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Sinohydro Corporation

Lusail Development Construction Package 1

Method Statement for Concrete Repairs

Lusail Development
Construction Package 1

Employer: Qatari Diar Real Estate Investment Company

Method Statement for Concrete Repairs

DOCUMENT REVIEW STATUS


STATUS 1: WORK MAY PROCEED.
STATUS 2: REVISE & RESUBMIT. WORK MAY PROCEED SUBJECT TO INCORPORATION OF
COMMENTS INDICATED.
STATUS 3: REVISE & RESUBMIT. WORK MAY NOT PROCEED.
STATUS 4: REVIEW NOT REQUIRED. WORK MAY PROCEED.

ENGINEERS REVIEW OF SUBMISSION SHALL NOT RELIEVE THE CONTRACTOR OF HIS


RESPONSIBILITIES UNDER THE CONTRACT.

________________________

HALCROW
Date___________________

Amendment Records
LD-CP1-SHC-MS-OW-005 Rev. 1 30-Oct-2010

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Sinohydro Corporation
Lusail Development Construction Package 1

Method Statement for Concrete Repairs

Rev
No.

Date

Amendment Record

Prepared By

Approved By

20th June 2010

General revision to incorporate


all concrete repair procedures.
First Version

Artemio T. del
Mundo, Jr.

Li Binghan

30th October 2010

Revised to incorporate new


repair procedures for major
concrete defects

Artemio T. del
Mundo, Jr.

Li Binghan

Table of Content

LD-CP1-SHC-MS-OW-005 Rev. 1 30-Oct-2010

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Sinohydro Corporation
Lusail Development Construction Package 1

Method Statement for Concrete Repairs

Purpose....................................................................................................3
Reference Document...............................................................................4
Organization Chart and Responsibility................................................4
Error: Reference source not foundConstruction Arrangement.........5
Repair Methodology...............................................................................5
Measure and Plan for Safety and Health.............................................9
Measure And Plan for Environment Protection................................12
Quality Plan..........................................................................................12
Appendix...............................................................................................12

Purpose
This Method Statement defines the methods required to execute concrete repairs at CP1 &
LD-CP1-SHC-MS-OW-005 Rev. 1 30-Oct-2010

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Sinohydro Corporation
Lusail Development Construction Package 1

Method Statement for Concrete Repairs

supersedes the following document:

Doc. No. LD-CP1-SHC-MS-CR-001 Rev. 3 Method Statement for Concrete


Repairs &

Doc. No. LD-CP1-SHC-MS-UT/R-007 Rev. 2 Proposal for Repairing Cracks


on Concrete Surface

Reference Document
Qatar Construction Specifications (QCS 2002) Section 5 Part 16.7.

Organization Chart and Responsibility


A Section Manager, who reports to the Construction Manager, will be incharge of the concrete repair works. He will coordinate with all concerned parties
and ensure site repair works in time and with proper quality.
A Section Engineer, who reports to the Section Manager, will be in-charge of
the concrete repairs quality.
A Quality Control Manager, who reports to the Technical Manager, will be incharge of the concrete repairs quality control.
A Quality Assurance Manager, who reports to the Project Manager and
Sinohydro Head Office shall organize preparation and amendments or changes in
QAP and other QM system documents and supervises their implementation and
manages document control system of the project.
A Safety Officer who reports to the Safety and Health Manager, will be incharge of the concrete repairs site safety & health.
Their contact telephone numbers are enumerated hereunder:
S/N

Name

Position

Mobile

Pan Jiliang

Construction Manager

5636816

Wang Wei

Section Manager

6094887

Zhu Jingping

Site Engineer

5035519

Artemio T. del Mundo, Jr.

Quality Control Manager (QC)

5153175

Zhang Shuo

Deputy Quality Assurance Manager (QA)

6574881

Tommy

Safety and Health Manager

5699208

Kamal

Safety Engineer

6739709

LD-CP1-SHC-MS-OW-005 Rev. 1 30-Oct-2010

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Sinohydro Corporation
Lusail Development Construction Package 1

Method Statement for Concrete Repairs

Error: Reference source not foundConstruction Arrangement


1.1

Materials
Nitomortar FC(B) - Approval Ref. No. GQ626/CP1/54/ad/0371
Conbextra GP - Approval Ref. No. GQ/626/CP1/54/ba/1825
Nitofill EPLV - Approval Ref. No. GQ626/CP1/54/ba/6622
Renderoc SPXtra - Approval awaited
Nitobond AR - Approval awaited
Concure A- Approval awaited
Renderoc BF2 - Approval awaited

1.2

Other Materials
Potable water
Hessian
Plastic Sheets

1.3

Equipments

Wire Brush
Grout Mixer
Steel Trowel/Scraper
Electric Chisel
Disk Cutter
Hand-held Hammer & Chisel
Grinder
Air compressor

Repair Methodology
1.4

Blow Holes
In accordance with Particular Specifications (Rev. 3 dated Apr-09) Section 5 Part 16
Clause 16.7, blowholes up to 15mm deep & 25mm x 25mm in dimension for buried
concrete shall be acceptable & will not be repaired. For exposed surfaces, blowholes
15mm deep & 15mm x 15mm in dimension shall also be acceptable & will not
require remedial action.
Surface Preparation: Concrete surface should be clean, dry & free from laitance.
All blow holes should be opened up to avoid the creation of air pockets. Wire
brushing shall be applied as necessary.
Mixing: The hardener and base components of Nitomortar FC(B) should be
stirred thoroughly in order to disperse any settlement before mixing them together.
The two components should be mixed together in a 1:1 ratio by volume, until a
uniform consistency and grey colour is achieved.
Application: After mixing, material can be taken directly from the can, or
subdivided onto spot boards for individual applicators. Applications shall be done
using trowel, scraper or filling knife to a satisfactory surface finish. Nitomortar FC(B)

LD-CP1-SHC-MS-OW-005 Rev. 1 30-Oct-2010

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Sinohydro Corporation
Lusail Development Construction Package 1

Method Statement for Concrete Repairs

can be overcoated with all epoxy coatings after a minimum curing period of 24
hours. Prior to overcoating, the fully cured surface should be dust-free. Curing shall
be performed by regularly spraying water &/or covering with wet hessian.

1.5

Honeycombs (Vertical & Overhead Surfaces)


In accordance with Particular Specifications (Rev. 3 dated Apr-09) Section 5 Part 16
Clause 16.7 (copy attached), honeycombs up to 15mm deep & 25mm x 25mm in
dimension for buried concrete shall be acceptable & will not be repaired. For
exposed surfaces, honeycombs 15mm deep & 15mm x 15mm in dimension shall also
be acceptable & will not require remedial action.
Surface Preparation: Defective areas shall be chipped down to sound substrate.
Prepared sections up to 10mm in depth shall be repaired using Nitomortar FC(B).
Concrete surfaces should be clean, dry, free from laitance & loosely adhering
particles. Wire brushing shall be used as necessary.
Mixing: The hardener and base components of Nitomortar FC(B) should be
stirred thoroughly in order to disperse any settlement before mixing them together.
The two components should be mixed together in a 1:1 ratio by volume, until a
uniform consistency and grey colour is achieved.
Application: Prepared surfaces shall be reprofiled using the mixed material until
satisfactory surface finish is achieved using steel trowel or scraper. Curing shall be
performed by regularly spraying water &/or covering with wet hessian.

Prepared sections deeper than 10mm shall be repaired using Renderoc SPXtra. All
contaminated, damaged or loose concrete shall be removed up to the pre-cut edge
of the repair. Where reinforcements are visible, chipping shall be made up to at least
20mm behind the reinforcements to ensure adequate bonding. Edges of the section
shall be roughened to provide a good mechanical key at the substrate interface. All
exposed reinforcements shall be wire brushed to completely remove all loose rust.
This shall be followed by water blasting to completely remove laitance, by-products
of corrosion & other contaminants.
Substrate Priming: Prepared surfaces shall be primed using Nitobond AR acrylic
resin-based concrete bonding agent. It must be scrubbed well into the surface using
a nylon brush.
Mixing: Only full bag mixing is permissible. Part mixing & addition of water to
mixed material to prolong workability is not allowed. Renderoc SPXtra shall be
thoroughly mixed & the temperature of the mixed material shall not exceed 30oC.
25kg. bag of Renderoc SPXtra shall be added to 4.25 to 4.5 liters of cool potable
water & mixing shall be done for 3 to 5 minutes until the mix is fully homogenous
using drill & paddle or forced action mixer.
Application: The repair mortar shall be applied when the bonding agent becomes
LD-CP1-SHC-MS-OW-005 Rev. 1 30-Oct-2010

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Sinohydro Corporation
Lusail Development Construction Package 1

Method Statement for Concrete Repairs

tacky, which may take 5 to 15 minutes depending on the ambient temperature. The
repair mortar shall not be applied when the bonding agent is wet.
Mixed Renderoc SPXtra shall be applied by trowel or gloved hand, thoroughly
compacting onto the primed substrate, while the primer is still tacky, & around any
exposed reinforcement. On sections having reinforcement congestion, the mixed
material shall first be filled behind the reinforcement with gloved hand. If sagging
occurs on vertical & overhead surfaces, the applied Renderoc SPXtra shall be
completely removed. The substrate must then be reprimed & Renderoc SPXtra
reapplied in layers of reduced thickness. After initial setting, the intermediate layers
should be scratched-keyed & applied Nitobond AR bonding agent prior to application
of the next layer of the repair material.
Repaired surfaces shall be finished by striking off with a straightedge & closing with
a steel or plastic float. Water can be drawn to the surface if overworking with the
float occurs & an unsightly finish may result. Damp sponges or plastic floats may be
used to achieve desired surface texture, but care shall be taken not to overwork the
surface.
After completion of finishing, the repaired section shall be applied Concure A curing
compound by spray or roller. In adverse weather conditions (e.g. wind conditions or
ambient temperature >30oC), supplementary curing in the form of polythene
sheeting, taped down at the edges, should be used.
If a smooth & non-porous finish is desired, a skim coat of Renderoc BF2 shall be
applied which does not require any curing.
1.6

Protruding Tie Rods


Surface Preparation: Circumference of protruding tie rods shall be chipped using
Electric Chisel up to a diameter of 150mm and depth of 50mm or until the tie rods
can be cut at the base using disk cutter of appropriate size. The prepared substrate
shall be free of oil, grease or any loosely adherent material & shall be sprayed with
water prior to repair materials application.
Mixing: Conbextra GP shall be mixed to a trowellable consistency (3.4 to 3.6
liters of water per 25 kg. bag) preferably using a mechanically powered grout mixer.
Application: Prepared surfaces shall be free of standing water & shall be filled &
reprofiled using the mixed material until satisfactory surface finish is achieved using
steel trowel. Curing shall be performed by regularly spraying water &/or covering
with wet hessian.

1.7

Unsatisfactory/Irregular/Uneven Concrete Surfaces


Surface Preparation: Defective areas shall be chipped down to sound substrate.
Prepared sections up to 10mm in depth shall be repaired using Nitomortar FC(B).
Concrete surfaces should be clean, dry & free from laitance & loosely adhering
particles. Wire brushing shall be used as necessary.

LD-CP1-SHC-MS-OW-005 Rev. 1 30-Oct-2010

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Sinohydro Corporation
Lusail Development Construction Package 1

Method Statement for Concrete Repairs

Mixing: The hardener and base components of Nitomortar FC(B) should be


stirred thoroughly in order to disperse any settlement before mixing them together.
The two components should be mixed together in a 1:1ratio by volume, until a
uniform consistency and grey colour is achieved.
Application: Prepared surfaces shall be reprofiled using the mixed material until
satisfactory surface finish & alignment is achieved using steel trowel or scraper.
Curing shall be performed by regularly spraying water &/or covering with wet
hessian.
Prepared sections deeper than 10mm shall be repaired using Renderoc SPXtra. All
contaminated, damaged or loose concrete shall be removed up to the pre-cut edge
of the repair. Edges of the section shall be roughened to provide a good mechanical
key at the substrate interface. Water blasting shall be applied if necessary, to
completely remove laitance & other contaminants.
Substrate Priming: Prepared surfaces shall be primed using Nitobond AR acrylic
resin-based concrete bonding agent. It must be scrubbed well into the surface using
a nylon brush.
Mixing: Only full bag mixing is permissible. Part mixing & addition of water to
mixed material to prolong workability is not allowed. Renderoc SPXtra shall be
thoroughly mixed & the temperature of the mixed material shall not exceed 30oC.
25kg. bag of Renderoc SPXtra shall be added to 4.25 to 4.5 liters of cool potable
water & mixing shall be done for 3 to 5 minutes until the mix is fully homogenous
using drill & paddle or forced action mixer.
Application: The repair mortar shall be applied when the bonding agent becomes
tacky, which may take 5 to 15 minutes depending on the ambient temperature. The
repair mortar shall not be applied when the bonding agent is wet.
Mixed Renderoc SPXtra shall be applied by trowel, thoroughly compacting onto the
primed substrate, while the primer is still tacky. If sagging occurs on vertical
surfaces, the applied Renderoc SPXtra shall be completely removed. The substrate
must then be reprimed & Renderoc SPXtra reapplied in layers of reduced thickness.
After initial setting, the intermediate layers should be scratched-keyed & applied
Nitobond AR bonding agent prior to application of the next layer of the repair
material.
Repaired surfaces shall be finished by striking off with a straightedge & closing with
a steel or plastic float. Water can be drawn to the surface if overworking with the
float occurs & an unsightly finish may result. Damp sponges or plastic floats may be
used to achieve desired surface texture, but care shall be taken not to overwork the
surface.
After completion of finishing, the repaired section shall be applied Concure A curing
compound by spray or roller. In adverse weather conditions (e.g. wind conditions or
ambient temperature >30oC), supplementary curing in the form of polythene
sheeting, taped down at the edges, should be used.

LD-CP1-SHC-MS-OW-005 Rev. 1 30-Oct-2010

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Sinohydro Corporation
Lusail Development Construction Package 1

Method Statement for Concrete Repairs

If a smooth & non-porous finish is desired, a skim coat of Renderoc BF2 shall be
applied which does not require any curing.
1.8 Cracks wider than 0.20mm
Verification of the width of cracks shall be conducted through the approved
independent laboratory (Gulf Lab.). No repairs shall be made on cracks up to
0.20mm wide. Cracks wider than 0.20mm shall be repaired through crack injection
using Nitofill EPLV.
Concrete surfaces along the line of the cracks shall be cleaned of dust, unsound or
contaminated material, plaster, oil, paint, grease, corrosion deposits or algae. The
surface shall preferably be prepared using high pressure water jetting & thorough
washing. Wire brushing or other mechanical means shall be applied as necessary to
remove dirt. This shall be followed by applying compressed air to the cracks to
ensure complete removal of all dust & loose particles. Surfaces shall be blown dry.
Holes shall be drilled at suitable interval along the crack length for the insertion of
injection packers. Spacing shall be close enough to ensure that resin will penetrate
along the crack to the next point of injection.
The surface of the cracks between packers shall be sealed with a band of Nitomortar
FC, 30mm to 40mm wide & 2mm to 3mm thick. Applied Nitomortar FC shall be
allowed to adequately cure. This shall be followed by the injection of the mixed
injection resin at a pressure of at least 0.40 MPa (4 bars). Injection shall continue
until the resin appears on the next port.

The hardener & base component of the injection resin shall be mixed thoroughly
until the liquid becomes clear.
Following completion of the injection works, the repaired section shall be allowed to
cure for 24 hours & shall be left undisturbed for this period. Packers shall then be
removed & holes/voids to be made good using Nitomortar FC & allowed to cure.
Surface protrusions of Nitomortar FC shall be ground off.

Measure and Plan for Safety and Health


Personnel engaged with this works shall follow safety and health Plan; Safety &
Health Manager shall arrange one safety person to checking and Monitoring safety
and health.
To follow Sinohydro Contractors Safety and Health management plan, please refer to
Document: Safety and Health Plan Rev.4 (No. LD-CP1-SHC-HSP-0015)

LD-CP1-SHC-MS-OW-005 Rev. 1 30-Oct-2010

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Sinohydro Corporation
Lusail Development Construction Package 1

Method Statement for Concrete Repairs

R ISK A SSESSMENT R EGISTER


Task
and
Activity

Persons at
Risk

Hazard

OF

W ORK A CTIVITIES

Risk

Control Measures

Vehicles falling
from the edge of
the excavation

Contractors,
Subcontractors
All personnel on
this
site
Operators

Injury,
Fractures, Cuts,
Bruises

Rigid safety barriers shall be erected around all


excavations to prevent vehicles falling into them. Vehicles
shall be kept away from excavations wherever possible.
Where vehicles have to tip materials into excavations,
stop blocks to prevent them from over-running shall be
used and a banksman shall be present before
discharging the load.

Project/Construction
Manager/s
& Supervisors

Vehicles reversing

Contractors,
Subcontractors
All personnel on
this
site
Operators

Injury,
Fractures, Cuts,
Bruises

Where vehicles have to reverse they shall be controlled


by properly trained banksman

Project/ Construction
Manager/s
& Supervisors

Night works
lighting

Contractors,
Subcontractors
All personnel on
this
site
Operators

Accidents

During the hours of darkness all the excavations and


other working areas shall be adequately illuminated and
warning lights about the excavation shall be placed to
ensure safety of pedestrians and the vehicular traffic.
Night work hours shall be structured to comply with all
rules and regulations.

Project/ Construction
Manager/s
& Supervisors

Improper access

Contractors,
Subcontractors
All personnel on
this
site
Operators

Injury,
Fractures, Cuts,
Bruises

There should be safe means of access or escape to all


the working areas, above or below ground level. This can
be a ladder, ramp, stairs and etc. It shall also be kept
well lit, clear of obstructions and well maintained.

Project/ Construction
Manager/s
& Supervisors

Steel reinforcement

Contractors,
Subcontractors
All personnel on
this
site
Operators

Fractures, Cuts,
Bruises

Pump and
Operation

Contractors,
Subcontractors

Fractures, Cuts,
Bruises

Concrete
Repairs

and

Boom

LD-CP1-SHC-MS-OW-005 Rev. 1 30-Oct-2010

To minimize cuts from reinforcement bar ends the


following shall be supllied.PPE for the required task.
Suitable strong and flexible leather gloves. When walking
on deck care shall be taken to eliminate slipping on wet
surfaces. Sharp edges on ends of steel reinforcement
shall be tuned down.
Concrete pump and boom operators should be
competent to safely operate relevant equipment.

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Risk Owner

Project/ Construction
Manager/s
& Supervisors
Project/ Construction
Manager/s

Sinohydro Corporation
Lusail Development Construction Package 1

Concrete Pouring

Method Statement for Concrete Repairs

All personnel on
this
site
Operators
Contractors,
Subcontractors
All personnel on
this
site
Operators

LD-CP1-SHC-MS-OW-005 Rev. 1 30-Oct-2010

Fractures, Cuts,
Bruises

Competence is achieved through training and supervision


and should be assessed by testing both theoretical
knowledge and physical operation of the machinery

& Supervisors

The rubber delivery hose should always be checked for


damage prior to being fitted. Care should be taken to
avoid damage to the hose during use. Use a hose that
has a pressure rating. Always wear PPE.

Project/ Construction
Manager/s
& Supervisors

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Sinohydro Corporation
Lusail Development Construction Package 1

Method Statement for Concrete Repairs

Measure And Plan for Environment Protection


All employees engaged in this works shall follow the Environment Management Plan
(Doc. No. LD-CP1-SHC-EHC-OC-0135). Environment Manager shall arrange one person
to check and monitor site environment.

Quality Plan
1.9 Contractual Requirements
Sinohydro Quality Assurance Plan (Doc. No. LD-CP1-SHC-QAP-001)

1.10 Inspection & Testing


Testing and inspections shall be performed by Sinohydro in accordance with Doc. No. LDCP1-SHC-QAP-015 Rev. 1 Inspection & Testing Program.

Appendix
1. Appendix 1: RFI
2. Appendix 2: Product Data Sheets for Nitomortar FC(B), Conbextra GP, Nitofill EPLV,
Renderoc SPXtra, Nitobond AR, Concure A & Renderoc BF2.

LD-CP1-SHC-MS-OW-005 Rev. 1 30-Oct-2010

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Sinohydro Corporation
Lusail Development Construction Package 1

Method Statement for Concrete Repairs

Appendix 1.

Request for Inspection


LUSAIL DEVELOPMENT CONSTRUCTION PACKAGE 1

RFI Number
LD-CP1-SHC-ITPSINOHYDRO CORPORATION
To

Halcrow

Cc
Type of Work
Location
Method with reference to
ITP/drawings
Inspection time

Inspection Date

Comments

APPROVED

Yes

No

Requested by

Received by

Site Engineer/Subcontractor

QC Engineer

QC Manager

Admin Representative

Name:

Name:

Name:

Name:

Signature:

Signature:

Signature:

Signature:

Date:

Date:

Date:

Date:

(SINOHYDRO)

(SINOHYDRO)

(HALCROW)

Company :(

LD-CP1-SHC-MS-OW-005 Rev. 1 30-Oct-2010

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Sinohydro Corporation
Lusail Development Construction Package 1

Method Statement for Concrete Repairs

Appendix 2

LD-CP1-SHC-MS-OW-005 Rev. 1 30-Oct-2010

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