011-METHOD STATEMENT FOR REPAIR OF CONCRETE WORKS.pdf

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

H E 01.10.08 Issued for Review ( Revised according to site

changes) SB EO AG IFR

G D 13.07.08 Issued for Review ( Revised according to site

changes) SB EO AG IFR

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 Rev.

Project Rev

Date Description Prepared

By Checked

By

Approved By

Status

No. No. ORIGINATOR

LINDE ENGINEERING AG

Document Title:

METHOD STATEMENT FOR REPAIR OF CONCRETE WORKS

Contractor

Gama Qatar Co. W. L. L.

Document No. LOC470

GAM MTS CIV GTL 011 I

Org.

Code

Doc.

Type

Disc. Code

Geogr. Area

Seq.

No

Rev. No

Vendor Code

Project Document Number: T-4.234.073

Rev No: F

Doc. Title : GAM-MTS-CIV-GTL-011 MS FOR REPAIR OF CONCRETE WORKS

Date : 01.12.2008 REV. I

T-4.234.073 Rev. F Page 4 of 23

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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


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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.


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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.


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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.


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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.


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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


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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.


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11. ATTACHMENTS

JSA

RENDEROC BF

RENDEROC SXTRA

NITOCOTE PE 135

REPAIR LOG

FOSROC LETTER - CURING

GAM-QCR-QAC-GTL-010

JSA Number:

Normal Approvals: Name DateJSA by:

Job Supervisor:

Name DateDiscipline Superindent(LINDE)SHES Representative(LINDE)

2.Permit To Work.

LINDE EMERGENCY TELEPHONE NO. RLIC: 474 88 88LINDE HSSE MANAGER: 583 40 72

JOB SAFETY ANALYSIS FORM

Page No:

Job being analysed: MS-Repair of Concrete Cracks

Additional Approvals (Determined by Job Supervisor in correlation withLINDE SHES Manager).

Department/Section doing JSA:HSE & Construction JSA Members: Job Performers:

General job requirements / Common Personnal Protective Equipment.

Signature

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.

Approval required for hazardous work detailed in the LINDE work permit procedure.Changing conditions and emergency proceduresStop 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.

1. The following Personal Protective Equipment shall be worn while repairing concrete cracks : Approved coveralls, safety glasses, safety helmet, safety shoes and gloves.

Signature

OTHERS(List Below):

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NEW REVISED

1

RISKRANK

1.1 Eye injuriesB 2 LOW

1.1.1 Ensure employee wear appropriate safety glasses.

Hands and fingers injuries B 2 LOW

1.1.2 Ensure employees have personal protective equipment i.e. coveralls, safety shoes, safety helmet, safety glasses and work gloves.

1.2 Dust inhalation B 2 LOW 1.2.1 Ensure employee wear approved dust masks.1.3 1.3.1 Ensure all materials, tools, equipment

are kept secure at all times while working at heights.

1.3.2 Barricades working area with signboard indicating work in progress.

1.4 Use of make shift tools. B 2 LOW 1.4.1 Use the right tools for the right job.1.5 1.5.1 ALL employees shall wear inspected

full body harness fitted with twin lanyards with shock absorbers, each lanyard shall be fitted with dual action self-locking safety hook for 100% Tie-off.

1.5.1.1

1.5.1.2

Discuss working at height hazards at daily TSTI.Training prior to start working @ heights.

1.5.2 Ensure 100% fall protection.2.1 2.1.1 Use appropriate working gloves.

2.1.2 Use the right tools for the right job.2.2 Fall of chipped concrete

(if working at height). B 3 MED2.2.1 Barricade working area & Warning

signboard to warn other.2.2.1.1 Discuss in daily TSTI.

A 3 LOW

2.2.2 Ensure employees have personal protective equipment i.e. coveralls, safety shoes, safety helmet, safety glasses and work gloves.

Hand & finger injury.22 LOW

Removal of chipped concrete. B

LOW5

1 Chipping of crack concrete.

Fall of personnel (if working at heights).

C 5 HIGH A

CONTROLSCURRENT

CONSEQUENCES

JOB SAFETY ANALYSIS / RISK ASSESSMENTT.4.234.073 SCOPE : Repair of Concrete Cracks

Initial Risk Residual RiskHAZARD / POTENTIAL C R

Fall of materials/Tools.

P

B 2 LOW

ITEM ACTIVITY C PCONTROLSADDITIONAL

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2

JOB SAFETY ANALYSIS / RISK ASSESSMENTT.4.234.073 SCOPE : Repair of Concrete Cracks

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3.1 Eye and skin irritation.

B 2 LOW

3.1.1 Ensure employees have personal protective equipment i.e. coveralls, safety shoes, safety helmet, safety glasses and rubber hand gloves to avoid skin contacts.

3.2 3.2.1 Use the right tools for the right job.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 LOW4.1 4.1.1 Ensure all materials shall be stored,

handled and used in a safe manner, by type, providing enough passageways between different stored materials.

4.1.2 Employee shall be trained for using safe methods in handling materials.

4.2 4.2.1 Material shall be stored in conditions compatible with the recommendations of the MSDS.

4.2.1.1 Remove unecessary combustible materials.

4.2.2 Ensure to maintained suitable fire extinguisher in the area.

4.3 Improper disposal of empty materials. B 2 LOW

4.3.1 Ensure empty containers shall be dumped at approved dump locations for hazardous materials.

3 Apply cementitious filler and mortars for concrete surface.

B 2

3 LOWMED A

B 2 LOW

4 Material handling/storage.

Physical injury due to mishandling of materials back, muscle strain , sprain.

Fire/explosion

B 3

LOWHands and fingers injuries

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constructive solutionsRenderoc BF*

One component polymer modified cementitious filler andreprofiling mortar

Uses

Renderoc BF is designed for application to imperfections inconcrete and masonry surfaces. It is suitable for applicationupto 5mm thickness, and can be used in the followingsituations:

! Filling blow holes prior to overcoating.

! Skim-coat over concrete to receive protective coatings.

! General reprofiling over large areas.

! Reprofiling, in association with other Renderoc mortars

Advantages

! Cost effective/ time saving - no independent primer orcuring agents required.

! High performance - excellent bond to substrate.

! User friendly - requires addition of water only.

! Suitable to receive protective coatings.

Description

Renderoc BF is supplied as a ready to use blend of drypowders and polymers, which requires only the addition ofwater to produce a highly consistent cementitious mortar,with good handling characteristics.

Renderoc BF exhibits excellent thermal compatibility withconcrete and is fully compatible with other Renderoc* mortarsand Dekguard* protective coatings.

Design Criteria

Renderoc BF is designed for vertical and overhead use toinfill surface imperfections of concrete upto 5mm thick.

Limitations

- Renderoc BF should not be used when the temperatureis below 5C and falling.

- Do not proceed with the application when rainfall isimminent unless in a sheltered or protected situation.

- If any doubts arise concerning temperature or substrateconditions, consult the local Fosroc office.

Properties

The following results were obtained at a water:powder ratioof 0.2

PropertyInitial setting time (BS EN 196): 115 minsFinal setting time (BS EN 196) : 165 minsFresh wet density : 1840 kg/m3

Compressive strength : 3days - 10N/mm 7days - 20N/mm

Average Linear Coefficient :of Thermal Expansion : 2.5 x 10-6 per oC

Note : Working life and setting time will vary dependenton ambient, substrate temperatures and windspeed.

Instructions for use

Preparation

Clean the surface and remove any dust, unsound material,plaster, oil, paint, grease, corrosion deposits or algae.Roughen the surface to remove any laitance and expose thefine aggregate by light scabbling or sweep blasting.

Oil and grease deposits should be removed by steamcleaning, detergent scrubbing or the use of a proprietarydegreaser. The effectiveness of decontamination should thenbe assessed by a pull-off test.

The cleaned areas should be blown clean with oil-freecompressed air before continuing. All prepared areas shouldbe thoroughly soaked with clean water immediately prior tothe application of Renderoc BF. Any residual surface watershould be removed prior to commencement.

Mixing

Care should be taken to ensure that Renderoc BF is thoroughlymixed. In all cases the powder component should beintroduced into water.

Mixing should be carried out in a suitably sized mixing vessel,using a slow speed (400/500 rpm), heavy duty drill and aFosroc mortar mixing paddle.

Pour 4 - 6litres of water (depending of workability required)into the mixer and, with the machine in operation, add one full20 kg bag of powder, then mix for 3 to 5 minutes, until fullyhomogeneous. Do not use more than 6 litres of water per20kg bag.

UAE/0492/07/H

Renderoc BF*

Al Gurg FosrocLLCPost Box 657, DubaiUnited Arab Emirates

www.fosroc.com

Important noteFosroc products are guaranteed against defective materials and manufacture and are sold subject to its standardConditions for the Supply of Goods and Service. All Fosroc datasheets are updated on a regular basis. It is the usersresponsibility to obtain the recent version. Refer to www.fosroc.com.

Head Officetelephone: (+9714) 2039699 fax: (+9714) 2859649 email: [email protected]

Regional officesAbu Dhabi, Al Gurg Fosroc telephone: 673 1779 fax: 673 1449 email: [email protected], YBA Kanoo telephone: 17735454 fax: 17732828 email: [email protected], Boodai telephone: 4817618 fax: 4832124 email: [email protected], Al Amana telephone: 24815080 fax: 24817554 email: [email protected], Tadmur telephone: 4500607 fax: 4500543 email: [email protected]

* Denotes the trademark of Fosroc International Limited

See separate data sheet

If mixing small quantities by hand, Renderoc BF should bevolume-batched. Add 3 volumes of the Renderoc BF powder(loose-filled to excess and struck off level with the top of themeasuring container) to one volume of potable water. Thisshould be mixed vigorously until fully homogeneous.

Application

Apply the mixed Renderoc BF to the blow holes by steel trowel.It should be applied with minimum working and be allowedto partly set before finally trowelling to a smooth finish. If avery smooth finish is required, a small amount of water maybe flicked on to the surface of the Renderoc BF with a paintbrush prior to final trowelling.

Curing

Curing is not generally required. However, under extremeconditions - high temperatures and drying winds - useNitobond AR* or Nitocote PE135* as a curing agent, or coverthe surface with polythene sheeting, taped down at the edges.

Nitobond AR does not require mechanical removal prior toovercoating with Dekguard system. If overcoating with epoxyor polyurethanes then use Nitocote PE135 as the curingmembrane.

Cleaning

Renderoc BF should be removed from tools, equipment andmixers with clean water immediately after use. Cured materialcan only be removed mechanically.

High temperature working

At ambient temperatures above 35C, the components shouldbe placed in air-conditioned storage of less than 25C, forspecial application procedures, refer to your local Fosrocoffice.

Overcoating with protective / decorative finishes

Renderoc BF may be overcoated after 48 hours, in ambientconditions of up to 75% relative humidity, dependant on thetype of coating. For further information consult the local Fosrocoffice before proceeding.

Estimating

SupplyRenderoc BF : 20 kg bag

YieldRenderoc BF : 14.4 litres per 20kg bag

(based on 6litre water)

Actual coverage of Renderoc BF will be wholly dependentupon the general substrate condition. It is recommended,therefore, that site trials over a typical area are carried out todetermine actual usage.

Storage

Shelf life

All products have a shelf life of 12 months if kept in a dry storein the original, unopened bags or packs @ 25oC. If stored athigh temperatures and/or high humidity conditions the shelflife may be considerably reduced to 4 to 6 months.

Precautions

Health and safety

Renderoc BF contains cement powders which, when mixedor become damp, release alkalis which can be harmful tothe skin. During use, avoid inhalation of dust and contactwith skin and eyes. Wear suitable protective clothing, gloves,eye protection and respiratory protective equipment. The useof barrier creams provide additional skin protection. In caseof contact with skin, rinse with plenty of clean water, thencleanse with soap and water. In case of contact with eyes,rinse immediately with plenty of clean water and seek medicaladvice. If swallowed, seek medical attention immediately -do not induce vomiting. For further information, refer to theProduct Material Safety Data Sheet.

Fire

Renderoc BF is a non-flammable product.

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constructive solutionsRenderoc SXtra*

Shrinkage controlled, structural grade cementitiousrepair mortar system

Uses

Renderoc SXtra is suitable for hand application to repairswhere significant load bearing is required. Typical applicationswould include, but not be limited to, the following :

Vertical and overhead repairs. Patch repairs to concrete floor slabs. Patch repairs to stairs, steps and other areas subject to

repeated, heavy trafficking.

Arris repairs to joint edges. General structural repairs where formwork cannot be

easily erected.

Advantages

Renderoc SXtra features Dimensional Stability Technology -a new materials technology which controls the rate of dryingshrinkage such that, when used correctly :

i. the dimensions of the repair remain stable; and thus

ii. eliminating failure, due to shrinkage cracking.

This in turn leads to a series of associated benefits :

Cost effective - shrinkage control enables repairs to becompleted right first time.

Enhanced durability - works in tandem with extremely lowpermeability to prolong effective working life.

Compatibility - aligns performance closer than ever before,to that of host concrete.

User friendly - specifically developed to provide aneasy-to-apply product, suitable for local conditions.

Definable performance - positive benefits are easilydemonstrated via a single, simple measurement.

Description

Renderoc SXtra is supplied as a ready to use blend of drypowders, which requires only the addition of clean water toproduce a highly consistent repair mortar suitable for moststructural and loadbearing repairs.

Properties

The following typical results were obtained at a water topowder ratio of 0.15.

Test method Typical result

Drying shrinkage to ASTM C 157-937 days : < 300 microstrain28 days : < 500 microstrain

Permeability : < 10 mm(DIN 1048 Part 5)Flexural strength : > 7 N/mm2 at 28 days(BS 6319 Pt.3)Tensile strength : > 3.5 N/mm2 at 28 days(BS 6319 Pt.7)Compressive strength : 50 N/mm2 at 7 days(BS 1881 Pt.1161) 55 N/mm2 at 28 daysWater absorption : < 2%(BS 1881 Pt.121)Note1: 50mm cubes, air cured @ 250C

Design criteria

Dimensional Stability Technology is a major step forward inthe general compatibility of repair mortar systems with thehost substrate, and the control of drying shrinkage in particular.

Attention to the basic design criteria given below should ensurethat the full benefits of this technology are gained in use :

(i) Recommended limits for a single application are:

Minimum applied thickness : 5 mmOverhead sections : up to 25 mm thickVertical sections : up to 35 mm thickSmall pockets or horizontal : up to 100 mm thickMaximum length : up to 3 m

NOTE : If the repair area exceeds 2.5 m2, considerationshould be given to the use of mass fill by meansof either Renderoc SPXtra* spray applied mortaror Renderoc LAXtra* microconcrete.

(ii) In situations where a substrate/repair barrier is required,or enhanced bond strength/working time is required, orwhere the substrate is likely to be damp (e.g. seawalls,quays etc.), Nitobond EP epoxy bonding agent should beused.

(iii) Water addition = 3.0 litres per 20 kg bagUnder no circumstances should part bags be used oradditional water be employed. Either of these two actionswill adversely affect material performance, automaticallyinvalidating Fosrocs standard product guarantee.

UAE/0252/04/G

Renderoc SXtra*


www.fosroc.com

Important noteFosroc products are guaranteed against defective materials and manufacture and are sold subject to its standardConditions for the Supply of Goods and Service


Regional officesDubai, Al Gurg Fosroc telephone: 285 8787 fax: 285 2023 email: [email protected] Dhabi, Al Gurg Fosroc telephone: 673 1779 fax: 673 1449 email: [email protected], YBA Kanoo telephone: 17735454 fax: 17732828 email: [email protected], Boodai telephone: 4817618 fax: 4832124 email: [email protected], Al Amana telephone: 771 5080 fax: 771 7554 email: [email protected], Tadmur telephone: 413628 fax: 440812 email: [email protected]



Galvanic Protection of repairs

It is likely that, steel reinforcement in the area around a patchrepair, particularly in a chloride contaminated environment,will typically corrode after the repairs are carried out, referredto as the incipient anode or Halo effect.

Galvashield XP* (eXtra Protection) anodes can beincorporated into patch repairs to galvanically protect steelreinforcement against corrosion in the adjacent concrete andmay also be used in new construction to provide CathodicPrevention. Galvashield XP are zinc based anodes encasedin a highly alkaline mortar which maintains the surface of thezinc in an active state. Galvanic systems are self regulatingand demand based and will start working only when corrosionof steel begins. Refer to product datasheet for further details.


Renderoc SXtra should be mixed and applied in strictaccordance with the Product Method Statement, a copy ofwhich may be obtained from your nearest Fosroc office.

Estimating

Supply

Renderoc SXtra : 20 kg bags

Yield

Renderoc SXtra : 10.9 litresper 20 kg bag

Limitations

- Renderoc SXtra should not be used when the ambienttemperature is below 50C and falling.

- Renderoc SXtra should not be part mixed, nor part bagsused.

- Renderoc SXtra should not be exposed to running watereither during application or prior to final set.

- Water ponding is not recommended for curing.

Storage

Shelf life

Renderoc SXtra has a shelf life of 12 months; if kept in a dryenvironment, in its original, unopened packing. If stored inconditions of high humidity and/or temperature, the shelf lifemay be reduced to as little as 4 months.

Standards compliance

Renderoc SXtra repair mortar system complies with thefollowing international standards :

ASTM C157-93 : Test for drying shrinkageDIN 1048 Part 5 : Test for permeabilityBS 1881 Pt.121 : Test for water absorption

Precautions

Health and safety

Renderoc SXtra contains cement powders which, when mixedwith water or upon becoming damp, release alkalis which can beharmful to the skin.

During use, avoid inhalation of the dust and contact with the skin oreyes. Wear suitable protective clothing - eye protection, gloves andrespiratory equipment (particularly in confined spaces).

The use of barrier creams to provide additional skin protection isalso advised. In case of contact with the skin, rinse with plenty ofclean water, then cleanse thoroughly with soap and water.

In case of contact with eyes, rinse immediately with plenty of cleanwater and seek medical advice. If swallowed seek medical attentionimmediately - do not induce vomiting.

Fire

Renderoc SXtra, is non-flammable and presents no firehazard.

For further information, please refer to the respective ProductMaterial Safety Data Sheet for Renderoc SXtra.

Nito

cote

PE

135*

constructive solutionsNitocote PE135*

Uses

Provides a highly effective protective coating, with chemicaland abrasion resistance to prevent corrosion of concretesubstrates and exhibits cost and labour savingsupplementary benefits. It can be used in a wide range ofapplications :

! Suitable for underground protection, foundations etc.

! Dual purpose protective coating and curing compound.

Advantages

! Can be applied on damp concrete which is one day old.

! Cost saving, material which can be used as a protectivecoating and curing compound in a single application.

! Single pack - no component mixing, no wastage, multipleapplications from single pack

! Labour saving, single component material which is alsowater based, and therefore non-toxic.

! UV stable - will not fade or deteriorate in strong sunlight.

! Environmentally friendly, solvent, pitch and asbestos freeand can be used in confined spaces.

! Excellent service life - resistant to chloride and sulphateions plus a wide range of chemicals.

! Durable finish - offers good abrasion resistance.

Standards compliance

Nitocote PE135 complies with the concrete curingrequirements of ASTM C309, when applied at the rate of 5m2

per litre.

Description

Nitocote PE135 is a single component, high performance,grey colour viscous liquid coating based on hydrophobicpolyester resin. It is totally free from hazardous materials/carcinogens such as coal tar pitch, hydrocarbon basedsolvents, aromatic amines etc. The coating displays itsprotective properties at a minium DFT of 200 microns.

Specification

Where shown on the contract documents, below groundsurfaces shall be protected with two coats of Nitocote PE135,a ` hydrophobic polyester emulsion coating applied at a rateof 400-500 microns wet film thickness per coat.

Eco friendly, protective coating based on hydrophobicpolyester resin

Properties

Specific gravity (20C) : 1.28 g/cm3

Solids content by weight : 53%Solids content by volume(ASTM D2697) : 43%Surface drying time(ASTM D1640) : 35 - 40 min @ 20C

10 - 15 min @ 35C04 - 06 min @ 45C

Overcoating time(ASTM D1640) : 6 - 7 hours @ 20C

3 - 4 hours @ 35C2 - 3 hours @ 45C

Complete cure : 7 days @ 25CWater absorption(BS 1881 Pt. 122) : < 0.2%Water permeability(BS EN 12390,: Part 8) : NilAdhesion strength(ASTM D4541) : >1.0 N/mm2

Chemical resistance

Lactic acid 20% : ExcellentAcetic acid 20% : ExcellentNitric acid 5% : ExcellentEthylene glycol 40% : ExcellentCopper Sulphate 25% : ExcellentZinc Sulphate 25% : ExcellentMagnesium Sulphate 25% : ExcellentTap water : ExcellentSea water : ExcellentGround water : ExcellentHigh sulphate water : ExcellentDistilled water : Excellent

For resistance to other chemical, consult the local Fosrocrepresentative.

UAE/0429/07/C

Nitocote PE135*


www.fosroc.com

Important noteFosroc products are guaranteed against defective materials and manufacture and are sold subject to its standardConditions for the Supply of Goods and Service. All Fosroc datasheets are updated on a regular basis. It is the usersresponsibility to obtain the recent version. Refer to www.fosroc.com.


Regional officesAbu Dhabi, Al Gurg Fosroc telephone: 673 1779 fax: 673 1449 email: [email protected], YBA Kanoo telephone: 17735454 fax: 17732828 email: [email protected], Boodai telephone: 4817618 fax: 4832124 email: [email protected], Al Amana telephone: 24815080 fax: 24817554 email: [email protected], Tadmur telephone: 4500607 fax: 4500543 email: [email protected]




Surface preparation

All surfaces must be clean and free from laitence, dirt, dust,oil and grease. In case of porous substrates, pre-soak thesurface with potable water for 30 minutes. Ensure excesswater is removed prior to application of Nitomortar PE135.

Application

Nitocote PE135 should be applied by roller to preparedsurfaces. Stir well before use, replace lid when not in use.Soak up any spillage with water and wash down immediately.

Vertical applications can be achieved by single coat applicationupto a maximum wft of 600 microns per coat. For multiplecoat application, the second coat should be applied at rightangles to the first within the stated overcoating times. Allapplications should be continued up verticals to the existingdamp proof course. Ensure that the coating is not damagedduring subsequent applications.

Repairs

Any damaged areas can be readily overcoated to restore themembrane continuity. The surface is to be properly preparedusing emery cloth to rub down the surface to provide a keyand is to be made dust free, prior to product application.

Cleaning

Nitocote PE135 can be removed using only clean water, whilststill damp. If left to dry, then use a scourer.

Limitations

- Application should not commence below 10C or above50C.

- Do not apply on running or standing water or when thereare chances of rain.

- Exposure to chemicals may result in slight colour changeover time.

Estimating

SupplyNitocote PE135 : 20 litre pails

Theoretical coverageGeneral use : 2.5m per litre @ 400

micron wft/coat (2 coatapplication recommended)(actual coverage rates willdepend upon substrateporosity)

Curing compound : 5m2 per litre per coatto give 200 micron wft

Storage

Nitocote PE135 will have a minimum shelf life of 12 monthsif stored in normal warehouse conditions at less than 25C.

Health and safety

Some people are sensitive to resins and solvents, so glovesand barrier creams (e.g. Kerodex Antisolvent) should be usedwhen handling these products. Remove any contaminationfrom the skin with soap and water, or resin removing creams(e.g. Kerocleanse Standard Grade Skin Cleaner) followed bywashing with soap and water. Do not use solvent.

The use of goggles is also recommended, but shouldaccidental eye contamination occur, wash thoroughly withplenty of clean water and seek medical treatment immediately.

GAMA LINDE

CONCRETE REPAIR LOG

S.NO AREA GRID CRACKSREPAIRED DATESIGNATURE

INSPECTION FORM FOR CONCRETE HONEY COMBS&CRACKS

DRAWING & REVISION No. TYPE OF STRUCTURE : LOCATION : No :

ITEM

DETAIL OF ACTIVITY

COMPLIANCE

REMARKS YES NO NA

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

Page 1 of 1

QSGTL PEARL PROJECT

C2 ASU Construction Works FORM NO:

GAM-QCR-QAC-GTL-010 INSPECTION FORM FOR CONCRETE

HONEYCOMBS &CRACKS ITP : GAM-QCR-QAC-GTL-

Date:

011-METHOD STATEMENT FOR REPAIR OF CONCRETE WORKS.pdf

Documents

Transcript of 011-METHOD STATEMENT FOR REPAIR OF CONCRETE WORKS.pdf