Bujagali Energy Limited

Bujagali Hydro-Electric Power Project

Salini Costruttori
Concrete Hollow Blocks Work Method Statement

SUMMARY

1. AIM OF THE DOCUMENT AND FIELD OF APPLICATION

2. REFERENCE DOCUMENT
3. PURPOSE AND DESCRIPTION OF THE HOLLOW CONCRETE BLOCK WORKS
4. RSPOSIBILITIES
5. EQUIPMENT
6. PERMANENT MATERIALS
7. OPERATIVE METHODS AND WORKING PHASES
8. PLANNING OF THE WORKS
9. SAFETY MEASURES
10. ENVIRONMENTAL ASPECTS

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Bujagali Hydro-Electric Power Project

Salini Costruttori
Concrete Hollow Blocks Work Method Statement

1. AIM OF THE DOCUMENT AND FIELD OF APPLICATION

The present Method Statement establishes the type of construction methods and techniques
carried out during the phase of work concerning the masonry blocks placing, floor screed
and wall plastering works, in order to meet the contract requirements.
The present document is applicable to all the permanent works which involve the above
operations within the construction of the Bujagali Hydro-electric Power Project.
2. REFERENCE DOCUMENTS
Quality Control Plan Construction SA-D-GE-QA-1002
Project Procedures SA-D-GE-QA-1003
BS 5628-1 : 19992 on use of masonry
FI-D-GE-SP-0011 Technical Specification for Concrete, Reinforcement and
Formworks
3. PURPOSE AND DESCRIPTION OF THE MASONRY
SCREED AND PLASTERING WORKS

BLOCK , FLOOR

The purpose of:

The masonry block works is to provide external and internal partition/wall
within the floor area for the intended purposes. Concrete Hollow Blocks
produced on site to approved standards are mainly used. The partitions/walls
are basically cladding and non load bearing structures.
The floor screed is to provide level, even and strong surface in some cases
meeting special requirements. The screed shown here is for equipment rooms
such as in Level 1081 of all units in the Power House.
The wall plastering is to provide even surface for application of paint where
shown on the drawing
4. RESPONSIBILITIES
The responsibilities for the implementation of the present Method Statement are assigned as
follows:
Project Manager :

He has the responsibility to approve this document.

He cooperates with the Construction Manager, the
Technical Services Manager and the Quality Control
Manager to establish proposal of non conformity
treatment and approves it.

Construction Manager :

He makes sure that the production activities are in line

with the present Method Statements and all Inspection
and Testing plans, he allocates all the resources needed
for their implementation.
He informs the Quality Control Manager and the
Technical Services Manager about the non conformities
found by himself or his collaborators. He cooperates to
establish the proper treatment of the non conformities.

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Bujagali Energy Limited

Bujagali Hydro-Electric Power Project

Technical Services
Manager:

Salini Costruttori
Concrete Hollow Blocks Work Method Statement

He cooperates with the Quality Control Manager to

draft the Quality Control Procedures giving all the
required technical support.
He organizes the Quality Control activities on Site
regarding the laboratory and the survey.
He prepares and distributes the method statements.
He is also responsible for the distribution of any
technical documents needed for the execution of the
work.
He cooperates with the Project Manager, with the
Construction Manager, and with the Quality Control
Manager to establish the proposal of non conformity
treatments.

Chief Laboratory
Technician:

He performs the laboratory mix proportions of the

mortar used for Hollow Concrete Block works.

Quality Control
Manager:

He drafts the quality procedures and checks their

implementation involving in these activities all the
relevant site organization.
He coordinates the registration of the non conformities
and the actions necessary to solve them.
He is responsible for the acceptance of the permanent material
described in the paragraph 6. He checks the conformity of the
incoming permanent material with the specifications and fills
the relevant fields of the incoming permanent material form.

5. EQUIPMENT
Masonry Hand Tools
Wheel Barrow or Dumper
Scaffolding
3 to 4 meter long straight edges
Small vibrator
6. PERMANENT MATERIAL
The Quality Requirements of the Permanent materials used in the construction of the block
works are described below:

Cement: OPC CEM I 42.5 N conform to EN 197-1 (for mortar)

Aggregate ( sand for mortar)
Hollow Concrete Blocks (conforming to BS 5628-1:1992)
Mortar (Designation iii of BS 5628-1:1992)
Mortar for screed

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Bujagali Energy Limited

Bujagali Hydro-Electric Power Project

Salini Costruttori
Concrete Hollow Blocks Work Method Statement

Mortar for plastering

Peneseal FH for concrete surface hardening and curing
Sika Latex

7. OPERATIVE METHODS AND WORKING PHASES

i) Masonry Block Works using Concrete Hollow Blocks
a. Marking of the line of the block and openings is done on the floor as per the
dimensions indicated on the relevant drawing. These markings must be checked
and confirmed by the Quality Control Inspector.
b. Plastic sheet (200mm wide DPC) laid along the of block line where indicated on
the drawing with 2 anchor bars (dia. 12mm, 1 to 1.5 meter long) inserted in the
floor along the line of the block at the specified spacing.
c. Mortar (20-40mm thick) laid for two guiding HCBs to true grade and alignment.
With similar application of mortar, intermediate HCBs are placed following the
string line between the two guiding blocks with constant check of level using the
spirit level. The holes where the vertical bars are passing through are filled with
mortar.
d. The above phase (c) is repeated for each course/layer of HCB.
e. Horizontal bar (12mm dia. rebar full length of the block work and inserted at one
end to the adjoining concrete column/structure) is placed where indicated on the
drawing. Introduction of intermediate beams for wall heights exceeding 3.5 meters
is foreseen.
f. Maximum number of courses to be laid in a day not to exceed 6 courses or 1.5
meters height.
g. Curing to be done as required.
ii) Floor Screed
a. The floor area is roughened or bush hammered and cleaned properly making it
free from dust, grease, oil or any other dirt.
b. Fix BRC mesh to the floor using nails(2.5 mm wire forming mesh)
c. Apply Sika Latex for bondage (Sika to water ratio of 1: 2)
d. Place special mortar {Heavy Duty Floor Finish(HDFF)} and vibrate using the
small vibrator and finish the floor surface to survey level with the cross fall shown
on the drawing (min. 0.04%)
e. Apply Peneseal FH (one litre for 5m2 area) immediately following the finishing
operation of the mortar screed i.e as soon as the surface is firm enough to walk on
before hairline or temperature cracking begins. The entire surface is kept wet with
Peneseal FH for 30 minutes.
Peneseal FH helps for curing and hardening the concrete surface and thereby
increase its density, abrasion resistance and durability.

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Salini Costruttori
Concrete Hollow Blocks Work Method Statement

iii)Wall Plastering
a. Protruding or excess mortar removed from the surface and the wall well wetted.
b. First stage application of mortar (Type BW) or rendering done on the whole
surface intended for plastering in order to make the surface rough enough to
receive second stage application of mortar as filler.
c. Second stage filler mortar (Type BW) is applied to required thickness to obtain an
even surface.
d. Then the third stage plastering or fine finishing is made using the special mortar
(Type BW1) with cement and sieved fine sand in the ratio of 1:1. This is
applicable for internal and external walls; however it can be substituted by the use
of gypsum for internal walls only.
e. Curing shall be carried out as required
8. PLANING OF THE WORKS
All masonry works are expected to be completed:
By end of 2010 in the PH rooms.
By August 2010 in the Switchyard Control Building
By October 2010 in the Erection Bay Control Building
By June 2011 in the Workshop/Store Building
By April 2012 in the Guard Houses and Visitor Center

9. SAFETY MEASURES
The risk analysis and the description of the safety measures to be considered to carry out the
works under safe conditions and complying with the legal requirements are described in the
document SA-D-GE-RA-1126-0

10. ENVIRONMENTAL ASPECTS

The analysis of the environmental aspects involved in the block works has been carried out.
Production of HCB aspects, operation and working phases do not show any significant
environmental aspects. Environmental management measures will be carried out on site
during the above mentioned activities, according to the document SA-D-GE-EA-1014.

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P R O D U C T
ICS PE N ETRON I NTE R NATIONAL

D A T A

S H E E T

45 Research Way, Suite 203 East Setauket, NY 11733

+1(631) 941-9700

info@penetron.com

PENESEAL FH
DESCRIPTION
Peneseal FH is a transparent, chemically reactive,
water-based sealer that penetrates concrete and masonry
building materials, protecting, preserving and strengthening
them permanently by:
Curing: Peneseal FH controls hairline and temperature
cracking on new concrete when applied to properly placed,
structurally sound, freshly finished concrete. Peneseal FH will
uniformly cure the concrete through a combined
chemical/moisture retention reaction so vital to the complete
hydration process.
Sealing: Peneseal FH penetrates deep into the concrete
forming a chemical reaction that locks the pores from within,
providing a deep permanent seal on all types of concrete
surfaces.
Hardening: Peneseal FH solidifies the component parts of
the concrete, increasing the density, toughness and hardness
and substantially increasing the abrasion resistance and
durability of the concrete surface. Smooth steel troweled
surfaces develop a marble-like finish and sheen. Peneseal
FH treated concrete has been compressively tested 38%
harder after 30 days than fully cured, untreated concrete.
Dustproofing: Peneseal FH chemically reacts with the salts
in the concrete, densifying the surface, greatly reducing
release of concrete dust through the surface pores.
Neutralizing Alkali: As the Peneseal FH progressively
penetrates the concrete; it neutralizes the alkali forcing them
to the surface where they can be washed away during the
application. The deep alkali and efflorescence are locked in
reducing the leaching of alkali to the surface.
Bonding: When properly applied, Peneseal FH prepares the
treated surface for paints, caulking compounds, adhesives
and floor coverings by eliminating the surface concrete salts
that are so detrimental to proper bonding. Peneseal FH is
coatable and compatible with any type of covering when
standard surface preparation guidelines are followed.
Treatment Results: A single application of Peneseal FH
helps cure and seal concrete and masonry, rendering them
highly resistant to oils, greases, and other surface
contaminants. The component parts of the concrete are
solidified into a solid mass, which toughens, hardens and
increases the density. The surface alkali is neutralized and
efflorescence and the leaching of lime and alkali are stopped.
Treatable Materials: Concrete, heavyweight concrete
block, mortar, plaster, stucco, terrazzo, exposed aggregate,
and any sand, aggregate, cement combination.
PACKAGING
5 gallon (19 l) pails, 55 gallon (208 l) drums and 275 gallon
(1041 l) containers.
T H E P E N E T R O N SYS T E M

Coverage: Approximately 200 square feet per gallon

(5m/l). Coverage depends on the temperature and porosity
of the concrete.
Storage Life: Indefinite. Agitate bucket or drum before
using. Do Not Allow to Freeze!
DIRECTIONS FOR USE
Methods of Application: Spray or pour and broom to
saturate the surface.
Tools Needed: Low-pressure sprayer, soft bristle broom,
squeegee, and water hose.
Surface Preparation: Remove surface dust, dirt and
contamination by sweeping all areas to be treated with a fine
bristle broom or scrub brush. Hose off with water and let dry.
Remove all form oil and breaking compound residue from
areas where forms have recently been removed. Peneseal
FH can be applied to damp surfaces as long as all puddled
areas are swept away so that the Peneseal FH is not diluted
before it is able to penetrate the surface.
For New Concrete:
Step 1. Apply Peneseal FH immediately following the
finishing operation as soon as the surface is firm enough to
walk on before hairline or temperature cracking begins. Keep
the entire surface wet with Peneseal FH for 30 minutes.
Step 2. As the Peneseal FH becomes slippery underfoot,
lightly mist the surface with water. This will keep the material
in solution providing maximum penetration. Do not allow the
Peneseal FH to dry on the surface.
Step 3. As the Peneseal FH again becomes slippery
underfoot, thoroughly flush the entire surface with water and
squeegee the surface completely dry to remove all surface
alkali or Peneseal FH residue. On exterior broom finished
surfaces, no flushing is required, but any remaining Peneseal
FH must be squeegeed or broomed from the surface after
30-40 minutes.
For Old Concrete (all cured surfaces):
Step 1. Saturate the surface with Peneseal FH so that the
entire surface is wet with Peneseal FH for 30 minutes. Mist
with water if necessary to keep material from drying on the
surface.
Step 2 (Option 1). If after 30-40 minutes the majority of the
Peneseal FH has been absorbed into the surface, broom or
squeegee any excess material from all low spots and puddles
so that all remaining Peneseal FH totally removed from the
surface. Porous surfaces way require an additional
application of Peneseal FH to achieve maximum protection.*
Step 2 (Option 2). If after 30-40 minutes the majority of the
Peneseal FH is still on the surface, wait until it becomes
slippery underfoot, then thoroughly flush the entire surface
with clear water and squeegee completely dry to remove all
Peneseal FH residue.
TOTA L C O N C R E T E P R OT E CT I O N

P R O D U C T

D A T A

S H E E T

PENESEAL FH
TECHNICAL DATA
Applicable Standards:
Abrasion: ASTM C 779 - 32.7% increase in abrasion
resistance.
Bonding: ASTM D3359 -17% increase in epoxy
adhesion. No change for polyurethane adhesion.
Curing: 94% greater moisture retention during the
initial critical 24 hour curing period as compared to
untreated samples.
Hardening:
ASTM c 39 - 40% increase in
compressive strength 7 days; 38% increase at 28
days over untreated samples. ASTM C 805 - Schmidt
hammer - 13.3% increase in impact resistance.
Permeability: The seepage rate using a 7 foot (213 cm)
head of water on a 4.91 square inch (31.7cm) area treated
with Peneseal FH was 0.022cc per hour.
Weathering: ASTMG2381 - ultra-violet light and water
spray exposure had no adverse effect on Peneseal FH treated
samples.
Thinners: None required. Clean all equipment with water
only.
Number of Applications Required:
One application is typically required. An additional application
may be required on porous substrates to achieve maximum
performance.
Duration of Effectiveness: Permanent. The concrete
becomes harder and better sealed the older it becomes.
Time Requirement for Curing, Sealing and Hardening:
60-90 days. Unlike surface coatings that wear away with use,
Peneseal FH seals the concrete from within by permanently
locking the pores, thus making the concrete itself the
penetration barrier. This process is essentially complete
within 90 days, but may continue at a much slower rate for up
to one year.
Color: Clear. Peneseal FH will not change the natural
appearance of the masonry or concrete. Where alkali, lime
and other impurities are forced to the surface and the natural
appearance is to be preserved, all treated surfaces must be
flushed clean with clear water according to the manufacturers
instructions.
Sheen: On smooth steel troweled concrete surfaces a
natural wax-like sheen will appear between 6 and 12 months
after treatment. This sheen is caused by the hardening and
sealing effects of the Peneseal FH as well as abrasion from
cleaning and use of the floor. As a permanent part of the
concrete surface, the sheen will last the lifetime of the surface
with proper cleaning and maintenance.
Application Temperature Limits: 100F, 40F (40C,
5C). At low temperatures completely protect new concrete
from freezing for a period of six days. The reaction of the
Peneseal FH will also be slowed during colder temperatures.
T H E P E N E T R O N SYS T E M

Drying Time: 1-3 hours. The surface can be used as soon

as the application is complete and the surface is again dry to
the touch. Newly placed concrete requires the normal
hardening period.
Painting or Covering Preparation: Old concrete - allow
3-7 days before applying paint or coverings. New concrete allow 30 days for proper curing.
Internal
Makeup:
Non-toxic,
non-combustible,
non-flammable. Not harmful to lungs or hands. Complies
with all V.O.C. and U.S.D.A. regulations.
Limitations: Do not apply Peneseal FH in the following
cases:
To seal lightweight block or other extremely porous
masonry that contains actual holes and air pockets.
When temperature falls to below 40F (5C).
To areas previously treated with curing or sealing
agents, unless these coatings have been removed by
chemical or mechanical means.
NOTE: Avoid use on glazed and finished surfaces such as
glass, aluminum, etc. In case of contact, flush immediately
with water.
AVAILABILITY AND COST
Peneseal FH manufactured exclusively by ICS Penetron
International Ltd. is distributed throughout the United States
direct to the job-site or through regional factory warehouses
and is competitively priced. For specific price information
contact ICS Penetron International Ltd.
MAINTENANCE
Floors: Wash or wet mop with neutral or high pH detergent.
Walls: Flush with water.
TECHNICAL SERVICES
Technical information and assistance can be obtained from
ICS Penetron International Ltd.
WARRANTY
ICS PENETRON INTERNATIONAL LTD. warrants that the
products manufactured by it shall be free from material
defects and will conform to formulation standards and contain
all components in their proper proportion. Should any of the
products be proven defective, the liability to ICS
PENETRON INTERNATIONAL LTD. shall be limited to
replacement of the material proven to be defective and shall
in no case be liable otherwise or for incidental or
consequential
damages.
ICS
PENETRON
INTERNATIONAL LTD. makes no warranty as to
merchantability or fitness for a particular purpose and this
warranty is in lieu of all other warranties expressed or implied.
User shall determine the suitability of the product for his
intended use and assume all risks and liability in connection
therewith.
TOTA L C O N C R E T E P R OT E CT I O N