CORROSION REPAIR AND PROTECTION WORKS

CONTRACT NO.: 560-S28

METHOD STATEMENT
FOR
REPAIR OF CONCRETE SURFACE WITH
CEMENT GROUT

DOCUMENT NO.: 00-000-00

REV DATE DESCRIPTION PREPARED BY CHECKED BY APPROVED BY

00 2013-10-06 ISSUED FOR RIZWAN MAJED ES KIM
APPROVAL

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 CORROSION REPAIR AND PROTECTION WORKS
CONTRACT NO.: 560-S28

TABLE OF CONTENTS

1. TITLE.

2. SCOPE OF WORK
General description.
Plant and equipment.
Site planning & preparation
Work methodology.
Organisation, Responsibilities & Supervision.
Work Force.

3. HEALTH & SAFETY

Risk assessments
Risk Abatement
NDIA E S & H Contractor Requirements
Protective & Safety Equipment.
Contractual Requirements.
Information to personnel.
Emergency Procedures.
Permit Requirements.

4. ENVIRONMENTAL ISSUES
Environmental Impact assessment.
NDIA E S & H Contractor Requirements
Contractual Requirements.
Emergency Procedures.

5. QUALITY ASSURANCE
Contractual Requirements.
Critical works.
Inspection & Testing.
Follow up & Evaluation.

6. APPENDICES

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 CORROSION REPAIR AND PROTECTION WORKS
CONTRACT NO.: 560-S28

1. TITLE
 REPAIR OF CONCRETE SURFACE WITH CEMENT GROUT

2. SCOPE OF WORK
General Description
 To repair unsound or scaling concrete using Cementitious grout as per RC Guideline
and Specification.

Plant and Equipment

 List of Equipments:
1. Compressor
2. Portable Concrete Cutter
3. Chipping Hammer
4. Generator Set
5. Water Truck

 Permits to be attached:
1. Encroachment permit
2. Work Permit

 Test certificate to be attached:

1. MSDS
2. Quality Assurance Test Certificate

Material
 List the type and approximate quantities to be used.
1. Cementitious Repair Mortar Grout

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CONTRACT NO.: 560-S28

 Explain how deliveries are handled on site and describe the logistic routines.
Big volume delivery will be receive and stock in the lay down area store room, in secured
and controlled room. Materials will be delivered in the site according to the requirement.

Site Planning & Preparation

Encroachment permit will be obtained first before starting any activity in the site. Once
the area is determined and granted, the safety personnel will established the perimeter
barricade to warn others and to prevent the public from entering the work site. If
rerouting is necessary the safety personnel will establish first the rerouting of access
roads and install warning devices to warn passing traffic in the area. Once all necessary
equipment is positioned, commenced the preparatory job, this isolation method will be
strongly employed thru out the duration of the project to prevent hazard to the public.

Work Methodology
 Listed below is the activity in sequence for the excavation:
1. Clean the unsound concrete. It must be free of oil, dirt, debris and paint.
2. Chipped the unsound concrete exposing the aggregates using scrabbles, bush hammer
with minimum thickness of 3mm until the unsound concrete is removed and exposing the
aggregates.
3. Remove all residue using vacuum cleaner or compressor then finally clean it with water
and dry it making the concrete open surface texture with all curing compound and
sealers removed.
4. Soak concrete surface for twenty four (240 hours prior to grouting. (patching will be done
according to RC specs. Section 03930, item 3.08).
5. Mix small amount of grout as per your requirement as working time usually only 10
minutes to avoid non-workable mix.
6. Then apply immediately to the prepared concrete surface and smooth it as per finishing
of the adjacent concrete.

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 CORROSION REPAIR AND PROTECTION WORKS
CONTRACT NO.: 560-S28

Organisation, Responsibility & Supervision

 Construction Manager – will be the one to plan and coordinate all the activity in the site
and he will be responsible for coordinating with other contractor working in the area.
 Safety Personnel – will be the one to establish all necessary warning signs and
barricades establish the high risk areas in coordination with the Construction Manager
and constantly monitor the activity in terms of safety to all the workers. Furthermore he
will give advice on current and forecasted safety issues and concern.
 Site Engineer - will be the one to implement the instruction of the Construction Manager
in the site, he will also directly supervise constantly the manpower and equipment
working in the area and implement all safety regulation and precaution set by the safety
personnel.
 Quality Control Inspector – Will be the one to inspect and monitor the repaired area
before recommending to RC Engineer for inspection.
 Supervisor – will be the one to supervise and assign the works as per schedule.
 Carpenters – will be the one to install and remove the shuttering.
 Mason – will be the one to perform the concrete works such as patching , surface
preparation and to install grouting.
 Technician – will be the one to do application of the water proofing membrane and coal
tar.

Work Force
 Listed below is the manual workforce :
1. Site Engineer = 1
2. Supervisor = 2
3. Compressor Operator = 4
4. Water Truck Driver = 3
5. Mason/Technician = 2
6. Skilled Helpers = 4

3. SAFETY AND HEALTH

Risk Assessment
 The following are the risk assessment for this activity:
1. Eye injury due to concrete chippings.
2. Chemical contamination of the skin due to spillage.
3. Chemical poisoning due to inhaling of hazardous chemical and dust.

Environmental Safety & Health Contractor Requirements

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CONTRACT NO.: 560-S28

 Section II series 15 ( Personal Protective Equipment)

Protective & Safety Equipment

 The following are the list of Personal Protective Equipment:
1. Hard hat, to be worn at all times
2. Safety shoes, to be worn all times
3. Safety gloves, to be worn all times
4. Safety goggles, for workers around working equipment
5. High visibility vest, especially for workers around machinery, to be worn all times
6. Ear plugs
7. Mask

Contractual Requirements
 SECTION II – 200 SERIES (15: Personal Protective Equipment):
15.1 Personal Protective Equipment shall be considered only as a “last resort of
defence” against potential risks and hazards. Where so ever possible hazards
and risk are to be addressed and reduced by other means.
15.2 Based upon the findings of 3.1.3 Section 1 and 11 above the contractor shall
ensure that adequate stock of Personal Protective Equipment are readily either
available on site or issued to personnel. PPE shall be considered as consumable
items.
15.3 All PPE utilised shall be manufactured to a recognized international acceptable
standards.

Information to Personnel
 All the manual workers that will be working in the site will be informed and reminded by
conducting morning tool box meeting in order to continuously remind them of the existing
safety risk and it will be handled by the designated site supervisor and sometimes with
the presence of the safety personnel.

Emergency Procedures
 The following are the safety procedure that will be implemented in case of accident:

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1. In case of traffic accident or person hit by the equipment notify immediately the police
and emergency crew do not engage in moving the person who are injured.
2. In case of eye injury the person injured shall immediately stop working and secured the
eye that were injured and avoid scrubbing it and bring him immediately to the clinic for
cleaning and if severe eye injury brings him to the nearest hospital for proper care.
3. In case of skin contamination due to chemical immediately clean the contaminated area
by washing it with clean water with soap if severe injury cover the injured part with a
clean cloth and bring him to the nearest hospital for proper care.
4. In case of respiratory contamination immediately remove him from the site area so that
he can breathe a clean air if it is severe injury bring him immediately to the nearest
hospital for proper care.
5. Emergency contact numbers including Police, Ambulance and Industrial Security will be
prominently posted on bulletin board.
6. First Aid box will be readily available on site.

Permit requirements
 The following are the required permit before implementing the activity:
1. Encroachment permit
2. Work permit
3. Transport Permit

4. ENVIRONMENTAL ISSUES
Environmental Impact Assessment
 One possible risk to the environment is oil spillage may be due to equipment breakdown.
If and when this will happen immediately contained the area of contamination then
remove the contaminated soil. In order to avoid this incident proper maintenance
procedure for the equipment shall be implemented.
 Other possible risk to environment is garbage and debris accumulated thru-out the
construction activity, for this matter collection bin shall be used and proper disposal and
housekeeping shall be done.
 Other possible risk to environment is chemical spillage due to improper mixing and
disposal of chemical used in the activity. In order to avoid this proper mixing container
shall be used and proper disposal and housekeeping shall be done.

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 CORROSION REPAIR AND PROTECTION WORKS
CONTRACT NO.: 560-S28

5. QUALITY ASSURANCE
Contractual Requirements
 The quality assurance requirements base in our contract specification are the following:
1. Prior to chipping of concrete activity RC Field Engineer shall inspect the unsound
concrete to verify the area of the repair.
2. Once chipping and preparation of concrete is complete RC Field Engineer shall inspect
it, if he is satisfied with the preparation he shall sign the Hold Point Release to
commence with the application.
3. Once application of grout is complete RC Field Engineer shall inspect and will sign the
Hold Point Release to commence with the application.
4. RC Engineer shall inspect the approved materials which will be incorporated into works.
5. RC engineers shall inspect hold point release (HPR) and witness points as per ITP.

Critical Works
 The possible critical works for this activity is the preparation of the concrete surface as it
will affect the quality and the duration. Once the preparation is not properly done redoing
the job will entail more time especially when aggregates is not properly exposed. The
other critical work is in the application of the grout as it shall be done systemically in
order to avoid drying of the chemical grout as it can affect the quality of work and if not
properly done it will be repaired again and it will affect the schedule.

Inspection & Testing

 Prior to chipping of concrete RC Engineer shall inspect the area of the unsound concrete
for area verification.
 Once concrete preparation is complete RC Engineer shall inspect the area and conduct
a dust cleaning test.
 After application of grout RC Field Engineer shall inspect the completed section
according to finishing and strength and shall conduct a hammer test.

Follow up & Evaluation

 We intend to follow up and evaluate our performance by constantly implementing strict
quality control as this is the most critical activity that can affect our progress and
constantly monitoring it and implement measures to expedite this activity. The crewing

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 CORROSION REPAIR AND PROTECTION WORKS
CONTRACT NO.: 560-S28

system shall be monitored constantly in order to meet the required volume installed and
any delays shall be recorded and evaluated in order to implement measures and
improvements to augment the productivity.

6. APPENDICES

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