Project : SWCC Al-Khobar SWRO Desalination Plant

Phase 2
Scope of Work: Civil and Architectural Works
Client: Acciona/RTCC
Contractor: Attiq ur Rehman Contracting Company
(AURCO)

METHOD STATEMENT

FOR CONCRETING REPAIR WORKS

Document
Rev: Date Prepared By Reviewed By Approved by
No.

SWCC-
Asad Ali Meilvin Naranjo Ahmad Saeed
00 02-27-2020 AURCO-CMD-
Engineer QHSE Manager Project Manager
PRO-001
AURCO AURCO AURCO

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SWCC-AURCO-CMD-PRO-001, Rev 00, 27-02-21
 Project : SWCC Al-Khobar SWRO Desalination Plant
Phase 2
Scope of Work: Civil and Architectural Works
Client: Acciona/RTCC
Contractor: Attiq ur Rehman Contracting Company
(AURCO)

TABLE OF CONTENTS

1. OBJECTIVE
2. SCOPE
3. REFERENCES
4. RESPONSIBILITIES
5. TOOLS AND EQUIPMENTS
6. PROCEDURES
7. ATTACHMENT

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 Project : SWCC Al-Khobar SWRO Desalination Plant
Phase 2
Scope of Work: Civil and Architectural Works
Client: Acciona/RTCC
Contractor: Attiq ur Rehman Contracting Company
(AURCO)

1. OBJECTIVE
The Objective of this method of statement is established the guidelines for surface treatment and
repairing of possible defect in the structural concrete.

2. SCOPE.

Concrete repair Method Statement encompass all required concrete repair work activities involved
associated with manufacturer's recommendations performed by AURCO in coordination with the QC
Department/Safety Department interfaces. To ensure that Concrete Repair Work is conducted in
accordance with good working practice, work is inspected and verified by the Client to satisfy and
attain the Client requirement in conjunction with the Project Quality Plan.

3. REFERENCES

(i) Project Quality Plan

(ii) IFC Drawing
(iii) Project Specification
(iv) ACI 546Concrete Repair Guide
(v) ACI 301Standard Specification for Structural Concrete
(vi) ACI 224Control of Cracking in Concrete Structures
(vii) ACI 224.1Causes-Evaluation and Repair of Cracks in Concrete Structures
(viii) ASTM Cl 107 Std. Spec. for Packaged Dry, Hydraulic-Cement Grout (Non-shrink)
(ix) Contractor Site Safety Plan (CSSP)
(x) Manufacturer Instruction of Material

4.RESPONSIBILITIES
It is the Site Construction Manager’s duty to ensure that all necessary safety and protective
equipment’s are provided along with properly trained and qualified personnel. Moreover,
to ensure that all concreting works are carried out in accordance with this method
statement.

It is the Site Engineer / Site Supervisor’s duty to organize the work force in a safe manner
and to ensure that safety and protective equipment are being properly utilized. He must

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 Project : SWCC Al-Khobar SWRO Desalination Plant
Phase 2
Scope of Work: Civil and Architectural Works
Client: Acciona/RTCC
Contractor: Attiq ur Rehman Contracting Company
(AURCO)

also ensure that the method statement procedure is followed and must observe any hold-
points noted on the ITP and notify the COMPANY for inspection.

The HSE Supervisor is responsible for devising and implementing programs and plans to
safeguard, health and safety of all employees, and to prevent loss or damage to the existing
assets and projects, He is responsible for the implementing of the safety programs. He is
also responsible to:
 Provide support to site safety officers advising them on safe working methods and
assisting with training of personnel.
 Carryout regular site safety audits and reports and correct unsafe work practices
and potential hazards.
 Investigate and report all accidents near misses and recommend prevention
measures. Ensure maintenances of good hygienic standards and availability of safety
equipment and first aid treatment.
 Present monthly safety reports and required documents.

HSE Officers are responsible for:

 The day to day activities of maintaining safety on project site, they must:
Understand and comply with requirements of the safety manual.
 Cooperate with the safety supervisor to create and maintain safe working
conditions.
 Assist the site engineers and foremen to organize the work area so that the men can
perform their duties with maximum efficiency and minimize risk to themselves or to
equipment.
 Inspect equipment and tools before use to ensure correct storage and properly
utilization.
 Maintain record of all injuries and damages on site, submit reports as required.
 Monitoring the agreed HSE programs and plans, carryout regular safety audits,
Monitor tool box talks, correct potential hazards, Investigate and report all
accidents & incidents and recommended preventive measures. Further, Ensure
maintenance of good hygienic standards and availability of safety equipment’s and
first aid treatments.
QC Inspectors are responsible for the implementation of QC Inspections and tests as defined
in related Inspection and Test Plan. Responsible for ensuring work is done in accordance
with this Method statement and manufacturer technical data sheet and does not progress
beyond Witness and Hold Points without the correct approvals and records being in place.
He is also responsible to ensure that all surveying equipment is being calibrated and
responsible for the reporting process and coordination with Client.
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 Project : SWCC Al-Khobar SWRO Desalination Plant
Phase 2
Scope of Work: Civil and Architectural Works
Client: Acciona/RTCC
Contractor: Attiq ur Rehman Contracting Company
(AURCO)

QC Lead is responsible coordination with the QA/QC document controller and the
requesting party for the submitted RFI's and CL's. Also responsible for evaluating the
reported defects based on all available data, to determine probable cause and best course
of remedial action. He is also responsible for the reporting process and coordination with
Client whenever required for the WITNESS and HOLD Point inspections as defined in the
related ITP.

5.TOOLS AND EQUIPMENTS

5.1 Application trowels
5.2 Smoothing trowels
5.3 Mixing container
5.4 Marker chalk or pen
5.5 Drill and mixing paddle small quantities
5.6 Double mixing paddle medium quantities
5.7 Forced action pan mixer large quantities
5.8 Drill bit
5.9 Vacuum cleaner
5.10 Water spray
5.11 Jack hammer
5.12 Grinding machine
5:13 Concrete Removal and cleaning equipment
5.14 Machine applied spray equipment and hopper gun
5.15 Proprietary blasting equipment
5.16 Disc cutter

6.PROCEDURES
6.1 Investigation and Evaluation of Damage Concrete Surface
Before performing repairs on damaged or defective surfaces, a visual
inspection of the exposed concrete on site shall be performed. The
prime purpose of such examination will be identify the types of
damage/cracks with structural impact for the facility and define areas of
distress. These types of investigations may require small area

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 Project : SWCC Al-Khobar SWRO Desalination Plant
Phase 2
Scope of Work: Civil and Architectural Works
Client: Acciona/RTCC
Contractor: Attiq ur Rehman Contracting Company
(AURCO)

destruction of the concrete body to verify the depth or rout. Few of

general concrete defects are below as:

 Honey Combs, broken edges

 Concrete Bulging / Sagging
 Concrete pinholes / Voids
 Concrete Cracks

6.2 Concrete Repair Classification

Based on the extent of Deterioration, Repair may be classified as following
Paragraphs.

6.2.1 Cosmetic Repair

This type of repair is aimed at improving the appearance of a
deteriorated component. It normally addresses the Deterioration of
Concrete in non-structural concrete or deterioration caused due to
exposure to aggressive agents. Concrete deterioration caused by acid
spillage may be one of the types repaired for cosmetic reasons.

6.2.2 Partial Repair

This type of repair is carried out with the intention of rectifying the
apparent defects without addressing the cause of the damage. This is
also a sort of deferred repair. Patch repair of the Areas where appalling
delamination has been detected and leaving the other areas for repair
at later date, as and when deterioration will be apparent, is an example
of a short-term repair.

6.2.3 Total Repair

A total repair shall address all aspects of concrete deterioration, viz., Structure,
and Durability, and should also include remedial actions to minimize future
deterioration.
The considerations supporting a total repair are the following;

• Structural safety of the components is compromised due to an

advanced stage of deterioration.
• Operation constraints do not permit the complete replacement of the
structural component.
As elaborated above, a total repair needs not only to address the
prevailing deterioration but to design methodologies for avoiding future
occurrence of the material.

6.3 Honeycomb and Broken Edges

6.3.1 Surface preparation
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 Project : SWCC Al-Khobar SWRO Desalination Plant
Phase 2
Scope of Work: Civil and Architectural Works
Client: Acciona/RTCC
Contractor: Attiq ur Rehman Contracting Company
(AURCO)

• Delaminated weak, damaged and deteriorated concrete shall be

removed by suitable means.
• The concrete substrate shall be in good sound condition and
free from dust, loose material, surface contamination and materials
which reduce bond.

• Identify the member which needs to be repair or dismantle and

mark on existing structure
• Cut and hack around at demarcated honeycomb area, broken
edges area and on concrete structure which need to remove with
suitable tools and equipment.
• Ensure all loose concrete must be removed down to sound
concrete.

• Breaking out shall continue along the reinforcement until non-

corroded steel is reached as directed by the supervising officer or
qualified engineer.

• Once the surface will be ready to apply grout materials, WIR

shall be raised by QC Civil inspector and get approved by client
representative to ascertain that procedures are properly initiated.
6.3.2 Pre Wetting substrate

• Concrete surface shall be saturated with clean water a minimum

2 hours before application ensuring that pores and pits are adequately
wet.
• The surface shall not be allowed to dry before application.

• Formworks shall be fixed immediately after pre wetting to avoid

loss of moisture from the substrate surface.

• Ensure there is no standing water on the surface before closing

the formwork.
• All the manufacture's recommendations will be considered for
surface preparation.

6.3.3 Formworks (if required)

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 Project : SWCC Al-Khobar SWRO Desalination Plant
Phase 2
Scope of Work: Civil and Architectural Works
Client: Acciona/RTCC
Contractor: Attiq ur Rehman Contracting Company
(AURCO)

• Formwork shall be clean and fixed in place as soon as possible after

the substrate has been prepared.
• Openings in the formworks shall be protected to prevent ingress of
debris or contamination.
• Formwork shall be watertight and free from obstruction to allow
the free flow of pourable mortar.
• Formwork shall be designed and allow the controlled escape of air
and water bleed.

6.3.4 Bonding Agent

• For standard repair conditions, soak with clean water and
remove excess.
• Prior to grouting, a bonding agent shall be poured or
brushed to the repaired surfaces to ensure that both new and
old materials will bond together to prevent a hollow sound.
• It will ensure that bonding agent shall be approved from
client prior to use.
• It will also ensure that all the safety and quality requirements which
recommended by manufacture are being considered.

6.3.5 Repair Material

• Sika Grout 114 SA (up to 500 mm)

• Nitobond AR
• TC2000

6.3.6 Testing & Sampling

As per data sheet of used material.

6.3.7 Curing

• Curing for the repair area shall be as per manufacture's

recommendations.
• Curing of repaired areas should be carried out as soon as possible
after the surface has been closed.

6.4 Concrete Bulging or Sagging

6.4.1 Surface preparation
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 Project : SWCC Al-Khobar SWRO Desalination Plant
Phase 2
Scope of Work: Civil and Architectural Works
Client: Acciona/RTCC
Contractor: Attiq ur Rehman Contracting Company
(AURCO)

• Mark out the area requiring the chipping.

• The perimeter of the area should be saw cut with a grinder to a
required depth and the edges cut as neatly as possible keeping the sides
square.
• Depth of chipping of bulged concrete shall be decided considering
the alignment, structure element's size as per design and approval of the
Engineer.
• Chipping shall be performed using electrically operated concrete
breaker with pointed chisel of the appropriate capacity.
• Heavy duty machinery or jack hammers should not be used to avoid
damage to the structure element by excessive hammering.
• For removing a very thin surface an electrically operated scrabbling
hammers may be used.
• Chipping shall continue to achieve the required decided depth.
• The substrate shall be prepared to a rough surface.
• The prepared surface must be sound, dense, and free of all oil,
grease loose and fractured aggregate or other contaminants that could
impair adhesion.

6.4.2 Bonding Agent

• For standard repair conditions, soak with clean water and
remove excess.
• Prior to grouting, a bonding agent shall be poured or
brushed to the repaired surfaces to ensure that both new and
old materials will bond together to prevent a hollow sound.
• It will ensure that bonding agent shall be approved from
client prior to use.
• It will also ensure that all the safety and quality requirements which
recommended by manufacture are being considered.

6.4.3 Repair Material

• Sika Grout 114 SA (up to 500 mm)

• Nitobond AR
• TC 2000

6.4.4 Testing & Sampling

As per data sheet of used material.

6.4.5 Curing

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 Project : SWCC Al-Khobar SWRO Desalination Plant
Phase 2
Scope of Work: Civil and Architectural Works
Client: Acciona/RTCC
Contractor: Attiq ur Rehman Contracting Company
(AURCO)

• Curing for the repair area shall be as per manufacture's

recommendations.
• Curing of repaired areas should be carried out as soon as possible
after the surface has been closed.

6.5 Concrete Pinhole or Voids

6.5.1 Surface preparation

• Identify the member which needs to be repair and mark for

deteriorated, damaged, or defective concrete.
• Thin cement slurry cover layer over air trapped holes will be
removed enough that fill material can be fill easily
• Hand operated sharped pointed chisel with three-pound hammer
shall be used to open the pinholes face
• It will ensure that all the surface need to repair is properly cheeped
and clean from chipping debris.
• Approved material to be use after surface preparation inspection.

6.5.2 Repair Material

• Grout Materials.

• Sika Rep Fine

6.6 Concrete Cracks
In case of cracks appear on concrete structure's outer surface a Technical
investigation will be done prior to start surface preparation.

6.6.1 Surface preparation

• In case of cracks appear on concrete structure's outer surface a

detailed investigation will be done prior to start surface preparation.
• Identify the member which needs to be repair and mark for
deteriorated, damaged, or defective concrete for plastic shrinkage cracks
surface hair cracks or drying shrinkage cracks
• Chesil chipping or electrical grinding will be utilizing to enlarge
the face of cracks.
• The enlargement of the face will be in "V" shape and will be
deep enough from crack depth.
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 Project : SWCC Al-Khobar SWRO Desalination Plant
Phase 2
Scope of Work: Civil and Architectural Works
Client: Acciona/RTCC
Contractor: Attiq ur Rehman Contracting Company
(AURCO)

• It will ensure that during chipping or grinding process

reinforcement will not be damage.
• Heavy hand operated tools like pneumatic jack hammers or
any other hammer over 12 Kg will not be utilize to avoid further
internal fracture.
• It will ensure that all the surface need to repair is properly
cheeped and clean from chipping debris.
• Oil and grease deposits are best to remove by steam
cleaning, detergent scrubbing or use of a propriety degreaser.
• Approved material to be use after surface preparation
inspection.
6.6.2 Repair Material

• Sika Grout 114 SA

• Sika Rep Fine

7-ATTACHMENTS

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 Project : SWCC Al-Khobar SWRO Desalination Plant
Phase 2
Scope of Work: Civil and Architectural Works
Client: Acciona/RTCC
Contractor: Attiq ur Rehman Contracting Company
(AURCO)

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 Project : SWCC Al-Khobar SWRO Desalination Plant
Phase 2
Scope of Work: Civil and Architectural Works
Client: Acciona/RTCC
Contractor: Attiq ur Rehman Contracting Company
(AURCO)

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 Project : SWCC Al-Khobar SWRO Desalination Plant
Phase 2
Scope of Work: Civil and Architectural Works
Client: Acciona/RTCC
Contractor: Attiq ur Rehman Contracting Company
(AURCO)

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