Project Reference: Precision Grouts
- MasterFlow 815 a cementitious high strength non-shrink precision grout
- MasterFlow 648 a high flow epoxy resin grout with adjustable viscosity
- MasterFlow 618 a heavy-duty epoxy resin grout
The Background
The Gorgon Project is one of the world's largest natural gas projects and the largest single resource development in Australia's history. This Project was a joint venture between the Australian subsidiaries of Chevron, ExxonMobil, Shell, Osaka Gas, Tokyo Gas and Chubu Electric Power. The project involved developing the gas fields within the Greater Gorgon area, located off the North West coast of Western Australia (WA). It also included the construction of a 15.6 million tonne per annum liquefied natural gas (LNG) plant on Barrow Island and a smaller domestic gas plant as well.
The Challenge
In order to build the state-of-the-art LNG facility, CK JV needed a supplier that could deliver the full range of precision grouting products. They also needed a supplier that understood the local environmental and regulatory challenges. They needed to adhere to the biosecurity restrictions put in place to protect the Class A reserve status of the site on Barrow Island. CK JV needed a trusted global company with the highest level of quality assurance. Also critical to the Project was the surety of supply. Given the remote location, the lead time from placement of order to arrival on-site, was a period of several weeks. This required careful management of scheduling between Master Builders Solutions and the several subcontractors involved.
Our Solution
In 2009, the Master Builders Solutions team first began working with the team of CK JV global engineers before construction commenced. These engineers then became the CK JV team leaders in Australia when the Project eventually began in 2011, and this early interaction built the trust and confidence required. Master Builders Solutions had the quality assurance systems the client was looking for. We further tailored these quality systems to meet the biosecurity requirements.
Master Builders Solutions‘ packaging and supply systems were aligned to meet the biosecurity restrictions, including labeling, packaging, transport, and fumigation. Individual quality assurance certificates were issued for every batch supplied to the project. We also implemented certified on-site applicator training for both placing and testing of our products. Master Builders Solutions facilitated bio-secured fresh product on site on time, in line with the arrival of overseas modules.
Project Facts at a Glance
- Construction of Gorgon LNG project was from 2011-2016
- A range of Master Builders Solutions’ cementitious precision and epoxy grouts were used, including MasterFlow 4500, MasterFlow 815, MasterFlow 648 and MasterFlow 618
Product Facts at a Glance
- MasterFlow 4500 is used for all precision, non-shrink grouting applications with clearances of 10mm or more
- It is specially formulated to provide extended working time even at high ambient temperatures when mixed and placed at any recommended consistency
- MasterFlow 815 is generally used for deep pour applications between 50mm and 500mm
- It provides good early and ultimate strengths, which ensure quick return to service and long term durability
- MasterFlow 648 provides high early and 7 day strengths as well as excellent resistance to high operating temperatures and crack inducing vibration
- MasterFlow 618 is supplied as a two-component system consisting of epoxy resin, combined with inert fillers and the hardener, to produce a high viscosity flowable liquid grout
The Customer's Benefit
- Exclusive partner from design to production over the five-year period
- Maintained the status Class A nature reserve
- Secured quality assurance for a unique project in a unique environment
- Met the strict biosecurity demand imposed for the Project
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