Professional Documents
Culture Documents
MAIN CONTRACTOR:
SUBCONTRACTOR:
QA/QC
Approved
M. Hussain (PM)
by
Document No.:
REVISION A
FCHPP/KCS/MS/0031
NUMBER
Document Status:
CONTENT
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
5. APPENDICES
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.
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.
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
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
2. QA/QC
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
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)
a. Submittals
Repair materials epoxy resin to be used shall comply with PROJECT specifications indicating the approved
suppliers/manufacturers.
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.
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;
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.
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
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
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.
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;
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
4.1.1 Safety
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;
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.
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.
APPENDICES
BASF_CC-UAE/Br_2200_12_2009 ksa/v1/12_13
The technical information and application advice given in this BASF publication are based on the present state of
STATEMENT OF our best scientific and practical knowledge. As the information herein is of a general nature, no assumption can be
RESPONSIBILITY made as to a product's suitability for a particular use or application and no warranty as to its accuracy, reliability or
completeness either expressed or implied is given other than those required by law. The user is responsible for
checking the suitability of products for their intended use.
Field service where provided does not constitute supervisory responsibility. Suggestions made by
NOTE BASF either orally or in writing may be followed, modified or rejected by the owner, engineer or contractor since
they, and not BASF, are responsible for carrying out procedures appropriate to a specific application.
DESCRIPTION ADVANTAGES
MasterBrace ADH 2200 is a non slumping epoxy • High strength.
bedding compound and adhesive. It is a two pack, • Non-slump.
fine aggregate filled, fast curing material, ideal for • Strong adhesion.
a variety of bedding, gap filling and concrete repair • Impact resistant
applications. • Chemical resistant.
MasterBrace ADH 2200 is a stiff but easily • Non shrink.
workable compound that can be applied by either • Epoxy based.
trowel, spatula or knife. It cures to give high • Trowels to a smooth finish.
mechanical properties typical of epoxy
• Easy to use.
compounds. It is resistant to oils, greases,
• Supplied in pre-weighed units.
petroleum, salts, many acids and alkalis and most
commonly met corrosive media. It does not shrink • No bonding agent or primer required.
on curing, and is designed to be used when cured
from below freezing point to 60°C. Its impact PACKAGING
resistance, and mechanical strength is greater MasterBrace ADH 2200 is available in 3kg units.
than that of concrete.
COMPOSITION
PRIMARY USES Two-component epoxy-based mortar filled with
For surface repairs of fine cracks and spalls. For selected fine aggregate.
gap filling, grouting, bedding fixtures etc. For
repairs to arrisses without the use of form work. TYPICAL PROPERTIES
Wherever a thixotropic epoxy mortar is required.
Colour: Cement grey
TYPICAL APPLICATIONS Mixed density at 25°C: 1758 kg/m³ (approx.)
• Bedding bridge beams or steel bridge bearings. Flashpoint: N/A
• Repairing surface defects or to honeycombing Compressive strength 60 N/mm² at 7 days
concrete in horizontal, vertical or overhead to ASTM C579
situations. Bond to concrete: In excess of the
• Fixing slip bricks to concrete. cohesive strength of
• Securing bolts into walls. concrete
• Dowel bars anchoring. Pot life at 25°C 1 hrs 45 minutes
• As a gap filling adhesive. at 40°C 45 minutes
• Filling bolt pockets. Tack free time at 7 hours
• Bedding tiles. 25°C
• Repairing concrete posts in-situ. at 40°C 2 hours 15 minutes
• Fixing of surface ports for crack injection. Full Cure at 25°C: 5 days
At 40°C 3 days
CHEMICAL RESISTANCE
MasterBrace ADH 2200 has excellent resistance
to the following: most aqueous systems, sewage,
urine, fresh water, sea water, diluted and
concentrated alkalis, diluted acids, sulphur gases,
mineral, vegetable and animal oils and fats,
ammonia and formaldehyde.