011-Method Statement For Repair of Concrete Works PDF
011-Method Statement For Repair of Concrete Works PDF
011-Method Statement For Repair of Concrete Works PDF
Project
Shell Project No: HP-3000-QAT
Project Document Number: T- 4.234.073
2MH127
Tag/Item Number(s):
N/A
Unit(s):
ASU
PCWBS:
LINDE ENGINEERING
Page 2 of 23
5887
01.12.08
SB
EO
AG
RFC
01.10.08
SB
EO
AG
IFR
13.07.08
SB
EO
AG
IFR
30.03.08
SB
UA
ZG
RFC
23.03.08
SB
UA
ZG
RFC
23.02.08
SB
UA
ZG
RFC
09.12.07
SB
AU/MC
ZG
ICC
23.11.07
SB
AU/MC
ZG
IFR
20.11.07
SB
AU/MC
ZG
IIR
Date
Description
GAMA
Rev.
No.
Project
Rev
No.
Status
Document Title:
LINDE ENGINEERING AG
Contractor
LOC470
GAM
MTS
CIV
GTL
011
Org.
Code
Doc.
Type
Disc.
Code
Geogr.
Area
Seq.
No
Rev.
No
Vendor Code
Rev No: F
Q A T A R
Doc. Title
GAM-MTS-CIV-GTL-011
MS FOR REPAIR OF CONCRETE WORKS
Date
01.12.2008
REV. I
TABLE OF CONTENTS
1.
PURPOSE _____________________________________________________________________ 5
2.
SCOPE ________________________________________________________________________ 5
3.
HSSE _________________________________________________________________________ 5
4.
REFERENCES _________________________________________________________________ 6
5.
DEFINITIONS _________________________________________________________________ 6
6.
RESPONSIBILITY ______________________________________________________________ 6
6.1 Site Manager _________________________________________________________________________6
6.2 Civil Works Manager __________________________________________________________________6
6.3 Site Engineer _________________________________________________________________________6
6.4 Work Supervisor ______________________________________________________________________7
6.5 QA/QC Officer / Inspector ______________________________________________________________7
7.
8.
9.
Curing ________________________________________________________________________ 10
10.
11.
ATTACHMENTS _____________________________________________________________ 11
T-4.234.073 Rev. F
Page 4 of 23
Q A T A R
Doc. Title
GAM-MTS-CIV-GTL-011
MS FOR REPAIR OF CONCRETE WORKS
Date
01.12.2008
REV. I
1. PURPOSE
This document describes the methods proposed to be used for the concrete repair
activities that will be carried out as part of ASU Construction Works of Qatar Shell GTL
Plant (Pearl) in Ras Laffan Industrial City of Qatar including similar works in TSF Area.
2. SCOPE
This method statement covers methods for Concrete repair works.
3. HSSE
All works shall be in compliance with the State of Qatar laws and regulations, Ras Laffan
Industrial City and international standards/codes, and Company and Contractor
requirements and instructions.
All personnel will go through Gama, Linde and Company Safety Induction courses as well
as other trainings as identified by their supervisor. A Job Safety Analysis (JSA) specific
for this work including a Risk Assessment is prepared and attached herein. Such JSA
addresses the hazards associated with each task within the scope of this Method
Statement and introduces the controls that will be implemented to reduce the associated
risks to acceptable levels. The JSA will be used by the Site Supervisor as the basis of his
TSTI / TSTO and Toolbox Talks.
All personnel will have PPE required for their specific tasks in addition to the minimum
PPE (coveralls, safety goggles, safety shoes, high-visibility vests, gloves) at site at all
times as required.
In the event of a release, fire or explosion, employees will secure their area and evacuate
to the nearest muster point. Once all employees are evacuated the supervisor will
conduct a headcount to verify all employees are out of harms way. The supervision will
report this to Contractor. Emergency Contact numbers for Company, Contractor and
Gama will be posted onsite.
All vehicles and equipment used for the subject work will be inspected and certified as
required.
Drivers and operators will be competent and will have attended all required trainings set
forth in project procedures and specifications.
T-4.234.073 Rev. F
Page 5 of 23
Q A T A R
Doc. Title
GAM-MTS-CIV-GTL-011
MS FOR REPAIR OF CONCRETE WORKS
Date
01.12.2008
REV. I
4. REFERENCES
Qatar Construction Standard
DEP 34.19.20.31- Reinforced Concrete Foundations and Structures
(Amendments T.13.376.358G-Clause 3.24)
ASTM 546 Concrete Repair Guide
Vendor Specifications
Other specifications and procedures of Contractor, Company and RLIC.
5. DEFINITIONS
Company
Contractor
Subcontractor
Contract
QCP
ITP
QA/QC
JSA
:
:
:
:
:
:
:
:
6. RESPONSIBILITY
6.1 SITE MANAGER
The site manager will provide inputs to the project execution plan to ensure that strategies &
philosophy are properly addressed.
6.2 CIVIL WORKS MANAGER
The Civil Works Manager is responsible for the overall management of the project
construction team to ensure that safe and effective operations are conducted and properly
documented.
6.3 SITE ENGINEER
He will be overall responsible for safe execution of the whole job including:
Confirming the installation location from schedule of approved construction drawings.
Organizing of equipments and tools needed for the job.
Assigning skilled personnel for the job.
T-4.234.073 Rev. F
Page 6 of 23
Q A T A R
Doc. Title
GAM-MTS-CIV-GTL-011
MS FOR REPAIR OF CONCRETE WORKS
Date
01.12.2008
REV. I
Sequence of activities to be carried out for the work as per this method of statement.
Conduct inspection and surveillance.
Notify to Contractor engineer for inspection as applicable.
Ensure all Contractor and Company regulations are followed.
Ensure all personnel involved are in safe working condition.
6.4 WORK SUPERVISOR
He will be responsible for safe execution of the following activities:
Conduct TSTI with the concerned work force prior to start the work.
Ensure that relevant work permits for the job are obtained prior to start the work.
Conduct daily toolbox talks for the entire work force prior to start day work.
Assigning a competent work crew for specific activities, details of activities and task
information will be given to the work crew.
Organizing tools and equipment needed to the work site.
Inspection and supervision of work.
Ensure all Contractor and Company safety regulations are followed as applicable.
6.5 QA/QC OFFICER / INSPECTOR
He will be responsible for:
Assurance of approved methods and materials are being used and conformance of
the specifications.
Stage inspections and surveillance in accordance with ITP and assurance of quality
of work as per specification and erection procedures.
Incoming material inspection and review of test certificates.
T-4.234.073 Rev. F
Page 7 of 23
Q A T A R
Doc. Title
GAM-MTS-CIV-GTL-011
MS FOR REPAIR OF CONCRETE WORKS
Date
01.12.2008
REV. I
7.1 EQUIPMENT
Disc cutter
:1
:1
Wire brush:
:1
Measuring jug:
:1
:1
Mixing paddle
:1
:1
Trowel
:1
Wooden float
:1
:1
Injection machine
:1
:1
:2
7.2 MANPOWER
Civil Foreman
:1
Safety Officer
:1
QA/QC Technician
:1
Mason
:2
Helper
:2
If the above-listed equipment or manpower proves not sufficient for the timely completion of
the facilities and project; additional will be provided to complete the works on time and in line
with rules, regulations and specifications of Contractor, Company and RLIC.
8. REPAIR PROCEDURE
8.1 GENERAL
As per the section 3.24 of T.13.376.358 all concrete repair is a HOLD POINT in the ITP
and only proprietary factory made materials approved by the Company shall be used
for the repair.
T-4.234.073 Rev. F
Page 8 of 23
Q A T A R
Doc. Title
GAM-MTS-CIV-GTL-011
MS FOR REPAIR OF CONCRETE WORKS
Date
01.12.2008
REV. I
The surface preparation of the concrete to be repaired and the mixing, application and
curing of the (proprietary) repair mortars/(micro) concrete shall be as per
manufacturers requirements/recommendations and /or the specifications applicable for
concrete shall be followed if specific requirements are not given by the manufacturer
(e.g. curing).
All repair areas shall be coverd from direct sunlight.
The repair shall only be carried out after the curing (as per T.13.376.358 paragragh
3.26) has been completed.
8.2
REPAIR OF CRACKS
Page 9 of 23
Q A T A R
Doc. Title
GAM-MTS-CIV-GTL-011
MS FOR REPAIR OF CONCRETE WORKS
Date
01.12.2008
REV. I
to the rebar zone (no rebar exposed). Defective concrete shall be removed up to sound
concrete. These major deficiencies shall be repaired by an approved shrinkage
controlled structural grade cementitious mortar system (approved is Renderoc Sxtra).
9. CURING
Curing will be done as per Manufacturer recommendation. Renderoc BF generally
needs to be protected by polythene sheets .In Hot & windy climate shall be coated
with Nitocote PE 135.Nitocote PE 135 need not removed for further surface coating
as per Manufacturer recommendation. Curing with damped Hessian is to be done for
one day. This coating can be done after one day in wet damped surface also.
T-4.234.073 Rev. F
Page 10 of 23
Q A T A R
Doc. Title
GAM-MTS-CIV-GTL-011
MS FOR REPAIR OF CONCRETE WORKS
Date
01.12.2008
REV. I
11. ATTACHMENTS
JSA
RENDEROC BF
RENDEROC SXTRA
NITOCOTE PE 135
REPAIR LOG
FOSROC LETTER - CURING
GAM-QCR-QAC-GTL-010
T-4.234.073 Rev. F
Page 11 of 23
Q A T A R
JSA Number:
NEW
Page No:
REVISED
Name
JSA Members:
Job Performers:
Signature
Date
Job Supervisor:
Additional Approvals (Determined by Job Supervisor in correlation withLINDE SHES Manager).
Name
Signature
Discipline Superindent(LINDE)
SHES Representative(LINDE)
OTHERS(List Below):
Date
Approval required for hazardous work detailed in the LINDE work permit procedure.
Changing conditions and emergency procedures
Stop work. Switch of equipment.Supervisor directs personnel to nearest and safest muster point considering wind direction. Supervisor counts all employees. Missing
employees are reported to to LINDE HSSE Dept. When all clear is given check with LINDE HSSE before returning to work.
LINDE EMERGENCY TELEPHONE NO.
RLIC:
LINDE HSSE MANAGER:
474 88 88
583 40 72
Note: 1) If any of the tasks involves biological, physical or chemical hazards, then The LINDE Industrial Hygienist must also approve the work.
2)Use additional sheets as necessary.
3)Details on safety (PPE,Hazard etc) and environmental requirements can be found in LINDE and QSGTL Safety and Environment Procedures.
Q
Q A
A T
T A
A R
R
ITEM
ACTIVITY
Chipping of crack
concrete.
HAZARD / POTENTIAL
CONSEQUENCES
Initial Risk
P C
B
RISK
RANK
CURRENT
CONTROLS
ADDITIONAL
CONTROLS
Residual Risk
P C
LOW
LOW 1.4.1 Use the right tools for the right job.
1.5 Fall of personnel (if
1.5.1 ALL employees shall wear inspected 1.5.1.1
working at heights).
full body harness fitted with twin
lanyards with shock absorbers, each 1.5.1.2
lanyard shall be fitted with dual action
C 5 HIGH
self-locking safety hook for 100% Tieoff.
1.5.2 Ensure 100% fall protection.
Removal of chipped 2.1 Hand & finger injury.
2.1.1 Use appropriate working gloves.
B 2 LOW
concrete.
2.1.2 Use the right tools for the right job.
2.2 Fall of chipped concrete
2.2.1 Barricade working area & Warning
2.2.1.1
B 3 MED
(if working at height).
signboard to warn other.
2.2.2 Ensure employees have personal
protective equipment i.e. coveralls,
safety shoes, safety helmet, safety
glasses and work gloves.
B
5 LOW
3 LOW
Q
Q A
A T
T A
A R
R
LOW
LOW
MED
LOW
Material
handling/storage.
4.2 Fire/explosion
MED
LOW
Discuss in TSTI
3 LOW
3 LOW
Renderoc BF*
constructive solutions
Property
Initial setting time (BS EN 196):
Final setting time (BS EN 196) :
Fresh wet density
:
Compressive strength
:
Average Linear Coefficient
of Thermal Expansion
Note :
:
:
115 mins
165 mins
1840 kg/m3
3days - 10N/mm
7days - 20N/mm
2.5 x 10-6 per oC
Description
Design Criteria
Renderoc BF is designed for vertical and overhead use to
infill surface imperfections of concrete upto 5mm thick.
Limitations
-
Properties
Renderoc BF*
Mixing
Care should be taken to ensure that Renderoc BF is thoroughly
mixed. In all cases the powder component should be
introduced into water.
Mixing should be carried out in a suitably sized mixing vessel,
using a slow speed (400/500 rpm), heavy duty drill and a
Fosroc mortar mixing paddle.
Pour 4 - 6litres of water (depending of workability required)
into the mixer and, with the machine in operation, add one full
20 kg bag of powder, then mix for 3 to 5 minutes, until fully
homogeneous. Do not use more than 6 litres of water per
20kg bag.
Renderoc BF*
If mixing small quantities by hand, Renderoc BF should be
volume-batched. Add 3 volumes of the Renderoc BF powder
(loose-filled to excess and struck off level with the top of the
measuring container) to one volume of potable water. This
should be mixed vigorously until fully homogeneous.
Estimating
Supply
Renderoc BF
Important note
20 kg bag
Yield
Renderoc BF
Application
Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard
Conditions for the Supply of Goods and Service. All Fosroc datasheets are updated on a regular basis. It is the users
responsibility to obtain the recent version. Refer to www.fosroc.com.
Al Gurg Fosroc
LLC
Post Box 657, Dubai
United Arab Emirates
www.fosroc.com
Head Office
telephone: (+9714) 2039699
email: [email protected]
Regional offices
Abu Dhabi, Al Gurg Fosroc
Bahrain, YBA Kanoo
email: [email protected]
email: [email protected]
Kuwait, Boodai
Oman, Al Amana
Qatar, Tadmur
telephone: 4817618
telephone: 24815080
telephone: 4500607
fax: 4832124
fax: 24817554
fax: 4500543
email: [email protected]
email: [email protected]
email: [email protected]
UAE/0492/07/H
Renderoc SXtra*
constructive solutions
Properties
Renderoc SXtra features Dimensional Stability Technology a new materials technology which controls the rate of drying
shrinkage such that, when used correctly :
i.
Design criteria
Renderoc SXtra*
Test method
Typical result
:
:
:
:
:
5 mm
up to 25 mm thick
up to 35 mm thick
up to 100 mm thick
up to 3 m
Renderoc SXtra*
Galvanic Protection of repairs
Storage
Shelf life
Precautions
Estimating
20 kg bags
Yield
Renderoc SXtra
Limitations
-
Supply
Renderoc SXtra
Important note
Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard
Conditions for the Supply of Goods and Service
Al Gurg Fosroc
LLC
Head Office
telephone: (+9714) 2858606
email: [email protected]
Regional offices
email: [email protected]
email: [email protected]
email: [email protected]
www.fosroc.com
Kuwait, Boodai
Oman, Al Amana
Qatar, Tadmur
telephone: 4817618
telephone: 771 5080
telephone: 413628
fax: 4832124
fax: 771 7554
fax: 440812
email: [email protected]
email: [email protected]
email: [email protected]
UAE/0252/04/G
Nitocote PE135*
constructive solutions
Properties
Specific gravity (20C)
Solids content by weight
Solids content by volume
(ASTM D2697)
Surface drying time
(ASTM D1640)
:
:
1.28 g/cm3
53%
43%
35 - 40 min @ 20C
10 - 15 min @ 35C
04 - 06 min @ 45C
6
3
2
7
< 0.2%
Nil
>1.0 N/mm2
:
:
:
:
:
:
:
:
:
:
:
:
Excellent
Excellent
Excellent
Excellent
Excellent
Excellent
Excellent
Excellent
Excellent
Excellent
Excellent
Excellent
Overcoating time
(ASTM D1640)
Complete cure
Water absorption
(BS 1881 Pt. 122)
Water permeability
(BS EN 12390,: Part 8)
Adhesion strength
(ASTM D4541)
- 7 hours @ 20C
- 4 hours @ 35C
- 3 hours @ 45C
days @ 25C
Nitocote PE135*
Specification
Where shown on the contract documents, below ground
surfaces shall be protected with two coats of Nitocote PE135,
a ` hydrophobic polyester emulsion coating applied at a rate
of 400-500 microns wet film thickness per coat.
Chemical resistance
Lactic acid 20%
Acetic acid 20%
Nitric acid 5%
Ethylene glycol 40%
Copper Sulphate 25%
Zinc Sulphate 25%
Magnesium Sulphate 25%
Tap water
Sea water
Ground water
High sulphate water
Distilled water
Nitocote PE135*
Instructions for use
Surface preparation
Estimating
All surfaces must be clean and free from laitence, dirt, dust,
oil and grease. In case of porous substrates, pre-soak the
surface with potable water for 30 minutes. Ensure excess
water is removed prior to application of Nitomortar PE135.
Application
Supply
Nitocote PE135
20 litre pails
General use
Curing compound
Theoretical coverage
Storage
Nitocote PE135 will have a minimum shelf life of 12 months
if stored in normal warehouse conditions at less than 25C.
Repairs
Cleaning
Nitocote PE135 can be removed using only clean water, whilst
still damp. If left to dry, then use a scourer.
Limitations
-
Important note
Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard
Conditions for the Supply of Goods and Service. All Fosroc datasheets are updated on a regular basis. It is the users
responsibility to obtain the recent version. Refer to www.fosroc.com.
Al Gurg Fosroc
LLC
Post Box 657, Dubai
United Arab Emirates
www.fosroc.com
Head Office
telephone: (+9714) 2039699
email: [email protected]
Regional offices
Abu Dhabi, Al Gurg Fosroc
Bahrain, YBA Kanoo
email: [email protected]
email: [email protected]
Kuwait, Boodai
Oman, Al Amana
Qatar, Tadmur
telephone: 4817618
telephone: 24815080
telephone: 4500607
fax: 4832124
fax: 24817554
fax: 4500543
email: [email protected]
email: [email protected]
email: [email protected]
UAE/0429/07/C
AREA
GRID
SIGNATURE
CRACKS
REPAIRED DATEGAMA
LINDE
ITP : GAM-QCR-QAC-GTLDate:
ITEM
1.
DETAIL OF ACTIVITY
COMPLIANCE
YES
NO
NA
REMARKS
HONEY COMBS
1. a. Removal of unwanted concrete
1.b. Preparing of concrete with bond
1.c. Curing
1.d. Finishing
2.
CRACKS.
a) Preparation of V cut if applicable
b) Injection of Repair Solution OR
mortar
c) Curing.
d) Finishing.
Comments:
ORGANIZATIONS
DATE
NAME
SIGNATURE
GAMA REP
LINDE REP
QSGTL REP
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