Pearl GTL

Project
Shell Project No: HP-3000-QAT
Project Document Number: T- 4.234.073

Purchase Order Number:

2MH127

Tag/Item Number(s):

N/A

Unit(s):

ASU

PCWBS:

LINDE ENGINEERING

Contractor Project No:

Project Rev.: F

Page 2 of 23

5887

QATAR SHELL GTL PROJECT (PEARL)

C2 AIR SEPARATION UNITS CONSTRUCTION
I

01.12.08

Ready For Construction

SB

EO

AG

RFC

01.10.08

Issued for Review ( Revised according to site

changes)

SB

EO

AG

IFR

13.07.08

Issued for Review ( Revised according to site

changes)

SB

EO

AG

IFR

30.03.08

Ready For Construction

SB

UA

ZG

RFC

23.03.08

Ready For Construction

SB

UA

ZG

RFC

23.02.08

Ready For Construction

SB

UA

ZG

RFC

09.12.07

Issued for Company comments

SB

AU/MC

ZG

ICC

23.11.07

Issued for Review

SB

AU/MC

ZG

IFR

20.11.07

Issued for Internal Review

SB

AU/MC

ZG

IIR

Date

Description

GAMA
Rev.
No.

Project
Rev
No.

Prepared Checked Approved

By
By
By
ORIGINATOR

Status

Document Title:

LINDE ENGINEERING AG

METHOD STATEMENT FOR REPAIR OF CONCRETE

WORKS
Document No.

Contractor

Gama Qatar Co. W. L. L.

LOC470
GAM

MTS

CIV

GTL

011

Org.
Code

Doc.
Type

Disc.
Code

Geogr.
Area

Seq.
No

Rev.
No

Project Document Number: T-4.234.073

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.

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

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

:
:
:
:
:
:
:
:

QSGTL or its PMC

Linde Engineering AG
Gama Qatar Co. W. L. L.
QSGTL Pearl Plant C2 ASU Construction Works
Quality Control Procedure
Inspection and Test Plan
Quality Assurance / Quality Control
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.
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.

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.

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

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

Hand held angle grinders

: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

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
T-4.234.073 Rev. F

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).

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.

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

JOB SAFETY ANALYSIS FORM

JSA Number:

NEW

Job being analysed: MS-Repair of Concrete Cracks

Department/Section doing JSA:HSE & Construction
Normal Approvals:
JSA by:

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

General job requirements / Common

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

JOB SAFETY ANALYSIS / RISK ASSESSMENT

T.4.234.073

Q
Q A
A T
T A
A R
R

ITEM

ACTIVITY
Chipping of crack
concrete.

HAZARD / POTENTIAL
CONSEQUENCES

1.1 Eye injuries

Hands and fingers

injuries
1.2 Dust inhalation

Initial Risk
P C
B

1.3 Fall of materials/Tools.

1.4 Use of make shift tools.

RISK
RANK

CURRENT
CONTROLS

1.1.1 Ensure employee wear appropriate

safety glasses.
1.1.2 Ensure employees have personal
protective equipment i.e. coveralls,
LOW
safety shoes, safety helmet, safety
glasses and work gloves.
1.2.1 Ensure employee wear approved dust
LOW
masks.
1.3.1 Ensure all materials, tools, equipment
are kept secure at all times while
working at heights.
LOW
1.3.2 Barricades working area with
signboard indicating work in progress.

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

SCOPE : Repair of Concrete Cracks

Discuss working at height hazards

at daily TSTI.
Training prior to start working @
heights.

Discuss in daily TSTI.

5 LOW

3 LOW

JOB SAFETY ANALYSIS / RISK ASSESSMENT

T.4.234.073

Q
Q A
A T
T A
A R
R

Apply cementitious 3.1 Eye and skin irritation.

filler and mortars for
concrete surface.

LOW

LOW

3.3 Chemical hazard.

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

MED

LOW

3.2 Hands and fingers

injuries
4

Material
handling/storage.

4.2 Fire/explosion

4.3 Improper disposal of

empty materials.

MED

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.
3.2.1 Use the right tools for the right job.
3.2.2 Ensure employee wearing safety work
gloves.
3.3.1 Review MSDS.
3.3.1.1
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.
4.2.1 Material shall be stored in conditions 4.2.1.1
compatible with the recommendations
of the MSDS.
4.2.2 Ensure to maintained suitable fire
extinguisher in the area.
4.3.1 Ensure empty containers shall be
dumped at approved dump locations
for hazardous materials.

SCOPE : Repair of Concrete Cracks

Discuss in TSTI

Remove unecessary combustible

materials.

3 LOW

3 LOW

Renderoc BF*

constructive solutions

One component polymer modified cementitious filler and

reprofiling mortar
Uses
Renderoc BF is designed for application to imperfections in
concrete and masonry surfaces. It is suitable for application
upto 5mm thickness, and can be used in the following
situations:
! 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 or
curing agents required.
! High performance - excellent bond to substrate.
! User friendly - requires addition of water only.

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

Working life and setting time will vary dependent

on ambient, substrate temperatures and wind
speed.

Instructions for use

Preparation

Description

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 the
fine aggregate by light scabbling or sweep blasting.

Renderoc BF is supplied as a ready to use blend of dry

powders and polymers, which requires only the addition of
water to produce a highly consistent cementitious mortar,
with good handling characteristics.

Oil and grease deposits should be removed by steam

cleaning, detergent scrubbing or the use of a proprietary
degreaser. The effectiveness of decontamination should then
be assessed by a pull-off test.

Renderoc BF exhibits excellent thermal compatibility with

concrete and is fully compatible with other Renderoc* mortars
and Dekguard* protective coatings.

The cleaned areas should be blown clean with oil-free

compressed air before continuing. All prepared areas should
be thoroughly soaked with clean water immediately prior to
the application of Renderoc BF. Any residual surface water
should be removed prior to commencement.

! Suitable to receive protective coatings.

Design Criteria
Renderoc BF is designed for vertical and overhead use to
infill surface imperfections of concrete upto 5mm thick.
Limitations
-

Renderoc BF should not be used when the temperature

is below 5C and falling.

Do not proceed with the application when rainfall is

imminent unless in a sheltered or protected situation.

If any doubts arise concerning temperature or substrate

conditions, consult the local Fosroc office.

Properties
Renderoc BF*

The following results were obtained at a water:powder ratio

of 0.2

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

Apply the mixed Renderoc BF to the blow holes by steel trowel.

It should be applied with minimum working and be allowed
to partly set before finally trowelling to a smooth finish. If a
very smooth finish is required, a small amount of water may
be flicked on to the surface of the Renderoc BF with a paint
brush prior to final trowelling.
Curing
Curing is not generally required. However, under extreme
conditions - high temperatures and drying winds - use
Nitobond AR* or Nitocote PE135* as a curing agent, or cover
the surface with polythene sheeting, taped down at the edges.
Nitobond AR does not require mechanical removal prior to
overcoating with Dekguard system. If overcoating with epoxy
or polyurethanes then use Nitocote PE135 as the curing
membrane.
Cleaning
Renderoc BF should be removed from tools, equipment and
mixers with clean water immediately after use. Cured material
can only be removed mechanically.
High temperature working
At ambient temperatures above 35C, the components should
be placed in air-conditioned storage of less than 25C, for
special application procedures, refer to your local Fosroc
office.
Overcoating with protective / decorative finishes
Renderoc BF may be overcoated after 48 hours, in ambient
conditions of up to 75% relative humidity, dependant on the
type of coating. For further information consult the local Fosroc
office before proceeding.

14.4 litres per 20kg bag

(based on 6litre water)

Actual coverage of Renderoc BF will be wholly dependent

upon the general substrate condition. It is recommended,
therefore, that site trials over a typical area are carried out to
determine actual usage.
Storage
Shelf life
All products have a shelf life of 12 months if kept in a dry store
in the original, unopened bags or packs @ 25oC. If stored at
high temperatures and/or high humidity conditions the shelf
life may be considerably reduced to 4 to 6 months.
Precautions
Health and safety
Renderoc BF contains cement powders which, when mixed
or become damp, release alkalis which can be harmful to
the skin. During use, avoid inhalation of dust and contact
with skin and eyes. Wear suitable protective clothing, gloves,
eye protection and respiratory protective equipment. The use
of barrier creams provide additional skin protection. In case
of contact with skin, rinse with plenty of clean water, then
cleanse with soap and water. In case of contact with eyes,
rinse immediately with plenty of clean water and seek medical
advice. If swallowed, seek medical attention immediately do not induce vomiting. For further information, refer to the
Product Material Safety Data Sheet.
Fire
Renderoc BF is a non-flammable product.
* Denotes the trademark of Fosroc International Limited

Important note

20 kg bag

Yield
Renderoc BF

Application

See separate data sheet

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

fax: (+9714) 2859649

email: agf@fosroc.com

Regional offices
Abu Dhabi, Al Gurg Fosroc
Bahrain, YBA Kanoo

telephone: 673 1779

telephone: 17735454

fax: 673 1449

fax: 17732828

email: abudhabi@fosroc.com
email: bahrain@fosroc.com

Kuwait, Boodai
Oman, Al Amana
Qatar, Tadmur

telephone: 4817618
telephone: 24815080
telephone: 4500607

fax: 4832124
fax: 24817554
fax: 4500543

email: kuwait@fosroc.com
email: oman@fosroc.com
email: qatar@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

where significant load bearing is required. Typical applications
would include, but not be limited to, the following :

The following typical results were obtained at a water to

powder ratio of 0.15.

Vertical and overhead repairs.

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

Drying shrinkage to ASTM C 157-93

7 days
: < 300 microstrain
28 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 days
Water absorption
: < 2%
(BS 1881 Pt.121)
Note1:
50mm cubes, air cured @ 250C

i.

Design criteria

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

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 be
completed right first time.
Enhanced durability - works in tandem with extremely low
permeability to prolong effective working life.
Compatibility - aligns performance closer than ever before,
to that of host concrete.
User friendly - specifically developed to provide an
easy-to-apply product, suitable for local conditions.
Definable performance - positive benefits are easily
demonstrated via a single, simple measurement.
Description

Renderoc SXtra*

Renderoc SXtra is supplied as a ready to use blend of dry

powders, which requires only the addition of clean water to
produce a highly consistent repair mortar suitable for most
structural and loadbearing repairs.

Test method

Typical result

Dimensional Stability Technology is a major step forward in

the general compatibility of repair mortar systems with the
host substrate, and the control of drying shrinkage in particular.
Attention to the basic design criteria given below should ensure
that the full benefits of this technology are gained in use :
(i) Recommended limits for a single application are:
Minimum applied thickness
Overhead sections
Vertical sections
Small pockets or horizontal
Maximum length

:
:
:
:
:

5 mm
up to 25 mm thick
up to 35 mm thick
up to 100 mm thick
up to 3 m

NOTE : If the repair area exceeds 2.5 m2, consideration

should be given to the use of mass fill by means
of either Renderoc SPXtra* spray applied mortar
or Renderoc LAXtra* microconcrete.
(ii) In situations where a substrate/repair barrier is required,
or enhanced bond strength/working time is required, or
where the substrate is likely to be damp (e.g. seawalls,
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
additional water be employed. Either of these two actions
will adversely affect material performance, automatically
invalidating Fosrocs standard product guarantee.

Renderoc SXtra*
Galvanic Protection of repairs

Storage

It is likely that, steel reinforcement in the area around a patch

repair, particularly in a chloride contaminated environment,
will typically corrode after the repairs are carried out, referred
to as the incipient anode or Halo effect.

Shelf life

Galvashield XP* (eXtra Protection) anodes can be

incorporated into patch repairs to galvanically protect steel
reinforcement against corrosion in the adjacent concrete and
may also be used in new construction to provide Cathodic
Prevention. Galvashield XP are zinc based anodes encased
in a highly alkaline mortar which maintains the surface of the
zinc in an active state. Galvanic systems are self regulating
and demand based and will start working only when corrosion
of steel begins. Refer to product datasheet for further details.

Renderoc SXtra has a shelf life of 12 months; if kept in a dry

environment, in its original, unopened packing. If stored in
conditions of high humidity and/or temperature, the shelf life
may be reduced to as little as 4 months.
Standards compliance
Renderoc SXtra repair mortar system complies with the
following international standards :
ASTM C157-93 :
DIN 1048 Part 5 :
BS 1881 Pt.121 :

Instructions for use

Precautions

Renderoc SXtra should be mixed and applied in strict

accordance with the Product Method Statement, a copy of
which may be obtained from your nearest Fosroc office.

Health and safety

Estimating

20 kg bags

Yield
Renderoc SXtra

10.9 litresper 20 kg bag

Limitations
-

Renderoc SXtra should not be used when the ambient

temperature is below 50C and falling.

Renderoc SXtra should not be part mixed, nor part bags

used.

Renderoc SXtra contains cement powders which, when mixed

with water or upon becoming damp, release alkalis which can be
harmful to the skin.
During use, avoid inhalation of the dust and contact with the skin or
eyes. Wear suitable protective clothing - eye protection, gloves and
respiratory equipment (particularly in confined spaces).

Supply
Renderoc SXtra

Test for drying shrinkage

Test for permeability
Test for water absorption

Renderoc SXtra should not be exposed to running water

either during application or prior to final set.
Water ponding is not recommended for curing.

The use of barrier creams to provide additional skin protection is

also advised. In case of contact with the skin, rinse with plenty of
clean water, then cleanse thoroughly with soap and water.
In case of contact with eyes, rinse immediately with plenty of clean
water and seek medical advice. If swallowed seek medical attention
immediately - do not induce vomiting.
Fire
Renderoc SXtra, is non-flammable and presents no fire
hazard.
For further information, please refer to the respective Product
Material Safety Data Sheet for Renderoc SXtra.
* Denotes the trademark of Fosroc International Limited

Important note

See separate data sheet

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

fax: (+9714) 2859649

email: agf@fosroc.com

Regional offices

Post Box 657, Dubai

United Arab Emirates

Dubai, Al Gurg Fosroc

telephone: 285 8787

fax: 285 2023

Abu Dhabi, Al Gurg Fosroc

Bahrain, YBA Kanoo

telephone: 673 1779

telephone: 17735454

fax: 673 1449

fax: 17732828

email: dubai@fosroc.com
email: abudhabi@fosroc.com
email: bahrain@fosroc.com

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: kuwait@fosroc.com
email: oman@fosroc.com
email: qatar@fosroc.com

UAE/0252/04/G

Nitocote PE135*

constructive solutions

Eco friendly, protective coating based on hydrophobic

polyester resin
Uses
Provides a highly effective protective coating, with chemical
and abrasion resistance to prevent corrosion of concrete
substrates and exhibits cost and labour saving
supplementary benefits. It can be used in a wide range of
applications :
! Suitable for underground protection, foundations etc.

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

! Dual purpose protective coating and curing compound.

Advantages

Overcoating time
(ASTM D1640)

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

! Cost saving, material which can be used as a protective
coating and curing compound in a single application.
! Single pack - no component mixing, no wastage, multiple
applications from single pack
! Labour saving, single component material which is also
water based, and therefore non-toxic.

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

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

! Environmentally friendly, solvent, pitch and asbestos free
and can be used in confined spaces.
! Excellent service life - resistant to chloride and sulphate
ions plus a wide range of chemicals.
! Durable finish - offers good abrasion resistance.
Standards compliance
Nitocote PE135 complies with the concrete curing
requirements 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 hydrophobic
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.

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

For resistance to other chemical, consult the local Fosroc

representative.

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

2.5m per litre @ 400

micron wft/coat (2 coat
application recommended)
(actual coverage rates will
depend upon substrate
porosity)
5m2 per litre per coat
to give 200 micron wft

Theoretical coverage

Nitocote PE135 should be applied by roller to prepared

surfaces. 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 application
upto a maximum wft of 600 microns per coat. For multiple
coat application, the second coat should be applied at right
angles to the first within the stated overcoating times. All
applications should be continued up verticals to the existing
damp proof course. Ensure that the coating is not damaged
during subsequent applications.

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

Repairs

Health and safety

Any damaged areas can be readily overcoated to restore the

membrane continuity. The surface is to be properly prepared
using emery cloth to rub down the surface to provide a key
and is to be made dust free, prior to product application.

Some people are sensitive to resins and solvents, so gloves

and barrier creams (e.g. Kerodex Antisolvent) should be used
when handling these products. Remove any contamination
from the skin with soap and water, or resin removing creams
(e.g. Kerocleanse Standard Grade Skin Cleaner) followed by
washing with soap and water. Do not use solvent.

Cleaning
Nitocote PE135 can be removed using only clean water, whilst
still damp. If left to dry, then use a scourer.
Limitations
-

Application should not commence below 10C or above

50C.

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.

The use of goggles is also recommended, but should

accidental eye contamination occur, wash thoroughly with
plenty of clean water and seek medical treatment immediately.

* 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 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

fax: (+9714) 2859649

email: agf@fosroc.com

Regional offices
Abu Dhabi, Al Gurg Fosroc
Bahrain, YBA Kanoo

telephone: 673 1779

telephone: 17735454

fax: 673 1449

fax: 17732828

email: abudhabi@fosroc.com
email: bahrain@fosroc.com

Kuwait, Boodai
Oman, Al Amana
Qatar, Tadmur

telephone: 4817618
telephone: 24815080
telephone: 4500607

fax: 4832124
fax: 24817554
fax: 4500543

email: kuwait@fosroc.com
email: oman@fosroc.com
email: qatar@fosroc.com

UAE/0429/07/C

CONCRETE REPAIR LOG

S.NO

AREA

GRID

SIGNATURE
CRACKS
REPAIRED DATEGAMA
LINDE

QSGTL PEARL PROJECT

C2 ASU Construction Works
FORM NO:
GAM-QCR-QAC-GTL-010

INSPECTION FORM FOR CONCRETE

HONEYCOMBS &CRACKS

ITP : GAM-QCR-QAC-GTLDate:

INSPECTION FORM FOR CONCRETE HONEY COMBS&CRACKS

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

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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