Cms 0002 Concrete Repair Rev. A

A 05/06/2017 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 (PACKAGE-1)

DOOSAN JOB No. XXXXXXXX
SUBCONTRACT No. XXXXXXX
MAIN CONTRACTOR:
SUBCONTRACTOR:
Document Title: NAME SIGNATURE DATE
Prepared by JM. Ando JMA 06 March 2017

METHOD STATEMENT
FOR A.Kojok (SM)
STRUCTURAL CONCRETE TOM

Checked by
REPAIR
SAFETY
QA/QC JMA
Approved
M. Hussain (PM)
by
Document No.:
REVISION A
FCHPP/KCS/MS/0002
NUMBER
Document Status:
□ FOR INFORMATION ■ FOR APPROVAL ■ FOR REVIEW
□ FOR CONSTRUCTION □ AS BUILT
Document No. Revision No. Date: Page No.

FCHPP/KCS/MS/0002 A 6 March 2017 1 of 13
FADHILI CHP PROJECT
Civil & Building Works (Package-1)
METHOD STATEMENT FOR STRUCTURAL CONCRETE REPAIR

FCHPP/KCS/MS/0002
CONTENT
1. GENERAL INFORMATION
Introduction
Purpose
Scope of Work
Location
Definitions
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

FADHILI CHP PROJECT

FCHPP/KCS/MS/0002
1. GENERAL INFORMATION
1.1 Introduction
DOOSAN HEAVY INDUSTRIES & CONSTRUCTION, the Contractor of FADHILI CHP Project has awarded the Civil &
Building Works (package-1) 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
deficiencies, and to ensure that all activities shall be conducted in accordance with FADHILI project
specifications, HSE requirements and Contract documents.
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 Repairs
works at all concrete surface of this project. Necessary scaffolding, permits and clearances as per
Contractor/Company HSE regulations shall be provided.
Major repairs of deteriorated concrete structure, as determined by Contractor/OE shall be treated as a special
case and shall be provided with separate Construction Method Statement.
1.4 Location
Fadhili CHP Project, Fadhili Gas Plant, Kingdom of Saudi Arabia
1.5 Definitions
Contractor : Doosan Heavy Industries & Construction

Sub Contractor : Kettaneh Construction S. A. Ltd. (KCS)
OE : Owner’s Engineer
CMS : Construction Method Statement
ITP : Inspection & Test Plan
QA / QC : Quality Assurance / Quality Control

FADHILI CHP PROJECT

FCHPP/KCS/MS/0002
2. QA/QC
2.1 Standard Reference
o FADHILI Project Specifications, Standards & Procedures

o Contract Specification (Civil & Building Works Package-1)
o GEMSS-C-20, SEC Concrete Specification
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 Approval 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
i. General
o KCS shall supply all the consumable and non-consumable materials for the execution of concrete
repairs;
o The material supplier shall submit materials data sheets stating that the materials meet the
requirements of Contractor/OE & project specifications. KCS shall ensure that proposed material
supplier is capable of on-site technical back up during the execution of work;
o Manufacturer’s instructions shall be available to operatives at site;
o No material shall be procured or used without prior Contractor/OE approval;
o The material shall be durable, chemically compatible with the substrate, non-shrinkable, of similar
color and texture, and it shall be tolerant of a wide range of temperature, moisture and other
environmental conditions;
o All materials for repairs and protection of concrete structures shall be obtained from a single
manufacturer. Alternative manufacturers may be proposed by contractor prior to commencement of
work, but their materials shall not be used prior to Contractor/OE approval.

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FCHPP/KCS/MS/0002
ii. Ingredients
o Aggregate shall be in accordance with PROJECT Specification for all repair material. In some cases,
only size of aggregate shall be based on manufacturer’s recommendation;
o Where repair thickness is in excess of 75 mm, the maximum aggregate size shall be 10 mm, except
in some case only, when size of aggregate shall be in accordance with manufacturer’s
recommendation;
o Water quality shall be in accordance with PROJECT Specification. The quantity of water shall be in
accordance with manufacturer’s instruction for all repair materials.
iii. Reinforcement
o Replacement reinforcing steel grade and type shall be the same as that of the original steel.
iv. Cementitious Materials

o Conventional concrete shall be used for the complete replacement of sections and major portion of
structural members. The concrete shall be in accordance with PROJECT Specification and shall meet
the following requirements:
The compressive strength of concrete (f’c) shall not be less than the original design;
The cement shall be type-I conforming to ASTM C 150.
v. Epoxy Mortar
o Epoxy mortar shall be used for thin sections subjected to vibrations or impact loading; severe
chemical attack; and other aggressive conditions. It shall meet the following requirements:
The material shall be pre packaged and shall consist of a two or three
component, epoxy based moisture-insensitive repair mortar;
It shall have minimum compressive strength of 45 MPa after 7 days of
curing, when tested in accordance with ASTM C 109;
Material shall conform to ACI 503 R and 503.4.
vi. Bonding Agent Compounds

o Bonding agent materials shall be in accordance with ASTM C 881 and repair material manufacturer’s
recommendations;
o The material shall be fully compatible to overlaying repair material and substrate;
o Material shall be able to withstand all operating conditions.
vii. Curing Water

o Maximum Total Dissolved Salts in water used for curing shall not exceed 3000 parts per million,
other specific requirements shall be as per GEMSS-C-20.
viii. Crack Injection Material

o The material selection shall be based on the type and size of crack, and operating conditions around
the cracks;
o Epoxy resin shall be used for bridging the crack, to reinstate the structural integrity and forms a
permanent seal for leaky cracks.

FADHILI CHP PROJECT

FCHPP/KCS/MS/0002
b. Tools & Equipments
o Masonry Tools;
o Air Compressor;
o Water Jet;
o Industrial Vacuum Cleaner;
o Fixing injection materials & accessories;
o PPE & Other Safety required Materials.
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
3.1 General Repair Procedure
a. Submittals
o Repair materials (non-shrink grout, epoxy, concrete, etc.) to be used shall comply with
PROJECT specifications indicating the approved suppliers/manufacturers.
b. Materials Handling, Storage & Protection
o All 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 Prior to start of any repairs, the structure shall be investigated for the cause(s) and extent of
deterioration;
o Prior to repairs, KCS shall review the condition survey report jointly conducted by KCS and
Contractor/OE, this report shall be approved by the Company;
o KCS shall submit the condition survey and the proposed repairs for Contractor/OE approval;
o If the cause of deterioration can be established without detailed investigation, then the extent of
deterioration shall be established before repairs;
o Minor repairs (e.g. cosmetic, etc.) shall be performed without further information & approval from
Contractor/OE.

FADHILI CHP PROJECT

FCHPP/KCS/MS/0002
d. Execution of Repairs
i. General
o KCS shall dedicate QC inspector to monitor the quality of repair work;
o A hammer survey shall be conducted to identify the location and extent of defects requiring repair;
o The limit of repair shall be marked as a series of straight lines, with a minimum distance of 50 mm
from the body of hollow sounding/cracked concrete;
o During repair, all durability factors shall conform to ACI 201.2R;
o Safety requirements shall be in accordance with this Method Statement and Contractor/Company HSE
regulations;
o All necessary supports or props shall be provided to the structure(s) under repair, prior to start of
execution.
ii. Removal of Unsound Concrete

o All unsound or loose concrete shall be removed by light weight chipping hammer, or ultra pressure
hydro-blast, or other Contractor/OE pre-approved method;
o Care shall be exercised to control damage to the surrounding concrete;
o The boundaries of all unsound concrete area to be removed shall be delineated with saw cuts, to a
minimum depth of 10 mm, to provide a neat edge, and the remainder of the cut out may be done
with percussive tools;
o Removal geometry should be rectilinear in shape, to avoid featheredges;
o All concrete shall be removed around the corroded re-bars to a minimum depth of 25 mm behind it;
o If less than half of the perimeter of the rebar is exposed after concrete removal, the bar shall be
inspected, cleaned as necessary, and the repair proceeded without further concrete removal.
However, if inspection indicates that a rebar lost its bonding, or became corroded and needs
removal, concrete shall be removed to give the clear space;
o Concrete removal shall extend to locations along the rebar free of bond inhibiting corrosion, and
where the rebar is well bonded to surrounding concrete;
o Adequate shoring, support and protection shall be provided to the surrounding facilities, which shall
be affected during the repair work;
o Complete removal of the loosely adhering debris at the concrete substrate, and debris trapped
between reinforcement and concrete substrate shall be ensured;
o All loose reinforcement shall be secured in place by tying it to other existing secured bars, or by
another Contractor/OE approved method.
iii. Preparation of Exposed Reinforcement

o Exposed reinforcing bars shall be cleaned of foreign products by following the provisions in the
approved procedure for Repair of FBE Coated Reinforcement;
o Damaged epoxy coated reinforcement shall be repaired;
iv. Surface Preparation of Existing Concrete

o Clean the surface and any dust, unsound or contaminated material, plaster, oil, paint, grease,
corrosion deposits or algae shall be completely removed;
o The surface shall preferably be prepared using high pressure water jetting or light abrasive blasting,
followed by thorough washing to remove dust and remaining particles. Dirt alone may be removed
with wire brushes or similar mechanical means;
o Oil and grease deposits shall be removed by steam cleaning, detergent scrubbing or the use of
degreaser;
o Prior to the application of repair material, the surface of the existing substrate shall be roughened, to
provide an adequate key for bonding agent or repair material, or both;
o The substrate shall be kept wet with potable water for 24 hours prior to placement of the repair
material;

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FCHPP/KCS/MS/0002
o If continuous pre-wetting for 24 hours is not possible, then cement slurry shall be applied at the
prepared surface of the old concrete;
o The overlaying repair material shall be fully compatible with substrate;
o For repairs using epoxy-patching mortar, bonding agent shall be used;
v. Testing During Repairs

o All testing during actual repairs shall be carried out by a Contractor/OE approved independent
laboratory;
o Sampling and testing of repair shall be in accordance with PROJECT specification;
o Four cube samples from mortar used for repairs shall be taken for a day’s work;
o One sample shall be tested at 7 days, two for 28 days and the remaining one shall be served as
spare;
o The average value for these cubes shall be taken as a strength result. In no case shall the strength
test result be less than the existing concrete material’s compressive strength;
o For resin based mortar, the number of cubes and age of tests shall be agreed among Contractor/OE,
KCS and material supplier;
o Test cubes shall be stored and cured in a manner appropriate to the materials under service. They
shall be delivered with proper identification to the approved independent laboratory;
o Cube test results shall be judged for compliance against the manufacturer’s quoted strength result.
vi. Repair Material Placement

o Concrete placement shall be in accordance with ACI 304R and PROJECT specification;
o The reinforcement and formwork shall be cooled by spraying water;
o The temperature of water intended for use in repair work, shall be lowered by adding ice;
o Formwork shall be used for repair of vertical surfaces, slab, beam soffits, and wherever else required;
o Formwork shall be mortar tight, and the formwork surfaces in contact with the repair material shall
be coated with de bonding agent;
o Grout material shall be deposited in a way that prevents air pocket formation;
o Vent holes shall be provided to eliminate air entrapment, at suitable locations with respect to
irregular shaped cavities in the member under repair;
o Repair of walls, columns and vertical surfaces shall be performed in stages, with each stage not
exceeding 500 mm in height. For the uppermost part, the grout shall be deposited through letter box
shaped formwork, with open end slightly higher than the upper limit of the repaired area;
o Repair of slab soffits shall be performed by placing the repair material from the top of the slab
through drilled holes by pumping or by other Contractor/OE approved means. Suitable vent holes
shall be provided to release entrapped air;
o Consolidation of the repair material in small areas may be accomplished by tapping the formwork
with a rubber hammer;
o Formwork shall be removed after the repair material has gained specified strength, or as
recommended by material manufacturer;
o Any projections left after formwork removal shall be trimmed to give the original shape and profile of
the member;
o Epoxy material placement shall conform to ACI 503.4 or in accordance with manufacturer’s
recommendations;
o Pre-bagged material mixing, handling and placement shall be in accordance with the approved
manufacturer’s recommendation.
vii. Curing Regime

o Continuous water curing of concrete shall be in accordance with PROJECT Specification, ACI 308 and
manufacturer’s recommendation’s to achieve maximum strength.

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FCHPP/KCS/MS/0002
e. Crack Repair
i. General
o Crack injection repair shall be performed as per CONTRACTOR/OE recommendation;
o Crack injection system shall prevent the ingress of corrosion promoting materials, for example
moisture, chlorides and carbon dioxide;
o Injection system shall reinstate the structural integrity of the element by restoring or increasing its
strength and stiffness;
o It shall improve the durability and water tightness;
o It shall improve the appearance of the concrete surface.
f. Repair by Injection
o Holes shall be drilled along crack route at close intervals, in accordance with manufacturer’s
recommendations;
o Injection nipples shall be fixed at these intervals, and the crack surface shall be sealed with epoxy
putty;
o The applied putty shall be allowed to cure completely, in accordance with manufacturer’s
recommendations;
o Mixing of injection material and its application shall be in accordance with manufacturer’s
recommendations;
o Injection of resin shall be under pressure, and shall proceed from point to point;
o Injection pressure shall be maintained for several minutes, to force the resin into finer parts of the
cracks;
o Filling of cracks during injection process shall be confirmed by oozing out of injection material
through adjacent nipple of cracks;
o Injection pressure should be controlled based on the location of the crack, and the strength of the
substrate under injection pressure;
g. Routing or Sealing
o This type of repair shall be applied for fine, large, isolated, dormant and non-dormant cracks and
honeycomb which do not have any significant structural integrity requirements;
o The sealing shall ensure resistance against ingress of moisture, chemicals and carbon dioxide;
o Sealing shall resist mechanical damage due to trolley wheel traffic or other impact loading;
o V or U groove shall be made 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;
o Back up rod or filling material shall be used prior to application of sealant material for deep cut
grooves;
o Application of sealant shall be in accordance with the approved manufacturer’s recommended
procedure.

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FCHPP/KCS/MS/0002
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 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;
 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.

FADHILI CHP PROJECT

FCHPP/KCS/MS/0002
4.0 SAFETY
4.1 Safety, Access and Temporary Support
4.1.1 Safety
o KCS shall follow Contractor/OE 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/OE 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/OE
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/OE;
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.

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FCHPP/KCS/MS/0002
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
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

FADHILI CHP PROJECT

FCHPP/KCS/MS/0002
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.
5.0 APPENDICES
o Appendix 1: JOB SAFETY ANALYSIS

o Appendix 2: RISK ASSESSMENT

Doc. No KCS/SMS/3/7/7C
Company Health, Safety & Environmental
Management Manual (SMS) Issue 2
BS OHSAS 18001:2007 & ISO 14001: 2004 Date 30th June 2009
Job Safety Analysis - Concrete Repair

Name of Organisation Completing the Work:
Job Name: FADHILI CHP PROJECT
KETTANEH CONSTTUCTION, S. A. LTD.
Task: CONCRETE REPAIR JSA Number:
Principal contractor: DOOSAN HEAVY INDUSTRIES & CONSTRUCTION Job location: FADHILI GAS PLANT
Date the JSA was Prepared: 05 March 2017 Number of pages in this JSA: 2 Pages: 1 of 2
This JSA Prepared by: JMA New:  Revised:
Normal Approvals: Name: Signature: Date: Team Members
Project Manager: MALIK HUSSAIN
Site Manager: AHMAD KOJOK
Site Engineer: FLOR
Job Supervisor: MIKAEL
Fire: Clinic: Emergency:
Additional Approvals (Determined by Senior HSE Manager and Project Manager)
Pre-Start Tool Box Talk and Task Briefing including Emergency Procedures.
General Job Requirements Prior Inspection of tools and equipment by team.
Supervisors familiar with EHS Procedures
COMMON PPE HARD HAT- OVERALLS – HI-VIS – GLOVES – GLASSES/GOGGLES/SHIELDS* – SAFETY FOOTWEAR
NB:* Eye Protection Clear/Dark dependant on time of day. Type = Task
CHANGING CONDITIONS & EMERGENCY PROCEDURES: Stop Work, Switch Off Equipment, Supervisor Directs Personnel to Nearest & Safest Muster Point Considering Wind Direction.
Supervisor accounts for ALL Workers.
Consequence
Consequence
Risk Rating
Risk Rating
Probability
Probability
Work activity Hazard Control Measures
Persons
Responsible
Break the job down into steps What could harm someone? What can be done to make the job safe
Document No. Revision No. Date: APPENDIX No. Page No.

FCHPP-KCS-MS-0002 A 6 March 2017 1 1 of 2
Doc. No KCS/SMS/3/7/7C
Company Health, Safety & Environmental
Only authorized persons are allowed within the Site Engineer and
Accidental contact with heavy
3 3 H vicinity or working area. 2 1 L Civil works foreman
Concrete Repair and Pouring equipment can cause serious injury Flagman to be deployed.
Contact with concrete mixture can Wear appropriate PPE and working clothes.
2 2 M 1 1 L All
cause skin irritation
Only power tools with g2 prong grounding cable
Use of Power Tools - electrocution,
will be used.
personnel injury (hand, finger, facial 3 M H 1 A L Engineers, Foreman
Only trained & qualified personnel to operate
& body)
plant and equipments.
Do not lift more than 25 kg at a time, use correct
Ergonomics 2 2 M 1 1 L All
Clearing of Debris lifting techniques
Sharp edges of concrete debris 2 2 M Wear appropriate PPE 1 1 L workers
---------- Nothing Follows ----------
Consequence: 1,2,3 (From low to high) Probability: A,B,C (From low to high) Risk Rating: L,M,H (From low to high)

Company Health, Safety & Environmental Doc. No KCS-SMS-2/007
RISK ASSESSMENT FOR Structural Concrete Repair

Name Signature Date
Compiled By: JMA 05 MARCH 2017
Department: Civil
Engineer: FLOR
Work Supervisor: MIKAEL
1.HAZARD IDENTIFICATION 2. RISK ASSESSMENT
Residual
Base Risk
Risk
Risk Category
Risk Category
Significant Existing Control Additional Control
Risk Ranking
Risk Ranking
Sl. Health and Measures Measures
Likelihood
Likelihood
Activity Sub-Activity Risk
No Safety
Severity
Severity
Hazard
Accidental contact
with heavy
equipment can Only authorized persons are Ensure proper
cause serious allowed within the vicinity or operation of traffic
Heavy
injury, Serious working area. control devices and
equipment
Concrete injury/fatality warning devices.
entry to work 2 4 8 M 1 4 4 L
Repair and damage to Flagman to be deployed. Assigned trained
area
Contact with property. Wear appropriate PPE and flagman to give proper
concrete mixture working clothes. signal to the operator
can cause skin
irritation

Only power tools with g2

prong grounding cable will
be used.
Only trained & qualified
personnel to operate plant
and equipments.
Do not lift more than 25 kg

at a time, use correct lifting
No personnel behind
techniques
Setting of the reversing vehicles.
Serious
Equipment Ergonnomic Issues; Neither should they be
Clearing of injury/fatality
(pumpcrete, Sharp edges of 2 4 8 M in the concreting area 1 4 4 L
Debris and damage to Wear appropriate PPE
concrete concrete debris. until the concrete
property.
mixers, etc.) mixer is in the pouring
position.

To Evaluate the Risk: Likelihood (L) x Severity (S) = Risk ®, Defined as HIGH (11-25), MEDIUM (6-10) or LOW (1-5)
Risk Rating:
L= Likelihood S = Severity
1. Very Unlikely - Never heard of in our industry 1. Minor - No Loss Time, First Aid etc.
2. Unlikely - Heard of in our industry 2. Significant - Equipment Damage < 2000SR, Medical Treatment
3. Likely - Accident has occurred in our Company 3. Major - Loss Time Injury, Equipment Damage >2000SR
4. Very Likely - Happens several times per year in our company 4. Severe - Single Fatality, Complete Loss of Plant/Equipment
5. Certain - Happens several times per year in a location 5. Catastrophic - Multiple Fatalities, Explosion, Fire etc.
Name Signature Date

Completed By: 18 July 2012
MR. ELEAZAR

CONSEQUENCES INCREASING LIKELIHOOD

1 2 3 4 5
Severity
Never Heard of Incident Happens Happens
Reputation
heard of in our has several several
in our industry occurred in times per times per
People
Assets
industry our year in our year in a
Company company location
1 Slight health Slight damage < SR10K Slight impact

effect/injury
2 Minor health Minor damage < SR 100K Limited impact Low Risk
effect/injury
3 Major health Localised damage< SR 1M Considerable impact Medium Risk

effect/injury
including LTI
4 Permanent Major damage<SR10M National impact
Disability* or 1
Fatality
5 Multiple fatalities Extensive damage >SR10M International impact
High Risk
Risk Assessment Matrix


Cms 0002 Concrete Repair Rev. A

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Cms 0002 Concrete Repair Rev. A

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A 05/06/2017 Issued for Review

Reviewed & Approved

FADHILI CHP PROJECT – CIVIL & BUILDING WORKS (PACKAGE-1)

Document Title: NAME SIGNATURE DATE

Prepared by JM. Ando JMA 06 March 2017

STRUCTURAL CONCRETE TOM

□ FOR INFORMATION ■ FOR APPROVAL ■ FOR REVIEW

□ FOR CONSTRUCTION □ AS BUILT

Document No. Revision No. Date: Page No.

METHOD STATEMENT FOR STRUCTURAL CONCRETE REPAIR

Safety / Highlight of Potential Risk

Appendix 1: Job Safety Analysis

Document No. Revision No. Date: Page No.

METHOD STATEMENT FOR STRUCTURAL CONCRETE REPAIR

1.3 Scope of Work

Fadhili CHP Project, Fadhili Gas Plant, Kingdom of Saudi Arabia

Contractor : Doosan Heavy Industries & Construction

Document No. Revision No. Date: Page No.

METHOD STATEMENT FOR STRUCTURAL CONCRETE REPAIR

2.1 Standard Reference

o FADHILI Project Specifications, Standards & Procedures

Document No. Revision No. Date: Page No.

METHOD STATEMENT FOR STRUCTURAL CONCRETE REPAIR

iv. Cementitious Materials

vi. Bonding Agent Compounds

vii. Curing Water

viii. Crack Injection Material

Document No. Revision No. Date: Page No.

METHOD STATEMENT FOR STRUCTURAL CONCRETE REPAIR

b. Tools & Equipments

3.1 General Repair Procedure

b. Materials Handling, Storage & Protection

c. Pre-repair Condition Survey of Structure

Document No. Revision No. Date: Page No.

METHOD STATEMENT FOR STRUCTURAL CONCRETE REPAIR

ii. Removal of Unsound Concrete

iii. Preparation of Exposed Reinforcement

iv. Surface Preparation of Existing Concrete

Document No. Revision No. Date: Page No.

METHOD STATEMENT FOR STRUCTURAL CONCRETE REPAIR

v. Testing During Repairs

vi. Repair Material Placement

vii. Curing Regime

Document No. Revision No. Date: Page No.

METHOD STATEMENT FOR STRUCTURAL CONCRETE REPAIR

Document No. Revision No. Date: Page No.

METHOD STATEMENT FOR STRUCTURAL CONCRETE REPAIR

General Foreman – Concrete

Document No. Revision No. Date: Page No.

METHOD STATEMENT FOR STRUCTURAL CONCRETE REPAIR

4.1 Safety, Access and Temporary Support

o KCS shall follow Contractor/OE HSE procedures;

Document No. Revision No. Date: Page No.

METHOD STATEMENT FOR STRUCTURAL CONCRETE REPAIR

4.1.3 Temporary Support

4.2 Safety / Highlight of Potential Risks

o Proper PPE’s shall be observed;

4.3 Highlight of Potential Risk

JSA/ HAZARD ANALYSIS

ITEM DESCRIPTION ACTION ITEM DESCRIPTION ACTION

Document No. Revision No. Date: Page No.

METHOD STATEMENT FOR STRUCTURAL CONCRETE REPAIR

Evaluation Table for Dangerousness

Section Dangerous Factor Measure

Accidents without wearing safe Workers and supervisor should wear