(St) Proj Unit Type Dev.

Serial Rev
(1) KZ611 00 xxxx SC xxxx 00
Contract No. AP/D/17/1452
DOCUMENT MS FOR CONCRETE CONRETE
TITLE REPAIR
PROJECT TITLE: Karachaganak Processing Complex (KPC) Gas Debottlenecking (KGDBN) Project

CONTRACT TITLE: “Provision of Construction and Associated Procurement Services for the KGDBN Project”

METHOD STATEMENT FOR

CONCRETE REPAIR
(KZ611-00-xxxx-SC-xxxx-00)

Charlie M. Chu Paolo Felletti Angelo Balestrero 01.07.2018

00 ISSUED FOR REVIEW & COMMENTS
Tech Engr. FEM PM
Prepared Checked Approved
Date
Rev. Description (name & initials) (name & initials) (name & initials)
DD/MM/YY
Position Position Position
DOCUMENT REVISIONS
This document is the property of COMPANY who will safeguard its rights according to the civil and penal provisions of the law.

REVISION DESCRIPTION SHEET

page 1 of 22
KZ611-00-xxxx-SC-xxxx-00
METHOD STATEMENT FOR CONCRETE REPAIR

REV. PARA. REVISION DESCRIPTION

00 ALL ISSUED FOR REVIEW & COMMENTS

page 2 of 22
KZ611-00-xxxx-SC-xxxx-00
METHOD STATEMENT FOR CONCRETE REPAIR

Table of Contents
1 SCOPE AND PURPOSE ........................................................................................................................... 4
2 REFERENCES .......................................................................................................................................... 4
3 DEFINITIONS AND ABBREVIATIONS ..................................................................................................... 5
4 ROLES AND RESPONSIBILITIES............................................................................................................ 6
4.1 Project Manager (PM) ....................................................................................................................... 6
4.2 Deputy Project Manager and General Construction Manager (DPM_GCM) .................................... 6
4.3 Project HSE Manager (PHSEM) ....................................................................................................... 7
4.4 Deputy HSE Manager (DHSEM) ....................................................................................................... 7
4.5 HSE Supervisor (HSE_SUP)............................................................................................................. 7
4.6 HSE Inspector (HSE_INS) ................................................................................................................ 7
4.7 Emergency Coordinator (EC) ............................................................................................................ 7
4.8 Environmental Lead Engineer (ENV_LE) .......................................................................................... 8
4.9 Road Safety Supervisor (RS_SUP)................................................................................................... 8
4.10 Project Quality Manager (PQM) ........................................................................................................ 8
4.11 Quality Inspector (QC_INS)............................................................................................................... 8
4.12 Lead Survey (LS) .............................................................................................................................. 8
4.13 Field Engineering Manager (FEM) .................................................................................................... 9
4.14 Area Construction Manager (ACM): .................................................................................................. 9
4.15 Construction Discipline Superintendent (D_SUPT):.......................................................................... 9
4.16 Construction Discipline Supervisor (D_SUP): ................................................................................... 9
5 TOOLS AND EQUIPMENT ..................................................................................................................... 10
6 LIST OF DIRECT PERSONNEL INVOLVED IN THE EXECUTION OF WORK .................................... 10
7 METHODOLOGY .................................................................................................................................... 10
7.1 Identification of Concrete Defect Types .......................................................................................... 11
7.2 Procedure for the Repair of Concrete (Major Surface Defects) ...................................................... 13
7.3 Procedure for the Repair of Concrete (Minor Surface Defects) ...................................................... 17
7.4 Activities Prior To Crack Repair on Horizontal and Vertical Surfaces............................................. 18
7.5 Pressure-Injection for Major Cracks (Cracks ≥ 0.2mm wide at surface) ......................................... 19
7.6 Surface Sealing for Minor Cracks (Cracks < 0.2mm wide at surface) ............................................ 19

page 3 of 22
KZ611-00-xxxx-SC-xxxx-00
METHOD STATEMENT FOR CONCRETE REPAIR

1 SCOPE AND PURPOSE

The purpose of this document is to delineate the methodologies associated in the effective concrete
repair works of structures which are included in the work packages that the CONTRACTOR received
from the COMPANY in accordance with Section 12 “Initiation and Execution of Works” of Schedule
H “Administration Requirements” of the project contract. This repair procedure shall be considered
as the minimum requirement and shall be used in conjunction with the vendor guidelines and
industry approved methodologies and practices.
This method statement was prepared to comply with the required technical documentations initiated
through the non-conformity reports received from the COMPANY. In addition, this document shall
serve as a construction guideline that the CONTRACTOR shall execute to perform the affiliated
repair works in a manner that is safe and conformant to the expected results of the COMPANY.
Prior to performing the associated Works, CONTRACTOR shall verify the scope of works on the
define concrete structure which requires repair. COMPANY shall then handover the area in which
the concrete structure is situated. Accordingly, CONTRACTOR shall conduct an examination on the
structure to discern the cause of the concrete damage. In cases where the concrete damage was
caused by “Others”, CONTRACTOR shall immediately inform the COMPANY by providing
necessary reports and supporting documentations. Section 9.0 “Variation Procedure” of the project
documents shall be implemented in these instances.
Encompassed in this document are the different aspects to be considered in concrete repair
activities:
 Identification of concrete defect types
 Procedure for the repair of concrete (major surface defects)
 Procedure for the repair of concrete (minor surface defects)
 Activities prior to crack repair on horizontal and vertical surfaces
 Procedure for the repair of concrete cracks (vertical and horizontal surfaces)
During the execution of the associated work the CONTRACTOR reserves the right to conduct
variations in the construction execution to suit unforeseen conditions. The initiation and execution
of the work variations shall be conducted as per the pertinent sections of the contract documents.

2 REFERENCES

DOCUMENT Ref. n. STANDARD

KZ611-00-0803-SC-0001
KPO-AL-QAC-PRO-00043
KPO-AL-HSE-PRO-00051-E
KPO-00-ENG-SPC-00038-E
SN RK1.03-05-2011
KGDBN-CO-PC-2017
KGDBN-50A-3PS-6700-10006
KZ611-00-0812-SC-0004
KZ611-00-0417-SC-0002
KZ611-00-0417-SC-0008
KZ611-00-0417-SC-0001
PROJECT QUALITY PLAN
CONSTRUCTION MATERIAL CONTROL
WORKS AT HEIGHT
CONCRETE MATERIALS AND CONSTRUCTION
RULES OF LABOUR PROTECTION AND SAFETY
DURING CONSTRUCTION
PROJECT MATERIALS CONCREYE GRADE
SPECIFICATION FOR DESIGN OF CONCRETE
STRUCTURES AND FOUNDATIONS
INSPECTION AND TEST PLAN FOR CONCRETE
STRUCTURES AND FOUNDATIONS
SUBCONTRACTOR CONCRETE PRODUCTION
METHOD STATEMENT
PRE-CAST CONCRETE MIX DESIGN B27.5
CONCRETE WINTER MIX DESIGN B27.5 & B7.5

page 4 of 22
KZ611-00-xxxx-SC-xxxx-00
METHOD STATEMENT FOR CONCRETE REPAIR

3 DEFINITIONS AND ABBREVIATIONS

COMPANY KPO Karachaganak Petroleum Operating BV

PROJECT Karachaganak Processing Complex Gas Debottlenecking Project
KPC Karachaganak Processing Complex
RoK Republic of Kazakhstan
OGP Orenburg Gas Processing plant
BF Brown Field
GF Green Field
PL Pipeline
MTO Material Take Off
TBT Tool Box Talk
OTHERS Private entity/Company who owns the property where the
crossings are situated.
CONTRACTOR KKS Sicim LLP
PM Project Manager
DPM_GCM Deputy Project Manager and General Construction Manager
PHSEM Project Health, Safety and Environment Manager
DHSEM Deputy Health, Safety and Environment Manager
HSE_SUP HSE Supervisor
HSE_INS HSE Inspector
EC Emergency Coordinator
ENV_LE Environmental Lead Engineer
RS_SUP Road Safety Supervisor
PQM Project Quality Manager
AQM Area Quality Manager
QC_INS QC Inspector
LS Lead Survey
FEM Field Engineering Manager
LDCC Lead Document Control Center
INT MAN Interface Manager
ACM Area Construction Manager
Construction Discipline Superintendent (Civ., Mec., Pip.,
D_SUPT ELE/INS.)
Construction Discipline Supervisor (Civ., Mec., Pip., ELE/INS.)
D_SUP Discipline Foreman
D.FOR Personnel and Protective Equipment
PPE Permit to Work
PTW Traffic Management Plan
TMP Quality Assurance / Quality Control
QA/QC Quality Control Procedure
QCP Inspection Test Plan
ITP Notice for Inspection
NFI Block Valves Stations
BVS Issued for Construction
IFC Underground
UG Horizontal Directional Drilling
HDD Titanium-mixed metal oxide
Ti-MMO Magnesium
Mg Isolation Joint
LJ Isolation Joint Test Station
SIJ Reference Electrode
RE Electrode
E Over voltage protection
OVP Insulating Flange

page 5 of 22
KZ611-00-xxxx-SC-xxxx-00
METHOD STATEMENT FOR CONCRETE REPAIR

FI Galvanic/ Insulating Test Station

FIJ Corrosion Coupon
CC Road or Water Pipeline crossing test station
EPC Permanent Potential Test
STP Galvanized Steel Wire Armour
GSWA Cross- linked Poly-Ethylene (Cable Insulation)
XLPE Polyvinyl Chloride (also Cable Insulation)
PVC Direct Buried
DB High Voltage
HV Medium Voltage
MV Low Voltage
LV Kilo Volt
kV Kilo Volt-Ampere
kVA Cathodic Protection (System)
CP Transformer rectifier
T/R Anode Junction Box
AJB Negative Junction Box
NJB Volts / Amperes
V/A Volt-ampere
VA Direct Current
DC Alternating Current
AC

4 ROLES AND RESPONSIBILITIES

4.1 Project Manager (PM)

Leading all the CONTRACTOR project Team, he ensures that the Project is delivered in a Safe
way and on time while respecting the Project Quality Standards. Ensures the project is effectively
resourced. Responsible in managing all the external consultants and subcontractors. Allocates
and utilizes resources in an efficient manner as well as maintaining a cooperative and motivated
team. Responsible for the communication between COMPANY and CONTRACTOR. To achieve
full control of the project, he coordinates with the Deputy Project Manager, General Construction
Manager, HSE Manager, Project Control Manager, Project Quality Manager, Field Engineering
Manager, Contract Manager and all the Construction Team.

4.2 Deputy Project Manager and General Construction Manager (DPM_GCM)

Supports the Project Manager in all decision making while leading all the Construction and
Survey Team. Leads all Area Construction Managers and the Survey Leader. Supports and
ensures that all the activities will be performed safely and in compliance with all the HSE
directions. Ensures the availability of all necessary equipment and facilities that are deemed
necessary for the execution of all activities. Ensures that all construction activities are
performed based of the latest revision of the IFC (i.e. Issued for Construction) documents,
Specifications and Procedures/Method of Statements. Ensure that all the Method of
Statements, Procedure and Specifications are well understand for all Construction team.
Lead the Survey Team through the Lead Survey. Assures that all the required Construction
personnel shall be mobilized prior to the start of the related activities while ensuring that
these personnel passed all the required induction. Ascertain the preservation of the project
materials by strictly complying with the vendor and project requirements. To achieve better
control of all the activities he/she shall utilize the help of the Warehouse Manager, Logistic
Manager and the Area Construction Managers.

page 6 of 22
KZ611-00-xxxx-SC-xxxx-00
METHOD STATEMENT FOR CONCRETE REPAIR

4.3 Project HSE Manager (PHSEM)

Ensures that all HSE requirements for the safe execution of the project activities are in place.
Assures that all project requirements as stated in Schedule D of the Contract as well as the
CONTRACTOR HSE Plan are implemented throughout the duration of the Contract.
Develops and executes the HSE plans. Prepares and enforces relevant policies that
establishes and/or implement the culture of HSE. Evaluates relevant practices, procedures
and facilities to assess risk as well as adherence to the Project documentation and the
Kazakhstan law. Monitors the safe execution of the project, highlights HSE issues, performs
risk assessments, make recommendations and verifies compliance with the Contract and
RoK requirements. Coordinates the issuance as well as the implementation of HSE Plans
and procedures in line with Contract requirements. Ensures that all CONTRACTOR Project
personnel (including Subcontractors) receive the appropriate orientation and training
regarding the Safety requirements. Organizes a periodic training/tool box for all Site and
Offices personnel with different and actual topics/subjects. To achieve better control of all
the activities he/she shall utilize the help of the Deputy HSE Manager, HSE Training
Coordinator and the HSE Inspectors.

4.4 Deputy HSE Manager (DHSEM)

Supports the HSE Manager in all activities. Participates in the development and monitoring
of the HSE Management system while ensuring its implementation. Monitors the working
conditions in all the areas where there are ongoing activities (e.g. CONTRACTOR Camp,
CONTRACTOR Facilities, Project Areas, Prefabrications Areas). Ensures the organization
of all required induction and trainings for all new arrivals/recruits. Coordinates the activities
of HSE team at every site while monitoring the performance of the HSE department.

4.5 HSE Supervisor (HSE_SUP)

Reports to the DHSEM, provides HSE support and guidance to the site supervisor on the
proper HSE procedures, identifying current and potential hazards as well as the employee
training requirements. Supervises the work execution and ensures that all safety and
environmental prevention/ protection measures are implemented. Reports any incidents or
accidents to the HSE manager as well as the site management and accordingly conduct
necessary investigations to understand the root causes. Periodically ensure that all the
trainings are up to date. Organizes a training or special training if the need arises for all or
some of the CONTRACTOR personnel working in his/her specific Area.

4.6 HSE Inspector (HSE_INS)

Reports to the SUP HSE, provides HSE support and guidance to the site supervisor on the
proper HSE procedures, identifying current and potential hazards as well as the employee
training requirements. Supervises the work execution and ensures that all safety and
environmental prevention/ protection measures are implemented. Reports any incidents or
accidents to the HSE manager as well as the site management and accordingly conduct
necessary investigations to understand the root causes. Organizes a daily tool box for the
entire personnel working in the area. Responsible for choosing from time to time the specific
topics which necessary for the safe execution of construction activities. Verifies if all
personnel have understood the methodology in performing the activity as well as the
associated risks, thereby minimizing work related dangers. Ascertains that all Construction
Team are involved in all toll box meetings.

4.7 Emergency Coordinator (EC)

The Emergency Coordinator is part of HSE Department. Manages all the medical staff
including the ambulance and the fire specialist. The main function of EC is to organize all

page 7 of 22
KZ611-00-xxxx-SC-xxxx-00
METHOD STATEMENT FOR CONCRETE REPAIR

emergency activates. Submits and implements the emergency plan. Conducts and
organizes trainings and emergency simulations to ensure that the emergency plan is properly
followed.
4.8 Environmental Lead Engineer (ENV_LE)
Coordinates and supports the PM and DPM_GCM in all aspects of the project to minimize
the construction impact on the environment by implementing the waste management
procedures, recycling process and exercising pollution reduction and prevention activities.
Ensures that all departments are aware of the relevant environmental control measures and
the responsibility to implement them through effective training and communication.
Responsible in preparing and implementing the environmental plan in accordance with the
COMPANY standards. Ensures that the CONTRACTOR complying with the environmental
Kazakhstan Legislation. Prepares and manages the environmental strategy. Keeps up to
date with the relevant changes in the environmental legislation and incorporates relevant
international legislation where applicable. Conducts inspections and prepares relevant data
which are needed for the environmental reporting guidelines of the COMPANY. Participates
in the arrangement of the waste storage area according to the sanitary and environmental
requirements of RoK. Ensures that all required waste related permits and other legal
documents are in place.

4.9 Road Safety Supervisor (RS_SUP)

Supports the HSE Manager in preparing the Traffic Management Plan (TMP) to maximize
the efficiency of the trucks and other vehicles. Prepares and updates the TMP on all project
areas by minimizing the interference between pedestrian, equipment and trucks. Individuate
in each working area the safe pedestrian path. Continuously update each TMP in accordance
with the status of the roads as well as the weather condition. Supports the Logistic
Coordinator in planning the transport activities.

4.10 Project Quality Manager (PQM)

Supports Project Manager in the implementation of the Project Quality Plan, ITPs and the
application of all Project Quality Standards. Shall serve as the focal point for all Project
QA/QC matters. Ensures that all the Contractual Quality requirements are identified,
understood and documented. Assures that a Contract compliant Project Quality System is
established, implemented and maintained. Organizes, provides and controls all
Instruments/tools as well as accordingly ensuring that it is properly calibrated and approved
by COMPANY. Ensures that all QC Inspectors or Third Party are well trained and capable to
perform the tests. Periodically report the progress of the QA/QC activities. Organizes and
controls the register of inspections. Ensures the inspection of all project materials including
the documentation and certificates/material passport. Ensures the preservation of all project
materials are complying with vendor and project requirements. Ensure that construction team
is working with the latest IFC drawing revision. To assure better control of the activities
he/she coordinates with the AREA Quality Managers.

4.11 Quality Inspector (QC_INS)

Support Project Quality Manager to perform all the inspections, in accordance to the ITPs.
Preparing the daily report of each inspection. Support Construction to carry out the activities
in accordance to the Quality plan.

4.12 Lead Survey (LS)

Support the PM and DPM_GCM, to make the exact measurements (within the Project
tolerances), provide the data relevant to the shape, contour, location elevation, for

page 8 of 22
KZ611-00-xxxx-SC-xxxx-00
METHOD STATEMENT FOR CONCRETE REPAIR

construction Quantities Surveys or other purposes, based to the coordinates of known points
received from COMPANY. Prepare and maintain the CONTRACTOR Benchmarks, if
needed. Ensure the topographic instrument are suitable for the Project and the tolerances
are within the Project requirements. Direct and Conduct surveys, collecting data and report.
Supporting Construction during all the phases preliminary, during and after. Prepare all data,
plots, maps, records and documents related to surveys. Calculate heights, depth, relative
positions, shape of natural soil etc. Plan and conduct ground surveys designed to establish
baselines, elevations and other geodetic measurements. Establish fixed points using
geodetic and engineering instruments. Knowledge of the geodetic instrument “total station”,
“laser and/or optic level”, “Theodolites”, etc. Managing the Survey crew to cover all the
needed of the Project areas. Train assistants and helpers and direct their works in such
activities as performing surveys or drafting maps. Develop criteria for survey methods and
procedures.

4.13 Field Engineering Manager (FEM)

Support the PM and DPM_GCM to manage and solve all the technical aspects related to the
Project. Preparing the technical bid evaluation to ensure the materials are within the technical
specifications. Managing all the documentation IN/OUT with the support of the DCC
(Document Control Center). Ensure that construction working with the latest revision of IFC
documentation. Preparing the updated Weekly Document Reporting Register. Supporting for
the preparation the Method od Statement. Preparing the technical support for the closure of
Non-Conformities. Preparing all the technical query / Site Query / Deviation Request. Field
engineering support for all the discipline Civil, Piping, E&I etc. works and ensuring
implementation and adherence to project specification, procedure and HSE policies. He shall
provide technical support ensuring that latest IFC drawings and project specification are met.
Continuously check and review the changes status during the work.

4.14 Area Construction Manager (ACM):

Support the DPM_GCM for the organization and perform for Construction activities. Organize
a specific tool box before the start of each activity sharing with the personnel the meaning of
method of statement, individuate the risk of the specific activity. Manage and organize the
production activities in the specific area. Ensure the availability of the Construction
equipment, tools and consumables. Implement the procedures for the execution of the
Works. Guarantee the timely and correct execution of the Project activities in accordance
with Project Specifications, Procedures and Standards. Monitor that Safety & Quality
requirements are continuously implemented. Coordinate and supervise the activities
performed by Subcontractors. For the better control of all the activities he makes use the
help of Discipline Superintendent (D_SUPT) and Discipline Supervisors (D_SUP).
4.15 Construction Discipline Superintendent (D_SUPT):
Support the ACM, for the organization of the Construction crews and perform the site
activities. Responsible for the execution of this procedure, monitoring and control the
activities. For each discipline ACM will be supported by a (D_SUPT) activities specialist
pertaining to all aspects in preparation (tools, equipment and materials), transportation
execution of the activity. Once the activities are completed he is responsible for the
submission of the NFI (Notification for Inspection). For the better control of all the activities
he makes use the help of Construction Discipline Supervisor (D_SUP).
4.16 Construction Discipline Supervisor (D_SUP):
Support the D_SUPT, for the organization of the Construction crews and perform the site
activities in environmentally safe and responsible manner in accordance with HSE and follow
all safety procedure, permit to work and all necessary requirement to proceed the work at
site the site activities and ensures the compliance with established construction schedule

page 9 of 22
KZ611-00-xxxx-SC-xxxx-00
METHOD STATEMENT FOR CONCRETE REPAIR

and project requirements as per the applicable specifications and standards. He will Lead
the Foreman and Construction Crew.

5 TOOLS AND EQUIPMENT

As part of the CONTRACTOR’s aim to execute the work properly, the CONTRACTOR will
utilize all equipment and tools deemed necessary for the execution of the work. These
equipment and tools are enumerated but are not limited to the following:

− Electric hammer drill

− High-air pressure compressor
− Steel brush
− Sponge
− Formworks
− Grinder
− Crack Width Gauge
− Manlift
− Scaffoldings
− Chisel
− Hammer

All equipment and tools shall be calibrated, certified (when required) and maintained in a state
of good working condition throughout the duration of the work. It will be part of the
CONTRACTOR’s responsibility to create a Maintenance Schedule that will not affect the target
construction deadlines as stated in the approved project schedule.

The CONTRACTOR shall also provide the proper training of its pertinent personnel who will
be tasked to utilize the equipment and tools. The trainings shall include but not limited to the
following:

− Proper handling of equipment and tools.

− Trouble shooting of equipment and tools.
− Risk assessment and management associated with the handling of tools and
equipment.
− Safety measures during the use of equipment and tools.

Heavy equipment (e.g. manlift, etc.) that will be employed in the work shall be provided with
proper and safe access inside the vicinity of the construction site during and after the execution
of the work.

6 LIST OF DIRECT PERSONNEL INVOLVED IN THE EXECUTION OF WORK

− Construction Manager (CM)

− Construction Discipline Superintendent (D_SUPT)
− Civil Supervisor (CIV-SUP)
− Civil Foreman
− QC Inspector
− Labors/Workers
− Safety watcher
− HSE inspector
− Flagman

7 METHODOLOGY

CONTRACTOR has planned and will execute the associated work in a manner that is
complying with this document and other related references. It will rely in its vast experience

page 10 of 22
KZ611-00-xxxx-SC-xxxx-00
METHOD STATEMENT FOR CONCRETE REPAIR

aside from the compliance to the best practices as depicted in relevant codes, RoK regulations,
KPO safety procedures, KPO IFC Project documentations and standards.

Prior to execution of the associated Works, the Area Construction Manager shall ensure that
the area is handed over and are released for works and all necessary tools and equipment are
available and inspected. In addition, the Area Construction Manager shall ensure that all
personnel as depicted in section 6 of this document including the necessary materials are on
site.

A responsible person will be delegated to monitor the execution and ensure that the work will
be carried out safely and accordingly make certain that all workers are aware of the risk related
to the execution of the activity and are wearing the necessary PPE.

CONTRACTOR shall ensure that welfare and safety facilities are provided for its site workers.
In addition, CONTRACTOR shall ensure that housekeeping is a permanent activity (e.g. daily,
weekly, etc.) to keep the area clean and safe.

Extreme weather conditions (e.g. strong wind, cold temperatures, ice/snow conditions and
potential lightning storms, etc.) shall be taken into consideration during the planning and
execution of the activities.
7.1 Identification of Concrete Defect Types
To effectively repair the concrete defects, CONTRACTOR shall conduct a verification activity
to ascertain the type of concrete damage. Using the acquired information, CONTRACTOR
shall use the proper methodology as well as the necessary tools and equipment to employ in
the associated work.

Surface Defects

 Rock Pocket / Honeycomb

The loss of cement or mortar through cracks or knot holes in the forms will cause pockets that
impair the appearance of the surface. This is most likely to occur when the concrete is
consolidated by over vibration and some concrete mortar escaping through the cracks and
knot holes in the forms.

page 11 of 22
KZ611-00-xxxx-SC-xxxx-00
METHOD STATEMENT FOR CONCRETE REPAIR

 Spalling of Concrete
Spalling involves the breaking-off of layers or pieces of concrete from the surface during
thermal exposure. This happen when there is moisture in the concrete which forces or pushes
the concrete outward.

 Sand Streaking
Sand streaking is caused by excessive bleeding. As bleed water moves upward along the form
in long channels, it washes away some of the paste and exposes sand in the concrete surface.

page 12 of 22
KZ611-00-xxxx-SC-xxxx-00
METHOD STATEMENT FOR CONCRETE REPAIR

 Dusting
The development of a soft, powdery material that can be easily rubbed off the surface of
hardened concrete. This is caused by beginning finishing operations while bleed water is
still on the surface, condensation worked into the surface, surface carbonation, inadequate
curing practices, and exposure to an unfavorable environment (e.g. rain and freezing).

Cracks

 Cracks in Newly Hardened Concrete

Cracks in newly hardened concrete can occur for a variety of reasons, but most commonly due
to incorrect curing leading to rapid drying of the concrete. This will cause shrinkage of the
concrete and the development of cracks. In addition, cracks can also form due to improper
heat treatment of concrete during winter periods.

7.2 Procedure for the Repair of Concrete (Major Surface Defects)

Step 1. Substrate Preparation

 Mark the defective concrete area with a spray paint.

page 13 of 22
KZ611-00-xxxx-SC-xxxx-00
METHOD STATEMENT FOR CONCRETE REPAIR

 Concrete removal
The damaged substrate shall be removed with the use of a chisel and hammer or an
electric hammer drill. The worker should ensure that only concrete within the marked
area is stricken with the chisel. To avoid propagation of any concrete damage (i.e.
unwanted cracks) and avoidance of feather edges, a shallow square cut shall be made
in the periphery of the pertinent concrete surface area using a portable concrete saw.
This square cut area shall serve as the boundary of the concrete repair area.

Chisel and Hammer

page 14 of 22
KZ611-00-xxxx-SC-xxxx-00
METHOD STATEMENT FOR CONCRETE REPAIR

Electric Hammer Drill

 After removing the unsuitable/defective concrete, a high-air pressure (compressor) will

be used to peel off loose concrete.

 The removal of concrete shall continue until a minimum depth of 1.5 times the largest
aggregate size used in the repair mix is attained behind the reinforcement.

 The pertinent concrete surface shall be roughened to a depth of approximately 2 mm.

Additionally the cut sides shall have an angle of:

page 15 of 22
KZ611-00-xxxx-SC-xxxx-00
METHOD STATEMENT FOR CONCRETE REPAIR

o Minimum side angle of 90 degrees to avoid under cutting.

o Maximum side angle of 135 degrees

Step 2. Exposing of Concrete Reinforcements

 Scrub the reinforcement with a steel brush to remove any concrete that is bonded in
the steel reinforcement.
 Shrub with clean potable water using a sponge.

Step 3. Install formworks (if damaged surface is in a vertical plane) and application of structural
concrete repair materials.
 Ensure an entry point for the structural repair mortar in the formwork. Use repair
materials BASF MasterFlow 928T for repair depths between 25mm and 100mm and
MasterEmaco S488 for repair depths between 12mm and 50mm. After the formworks
have been installed pour the structural repair material.
 In cases where the damaged portion is on horizontal plane, the repair materials shall
be applied using trowels.
 Repair material shall be mixed by way of a mechanical mixer or as per manufacturer’s
instruction and shall be poured through the envelope entry on the shutters.
 CONTRACTOR shall repair the damaged concrete considering the concrete repair
manufacturer’s data sheet. Additionally, instructions related to surface preparation and
application of compatible bonding agent shall be used. Where bonding agents is not
required in the concrete substrate, the concrete surface shall be wetted with clean
potable water prior to the application of the repair compound.

page 16 of 22
KZ611-00-xxxx-SC-xxxx-00
METHOD STATEMENT FOR CONCRETE REPAIR

Step 4. Stripping of the formwork

 Removal of the formwork shall be done after 7 days.

7.3 Procedure for the Repair of Concrete (Minor Surface Defects)

Step 1. Substrate Preparation

 Mark the defective concrete area with a spray paint.

 Remove the unsuitable/defective concrete by grinding or scarifying or other suitable

method as agreed upon with the COMPANY representative on site.

 Grind to roughen the surface of the defective area until a Concrete Surface Profile
(CSP) between 3 to 5 is achieved. The roughening process shall consider
manufacturer’s instructions for surface preparation. In all instances, the concrete
surface shall not be loose and free from dust as well as laitance.

Step 2. Application of Structural Concrete Repair Materials.

 Apply the Nitomortar on the roughen defective area using a concrete plate trowel. The
thickness of application shall be gradual until such time that required surface is
achieved.

page 17 of 22
KZ611-00-xxxx-SC-xxxx-00
METHOD STATEMENT FOR CONCRETE REPAIR

7.4 Activities Prior To Crack Repair on Horizontal and Vertical Surfaces

Prior to any remediation work on concrete, contractor shall:

 Map cracks along the concrete surface after their discovery (i.e. cracks shall be
recorded and surveyed). A survey report and pertinent drawings shall be submitted to
COMPANY within 7 days of their discovery. The mapping includes determining the
crack width and depth. Crack width determination shall be based on the below
procedure. Pertinent depth of cracks is difficult to measure, assumptions can be done
considering the correlation of crack width to the crack depth.

Procedure for the concrete crack width measurement

a. Crack Detection

Upon completion of the removal of formworks and concrete curing period, crack
detection on the newly hardened concrete shall proceed.

- Cracks shall be detected by visual inspection by a concrete specialist.

- The concrete specialist shall then record the location of the discovered cracks
and accordingly mark the extent and label the cracks using a marker or a paint.
- Preliminary measurements and an in-situ condition assessment of each
discovered cracks shall be recorded and filed.

b. Surface Preparation

Prior to commencing crack width measurement, the concrete surface shall be

grinded back to a smooth surface approximately 2 mm below the original surface.

c. Crack Width Measurement

Measurement of cracks shall be done using a Crack Width Gauge (see figure).
The pertinent crack width shall then be recorded and filed.

 Monitor cracks for 14 days after discovery. COMPANY shall indicate if additional
monitoring is necessary. In case the cracks are originating during curing, 14 days of
monitoring period is enough.
 Upon ensuring that the cracks will no longer self-propagate, CONTRACTOR shall
obtain pertinent instruction from COMPANY to start on the crack repair.

page 18 of 22
KZ611-00-xxxx-SC-xxxx-00
METHOD STATEMENT FOR CONCRETE REPAIR

7.5 Pressure-Injection for Major Cracks (Cracks ≥ 0.2mm wide at surface)

CONTRACTOR shall utilize Fosroc Nitofill EPLV. It is a low viscosity epoxy injection resin
system and is suitable for crack depths between 0.1 mm wide and 9mm. Prior to any crack
repair work, the pertinent crack width measurements shall be conducted using section 7.4 of
this document.

a. Surface Preparation
- Provide a V-shaped groove along the crack if crack is larger than 3 mm.
- Drill holes to permit the installation of the injection ports or mount the ports on the
surface as required. Injection ports shall be mounted at appropriate intervals.
- Clean the interior of the cracks, and V shape groove, using either compressed air or
vacuum systems to remove all loose materials entrapped in the cracks.
- Remove any contaminants where the surface seal will be applied. This includes
laitance, oil, dust, debris, or other foreign particles.
- QC inspector shall assess the crack prior to the application of Fosroc Nitofill EPLV.
b. Mixing of Fosroc Nitofill EPLV
- Thoroughly mix the entire hardener and base resin contents until the liquid becomes
clear.
- Do not shake vigorously otherwise air will be incorporated.
c. Application
The work shall be performed in a controlled environment (i.e. habitat) to obtain a positive
outcome on the application of the repair material. As such, air temperature and the
temperature of the substrate concrete (i.e. immediately adjacent to the crack) must be
above the freezing temperature. The working temperature as specified in pertinent
concrete repair material shall always be considered.
- Install the injection ports.
- Nitofill EPLV should be used with standard injection equipment having closed
containers. The injection pressure should be at least 0.4N/mm2 (4 bar).
- Insert an air release pin into the next nipple adjacent to the injection point. It is
important to note not to start pumping until the air release pin is inserted to release
the non-return valve and enable the release of trapped air.
- Commence pumping slowly. Do not use excessive pressure. The rate of acceptance
into fine cracks may be very slow.
- When resin appears at the nipple adjacent to the injection point:
 Stop pumping.
 Release the pressure on the injection gun.
 Remove the air release pin.
 Unscrew the cap with a twisting movement and accordingly pull off the hose.
- Attach the hose to the next nipple, insert the air release pin in the nipple and
recommence pumping.
- Repeat the process until the entire length of crack has been injected.
7.6 Surface Sealing for Minor Cracks (Cracks < 0.2mm wide at surface)

CONTRACTOR shall utilize Nitomortar FC. It is a two-component thixotropic material based

on high quality solvent-free epoxy resin systems. Prior to any crack repair work, the pertinent
crack width measurements shall be conducted using section 7.4 of this document.

a. Surface Preparation
- Provide a V-shaped groove along the crack.
- Clean the interior of the cracks using either compressed air or vacuum systems to
remove all loose materials entrapped in the cracks.

page 19 of 22
KZ611-00-xxxx-SC-xxxx-00
METHOD STATEMENT FOR CONCRETE REPAIR

- Remove contaminants where the surface seal will be applied, including laitance, oil,
dust, debris, or other foreign particles.
b. Mixing
- Mix both components till a homogeneous mixture is obtained. It is important that both
components are intermixed thoroughly and that no traces of the components remain
unmixed. Total mixing time 3 to 5 minutes.
- The “base” and “hardener” components should be stirred thoroughly in order to
disperse any settlement before mixing them together. The entire contents of the
‘hardener’ tub should be emptied into the ‘base’ container and the components mixed
thoroughly until a uniform color consistency is obtained, taking particular care to
scrape the sides and bottom of the container. Under no circumstances should part
packs be used.
c. Application
- Apply sealant using spatula, palette knife, Swedish knife or squeeze cartridge directly
over the cracks.

page 20 of 22
KZ611-00-xxxx-SC-xxxx-00
METHOD STATEMENT FOR CONCRETE REPAIR

ANNEX 1
MasterEmaco S 488 and MasterFlow 928T Data Sheets

page 21 of 22
KZ611-00-xxxx-SC-xxxx-00
METHOD STATEMENT FOR CONCRETE REPAIR

ANNEX 2
Nitofill EPLV and Nitomortar FC Data Sheets

page 22 of 22