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B 25/01/2018 Issued for Review

Reviewed & Approved


Reviewed by Reviewed by Reviewed &
Rev. Date Status Description by
Construction HSE Checked by QC
DOOSAN PMT
CONTRACTOR’s & COMPANY’s APPROVAL STATUS
OWNER:

FADHILI CHP PROJECT – CIVIL & BUILDING WORKS


SUBCONTRACT No. DOOSAN-FADHILI-C-004

MAIN CONTRACTOR:

SUBCONTRACTOR:

Document Title: NAME SIGNATURE DATE

Prepared by Z.Alam 25 January 2018


METHOD STATEMENT
FOR A.Kojok (SM)

CRACK REPAIR AT WWTP Checked by


TOM

CONCRETE WALL SAFETY

QA/QC

Approved
M. Hussain (PM)
by

Document No.:
REVISION A
FCHPP/KCS/MS/0031
NUMBER

Document Status:

□ FOR INFORMATION ■ FOR APPROVAL ■ FOR REVIEW

□ FOR CONSTRUCTION □ AS BUILT

CONTENT

FCHPP/KCS/MS/0002 B 27 January 1 of 10
2018
FADHILI CHP PROJECT
Civil & Building Works

METHOD STATEMENT FOR CRACK REPAIR AT WWTP INSIDE CONCRETE WALL


FCHPP/KCS/MS/0031

1. GENERAL INFORMATION

Introduction
Purpose
Scope of Work
Causes of Crack
Location

2. QA / QC

Reference Standard
Documentation
Inspection, Test and Measurement

3. EXECUTION

Materials
Tools & Equipments
Required Manpower
Procedure of Work
Responsibilities

4. SAFETY

Safety / Highlight of Potential Risk


Hazard Analysis

5. APPENDICES

Appendix 1: Job Safety Analysis


Appendix 2: Risk Assessment
Appendix 3: Material Technical Data Sheet
Appendix 4: IFC Drawing

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FADHILI CHP PROJECT
Civil & Building Works

METHOD STATEMENT FOR CRACK REPAIR AT WWTP INSIDE CONCRETE WALL


FCHPP/KCS/MS/0031

1. GENERAL INFORMATION

1.1 Introduction

DOOSAN HEAVY INDUSTRIES & CONSTRUCTION, the Contractor of FADHILI CHP Project has awarded the Civil &
Building Works Contract to Kettaneh Construction S. A. Ltd (KCS).

It is important to act quickly when you noticed deteriorating concrete before the problem becomes serious. With
the already established Concrete Specifications, KCS shall be focusing in implementing the provisions and
recommendations written on it to maintain the efficiency, safety and quality of concrete repairs.

1.2 Purpose

The purpose of this method statement is to describe in detail the method of repairing of concrete crack and
deficiencies, and to ensure that all activities shall be conducted in accordance with FADHILI project
specifications, HSE requirements and Contract documents.
This Method statement did not confer in point concerning the designs, raw materials, and mix design that are
main considerations for concrete structures integrity and was focused only on crack’s physical aspect (i. e. number
of cracks and their width) that KETTANEH has an influence and credibility to define in accordance with the
established International Codes (i. e. ACI) and an approved Method Statement for Structural Concrete Repair
(Document No.: T16182-DD03-P0ZEN-720004, Rev. 0).

This method statement shall be communicated and be understood by all personnel associated with the task
before commencing the activity.

1.3 Scope of Work

This method statement shall cover the preparations and required operations for Structural Concrete crack
Repairs works at waste water treatment plant inside wall. Necessary scaffolding, permits and clearances as
per Contractor/Company HSE regulations shall be provided.

1.4 Causes of Cracks:

Before discussing vital contents of this report, it is worthwhile to mention the basic cause of crack. It is restraint. If
all parts of the concrete in a concrete structure are free to move as concrete expands or contracts, particularly the
latter, there will be no cracking due to volume change. Obviously, however, all parts of concrete structures are not
free, and inherently, cannot be free to respond to the same degree to volume changes. Consequently, differential
strains develop, and tensile stresses are induced. When these differential responses exceed the capability of the

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FADHILI CHP PROJECT
Civil & Building Works

METHOD STATEMENT FOR CRACK REPAIR AT WWTP INSIDE CONCRETE WALL


FCHPP/KCS/MS/0031

concrete to withstand them at that time, crack occurs. This points to the importance of protecting new concrete for
as long as practicable from the loss of moisture or a drop-in temperature.

1.5 Lacation

Fadhili CHPProject, Fadhili Gas Plant, Kingdom of Saudi Arabia

2. QA/QC

2.1 Standard Reference

o FADHILI Project Specifications, Standards & Procedures


o Contract Specification (Civil & Building Works)
o GEMSS-C-20, SEC Concrete Specification
o ACI 224R.1 Concrete Crack investigation and repair procedure
o ACI-301 Specifications for Structural Concrete
o Company Construction Safety Manual
o Approved Project Quality Plan
o Approved Project Safety Plan

2.2 Documentation
The following documents are needed in order to comply with this Method
Statement:
Input document:
o IFC drawings
o Materials Information for Concrete Repair
o Work Permit, as applicable

Output document:
o RFI
o Inspection records

2.3 Inspection

o Request of Inspection (RFI) shall be submitted to Contractor QA/QC in advance as per ITP for
approval;
o The QA/QC Inspector has to make sure that all required Test & Measurement has been carried out as
per required procedure & standard.

3. EXECUTION

a. Materials

Master Brace ADH 2200: Two-component epoxy based mortar filled with selected fine aggregates

b. Tools & Equipments

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FADHILI CHP PROJECT
Civil & Building Works

METHOD STATEMENT FOR CRACK REPAIR AT WWTP INSIDE CONCRETE WALL


FCHPP/KCS/MS/0031

o Masonry Tools;
o Gauge;
o Air Compressor;
o Water Jet;
o Industrial Vacuum Cleaner;
o Fixing injection materials & accessories;
o PPE & Other Safety required Materials;
o Special tools as per manufacturer’s requirement (if required)

c. Required Manpower
Discipline

o Safety Officer;
o QA/QC Engineer or QC Inspector;
o Site Engineer;
o Supervisor / Foreman;
o Masonry group / Applicators;
o Skilled Labors;
o Concrete repair specialist (if required)

3.1 General Repair Procedure

a. Submittals

Repair materials epoxy resin to be used shall comply with PROJECT specifications indicating the approved
suppliers/manufacturers.

b. Materials Handling, Storage & Protection

o Repair materials shall be delivered to the jobsite in original containers and packages bearing
the manufacturer’s labels;
o These labels shall indicate the type, brand, contents by volume, color and other important
related information;
o Materials shall be stored in an environment conforming with manufacturer’s requirements;
o Material shall not be removed from storage until immediately prior to mixing or use;
o Material from damaged containers shall be discarded;
o Mixing of part bags or other containers of components shall be allowed only with prior permission of
Contractor/OE and manufacturer.

c. Pre-repair Condition Survey of Structure

o Determination of location and extent of concrete cracking shall be as per applicable and most
practical method mentioned in ACI 224R.1, Section 2.2;
o This method shall be direct observation by noting on the IFC drawing the exact locations of the
identified cracks;

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FADHILI CHP PROJECT
Civil & Building Works

METHOD STATEMENT FOR CRACK REPAIR AT WWTP INSIDE CONCRETE WALL


FCHPP/KCS/MS/0031

o Each crack’s width shall be measured accordingly using filler gauge of specified width marked on the
gauge’s leaves;
o Tapping technique using a hammer shall be done to identify laminar cracking near the surface. A
hollow sound indicates one or more cracks below and parallel to the surface;
o All cracks shall be opened by V or U groove to determine the extent of the crack.

d. Cracks Repair Procedure Proposal

Based on the result of the cracks survey and relating the values obtained, KCS perceived and proposed that the
appropriate and practical way to restore them is to Repair by MasterBrace ADH 2200 is a non slumping
epoxy bedding compound and adhesive

e. Execution of Repairs of Cracks

I. Surface Preparation of Existing Concrete


o All unsound or loose concrete shall be removed by light weight chipping hammer, or other
appropriate method;
o Complete removal of the loosely adhering debris at the concrete substrate shall be
ensured;
o Clean the surface and any dust, unsound or contaminated material, plaster, oil deposits
shall be completely removed.

II. Repair Techniques


 Routing & Sealing
o This type of repair is applied to fine, large, isolated, dormant and non-dormant cracks
which do not have any significant structural integrity requirements;
o The sealing shall ensure resistance against ingress of moisture, chemicals and carbon
dioxide;
o V or U groove is made using mechanical grinder by chasing the crack along its length to
open the gap to around 10 to 12 mm in width;
o The groove shall be cleaned off prior to application of bonding agent and sealer material.

 Patching & Resurfacing


o Usually applied to sections of concrete, like wall & columns with uneven & deeper surface;
o The defect is corrected by patching repair material and textured to the required finish.

 Grinding & Resurfacing


o When bulging occurs due to minimum form failure in wall or columns, the bulged section is
mechanically grinded or chipped off;
o The defect is corrected by patching repair material and textured to the required finish.

III. Repair Material Application

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Civil & Building Works

METHOD STATEMENT FOR CRACK REPAIR AT WWTP INSIDE CONCRETE WALL


FCHPP/KCS/MS/0031

o Knife or trowel MasterBrace ADH 2200 to the required level using the minimum of solvent
on the trowel to aid workability.
o The surface may be finished smooth by use of a paint brush dipped in MasterTop Solvent
o Where a very deep recess is to be filled, it may be necessary to build up in layers.
o Repairs may be camouflaged if required by covering surface with cement powderbefore full
cure is affected.

3.2 Responsibilities

Site Manager
 He shall establish and ensure effective implementation of this Construction Method Statement.

Site Engineer
 Site Engineer shall organize and manage all activities related to concrete repair & pouring including preparation of
Safe Working Plan, Work Permit, planning & scheduling equipment arrangements. He shall be in the helm in
overall supervision & ensure that site safety plan is in place and implemented; after confirming that all
prerequisites are followed according to the IFC drawings, he shall coordinate with QC Inspector to arrange
necessary inspection as applicable.

General Foreman – Concrete


 General Foreman (concrete) shall supervise the workforce so as to achieve the proper and safe execution of
work as per Project Quality & Safety Plans.

 Is responsible for site daily implementation and execution of this procedure. He shall organize and manage all
activities for the implementation of this procedure. Protective measures and day-to-day activities.
QA/QC Manager
 He shall review this CMS (Construction Method Statement) for quality compliance and be responsible for its
implementation;

 He shall issue approved CMS to Site Manager / Engineer for implementation, and shall be responsible for
monitoring of effective implementation of this procedure,
 He shall ensure necessary inspections/monitoring is being done.

QA/QC Engineer
QA/QC Engineer shall make sure that:

 All works are carried out as per the latest revision of the IFC drawings;
 All materials to be used are approved;
 Area to be repaired is clean and free from dirt and any other foreign objects;
 He prepared and submitted RFI to Contractor/Company, 24 hours during working days & 48 hours during weekend
in advance before the inspection schedule;

Safety officer
 Safety Inspector in conjunction with the supervisor shall physically check and conform that all approved safety
procedures in this Method Statement & FADHILI HSE requirements have been, and will continue to be adhered
to;

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 The Safety Inspector shall confirm that all access to the working area is clear of hazards and debris that may
hinder access and egress of the work platform. He shall confirm this to the activity supervisor before work
begins. The Safety Inspector shall ensure that vehicles, machinery and equipment involved in the activity are
controlled by a banks-man;
 The Safety Inspector shall observe the operation of critical junctures i.e. start of concrete repair work.

4.0 SAFETY

4.1 Safety, Access and Temporary Support

4.1.1 Safety

o KCS shall follow Contractor HSE procedures;


o Safety inspector shall organize and monitor all safety requirement of the project.
o Safety inspector shall be solely responsible for safety activities only. He shall not be
assigned any other activities like production, manpower management or quality control
work;
o All the safety gears, equipment and other safety requirements shall be procured and made
available by KCS at site during execution of work;
o General safety orientation and awareness program shall be conducted for manpower prior
to mobilization for the project site;
o Morning toolbox meeting, with due emphasis on the hazard of the current day activities;
o Safety inspector and Contractor representative shall conduct a joint safety tour, on a daily
basis. All non-conformances shall be rectified by KCS immediately;
o KCS shall train and orient all the workers regarding confined space entry procedures
prior to proceeding for any confined space work;
o The confined space entry and work procedure shall be in accordance with Contractor
procedures;
o The workers shall be familiar with emergency sirens and designated evacuation area;
o In case of emergency, the workers shall assemble in the designated area, or they shall
follow the instructions being paged;
o KCS shall provide garbage container at the designated area near the job site;
o Daily housekeeping shall be carried out to collect and dispose the garbage/debris
generated each day into the container;
o KCS shall ensure that the garbage container is not overflowing, and is being disposed on a
regular basis;
o The tools and equipment intended for the work shall be in sound condition.

4.1.2 Access

o Protection of surrounding plant facilities, and cordoning of the working space with all safety
measures, shall be made to the satisfaction of Contractor;

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Civil & Building Works

METHOD STATEMENT FOR CRACK REPAIR AT WWTP INSIDE CONCRETE WALL


FCHPP/KCS/MS/0031

o KCS shall provide means of access to all repair areas for repairs and inspections;
o Scaffolding, platforms and cradles shall be designed, erected, operated, and maintained by
KCS, to ensure that safe working conditions are provided for site personnel;
o The erection, alteration and dismantling of scaffold, platforms and cradles shall only be
undertaken by skilled personnel.

4.1.3 Temporary Support

o Prior to starting any chipping work, temporary support shall be provided to the component
under repair, to ensure structural stability;
o KCS shall be solely responsible for the design and installation of temporary supports. The
design shall ensure the integrity of the structure under support throughout the repairs, and
shall be reviewed and approved by Contractor/Company before installation.

4.2 Safety / Highlight of Potential Risks

o Proper PPE’s shall be observed;


o Hand tools shall be in good conditions at all times;
o Air compressor, Water jet and Vacuum Cleaner shall be operated only by trained and
approved operators;
o Materials and equipment shall be stored in a designated storage space on the site.
Storage Room shall be keep neat, clean and accessible at all time;
o Paints, solvent soaked rags, waste or other materials which might constitute a fire
hazard shall be put in metal containers and shall be removed from the premises at the
close of each day’s work;
o All barricades, signs, lights, and other protective devices shall be installed and maintained.
Information and warning signs should be cleared and visible to the vehicles and
pedestrians;
o Signs, signals and barricades shall be removed when the hazard no longer exists.

4.3 Highlight of Potential Risk

JSA/ HAZARD ANALYSIS


DESCRIPTION OF WORK : CONCRETE REPAIR
MANAGING CONTRACTOR : KETTANEH CONSTRUCTION SAUDI ARABIA, Ltd.
LOCATION : FADHILI CHP PROJECT
Please refer to attached JSA sheet
FOLLOWING CONSIDERATIONS

ITEM DESCRIPTION ACTION ITEM DESCRIPTION ACTION


Permit to Work Y Training required * Y
Adjacent Operation Y Temporary Access/Platforms Y
Hazardous Material Y Personnel Protective Equipment Y

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FADHILI CHP PROJECT
Civil & Building Works

METHOD STATEMENT FOR CRACK REPAIR AT WWTP INSIDE CONCRETE WALL


FCHPP/KCS/MS/0031

Waste Disposal Y Safe Access Y


Material Storage Y Emergency Contingency Plan Y
Communications Y Weather Limitations Y
Underground Utilities N/A Process Areas N
Overhead Power Lines N/A Lighting (No night work) Y
Noise Y Electrical Equipment Y
Radiation N
Where: Y = Yes
N = No
N/A = Not applicable
Evaluation Table for Dangerousness

Section Dangerous Factor Measure


Human factor

*Accidents without wearing safe * Workers and supervisor should wear


equipment’s safe equipment’s.
Work Method *inversion of an equipment by *Execute inspection before work,
non-following safe procedure. follow safe procedure during work.
*inversion by proceeding *arrange a supervisor to prevent
excessive works of unskilled workers from excessive works.
worker.
Machine *Falling and inversion of an *Check the connection part of
equipment accessories, disconnecting the equipment’s and machine before
connection part when carrying work.
equipment’s
*Collapse of equipment’s by an *Install an incline securely to prevent
incline fallen from a truck. disconnecting.

APPENDICES

o Appendix 1: JOB SAFETY ANALYSIS


o Appendix 2: RISK ASSESSMENT
o Appendix 3: MATERIAL TECHNICAL DATA SHEET-Master Brace ADH 2200
o Appendix 4: IFC Drawing

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