011-METHOD STATEMENT FOR REPAIR OF CONCRETE WORKS.pdf

Pearl GTL Project Shell Project No: HP-3000-QAT Project Document Number: T- 4.234.073

Purchase Order Number:

2MH127

Tag/Item Number(s):

N/A

Unit(s):

ASU

PCWBS:

Z

LINDE ENGINEERING

Contractor Project No: Project Rev.: F

Page 2 of 23

5887

QATAR SHELL GTL PROJECT (PEARL) C2 AIR SEPARATION UNITS CONSTRUCTION I

F

01.12.08

Ready For Construction

SB

EO

AG

RFC

H

E

01.10.08

Issued for Review ( Revised according to site changes)

SB

EO

AG

IFR

G

D

13.07.08

Issued for Review ( Revised according to site changes)

SB

EO

AG

IFR

F

C

30.03.08


SB

UA

ZG

RFC

E

B

23.03.08


SB

UA

ZG

RFC

D

A

23.02.08


SB

UA

ZG

RFC

C

O

09.12.07

Issued for Company comments

SB

AU/MC

ZG

ICC

B

23.11.07

Issued for Review

SB

AU/MC

ZG

IFR

A

20.11.07

Issued for Internal Review

SB

AU/MC

ZG

IIR

Date

Description

GAMA Rev. No.

Project Rev No.

Prepared Checked Approved By By By ORIGINATOR

Status

Document Title:

LINDE ENGINEERING AG

METHOD STATEMENT FOR REPAIR OF CONCRETE WORKS Document No.

Contractor

Gama Qatar Co. W. L. L.

LOC470 GAM

MTS

CIV

GTL

011

I

Org. Code

Doc. Type

Disc. Code

Geogr. Area

Seq. No

Rev. No

Project Document Number: T-4.234.073

Vendor Code

Rev No: F

Q A T A R

Doc. Title

:

GAM-MTS-CIV-GTL-011 MS FOR REPAIR OF CONCRETE WORKS

Date

:

01.12.2008

REV. I

TABLE OF CONTENTS 1.

PURPOSE _____________________________________________________________________ 5

2.

SCOPE ________________________________________________________________________ 5

3.

HSSE _________________________________________________________________________ 5

4.

REFERENCES _________________________________________________________________ 6

5.

DEFINITIONS _________________________________________________________________ 6

6.

RESPONSIBILITY ______________________________________________________________ 6 6.1 Site Manager _________________________________________________________________________6 6.2 Civil Works Manager __________________________________________________________________6 6.3 Site Engineer _________________________________________________________________________6 6.4 Work Supervisor ______________________________________________________________________7 6.5 QA/QC Officer / Inspector ______________________________________________________________7

7.

EQUIPMENT & MANPOWER ____________________________________________________ 7 7.1 Equipment ___________________________________________________________________________8 7.2 manpower ____________________________________________________________________________8

8.

REPAIR PROCEDURE __________________________________________________________ 8 8.1 General ______________________________________________________________________________8 8.2 repair of cracks ______________________________________________________________________9 8.3 repair of minor surface deficiencies in the concrete (air voids, etc) _____________________________9 8.4 repair of major surface deficiencies in the concrete __________________________________________9 8.5 major concrete repairs ________________________________________________________________10

9.

Curing ________________________________________________________________________ 10

10.

QUALITY ASSURANCE _______________________________________________________ 10

11.

ATTACHMENTS _____________________________________________________________ 11

T-4.234.073 Rev. F

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Q A T A R

Doc. Title

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Date

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REV. I

1. PURPOSE This document describes the methods proposed to be used for the concrete repair activities that will be carried out as part of ASU Construction Works of Qatar Shell GTL Plant (Pearl) in Ras Laffan Industrial City of Qatar including similar works in TSF Area.

2. SCOPE This method statement covers methods for Concrete repair works.

3. HSSE All works shall be in compliance with the State of Qatar laws and regulations, Ras Laffan Industrial City and international standards/codes, and Company and Contractor requirements and instructions. All personnel will go through Gama, Linde and Company Safety Induction courses as well as other trainings as identified by their supervisor. A Job Safety Analysis (JSA) specific for this work including a Risk Assessment is prepared and attached herein. Such JSA addresses the hazards associated with each task within the scope of this Method Statement and introduces the controls that will be implemented to reduce the associated risks to acceptable levels. The JSA will be used by the Site Supervisor as the basis of his TSTI / TSTO and Toolbox Talks. All personnel will have PPE required for their specific tasks in addition to the minimum PPE (coveralls, safety goggles, safety shoes, high-visibility vests, gloves) at site at all times as required. In the event of a release, fire or explosion, employees will secure their area and evacuate to the nearest muster point. Once all employees are evacuated the supervisor will conduct a headcount to verify all employees are out of harm’s way. The supervision will report this to Contractor. Emergency Contact numbers for Company, Contractor and Gama will be posted onsite. All vehicles and equipment used for the subject work will be inspected and certified as required. Drivers and operators will be competent and will have attended all required trainings set forth in project procedures and specifications.

T-4.234.073 Rev. F

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4. REFERENCES Qatar Construction Standard DEP 34.19.20.31- Reinforced Concrete Foundations and Structures (Amendments T.13.376.358G-Clause 3.24) ASTM 546 Concrete Repair Guide Vendor Specifications Other specifications and procedures of Contractor, Company and RLIC.

5. DEFINITIONS Company Contractor Subcontractor Contract QCP ITP QA/QC JSA

: : : : : : : :

QSGTL or its PMC Linde Engineering AG Gama Qatar Co. W. L. L. QSGTL Pearl Plant – C2 ASU Construction Works Quality Control Procedure Inspection and Test Plan Quality Assurance / Quality Control Job Safety Analysis

6. RESPONSIBILITY 6.1 SITE MANAGER The site manager will provide inputs to the project execution plan to ensure that strategies & philosophy are properly addressed. 6.2 CIVIL WORKS MANAGER The Civil Works Manager is responsible for the overall management of the project construction team to ensure that safe and effective operations are conducted and properly documented. 6.3 SITE ENGINEER He will be overall responsible for safe execution of the whole job including: Confirming the installation location from schedule of approved construction drawings. Organizing of equipments and tools needed for the job. Assigning skilled personnel for the job. T-4.234.073 Rev. F

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Sequence of activities to be carried out for the work as per this method of statement. Conduct inspection and surveillance. Notify to Contractor engineer for inspection as applicable. Ensure all Contractor and Company regulations are followed. Ensure all personnel involved are in safe working condition. 6.4 WORK SUPERVISOR He will be responsible for safe execution of the following activities: Conduct TSTI with the concerned work force prior to start the work. Ensure that relevant work permits for the job are obtained prior to start the work. Conduct daily toolbox talks for the entire work force prior to start day work. Assigning a competent work crew for specific activities, details of activities and task information will be given to the work crew. Organizing tools and equipment needed to the work site. Inspection and supervision of work. Ensure all Contractor and Company safety regulations are followed as applicable. 6.5 QA/QC OFFICER / INSPECTOR He will be responsible for: Assurance of approved methods and materials are being used and conformance of the specifications. Stage inspections and surveillance in accordance with ITP and assurance of quality of work as per specification and erection procedures. Incoming material inspection and review of test certificates.

7. EQUIPMENT & MANPOWER All equipment will be inspected and approved by the Contractor, when required, and all personnel will be inducted and trained before and during mobilization.

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7.1 EQUIPMENT Disc cutter

:1

Electric/pneumatic breaker or hammer and chisel

:1

Wire brush:

:1

Measuring jug:

:1

Slow speed drill (400 or 500rpm):

:1

Mixing paddle

:1

Suitably sized mixing vessel

:1

Trowel

:1

Wooden float

:1

Steel or plastic finishing float or sponge

:1

Injection machine

:1

High speed percussion drill Hand held angle grinders

:1 :2

7.2 MANPOWER Civil Foreman

:1

Safety Officer

:1

QA/QC Technician

:1

Mason

:2

Helper

:2

If the above-listed equipment or manpower proves not sufficient for the timely completion of the facilities and project; additional will be provided to complete the works on time and in line with rules, regulations and specifications of Contractor, Company and RLIC.

8. REPAIR PROCEDURE 8.1 GENERAL As per the section 3.24 of T.13.376.358 all concrete repair is a HOLD POINT in the ITP and only proprietary factory made materials approved by the Company shall be used for the repair. T-4.234.073 Rev. F

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The surface preparation of the concrete to be repaired and the mixing, application and curing of the (proprietary) repair mortars/(micro) concrete shall be as per manufacturers requirements/recommendations and /or the specifications applicable for concrete shall be followed if specific requirements are not given by the manufacturer (e.g. curing). All repair areas shall be coverd from direct sunlight. The repair shall only be carried out after the curing (as per T.13.376.358 paragragh 3.26) has been completed. 8.2

REPAIR OF CRACKS

All cracks with a crack width greater than 0.3mm Note: Cracks with a width exceeding 0.3mm are not confirming to the specification and a Non Conformance Report (NCR) shall be raised. Open the crack, by chiselling a V –cut, to a depth where the crack visually seems to stop; however the maximum depth for chiselling is 20mm. The crack shall be cleaned with compressed air. Fill the crack up with water and observe whether or not the crack continues by looking for air bubbles in the water due to air escaping out of the crack. If air bubbles are observed, an approved low viscosity resin shall be poured into the crack as per manufactures recommendation until the crack is fully saturated with the resin. Repair / seal the V-cut of the crack, after injection, with an approved shrinkage controlled structural grade cementitious repair mortar system (approved is Renderoc Sxtra). If no air bubbles are observed, the V-cut shall only be repaired/sealed as per above. Where detection of a possible continuation of the crack with water filling is not possible (on vertical faces) the crack repair shall be discussed between Company and Contractor, looking for similarities with horizontal cracks in the same area. Where similarities are not found and/or agreed the crack shall be deemed to be deep and injected with epoxy and the V-cut further repaired/sealed as per above. All cracks with a crack width between 0.1 and 0.3mm (Only for Non Coated Areas) If the crack is reaching anchor bolts or box-outs, apply the same repair method as for cracks with a crack width of greater than 0.3mm. 8.3 REPAIR OF MINOR SURFACE DEFICIENCIES IN THE CONCRETE (AIR VOIDS, ETC) Surface defects that can be enclosed by a 50mm circle and in which circle the concrete cover is not reduced by more than 10mm are defined as minor surface deficiencies (refer to section 3.24 of T-13.376.358). These minor voids shall be filled with fine mortar incorporating polyvinyl acetate (approved is Renderoc RF, for a maximum thickness of 5mm). 8.4 REPAIR OF MAJOR SURFACE DEFICIENCIES IN THE CONCRETE Note: Major surface deficiencies are not confirming to the specification and a Non Conformance Report (NCR) shall be raised. Major surfaces deficiencies are deficiencies that cannot be enclosed by a circle of 50mm and/or where the concrete cover has been reduced by more than 10mm and up T-4.234.073 Rev. F

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REV. I

to the rebar zone (no rebar exposed). Defective concrete shall be removed up to sound concrete. These major deficiencies shall be repaired by an approved shrinkage controlled structural grade cementitious mortar system (approved is Renderoc Sxtra).

8.5 MAJOR CONCRETE REPAIRS Note: Major concrete repairs are not confirming to the specification and a Non Conformance Report (NCR) shall be raised. Areas where after removal of the defective concrete the rebar becomes exposed and/or where the extend of the repair is such that formwork has to be used are defined as Major Concrete Repairs. The defective concrete shall be removed up to sound concrete. If the defective concrete extends to the rebar a clear gap of at least 20mm shall be created behind the rear face of the rebar, such that a gloved hand can comfortably reach behind the main bars. All exposed rebar shall be carefully cleaned by wire brushing before the repair and the concrete faces to be scabbled and wetted as per requirement/recommendation of the manufacturer of the repair micro concrete.

9. CURING Curing will be done as per Manufacturer recommendation. Renderoc BF generally needs to be protected by polythene sheets .In Hot & windy climate shall be coated with Nitocote PE 135.Nitocote PE 135 need not removed for further surface coating as per Manufacturer recommendation. Curing with damped Hessian is to be done for one day. This coating can be done after one day in wet damped surface also.

10. QUALITY ASSURANCE A Quality Assurance System will be operated conforming to related standards. Controls and checks will be established and documented in Concrete Repair form GAM-QCR-QAC-GTL-010.Repaired surface Inspection will be offered to client. All deficiencies will be logged, photographed and repaired. Repair of concrete will be Hold point in ITP T.4.234.075. Separate Repair Log sheet will be maintained.

T-4.234.073 Rev. F

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11. ATTACHMENTS JSA RENDEROC BF RENDEROC SXTRA NITOCOTE PE 135 REPAIR LOG FOSROC LETTER - CURING GAM-QCR-QAC-GTL-010

T-4.234.073 Rev. F

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JOB SAFETY ANALYSIS FORM

JSA Number:

NEW

Job being analysed: MS-Repair of Concrete Cracks Department/Section doing JSA:HSE & Construction Normal Approvals: JSA by:

Page No:

REVISED

Name

JSA Members: Job Performers: Signature

Date

Job Supervisor: Additional Approvals (Determined by Job Supervisor in correlation withLINDE SHES Manager). Name Signature Discipline Superindent(LINDE) SHES Representative(LINDE) OTHERS(List Below):

Date

General job requirements / Common Personnal Protective Equipment. 1. The following Personal Protective Equipment shall be worn while repairing concrete cracks : Approved coveralls, safety glasses, safety helmet, safety shoes and gloves. 2.Permit To Work.

Approval required for hazardous work detailed in the LINDE work permit procedure. Changing conditions and emergency procedures Stop work. Switch of equipment.Supervisor directs personnel to nearest and safest muster point considering wind direction. Supervisor counts all employees. Missing employees are reported to to LINDE HSSE Dept. When all clear is given check with LINDE HSSE before returning to work. LINDE EMERGENCY TELEPHONE NO.

RLIC: LINDE HSSE MANAGER:

474 88 88 583 40 72

Note: 1) If any of the tasks involves biological, physical or chemical hazards, then The LINDE Industrial Hygienist must also approve the work. 2)Use additional sheets as necessary. 3)Details on safety (PPE,Hazard etc) and environmental requirements can be found in LINDE and QSGTL Safety and Environment Procedures.

1

JOB SAFETY ANALYSIS / RISK ASSESSMENT T.4.234.073

Q Q A A T T A A R R

ITEM

1

ACTIVITY Chipping of crack concrete.

HAZARD / POTENTIAL CONSEQUENCES

1.1 Eye injuries

Hands and fingers injuries 1.2 Dust inhalation

Initial Risk P C B

2

B

2

B

2

B

2

1.3 Fall of materials/Tools.

1.4 Use of make shift tools.

2

RISK RANK

CURRENT CONTROLS

1.1.1 Ensure employee wear appropriate safety glasses. 1.1.2 Ensure employees have personal protective equipment i.e. coveralls, LOW safety shoes, safety helmet, safety glasses and work gloves. 1.2.1 Ensure employee wear approved dust LOW masks. 1.3.1 Ensure all materials, tools, equipment are kept secure at all times while working at heights. LOW 1.3.2 Barricades working area with signboard indicating work in progress.

ADDITIONAL CONTROLS

Residual Risk

P C

R

LOW

LOW 1.4.1 Use the right tools for the right job. 1.5 Fall of personnel (if 1.5.1 ALL employees shall wear inspected 1.5.1.1 working at heights). full body harness fitted with twin lanyards with shock absorbers, each 1.5.1.2 lanyard shall be fitted with dual action C 5 HIGH self-locking safety hook for 100% Tieoff. 1.5.2 Ensure 100% fall protection. Removal of chipped 2.1 Hand & finger injury. 2.1.1 Use appropriate working gloves. B 2 LOW concrete. 2.1.2 Use the right tools for the right job. 2.2 Fall of chipped concrete 2.2.1 Barricade working area & Warning 2.2.1.1 B 3 MED (if working at height). signboard to warn other. 2.2.2 Ensure employees have personal protective equipment i.e. coveralls, safety shoes, safety helmet, safety glasses and work gloves. B

SCOPE : Repair of Concrete Cracks

2

Discuss working at height hazards at daily TSTI. Training prior to start working @ heights.

Discuss in daily TSTI.

A

5 LOW

A

3 LOW

2

JOB SAFETY ANALYSIS / RISK ASSESSMENT T.4.234.073

Q Q A A T T A A R R

3

Apply cementitious 3.1 Eye and skin irritation. filler and mortars for concrete surface.

B

2

LOW

B

2

LOW

3.3 Chemical hazard. B 4.1 Physical injury due to mishandling of materials back, muscle strain , B sprain.

3

MED

2

LOW

3.2 Hands and fingers injuries 4

Material handling/storage.

4.2 Fire/explosion

4.3 Improper disposal of empty materials.

B

3

MED

B

2

LOW

3.1.1 Ensure employees have personal protective equipment i.e. coveralls, safety shoes, safety helmet, safety glasses and rubber hand gloves to avoid skin contacts. 3.2.1 Use the right tools for the right job. 3.2.2 Ensure employee wearing safety work gloves. 3.3.1 Review MSDS. 3.3.1.1 4.1.1 Ensure all materials shall be stored, handled and used in a safe manner, by type, providing enough passageways between different stored materials. 4.1.2 Employee shall be trained for using safe methods in handling materials. 4.2.1 Material shall be stored in conditions 4.2.1.1 compatible with the recommendations of the MSDS. 4.2.2 Ensure to maintained suitable fire extinguisher in the area. 4.3.1 Ensure empty containers shall be dumped at approved dump locations for hazardous materials.

SCOPE : Repair of Concrete Cracks

Discuss in TSTI

Remove unecessary combustible materials.

A

3 LOW

A

3 LOW

3

Renderoc BF*

constructive solutions

One component polymer modified cementitious filler and reprofiling mortar Uses Renderoc BF is designed for application to imperfections in concrete and masonry surfaces. It is suitable for application upto 5mm thickness, and can be used in the following situations: ! Filling blow holes prior to overcoating. ! Skim-coat over concrete to receive protective coatings. ! General reprofiling over large areas. ! Reprofiling, in association with other Renderoc mortars Advantages ! Cost effective/ time saving - no independent primer or curing agents required. ! High performance - excellent bond to substrate. ! User friendly - requires addition of water only.

Property Initial setting time (BS EN 196): Final setting time (BS EN 196) : Fresh wet density : Compressive strength : Average Linear Coefficient of Thermal Expansion Note :

: :

115 mins 165 mins 1840 kg/m3 3days - 10N/mm² 7days - 20N/mm² 2.5 x 10-6 per oC

Working life and setting time will vary dependent on ambient, substrate temperatures and wind speed.

Instructions for use Preparation

Description

Clean the surface and remove any dust, unsound material, plaster, oil, paint, grease, corrosion deposits or algae. Roughen the surface to remove any laitance and expose the fine aggregate by light scabbling or sweep blasting.

Renderoc BF is supplied as a ready to use blend of dry powders and polymers, which requires only the addition of water to produce a highly consistent cementitious mortar, with good handling characteristics.

Oil and grease deposits should be removed by steam cleaning, detergent scrubbing or the use of a proprietary degreaser. The effectiveness of decontamination should then be assessed by a pull-off test.

Renderoc BF exhibits excellent thermal compatibility with concrete and is fully compatible with other Renderoc* mortars and Dekguard* protective coatings.

The cleaned areas should be blown clean with oil-free compressed air before continuing. All prepared areas should be thoroughly soaked with clean water immediately prior to the application of Renderoc BF. Any residual surface water should be removed prior to commencement.

! Suitable to receive protective coatings.

Design Criteria Renderoc BF is designed for vertical and overhead use to infill surface imperfections of concrete upto 5mm thick. Limitations -

Renderoc BF should not be used when the temperature is below 5°C and falling.

-

Do not proceed with the application when rainfall is imminent unless in a sheltered or protected situation.

-

If any doubts arise concerning temperature or substrate conditions, consult the local Fosroc office.

Properties Renderoc BF*

The following results were obtained at a water:powder ratio of 0.2

Mixing Care should be taken to ensure that Renderoc BF is thoroughly mixed. In all cases the powder component should be introduced into water. Mixing should be carried out in a suitably sized mixing vessel, using a slow speed (400/500 rpm), heavy duty drill and a Fosroc mortar mixing paddle. Pour 4 - 6litres of water (depending of workability required) into the mixer and, with the machine in operation, add one full 20 kg bag of powder, then mix for 3 to 5 minutes, until fully homogeneous. Do not use more than 6 litres of water per 20kg bag.

Renderoc BF* If mixing small quantities by hand, Renderoc BF should be volume-batched. Add 3 volumes of the Renderoc BF powder (loose-filled to excess and struck off level with the top of the measuring container) to one volume of potable water. This should be mixed vigorously until fully homogeneous.

Estimating Supply Renderoc BF

Apply the mixed Renderoc BF to the blow holes by steel trowel. It should be applied with minimum working and be allowed to partly set before finally trowelling to a smooth finish. If a very smooth finish is required, a small amount of water may be flicked on to the surface of the Renderoc BF with a paint brush prior to final trowelling. Curing Curing is not generally required. However, under extreme conditions - high temperatures and drying winds - use Nitobond AR*† or Nitocote PE135*† as a curing agent, or cover the surface with polythene sheeting, taped down at the edges. Nitobond AR does not require mechanical removal prior to overcoating with Dekguard system. If overcoating with epoxy or polyurethanes then use Nitocote PE135 as the curing membrane. Cleaning Renderoc BF should be removed from tools, equipment and mixers with clean water immediately after use. Cured material can only be removed mechanically. High temperature working At ambient temperatures above 35°C, the components should be placed in air-conditioned storage of less than 25°C, for special application procedures, refer to your local Fosroc office. Overcoating with protective / decorative finishes Renderoc BF may be overcoated after 48 hours, in ambient conditions of up to 75% relative humidity, dependant on the type of coating. For further information consult the local Fosroc office before proceeding.

:

14.4 litres per 20kg bag (based on 6litre water)

Actual coverage of Renderoc BF will be wholly dependent upon the general substrate condition. It is recommended, therefore, that site trials over a typical area are carried out to determine actual usage. Storage Shelf life All products have a shelf life of 12 months if kept in a dry store in the original, unopened bags or packs @ 25oC. If stored at high temperatures and/or high humidity conditions the shelf life may be considerably reduced to 4 to 6 months. Precautions Health and safety Renderoc BF contains cement powders which, when mixed or become damp, release alkalis which can be harmful to the skin. During use, avoid inhalation of dust and contact with skin and eyes. Wear suitable protective clothing, gloves, eye protection and respiratory protective equipment. The use of barrier creams provide additional skin protection. In case of contact with skin, rinse with plenty of clean water, then cleanse with soap and water. In case of contact with eyes, rinse immediately with plenty of clean water and seek medical advice. If swallowed, seek medical attention immediately do not induce vomiting. For further information, refer to the Product Material Safety Data Sheet. Fire Renderoc BF is a non-flammable product. * Denotes the trademark of Fosroc International Limited †

Important note

20 kg bag

Yield Renderoc BF

Application

:

See separate data sheet

Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply of Goods and Service. All Fosroc datasheets are updated on a regular basis. It is the user’s responsibility to obtain the recent version. Refer to www.fosroc.com.

Al Gurg Fosroc LLC Post Box 657, Dubai United Arab Emirates

www.fosroc.com

Head Office telephone: (+9714) 2039699

fax: (+9714) 2859649

email: [email protected]

Regional offices Abu Dhabi, Al Gurg Fosroc Bahrain, YBA Kanoo

telephone: 673 1779 telephone: 17735454

fax: 673 1449 fax: 17732828

email: [email protected] email: [email protected]

Kuwait, Boodai Oman, Al Amana Qatar, Tadmur

telephone: 4817618 telephone: 24815080 telephone: 4500607

fax: 4832124 fax: 24817554 fax: 4500543

email: [email protected] email: [email protected] email: [email protected]

UAE/0492/07/H

Renderoc SXtra*


Shrinkage controlled, structural grade cementitious repair mortar system Uses

Properties

Renderoc SXtra is suitable for hand application to repairs where significant load bearing is required. Typical applications would include, but not be limited to, the following :

The following typical results were obtained at a water to powder ratio of 0.15.

Vertical and overhead repairs.

Renderoc SXtra features Dimensional Stability Technology a new materials technology which controls the rate of drying shrinkage such that, when used correctly :

Drying shrinkage to ASTM C 157-93 7 days : < 300 microstrain 28 days : < 500 microstrain Permeability : < 10 mm (DIN 1048 Part 5) Flexural strength : > 7 N/mm2 at 28 days (BS 6319 Pt.3) Tensile strength : > 3.5 N/mm2 at 28 days (BS 6319 Pt.7) Compressive strength : 50 N/mm2 at 7 days (BS 1881 Pt.1161) 55 N/mm2 at 28 days Water absorption : < 2% (BS 1881 Pt.121) Note1: 50mm cubes, air cured @ 250C

i.

Design criteria

Patch repairs to concrete floor slabs. Patch repairs to stairs, steps and other areas subject to repeated, heavy trafficking. Arris repairs to joint edges. General structural repairs where formwork cannot be easily erected. Advantages

the dimensions of the repair remain stable; and thus

ii. eliminating failure, due to shrinkage cracking. This in turn leads to a series of associated benefits : Cost effective - shrinkage control enables repairs to be completed ‘right first time’. Enhanced durability - works in tandem with extremely low permeability to prolong effective working life. Compatibility - aligns performance closer than ever before, to that of host concrete. User friendly - specifically developed to provide an easy-to-apply product, suitable for local conditions. Definable performance - positive benefits are easily demonstrated via a single, simple measurement. Description

Renderoc SXtra*

Renderoc SXtra is supplied as a ready to use blend of dry powders, which requires only the addition of clean water to produce a highly consistent repair mortar suitable for most structural and loadbearing repairs.

Test method

Typical result

Dimensional Stability Technology is a major step forward in the general compatibility of repair mortar systems with the host substrate, and the control of drying shrinkage in particular. Attention to the basic design criteria given below should ensure that the full benefits of this technology are gained in use : (i) Recommended limits for a single application are: Minimum applied thickness Overhead sections Vertical sections Small pockets or horizontal Maximum length

: : : : :

5 mm up to 25 mm thick up to 35 mm thick up to 100 mm thick up to 3 m

NOTE : If the repair area exceeds 2.5 m2, consideration should be given to the use of mass fill by means of either Renderoc SPXtra* spray applied mortar or Renderoc LAXtra* microconcrete. (ii) In situations where a substrate/repair barrier is required, or enhanced bond strength/working time is required, or where the substrate is likely to be damp (e.g. seawalls, quays etc.), Nitobond EP epoxy bonding agent should be used. (iii) Water addition = 3.0 litres per 20 kg bag Under no circumstances should part bags be used or additional water be employed. Either of these two actions will adversely affect material performance, automatically invalidating Fosroc’s standard product guarantee.

Renderoc SXtra* Galvanic Protection of repairs

Storage

It is likely that, steel reinforcement in the area around a patch repair, particularly in a chloride contaminated environment, will typically corrode after the repairs are carried out, referred to as the incipient anode or Halo effect.

Shelf life

Galvashield XP* † (eXtra Protection) anodes can be incorporated into patch repairs to galvanically protect steel reinforcement against corrosion in the adjacent concrete and may also be used in new construction to provide Cathodic Prevention. Galvashield XP are zinc based anodes encased in a highly alkaline mortar which maintains the surface of the zinc in an active state. Galvanic systems are self regulating and demand based and will start working only when corrosion of steel begins. Refer to product datasheet for further details.

Renderoc SXtra has a shelf life of 12 months; if kept in a dry environment, in its original, unopened packing. If stored in conditions of high humidity and/or temperature, the shelf life may be reduced to as little as 4 months. Standards compliance Renderoc SXtra repair mortar system complies with the following international standards : ASTM C157-93 : DIN 1048 Part 5 : BS 1881 Pt.121 :

Instructions for use

Precautions

Renderoc SXtra should be mixed and applied in strict accordance with the Product Method Statement, a copy of which may be obtained from your nearest Fosroc office.

Health and safety

Estimating

:

20 kg bags

Yield Renderoc SXtra

:

10.9 litresper 20 kg bag

Limitations -

Renderoc SXtra should not be used when the ambient temperature is below 50C and falling.

-

Renderoc SXtra should not be part mixed, nor part bags used.

-

Renderoc SXtra contains cement powders which, when mixed with water or upon becoming damp, release alkalis which can be harmful to the skin. During use, avoid inhalation of the dust and contact with the skin or eyes. Wear suitable protective clothing - eye protection, gloves and respiratory equipment (particularly in confined spaces).

Supply Renderoc SXtra

Test for drying shrinkage Test for permeability Test for water absorption

Renderoc SXtra should not be exposed to running water either during application or prior to final set. Water ponding is not recommended for curing.

The use of barrier creams to provide additional skin protection is also advised. In case of contact with the skin, rinse with plenty of clean water, then cleanse thoroughly with soap and water. In case of contact with eyes, rinse immediately with plenty of clean water and seek medical advice. If swallowed seek medical attention immediately - do not induce vomiting. Fire Renderoc SXtra, is non-flammable and presents no fire hazard. For further information, please refer to the respective Product Material Safety Data Sheet for Renderoc SXtra. * Denotes the trademark of Fosroc International Limited †

Important note


Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply of Goods and Service

Al Gurg Fosroc LLC


fax: (+9714) 2859649


Regional offices

Post Box 657, Dubai United Arab Emirates

Dubai, Al Gurg Fosroc

telephone: 285 8787

fax: 285 2023

Abu Dhabi, Al Gurg Fosroc Bahrain, YBA Kanoo


fax: 673 1449 fax: 17732828


www.fosroc.com


telephone: 4817618 telephone: 771 5080 telephone: 413628

fax: 4832124 fax: 771 7554 fax: 440812


UAE/0252/04/G

Nitocote PE135*


Eco friendly, protective coating based on hydrophobic polyester resin Uses Provides a highly effective protective coating, with chemical and abrasion resistance to prevent corrosion of concrete substrates and exhibits cost and labour saving supplementary benefits. It can be used in a wide range of applications : ! Suitable for underground protection, foundations etc.

Properties Specific gravity (20°C) Solids content by weight Solids content by volume (ASTM D2697) Surface drying time (ASTM D1640)

: :

1.28 g/cm3 53%

:

43%

:

35 - 40 min @ 20°C 10 - 15 min @ 35°C 04 - 06 min @ 45°C

:

:

6 3 2 7

:

< 0.2%

:

Nil

:

>1.0 N/mm2

: : : : : : : : : : : :

Excellent Excellent Excellent Excellent Excellent Excellent Excellent Excellent Excellent Excellent Excellent Excellent

! Dual purpose protective coating and curing compound. Advantages

Overcoating time (ASTM D1640)

! Can be applied on damp concrete which is one day old. ! Cost saving, material which can be used as a protective coating and curing compound in a single application. ! Single pack - no component mixing, no wastage, multiple applications from single pack ! Labour saving, single component material which is also water based, and therefore non-toxic.

Complete cure Water absorption (BS 1881 Pt. 122) Water permeability (BS EN 12390,: Part 8) Adhesion strength (ASTM D4541)

- 7 hours @ 20°C - 4 hours @ 35°C - 3 hours @ 45°C days @ 25°C

! UV stable - will not fade or deteriorate in strong sunlight. ! Environmentally friendly, solvent, pitch and asbestos free and can be used in confined spaces. ! Excellent service life - resistant to chloride and sulphate ions plus a wide range of chemicals. ! Durable finish - offers good abrasion resistance. Standards compliance Nitocote PE135 complies with the concrete curing requirements of ASTM C309, when applied at the rate of 5m2 per litre. Description Nitocote PE135 is a single component, high performance, grey colour viscous liquid coating based on hydrophobic polyester resin. It is totally free from hazardous materials/ carcinogens such as coal tar pitch, hydrocarbon based solvents, aromatic amines etc. The coating displays its protective properties at a minium DFT of 200 microns.

Nitocote PE135*

Specification Where shown on the contract documents, below ground surfaces shall be protected with two coats of Nitocote PE135, a ` hydrophobic polyester emulsion coating applied at a rate of 400-500 microns wet film thickness per coat.

Chemical resistance Lactic acid 20% Acetic acid 20% Nitric acid 5% Ethylene glycol 40% Copper Sulphate 25% Zinc Sulphate 25% Magnesium Sulphate 25% Tap water Sea water Ground water High sulphate water Distilled water

For resistance to other chemical, consult the local Fosroc representative.

Nitocote PE135* Instructions for use Surface preparation

Estimating

All surfaces must be clean and free from laitence, dirt, dust, oil and grease. In case of porous substrates, pre-soak the surface with potable water for 30 minutes. Ensure excess water is removed prior to application of Nitomortar PE135. Application

Supply Nitocote PE135

:

20 litre pails

General use

:

Curing compound

:

2.5m² per litre @ 400 micron wft/coat (2 coat application recommended) (actual coverage rates will depend upon substrate porosity) 5m2 per litre per coat to give 200 micron wft

Theoretical coverage

Nitocote PE135 should be applied by roller to prepared surfaces. Stir well before use, replace lid when not in use. Soak up any spillage with water and wash down immediately. Vertical applications can be achieved by single coat application upto a maximum wft of 600 microns per coat. For multiple coat application, the second coat should be applied at right angles to the first within the stated overcoating times. All applications should be continued up verticals to the existing damp proof course. Ensure that the coating is not damaged during subsequent applications.

Storage Nitocote PE135 will have a minimum shelf life of 12 months if stored in normal warehouse conditions at less than 25°C.

Repairs

Health and safety

Any damaged areas can be readily overcoated to restore the membrane continuity. The surface is to be properly prepared using emery cloth to rub down the surface to provide a key and is to be made dust free, prior to product application.

Some people are sensitive to resins and solvents, so gloves and barrier creams (e.g. Kerodex Antisolvent) should be used when handling these products. Remove any contamination from the skin with soap and water, or resin removing creams (e.g. Kerocleanse Standard Grade Skin Cleaner) followed by washing with soap and water. Do not use solvent.

Cleaning Nitocote PE135 can be removed using only clean water, whilst still damp. If left to dry, then use a scourer. Limitations -

Application should not commence below 10°C or above 50°C.

-

Do not apply on running or standing water or when there are chances of rain.

-

Exposure to chemicals may result in slight colour change over time.

The use of goggles is also recommended, but should accidental eye contamination occur, wash thoroughly with plenty of clean water and seek medical treatment immediately.

* Denotes the trademark of Fosroc International Limited †


Important note

Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply of Goods and Service. All Fosroc datasheets are updated on a regular basis. It is the user’s responsibility to obtain the recent version. Refer to www.fosroc.com.

Al Gurg Fosroc LLC Post Box 657, Dubai United Arab Emirates

www.fosroc.com


fax: (+9714) 2859649


Regional offices Abu Dhabi, Al Gurg Fosroc Bahrain, YBA Kanoo


fax: 673 1449 fax: 17732828

email: [email protected] email: [email protected]


telephone: 4817618 telephone: 24815080 telephone: 4500607

fax: 4832124 fax: 24817554 fax: 4500543


UAE/0429/07/C

CONCRETE REPAIR LOG S.NO

AREA

GRID

SIGNATURE CRACKS REPAIRED DATEGAMA LINDE

QSGTL PEARL PROJECT C2 ASU Construction Works FORM NO: GAM-QCR-QAC-GTL-010

INSPECTION FORM FOR CONCRETE HONEYCOMBS &CRACKS

ITP : GAM-QCR-QAC-GTLDate:

INSPECTION FORM FOR CONCRETE HONEY COMBS&CRACKS DRAWING & REVISION No. TYPE OF STRUCTURE : LOCATION : No :

ITEM 1.

DETAIL OF ACTIVITY

COMPLIANCE YES NO NA

REMARKS

HONEY COMBS 1. a. Removal of unwanted concrete 1.b. Preparing of concrete with bond 1.c. Curing 1.d. Finishing

2.

CRACKS. a) Preparation of V cut if applicable b) Injection of Repair Solution OR mortar c) Curing. d) Finishing.

Comments: ORGANIZATIONS

DATE

NAME

SIGNATURE

GAMA REP LINDE REP QSGTL REP

Page 1 of 1

011-METHOD STATEMENT FOR REPAIR OF CONCRETE WORKS.pdf

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