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AL JUBAIL HAYCO!AMMONIA PLANT

PROJECT NO.: 2410 A049
PROJECT CODE: AL JUBAIL to

METHOD STATEMENT
FOR
CONCRETE REPAIR

SITE MASTER

111S-1099-0002

SA -oD

~I T
1 3 AUG 2013
eee - DeG

JHP PROJECT
comments:

Opt.:

Date:

Name:

LINDE AG - GAS AND ENGINEERING

No further submission.
Document accepted as final.

PO

Incorporate comments and

resubmit document.

XO

Document not accepted and

rejected.

AI JUBAIL HYCO / AMMONIA PLANT

This review does not constiMe acceptance or appro'J~1 of deSlgl

details, calculatioos, analysis. test, methods or maten~s
developed or selected by the supplier and does not reheve
suppti6r from full collliiance with spedfications and contractual
obliaations.

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Dale:

Linde Engineering Middle East

12. Aug 2013

Dept

_E_N_D__

Name: Binu Kumar

Issued for Review & Approval

23.10.2012

Rev

Desrription

Date

Page 1 of8

Prepared By

Checked By

Verified By

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LINDE AG - GAS AND ENGINEERING /

CONSOLIDATED CONTRACTORS CO.
AL JUBAIL HA YCO/AMMONIA PLANT
PROJECT NO.: 2410 A049
PROJECT CODE:
JUBAIL 10

INDEX
1. PURPOSE
2. SCOPE
3. DEFINITIONS
4. REFERENCE DOCUMENTS
5. RESPONSIBILITIES
6. PROCEDURES

7. RESOURCES
8. SAFETY

Page 2 of8

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LINDE AG - GAS AND ENGINEERING I

CONSOLIDATED CONTRACTORS CO.
ALJUBAIL HAYCO/AMMONIA PLANT
PROJECT NO.: 2410 A049
PROJECT CODE : ALJUBAIL 10

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1.0 Purpose
The purpose of this Method Statement is to set guidelines and
methodology to be followed while repairing poured Concrete.

2.0 Scope
This method statement covers all works related to concrete repair in the
JUABIL HJyCO AMMONIA project unless their very special cassis is not
covered in 'this method.

3.0 Responsibilities
3.1

Construction Manager - To ensure that all work is executed as per

Project procedure, standard, and specification. Also he should make
sure that all project & SADARA safety requirements are applied during
construction.

3.2 Site lor section engineer - Responsible for the implementation of

This procedure as describe in this method and to mange, coordinate all
Activates /'. ','
3.3 Site Foreman - Responsible for the execution and site control of the
works on site.
3.4 QC Engineer - Responsible to ensure that all activities are carried out as
per the QC reqUirements of the project.
3.5 HSE Engineer - Responsible to ensure that all activities are carried out
safely and in compliance with SADARA regulations and the project
safety procedures. Also he is responsible to make sure that all permits
are obtained for any activity as SADARA requirements.

4.0 Definitions
4.1- Clint:
LINDE AG - GAS ENGINEERING
4.2 Contractor: CONSOLIDATED Contractor Company
4.3 JHAP:
JUBAIL HYCO\ AMMONIA PLANT PROJECT

5.0 REFERENCES
5.1

&AA-C-ZA-10001,001 STANDERD DRAWING CIVIL WORK

5.2 CCC-Q-PA-1230(QCP-1099-230) Quality Control plan for

Concrete work
5.4

Page 3 of8

CCC-Q-PB-1233(ITP-1099-233) lTP FOR CONCRETE WORK

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LINDE AG - GAS AND ENGINEERING I

CONSOLIDATED CONTRACTORS CO.

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PROCEDURES
6.1 Air Bubbles

An air bubble doesn't need any repair.

6.2 Honeycombing
If minor honeycombs apparent on any orientation, where the
reinforcement not exposed:
1. Mark out the defective area and grind it.
2. Break out the area until a sound homogenous substrate
has been reached.
3. Wash the substrate with potable water to remove all dust
deposits.
4. Thoroughly soak the substrate with potable water
approximately one hour prior to application of repair.
5. Apply bonding agent to the concrete substrate by brush,
ensuring the concrete surface is wetted out.
6. Apply the repair material in layers, 20mm each whilst
bonding agent is still tacky. If bonding agent dries, the
substrate can be primed
7.
If the substrate can't be reached or hard to handle
by trowel, apply flow able material should be used.
8. If its need any cosmetic repair, fine grout will be used for
the last layer.
9. Cure the repaired area for 48 hours.

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Page 4 of8

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AL JUBAIL HAYCO/AMMONIA PLANT

PROJECT NO.: 2410 A049
PROJECT CODE: ALJUBAIL 10

6.0

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LINDE AG - GAS AND ENGINEERING I

CONSOLIDATED CONTRACTORS CO.
AL JUBAIL HAYCO/AMMONIA PLANT
PROJECT NO.: 2410 A049
10

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reinforcement are exposed:

1. Break out the area until a sound homogenous substrate
has been reached.
2. Wash the substrate with potable water to remove all dust
deposits.
3. Make sure the reinforcement is clean and paint it with
Zinc-Rich epoxy bonding agent for all rebar sides.
4. Develop a form system which permits placement from the
top of the void with the form extending above the void by
at least a few inches.
5. Apply a shrinkage controlled, fluid micro-concrete
continuously Roding to ensure a sound placement. The
concrete shall be placed to extend above the void area.
6. Upon initial set, remove the form and chip excess
concrete from the repaired surface.
7. Cure the repaired area for 48 hours.

Provide Undercut
for Key

Form Extended
Above Void

Page 5 ofa

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If major honeycombs apparent on any orientation, and the

Honey Comb

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LINDE AG - GAS AND ENGINEERING I

CONSOLIDATED CONTRACTORS CO.

AL JUBAIL HAYCO/AMMONIA PLANT

PROJECT NO.: 2410 A049
PROJECT CODE: AL JUBAIL 10

6.3 Cracks
-

for minor (surface) cracks, repair will be as follow:

1. Cracks equal to or less than O.2mm (Hair crack) which
are the capillary cracks will not need any repair
2. Cracks more than 0.2mm and less than 0.5mm (line
crack) will be repaired by open the crack using the
grinder.
3. Cracks between 0.5 and 3mm, the crack should be
opened in V shape.
4. Wash the substrate with potable water to remove all dust
deposits
5. Thoroughly soak the substrate with potable water
approximately one hour prior to application of repair.
6. Apply approved material of fine non-shrinkage grout.
7. Cure the repaired area for 48 hours.

for major (deep) cracks, repair will be as follow:

Deep cracks shall be studied on a case by case basis and the
corrective plan shall be proposed and agreed with LINDE prior
to commencement of work at site

6.4closing tie rod hole's concrete

1. Remove the plastic cones.
2. Thoroughly soak the hole with potable water
approximately one hour prior to application of nonshrinkage grout and cement mortar.
3. Apply cement mortar in the middle and non-shrinkage
grout in the edges of a depth of 20mm.
4. Compact the cement mortar into the tie rod hole by
trowel, and finish with a steel trowel.
5. Cure the exposed surface area for 48 hours.

~
'\. CEMENT

MORTAR

Page 6 of8

""NON-SHRINKAGE

GROUT

--------------------------

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LINDE AG - GAS AND ENGINEERING I

CONSOLIDATED CONTRACTORS CO.
AL JUBAIL HA YCO/AMMONIA PLANT
PROJECT NO.: 2410 A049
PROJECT CODE: AL JUBAIL 10

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6.5 Repair the edge of joint

1. Detect poor finished surface and mark it.
2. Poor finished surtace should be chiseled to a sound
homogenous surtace.
3. Wash the substrate with potable water to remove all dust
deposits.
4. Thoroughly soak the substrate with potable water
approximately one hour prior to application of repair.
5. Apply bonding agent to the concrete substrate by brush.
ensuring the concrete surface is wetted out.
6. Repair material shall be applied in layers, 20mm each
whilst bonding agent is still tacky. If bonding agent dries,
the substrate can be primed.
7. Cure the exposed surface area for 48 hours.
6.6 Repair concrete around any sleeves
1. Detect dedicative area.
2. Break out the area until a sound homogenous substrate
has been reached.
3. Wash the substrate with potable water to remove all dust
deposits.
4. Thoroughly soak the substrate with potable water
approximately one hour prior to application of repair.
5. Apply bonding agent to the concrete substrate by brush.
ensuring the concrete surface is wetted out.
6. Apply the repair material in layers, 20mm each whilst
bonding agent is still tacky. If bonding agent dries, the
substrate can be primed
7.
If the substrate can't be reached or hard to handle
by trowel, flow able material should be used
8. Cure the repaired area for 48 hours.

Page 7 of 8

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LINDE AG - GAS AND ENGINEERING I

CONSOLIDATED CONTRACTORS CO.
AL JUBAIL HAyeO/AMMONIA PLANT
PROJECT NO.: 2410 A049

7.0

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RESOURCES:
7.1 Hand tools
Drill.
Electrical mixer.

Trowel.
Hammer.

Chisel.
7.2 Manpower

Supervisor/foreman.
Mason.
laborer.

8.0 SAFETY

All personnel involved in the above activity shall follow the

construction HSE Plans/Procedure as well as SADARA relevant
HSE manuals.

All safety measures defined in the relevant procedures shall be

implemented.

In case of contact with 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.

Page 8 of8

All materials shall be stored, handled and used in a safe and proper
manner, and as advised by the material safety data sheet.
Contents of Material safety data sheet for a certain product shall be
explained to the workers in a Tool Box Talk prior to using this
product.

All personnel involved shall wear PPE.

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