E 4 M
d
a Restricted areas
A Injury D 3 M
b Mechanical failure allows boom Maintenance
57 Raised boom
c to drop on worker
B Fatality E 4 M
d
a Restricted access near wall
A Injury D 3 M
b Working in Regular inspections of wall
58 Failure of slopes
c excavation Cabin protection
B Fatality E 4 M
d Wall protection / stabilisation
A Injury D 3 M
b Working in Rock fall from unprotected Regular inspections of wall
59
c excavation slopes of excavation Cabin protection
B Fatality E 4 M
BULLDOZER / GRADER
a Designated roads
b Speed limits
c /Bulldozer Licenced operators
B Fatality E 4 M
d
a Designated roads
b Speed limits
B Fatality E 4 M
d
a Designated roads
b Speed limits
B Fatality E 4 M
d Slow moving

BASE RL
Environmental
Health Safety
ID
EXISTING CONTROL P

100 Equipment (SME)
c /Bulldozer excessive dust / noise
d
a Designated roads
A Excavated Accident - fatality E 4 M
b Bulldozer overdriving heap or Speed limits
101 material heap /
c Excavation deep excavation edge Licenced operators
B Accident - injury D 3 M
d Berms / barriers
Designated areas for refuel


A Injury D 3 M
B Fatality E 4 M
A Injury D 3 M
105
B Fatality E 4 M
a Designated roads
b Speed limits
c / Grader Licenced operators
B Fatality E 4 M
d
a Designated roads
b Speed limits
B Fatality E 4 M
d
a Designated roads
b Speed limits
B Fatality E 4 M
d
109 Equipment (SME)
c excessive dust / noise
B / Grader Exceeds noise limits E 2
d
CONCRETE PUMP / CONCRETE TRUCK
a Designated roads
b Speed limits
146 movement of Collision between Trucks
B Fatality E 4 M
d
a Designated roads
b Speed limits
147 movement of Collision with light vehicle
B Fatality E 4 M
d
a Designated roads
A General site Injury D 3 M 2 L
b Speed limits
148 movement of Roll over / tipping over
B Fatality E 4 M 2 L
d
a Maintenance programme
A Injury, spill C 2 M 2 M
b Steel components
149 Pumping Concrete Burst pipe / failed equipment
c
B Fatality, spill E 4 M 2 L
d
a
b
b
BASE RL
Environmental
Health Safety
ID
EXISTING CONTROL P
a Injury (burns, irritation, eye Cleaning process

A C 2 M
b injury) Designated area for cleaning
152 Cleaning after use Loss of control of waste material
a Trained operators
B Environmental incident B 1 M
b PPE
a Guards
A Rotating Injury C 2 M
b Caught in rotating plant (or Trained operators
153 equipment (both
a loose clothing caught)
B pump and truck) Fatality E 4 M
b
a Injury and environmental Barriers around excavation
A D 3 M
b Edge of Park vehicle too close - unstable incident Inspections of slope stability
154
a excavation edge fails Fatality and environmental
B E 4 M
b incident
a Site inspection
A Electric burns - injury D 3 M
b Overhead services Certified operators
155 Contact with electrical cable
a (pump)
B Electrocution - fatality E 4 M
b
LIGHT VEHICLE
a Staff licences recorded

A Injury D 3 M
b Accident travelling between and
197 Light vehicle
c on sites (vehicle to vehicle) Staff licences recorded
B Fatality E 4 M
d
a Site lighting
A Injury D 3 M
b Impact pedestrian (worker) on Speed limits
198 Light vehicle
c site Site lighting
B Fatality E 4 M
d Designated zones
b Traffic movements creates
199 Light vehicle
c excessive dust / noise
d
b
WHEELED / TRACK LOADER
a Designated roads
b Speed limits
c / Bucket Loader Licenced operators
B Fatality E 4 M
d
a Designated roads
b Speed limits
B Fatality E 4 M
d
a Designated roads
b Speed limits
B Fatality E 4 M
d
A Exceeds dust limits C 2 M
b Surface Mobile Traffic movements creates Plant moves very slowly
248 Equipment (SME)
c / Bucket Loader excessive dust / noise
d
b Distance to boundary
249 Loading trucks Creates excessive dust / noise.
c
d
a
b
BASE RL
Environmental
Health Safety
ID
EXISTING CONTROL P

b
a Restricted areas
A Injury D 3 M
b Mechanical failure allows bucket Maintenance
252 Raised bucket
c to drop on worker
B Fatality E 4 M
d
A Injury D 3 M
B Fatality E 4 M
A Injury D 3 M
254
B Fatality E 4 M
DRILL
a Drilling - geotech Contamination of sub surface MS provided

296 A Environmental incident D 3 M
b investigation water H2O used as lubricant
a Trained operators
A Unstable ground at edge of Accident injury D 3 M
b Drilling - geotech Pre setup inspections
297 excavation causes rig to topple
a investigation MS sets out set back distance
B over Accident - fatality E 4 M
b
a Hydraulic lines - Plant maintained
298 A Burst line Environmental issue C 2 M
b all drills
a Refuelling on site -
299 A Spill in uncontained area Environmental issue C 2 M
b all drills
a Trained operators
A Rotating Accident minor injury C 2 M
b Operator contacts rotating Area cordoned off
300 equipment - all
a drills equipment
B Accident - fatality E 4 M
b
a Working near edge of bench MS requires safe clearance
A Rock drilling- Accident injury D 3 M
b and / or unstable ground at Barriers in place at edge
301 rocks bolts /
a anchors edge of excavation causes rig to
B topple over Accident - fatality E 4 M
b
a Rock drilling- Drilling onto rock - chips fly from PPE -face masks/eye protection
302 A rocks bolts / Accident - injury D 3 M
contact point
b anchors
a PPE -face masks/ear protection
A Excessive noise levels D 3 M 1 L
b
303 Drilling - all drills Drilling into rock
c
B Excessive dust D 3 M 2 L
d
a Trained operators
A Large diameter Unstable ground at edge of Accident injury D 3 M
b Preset up inspections
304 drilling - piles / excavation causes rig to topple
c water extraction over MS sets out set back distance
d
a Trained operators
A Large diameter Accident injury D 3 M
b Uneven ground, uncompacted Preset up inspections
305 drilling - piles /
a water extraction ground causes rig to topple over
b
a Trained operators
A Large diameter Accident injury C 2 M
b Lose control of casing while Restricted area around rig
306 drilling - piles /
a water extraction installing / removing
b

BASE RL
Environmental
Health Safety
ID
EXISTING CONTROL P
TOWER AND MOBILE CRANES (incl TRUCK MOUNTED)
a Area inspection
A Uneven surface, poor load Load falls - injury D 3 M
b Positioning crane - Use of outriggers
399 carrying capacity or subsurface
c soil conditions Certified operators
B voids causes crane to topple Load falls - fatality E 4 M
d
a Positioning of Load falls crane topples - Area inspection
A Outrigger punctures through D 3 M
b crane on man injury Use of outriggers
400 structure - causes crane to
c made surface / Load falls crane topples - Certified operators
B topple E 4 M
d structure fatality
a Load inspected
A Exceeds safe load of crane / Load falls - injury E 3 L
b All equipment inspected
401 Load to be lifted rigging equipment - lift
c equipment fails Certified operators
B Load falls - fatality E 4 M
d Equipment certified
a Load inspected
A Load to be lifted outside safe Load falls - injury D 3 M
b All equipment inspected
402 Load to be lifted radius of operation of crane -
c crane topples Certified operators
B Load falls - fatality E 4 M
d Equipment certified
a Load falls crane topples - Certified operators
A Results in excess horizontal D 3 M
b injury
403 High wind loads on crane - cause s crane
c to topple Load falls crane topples -
B E 4 M
d fatality
a Equipment inspected
A Rigging gear, Load falls - injury D 3 M
b Damaged or in poor condition - No Go Zones under load
404 shackles, chains
c fails dropping load Certified operators
B etc Load falls - fatality E 4 M
d
b
a Load falls - injury + Equipment inspected
A E 4 M 2 L
b environmental No Go Zones under load
406 Hydraulic lines Burst Line
c Load falls - fatality +
B E 5 H 2 L
d environmental
A Electro / Load falls - injury D 3 M
b Failure of item results in loss of No Go Zones under load
407 Mechanical
c control of load
B equipment Load falls - fatality E 4 M
d
Site inspection
A Electric burns - injury D 2 L
Certified operators
408 Overhead services Contact with electrical cable
B Electrocution - fatality E 4 M
HYDRAULIC ROTARY CUTTER
a Trained operators
A Rotating Operator contacts rotating Accident minor injury D 3 M
b Area cordoned off
413 equipment - cutter equipment - caught in rotating
c head plant (or loose clothing caught) Accident - fatality
B E 4 M
d
a Restricted areas
A Unauthorised personal entry in Injury C 2 M
b Cutterhead boom / Trained operators
414 area of swinging cutterhead -
c arm person hit
B Fatality E 4 M
d
a Restricted areas
A Action of cutting Results in fly rock - fragment of Injury C 2 M
b Inside excavation
415 rock - face of rock that flies off and impacts
c excavation person in area PPE / glasses
B Fatality E 4 M
d
a Restricted areas
A Injury D 3 M
b Raised boom / Mechanical failure allows boom Maintenance
416
c arm to drop on worker Safety valve on system
B Fatality E 4 M
d
BASE RL
Environmental
Health Safety
ID
EXISTING CONTROL P
a Environmental issue / Working below ground

417 A Hydraulic lines Burst line C 2 M 2 M
b injury Soil disposal separate
a Working below ground
418 A Refuelling on site Spill in uncontained area Environmental issue C 2 M 2 M
b Soil disposal separate
A Injury D 3 M
B Fatality E 4 M
A Injury C 2 M
420
B Fatality E 4 M
Lock out procedures
A Maintaining Injury D 3 M
Cutterhead starts to rotate - Trained operators
421 cutterhead - new
impacts / hits / cuts operator
B teeth etc Fatality E 4 M
FORKLIFT and TELEHANDLER
a Uneven surface, poor load Load falls, unit topples - Area inspection
A Positioning D 3 M
b carrying capacity or subsurface injury Use stabilizers (if fitted)
446 telehandler - soil
c conditions voids causes telehandler to Load falls, unit topples - Certified operators
B topple E 4 M
d fatality
a Edges of pits or heaps unable to Load falls, unit topples - Keep load low
A C 2 M
b Ground conditions carry load, uneven surfaces, injury Drive slowly
447
c while moving slippery conditions etc - load Load falls, unit topples - Certified operator
B shifts E 4 M
d fatality Use seat belts
a Load falls, unit topples - Licenced driver
A Driving too fast (in corners), C 2 M
b Driving - moving / injury Load low to ground
448 need to brake for third party etc -
c carrying load load shifts - roll over Load falls, unit topples - Use seat belts
B E 4 M
d fatality
a Restricted areas
A Injury D 3 M
449
c arm / forks / arm / forks to drop on worker Safety valve on system
B Fatality E 4 M
d
a All services identified / removed
A Injury D 3 M
b Overhead services Travel with load low to ground
450 Contact with services / lines
c and power lines Full area inspection
B Fatality - electrocution E 4 M
d
a Environmental issue / Maintenance
451 A Hydraulic lines Burst line C 2 M
b injury
a Refuelling areas
b
a Designated roads
A Injury D 3 M
b Tele handler / Collision with light (or other) Speed limits
453
c forklift movement vehicle Licenced operators
B Fatality E 4 M
d
a Site lighting
A Injury D 3 M
b Mobile / moving Impact pedestrian (worker) on Speed limits
454
c equipment site Licenced drivers
B Fatality E 4 M
d Designated zones
A Exceeds dust limits E 2 L
b Mobile / moving Traffic movements creates
455
c equipment excessive dust / noise
d
a Load falls, unit topples - Keep load low
A C 2 M
b Load exceeds or near capacity injury Test lift
456 Load size (weight)
c of unit - causes unit to topple Load falls, unit topples - Certified operator
B E 4 M
d fatality Use seat belts
BASE RL
Environmental
Health Safety
ID
EXISTING CONTROL P
MAN LIFT, BOOM LIFT, AERIAL LIFT etc
a Area inspection
A Uneven surface, poor load Unit topples - injury D 3 M
b Positioning man Use stabilizers (if fitted)
462 carrying capacity or subsurface
c lift - soil conditions Certified operators
B voids causes man lift to topple Unit topples - fatality E 4 M
d
a All services identified / removed
A Injury D 3 M
b Overhead services Full area inspection
463 Contact with services / lines
c and power lines
B Fatality - electrocution E 4 M
d
a Restricted areas
A Injury D 3 M
464
c arm / forks / arm / forks to drop on worker Safety valve on system
B Fatality E 4 M
d
a Observe load placards
A Unit topples - injury D 3 M
b Load exceeds or near capacity Test lift
465 Load size (weight)
c of unit - causes unit to topple Certified operator
B Unit topples - fatality E 4 M
d
a Activity not permitted
A Push / move / drive man lift Unit topples - injury D 3 M
b Repositioning man Cannot move while in use
466 while boom raised and person in
c lift Certified operator
B basket Unit topples - fatality E 4 M
d
a Activity not permitted
A Load exceeds or near capacity Unit topples - injury D 3 M
b Using basket / Observe rules for use
467 of unit or creates off centre load-
c boom to lift load Certified operator
B causes unit to topple Unit topples - fatality E 4 M
d No side loads permitted
a Environmental issue / Maintenance
468 A Hydraulic lines Burst line C 2 M
b injury
a Refuelling areas
b
Do not use in wind
Wing creates side load - Use stabilizers (if fitted)
470 Use in high wind
causes man lift to topple Certified operators
Manufacturers safe use rules
Inspect prior to use
Tyre failure during Causes / permits uneven load - Use stabilizers (if fitted)
471
use causes man lift to topple Certified operators
Person in basket Observe rules for use

A Causes / permits uneven load - Unit topples - injury D 3 M
reaches / leans / Use stabilizers (if fitted)
472 causes man lift to topple or
climbs over the Certified operators
B person falls out of basket Unit topples - fatality E 4
guardrail Use harness
Rollers, Compactors
Operating Roller/ Worker Rotation
473 A Compactor for Excessive Vibration Injury D 2 L
long periods
Operating Roller/ Pre Task Briefing
474 A Pinch points Injury C 3 H
Compactor
Operating Water Tanker for Dust Control
475 A Creates Excessive Dust Injury C 2 M
Roller/Compactor Dust Masks
Operator Training
A Moving Injury C 3 H
Emergency Stop Button
476 Roller/Compactor Impacts worker on site
(All sizes) Flagman
B Fatality E 4 M
Operating Clothes get caught in moving No Loose Clothing

477 A Injury D 3 M
Roller/Compactor plant

BASE RL
Environmental
Health Safety
ID
EXISTING CONTROL P
Hand Gloves
Maintaining Roller/ Hand Gets caught in moving
478 A Injury D 3 M
Compactor part Training
Emergency Stop Button

A Injury D 3 M
Operating Training
479 Lose control of equipment
Roller/Compactor
B Fatality E 4 M
Spill Kit
480 A Refuelling on site Fuel Spill Environmental Incident C 2 M
Designated person to refuel
Operating/Maintai Spill Kit
481 A Oil leakage on site Environmental Incident C 2 M
ning equipment
Conveyor
Manual Handling - improper Training
482 A Assembly/Erection Injury C 2 M
handling of tools
Lift Plan
A Injury D 3 M
Working under lifted load - Load Adequate Lifting Gear
483 Assembly/Erection
falls
B Fatality E 4 M
Fall Arrest system

A Injury C 2 M
Training
484 Assembly/Erection Falling from height
B Fatality E 4 M
Trained workers
A Injury D 3 M
Operating Pinch points- hands or clothing Mesh Guards
485
Conveyor caught in moving parts No Loose clothing
B Fatality E 4 M
Loss of belt tension, belt Self Aligning Rollers

Operating
486 A missalignment, high belt speed - Injury D 3 M
Conveyor Regular Inspection/Maintenance
Load Falls
Electrocution, Electric Shock, Adequate Earthing
A Electric Fire Injury C 2 M
Fire extinguishers
Operating
487
Conveyor Emergency stop grap wire system
B Fatality E 4 M

Appendix 5

MasterRoc SA 430
Formerly MEYCO SA 430
Liquid sprayed concrete accelerator for wet-mix spraying
Product description Consumption

MasterRoc SA 430 is an accelerator for the wet- The consumption of MasterRoc SA 430 also
mix spraying process, but can also be used in the depends on the w/c+b ratio, temperature
dry-mix spraying process. It is a liquid additive conditions (concrete and ambient), cement
whose dosage can be varied to the desired setting reactivity and on required layer thickness, setting
and hardening times. time and early strength development. The
consumption is normally in the range of 3 to 8% of
Fields of application binder weight.
MasterRoc SA 430 is suitable for all applications
Overdosing (>8%) may result in decreased final
where high early strength and very thick sprayed
strength.
concrete layers are required.
For temporary ground support in tunneling and Storage
mining
Slope stabilization Storage temperature for MasterRoc SA 430 is
between + 5C and + 60C. If it has frozen, thaw at
+20 C or above and completely reconstitute with a
Features and benefits mild mechanical agitation. Please contact your
Fast setting and higher early strength local BASF representative prior to the use of any
Rapid word progress product that has been frozen. Performance tests
Low viscosity should always be carried out before use. If stored
tightly closed in original containers and under the
Easy to mix into the concrete, also at low
above conditions, MasterRoc SA 430 has a shelf
temperatures
life of at least 12 months.
Low consumption
Safety precautions
Packaging
MasterRoc SA 430 is an irritant fluid - any contact
MasterRoc SA 430 is supplied in IBCs or in bulk. with skin and eyes must be avoided. It is essential
that safety glasses and rubber gloves always be
Technical data worn during handling. The use of a protective
Form Liquid cream e.g. Ketodex 1, is recommended. In case of
Color Transparent contact with eyes or skin, flush immediately with
Density (at +20C) 1.34 0.02 plenty of water and seek medical advice.
pH value <11.5
Viscosity (at +20C) 30-70 mPa.s (cps) Further details can be found in the Material Safety
Solubility in water Total Data Sheet.
Thermal stability +5C
Chloride content <0.1%
Physiological effect Irritant to skin and eyes
Application procedure
The substrate must be clean and free from loose
particles and preferably damp. Fresh standard
Portland cement should be used because the
reaction time is increased by prolonged storage.
Preliminary tests are recommended for cements
providing high sulphate resistance.

MasterRoc SA 430
Formerly MEYCO SA 430
BASF_CC-UAE/Roc_SA430/v1/10_13
The technical information and application advice given in this BASF publication are based on the present state of
STATEMENT OF our best scientific and practical knowledge. As the information herein is of a general nature, no assumption can be
RESPONSIBILITY made as to a product's suitability for a particular use or application and no warranty as to its accuracy, reliability or
completeness either expressed or implied is given other than those required by law. The user is responsible for
checking the suitability of products for their intended use.
Field service where provided does not constitute supervisory responsibility. Suggestions made by
NOTE BASF either orally or in writing may be followed, modified or rejected by the owner, engineer or contractor since
they, and not BASF, are responsible for carrying out procedures appropriate to a specific application.
BASF Construction Chemicals UAE LLC

P.O. Box 37127, Dubai, UAE
Tel: +971 4 8090800 Fax: +971 4 8851002
www.basf-cc.ae

Safety data sheet
Page: 1/13
BASF Safety data sheet according to Regulation (EC) No. 1907/2006
Date / Revised: 10.06.2013 Version: 2.0
Product: MasterPozzolith 55R also POZZOLITH 55R
(ID no. 30601107/SDS_GEN_EU/EN)
Date of print 31.08.2013
SECTION 1: Identification of the substance/mixture and of the

company/undertaking
1.1. Product identifier
MasterPozzolith 55R also POZZOLITH 55R

1.2. Relevant identified uses of the substance or mixture and uses advised against
Relevant identified uses: Product for construction chemicals
1.3. Details of the supplier of the safety data sheet
Company:
BASF SE
67056 Ludwigshafen
GERMANY
Operating Division Construction Chemicals
Telephone: +49 621 60-74354

E-mail address: info.construction-chemicals@basf.com
1.4. Emergency telephone number
International emergency number:

Telephone: +49 180 2273-112
SECTION 2: Hazards Identification
2.1. Classification of the substance or mixture
According to Directive 67/548/EEC or 1999/45/EC
Possible Hazards:
May cause sensitization by skin contact.

Page: 2/13
2.2. Label elements
Directive 1999/45/EC ('Preparation Directive')
Hazard symbol(s)
Xi Irritant.
R-phrase(s)
R43 May cause sensitization by skin contact.
S-phrase(s)
S2 Keep out of the reach of children.
S24 Avoid contact with skin.
S37 Wear suitable gloves.
Hazard determining component(s) for labelling: MIXTURE OF: 5-CHLORO-2-METHYL-4-

ISOTHIAZOLIN-3-ONE AND 2-METHYL-2H-ISOTHIAZOL-3-ONE (3:1), FORMALDEHYDE
2.3. Other hazards
According to Regulation (EC) No 1272/2008 [CLP]
If applicable information is provided in this section on other hazards which do not result in
classification but which may contribute to the overall hazards of the substance or mixture.
SECTION 3: Composition/Information on Ingredients

3.1. Substances
Not applicable
3.2. Mixtures
Chemical nature
Aqueous solution based on: sodium salt, organic acids
Hazardous ingredients (GHS)

according to Regulation (EC) No. 1272/2008

Page: 3/13
sodium hydroxide; caustic soda

Content (W/W): < 0.5 % Skin Corr./Irrit. 1A
CAS Number: 1310-73-2 H314
EC-Number: 215-185-5
REACH registration number: 01-
2119457892-27
INDEX-Number: 011-002-00-6
formaldehyde...%
Content (W/W): >= 0.2 % - < 1 % Acute Tox. 3 (Inhalation - vapour)
CAS Number: 50-00-0 Acute Tox. 3 (oral)
EC-Number: 200-001-8 Acute Tox. 3 (dermal)
REACH registration number: 01- Skin Corr./Irrit. 1B
2119488953-20 Skin Sens. 1
INDEX-Number: 605-001-00-5 Carc. 2
H314, H311, H331, H301, H317, H351
mixture of: 5-chloro-2-methyl-4-isothiazolin-3-one [EC no.247- 500-7] and 2-methyl-2H-isothiazol-3-

one [EC no. 220-239-6] (3:1); mix ture of: 5-chloro-2-methyl-4-isothiazolin-3-one [EC no.247- 500-7]
and 2-methyl-4-isothiazolin-3-one [EC no. 220-239-6] (3:1)
Content (W/W): >= 0.0015 % - <= Acute Tox. 3 (oral)
0.02 % Acute Tox. 2 (Inhalation - mist)
CAS Number: 55965-84-9 Acute Tox. 2 (dermal)
INDEX-Number: 613-167-00-5 Skin Corr./Irrit. 1B
Skin Sens. 1
Aquatic Acute 1
Aquatic Chronic 1
M-factor acute: 10
M-factor chronic: 1
H314, H310, H330, H301, H317, H400, H410
Hazardous ingredients
according to Directive 1999/45/EC
sodium hydroxide; caustic soda

Content (W/W): < 0.5 %
CAS Number: 1310-73-2
REACH registration number: 01-2119457892-27
Hazard symbol(s): C
R-phrase(s): 35

Page: 4/13
formaldehyde...%
Content (W/W): >= 0.2 % - < 1 %
CAS Number: 50-00-0
REACH registration number: 01-2119488953-20
Hazard symbol(s): T
R-phrase(s): 23/24/25, 34, 40, 43
Carc. Cat. 3
mixture of: 5-chloro-2-methyl-4-isothiazolin-3-one [EC no.247- 500-7] and 2-methyl-2H-isothiazol-3-

one [EC no. 220-239-6] (3:1); mix ture of: 5-chloro-2-methyl-4-isothiazolin-3-one [EC no.247- 500-7]
and 2-methyl-4-isothiazolin-3-one [EC no. 220-239-6] (3:1)
Content (W/W): >= 0.0015 % - <= 0.02 %
CAS Number: 55965-84-9
Hazard symbol(s): T, N
R-phrase(s): 23/24/25, 34, 43, 50/53
For the classifications not written out in full in this section, including the indication of danger, the
hazard symbols, the R phrases, and the hazard statements, the full text is listed in section 16.
SECTION 4: First-Aid Measures

4.1. Description of first aid measures
First aid personnel should pay attention to their own safety. Immediately remove contaminated
clothing.
If inhaled:
If difficulties occur after vapour/aerosol has been inhaled, remove to fresh air and seek medical
attention.
On skin contact:
After contact with skin, wash immediately with plenty of water and soap. Under no circumstances
should organic solvent be used. If irritation develops, seek medical attention.
On contact with eyes:

Wash affected eyes for at least 15 minutes under running water with eyelids held open, consult an
eye specialist.
On ingestion:
Rinse mouth immediately and then drink plenty of water, seek medical attention. Do not induce
vomiting unless told to by a poison control center or doctor.
4.2. Most important symptoms and effects, both acute and delayed
Symptoms: allergic symptoms

Page: 5/13
4.3. Indication of any immediate medical attention and special treatment needed
Treatment: Treat according to symptoms (decontamination, vital functions), no known specific
antidote.
SECTION 5: Fire-Fighting Measures

5.1. Extinguishing media
Suitable extinguishing media:
foam, water spray, dry powder, carbon dioxide
Unsuitable extinguishing media for safety reasons:

water jet
5.2. Special hazards arising from the substance or mixture

Carbon dioxide, carbon monoxide, harmful vapours, nitrogen oxides, fumes/smoke, carbon black
5.3. Advice for fire-fighters

Special protective equipment:
Wear a self-contained breathing apparatus.
Further information:
The degree of risk is governed by the burning substance and the fire conditions. If exposed to fire,
keep containers cool by spraying with water. Collect contaminated extinguishing water separately, do
not allow to reach sewage or effluent systems. Contaminated extinguishing water must be disposed
of in accordance with official regulations.
SECTION 6: Accidental Release Measures

6.1. Personal precautions, protective equipment and emergency procedures
Do not breathe vapour/aerosol/spray mists. Wear eye/face protection. If exposed to high vapour
concentration, leave area immediately. Use personal protective clothing. Handle in accordance with
good building materials hygiene and safety practice.
6.2. Environmental precautions

Contain contaminated water/firefighting water. Do not discharge into drains/surface
waters/groundwater.
6.3. Methods and material for containment and cleaning up

For small amounts: Pick up with inert absorbent material (e.g. sand, earth etc.). Dispose of
contaminated material as prescribed.
For large amounts: Pump off product.
6.4. Reference to other sections

Information regarding exposure controls/personal protection and disposal considerations can be
found in section 8 and 13.

Page: 6/13
SECTION 7: Handling and Storage
7.1. Precautions for safe handling
Avoid aerosol formation. Avoid inhalation of mists/vapours. Avoid skin contact. No special measures
necessary provided product is used correctly.
7.2. Conditions for safe storage, including any incompatibilities
Suitable materials for containers: High density polyethylene (HDPE), Low density polyethylene
(LDPE)
Further information on storage conditions: Keep only in the original container in a cool, dry, well-
ventilated place away from ignition sources, heat or flame. Protect from direct sunlight.
7.3. Specific end use(s)

For the relevant identified use(s) listed in Section 1 the advice mentioned in this section 7 is to be
observed.
SECTION 8: Exposure Controls/Personal Protection

8.1. Control parameters
Components with occupational exposure limits
The substances without values are not listed in the occupational exposure regulations for the validity
area of this safety data sheet.
8.2. Exposure controls

Personal protective equipment
Hand protection:
Suitable chemical resistant safety gloves (EN 374) also with prolonged, direct contact
(Recommended: Protective index 6, corresponding > 480 minutes of permeation time according to
EN 374): E.g. nitrile rubber (0.4 mm), chloroprene rubber (0.5 mm), butyl rubber (0.7 mm) and other
Manufacturer's directions for use should be observed because of great diversity of types.
Eye protection:
Safety glasses with side-shields (frame goggles) (e.g. EN 166)
Body protection:
Body protection must be chosen depending on activity and possible exposure, e.g. apron, protecting
boots, chemical-protection suit (according to EN 14605 in case of splashes or EN ISO 13982 in case
of dust).
General safety and hygiene measures

Do not inhale gases/vapours/aerosols. Avoid contact with the skin, eyes and clothing. Avoid
exposure - obtain special instructions before use. Handle in accordance with good building materials
hygiene and safety practice. Wearing of closed work clothing is recommended. When using, do not
eat, drink or smoke. Hands and/or face should be washed before breaks and at the end of the shift.
At the end of the shift the skin should be cleaned and skin-care agents applied. Gloves must be
inspected regularly and prior to each use. Replace if necessary (e.g. pinhole leaks).

Page: 7/13
SECTION 9: Physical and Chemical Properties

9.1. Information on basic physical and chemical properties
Form: liquid
Colour: light yellow
Odour: almost odourless
pH value: approx. 6.0 - 9.0
slightly alkaline
Melting temperature: approx. 0 C
boiling temperature: > 100 C
(1,013 hPa)
Flash point: > 100 C
Evaporation rate:
not determined
Flammability: not flammable
Lower explosion limit:
not applicable
Upper explosion limit:
not applicable
Vapour pressure:
not applicable
Density: approx. 1.00 - 1.30 g/cm3
(25 C)
Relative vapour density (air):
not determined
Solubility in water: soluble
(20 C)
Thermal decomposition: No decomposition if stored and handled as prescribed/indicated.
Viscosity, dynamic: approx. 50 - 300 mPa.s
(25 C)
Explosion hazard: not explosive
9.2. Other information
Miscibility with water:

(20 C)
miscible
Solids content: 20 - 40 %
Other Information:
If necessary, information on other physical and chemical parameters is indicated in this section.
SECTION 10: Stability and Reactivity

10.1. Reactivity
No hazardous reactions if stored and handled as prescribed/indicated.

Page: 8/13
Corrosion to metals: No corrosive effect on metal.
10.2. Chemical stability

The product is stable if stored and handled as prescribed/indicated.
10.3. Possibility of hazardous reactions

10.4. Conditions to avoid

See MSDS section 7 - Handling and storage.
10.5. Incompatible materials
Substances to avoid:
strong acids, strong bases, strong oxidizing agents, strong reducing agents
10.6. Hazardous decomposition products
No hazardous decomposition products if stored and handled as prescribed/indicated.
SECTION 11: Toxicological Information

11.1. Information on toxicological effects
Acute toxicity
Assessment of acute toxicity:

Virtually nontoxic after a single ingestion. Based on available Data, the classification criteria are not
met.
Irritation
Assessment of irritating effects:

No irritation is expected under intended use and appropriate handling. Based on available Data, the
classification criteria are not met.
Respiratory/Skin sensitization
Assessment of sensitization:
May cause sensitization by skin contact.
Germ cell mutagenicity
Assessment of mutagenicity:
The chemical structure does not suggest a specific alert for such an effect. Based on available Data,
the classification criteria are not met.
Carcinogenicity
Assessment of carcinogenicity:

Page: 9/13
Reproductive toxicity
Assessment of reproduction toxicity:

Developmental toxicity
Assessment of teratogenicity:
Repeated dose toxicity and Specific target organ toxicity (repeated exposure)
Assessment of repeated dose toxicity:

No reliable data was available concerning repeated dose toxicity. Based on available Data, the
classification criteria are not met.
Other relevant toxicity information
Based on our experience and the information available, no adverse health effects are expected if
handled as recommended with suitable precautions for designated uses. The product has not been
tested. The statements on toxicology have been derived from the properties of the individual
components.
SECTION 12: Ecological Information

12.1. Toxicity
Assessment of aquatic toxicity:

Based on available Data, the classification criteria are not met. There is a high probability that the
product is not acutely harmful to aquatic organisms.
12.2. Persistence and degradability
Assessment biodegradation and elimination (H2O):

Inherently biodegradable. The insoluble fraction can be removed by mechanical means in suitable
waste water treatment plants.
12.3. Bioaccumulative potential
Assessment bioaccumulation potential:

No data available.
Discharge into the environment must be avoided.
12.4. Mobility in soil
Assessment transport between environmental compartments:

Page: 10/13
No data available.
12.5. Results of PBT and vPvB assessment
The product does not fulfill the criteria for PBT (Persistent/bioaccumulative/toxic) and vPvB (very
persistent/very bioaccumulative).
12.6. Other adverse effects
The product does not contain substances that are listed in Regulation (EC) 1005/2009 on
substances that deplete the ozone layer.
SECTION 13: Disposal Considerations
13.1. Waste treatment methods
Observe national and local legal requirements.

Residues should be disposed of in the same manner as the substance/product.
Contaminated packaging:
Contaminated packaging should be emptied as far as possible; then it can be passed on for
recycling after being thoroughly cleaned.
SECTION 14: Transport Information
Land transport
ADR
Not classified as a dangerous good under transport regulations
UN number: Not applicable
UN proper shipping name: Not applicable
Transport hazard class(es): Not applicable
Packing group: Not applicable
Environmental hazards: Not applicable
Special precautions for None known
user
RID
user

Page: 11/13
Inland waterway transport

ADN
user
Transport in inland Not evaluated
waterway vessel:
Sea transport
IMDG
user
Air transport
IATA/ICAO
user
14.1. UN number
See corresponding entries for UN number for the respective regulations in the tables above.
14.2. UN proper shipping name

See corresponding entries for UN proper shipping name for the respective regulations in the tables
above.

Page: 12/13
14.3. Transport hazard class(es)

See corresponding entries for Transport hazard class(es) for the respective regulations in the
tables above.
14.4. Packing group

See corresponding entries for Packing group for the respective regulations in the tables above.
14.5. Environmental hazards

See corresponding entries for Environmental hazards for the respective regulations in the tables
above.
14.6. Special precautions for user

See corresponding entries for Special precautions for user for the respective regulations in the
tables above.
14.7. Transport in bulk according to Annex II of MARPOL73/78 and the IBC Code
Regulation: Not evaluated
Shipment approved: Not evaluated
Pollution name: Not evaluated
Pollution category: Not evaluated
Ship Type: Not evaluated
SECTION 15: Regulatory Information

15.1. Safety, health and environmental regulations/legislation specific for the
substance or mixture
15.2. Chemical Safety Assessment
Chemical Safety Assessment not required
SECTION 16: Other Information
Full text of the classifications, including the indication of danger, the hazard symbols, the R phrases,
and the hazard statements, if mentioned in section 2 or 3:
C Corrosive.
T Toxic.
N Dangerous for the environment.
35 Causes severe burns.
23/24/25 Toxic by inhalation, in contact with skin and if swallowed.
34 Causes burns.
40 Limited evidence of a carcinogenic effect.
43 May cause sensitization by skin contact.
50/53 Very toxic to aquatic organisms, may cause long-term adverse effects in
the aquatic environment.
Skin Corr./Irrit. Skin corrosion/irritation
Acute Tox. Acute toxicity

Page: 13/13
Skin Sens. Skin sensitization
Carc. Carcinogenicity
Aquatic Acute Hazardous to the aquatic environment - acute
Aquatic Chronic Hazardous to the aquatic environment - chronic
Carc. Cat. 3 Carcinogenic substances Category 3: Substances which cause concern
for man owing to possible carcinogenic effects.
H314 Causes severe skin burns and eye damage.
H311 Toxic in contact with skin.
H331 Toxic if inhaled.
H301 Toxic if swallowed.
H317 May cause an allergic skin reaction.
H351 Suspected of causing cancer.
H310 Fatal in contact with skin.
H330 Fatal if inhaled.
H400 Very toxic to aquatic life.
H410 Very toxic to aquatic life with long lasting effects.
The data contained in this safety data sheet are based on our current knowledge and experience and
describe the product only with regard to safety requirements. The data do not describe the product's
properties (product specification). Neither should any agreed property nor the suitability of the product for
any specific purpose be deduced from the data contained in the safety data sheet. It is the responsibility
of the recipient of the product to ensure any proprietary rights and existing laws and legislation are
observed.
Vertical lines in the left hand margin indicate an amendment from the previous version.

Safety data sheet
Page: 1/9
Product: MasterRoc SA 430 also MEYCO SA 430
1. Identification of the substance/mixture and of the company/undertaking

Product identifier
MasterRoc SA 430 also MEYCO SA 430

Relevant identified uses of the substance or mixture and uses advised against
Relevant identified uses: Product for construction chemicals
Details of the supplier of the safety data sheet
Company:
BASF SE
67056 Ludwigshafen
GERMANY
Operating Division Construction Chemicals
Telephone: +49 621 60-74354

E-mail address: info.construction-chemicals@basf.com
Emergency telephone number
International emergency number:

Telephone: +49 180 2273-112
2. Hazards Identification
Label elements
EEC Directives
The product does not require a hazard warning label in accordance with EC Directives.
Classification of the substance or mixture

Page: 2/9
Possible Hazards:
No specific dangers known, if the regulations/notes for storage and handling are considered.
Other hazards
According to Regulation (EC) No 1272/2008 [CLP]
Other Hazards (GHS):

No specific dangers known, if the regulations/notes for storage and handling are considered.
3. Composition/Information on Ingredients
Mixtures
Chemical nature
silicates, modified, aqueous solution
4. First-Aid Measures
Description of first aid measures
First aid personnel should pay attention to their own safety. Remove contaminated clothing.
If inhaled:
If difficulties occur after vapour/aerosol has been inhaled, remove to fresh air and seek medical
attention.
On skin contact:
After contact with skin, wash immediately with plenty of water and soap. If irritation develops, seek
medical attention.
On contact with eyes:

Wash affected eyes for at least 15 minutes under running water with eyelids held open, consult an eye
specialist.
On ingestion:
Rinse mouth immediately and then drink plenty of water, seek medical attention. Do not induce
vomiting unless told to by a poison control center or doctor.
Most important symptoms and effects, both acute and delayed

Symptoms: No significant symptoms are expected due to the non-classification of the product.
Indication of any immediate medical attention and special treatment needed

Treatment: Treat according to symptoms (decontamination, vital functions), no known specific
antidote.

Page: 3/9
5. Fire-Fighting Measures
Extinguishing media
Suitable extinguishing media:
foam, water spray, dry powder, carbon dioxide
Unsuitable extinguishing media for safety reasons:

water jet
Special hazards arising from the substance or mixture

carbon monoxide, carbon dioxide, harmful vapours, nitrogen oxides, fumes/smoke, carbon black
Advice for fire-fighters

Special protective equipment:
Wear a self-contained breathing apparatus.
Further information:
The degree of risk is governed by the burning substance and the fire conditions. Contaminated
extinguishing water must be disposed of in accordance with official regulations.
6. Accidental Release Measures

Personal precautions, protective equipment and emergency procedures
Use personal protective clothing. Do not breathe vapour/aerosol/spray mists. Sources of ignition
should be kept well clear. Handle in accordance with good building materials hygiene and safety
practice.
Environmental precautions
Contain contaminated water/firefighting water. Do not discharge into drains/surface
waters/groundwater.
Methods and material for containment and cleaning up

For small amounts: Pick up with inert absorbent material (e.g. sand, earth etc.). Dispose of
contaminated material as prescribed.
For large amounts: Pump off product.
Reference to other sections

Information regarding exposure controls/personal protection and disposal considerations can be found
in section 8 and 13.
7. Handling and Storage

Precautions for safe handling
Avoid aerosol formation. Avoid inhalation of mists/vapours. Avoid skin contact. No special measures
necessary provided product is used correctly.
Protection against fire and explosion:

No special precautions necessary.
Conditions for safe storage, including any incompatibilities

Segregate from foods and animal feeds.

Page: 4/9
Suitable materials for containers: High density polyethylene (HDPE)

Further information on storage conditions: Keep only in the original container in a cool, dry,
well-ventilated place away from ignition sources, heat or flame. Store protected against freezing.
Protect from direct sunlight.
Protect from temperatures below: 0 C

The packed product must be protected from temperatures below the indicated one.
Specific end use(s)

For the relevant identified use(s) listed in Section 1 the advice mentioned in this section 7 is to be
observed.
8. Exposure Controls/Personal Protection

Control parameters
Components with workplace control parameters
The substances without values are not listed in the occupational exposure regulations for the validity
area of this safety data sheet.
Exposure controls
Personal protective equipment
Respiratory protection:
Wear respiratory protection if ventilation is inadequate. Combination filter for gases/vapours of
organic, inorganic, acid inorganic and alkaline compounds (e.g. EN 14387 Type ABEK).
Hand protection:
impermeable gloves
Synthetic rubber gloves
Manufacturer's directions for use should be observed because of great diversity of types.
Eye protection:
Safety glasses with side-shields (frame goggles) (e.g. EN 166)
Body protection:
light protective clothing
General safety and hygiene measures

In order to prevent contamination while handling, closed working clothes and working gloves should be
used. Handle in accordance with good building materials hygiene and safety practice. When using, do
not eat, drink or smoke. Hands and/or face should be washed before breaks and at the end of the shift.
At the end of the shift the skin should be cleaned and skin-care agents applied. Gloves must be
inspected regularly and prior to each use. Replace if necessary (e.g. pinhole leaks).
9. Physical and Chemical Properties

Information on basic physical and chemical properties
Form: liquid

Page: 5/9
Colour: transparent
Odour: odourless
pH value: approx. 11.3
(20 C)
Information on: water
Melting point: 0 C
----------------------------------
Boiling point: 100 C
----------------------------------
Flash point:
Non-flammable.
Flammability: does not ignite
Vapour pressure: 23.4 hPa
(20 C)
Literature data.
----------------------------------
Density: approx. 1.34 - 1.37 g/cm3
(20 C)
Solubility in water: miscible
(20 C)
Thermal decomposition: No decomposition if stored and handled as prescribed/indicated.
Viscosity, dynamic: approx. 30 - 70 mPa.s
(approx. 20 C)
Explosion hazard: not explosive
Other information
Miscibility with water:

(20 C)
miscible in all proportions
Hygroscopy: Non-hygroscopic
Other Information:
If necessary, information on other physical and chemical parameters is indicated in this section.
10. Stability and Reactivity

Reactivity
No hazardous reactions if stored and handled as prescribed/indicated.
Corrosion to metals: Corrosive effects to metal are not anticipated.
Chemical stability
Possibility of hazardous reactions

Conditions to avoid
See MSDS section 7 - Handling and storage.
Incompatible materials

Page: 6/9
Substances to avoid:
strong acids, strong bases, strong oxidizing agents
Hazardous decomposition products
No hazardous decomposition products if stored and handled as prescribed/indicated.
11. Toxicological Information

Information on toxicological effects
Acute toxicity
Assessment of acute toxicity:

Virtually nontoxic after a single ingestion. The product has not been tested. The statement has been
derived from products of a similar structure or composition.
Irritation

Not irritating to eyes and skin. No irritation is expected under intended use and appropriate handling.
Information on: Silicic acid, sodium salt

Corrosive! Damages skin and eyes.
----------------------------------
Respiratory/Skin sensitization
Assessment of sensitization:
The product has not been tested. The statement has been derived from the properties of the individual
components.
Germ cell mutagenicity
Assessment of mutagenicity:
The chemical structure does not suggest a specific alert for such an effect. The product has not been
tested. The statement has been derived from the properties of the individual components.
Carcinogenicity
Assessment of carcinogenicity:
The chemical structure does not suggest a specific alert for such an effect.
Reproductive toxicity
Assessment of reproduction toxicity:

The chemical structure does not suggest such an effect. The product has not been tested. The
statement has been derived from the properties of the individual components.
Developmental toxicity
Assessment of teratogenicity:

Page: 7/9
The chemical structure does not suggest such an effect. The product has not been tested. The
statement has been derived from the properties of the individual components.
Repeated dose toxicity and Specific target organ toxicity (repeated exposure)
Assessment of repeated dose toxicity:

No reliable data was available concerning repeated dose toxicity.
Other relevant toxicity information
Based on our experience and the information available, no adverse health effects are expected if
handled as recommended with suitable precautions for designated uses. The product has not been
tested. The statements on toxicology have been derived from products of a similar structure and
composition.
12. Ecological Information

Toxicity
Assessment of aquatic toxicity:

At the present state of knowledge, no negative ecological effects are expected. There is a high
probability that the product is not acutely harmful to aquatic organisms. The product has not been
tested. The statement has been derived from products of a similar structure or composition.
Persistence and degradability
Assessment biodegradation and elimination (H2O):

Inherently biodegradable. The insoluble fraction can be removed by mechanical means in suitable
waste water treatment plants.
Bioaccumulative potential
Assessment bioaccumulation potential:

No data available concerning bioaccumulation.
Mobility in soil (and other compartments if available)
Assessment transport between environmental compartments:

No data available.
Results of PBT and vPvB assessment
The product does not fulfill the criteria for PBT (persistent/bioaccumulative/toxic) or vPvB (very
persistent/very bioaccumulative).
13. Disposal Considerations
Waste treatment methods
Observe national and local legal requirements.

Residues should be disposed of in the same manner as the substance/product.
Waste key:

Page: 8/9
16 03 04 inorganic wastes other than those mentioned in 16 03 03
Contaminated packaging:
Contaminated packaging should be emptied as far as possible; then it can be passed on for recycling
after being thoroughly cleaned.
14. Transport Information
Land transport
ADR
RID
Inland waterway transport

ADN
Sea transport
IMDG
Air transport
IATA/ICAO
15. Regulatory Information

Safety, health and environmental regulations/legislation specific for the substance or
mixture
If other regulatory information applies that is not already provided elsewhere in this safety data sheet,
then it is described in this subsection.
16. Other Information
The data contained in this safety data sheet are based on our current knowledge and experience and
describe the product only with regard to safety requirements. The data do not describe the product's
properties (product specification). Neither should any agreed property nor the suitability of the product for
any specific purpose be deduced from the data contained in the safety data sheet. It is the responsibility of
the recipient of the product to ensure any proprietary rights and existing laws and legislation are observed.

Page: 9/9
Vertical lines in the left hand margin indicate an amendment from the previous version.

Appendix 6

Al Messila Batching Plant #1 - ANNULUS GROUT SAMPLES - January 2016
Flow (SEC.) Gel Time Density Bleeding (%) Initial Set Time (MPA) Volume Required
Date Certificate 3
Time Ref No: Marsh Cone (SEC.) (KG/M ) BS 8110 ASTM C403 Batched M Samples
Sampled Number
1 2 AVG 1 Hr. 2 Hr. 3 Hr. 4 Hr. 5 Hr. 8 Hr. 11 Hr. 14 Hr. 17 Hr. 20 Hr. 23Hr. 24 Hr. 1 Hr. 2 Hr. 3 Hr. 5 Hr. 10 Hr. 15 Hr. 20 Hr. 24 Hr. 1/25m
< 15 Sec < 15 Secs > 0.05 > 0.3 > 1.0
04-12-15
05-12-15 2:00 7.9 7.9 7.9 9.8 1258 28 36 48 0.19 0.55 7.17
05-12-15 8:00 7.9 7.9 7.9 7.1 1273 28 39 48 0.15 0.52 5.52
05-12-15 23:00 7.9 7.9 7.9 9.7 1272 25 40 49 0.21 0.58 6.90
06-12-15 20:00 7.9 7.9 7.9 10.1 1251 23 34 44 0.14 0.69 7.45
06-12-15 22:00 7.9 7.8 7.9 10.4 1238 25 35 45 0.15 0.66 6.90
06-12-15 23:00 7.9 7.8 7.9 10.3 1242 24 35 46 0.18 0.63 7.17
07-12-15 1:00 8.1 8.2 8.1 9.8 1218 18 35 50 0.14 0.58 6.34
07-12-15 7:00 7.9 7.9 7.9 7.1 1269 20 33 43 0.14 0.47 5.52
07-12-15 10:00 7.9 8.0 7.9 7.1 1264 23 35 45 0.14 0.50 5.52
07-12-15 15:00 7.9 7.9 7.9 7.1 1270 19 31 41 0.15 0.52 5.52
07-12-15 18:00 8.2 8.2 8.2 9.7 1234 15 34 49 0.14 0.61 6.62
07-12-15 22:00 8.2 8.3 8.3 9.5 1248 13 35 48 0.15 0.63 7.17
08-12-15 7:00 7.9 7.9 7.9 7.1 1255 19 30 46 0.15 0.52 5.79
08-12-15 11:00 7.9 8.0 7.9 7.1 1251 16 28 44 0.15 0.50 5.52
08-12-15 17:00 7.9 8.0 8.0 9.7 1308 15 25 36 0.22 0.63 6.90
08-12-15 23:00 7.8 7.9 7.9 10.0 1287 18 29 39 0.19 0.58 7.17
09-12-15 7:00 8.0 8.1 8.0 7.5 1216 18 39 53 0.15 0.52 5.52
10-12-15
11-12-15
12-12-15 8:00 7.9 7.9 7.9 7.5 1273 29 40 49 0.15 0.52 5.52
13-12-15
14-12-15
15-12-15
16-12-15
17-12-15
18-12-15
19-12-15 0:00 8.2 8.2 8.2 9.4 1208 9 11 13 0.14 0.52 6.07
19-12-15 8:00 8.0 8.1 8.1 7.5 1269 21 33 45 0.14 0.50 5.52
19-12-15 12:00 8.1 8.1 8.1 7.5 1270 24 35 48 0.14 0.52 5.52
19-12-15 19:00 8.2 8.1 8.2 9.5 1184 10 13 14 0.14 0.50 5.52
20-12-15 10:00 8.1 8.2 8.1 7.5 1280 21 30 44 0.14 0.47 5.52
21-12-15
22-12-15
23-12-15
24-12-15 12:00 8.0 8.0 8.0 7.5 1238 24 39 48 0.14 0.50 5.52
24-12-15 15:00 7.9 7.9 7.9 7.4 1240 25 39 49 0.14 0.52 5.52
25-12-15
26-12-15 8:00 8.0 8.0 8.0 7.6 1296 25 39 48 0.14 0.52 5.79
27-12-15 0:00 8.1 8.1 8.1 9.6 1218 9 14 23 0.15 0.55 6.07
27-12-15 10:00 8.0 8.1 8.1 7.6 1269 20 33 43 0.14 0.50 5.52
27-12-15 13:00 8.1 8.1 8.1 7.5 1272 18 30 40 0.14 0.47 5.52

Al Messila Batching Plant #1 - ANNULUS GROUT SAMPLES - January 2016
Flow (SEC.) Gel Time Density Bleeding (%) Initial Set Time (MPA) Volume Required
Date Certificate 3
Time Ref No: Marsh Cone (SEC.) (KG/M ) BS 8110 ASTM C403 Batched M Samples
Sampled Number
1 2 AVG 1 Hr. 2 Hr. 3 Hr. 4 Hr. 5 Hr. 8 Hr. 11 Hr. 14 Hr. 17 Hr. 20 Hr. 23Hr. 24 Hr. 1 Hr. 2 Hr. 3 Hr. 5 Hr. 10 Hr. 15 Hr. 20 Hr. 24 Hr. 1/25m
< 15 Sec < 15 Secs > 0.05 > 0.3 > 1.0
27-12-15 21:00 8.2 8.1 8.2 9.5 1184 10 13 19 0.14 0.50 5.52
28-12-15 6:00 8.2 8.2 8.2 7.6 1287 23 30 44 0.14 0.52 5.52
29-12-15 9:00 8.1 8.2 8.2 7.5 1259 20 29 44 0.14 0.50 5.79
29-12-15 12:00 8.2 8.2 8.2 7.6 1262 23 31 46 0.14 0.52 5.79
30-12-15
31-12-15 1308.0 53
27039
Number Samples 834 Sampling % Compliant = 74 Required 1128
Total Samples 2516
Total Volume 86878
Samples Req 3475
Total Compliance % 72

ANNULUS GROUT GRAPHS - January 2016
14.0
Flow
12.0 Series1
10.0
Seconds
8.0
6.0
4.0
2.0
0.0
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500
Setting Mpa
16.0
1 Hour Set Time 2 Hrs
14.0
12.0
Set Time 24 Hours
10.0
Mpa
8.0
6.0
4.0
2.0
0.0
1 101 201 301 401 501 601 701 801 901 1001 1101 1201 1301 1401 1501 1601 1701 1801 1901 2001 2101 2201 2301 2401
16.0
Gel Time
Gel Time - Seconds
14.0
12.0
10.0
Seconds
8.0
6.0
4.0
2.0
0.0
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500


Method Statement - Grouting of Segmental Lining Green Line

Загружено:

Сведения о документе

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Method Statement - Grouting of Segmental Lining Green Line

Загружено:

Авторское право:

Доступные форматы

Document History

Rev. No. Description of Revision Date of Revision

1/2 Incorporated comments, additional chapter 28.07.2015

3 Incorporated comments, additional chapter 14.01.2016

4 Incorporated comments 01.03.2016

Method Statement for Grouting of Segmental Lining Rev 04

Method Statement for Grouting of Segmental Lining Rev 04

Appendix 1 PMC Comments / Contractor Response Rev 2

HARDCOPY DISTRIBUTION LIST

Hardcopy Distribution List*

Copy No. Name Company Position Signature

001 Qatar Rail Project Owner

003 PSH Project Director

006 PSH QA / QC Manager

007 PSH HSE Manager

** It is the responsibility of the Construction Manager to provide this Method Statement

Method Statement for Grouting of Segmental Lining Rev 04

ARCH Project Archive

Method Statement for Grouting of Segmental Lining Rev 04

Methodology for execution of Grouting works of Segmental Lining

Method Statement for Grouting of Segmental Lining Rev 04

Qatar Construction Specification 2010 (QCS 2010)

Method Statements for:

Title Code Status

2.2 Revisions of Method Statement Documents

The revised MS shall be submitted to the Engineer for SONO.

3 ROLES AND RESPONSIBILITIES

The Material Engineer is part of the QA/QC team.

4 EQUIPMENT AND MATERIALS USED

Method Statement for Grouting of Segmental Lining Rev 04

4.2 Material used

5 QUALITY ASSURANCE / QUALITY CONTROL

5.1 Handling and Storing of Materials

6 HEALTH, SAFETY, ENVIRONMENT

Method Statement for Grouting of Segmental Lining Rev 04

Daily Tool Box talks are held and attendance logged.

Specific HSE Hazards are mitigated in the Job Hazard Analysis.

7 JOB HAZARD ANALYSIS

8.1 Temporary Works

Method Statement for Grouting of Segmental Lining Rev 04

8.2.2 Bi-component grouting system

Method Statement for Grouting of Segmental Lining Rev 04

8.2.2.1 Injection material Component A

Method Statement for Grouting of Segmental Lining Rev 04

8.2.2.3 System components batching plant

Figure 8.2-2 Layout of the Mixing Unit

Method Statement for Grouting of Segmental Lining Rev 04

Table 8.2-1 Required Equipment

Water Tank 3x 10,000 gal

8.2.2.3.2 Function of the Mixing Unit

Figure 8.2-3 Principle of the Mixing Unit

Method Statement for Grouting of Segmental Lining Rev 04

Wet bulb temperature 30C

8.2.2.3.4 Mixing Unit

Figure 8.2-4 Colloidal mixer

Figure 8.2-5 Particular of an open impeller pump

8.2.2.3.5 Buffer tank

Figure 8.2-6 Buffer tank (capacity 20m)

Method Statement for Grouting of Segmental Lining Rev 04

8.2.2.3.6 Screw pumps

Table 8.2-2 Technical Data Screw pump

8.2.2.4 System components on the TBM

8.2.2.4.1 Basic principle

Method Statement for Grouting of Segmental Lining Rev 04