method statement for repair concrete - vinaincon

Total Sheets: 32 sheet

(Including this coversheet)

Subcontractors name : SIC & E

Employer : Nghi Son Refinery and Petrochemical LLC.

Contractor : JGCS Consortium

Zone : Zone - 3

Project name : NSRP Complex Project

Subcontract No. : CNT-6495-BLD3-001

Document Title : METHOD STATEMENT FOR REPAIR CONCRETE

Contractors Doc. No. : VV 3140-002-A-112 Revision No. : 0

Issue Purpose to Contractor (FA, FC) : FA

Review Result Sticker (Filled By JGCS)

RESULT CODE : A, B, R, F ( )

NEXT STATUS: FA, FC ( )

Re-submission Date: ( )

Responsible Dept./ Person ( )

Construction HSSE QC

Checked By (Name, sign):

Result code

Date

( ) (

)

( )

( ) (

)

( )

( ) (

)

( )

Approved By (Name, sign):

A: Approved without Comment; B: Approved with Comments

R: Not Approved ; F: Not Subject to Review

Issue Purpose Sticker

Issue Purpose to Employer : FA, FR, FI, FC ( FR )

Document Class: Z, X, Others ( X )

NGHI SON REFINERY AND PETROCHEMICAL PROJECT SI C& E

Title: Method Statement for Repair Concrete Contractor Doc. No.

VV3140-002-A-112 Rev:0

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METHOD STATEMENT FOR

REPAIR CONCRETE

(Document Class: X)

Issue Purpose For Approval

Rev Date Page Description Prepd Chkd Appd

0 10/Oct/2014 All For Approval N.D.T P.H.A K.H.I

Operation Centre JOB Code : Operation Center Doc. No.

Responsible Company

SIC&E

Prepared by

Nguyen Duc TOAN

Checked by

Phan Hoang ANH

Approved by

Kim Huyn II



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Contents

1. PURPOS E ............................................................................................................................................................................ 3

2. SCOPE OF WORKS ......................................................................................................................................................... 3

3. REFERENCE DOCUMENTS. ...................................................................................................................................... 3

4. MACHINERY AND EQUIPMENT. ............................................................................................................................ 3

5. RESPONS IBILITIES ....................................................................................................................................................... 4

6. PROCEDURE AND S EQUENCE ................................................................................................................................ 4

7. ENVIRONMENTAL, HEALTH AND SAFETY (EHS ) ......................................................................................... 7

8. INFORMATION ABOUT PRODUCT........................................................................................................................ 8

9. RIS K ASS ESSMENT FOR SAFETY AND ENVIRONMENTAL ISSUES .................................................. 26

10. JOB SAFETY ANNALYS IS ....................................................................................................................................... 30



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1. PURPOSE

The objectives of this method statement is to describe a work explanation of the method to

be carried out during an execution stage of Concrete Repair Works, to ensure that during the

entire execution stage the work is done in line with good engineering practices and is

compliance with engineering standard practices national & local codes. Also it shows the site

management control and safety procedure.

2. SCOPE OF WORKS

This method statement outline the general requirements of concrete repair works for

minor, Specification for concrete repair works of which the method of monitoring will be

included, all incidentals necessary to complete the entire works.

This is also describes details of EHS Requirement, Equipments, Materials

3. REFERENCE DOCUMENTS.

Issued For Construction Drawings

Approved Contract Quantity Plan.

Project HSSE Management Plan.

4. MACHINERY AND EQUIPMENT.

Prior to using any machineries/ equipment at site it will be inspected and certified by

qualified person.

Periodic Preventive Maintenance will be made on all equipment and machineries.

Estimated machinery and equipment.

1. Chipping hammer, Concrete cutting machine, grinder

2. Bucket

3. Air compressor or broom

4. Trowel

5. Jack hammer

6. Scrabbler

7. Hand Tools

8. Chisel



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5. RESPONSIBILITIES

It is overall responsibility of Project Manager to organize resources prior to perform

construction activities as per project specification in compliance with quality,

schedule & safety requirements.

It is the responsibility of Construction Manager/Site Manager that construction

activities are executed according to the relevant project specification in compliance

with quality, schedule & safety requirements.

EHS Manager will ensure coordination with Site Engineer that all

measures/construction taken shall be maintained till completion of job

The QC Inspector will ensure that the works is executed according to the project

requirements and dossier are fulfilled.

6. PROCEDURE AND SEQUENCE

6.1 Procedure for inspection:

Nos Item CODE FOR INSPECTION

SIC&E JGCS IPMT

1 Making areas to repair I W IW

2 Prepairation of surface and Material

I W IW

3 Repair I

4 Inspection for finish

surface I W IW

6.2 General:

The objective of this method statement is to described how to repair concrete surface, that

is damage to concrete that has cracked, concrete that is honeycombed, fractured, or otherwise

defective shall be repaired in accordance with these requirements. As for the repairing

materials, Sika Monotop 610, Sika Monotop R, Sikadur 732, Pre U-lox will be applied. These

materials effective for repairing defects on concrete surface.



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6.3 Repair method for concrete surface:

The materials are selected for each kind of defect.

For air bubbles and honeycomb: Sika Monotop R, 610 and Pre U-LOX will be applied.

This material is ready to use and requiring only additional water and has enough compressive

strength and bonding strength.

For Crack and cold construction joint up to 30mm in depth: Sika dur 731 will be applied.

For short and small crack on top surface : use cement laitance

These materials are ready to use requiring only additional water and have high

impermeability to water and chlorides and enough compressive strength.

These materials have high compressive and bonding strength.

Materials

Bonding

Strength

Compressive strength (1

days)

Compressive

strength(28 days)

Air Bubble;

Honeycomb

Sika Monotop R 1.5N/mm2 15N/ mm2

1-Sika Monotop 610

1.5N/mm2 50N/mm2

Pre U-LOX 37N/mm2 67N/ mm2

Crack and cold

joint Sikadur 731

10N/mm2

(at 14days)

Mix proportion of repairing material is following as below.

Mix Proportion

Material name Sika/ Pre-U LOX Materials (kg)

Water (ltr)

Air Bubble Rough CJ

Honeycomb

Sika Monotop R 1199 163

Sika Monotop 610 25kg 5.25

Pre U-LOX 25kg 4.5

Crack and cold joint Sikadur 731 Mix component A and B

Cement laitance Cement: 1kg 2

6.2.1 Air Bubble, Honeycomb :

a,) Material

Sika Monotop R



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-This material is one component, polymer modified, cementations mortar containing silica

fume.

Sika Monotop 610 is one component, cementations, polymer modified mortar containing

silica fume and corrosion inhibitors.

And Pre U-LOX: cementitous non-shrink grout.

b.) Equipment and tools

-Drilling machine (500rpm) with two armed drilling bit, bucket rug, brush and trowel.

- Trowel.

c.) Preparation.

-Use broom and rug to remove surface dust, water and loosely adhering particles at concrete

surface.

-Above areas shall be cleaned using air compressor.

d.) Application

-Chipping loose concrete.

-All damaged deteriorated, loosened or unbounded portions of existing concrete shall first be

removed with approved method and equipment, after which the surface of existing concrete

shall be prepared to remove any micro fractured surfaces resulting from the initial removal

process.

-Wet the substrate.

-Wipe away excess water.

- Mixing of Sika Monotop repair mortar with water (content follows manufacture)

- Or mixing Pre-u LOT with water (content follows manufacture)

-Press firmly the repair mortar into the repair using a trowel.

-Sika monotop R can be applied by trowel

-The surface shall be finished with wooden or PVC trowel and close the surface using a steel

float.

-Do not spray additional water over the surface.

6.2.2 Crack and Cold construction joint:

a.) Material

-For surfaces with crack and Col CJ up to 30mm in depth Sikadur 731 will be applied.

Sikadur 731 is thixotropic 2-component adhesive and repair motar.

b.) Equipment and tools

-Bucket, clean rug, brush, trowel,



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- Concrete cutting Machine

c.) Preparation

-Mark out all of the crack, cold CJ areas of concrete to be removed.

- Cut thickness up to 3cm

-The concrete surfaces to be repaired must be free from dust, loose of friable materials,

surface contaminants and any other materials which could reduce the bond of the repair

materials.

-Prepair all cracks before mixing the material

d.) Application

Use Concrete cutting machine to V-cut crack surface.

Use broom to make clean

Mix Sikadur 731 component A and B and fill V-cut follow instruction of manufacture.

6.2.3 Cement laitance

Mix cement and water follow mix and put it in crack.

7. ENVIRONMENTAL, HEALTH AND SAFETY (EHS)

a) Safety Manager:

- Organizing and managing to follow the safety plan which made by contractor.

- To oversight the safety matters with respect to control.

- To ensure observing of safety rules.

- To plan of work organization, observe and approve the method with respect to safety during

prior to construction.

b) Responsibilities and instructions:

- The safety member is in charge of safety supervising and monitoring operation activities at

site together with Safety Manager.

- Taking prevention measures and ensuring safety and stability of all items at site, which are

under construction.

- To observing the procedure and requirement at work location



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Ensure all supervisors and workers are informed of all safety requirements and

responsibilities and comply with requirement.

- Safety training should be conducted to all personal assigned at site prior to commence any

work.

- Carry-out daily tool box and safety talks.

- Personal Protective Equipment (PPE) shall be worn all times.

- Good housekeeping shall be observed in work areas.

- Construction wastes shall be segregated and disposed to an approved dump yard area.

- Perimeter safety barricade is required to avoid accidents and should be at least 1 m away

from the execution line.

- Proper inspection of all requirements prior to use to avoid leakage and equipment failure.

- Permit to work shall be obtained appropriately for the type of work and location.

c) Safety (PPE)

- Safety helmets (for all personnel present at site)

- Safety Shoes (for all personnel present at site)

- Gloves

- Safety goggles

- Dust Mask

- Reflective Vest

- Fire extinguisher

- Body protective gear

d) First Aid Facilities

- First aid facility is always made available during working hours by a qualified first aiders.

8. INFORMATION ABOUT PRODUCT



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Check the crack

Repair by V-cut and fill with Sikadur 731



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9. RISK ASSESSMENT FOR SAFETY AND ENVIRONMENTAL ISSUES



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Item Description

of Job List of Hazard

Base Risk (Without Control) Pre-cautions / Preventive measures

Residual Risk (with Control)

L S Risk L S Risk

1

Equipment/ Tools and Material

Preparation

1.1 Injury by using hand

tools and both manual and power drive

3 5 S

1.1a Be operated only by workers who have been authorized and given appropriate training. 1.1b Daily checklist of equipment must be

provided prior to start any work. 1.1c Safety operating procedure should be

established and used for all tools and equipment. 1.1d Every power driven tools should be provided with adequate means, immediately

accessible and readily identifiable by operator, of stopping it quickly and preventing it from being started again inadvertently.

2 2 T



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1.2 Electric shock due to without ground external box and circuit breakers

4 5 U

1.2a Provide adequate ground and circuit breakers

1.2b Must use 3 core codes electric wire and separate distribution panel (must pass arrangement of ELCB) and avoid any water

affect. 1.2c All kind of electric cable must be hang over ground.

1.2d Must use industrial socket and plug.

2 2 T

2

During

Carrying out Repair

Works

2.1 Use interior quality/

electric tools with faulty wirings/ insulation

4 5 U

2.1a Use them only for the purpose for which

they are designed. 2.1b Keep them in a safe working condition. Defective tools must not be used.

2.1c Keep them clean, frequently checked and well maintained. Defective parts must be

replaced. Cutting edges must be kept sharp.

3 3 M



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2.2 Improper use of tools

(i.e use of screw driver as crow bar/ length of a pipe as an extra lever for a

spanner.

3 3 M

2.2a The correct use of portable tools is primarily

a matter for a individual user. 2.2b Be protected against damage from dirt, oil,

water etc. 2.2c Not be used when there is any detectable flammable gas in the area.

2.2d Wear appropriate PPE (e,g. safety goggles when using abrasive wheels and power sanders. Full face protector is used.

2 2 T

2.3 Injury by hand tools. 3 4 S

2.3a Proper working platform available for carrying out repair works. 2.3b Proper use of tools.

2 3 M

3

Mixing and

application of concrete

Mortar

3.1 Accident and skin irritation due to not

wearing safety helmet, gloves and safety shoes.

3

3 M

3.1 Wear always PPE like Safety helmets, gloves and safety shoes.

2 2 T

3.2 Falling due to without safety measures on filling

and application of concrete mortars

2 4 S

3.2 Placing based on plan and order. Check for all the process by supervisor.

1 3 T

3.3 Mixed concrete mortar splashes into the eyes and

skin

3 3 M

3.3 Always wear safety PPE at all times.

2 2 T



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10. JOB SAFETY ANNALYSIS

List of All Job Steps List of All Known Hazards How to Eliminate Hazards

1. Equipment/ Tools and Material

Preparation

1.1 Injury by using hand tools and both manual

and power driven

1.2 Electric shock due to without ground external box and circuit breakers

1.1a Be operated only by workers who have been

authorized and given appropriate training. 1.1b Daily checklist of equipment must be provided prior to start any work.

1.1c Safety operating procedure should be established and used for all tools and equipment.

1.1d Every power driven tools should be provided with adequate means, immediately accessible and readily identifiable by operator, of stopping it

quickly and preventing it from being started again inadvertently.

1.2a Provide adequate ground and circuit breakers

1.2b Must use 3 core codes electric wire and separate distribution panel (must pass arrangement of ELCB) and avoid any water

affect. 1.2c All kind of electric cable must be hang over

ground. 1.2d Must use industrial socket and plug.



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2. During Carrying out Repair

Works

2.1 Use interior quality/ electric tools with

faulty wirings/ insulation

2.2 Improper use of tools (i.e use of screw

driver as a crow bar/ length of a pipe as an extra lever for spanner.

2.3 Injury by hand tools.

2.1a Use them only for the purpose for which

they are designed. 2.1b Keep them in a safe working condition.

Defective tools must not be used. 2.1c Keep them clean, frequently checked and well maintained. Defective parts must be

replaced. Cutting edges must be sharp.

2.2a The correct use of portable tools is primarily

a matter for a individual user. 2.2b Be protected against damage from dirt, oil,

water etc. 2.2c Not be used when there is any detectable flammable gas in the area.

2.2d Wear appropriate PPE (e.g safety goggles when using abrasive wheels and power sanders.

Full face protector is used. 2.3a Proper working platform available for

carrying out repair works. 2.3b Proper use of tools.

3. Mixing and application of concrete

Mortar

3.1 Accident and skin irritation due to not

wearing helmet, gloves, and safety shoes. 3.2 Falling due to without safety measures on

filling and application of concrete mortars

3.1 Wear always PPE like Safety helmets, gloves

and safety shoes. 3.2 Placing based on plan and order. Check for all

the process by supervisor.

method statement for repair concrete - vinaincon

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