Sinohydro Corporation

Lusail Development Construction Package 1 Method Statement for Concrete Repairs

Lusail Development
Construction Package 1

Employer: Qatari Diar Real Estate Investment Company

Method Statement for Concrete Repairs

DOCUMENT REVIEW STATUS

STATUS 1: WORK MAY PROCEED.

STATUS 2: REVISE & RESUBMIT. WORK MAY PROCEED SUBJECT TO INCORPORATION OF

COMMENTS INDICATED.

STATUS 3: REVISE & RESUBMIT. WORK MAY NOT PROCEED.

STATUS 4: REVIEW NOT REQUIRED. WORK MAY PROCEED.

ENGINEER’S REVIEW OF SUBMISSION SHALL NOT RELIEVE THE CONTRACTOR OF HIS

RESPONSIBILITIES UNDER THE CONTRACT.

________________________
HALCROW
Date___________________

LD-CP1-SHC-MS-OW-005 Rev. 1 30-Oct-2010 Page 1 of 14

Sinohydro Corporation
Lusail Development Construction Package 1 Method Statement for Concrete Repairs

Amendment Records

Rev
Date Amendment Record Prepared By Approved By
No.
General revision to incorporate
Artemio T. del
0 20th June 2010 all concrete repair procedures. Li Binghan
Mundo, Jr.
First Version

Revised to incorporate new

th Artemio T. del
1 30 October 2010 repair procedures for major Li Binghan
Mundo, Jr.
concrete defects

Table of Content

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Sinohydro Corporation
Lusail Development Construction Package 1 Method Statement for Concrete Repairs

1 Purpose 4

2 Reference Document 4

3 Organization Chart and Responsibility 4

4 Construction Arrangement 5

5 Repair Methodology 6

6 Measure and Plan for Safety and Health 10

7 Measure And Plan for Environment Protection 13

8 Quality Plan 13

9 Appendix 13

1 Purpose

This Method Statement defines the methods required to execute concrete repairs at CP1 &
supersedes the following document:
 Doc. No. LD-CP1-SHC-MS-CR-001 Rev. 3 “Method Statement for Concrete Repairs”

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Sinohydro Corporation
Lusail Development Construction Package 1 Method Statement for Concrete Repairs

&
 Doc. No. LD-CP1-SHC-MS-UT/R-007 Rev. 2 “Proposal for Repairing Cracks on
Concrete Surface”

2 Reference Document

Qatar Construction Specifications (QCS 2002) Section 5 Part 16.7.

3 Organization Chart and Responsibility

A Section Manager, who reports to the Construction Manager, will be in-

charge of the concrete repair works. He will coordinate with all concerned parties
and ensure site repair works in time and with proper quality.

A Section Engineer, who reports to the Section Manager, will be in-charge of

the concrete repairs quality.

A Quality Control Manager, who reports to the Technical Manager, will be in-
charge of the concrete repairs quality control.

A Quality Assurance Manager, who reports to the Project Manager and

Sinohydro Head Office shall organize preparation and amendments or changes in
QAP and other QM system documents and supervises their implementation and
manages document control system of the project.

A Safety Officer ，who reports to the Safety and Health Manager, will be in-
charge of the concrete repairs site safety & health.

Their contact telephone numbers are enumerated hereunder:

S/N Name Position Mobile

1 Pan Jiliang Construction Manager 5636816

2 Wang Wei Section Manager 6094887

3 Zhu Jingping Site Engineer 5035519

4 Artemio T. del Mundo, Quality Control Manager (QC) 5153175

Jr.
5 Zhang Shuo Deputy Quality Assurance Manager (QA) 6574881

6 Tommy Safety and Health Manager 5699208

7 Kamal Safety Engineer 6739709

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Lusail Development Construction Package 1 Method Statement for Concrete Repairs

4 Error: Reference source not foundConstruction Arrangement

4.1 Materials
 Nitomortar FC(B) - Approval Ref. No. GQ626/CP1/54/ad/0371
 Conbextra GP - Approval Ref. No. GQ/626/CP1/54/ba/1825
 Nitofill EPLV - Approval Ref. No. GQ626/CP1/54/ba/6622
 Renderoc SPXtra - Approval awaited
 Nitobond AR - Approval awaited
 Concure A- Approval awaited
 Renderoc BF2 - Approval awaited
4.2 Other Materials
 Potable water
 Hessian
 Plastic Sheets
4.3 Equipments
 Wire Brush
 Grout Mixer
 Steel Trowel/Scraper
 Electric Chisel
 Disk Cutter
 Hand-held Hammer & Chisel
 Grinder
 Air compressor

5 Repair Methodology

5.1 Blow Holes

In accordance with Particular Specifications (Rev. 3 dated Apr-09) Section 5 Part 16
Clause 16.7, blowholes up to 15mm deep & 25mm x 25mm in dimension for buried
concrete shall be acceptable & will not be repaired. For exposed surfaces, blowholes
15mm deep & 15mm x 15mm in dimension shall also be acceptable & will not
require remedial action.

Surface Preparation: Concrete surface should be clean, dry & free from laitance.
All blow holes should be ‘opened up’ to avoid the creation of air pockets. Wire
brushing shall be applied as necessary.

Mixing: The hardener and base components of Nitomortar FC(B) should be

stirred thoroughly in order to disperse any settlement before mixing them together.
The two components should be mixed together in a 1:1 ratio by volume, until a
uniform consistency and grey colour is achieved.

Application: After mixing, material can be taken directly from the can, or

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Lusail Development Construction Package 1 Method Statement for Concrete Repairs

subdivided onto spot boards for individual applicators. Applications shall be done
using trowel, scraper or filling knife to a satisfactory surface finish. Nitomortar FC(B)
can be overcoated with all epoxy coatings after a minimum curing period of 24
hours. Prior to overcoating, the fully cured surface should be dust-free. Curing shall
be performed by regularly spraying water &/or covering with wet hessian.

5.2 Honeycombs (Vertical & Overhead Surfaces)

In accordance with Particular Specifications (Rev. 3 dated Apr-09) Section 5 Part 16

Clause 16.7 (copy attached), honeycombs up to 15mm deep & 25mm x 25mm in
dimension for buried concrete shall be acceptable & will not be repaired. For
exposed surfaces, honeycombs 15mm deep & 15mm x 15mm in dimension shall
also be acceptable & will not require remedial action.

Surface Preparation: Defective areas shall be chipped down to sound substrate.

Prepared sections up to 10mm in depth shall be repaired using Nitomortar FC(B).

Concrete surfaces should be clean, dry, free from laitance & loosely adhering
particles. Wire brushing shall be used as necessary.

Mixing: The hardener and base components of Nitomortar FC(B) should be

stirred thoroughly in order to disperse any settlement before mixing them together.
The two components should be mixed together in a 1:1 ratio by volume, until a
uniform consistency and grey colour is achieved.

Application: Prepared surfaces shall be reprofiled using the mixed material until
satisfactory surface finish is achieved using steel trowel or scraper. Curing shall be
performed by regularly spraying water &/or covering with wet hessian.

Prepared sections deeper than 10mm shall be repaired using Renderoc SPXtra. All
contaminated, damaged or loose concrete shall be removed up to the pre-cut edge
of the repair. Where reinforcements are visible, chipping shall be made up to at
least 20mm behind the reinforcements to ensure adequate bonding. Edges of the
section shall be roughened to provide a good mechanical key at the substrate
interface. All exposed reinforcements shall be wire brushed to completely remove all
loose rust. This shall be followed by water blasting to completely remove laitance,
by-products of corrosion & other contaminants.

Substrate Priming: Prepared surfaces shall be primed using Nitobond AR acrylic

resin-based concrete bonding agent. It must be scrubbed well into the surface using
a nylon brush.

Mixing: Only full bag mixing is permissible. Part mixing & addition of water to
mixed material to prolong workability is not allowed. Renderoc SPXtra shall be
thoroughly mixed & the temperature of the mixed material shall not exceed 30 oC.

25kg. bag of Renderoc SPXtra shall be added to 4.25 to 4.5 liters of cool potable
water & mixing shall be done for 3 to 5 minutes until the mix is fully homogenous
using drill & paddle or forced action mixer.

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Lusail Development Construction Package 1 Method Statement for Concrete Repairs

Application: The repair mortar shall be applied when the bonding agent becomes
tacky, which may take 5 to 15 minutes depending on the ambient temperature. The
repair mortar shall not be applied when the bonding agent is wet.

Mixed Renderoc SPXtra shall be applied by trowel or gloved hand, thoroughly

compacting onto the primed substrate, while the primer is still tacky, & around any
exposed reinforcement. On sections having reinforcement congestion, the mixed
material shall first be filled behind the reinforcement with gloved hand. If sagging
occurs on vertical & overhead surfaces, the applied Renderoc SPXtra shall be
completely removed. The substrate must then be reprimed & Renderoc SPXtra
reapplied in layers of reduced thickness. After initial setting, the intermediate layers
should be scratched-keyed & applied Nitobond AR bonding agent prior to application
of the next layer of the repair material.

Repaired surfaces shall be finished by striking off with a straightedge & closing with
a steel or plastic float. Water can be drawn to the surface if overworking with the
float occurs & an unsightly finish may result. Damp sponges or plastic floats may be
used to achieve desired surface texture, but care shall be taken not to overwork the
surface.

After completion of finishing, the repaired section shall be applied Concure A curing
compound by spray or roller. In adverse weather conditions (e.g. wind conditions or
ambient temperature >30oC), supplementary curing in the form of polythene
sheeting, taped down at the edges, should be used.

If a smooth & non-porous finish is desired, a skim coat of Renderoc BF2 shall be
applied which does not require any curing.

5.3 Protruding Tie Rods

Surface Preparation: Circumference of protruding tie rods shall be chipped using

Electric Chisel up to a diameter of 150mm and depth of 50mm or until the tie rods
can be cut at the base using disk cutter of appropriate size. The prepared substrate
shall be free of oil, grease or any loosely adherent material & shall be sprayed with
water prior to repair materials application.

Mixing: Conbextra GP shall be mixed to a trowellable consistency (3.4 to 3.6

liters of water per 25 kg. bag) preferably using a mechanically powered grout mixer.

Application: Prepared surfaces shall be free of standing water & shall be filled &
reprofiled using the mixed material until satisfactory surface finish is achieved using
steel trowel. Curing shall be performed by regularly spraying water &/or covering
with wet hessian.

5.4 Unsatisfactory/Irregular/Uneven Concrete Surfaces

Surface Preparation: Defective areas shall be chipped down to sound substrate.

Prepared sections up to 10mm in depth shall be repaired using Nitomortar FC(B).

Concrete surfaces should be clean, dry & free from laitance & loosely adhering

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Lusail Development Construction Package 1 Method Statement for Concrete Repairs

particles. Wire brushing shall be used as necessary.

Mixing: The hardener and base components of Nitomortar FC(B) should be

stirred thoroughly in order to disperse any settlement before mixing them together.
The two components should be mixed together in a 1:1ratio by volume, until a
uniform consistency and grey colour is achieved.

Application: Prepared surfaces shall be reprofiled using the mixed material until
satisfactory surface finish & alignment is achieved using steel trowel or scraper.
Curing shall be performed by regularly spraying water &/or covering with wet
hessian.

Prepared sections deeper than 10mm shall be repaired using Renderoc SPXtra. All
contaminated, damaged or loose concrete shall be removed up to the pre-cut edge
of the repair. Edges of the section shall be roughened to provide a good mechanical
key at the substrate interface. Water blasting shall be applied if necessary, to
completely remove laitance & other contaminants.

Substrate Priming: Prepared surfaces shall be primed using Nitobond AR acrylic

resin-based concrete bonding agent. It must be scrubbed well into the surface using
a nylon brush.

Mixing: Only full bag mixing is permissible. Part mixing & addition of water to
mixed material to prolong workability is not allowed. Renderoc SPXtra shall be
thoroughly mixed & the temperature of the mixed material shall not exceed 30 oC.

25kg. bag of Renderoc SPXtra shall be added to 4.25 to 4.5 liters of cool potable
water & mixing shall be done for 3 to 5 minutes until the mix is fully homogenous
using drill & paddle or forced action mixer.

Application: The repair mortar shall be applied when the bonding agent becomes
tacky, which may take 5 to 15 minutes depending on the ambient temperature. The
repair mortar shall not be applied when the bonding agent is wet.

Mixed Renderoc SPXtra shall be applied by trowel, thoroughly compacting onto the
primed substrate, while the primer is still tacky. If sagging occurs on vertical
surfaces, the applied Renderoc SPXtra shall be completely removed. The substrate
must then be reprimed & Renderoc SPXtra reapplied in layers of reduced thickness.
After initial setting, the intermediate layers should be scratched-keyed & applied
Nitobond AR bonding agent prior to application of the next layer of the repair
material.

Repaired surfaces shall be finished by striking off with a straightedge & closing with
a steel or plastic float. Water can be drawn to the surface if overworking with the
float occurs & an unsightly finish may result. Damp sponges or plastic floats may be
used to achieve desired surface texture, but care shall be taken not to overwork the
surface.

After completion of finishing, the repaired section shall be applied Concure A curing
compound by spray or roller. In adverse weather conditions (e.g. wind conditions or
ambient temperature >30oC), supplementary curing in the form of polythene

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Lusail Development Construction Package 1 Method Statement for Concrete Repairs

sheeting, taped down at the edges, should be used.

If a smooth & non-porous finish is desired, a skim coat of Renderoc BF2 shall be
applied which does not require any curing.

5.5 Cracks wider than 0.20mm

Verification of the width of cracks shall be conducted through the approved

independent laboratory (Gulf Lab.). No repairs shall be made on cracks up to
0.20mm wide. Cracks wider than 0.20mm shall be repaired through crack injection
using Nitofill EPLV.

Concrete surfaces along the line of the cracks shall be cleaned of dust, unsound or
contaminated material, plaster, oil, paint, grease, corrosion deposits or algae. The
surface shall preferably be prepared using high pressure water jetting & thorough
washing. Wire brushing or other mechanical means shall be applied as necessary to
remove dirt. This shall be followed by applying compressed air to the cracks to
ensure complete removal of all dust & loose particles. Surfaces shall be blown dry.

Holes shall be drilled at suitable interval along the crack length for the insertion of
injection packers. Spacing shall be close enough to ensure that resin will penetrate
along the crack to the next point of injection.

The surface of the cracks between packers shall be sealed with a band of Nitomortar
FC, 30mm to 40mm wide & 2mm to 3mm thick. Applied Nitomortar FC shall be
allowed to adequately cure. This shall be followed by the injection of the mixed
injection resin at a pressure of at least 0.40 MPa (4 bars). Injection shall continue
until the resin appears on the next port.

The hardener & base component of the injection resin shall be mixed thoroughly
until the liquid becomes clear.

Following completion of the injection works, the repaired section shall be allowed to
cure for 24 hours & shall be left undisturbed for this period. Packers shall then be
removed & holes/voids to be made good using Nitomortar FC & allowed to cure.
Surface protrusions of Nitomortar FC shall be ground off.

6 Measure and Plan for Safety and Health

 Personnel engaged with this works shall follow safety and health Plan; Safety &
Health Manager shall arrange one safety person to checking and Monitoring safety
and health.
 To follow Sinohydro Contractor’s Safety and Health management plan, please refer
to Document: Safety and Health Plan Rev.4 (No. LD-CP1-SHC-HSP-0015)

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Lusail Development Construction Package 1 Method Statement for Concrete Repairs
Risk Assessment Register of Work Activities
Task
Persons at
and Hazard Risk Control Measures Risk Owner
Risk
Activity
Concrete Rigid safety barriers shall be erected around all
Repairs Contractors’, excavations to prevent vehicles falling into them.
Vehicles falling Subcontractors Injury, Vehicles shall be kept away from excavations wherever Project/Construction
from the edge of All personnel on Fractures, Cuts, possible. Where vehicles have to tip materials into Manager/s
the excavation this site Bruises excavations, stop blocks to prevent them from over- & Supervisors
Operators running shall be used and a banksman shall be present
before discharging the load.
Contractors’,
Subcontractors Injury, Project/ Construction
Where vehicles have to reverse they shall be controlled
Vehicles reversing All personnel on Fractures, Cuts, Manager/s
by properly trained banksman
this site Bruises & Supervisors
Operators
During the hours of darkness all the excavations and
Contractors’,
other working areas shall be adequately illuminated and
Subcontractors Project/ Construction
Night works and warning lights about the excavation shall be placed to
All personnel on Accidents Manager/s
lighting ensure safety of pedestrians and the vehicular traffic.
this site & Supervisors
Night work hours shall be structured to comply with all
Operators
rules and regulations.
Contractors’,
There should be safe means of access or escape to all
Subcontractors Injury, Project/ Construction
the working areas, above or below ground level. This can
Improper access All personnel on Fractures, Cuts, Manager/s
be a ladder, ramp, stairs and etc. It shall also be kept
this site Bruises & Supervisors
well lit, clear of obstructions and well maintained.
Operators
Steel reinforcement Contractors’, Fractures, Cuts, To minimize cuts from reinforcement bar ends the Project/ Construction
Subcontractors Bruises following shall be supllied.PPE for the required task. Manager/s
All personnel on Suitable strong and flexible leather gloves. When walking & Supervisors
this site on deck care shall be taken to eliminate slipping on wet
Operators surfaces. Sharp edges on ends of steel reinforcement
shall be tuned down.

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Sinohydro Corporation
Lusail Development Construction Package 1 Method Statement for Concrete Repairs

Contractors’, Concrete pump and boom operators should be

Subcontractors competent to safely operate relevant equipment. Project/ Construction
Pump and Boom Fractures, Cuts,
All personnel on Competence is achieved through training and supervision Manager/s
Operation Bruises
this site and should be assessed by testing both theoretical & Supervisors
Operators knowledge and physical operation of the machinery
Contractors’,
The rubber delivery hose should always be checked for
Subcontractors Project/ Construction
Fractures, Cuts, damage prior to being fitted. Care should be taken to
Concrete Pouring All personnel on Manager/s
Bruises avoid damage to the hose during use. Use a hose that
this site & Supervisors
has a pressure rating. Always wear PPE.
Operators

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Sinohydro Corporation
Lusail Development Construction Package 1 Method Statement for Concrete Repairs

7 Measure And Plan for Environment Protection

 All employees engaged in this works shall follow the Environment Management Plan
(Doc. No. LD-CP1-SHC-EHC-OC-0135). Environment Manager shall arrange one person
to check and monitor site environment.

8 Quality Plan

8.1 Contractual Requirements

Sinohydro Quality Assurance Plan (Doc. No. LD-CP1-SHC-QAP-001)
8.2 Inspection & Testing
Testing and inspections shall be performed by Sinohydro in accordance with Doc. No. LD-
CP1-SHC-QAP-015 Rev. 1 “Inspection & Testing Program”.

9 Appendix

1. Appendix 1: RFI
2. Appendix 2: Product Data Sheets for Nitomortar FC(B), Conbextra GP, Nitofill EPLV,
Renderoc SPXtra, Nitobond AR, Concure A & Renderoc BF2.

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 Sinohydro Corporation
Lusail Development Construction Package 1 Method Statement for Concrete Repairs

Appendix 1.

Request for Inspection

LUSAIL DEVELOPMENT CONSTRUCTION PACKAGE 1
RFI Number

LD-CP1-SHC-ITP-
SINOHYDRO CORPORATION

To Halcrow

Cc

Type of Work

Location

Method with reference to

ITP/drawings

Inspection time Inspection Date

Comments

APPROVED Yes No

Requested by Received by

Site Engineer/Subcontractor QC Engineer QC Manager Admin Representative

Name: Name: Name: Name:

Signature: Signature: Signature: Signature:

Date: Date: Date: Date:

Company :( ) (SINOHYDRO) (SINOHYDRO) (HALCROW)

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Lusail Development Construction Package 1 Method Statement for Concrete Repairs

Appendix 2

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