Pearl GTL

Project
LINDE ENGINEERING

Shell Project No: HP-3000-QAT Contractor Project No: 5887

Project Document Number: T- 4.234.073 Project Rev.: F Page 2 of 23

Purchase Order Number: 2MH127

Tag/Item Number(s): N/A

Unit(s): ASU

PCWBS: Z
 QATAR SHELL GTL PROJECT (PEARL)
C2 AIR SEPARATION UNITS CONSTRUCTION

I F 01.12.08 Ready For Construction SB EO AG RFC

Issued for Review ( Revised according to site

H E 01.10.08 SB EO AG IFR
changes)
Issued for Review ( Revised according to site
G D 13.07.08 SB EO AG IFR
changes)

F C 30.03.08 Ready For Construction SB UA ZG RFC

E B 23.03.08 Ready For Construction SB UA ZG RFC

D A 23.02.08 Ready For Construction SB UA ZG RFC

C O 09.12.07 Issued for Company comments SB AU/MC ZG ICC

B 23.11.07 Issued for Review SB AU/MC ZG IFR

A 20.11.07 Issued for Internal Review SB AU/MC ZG IIR

GAMA Project Prepared Checked Approved

Date Description Status
Rev. Rev By By By
No. No. ORIGINATOR

Document Title:

METHOD STATEMENT FOR REPAIR OF CONCRETE

LINDE ENGINEERING AG WORKS
Contractor Document No.
LOC470
GAM MTS CIV GTL 011 I
Gama Qatar Co. W. L. L. Org. Doc. Disc. Geogr. Seq. Rev.
Vendor Code
Code Type Code Area No No

Project Document Number: T-4.234.073 Rev No: F

 GAM-MTS-CIV-GTL-011
Doc. Title :
MS FOR REPAIR OF CONCRETE WORKS
Q A T A R 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. EQUIPMENT & MANPOWER ____________________________________________________ 7
7.1 Equipment ___________________________________________________________________________8
7.2 manpower ____________________________________________________________________________8
8. REPAIR PROCEDURE __________________________________________________________ 8
8.1 General ______________________________________________________________________________8
8.2 repair of cracks ______________________________________________________________________9
8.3 repair of minor surface deficiencies in the concrete (air voids, etc) _____________________________9
8.4 repair of major surface deficiencies in the concrete __________________________________________9
8.5 major concrete repairs ________________________________________________________________10
9. Curing ________________________________________________________________________ 10
10. QUALITY ASSURANCE _______________________________________________________ 10
11. ATTACHMENTS _____________________________________________________________ 11

Page 4 of 23
T-4.234.073 Rev. F
 GAM-MTS-CIV-GTL-011
Doc. Title :
MS FOR REPAIR OF CONCRETE WORKS
Q A T A R 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 harm’s 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.

Page 5 of 23
T-4.234.073 Rev. F
 GAM-MTS-CIV-GTL-011
Doc. Title :
MS FOR REPAIR OF CONCRETE WORKS
Q A T A R 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 : QSGTL or its PMC
Contractor : Linde Engineering AG
Subcontractor : Gama Qatar Co. W. L. L.
Contract : QSGTL Pearl Plant – C2 ASU Construction Works
QCP : Quality Control Procedure
ITP : Inspection and Test Plan
QA/QC : Quality Assurance / Quality Control
JSA : Job Safety Analysis

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.
Page 6 of 23
T-4.234.073 Rev. F
 GAM-MTS-CIV-GTL-011
Doc. Title :
MS FOR REPAIR OF CONCRETE WORKS
Q A T A R 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.

7. EQUIPMENT & MANPOWER

All equipment will be inspected and approved by the Contractor, when required, and all
personnel will be inducted and trained before and during mobilization.

Page 7 of 23
T-4.234.073 Rev. F
 GAM-MTS-CIV-GTL-011
Doc. Title :
MS FOR REPAIR OF CONCRETE WORKS
Q A T A R Date : 01.12.2008 REV. I

7.1 EQUIPMENT

Disc cutter :1

Electric/pneumatic breaker or hammer and chisel :1

Wire brush: :1
Measuring jug: :1
Slow speed drill (400 or 500rpm): :1
Mixing paddle :1
Suitably sized mixing vessel :1
Trowel :1
Wooden float :1
Steel or plastic finishing float or sponge :1
Injection machine :1
High speed percussion drill :1
Hand held angle grinders :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.

Page 8 of 23
T-4.234.073 Rev. F
 GAM-MTS-CIV-GTL-011
Doc. Title :
MS FOR REPAIR OF CONCRETE WORKS
Q A T A R 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

All cracks with a crack width greater than 0.3mm

Note: Cracks with a width exceeding 0.3mm are not confirming to the specification and
a Non Conformance Report (NCR) shall be raised.
Open the crack, by chiselling a V –cut, to a depth where the crack visually seems to
stop; however the maximum depth for chiselling is 20mm. The crack shall be cleaned
with compressed air. Fill the crack up with water and observe whether or not the crack
continues by looking for air bubbles in the water due to air escaping out of the crack.
If air bubbles are observed, an approved low viscosity resin shall be poured into the
crack as per manufactures recommendation until the crack is fully saturated with the
resin. Repair / seal the V-cut of the crack, after injection, with an approved shrinkage
controlled structural grade cementitious repair mortar system (approved is Renderoc
Sxtra). If no air bubbles are observed, the V-cut shall only be repaired/sealed as per
above. Where detection of a possible continuation of the crack with water filling is not
possible (on vertical faces) the crack repair shall be discussed between Company and
Contractor, looking for similarities with horizontal cracks in the same area. Where
similarities are not found and/or agreed the crack shall be deemed to be deep and
injected with epoxy and the V-cut further repaired/sealed as per above.
All cracks with a crack width between 0.1 and 0.3mm (Only for Non Coated Areas)
If the crack is reaching anchor bolts or box-outs, apply the same repair method as for
cracks with a crack width of greater than 0.3mm.
8.3 REPAIR OF MINOR SURFACE DEFICIENCIES IN THE CONCRETE (AIR VOIDS, ETC)

Surface defects that can be enclosed by a 50mm circle and in which circle the
concrete cover is not reduced by more than 10mm are defined as minor surface
deficiencies (refer to section 3.24 of T-13.376.358). These minor voids shall be filled
with fine mortar incorporating polyvinyl acetate (approved is Renderoc RF, for a
maximum thickness of 5mm).
8.4 REPAIR OF MAJOR SURFACE DEFICIENCIES IN THE CONCRETE

Note: Major surface deficiencies are not confirming to the specification and a Non
Conformance Report (NCR) shall be raised.
Major surfaces deficiencies are deficiencies that cannot be enclosed by a circle of
50mm and/or where the concrete cover has been reduced by more than 10mm and up
Page 9 of 23
T-4.234.073 Rev. F
 GAM-MTS-CIV-GTL-011
Doc. Title :
MS FOR REPAIR OF CONCRETE WORKS
Q A T A R 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).

8.5 MAJOR CONCRETE REPAIRS

Note: Major concrete repairs are not confirming to the specification and a Non
Conformance Report (NCR) shall be raised.
Areas where after removal of the defective concrete the rebar becomes exposed
and/or where the extend of the repair is such that formwork has to be used are defined
as Major Concrete Repairs. The defective concrete shall be removed up to sound
concrete. If the defective concrete extends to the rebar a clear gap of at least 20mm
shall be created behind the rear face of the rebar, such that a gloved hand can
comfortably reach behind the main bars. All exposed rebar shall be carefully cleaned
by wire brushing before the repair and the concrete faces to be scabbled and wetted
as per requirement/recommendation of the manufacturer of the repair micro concrete.

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.

10. QUALITY ASSURANCE

A Quality Assurance System will be operated conforming to related standards.
Controls and checks will be established and documented in Concrete Repair form -
GAM-QCR-QAC-GTL-010.Repaired surface Inspection will be offered to client. All
deficiencies will be logged, photographed and repaired. Repair of concrete will be
Hold point in ITP T.4.234.075. Separate Repair Log sheet will be maintained.

Page 10 of 23
T-4.234.073 Rev. F
 GAM-MTS-CIV-GTL-011
Doc. Title :
MS FOR REPAIR OF CONCRETE WORKS
Q A T A R 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

Page 11 of 23
T-4.234.073 Rev. F
 Q A T A R JOB SAFETY ANALYSIS FORM
JSA Number: NEW REVISED Page No:
Job being analysed: MS-Repair of Concrete Cracks
Department/Section doing JSA:HSE & Construction JSA Members:
Job Performers:
Normal Approvals: Name Signature Date General job requirements / Common
JSA by: Personnal Protective Equipment.

Job Supervisor: 1. The following Personal Protective

Equipment shall be worn while repairing
Additional Approvals (Determined by Job Supervisor in correlation withLINDE SHES Manager). concrete cracks : Approved coveralls, safety
Name Signature Date glasses, safety helmet, safety shoes and
Discipline Superindent(LINDE) gloves.
SHES Representative(LINDE)
OTHERS(List Below): 2.Permit To Work.

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: 474 88 88

LINDE HSSE MANAGER: 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.

1
 JOB SAFETY ANALYSIS / RISK ASSESSMENT
SCOPE : Repair of Concrete Cracks
Q T.4.234.073
Q A
A T
T A
A R
R

Initial Risk Residual Risk

HAZARD / POTENTIAL RISK CURRENT ADDITIONAL
ITEM ACTIVITY P C P C R
CONSEQUENCES RANK CONTROLS CONTROLS
1 Chipping of crack 1.1 Eye injuries 1.1.1 Ensure employee wear appropriate
B 2 LOW
concrete. safety glasses.
Hands and fingers 1.1.2 Ensure employees have personal
injuries protective equipment i.e. coveralls,
B 2 LOW
safety shoes, safety helmet, safety
glasses and work gloves.
1.2 Dust inhalation 1.2.1 Ensure employee wear approved dust
B 2 LOW
masks.
1.3 Fall of materials/Tools. 1.3.1 Ensure all materials, tools, equipment
are kept secure at all times while
working at heights.
B 2 LOW
1.3.2 Barricades working area with
signboard indicating work in progress.

1.4 Use of make shift tools. LOW 1.4.1 Use the right tools for the right job.
B 2
1.5 Fall of personnel (if 1.5.1 ALL employees shall wear inspected 1.5.1.1 Discuss working at height hazards
working at heights). full body harness fitted with twin at daily TSTI.
lanyards with shock absorbers, each 1.5.1.2 Training prior to start working @
C 5 HIGH lanyard shall be fitted with dual action heights. A 5 LOW
self-locking safety hook for 100% Tie-
off.
1.5.2 Ensure 100% fall protection.
2 Removal of chipped 2.1 Hand & finger injury. 2.1.1 Use appropriate working gloves.
concrete. B 2 LOW
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 Discuss in daily TSTI.
B 3 MED A 3 LOW
(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.

2
 JOB SAFETY ANALYSIS / RISK ASSESSMENT
SCOPE : Repair of Concrete Cracks
Q T.4.234.073
Q A
A T
T A
A R
R

3 Apply cementitious 3.1 Eye and skin irritation. 3.1.1 Ensure employees have personal
filler and mortars for protective equipment i.e. coveralls,
concrete surface. B 2 LOW safety shoes, safety helmet, safety
glasses and rubber hand gloves to
avoid skin contacts.
3.2 Hands and fingers 3.2.1 Use the right tools for the right job.
injuries B 2 LOW 3.2.2 Ensure employee wearing safety work
gloves.
3.3 Chemical hazard. B 3 MED 3.3.1 Review MSDS. 3.3.1.1 Discuss in TSTI A 3 LOW
4 Material 4.1 Physical injury due to 4.1.1 Ensure all materials shall be stored,
handling/storage. mishandling of materials handled and used in a safe manner,
back, muscle strain , by type, providing enough
sprain. B 2 LOW passageways between different
stored materials.
4.1.2 Employee shall be trained for using
safe methods in handling materials.
4.2 Fire/explosion 4.2.1 Material shall be stored in conditions 4.2.1.1 Remove unecessary combustible
compatible with the recommendations materials.
B 3 MED of the MSDS. A 3 LOW
4.2.2 Ensure to maintained suitable fire
extinguisher in the area.
4.3 Improper disposal of 4.3.1 Ensure empty containers shall be
empty materials. B 2 LOW dumped at approved dump locations
for hazardous materials.

3
 Renderoc BF* constructive solutions

One component polymer modified cementitious filler and

reprofiling mortar

Uses The following results were obtained at a water:powder ratio

of 0.2
Renderoc BF is designed for application to imperfections in
concrete and masonry surfaces. It is suitable for application
Property
upto 5mm thickness, and can be used in the following
Initial setting time (BS EN 196): 115 mins
situations:
Final setting time (BS EN 196) : 165 mins
! Filling blow holes prior to overcoating. Fresh wet density : 1840 kg/m3
Compressive strength : 3days - 10N/mm²
! Skim-coat over concrete to receive protective coatings.
7days - 20N/mm²
! General reprofiling over large areas. Average Linear Coefficient :
of Thermal Expansion : 2.5 x 10-6 per oC
! Reprofiling, in association with other Renderoc mortars
Note : Working life and setting time will vary dependent
Advantages on ambient, substrate temperatures and wind
speed.
! Cost effective/ time saving - no independent primer or
curing agents required.
Instructions for use
! High performance - excellent bond to substrate.
Preparation
! User friendly - requires addition of water only.
Clean the surface and remove any dust, unsound material,
! Suitable to receive protective coatings. plaster, oil, paint, grease, corrosion deposits or algae.
Roughen the surface to remove any laitance and expose the
Description fine aggregate by light scabbling or sweep blasting.
Renderoc BF is supplied as a ready to use blend of dry Oil and grease deposits should be removed by steam
powders and polymers, which requires only the addition of cleaning, detergent scrubbing or the use of a proprietary
water to produce a highly consistent cementitious mortar, degreaser. The effectiveness of decontamination should then
with good handling characteristics. be assessed by a pull-off test.
Renderoc BF exhibits excellent thermal compatibility with The cleaned areas should be blown clean with oil-free
concrete and is fully compatible with other Renderoc* mortars compressed air before continuing. All prepared areas should
and Dekguard* protective coatings. be thoroughly soaked with clean water immediately prior to
the application of Renderoc BF. Any residual surface water
Design Criteria should be removed prior to commencement.
Renderoc BF is designed for vertical and overhead use to Mixing
infill surface imperfections of concrete upto 5mm thick.
Care should be taken to ensure that Renderoc BF is thoroughly
mixed. In all cases the powder component should be
Limitations
introduced into water.
- Renderoc BF should not be used when the temperature
is below 5°C and falling. Mixing should be carried out in a suitably sized mixing vessel,
using a slow speed (400/500 rpm), heavy duty drill and a
- Do not proceed with the application when rainfall is
Fosroc mortar mixing paddle.
imminent unless in a sheltered or protected situation.
- If any doubts arise concerning temperature or substrate Pour 4 - 6litres of water (depending of workability required)
conditions, consult the local Fosroc office. 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
Properties homogeneous. Do not use more than 6 litres of water per
20kg bag.
Renderoc BF*
Renderoc BF*

If mixing small quantities by hand, Renderoc BF should be Estimating

volume-batched. Add 3 volumes of the Renderoc BF powder
Supply
(loose-filled to excess and struck off level with the top of the
Renderoc BF : 20 kg bag
measuring container) to one volume of potable water. This
should be mixed vigorously until fully homogeneous. Yield
Renderoc BF : 14.4 litres per 20kg bag
Application
(based on 6litre water)
Apply the mixed Renderoc BF to the blow holes by steel trowel.
Actual coverage of Renderoc BF will be wholly dependent
It should be applied with minimum working and be allowed
upon the general substrate condition. It is recommended,
to partly set before finally trowelling to a smooth finish. If a
therefore, that site trials over a typical area are carried out to
very smooth finish is required, a small amount of water may
determine actual usage.
be flicked on to the surface of the Renderoc BF with a paint
brush prior to final trowelling.
Storage
Curing
Shelf life
Curing is not generally required. However, under extreme
All products have a shelf life of 12 months if kept in a dry store
conditions - high temperatures and drying winds - use
in the original, unopened bags or packs @ 25oC. If stored at
Nitobond AR*† or Nitocote PE135*† as a curing agent, or cover
high temperatures and/or high humidity conditions the shelf
the surface with polythene sheeting, taped down at the edges.
life may be considerably reduced to 4 to 6 months.
Nitobond AR does not require mechanical removal prior to
overcoating with Dekguard system. If overcoating with epoxy Precautions
or polyurethanes then use Nitocote PE135 as the curing
Health and safety
membrane.
Renderoc BF contains cement powders which, when mixed
Cleaning
or become damp, release alkalis which can be harmful to
Renderoc BF should be removed from tools, equipment and the skin. During use, avoid inhalation of dust and contact
mixers with clean water immediately after use. Cured material with skin and eyes. Wear suitable protective clothing, gloves,
can only be removed mechanically. eye protection and respiratory protective equipment. The use
of barrier creams provide additional skin protection. In case
High temperature working
of contact with skin, rinse with plenty of clean water, then
At ambient temperatures above 35°C, the components should cleanse with soap and water. In case of contact with eyes,
be placed in air-conditioned storage of less than 25°C, for rinse immediately with plenty of clean water and seek medical
special application procedures, refer to your local Fosroc advice. If swallowed, seek medical attention immediately -
office. do not induce vomiting. For further information, refer to the
Product Material Safety Data Sheet.
Overcoating with protective / decorative finishes
Fire
Renderoc BF may be overcoated after 48 hours, in ambient
conditions of up to 75% relative humidity, dependant on the Renderoc BF is a non-flammable product.
type of coating. For further information consult the local Fosroc
office before proceeding. * Denotes the trademark of Fosroc International Limited
†
See separate data sheet
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 user’s
responsibility to obtain the recent version. Refer to www.fosroc.com.

Head Office
Al Gurg Fosroc telephone: (+9714) 2039699 fax: (+9714) 2859649 email: [email protected]
LLC Regional offices
Abu Dhabi, Al Gurg Fosroc telephone: 673 1779 fax: 673 1449 email: [email protected]
Post Box 657, Dubai Bahrain, YBA Kanoo telephone: 17735454 fax: 17732828 email: [email protected]
United Arab Emirates Kuwait, Boodai telephone: 4817618 fax: 4832124 email: [email protected]
Oman, Al Amana telephone: 24815080 fax: 24817554 email: [email protected]
Qatar, Tadmur telephone: 4500607 fax: 4500543 email: [email protected]
www.fosroc.com
UAE/0492/07/H
 Renderoc SXtra* constructive solutions

Shrinkage controlled, structural grade cementitious

repair mortar system

Uses Properties

Renderoc SXtra is suitable for hand application to repairs The following typical results were obtained at a water to
where significant load bearing is required. Typical applications powder ratio of 0.15.
would include, but not be limited to, the following :
Test method Typical result
„ Vertical and overhead repairs. Drying shrinkage to ASTM C 157-93
„ Patch repairs to concrete floor slabs. 7 days : < 300 microstrain
28 days : < 500 microstrain
„ Patch repairs to stairs, steps and other areas subject to Permeability : < 10 mm
repeated, heavy trafficking. (DIN 1048 Part 5)
„ Arris repairs to joint edges. Flexural strength : > 7 N/mm2 at 28 days
(BS 6319 Pt.3)
„ General structural repairs where formwork cannot be Tensile strength : > 3.5 N/mm2 at 28 days
easily erected. (BS 6319 Pt.7)
Compressive strength : 50 N/mm2 at 7 days
Advantages (BS 1881 Pt.1161) 55 N/mm2 at 28 days
Renderoc SXtra features Dimensional Stability Technology - Water absorption : < 2%
a new materials technology which controls the rate of drying (BS 1881 Pt.121)
shrinkage such that, when used correctly : Note1: 50mm cubes, air cured @ 250C

i. the dimensions of the repair remain stable; and thus Design criteria
ii. eliminating failure, due to shrinkage cracking. Dimensional Stability Technology is a major step forward in
the general compatibility of repair mortar systems with the
This in turn leads to a series of associated benefits :
host substrate, and the control of drying shrinkage in particular.
„ Cost effective - shrinkage control enables repairs to be
Attention to the basic design criteria given below should ensure
completed ‘right first time’.
that the full benefits of this technology are gained in use :
„ Enhanced durability - works in tandem with extremely low
(i) Recommended limits for a single application are:
permeability to prolong effective working life.
Minimum applied thickness : 5 mm
„ Compatibility - aligns performance closer than ever before,
Overhead sections : up to 25 mm thick
to that of host concrete.
Vertical sections : up to 35 mm thick
„ User friendly - specifically developed to provide an Small pockets or horizontal : up to 100 mm thick
easy-to-apply product, suitable for local conditions. Maximum length : up to 3 m

„ Definable performance - positive benefits are easily NOTE : If the repair area exceeds 2.5 m2, consideration
demonstrated via a single, simple measurement. should be given to the use of mass fill by means
of either Renderoc SPXtra* spray applied mortar
Description or Renderoc LAXtra* microconcrete.

Renderoc SXtra is supplied as a ready to use blend of dry (ii) In situations where a substrate/repair barrier is required,
powders, which requires only the addition of clean water to or enhanced bond strength/working time is required, or
produce a highly consistent repair mortar suitable for most where the substrate is likely to be damp (e.g. seawalls,
structural and loadbearing repairs. quays etc.), Nitobond EP epoxy bonding agent should be
used.

(iii) Water addition = 3.0 litres per 20 kg bag

Under no circumstances should part bags be used or
Renderoc SXtra*

additional water be employed. Either of these two actions

will adversely affect material performance, automatically
invalidating Fosroc’s standard product guarantee.
Renderoc SXtra*

Galvanic Protection of repairs Storage

It is likely that, steel reinforcement in the area around a patch Shelf life
repair, particularly in a chloride contaminated environment,
Renderoc SXtra has a shelf life of 12 months; if kept in a dry
will typically corrode after the repairs are carried out, referred
environment, in its original, unopened packing. If stored in
to as the incipient anode or Halo effect.
conditions of high humidity and/or temperature, the shelf life
Galvashield XP* † (eXtra Protection) anodes can be may be reduced to as little as 4 months.
incorporated into patch repairs to galvanically protect steel
reinforcement against corrosion in the adjacent concrete and Standards compliance
may also be used in new construction to provide Cathodic
Renderoc SXtra repair mortar system complies with the
Prevention. Galvashield XP are zinc based anodes encased
following international standards :
in a highly alkaline mortar which maintains the surface of the
zinc in an active state. Galvanic systems are self regulating ASTM C157-93 : Test for drying shrinkage
and demand based and will start working only when corrosion DIN 1048 Part 5 : Test for permeability
of steel begins. Refer to product datasheet for further details. BS 1881 Pt.121 : Test for water absorption

Instructions for use Precautions

Renderoc SXtra should be mixed and applied in strict Health and safety
accordance with the Product Method Statement, a copy of
Renderoc SXtra contains cement powders which, when mixed
which may be obtained from your nearest Fosroc office.
with water or upon becoming damp, release alkalis which can be
harmful to the skin.
Estimating
During use, avoid inhalation of the dust and contact with the skin or
Supply
eyes. Wear suitable protective clothing - eye protection, gloves and
Renderoc SXtra : 20 kg bags respiratory equipment (particularly in confined spaces).

Yield The use of barrier creams to provide additional skin protection is

also advised. In case of contact with the skin, rinse with plenty of
Renderoc SXtra : 10.9 litresper 20 kg bag
clean water, then cleanse thoroughly with soap and water.

Limitations In case of contact with eyes, rinse immediately with plenty of clean
water and seek medical advice. If swallowed seek medical attention
- Renderoc SXtra should not be used when the ambient
immediately - do not induce vomiting.
temperature is below 50C and falling.
Fire
- Renderoc SXtra should not be part mixed, nor part bags
used. Renderoc SXtra, is non-flammable and presents no fire
hazard.
- Renderoc SXtra should not be exposed to running water
either during application or prior to final set. For further information, please refer to the respective Product
Material Safety Data Sheet for Renderoc SXtra.
- Water ponding is not recommended for curing.
* Denotes the trademark of Fosroc International Limited
†
See separate data sheet
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

Head Office
Al Gurg Fosroc telephone: (+9714) 2858606 fax: (+9714) 2859649 email: [email protected]
LLC Regional offices
Dubai, Al Gurg Fosroc telephone: 285 8787 fax: 285 2023 email: [email protected]
Post Box 657, Dubai Abu Dhabi, Al Gurg Fosroc telephone: 673 1779 fax: 673 1449 email: [email protected]
United Arab Emirates Bahrain, YBA Kanoo telephone: 17735454 fax: 17732828 email: [email protected]
Kuwait, Boodai telephone: 4817618 fax: 4832124 email: [email protected]

www.fosroc.com
Oman, Al Amana telephone: 771 5080 fax: 771 7554 email: [email protected]
Qatar, Tadmur telephone: 413628 fax: 440812 email: [email protected]

UAE/0252/04/G
 Nitocote PE135* constructive solutions

Eco friendly, protective coating based on hydrophobic

polyester resin

Uses Properties

Provides a highly effective protective coating, with chemical

Specific gravity (20°C) : 1.28 g/cm3
and abrasion resistance to prevent corrosion of concrete
Solids content by weight : 53%
substrates and exhibits cost and labour saving
Solids content by volume
supplementary benefits. It can be used in a wide range of
(ASTM D2697) : 43%
applications :
Surface drying time
! Suitable for underground protection, foundations etc. (ASTM D1640) : 35 - 40 min @ 20°C
10 - 15 min @ 35°C
! Dual purpose protective coating and curing compound.
04 - 06 min @ 45°C
Overcoating time
Advantages
(ASTM D1640) : 6 - 7 hours @ 20°C
! Can be applied on damp concrete which is one day old. 3 - 4 hours @ 35°C
2 - 3 hours @ 45°C
! Cost saving, material which can be used as a protective
Complete cure : 7 days @ 25°C
coating and curing compound in a single application.
Water absorption
! Single pack - no component mixing, no wastage, multiple (BS 1881 Pt. 122) : < 0.2%
applications from single pack Water permeability
(BS EN 12390,: Part 8) : Nil
! Labour saving, single component material which is also
Adhesion strength
water based, and therefore non-toxic.
(ASTM D4541) : >1.0 N/mm2
! UV stable - will not fade or deteriorate in strong sunlight.
Chemical resistance
! Environmentally friendly, solvent, pitch and asbestos free
and can be used in confined spaces.
Lactic acid 20% : Excellent
! Excellent service life - resistant to chloride and sulphate Acetic acid 20% : Excellent
ions plus a wide range of chemicals. Nitric acid 5% : Excellent
Ethylene glycol 40% : Excellent
! Durable finish - offers good abrasion resistance.
Copper Sulphate 25% : Excellent
Zinc Sulphate 25% : Excellent
Standards compliance
Magnesium Sulphate 25% : Excellent
Nitocote PE135 complies with the concrete curing Tap water : Excellent
requirements of ASTM C309, when applied at the rate of 5m2 Sea water : Excellent
per litre. Ground water : Excellent
High sulphate water : Excellent
Description Distilled water : Excellent

Nitocote PE135 is a single component, high performance,

For resistance to other chemical, consult the local Fosroc
grey colour viscous liquid coating based on hydrophobic
representative.
polyester resin. It is totally free from hazardous materials/
carcinogens such as coal tar pitch, hydrocarbon based
solvents, aromatic amines etc. The coating displays its
protective properties at a minium DFT of 200 microns.

Specification

Where shown on the contract documents, below ground

Nitocote PE135*

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.
Nitocote PE135*

Instructions for use

Surface preparation
Estimating
All surfaces must be clean and free from laitence, dirt, dust,
Supply
oil and grease. In case of porous substrates, pre-soak the
Nitocote PE135 : 20 litre pails
surface with potable water for 30 minutes. Ensure excess
water is removed prior to application of Nitomortar PE135. Theoretical coverage

Application General use : 2.5m² per litre @ 400

micron wft/coat (2 coat
Nitocote PE135 should be applied by roller to prepared application recommended)
surfaces. Stir well before use, replace lid when not in use. (actual coverage rates will
Soak up any spillage with water and wash down immediately. depend upon substrate
Vertical applications can be achieved by single coat application porosity)
upto a maximum wft of 600 microns per coat. For multiple Curing compound : 5m2 per litre per coat
coat application, the second coat should be applied at right to give 200 micron wft
angles to the first within the stated overcoating times. All
applications should be continued up verticals to the existing Storage
damp proof course. Ensure that the coating is not damaged Nitocote PE135 will have a minimum shelf life of 12 months
during subsequent applications. if stored in normal warehouse conditions at less than 25°C.
Repairs Health and safety
Any damaged areas can be readily overcoated to restore the Some people are sensitive to resins and solvents, so gloves
membrane continuity. The surface is to be properly prepared and barrier creams (e.g. Kerodex Antisolvent) should be used
using emery cloth to rub down the surface to provide a key when handling these products. Remove any contamination
and is to be made dust free, prior to product application. from the skin with soap and water, or resin removing creams
Cleaning (e.g. Kerocleanse Standard Grade Skin Cleaner) followed by
washing with soap and water. Do not use solvent.
Nitocote PE135 can be removed using only clean water, whilst
still damp. If left to dry, then use a scourer. The use of goggles is also recommended, but should
accidental eye contamination occur, wash thoroughly with
Limitations plenty of clean water and seek medical treatment immediately.

- Application should not commence below 10°C or above

50°C.

- Do not apply on running or standing water or when there

are chances of rain.

- Exposure to chemicals may result in slight colour change

over time. * Denotes the trademark of Fosroc International Limited
†
See separate data sheet

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 user’s
responsibility to obtain the recent version. Refer to www.fosroc.com.

Head Office
Al Gurg Fosroc telephone: (+9714) 2039699 fax: (+9714) 2859649 email: [email protected]
LLC Regional offices
Abu Dhabi, Al Gurg Fosroc telephone: 673 1779 fax: 673 1449 email: [email protected]
Post Box 657, Dubai Bahrain, YBA Kanoo telephone: 17735454 fax: 17732828 email: [email protected]
United Arab Emirates Kuwait, Boodai telephone: 4817618 fax: 4832124 email: [email protected]
Oman, Al Amana telephone: 24815080 fax: 24817554 email: [email protected]
Qatar, Tadmur telephone: 4500607 fax: 4500543 email: [email protected]
www.fosroc.com
UAE/0429/07/C
 CONCRETE REPAIR LOG
SIGNATURE
S.NO AREA GRID CRACKS
REPAIRED DATEGAMA LINDE
 QSGTL PEARL PROJECT

C2 ASU Construction Works

FORM NO: INSPECTION FORM FOR CONCRETE ITP : GAM-QCR-QAC-GTL-
GAM-QCR-QAC-GTL-010 HONEYCOMBS &CRACKS Date:

INSPECTION FORM FOR CONCRETE HONEY COMBS&CRACKS

DRAWING & REVISION No.

TYPE OF STRUCTURE :
LOCATION :
No :

COMPLIANCE
ITEM DETAIL OF ACTIVITY YES NO NA REMARKS
1. 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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