Procedure System of Repair Procedure For Pile Concrete Surface

Al-Jaber International Company
Procedure
System of Repair Procedure for Pile Concrete Surface
1 Revision History
Revision Description of
DATE Initiated By Completed By
No# Changes
20th July Management Integration for ISO Management
2018 Representative 14001 and OHSAS Representative
01
18001 & ISO 31000
RISK MANAGEMENT
2 Distribution List
Sr. No/ Designation Issue Date Distributed by
Projects Manager & Management

01 20th July 2018
Construction Manager Representative
Management Management
02 20th July 2018
Representative Representative
03 Management
CEO 20th July 2018
Representative
04 Management
Chairman 20th July 2018
Representative
Document Issue Revision Original Revision Document Document Document

Number Number Number Issue Date Issue Date Prepared By Reviewed by Approved By
Projects
Manager & CM /PM /MR /
Chairman
AJB-RPCS- Construction CEO
1.1 01 01-01-16 20-07-18 Manager
PR-02
Copyright
This document contains confidential information. It may be copied in full or in parts only by Al-Jaber
International Company and only for the purpose of Al-Jaber International Company related activities.
Disclosure of any information contained within this procedure to any person (s) outside the employee of Al-
Jaber International Company without written permission of the Top Management is strictly prohibited.
Page 1 of 13
Procedure System of Repair
Procedure For Pile Concrete Surface
Original Issue Date: Revision Issue date:
Doc. No: AJB- RPCS-PR-01 Issue Number: 01 Revision Number: 01
01st January 2016 20th July 2018
TABLE OF CONTENTS
1 DEFINITIONS AND ACRONYMS ................................... ERROR! BOOKMARK NOT DEFINED.

2 REFERENCES AND DOCUMENTS ............................... ERROR! BOOKMARK NOT DEFINED.
3 PURPOSE ...................................................................... ERROR! BOOKMARK NOT DEFINED.
4 SCOPE ........................................................................... ERROR! BOOKMARK NOT DEFINED.
5 PERSONNEL AND RESPONSIBILITIES .................................................................................. 6
5.1 SITE SUPERVISOR ................................................................................................................... 6
5.2 WORK TEAM ............................................................................................................................. 6
5.3 QA/QC ENGINEER .................................................................................................................... 6
6 MACHINERY AND EQUIPMENT ............................................................................................... 6
7 WORK PROCESS FLOW .......................................................................................................... 6
7.1 DEFECT CRITERIA ................................................................................................................... 6
7.2 REPAIR MATERIALS ................................................................................................................ 7
7.3 PROCEDURE OF REPAIR ........................................................................................................ 7
7.3.1 REPAIR OF HONEYCOMBS ..................................................................................................... 7
7.3.2 REPAIR OF CRACKS ................................................................................................................ 7
7.4 INSPECTION ............................................................................................................................. 8
8 SAFETY, HEALTH AND ENVIRONMENT PLAN ...................................................................... 8
8.1 PPE REQUIREMENTS .............................................................................................................. 8
8.2 PERMIT TO WORK (PTW) ........................................................................................................ 9
8.3 EXCAVATION............................................................................................................................ 9
8.4 SCAFFOLDING PROCESS ....................................................................................................... 9
8.5 WORKING AT HEIGHT ........................................................................................................... 10
8.6 CONFINED SPACE ................................................................................................................. 10
8.7 H2S AWARENESS AND MONITORING ................................................................................. 10
8.8 MACHINERY AND EQUIPMENT ............................................................................................. 11
8.9 CONTROL OF WORK ............................................................................................................. 11
8.10 EMERGENCY RESPONSE ..................................................................................................... 12
8.11 SHE TRAININGS ..................................................................................................................... 13
8.12 WASTE REMOVAL ................................................................................................................. 13
This document is the property of Al-Jaber International Company. Any copying and distribution of this document
without the approval of the Management is prohibited. Page 2 of 13
LIST OF TABLES
Table 1-1 Acronyms ............................................................................ Error! Bookmark not defined.
Table 1-2 Definitions .......................................................................................................................... 5
1. Purpose
The purpose of this program is to ensure the protection of all employees of the Al Jaber from the
hazards associated with Repair Procedure for Pile Concrete Surface. This document contains
requirements for practices and procedures to protect employees from those hazards of entry into
and work within permit required Repair Procedure for Pile Concrete Surface.
It shall be the policy of the al jaber to reduce the need for Repair Procedure for Pile Concrete
Surface. It shall also be the policy of the al jaber to eliminate whenever possible, all Repair
Procedure for Pile Concrete Surface in order to reclassify permit-required Repair Procedure for Pile
Concrete Surface to non-permit required Repair Procedure for Pile Concrete Surface. When Repair
Procedure for Pile Concrete Surface is necessary, all provisions of this document are to be followed.
1. ACRONYMS & DEFINITIONS

Table 1: List of Acronyms
Acronym Description
SGPS Suleimanya Gas Power Station
ISO International Organization for Standardization
SE Safety & Environmental (Overlays)
SHE Safety Health and Environmental
FOD Field Operating Division
QC Quality Control
JHA Job Hazard Analysis
STARRT Safety Task Analysis Risk Reduction Talk
TBRA Task Based Risk Analysis
PPE Personal Protective Equipment
OSHA Occupational Safety and Health Administration
ACI American Concrete Institute
ASTM American Society for Testing and Materials
PTW Permit to Work
H2S Hydrogen Sulfide
ANSI American National Standards Institute
UXO Unexploded Ordnance
IR Inspection Request
Table 0-1 Definitions

Term Definition
COMPANY Mass Group Holding Company & Donaldson Company
CONTRACT The Principal document and the Job Description
CONTRACTOR WAJDI GROUP W.T.E
SUBCONTRACTOR AL-JABER INTERNATIONAL COMPANY
2 CONTRACT Definitions
The below Table 2: List of CONTRACT Definitions, summaries definitions for terms used through
this procedure and other CONTRACT procedures.
In instances where Table 2: List of Definitions does not provide definitions for terms identified
through this document, reference shall be retrieved from Contract No. 602118 PRINCIPAL
DOCUMENT, Section 1.1 Defined Terms.
Table 2: List of CONTRACT Definitions

Acronym Description/Meaning
COMPANY Mass Group Holding Company & Donaldson Company
OTHERS. COMPANY suppliers, Contractors, consultants, vendors and/ or
subcontracts under SGPS’ management, or under the management
of COMPANY’s Contractor and other owners, external authorities or
otherwise
CONTRACTOR WAJDI GROUP W.T.E – AL-JABER INTERNATIONAL COMPANY
IN COUNTRY (IC) AL-JABER INTERNATIONAL COMPANY
CONTRACTOR
OUT OF COUNTRY --
(OOC)
CONTRACTOR
SUBCONTRACTOR Any company or person, to whom, with approval, the
CONTRACTOR has subcontracted performance of any part(s) of the
WORK
Shall The use of the word “shall” indicates a mandatory requirement.
May The use of the word ‘may’ is to be understood as indicating a
possible cause of action.
3 PERSONNEL AND RESPONSIBILITIES

3.1 Site Supervisor
Site Supervisor shall monitor control and plan the process for repairing of
segregated or cracked precast pile. Site Supervisor shall be responsible to
ensure that the work is executed in accordance with the project procedures.
3.2 Work Team

The work team shall be responsible to work in accordance with the procedures,
SUBCONTRACTOR training and safe methods of work communicated to them
by their direct supervision, ensuring that the best industrial practices are adopted
and maintained at all times.
They shall be responsible to use correct tools and personal protective equipment
and to participate in the daily tool box talks.
3.3 QA/QC Engineer

QA/QC Engineer is responsible for verifying the repair process is done according to the
procedures and international standards.
4 MACHINERY AND EQUIPMENT

The following equipment will be used:
 Electrical Hand Tools
 Hand Tools
 Personal Protective Equipment
Perform inspections to all equipment brought into the Site prior to initial use.
5 WORK PROCESS FLOW

5.1 Defect Criteria
The defect criteria for repair shall be based on ACI 117 and ACI 301, extracted
as follows:
“1. LER and Substation building – Designated class of surface will be “B”. Surface finish
will be done as SF-2.0 (Refer section 5.3.3.3b of ACI 301)
2 Remaining all above and below ground concrete structures – Designated class of surface
will be “C”. Surface finish will be done as per below.
Surface finish for item #2:
-Patch voids larger than 1 in. wide or ½ in. deep;
-Remove projections larger than ½ in.;
-Patch tie holes”
In ACI 301, SF-2.0 is determined in Section 5.3.3.3.b as below:
“Surface finish-2.0 (SF-2.0):
-Patch voids larger than 20mm wide or 13mm deep;
-Remove projections larger than 6mm;
-Patch tie holes.”
In ACI 117, Class B and Class C surfaces are defined as follows:
“Class B - Coarse-textured concrete-formed surfaces intended to receive plaster, stucco,
or wainscoting.
Class C - General standard for permanently exposed surfaces where other finishes are not
specified.”
5.2 Repair Materials

The following approved materials shall be used for repair:
 Fosroc Renderoc HSXtra (For honeycombs with size 10mm plus)
 Fosroc Renderoc FC (For cracks with size 0-5mm)
 Fosroc Renderoc S (For cracks with size 5-10mm)
Please see Attachment-1 for the TDS of the proposed materials.
5.3 Procedure of Repair

5.3.1 Repair of Honeycombs
If honeycomb does occur which is more than 12mm in size, it can be repaired
with the following methods; at first the honeycomb needs to be identified and the
affected area will be chipped out by chisel or small grinder till hard concrete
surface.
The area should be cleaned by water and it can be repaired by patching with
Fosroc Renderoc HSXtra. Any loose aggregate should be removed before the
repair mortar application into the void. It must be ensured that it completely
penetrates the honeycombed area. The area should be slightly overfilled and
repair surface finishing quality should be similar to acceptable finishing quality of
cast piles. The patch should be cured after completing the work for one day.
5.3.2 Repair of Cracks
Cracks will be repaired if they are structural defects. If it is narrow cracks which is
0 to 5 mm then repair mortar Fosroc Renderoc FC will be used. Repair mortar
Fosroc Renderoc S shall be used for repair of “V” shape cracks. It will be made a
"V" shape profile and cleaned the area from any loose aggregate and dust by
brush or using air blower and applied the approved material. Curing must be done
on it by using burlap. Repair surface finishing quality shall be similar to acceptable
finishing quality of cast piles.
Wider cracks will be cleaned by the brush or using air blower, then it will be filled
with approved repair material with the smooth finishes by the trowel. Curing must
be done for a day and the area should be covered by burlap.
5.4 Inspection
Repaired area will be visually inspected during the repairing works by
CONTRACTOR representative and once found satisfactory, CONTRACTOR
shall raise an IR to invite COMPANY representative for final inspection.
The acceptance criteria shall be based on the relevant ACI given in the references.
6 SAFETY, HEALTH AND ENVIRONMENT PLAN

A job hazard analysis which shall be used to control or minimize the associated
risks with required mitigations is attached to this procedure. Prior to
commencement of each activity, the supervisor in charge shall confirm that the
equipment, tools, and components or lifting apparatus are suitable for the job by
performing a visual inspection and reviewing the certificates.
CONTRACTOR shall ensure that STARRT briefing is primarily conducted as per
each activity prior to commencement. The personnel engaged with the work shall
be informed about the risks and precautionary measures in associated with the
activities during STARRT briefing. Toolbox talk shall also be conducted prior to
commencement of the shift by responsible supervisor. CONTRACTOR SHE
supervisors shall verify compliance with STARRT card and Toolbox Talk. He
shall actively participate in development of STARRT card and implementation of
toolbox talk on a daily basis. SHE department shall prepare and communicate
weekly toolbox program to relevant supervisors for the implementation in
advance. In case of using SUBCONTRACTOR, He / She shall adhere to
CONTRACTOR’s SHE Plans and Procedures during all planned activities as
defined in this procedure.
The health and welfare of the employees shall be provided for with a shaded rest
area, portable toilet, with hand washing facility that shall be set up on site.
Drinking water shall be supplied at the site.
Action items from TBRA to be incorporated into safe working practices of
execution.
MSDS form the suppliers to be obtained and required safety precaution to be
observed.
6.1 PPE Requirements

Hard hats are to be worn in all designated work areas per OSHA 1926.100. Head
protection shall meet specification contained in ANSI Z89.1-1981 and/or Z89.2-
1971, complies with BS EN 397/ BS EN 812, or equivalent International
Standards.
Safety glasses with side shields are required in construction areas at all time as
per OSHA 1926.102; BS EN 166 as minimum. Prescription glasses shall be worn
per OSHA 1926.102
Foot protection shall comply with ASTM standard F-2413 (Formerly ANSI Z41) or
BS EN ISO 20345: 2004.
Hand protection, gloves shall be worn when handling material that could burn,
cut, tear, impact or cause injury to the skin.
Only approved hearing and respiratory equipment shall be worn. CONTRACTOR
shall meet the requirements for selection, fitting, and maintenance for such
equipment as per OSHA 1926.101
Fire retardant rated clothing shall be used at all times by employees working
within and in the vicinity of IOT worksite.
6.2 Permit to Work (PTW)

CONTRACTOR shall adhere to COMPANY and Permit to Work System in
Greenfield and Brownfield basis operation with respect to COMPANY limitations.
CONTRACTOR SHE Supervisor shall be in collaboration to obtain PTW from
COMPANY. Site Supervisor shall be Permit Holder and SHE Supervisor shall be
the authority to verify the permit from COMPANY prior to commencement of the
work.
CONTRACTOR shall track, update and submit PTW follow up log to COMPANY
(Refer to MAEE012-F0000-0039 Worksite Safety Plan Implementation Strategy).
CONTRACTOR shall also follow up COMPANY mandatory training program and
ensure Work Management Systems Training is received by all personnel
engaged in the project. The following documents related to the work shall be
attached to PTW sheet:
 Job Safety Analysis,
 Pre-lift checklist for Building Erection
 Certification of lifting equipment and apparatus, and
 Certificates of crane operator and riggers.
 Rescue Plan
6.3 Excavation
All excavation activities will be performed as explained on the (Doc. No: AJB-
EATP-PR-01) Excavation and Trenching Procedure.
Safe vibratory equipment / pile driving distance of 4 meters to be maintained
during 2.5 m and deeper excavations or otherwise as directed by engineering.
Location of Underground facilities (pipelines, electrical cable, instrument cable,
etc.) which are identified and documented in the TOPOGRAPHICAL VISUAL
SURVEY / UNDER GROUND SURVEY REPORT. Physical markers to be
maintained throughout the duration of the construction period.
6.4 Scaffolding Process

CONTRACTOR will apply and follow (Doc. No: AJB-WHP-RISK-01) Scaffolding
Procedure during execution of task.
 All scaffolding materials are certified as per OSHA, EN or BS.
 All scaffolding erectors shall be certified
 Scaffolding Supervisor and Inspector need to be assigned and certified.
6.5 Working at Height

During execution of all defined activities in this document, (Doc. No: AJB-WHP-
RISK-01) CONTRACTOR shall ensure the following:
 Adhere to %100 tie-off policy when working at or above 1.80 m at height
at any location where there is risk of fall from height,
 Enforce use of fall protection as a last resort with double lanyard and
shock absorber,
 Ensure a positive attachment point is provided for full body harness (i.e.,
overhead position to limit free fall distance in particular loading and unloading
works),
 Ensure all involved personnel are trained in correct use, inspection and
storage of fall protection and arrest systems (Refer to MAEE012-F0000-0039
Worksite Safety Plan and Implementation Strategy,
 Ensure that all ladders are secured from top and bottom. If not practical,
assign a stand-by person to hold the ladder through the completion of the task,
 Ensure adequate training, supervision, instruction and information to the
engaged personnel.
6.6 Confined Space

Task will be considered as a confined space activity. Doc. No: AJB-CSE-PR-01 -
CONFINED SPACE WORKING PROCEDURE will be applied during execution of
work. Below topics will be considered and applied.
 PTW for confined space entry
 Inclusive ventilation with flexible hoses
 Pre gas tests
 Safety watcher
 Continuous gas monitoring
 Proper access & egress to the pit and formworks
 Proper excavated material storage
 Rescue from confined space in case of emergency
 Kick Off meeting, which will cover safe work practices, procedures etc.,
will be held with all crew, who involves in the particular activity, prior to starting
installation of the critical foundation which are required more than 1.2 m depth
excavation,
6.7 H2S Awareness and Monitoring

CONTRACTOR shall ensure the following:
 Ensure all engaged personnel participate H2S Awareness Training
session provided by COMPANY before site entry,
 Raise awareness through visual practices such as posters, bulletins and
equivalent,
 Provide portable gas detectors to monitor H2S level,
 Ensure adequate maintenance is provided for H2S monitoring devices,
 Use of wind sock to determine the direction of wind,
 Designation of muster point/s visibly,
 Train all personnel in location of muster points, use of gas detectors &
notification of emergency,
 Provide adequate supervision, instruction and information.
6.8 Machinery and Equipment

CONTRACTOR shall ensure the following:
Perform inspections to all equipment brought into the site prior to initial use;
 Ensure all crane and lifting equipment procedure in place prior any
work,
 Perform daily start up inspections before every beginning of the shift,
 Assign competent and trained operators and drivers,
 Assign trained experienced and qualified crane operators for the
operation of that specific make and model of crane,
 Perform crane operations in accordance with Safe Lifting Procedure for
Material, Plant and Equipment, Doc. No: AJB-PME-MH-PR-01;
 Keep the manufacturer’s operator manual with the crane while it is on
the site,
 Conduct regular inspections and maintenance to the cranes in
accordance with manufacturer’s specification.,
 Monitor wind velocity constantly and interrupt the work over permissible
wind velocity limit,(Refer To Safe Lifting Procedure for Material, Plant and
Equipment, Doc. No: AJB-PME-MH-PR-01)
 Work with the lifting equipment holding valid certification (Refer to Safe
Lifting Procedure for Material, Plant and Equipment, Doc. No: AJB-PME-
MH-PR-01).
In accordance with MAEE012-F0000-0012 Drug, Alcohol and Contraband
Procedure, Heavy Equipment Operators and Vehicle Drivers shall be frequently
subject to alcohol test by portable alcohol meter. CONTRACTOR SHE
Supervisor shall conduct frequent tests to the operators and the drivers in the
beginning of the shift and whenever necessary. The records shall be made
available for COMPANY upon request.
6.9 Control of Work

 STARRT briefing shall be conducted to engaged personnel in order to
communicate the associated risks and identified mitigation measures to be put in
place.
 Toolbox talk, prior to commencement of the shift, shall be conducted on
day to day basis.
 Loading, unloading and erection works shall be restricted to
unauthorized access to non-involved personnel.
 Only certified lifting equipment and apparatus shall be used and
discarded in case of any deficiency immediately.
 Color code applied to all lifting equipment and accessories and electrical
tools and equipment.
 Pre-lift checklist shall be prepared. Lifting supervisor/foreman shall
verify and authorize lifting crew to commence to the lifting operations defined as
routine lifting.
 Only competent/trained riggers shall be assigned for lifting works.
 During lifting operations, operators must clear/monitor the area visually
and use hand signals as appropriate.
 Appropriate signs and posters shall be posted at the source of hazards
pertaining to construction activities and nearby structures or lands such as UXO,
H2S and equivalent.
 All waste shall be collected in waste containers with covers on site and
disposed of in accordance with local requirements.
 Fuelling of equipment shall be done at the designated area with the fuel
truck on site Spill kit shall be available at that area.
 Safety signs shall be posted at the construction site.
 All construction vehicles shall have a functioning and audible back-up
alarm.
 Lifting Plans should be prepared for each work. Regarding to lifting plan,
lifting equipment(s) and lifting accessories should be brought to working area.
 Safety harness shall be used by personnel working at height as last
resort.
 Harness/lanyards shall be checked and make sure they are in good
condition.
 Electrical tools are needed to be checked for monthly, prior to use color
code must be implemented.
 Lifting accessories and other tools are required to be inspected prior to
use.
 Excavator, JCB, forklift and similar heavy equipment shall be inspected
initially and records shall be documented. Daily checklists shall be filled by the
operator and verified.
6.10 Emergency Response

All incidents, regardless of minor or major, shall be immediately reported in
accordance with COMPANY reporting requirements within an hour of occurrence.
CONTRACTOR shall follow up site specific incident notification process. This
process shall be clearly defined and communicated to all Project personnel by
means of emergency response flowcharts and phone numbers located within the
Project site and locations. CONTRACTOR shall also report security and/or
socioeconomic basis incidents to COMPANY.
MAEE012- F0000-0034 Emergency Preparedness and Response Plan will be
applied during execution of work.
Rescue plan will be attached to PTW and will be approved by COMPANY before
start any activity.
6.11 SHE Trainings

Besides safety induction training provided by CONTRACTOR, the following
trainings shall be received from the COMPANY or COMPANY approved
personnel as necessary:
CONTRACTOR shall follow up the training schedule as follows:
 SGPS Safety Induction Training;
 UXO Awareness;
 H2S Training;
 JSA Training
6.12 Waste Removal

All wastes shall be segregated and controlled in accordance with Waste
Management Plan Doc. No: AJB-IMS-PR-19 throughout the installation process.
It shall be dug a proper pit to collect the rain water inside the excavating area, then the
collected water will be discharged via submersible pump and water truck. All rain water will
be discharged to existing drainage channels. In case of need, it will be discharged to out of
IOT site.

Procedure System of Repair Procedure For Pile Concrete Surface

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Al-Jaber International Company

Projects Manager & Management

Document Issue Revision Original Revision Document Document Document

1 DEFINITIONS AND ACRONYMS ................................... ERROR! BOOKMARK NOT DEFINED.

1. ACRONYMS & DEFINITIONS

Table 0-1 Definitions

Table 2: List of CONTRACT Definitions

3 PERSONNEL AND RESPONSIBILITIES

3.2 Work Team

3.3 QA/QC Engineer

4 MACHINERY AND EQUIPMENT

5 WORK PROCESS FLOW

5.2 Repair Materials

5.3 Procedure of Repair

5.3.2 Repair of Cracks

6 SAFETY, HEALTH AND ENVIRONMENT PLAN

6.1 PPE Requirements

6.2 Permit to Work (PTW)

6.4 Scaffolding Process

6.5 Working at Height

6.6 Confined Space

6.7 H2S Awareness and Monitoring

6.8 Machinery and Equipment

6.9 Control of Work

6.10 Emergency Response

6.11 SHE Trainings

6.12 Waste Removal

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