MD1-0-T-052-05-00138-A

FOR INFORMATION INFORMATION

A

12.Sep.2012

Issue for information

REV.

DATE

DESCRIPTION DESCRIPTI ON

H.M.Kim

S.H.Kim

DSGN

CHKD

Son.Joon

APPD

PROJECT :

TWO(2) x 500 MW MONG DUONG 1 THERMAL POWER POWER PLANT EMPLOYER :

The repair material is not suitable for structural repairs. The document title should be Method Statement for non structural concrete repair.

CONSULTANT CONSULTANT :

CONTRACTOR :

DESIGNED BY

H.M. Kim CHECKED BY

S.H. Kim APPROVED BY

Son Joon

DATE

TITLE :

12, Sep, 2012 DATE

Method Statement for Concrete Repair Works

12, Sep, 2012 DATE DATE

PROJECT NUMBER NUMBER

DOCUMENT NUMBER NUMBER

REV. REV.

12, Sep, 2012

ADB/MD1-TPIP/EPC150911 ADB/MD1-TPIP/EPC15 0911

MD1-0-T-052-05-00138 MD1-0-T-052-05-00138

A

TWO(2) X 500MW Mong Duong 1 Thermal Power Plant Method statement for Concrete Repair Works

TABLE OF CONTENTS

1.

PURPOSE AND SCOPE

2.

REFERENCE

3.

TOOLS AND EQUIPMENT

4. RESPONSIBILITIES

5.

PROCEDURES

6.

ATTACHMENT

i

Rev. A

TWO(2) X 500MW Mong Duong 1 Thermal Power Plant Method statement for Concrete Repair Works 1.0

Rev. A

PURPOSE AND SCOPE This method statement describes the methods to be undertaken during the concrete repair works to ensure that the work is planned and performed in accordance with the specification. This method statement details the materials, methods, tools and equipments required for the concrete repair works.

2.0

REFERENCE Data sheet of

2.1

Sika Refit 2000

2.2

Sika MonoTop 610

2.3

Sika MonoTop 615HB

3.0

TOOLS AND EQUIPMENT

3.1

Mixing equipment (drill fitted with paddle, or drum mixer)

3.2

Minor tools like trowels, floats etc.

3.3

Grinder

3.4

Sand paper

3.5

Jack Hammer

3.6

Chisel

4.0

RESPONSIBILITIES The work will be carried out under the responsibility of Site engineer. Foreman will assist the site engineer in implementation and control of work and associated safety procedures. Safety officer will ensure that all the activities are carried out in accordance with the relevant safety regulations.

1


Rev. A

5.0

PROCEDURES

5.1

Pinholes and minor surface imperfections in the range of 0 – 10 mm

HDEC are required to carry out trial panels of their proposed repair 5.1.1 Surface Preparation: procedure for The surface contamination and laitance shall be removed by wire brushes prior to the application inspection by the SIKA REFIT 2000. The substrate shall be thoroughly soaked with clean water If approximately Owner. the trial is one hour prior to applying the repair. Any residual water shall be removed immediately before the not satisfactory then repair shall be start of repair works. carried out in accordance with 5.1.2 Mixing ERQ 23.3.1.9 Material – SIKA REFIT 2000

Sika Refit 2000 should be mechanically mixed in a clean container using a low-speed electric mixer (max. 500 rpm). Place required quantity of clean water (5.0 ltr for 20kg of Sika Refit 2000) into a clean container and then add Sika Refit 2000 slowly while mixing. A minimum mixing time of 3 minutes is recommended to thoroughly blends the components.

5.1.3 Application Sika Refit 2000 can be applied by trowel or spatula. Work the mixed mortar well into the substrate. Force material against the edge of the repair, working towards the center.

5.1.4 Curing To achieve the full potential of any cement based material, curing is essential. In warm or windy weather, the use of standard curing methods are necessary (use of polyethylene sheets of damp hessian) to prevent premature drying out of mortar.

5.2

Blow hole and surface imperfections more than 10 mm thickenss

According to manufacturers recommendations Sika MonoTop 615HB minimum layer thickness is 5mm. All areas to be treated shall have feathered edges removed by grinding or similar to ensure this minimum thickness.

Material : Sika MonoTop 610 Sika MonoTop 615HB

5.2.1 Surface preparation

All concrete and mortar substrate must be sound, clean and free from oil, grease and surface contaminants. All loose materials and surface laitance must be removed. For large areas, grit or grit-water blasting or scabbling is recommended. For small areas and for “spot” repairs, needle gunning or jack-hammering is effective. The prepared substrate should be thoroughly soaked with clean water until uniformly saturated but with no surface water. This condition is referred to as saturated surface dry and care should be taken to remove any cement slurry or dust produced during surface preparation. Steel 2


Rev. A

reinforcements should have all traces of rust removed and be primed with two coats of Sika MonoTop 610.

5.2.2 Priming -Concrete Prior to the application of Sika MonoTop 615 HB, Sika Monotop 610 should be applied as bonding bridge. Always work “wet on wet” on priming coats (refer to Sika Monotop 610 Data Sheet)

-Reinforcement Two coats of Sika MonoTop 610 should be brush applied to the prepared steel (refer to Sika Monotop 610 Data Sheet)

5.2.3 Mixing Sika MonoTop 615 HB should be mechanically mixed in a clean container using a low-speed electric mixer (max. 500 rpm). Place required quantity of clean water (3.80

–

3.90 ltr for 25kg of

Sika Monotop 615HB) into a clean container and then add Sika MonoTop 615HB slowly while mixing. A minimum mixing time of 3 minutes is recommended to thoroughly blends the components.

5.2.4 Application Brush apply a bonding coat onto the saturated surface dry substrate. Then, working wet-on-wet, work the mixed mortar well into the substrate using a placing rather than a rendering technique to fill all pores and voids. Compact well. Force material against the edge of the repair, working towards the centre. For repairs in excess of 60mm deep, apply in layers with a heavy brush stipple to form a key for subsequent layers. If previous layers are over 48 hours old, needle gun the surface and dampen. Steel trowel the final coat if required.

5.2.5 Curing To achieve the full potential of any cement based material, curing is essential. In warm or windy weather, the use of standard curing methods are necessary (use of polyethylene sheets of damp hessian) to prevent premature drying out of mortar.

6.0

ATTACHMENT

6.1

Sika Refit 2000

6.2

Sika MonoTop 610

6.3

Sika MonoTop 615HB 3

Product Data Sheet Edition 04,2009. Identification no. 3.2.005 Version No. 05 Sika Refit® 2000

®

Sika Refit 2000 Mortar for Cosmetic Concrete Surface Repair and Fairing Coat

n o i t c u r t s n o C

Description

Sika Refit 2000 is one component, polymer modified, cementitious mortar based containing silica fume.

Uses

Sika Refit 2000 is used as repair mortar for minor surface defects on: p

Concrete

p

Mortar

p

Stone

Sika Refit 2000 is a cosmetic mortar designed to eliminate surface defects due to demoulding, pores or honeycombs, and is suitable for small repairs on: p

Precast concrete elements

p

Fair-face concrete

p

Columns and beams

As levelling mortar and fairing coat or finishing skim coat to concrete, mortar patches and screeds. Advantages

Ready to use requiring only the addition of water.

p p

Excellent workability

p

Rapid strength development

p

Good mechanical strength

p

Good adhesion to substrate

p

No corrosive effect on reinforcement steel

p

Non-toxic

Product Data Form/Colour

Powder / Grey

Packaging

20 kg bag

Storage

Dry, cool, shaded place

Shelf life

Min. 6 months if stored properly in unopened, original packaging

1

®

Sika Refit 2000 1/3

Technical Data Density

~ 1.25 kg/ltr (bulk density of powder) ~ 2.05 kg/ltr (density of fresh mortar)

Mixing ratio

Water : Sika Refit 2000 powder = 1 : 4.0 (parts by weight) Water : Sika Refit 2000 powder = 1 : 3.2 (parts by volume) Approx. 5.0 litres of clean water per 20 kg bag

Consumption

1 bag yields approx. 12.2 litres of mortar 3

Approx. 82 bags required for 1 (one) m of mortar o

Pot life

~ 30 minutes (at 27 C / 65 % r.h)

Compressive strength

∼ 6 N/mm (1 day), ASTM C-349

2

2

∼ 40 N/mm (28 days) 2

Flexural strength

∼ 6 N/mm (28 days), ASTM C-348

Bond strength

∼ 1.5 N/mm (on dampened, prepared concrete surface)

Layer thickness per application

Maximum 2 mm

Application temperature

Minimum 6 C

2

o

o

Maximum 40 C

Application Surface preparation

Concrete, mortar and masonry surfaces must be clean, free from grease, oil and loosely adhering particles. Absorbent surfaces have to be thoroughly saturated with water prior application of Sika Refit 2000.

Mixing

Sika Refit 2000 should be mechanically mixed in a clean container using a low-speed electric mixer (max. 500 rpm). Place required quantity of clean water (5.0 ltr for 20-kg of Sika Refit 2000) into a clean container and then add Sika Refit 2000 slowly while mixing. A minimum mixing time of 3 minutes is recommended to thoroughly blends the components.

Application

Sika Refit 2000 can be applied by spatula or trowel. Work the mixed mortar well into the substrate. Force material against the edge of the repair, working towards the center.

Curing

To achieve the full potential of any cement based material, curing is essential. In warm or windy weather, the use of standard curing methods are necessary (use of polyethylene sheets or damp hessian) to prevent premature drying out of mortar.

Cleaning

Remove non-hardened Sika Refit 2000 products from tools and equipment with water. Hardened material can only be removed mechanically.

2

®

Sika Refit 2000 2/3

Health and Safety information Ecology

Do not dispose into waterlines sewers etc.

Trasportation class

Non hazardous

Waste disposal Important notes

According to local law Sika Refit 2000 is cement base and is therefore alkaline. Suitable precautions should be taken to minimize direct contact with the skin. If the material gets into the eyes, rinse immediately with clean water and seek medical attention.

Disclaimer


The information, and, in particular, the recommendations relating to the application and end-use of Sika products, are given in good faith based on Sika’s current knowledge and experience of the products when properly stored, handled and applied under normal conditions in accordance with Sika’s recommendations. In practice, the differences in materials, substrates and actual site conditions are such that no warranty in respect of merchantability or of fitness for a particular purpose, nor any liability arising out of any legal relationship whatsoever, can be inferred either from this information, or from any written rec ommendations, or from any other advice offered. The user of the product must test the product’s suitability for the intended application and purpose. Sika reserves the right to change the properties of its products. The proprietary rights of third parties must be observed. All orders are accepted subject to our current terms of sale and delivery. Users must always refer to the most recent issue of the local Product Data Sheet for the product concerned, copies of which will be supplied on request.

Sika Limited (Vietnam) Nhon Trach 1 Industrial Zone, Nhon Trach Dist., Dong Nai Province Tel: (84-61) 3560 700 Fax: (84-61) 3560 699 www.sika.com.vn, [email protected]

3

®

Sika Refit 2000 3/3

Product Data Sheet Edition 04,2009. Identification no. 3.2.001 Version No. 06 Sika MonoTop® 610

Sika® MonoTop® 610 Bonding Slurry and Reinforcement Corrosion Protection Description

Sika MonoTop 610 is a one component, cementitious, polymer modified mortar containing silica fume and corrosion inhibitors.

Uses


Advantages

As a treatment for preventing continued corrosion of reinforcement in concrete and as a bonding bridge for concrete repair using the Sika MonoTop concrete repair system comprising: p

Sika MonoTop 610 Bonding Slurry and Reinforcement Corrosion Protection

p

Sika MonoTop 615 HB High Build Polymer Modified Repair Mortar

p

Sika MonoTop R High Performance Polymer Modified Repair Mortar

p

One component system requiring only the addition of clean water

p

Easy application with brush, roller or spray

p

Excellent bonding to steel and concrete

p

High impermeability to water and chlorides

p

Moisture insensitive

p

High mechanical strength

p

Non- toxic

p

Alkaline passivation of reinforcement steel

p

Sprayable using wet spray method

p

Containing corrosion inhibitors


Powder / Grey

Packaging

25 kg bag

Storage


Shelf life


1

®

Sika MonoTop 610 1/3



Mixing ratio

Water : Sika Monotop 610 powder = 1 : 4.55 – 5.00

(parts by weight)

Water : Sika Monotop 610 powder = 1 : 3.95 – 4.35

(parts by volume)

5.00 - 5.50 litres of clean water per 25 kg bag Consumption

2

Bonding agent: 1,5 - 2.0 kg/m (depending on the surface structure of the substrate). 2

Reinforcement protection: approximately 2.0 kg/m /coat of 1 mm thick (2 coats are required). o

Pot life

~ 30 minutes (at 27 C / 65 % r.h)


∼ 50 N/mm (28 days) ASTM C-349

Flexural strength

∼ 7 N/mm (28 days) ASTM C-348

Bond strength

∼ 1.5 N/mm (on prepared concrete surface)

Application temperature

Minimum 6 C

2

2

2

o

o

Maximum 40 C

Application Precise and efficient surface preparation is essential to achieve the high adhesive qualities of Sika MonoTop 610. Concrete: All concrete and mortar substrate must be sound, clean and free from oil, grease and surface contaminants. All loose materials and surface laitance must be removed. For large areas, grit or grit-water blasting or scabbling is recommended. For small areas and for “spot” repairs, needle gunning or jack-hammering is effective. The concrete or mortar substrate must have a minimum compressive strength of 20 MPa. If in doubt test with a Concrete Test Hammer. Special care must be taken to ensure that the substrate does not contain any coating, such as a curing membrane, that will prevent the Sika Monotop 610 from penetrating the surface. Steel : Reinforcement must be suitably wire-brushed or water/ grit-blasted to provide a surface free of rust, oil, grease or any other contaminants.

2

®

Sika MonoTop 610 2/3

Mixing

Sika Monotop 610 should be mechanically mixed in a clean container using a low-speed electric mixers (max. 500 rpm). For small quantity or small repair area application, Sika Monotop 610 shall be hand-mixed, this is to ensure “wet on wet” application of subsequent patch repair mortars (either Sika Monotop R or 615 HB) and thus minimizing wastage. Fill sufficient clean water into a small clean container. Add Sika Monotop 610 to the water and mix thoroughly until you obtain a thick “slurry” consistency. Always ensure that there are no lumps in the mix. If a mix has thickened due to delayed application, DO NOT dilute further with water. This should be discarded.

Application

As a bonding slurry: Apply by brush, roller or suitable spraying equipment to the prepared (pre-wetted) substrate. To achieve a good bond Sika Monotop 610 must be rubbed well into substrate, fill all unevenness.


Cleaning

Any following repair mortars have to be applied wet on wet to the bonding slurry. As a reinforcement protection: Apply first layer of approx. 1 mm thickness, using medium hard brush, roller or spray to the cleaned reinforcement. Apply the second layer at identical thickness as soon as the first layer is hardened enough to receive following layer application (waiting time is min. 4 hours at 27 °C). Care should be taken to ensure that the back of the reinforcement is also coated. Following repair mortars can be applied after a similar waiting time. Remove non-hardened Sika Monotop products from tools and equipment with water. Hardened material can only be removed mechanically.


Do not dispose into water or soil.

Transportation Class

Non hazardous

Waste disposal

According to local law

Important notes

Sika Monotop 610 contains cement and is therefore alkaline. Suitable precautions should be taken to minimize direct contact with the skin. Should the material enter the eyes, rinse immediately with clean water and seek medical attention.

Disclaimer

The information, and, in particular, the recommendations relating t o the application and end-use of Sika products, are given in good faith based on Sika’s current knowledge and experience of the products when properly stored, handled and applied under normal conditions in accordance with Sika’s recommendations. In practice, the differences in materials, substrates and actual site conditions are such that no warranty in respect of merchantability or of fitness for a particular purpose, nor any liability arising out of any legal relationship whatsoever, can be inferred either from this information, or from any written recommendations, or from any other advice offered. The user of the product must test the product’s suitability for the intended application and purpose. Sika reserves the right to change the properties of its products. The proprietary rights of third parties must be observed. All orders are accepted subject to our current terms of sale and delivery. Users must always refer to the most recent issue of t he local Product Data Sheet for the product concerned, copies of which will be supplied on request.


3

®

Sika MonoTop 610

3/3

Product Data Sheet Edition 04,2009. Identification no. 3.2.003 Version No. 07 Sika MonoTop® 615 HB

®

®

Sika MonoTop 615 HB High Build Polymer Modified Repair mortar

Description Uses


·Advantages

Sika Monotop 615 HB is a one component, thixotropic, high build, polymer modified, cementitious mortar containing silica fume. p

Fast repair to overhead, horizontal or vertical concrete or mortar surfaces above and below ground level

p

Filling/ repair mortar for voids, honeycombed areas, etc.

p

Repair of spalled concrete caused by reinforcement corrosion

p

Repairs with improved resistance to oils, sewage, chemicals, etc.

p

Fast and easy to apply to clean,sound substrate in layers up to 60 mm thick

p

Excellent thixotropic behaviour, especially suitable for overhead and vertical application

p

One component system requiring only the addition of clean water

p

Compatible with the thermal expansion properties of concrete

p

Chloride free

p

Non-corrosive to reinforcing steel

p

Non-toxic, suitable for potable water

p

Fiber reinforced to prevent micro crack

p

Minimized shrinkage tendency

p

Good sulfate resistance


Powder / Grey

Packaging

25 kg bag

Storage


Shelf life


1

®

Sika MonoTop 615 HB 1/3



Mixing ratio

Water : Sika Monotop 615HB powder = 1 : 6.40 – 6.60 weight)

(parts by

Water : Sika Monotop 615HB powder = 1 : 5.60 – 5.70 volume)

(parts by

3.80 - 3.90 litres of clean water per 25 kg bag Consumption

1 bag yields approx. 16.5 litres of mortar 3

Approx. 60 bags required for 1m of mortar o

Pot life

~ 30 minutes (at 27 C / 65 % r.h)


∼ 6 N/mm (1 day), ASTM C-349

2

2

∼ 30 to 35 N/mm (28 days) 2

Flexural strength

∼ 6 N/mm (28 days), ASTM C-348

Bond strength

∼ 1.5 N/mm (on prepared concrete surface with bonding bridge)

Layer thickness per application

Minimum

2

5 mm

Maximum 60 mm (20-mm for overhead application) Application temperature

o

Minimum 6 C o Maximum 40 C

Application Surface preparation

All concrete and mortar substrate must be sound, clean and free from oil, grease and surface contaminants. All loose materials and surface laitance must be removed. For large areas, grit or grit-water blasting or scabbling is recommended. For small areas and for “spot” repairs, needle gunning or jack-hammering is effective. The concrete or mortar substrate must have a minimum compressive strength of 20 MPa. If in doubt test with a Concrete Test Hammer. The prepared substrate should be thoroughly soaked with clean water until uniformly saturated but with no surface water. This condition is referred to as saturated surface dry and care should be taken to remove any cement slurry or dust produced during surface preparation. Steel reinforcements should have all traces of rust removed and be primed with two coats of Sika Monotop 610.

Priming

Concrete: Prior to the application of Sika Monotop 615 HB, Sika Monotop 610 should be applied as bonding bridge. Always work “wet on wet” on priming coats (refer to Sika Monotop 610 Data Sheet) Reinforcement: Two coats of Sika Monotop 610 should be brush applied to the prepared steel (refer to Sika Monotop 610 Data Sheet).

Mixing

Sika Monotop 615HB should be mechanically mixed in a clean container using a low-speed electric mixer (max. 500 rpm). Place required quantity of clean water (3.80 - 3.90 ltr for 25-kg of Sika Monotop 615HB) into a clean container and then add Sika Monotop 615HB slowly while mixing. A minimum mixing time of 3 minutes is recommended to thoroughly blends the components.

2

®


Application

Brush apply a bonding coat onto the saturated surface dry substrate. Then, working wet-on-wet, work the mixed mortar well into the substrate using a placing rather than a rendering technique to fill all pores and voids. Compact well. Force material against the edge of the repair, working towards the centre. For repairs in excess of 60 mm deep, apply in layers with a heavy brush stipple to form a key for subsequent layers. If previous layers are over 48 hours old, needle gun the surface and dampen. Steel trowel the final coat if required.

Curing

To achieve the full potential of any cement based material, curing is essential. In warm or windy weather, the use of standard curing methods are necessary (use of polyethylene sheets or damp hessian) to prevent premature drying out of mortar.

Cleaning

Remove non-hardened Sika Monotop products from tools and equipment with water. Hardened material can only be removed mechanically.

Notes on application / limits

p

Mix to a uniform consistency (no lumps). A small reduction in the water gives a stiffer mix.

p

Repairs with Sika Monotop system cannot bridge live cracks or moving joints, etc.

p

Repairs in excess of 60 mm deep must be layered as indicated above.

p

Sika Monotop mortars that are wetted during the initial cure period may produce a white “bloom” on the surface which does not affect the long term properties of the mortar.



Product is water poluting do not dispose into water canals ,sewer lines etc.

Transportation class

Non hazardous

Waste disposal

According to local law

Important notes

Sika Monotop 615 HB is cement base and is therefore alkaline. Suitable precautions should be taken to minimize direct contact with t he skin. If the material gets into the eyes, rinse immediately with clean water and seek medical attention.

Disclaimer

The information, and, in particular, the recommendations relating t o the application and end-use of Sika products, are given in good faith based on Sika’s current knowledge and experience of the products when properly stored, handled and applied under normal conditions in accordance with Sika’s recommendations. In practice, the differences in materials, substrates and actual site conditions are such that no warranty in respect of merchantability or of fitness for a particular purpose, nor any liability arising out of any legal relationship whatsoever, can be inferred either from this information, or from any written recommendations, or from any other advice offered. The user of the product must test the product’s suitability for the intended application and purpose. Sika reserves the right to change the properties of its products. The proprietary rights of third parties must be observed. All orders are accepted subject to our current terms of sale and delivery. Users must always refer to the most recent issue of the local Product Data Sheet for the product concerned, copies of which will be supplied on request.


3

®


MD1-0-T-052-05-00138-A

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