Project Reference: Precision Grouts - Pluto Liquefied Natural Gas (LNG) Facility
Source: Monford Group
Location: Karratha, Western Australia
Applicator/Contractor: Foster Wheeler Worley Parsons
Market Sector: Precision grouts
Products used:
- MasterFlow 4500 a cementitious non-shrink precision grout with excellent high early and ultimate strengths
- MasterFlow 815 a cementitious high strength non-shrink precision grout for deep pour applications
- MasterFlow 648 a high strength, high temperature, high flow epoxy resin grout
- MasterFlow 618 a heavy-duty epoxy resin grout with rapid hardening properties
Download the Project Reference PDF
The Background
Woodside is Australia’s most experienced LNG operator and largest independent oil and gas company. In a joint venture with Tokyo Gas and Kansai Electric, they began developing plans for a world-class LNG facility, Pluto, in 2005. The project captured gas from fields located 190 kilometres off the coast of Karratha, in Western Australia. The gas is then sent to shore through a pipeline for processing. One of the project’s major contractors, Foster Wheeler WorleyParsons (FWW), turned to Master Builders Solutions for a suite of high-precision grouts during the construction phase of the Pluto processing plant.
The Challenge
In order to build the state-of-the-art LNG facility, FWW needed to engage a supplier that could deliver the full range of precision grout products. They also needed a supplier that understood the environmental and regulatory challenges. FWW needed a trusted global company with the highest level of quality assurance. Also critical to the Project was 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 other subcontractors involved.
Our Solution
In 2007, Master Builders Solutions began working with a team of FWW global engineers before the construction process took place. These engineers then became the FWW team leaders in Australia when the Project eventually began in 2008.
This early interaction established the trust and confidence required between Master Builders Solutions and FWW, both locally and globally. Master Builders Solutions had the quality assurance systems the client was looking for. We further tailored the systems to align with the local environmental, and regulatory quality requirements. Individual quality assurance certificates were issued with every batch supplied to the project. Master Builders Solutions also implemented certified on-site applicator training for both the placing and testing of our products. Master Builders Solutions aligned production schedules with sub-contractors well in advance of product requirements. This allowed fresh product to be on site on time, and in line with the arrival of overseas modules.
Project Facts at a Glance
- The construction period was between 2008 - 2012
- A range of Master Builders Solutions cementitious, precision and epoxy grouts were specified including MasterFlow 4500, MasterFlow 815, MasterFlow 648 and MasterFlow 618
Product Facts at a Glance
- MasterFlow 4500 is specially formulated to provide extended working time even at high ambient temperatures
- MasterFlow 815 contains specially graded natural aggregate and provides high early and ultimate compressive strengths and is generally used for deep pour applications
- MasterFlow 648 has high flow making it very effective for narrow gaps and large baseplates, it also has great chemical resistance
- MasterFlow 618 is resistant to vibration and impact, particularly applicable where cycles of compression/ tension make cementitious grouts unsuitable
Customer's Benefit
- Exclusive partner from design to production, over the five year period
- Master Builders Solutions delivered the right solutions on time as required
- Strategic expertise and advice to address challenges as they arose during construction
The Pluto facility in Western Australia. Image source: Woodside image gallery
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