method statement for repair concrete - vinaincon
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Total Sheets: 32 sheet
(Including this coversheet)
Subcontractors name : SIC & E
Employer : Nghi Son Refinery and Petrochemical LLC.
Contractor : JGCS Consortium
Zone : Zone - 3
Project name : NSRP Complex Project
Subcontract No. : CNT-6495-BLD3-001
Document Title : METHOD STATEMENT FOR REPAIR CONCRETE
Contractors Doc. No. : VV 3140-002-A-112 Revision No. : 0
Issue Purpose to Contractor (FA, FC) : FA
Review Result Sticker (Filled By JGCS)
RESULT CODE : A, B, R, F ( )
NEXT STATUS: FA, FC ( )
Re-submission Date: ( )
Responsible Dept./ Person ( )
Construction HSSE QC
Checked By (Name, sign):
Result code
Date
( ) (
)
( )
( ) (
)
( )
( ) (
)
( )
Approved By (Name, sign):
A: Approved without Comment; B: Approved with Comments
R: Not Approved ; F: Not Subject to Review
Issue Purpose Sticker
Issue Purpose to Employer : FA, FR, FI, FC ( FR )
Document Class: Z, X, Others ( X )
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NGHI SON REFINERY AND PETROCHEMICAL PROJECT SI C& E
Title: Method Statement for Repair Concrete Contractor Doc. No.
VV3140-002-A-112 Rev:0
Page 1 of 31
METHOD STATEMENT FOR
REPAIR CONCRETE
(Document Class: X)
Issue Purpose For Approval
Rev Date Page Description Prepd Chkd Appd
0 10/Oct/2014 All For Approval N.D.T P.H.A K.H.I
Operation Centre JOB Code : Operation Center Doc. No.
Responsible Company
SIC&E
Prepared by
Nguyen Duc TOAN
Checked by
Phan Hoang ANH
Approved by
Kim Huyn II
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NGHI SON REFINERY AND PETROCHEMICAL PROJECT SI C& E
Title: Method Statement for Repair Concrete Contractor Doc. No.
VV3140-002-A-112 Rev:0
Page 2 of 31
Contents
1. PURPOS E ............................................................................................................................................................................ 3
2. SCOPE OF WORKS ......................................................................................................................................................... 3
3. REFERENCE DOCUMENTS. ...................................................................................................................................... 3
4. MACHINERY AND EQUIPMENT. ............................................................................................................................ 3
5. RESPONS IBILITIES ....................................................................................................................................................... 4
6. PROCEDURE AND S EQUENCE ................................................................................................................................ 4
7. ENVIRONMENTAL, HEALTH AND SAFETY (EHS ) ......................................................................................... 7
8. INFORMATION ABOUT PRODUCT........................................................................................................................ 8
9. RIS K ASS ESSMENT FOR SAFETY AND ENVIRONMENTAL ISSUES .................................................. 26
10. JOB SAFETY ANNALYS IS ....................................................................................................................................... 30
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NGHI SON REFINERY AND PETROCHEMICAL PROJECT SI C& E
Title: Method Statement for Repair Concrete Contractor Doc. No.
VV3140-002-A-112 Rev:0
Page 3 of 31
1. PURPOSE
The objectives of this method statement is to describe a work explanation of the method to
be carried out during an execution stage of Concrete Repair Works, to ensure that during the
entire execution stage the work is done in line with good engineering practices and is
compliance with engineering standard practices national & local codes. Also it shows the site
management control and safety procedure.
2. SCOPE OF WORKS
This method statement outline the general requirements of concrete repair works for
minor, Specification for concrete repair works of which the method of monitoring will be
included, all incidentals necessary to complete the entire works.
This is also describes details of EHS Requirement, Equipments, Materials
3. REFERENCE DOCUMENTS.
Issued For Construction Drawings
Approved Contract Quantity Plan.
Project HSSE Management Plan.
4. MACHINERY AND EQUIPMENT.
Prior to using any machineries/ equipment at site it will be inspected and certified by
qualified person.
Periodic Preventive Maintenance will be made on all equipment and machineries.
Estimated machinery and equipment.
1. Chipping hammer, Concrete cutting machine, grinder
2. Bucket
3. Air compressor or broom
4. Trowel
5. Jack hammer
6. Scrabbler
7. Hand Tools
8. Chisel
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NGHI SON REFINERY AND PETROCHEMICAL PROJECT SI C& E
Title: Method Statement for Repair Concrete Contractor Doc. No.
VV3140-002-A-112 Rev:0
Page 4 of 31
5. RESPONSIBILITIES
It is overall responsibility of Project Manager to organize resources prior to perform
construction activities as per project specification in compliance with quality,
schedule & safety requirements.
It is the responsibility of Construction Manager/Site Manager that construction
activities are executed according to the relevant project specification in compliance
with quality, schedule & safety requirements.
EHS Manager will ensure coordination with Site Engineer that all
measures/construction taken shall be maintained till completion of job
The QC Inspector will ensure that the works is executed according to the project
requirements and dossier are fulfilled.
6. PROCEDURE AND SEQUENCE
6.1 Procedure for inspection:
Nos Item CODE FOR INSPECTION
SIC&E JGCS IPMT
1 Making areas to repair I W IW
2 Prepairation of surface and Material
I W IW
3 Repair I
4 Inspection for finish
surface I W IW
6.2 General:
The objective of this method statement is to described how to repair concrete surface, that
is damage to concrete that has cracked, concrete that is honeycombed, fractured, or otherwise
defective shall be repaired in accordance with these requirements. As for the repairing
materials, Sika Monotop 610, Sika Monotop R, Sikadur 732, Pre U-lox will be applied. These
materials effective for repairing defects on concrete surface.
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NGHI SON REFINERY AND PETROCHEMICAL PROJECT SI C& E
Title: Method Statement for Repair Concrete Contractor Doc. No.
VV3140-002-A-112 Rev:0
Page 5 of 31
6.3 Repair method for concrete surface:
The materials are selected for each kind of defect.
For air bubbles and honeycomb: Sika Monotop R, 610 and Pre U-LOX will be applied.
This material is ready to use and requiring only additional water and has enough compressive
strength and bonding strength.
For Crack and cold construction joint up to 30mm in depth: Sika dur 731 will be applied.
For short and small crack on top surface : use cement laitance
These materials are ready to use requiring only additional water and have high
impermeability to water and chlorides and enough compressive strength.
These materials have high compressive and bonding strength.
Materials
Bonding
Strength
Compressive strength (1
days)
Compressive
strength(28 days)
Air Bubble;
Honeycomb
Sika Monotop R 1.5N/mm2 15N/ mm2
1-Sika Monotop 610
1.5N/mm2 50N/mm2
Pre U-LOX 37N/mm2 67N/ mm2
Crack and cold
joint Sikadur 731
10N/mm2
(at 14days)
Mix proportion of repairing material is following as below.
Mix Proportion
Material name Sika/ Pre-U LOX Materials (kg)
Water (ltr)
Air Bubble Rough CJ
Honeycomb
Sika Monotop R 1199 163
Sika Monotop 610 25kg 5.25
Pre U-LOX 25kg 4.5
Crack and cold joint Sikadur 731 Mix component A and B
Cement laitance Cement: 1kg 2
6.2.1 Air Bubble, Honeycomb :
a,) Material
Sika Monotop R
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NGHI SON REFINERY AND PETROCHEMICAL PROJECT SI C& E
Title: Method Statement for Repair Concrete Contractor Doc. No.
VV3140-002-A-112 Rev:0
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-This material is one component, polymer modified, cementations mortar containing silica
fume.
Sika Monotop 610 is one component, cementations, polymer modified mortar containing
silica fume and corrosion inhibitors.
And Pre U-LOX: cementitous non-shrink grout.
b.) Equipment and tools
-Drilling machine (500rpm) with two armed drilling bit, bucket rug, brush and trowel.
- Trowel.
c.) Preparation.
-Use broom and rug to remove surface dust, water and loosely adhering particles at concrete
surface.
-Above areas shall be cleaned using air compressor.
d.) Application
-Chipping loose concrete.
-All damaged deteriorated, loosened or unbounded portions of existing concrete shall first be
removed with approved method and equipment, after which the surface of existing concrete
shall be prepared to remove any micro fractured surfaces resulting from the initial removal
process.
-Wet the substrate.
-Wipe away excess water.
- Mixing of Sika Monotop repair mortar with water (content follows manufacture)
- Or mixing Pre-u LOT with water (content follows manufacture)
-Press firmly the repair mortar into the repair using a trowel.
-Sika monotop R can be applied by trowel
-The surface shall be finished with wooden or PVC trowel and close the surface using a steel
float.
-Do not spray additional water over the surface.
6.2.2 Crack and Cold construction joint:
a.) Material
-For surfaces with crack and Col CJ up to 30mm in depth Sikadur 731 will be applied.
Sikadur 731 is thixotropic 2-component adhesive and repair motar.
b.) Equipment and tools
-Bucket, clean rug, brush, trowel,
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NGHI SON REFINERY AND PETROCHEMICAL PROJECT SI C& E
Title: Method Statement for Repair Concrete Contractor Doc. No.
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- Concrete cutting Machine
c.) Preparation
-Mark out all of the crack, cold CJ areas of concrete to be removed.
- Cut thickness up to 3cm
-The concrete surfaces to be repaired must be free from dust, loose of friable materials,
surface contaminants and any other materials which could reduce the bond of the repair
materials.
-Prepair all cracks before mixing the material
d.) Application
Use Concrete cutting machine to V-cut crack surface.
Use broom to make clean
Mix Sikadur 731 component A and B and fill V-cut follow instruction of manufacture.
6.2.3 Cement laitance
Mix cement and water follow mix and put it in crack.
7. ENVIRONMENTAL, HEALTH AND SAFETY (EHS)
a) Safety Manager:
- Organizing and managing to follow the safety plan which made by contractor.
- To oversight the safety matters with respect to control.
- To ensure observing of safety rules.
- To plan of work organization, observe and approve the method with respect to safety during
prior to construction.
b) Responsibilities and instructions:
- The safety member is in charge of safety supervising and monitoring operation activities at
site together with Safety Manager.
- Taking prevention measures and ensuring safety and stability of all items at site, which are
under construction.
- To observing the procedure and requirement at work location
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Title: Method Statement for Repair Concrete Contractor Doc. No.
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Ensure all supervisors and workers are informed of all safety requirements and
responsibilities and comply with requirement.
- Safety training should be conducted to all personal assigned at site prior to commence any
work.
- Carry-out daily tool box and safety talks.
- Personal Protective Equipment (PPE) shall be worn all times.
- Good housekeeping shall be observed in work areas.
- Construction wastes shall be segregated and disposed to an approved dump yard area.
- Perimeter safety barricade is required to avoid accidents and should be at least 1 m away
from the execution line.
- Proper inspection of all requirements prior to use to avoid leakage and equipment failure.
- Permit to work shall be obtained appropriately for the type of work and location.
c) Safety (PPE)
- Safety helmets (for all personnel present at site)
- Safety Shoes (for all personnel present at site)
- Gloves
- Safety goggles
- Dust Mask
- Reflective Vest
- Fire extinguisher
- Body protective gear
d) First Aid Facilities
- First aid facility is always made available during working hours by a qualified first aiders.
8. INFORMATION ABOUT PRODUCT
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Check the crack
Repair by V-cut and fill with Sikadur 731
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NGHI SON REFINERY AND PETROCHEMICAL PROJECT SI C& E
Title: Method Statement for Repair Concrete Contractor Doc. No.
VV3140-002-A-112 Rev:0
Page 26 of 31
9. RISK ASSESSMENT FOR SAFETY AND ENVIRONMENTAL ISSUES
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NGHI SON REFINERY AND PETROCHEMICAL PROJECT SI C& E
Title: Method Statement for Repair Concrete Contractor Doc. No.
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Item Description
of Job List of Hazard
Base Risk (Without Control) Pre-cautions / Preventive measures
Residual Risk (with Control)
L S Risk L S Risk
1
Equipment/ Tools and Material
Preparation
1.1 Injury by using hand
tools and both manual and power drive
3 5 S
1.1a Be operated only by workers who have been authorized and given appropriate training. 1.1b Daily checklist of equipment must be
provided prior to start any work. 1.1c Safety operating procedure should be
established and used for all tools and equipment. 1.1d Every power driven tools should be provided with adequate means, immediately
accessible and readily identifiable by operator, of stopping it quickly and preventing it from being started again inadvertently.
2 2 T
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NGHI SON REFINERY AND PETROCHEMICAL PROJECT SI C& E
Title: Method Statement for Repair Concrete Contractor Doc. No.
VV3140-002-A-112 Rev:0
Page 28 of 31
1.2 Electric shock due to without ground external box and circuit breakers
4 5 U
1.2a Provide adequate ground and circuit breakers
1.2b Must use 3 core codes electric wire and separate distribution panel (must pass arrangement of ELCB) and avoid any water
affect. 1.2c All kind of electric cable must be hang over ground.
1.2d Must use industrial socket and plug.
2 2 T
2
During
Carrying out Repair
Works
2.1 Use interior quality/
electric tools with faulty wirings/ insulation
4 5 U
2.1a Use them only for the purpose for which
they are designed. 2.1b Keep them in a safe working condition. Defective tools must not be used.
2.1c Keep them clean, frequently checked and well maintained. Defective parts must be
replaced. Cutting edges must be kept sharp.
3 3 M
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NGHI SON REFINERY AND PETROCHEMICAL PROJECT SI C& E
Title: Method Statement for Repair Concrete Contractor Doc. No.
VV3140-002-A-112 Rev:0
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2.2 Improper use of tools
(i.e use of screw driver as crow bar/ length of a pipe as an extra lever for a
spanner.
3 3 M
2.2a The correct use of portable tools is primarily
a matter for a individual user. 2.2b Be protected against damage from dirt, oil,
water etc. 2.2c Not be used when there is any detectable flammable gas in the area.
2.2d Wear appropriate PPE (e,g. safety goggles when using abrasive wheels and power sanders. Full face protector is used.
2 2 T
2.3 Injury by hand tools. 3 4 S
2.3a Proper working platform available for carrying out repair works. 2.3b Proper use of tools.
2 3 M
3
Mixing and
application of concrete
Mortar
3.1 Accident and skin irritation due to not
wearing safety helmet, gloves and safety shoes.
3
3 M
3.1 Wear always PPE like Safety helmets, gloves and safety shoes.
2 2 T
3.2 Falling due to without safety measures on filling
and application of concrete mortars
2 4 S
3.2 Placing based on plan and order. Check for all the process by supervisor.
1 3 T
3.3 Mixed concrete mortar splashes into the eyes and
skin
3 3 M
3.3 Always wear safety PPE at all times.
2 2 T
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Title: Method Statement for Repair Concrete Contractor Doc. No.
VV3140-002-A-112 Rev:0
Page 30 of 31
10. JOB SAFETY ANNALYSIS
List of All Job Steps List of All Known Hazards How to Eliminate Hazards
1. Equipment/ Tools and Material
Preparation
1.1 Injury by using hand tools and both manual
and power driven
1.2 Electric shock due to without ground external box and circuit breakers
1.1a Be operated only by workers who have been
authorized and given appropriate training. 1.1b Daily checklist of equipment must be provided prior to start any work.
1.1c Safety operating procedure should be established and used for all tools and equipment.
1.1d Every power driven tools should be provided with adequate means, immediately accessible and readily identifiable by operator, of stopping it
quickly and preventing it from being started again inadvertently.
1.2a Provide adequate ground and circuit breakers
1.2b Must use 3 core codes electric wire and separate distribution panel (must pass arrangement of ELCB) and avoid any water
affect. 1.2c All kind of electric cable must be hang over
ground. 1.2d Must use industrial socket and plug.
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NGHI SON REFINERY AND PETROCHEMICAL PROJECT SI C& E
Title: Method Statement for Repair Concrete Contractor Doc. No.
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2. During Carrying out Repair
Works
2.1 Use interior quality/ electric tools with
faulty wirings/ insulation
2.2 Improper use of tools (i.e use of screw
driver as a crow bar/ length of a pipe as an extra lever for spanner.
2.3 Injury by hand tools.
2.1a Use them only for the purpose for which
they are designed. 2.1b Keep them in a safe working condition.
Defective tools must not be used. 2.1c Keep them clean, frequently checked and well maintained. Defective parts must be
replaced. Cutting edges must be sharp.
2.2a The correct use of portable tools is primarily
a matter for a individual user. 2.2b Be protected against damage from dirt, oil,
water etc. 2.2c Not be used when there is any detectable flammable gas in the area.
2.2d Wear appropriate PPE (e.g safety goggles when using abrasive wheels and power sanders.
Full face protector is used. 2.3a Proper working platform available for
carrying out repair works. 2.3b Proper use of tools.
3. Mixing and application of concrete
Mortar
3.1 Accident and skin irritation due to not
wearing helmet, gloves, and safety shoes. 3.2 Falling due to without safety measures on
filling and application of concrete mortars
3.1 Wear always PPE like Safety helmets, gloves
and safety shoes. 3.2 Placing based on plan and order. Check for all
the process by supervisor.
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