PREPARED

SOMJIT.B 05 Apr 17
BY PTT Public Company Limited
CHECKED Fourth Transmission Pipeline
PRASOBSUK T 07 Apr 17
BY Midline Compressor Station
Project
APPROVED THUSSAKORN
07 Apr 17
BY K.

REV REVIEWED APPROVED

DATE DESCRIPTION
NO. BY BY
O1 06 May 16 Sun Xiuquan Zhang Shuiqing Issued for Comment (IFC)
F1 07 Apr 17 Sun Xiuquan Zhang Shuiqing Approve for Construction (AFC)

METHOD STATEMENT FOR CONCRETE REPAIRING

IBC-MS.C0-40-1304.04-4800-013 Rev. F1

TOTAL 12 PAGES

PTT CONTRACT NO. : PROJECT NO. : AREA CODE:

PTT.SP./2/7258 1304.04 4800
 PTT Public Company Limited
Method Statement for Concrete Repairing Fourth Transmission Pipeline Midline Compressor Station Project

Contents

1.0 PURPOSE………………………………………………………………………3

2.0 SCOPE OF WORKS…………………………………………………………...3

3.0 REFERENCE DOCUMENTS…………………………………………………3

4.0 TYPE OF DEFECT……………………………………………….…………….3

4.1 BUBBLES/BLOW HOLES……………………………….…………………….3
4.2 FORM AND SAND STREAKING………………………….………………….4
4.3 FINS………………………………………………………….…………………..4
4.4 CRACKS……………………………………………………….…….………….4
4.5 HONEYCOMB/VOID/CAVITY……………………………….……….............5
4.6 PROTRUDING TIE WIRES……………………..…………….………………5
4.7 FORM OFFSETS..…………….……………………………….………………6

5.0 REPAIR METHODS………………………………………………….……….6

5.1 HANDPATCHING……………………………………………………………...6
5.2 FLUID GROUTING…………………………………………………................6
5.3 EPOXY INJECTION………………………………………….……….……….8

6.0 SAFETY PRECAUTIONS…………………………………………………..10

7.0 INSPECTION TEST AND RECORD………………………………………10

8.0. ATTACHEMENT…………………………………………………………….11

Page of IBC-MS.C0-40-1304.04-4800-013 Rev.F1

 PTT Public Company Limited
Method Statement for Concrete Repairing Fourth Transmission Pipeline Midline Compressor Station Project

Page of IBC-MS.C0-40-1304.04-4800-013 Rev.F1

 PTT Public Company Limited
Method Statement for Concrete Repairing Fourth Transmission Pipeline Midline Compressor Station Project

1.0. PURPOSE

This procedure describes the basic method to be used for the field repair of concrete with the
purpose of ensuring that the work to be performed is carried out in accordance with the applicable
codes and standards and satisfies the requirements of the Contract Specification.

2.0. SCOPE OF WORKS

Verifying and repairing defects on the concrete structure for further construction of buildings,
structures, equipment foundations and foundations for the piping in all areas of the project
including method of work, materials, Manpower, equipment, Inspection and testing. Joint
inspection between representatives from PTT and CPP shall be carried out for any concrete
defects. Representative from PTT will then identify the defects and decide the repairing
method, either cement plastering, cement patching, fluid grouting, and pressure grouting or
concreting.

3.0. REFERENCE DOCUMENTS

 IBCI-PR.Q0-40-1304.04-4800-001 REV.A2 Inspection test plan for civil work.
 GES.01.40.001 Rev D1 Specification of Civil works.
 GES.01.95.092 Construction Inspection
 GES.01.40.004 Rev.D1 Architectural Materials and Workmanship.

4.0. TYPE OF DEFECT

Any remedial treatment to surfaces shall be subjected to PTT. Any concrete surface shall not be
repaired prior to inspection of PTT.
4.1. Bubbles / Blow Holes
The acceptance criteria for identifying defects are as follows:
- Maximum area of bubble: 3cm²
- Maximum depth: 10mm
- Maximum total area of bubbles: 10% of the area of the concrete element, and 10%
of a part of the concrete element in case of concentrated bubbles.
The bubbles area fall outside the acceptance criteria shall be patched using dry packed

Blow Holes

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 PTT Public Company Limited
Method Statement for Concrete Repairing Fourth Transmission Pipeline Midline Compressor Station Project

4.2. Form and sand streaking

Streaking shall be patched using dry packed grout. All shuttering surfaces which have been
previously used for formwork must be thoroughly cleaned before re-use.

4.3. Fins
All fins area shall be removed by chiseling or grinding and removed parts must be filled back
with non-shrink mortar grout. The correct use of formwork release agent shall be applied to the
surface before to close the form to prevent fins due to concrete adhesion.

4.4. Cracks
Crack width shall be limited to 0.3mm for reinforced concrete (base slab and roof) and 0.2mm
for pre-stressing concrete (wall and ring beam) during construction stage. Crack of width less
than acceptance criteria shall be monitored and not be treated as crack for repair, unless they
increase to the limit value or more.
Any crack exceeding 0.3mm wide for RC or 0.2mm wide for RC on the concrete surface shall be
repaired by using epoxy base grout or equivalent.
Final monitoring of crack inside wall to be performed after air rising of root and prior to start
installation of wall liner.
Final monitoring of crack inside wall to be performed after completion of hydrostatic/pneumatic
testing.

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Method Statement for Concrete Repairing Fourth Transmission Pipeline Midline Compressor Station Project

4.5. Honeycomb / Void / Cavity

Honeycombs, voids and surface damages larger than 10mm diameter caused by honey-
combing or improper compaction, loose particles, laitance and unsound material shall be removed by
Chiseling, back to sound concrete.

4.6. Protruding Tie wires

Visible tie wires from reinforcement bars shall be removed my mechanical cutting after concrete
chiseling as deep as concrete cover. Chipped parts must be filled back with non-shrink mortar
grout. All wire ends shall be bent in to concrete body before casting in a way that they do not
protrude into the concrete cover zone.
4.7. Form offsets
Concrete offset must be flattened by grinding.

5.0. REPAIR METHODS

The specific repair method will be decided according to the following criteria.

Depth of defect Type of defect Repair Method Material

0~50Lmm a n k
Outside o
criteria bubble , 7 3 patching
Hand 1 LankoR731 Repair
e p a
honeycomb, non-structural
Motar
crack, protruding wire , fin,
streaking, damage concrete
>50mm Honeycomb, damaged Fluid grouting Lanko 701 Calvex
concrete
c e m e n t , f i b e r
Crack growing in depth Structural crack Epoxy injection Sikadur-52TH(Epoxy
Resin)

MOTAR protects steel rebar from corrosion.

Lanko 701 Clavex is a premixed cementitious non-shrink, high strength developing grout
composed of
special cement, sand and admixtures.
Sikadur-52TH is low viscosity injection liquid, based on high strength epoxy resinafter mixing
is injected into cavities and cracks in concrete where it cures to a high strength material.

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 PTT Public Company Limited
Method Statement for Concrete Repairing Fourth Transmission Pipeline Midline Compressor Station Project
5.1. Hand Patching
5.1.1. Determine the affected area and saw cut perimeter of the repair. The perimeter should be
recessed to a depth of 5mm to prevent feather edging.
5.1.2. The saw cuts should be perpendicular to the concrete surface or tilted inward 2 to 3 degrees to
provide retaining keyways that mechanically the repair material into the area. The saw cut
perimeters should have rounded corners whenever reasonable.

5.1.3. Break out the repair area to remove all unsound, contaminated of damage concrete to a
minimum depth of 10mm, up to the pre-cut perimeter of the repair, by means of bush-hammering,
scrabbling, or jack-hammering.
5.1.4. Clean the concrete surface to remove laitance.
5.1.5. Saturate the area to be repaired with water and remove any excess.
5.1.6. Machine-mix or hand-mix one 25 kg bag of 731 REPAIR MORTAR with 4.25 litres of clean water
(i.e. 17% water content) for 3 minutes minimum until evenly distributed.
5.1.7. Apply a first batch of 731 REPAIR MOTAR with a stainless steel trowel, pressing firmly to ensure
bonding.
5.1.8. Apply additional mortar to obtain the desired overall thickness.
5.1.9. Trowel or float the repaired surface for a smooth finish.
5.1.10. For a large surfaces, the mortar may be applied by machine spray.
5.2. Fluid Grouting
5.2.1. Determine the affected area and cut perimeter of the repair. The perimeter should be recessed
to a depth of minimum 25mm.
5.2.2. Break out the repair area to remove all unsound. Contaminated or damage concrete to sound
Concrete by means of bush-hammering, scrabbling, or jack-hammering
5.2.3. The maximum size of jack-hammers should not larger than 30 kg to prevent damage
surrounding
Sound concrete. If any rebar is exposed, precaution shall be taken to not damage it and hand
Chiseling shall be done around the exposed rebar.
5.2.4. Top side of repair area should be sloping downward from outer concrete face.

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Method Statement for Concrete Repairing Fourth Transmission Pipeline Midline Compressor Station Project

5.2.5. Reinforcement bars exposed during concrete removal require special treatment. As a minimum,
Boned concrete must be removed by wire brushing.
5.2.6. Clean the concrete surface to remove laitance, oil, grease or any other loose adhering particles.
5.2.7. Joint inspection with CPP’s QA/QC engineer for the concrete condition.
5.2.8. Thoroughly wet all surface and remove any excess water just before introducing the grout.
5.2.9. Close and secure the formwork.
5.2.10. Formworks shall be sufficiently tight-fitting and sealed against leakages.
5.2.11. On the placement side, the forms should be constructed above the bottom of the plate to form a
head box. The head box should be positioned at a minimum of 50 mm from the plate and slope
way at a 45° angle to assist grout placement as well as prevent air entrapment.
5.2.12. The form should be minimum 50 mm away from the plate and extend at least 25 mm above the
bottom of the plate.
5.2.13. Non-absorbent formwork is preferred, otherwise, it should be properly oiled to prevent grout
adhesion.
5.2.14. Thoroughly wet all surfaces prior placement and remove any excess water just before
introducing grout.
5.2.15. The mixed grout should be placed promptly before it stiffens. Higher temperature will accelerate
setting time.
5.2.16. Pour grout from one side only to avoid air entrapment.
5.2.17. adequate grout head must be maintained at all time to achieve a continuous flow.
5.2.18. Use a rod or strap to assist in large/difficult placement as well to as to facilitate maximum surface
contact. Vibrator should not be used. Excessive vibration will cause separation of each
ingredient
5.2.19. As soon as the mortar begins to set, the exposed surface should be treated with a protective
coating.

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Method Statement for Concrete Repairing Fourth Transmission Pipeline Midline Compressor Station Project

5.3. Epoxy Injection as per ACI 224.1R-07 Chapter 3.2

Crack which are primarily due to drying shrinkage shall be repaired after the crack is stabilized
over a period of time.
Cracks that are due to ongoing foundation settlement shall be repaired only after the settlement
problem is corrected, after crack became stable.

Crack width gauge will be used for measure the crack width.

For monitoring the growing crack, 2-directions crack monitoring gauge shown in figure below
Shall be used. Accuracy of the monitoring device is +/- 1.00mm; for more accurate monitoring
to +/-0.1mm, Vernier, dial or digital calipers can be used to measure the distance between the
monitoring spigots.

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 PTT Public Company Limited
Method Statement for Concrete Repairing Fourth Transmission Pipeline Midline Compressor Station Project
5.3.1. Clean and remove any contaminants, such as oil, grease, dirt, or fine particles of concrete from
cracks by vacuuming or flush with water or other effective cleaning solutions.
5.3.2. The Solution is then flushed out using compressed air and neutralizing agent or adequate time is
provided for air drying.
5.3.3. Open up the two containers of Sikadur 52-TH epoxy crack sealer and scoop out the two
components. Proportion two parts by volume of component “A” to one part of components “B” into
clean, dry mixing pail. Use separate sticks to avoid contamination.
5.3.4. Mix the two parts on a scrap board using a clean putty knife; blend until achieve a uniform color
(around 3 minutes). Mix only that quantity of material that can be used within its pot life
( see potlife table below ). Sikadur 52-th potlife:

Temperature Potlife

30°C 30 minutes

40°C 15 minutes

5.3.5. Spread some sealer onto the base of plastic injection ports; being careful not to plug up its hole.
A steel nail can be placed into port to insure the injection canal to be blocked.
5.3.6. Align the port over the crack and press it to concrete surface. Install remaining ports in a similar
manner (every 30cm to 50cm).

5.3.7. Mix up a slightly large batch of epoxy sealer and apply it to entire crack using a putty knife or
margin trowel. Spread the sealer about 3mm thick 20mm on either side of the crack. Also, cover
the entire flange of each injection port with crack sealer, leaving only the extended neck portion.
5.3.8. Start injection under pressure from one end of the crack (the lowest flange) until the epoxy
overflows from the flange immediately above, seal of the first and proceed to inject from second
flange above etc. Note: substrate temperature shall not exceed 30 degrees to be injected.
5.3.9. After the injected epoxy has cure (5 to 7 days), flanges and surface seal should be removed by
grinding or by other appropriate manners for subsequent painting work (by others).
5.3.10. Clean up: uncured material can be removed with approved solvent, cured material can only be
removed mechanically.

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Method Statement for Concrete Repairing Fourth Transmission Pipeline Midline Compressor Station Project
5.3.11. Structural cracks shall be tested if required by Electronic pulse velocity method.

6.0. SAFETY PRECAUTONS

6.1. All material shall be stored, handled and used in the proper way as recommended by
the manufacturer.
6.2. Consider environmental impact and control.
6.3. All necessary PPE shall be issued prior to start of work, such as rubber gloves, face masks,
safety goggle, etc.
6.4. Precaution while mixing and handing of chemicals must be taken as per manufacturers
recommendation.
6.5. Material Safety Data Sheets (MSDS) shall be provided to the site supervisor and briefing the
workers involve in the task.
6.7. Being cement based, Lanko 701 Duragrout is alkali in nature, which can cause dermatitis.
Thus, when using Lanko 701 Duragrout, it is recommended that applicators wear PVC or similar
gloves and safety goggles. If dust is generated, wear a suitable dust mask.

7.0. INSPECTION ANDTEST RECORD

7.1. All necessary testing shall be carried out and witnessed by PTT/CPP.
7.2. Inspections and tests shall be carried out based on standard/documents listed in
IBC-PR.Q0-40-1304.04-4800-001 Rev.A2 Inspection test plan for civil work.
7.3. All reports and test results shall be submitted to PTT/CPP.in a timely manner.

8.0. ATTACHEMENT

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Method Statement for Concrete Repairing Fourth Transmission Pipeline Midline Compressor Station Project
8.1. Method statement for repair concrete by LANKO 731.
Case of Cover Bracing steel rod in footing
(การซ่อมคอนกรี ตที่สกัดเพื่อตัดเหล็กรัดแบบออก) –กรรมวิธีการซ่ อมโดยใช้ วสั ดุ LANKO 731

8.2. Cutting concrete to depth 25 mm (75x75 mm.) cut steel rod, Mark bottom line 50 mm
under cutting hole

(สกัดคอนกรี ตออก ให้ลึกประมาณ 25 มม ทำการตัดเหล็กออก)

8.3. Application ขั้นตอนการใช้งานของ LANKO 731

8.3.1. Machine-mix or hand-mix one 25 kg bag of 731 REPAIR MORTAR with 4.25 litres of clean water
(i.e. 17% water content) for 3 minutes minimum until evenly distributed.

ทำการผสมผงมอร์ ต้า ในอัตราส่วนผงมอร์ ต้า 25 กิโลกรัมต่อน้ำ 4.25 ลิตร การผสมสามารถผสมด้ วยมือ

หรื อ ผสมโดยการใช้ เครื่ องปั่ น โดยใช้ เวลาประมาณ 3 นาที จนส่วนผสมเข้ ากันดีแล้ ว

8.3.2. Apply a first batch of 731 REPAIR MOTAR with a stainless steel trowel, pressing firmly to
Ensure bonding.

ทำการปะอุดส่วนผสม ส่วนแรกด้ วยเกรี ยงเหล็ก จนเนื ้อผงมอร์ ต้าเกาะติดกับคอนกรี ตแน่น

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Method Statement for Concrete Repairing Fourth Transmission Pipeline Midline Compressor Station Project
8.3.3. Apply additional mortar to obtain the desired overall thickness

ปะอุดส่วนผสมเพิ่มเติม จนได้ ความหนา ตามที่ต้องการ โดยให้ เนื ้อส่วนผสมนูนออกมา

8.3.4. Trowel or float the repaired surface for a smooth finish.

แต่งผิวด้ วยเกรี ยงเหล็ก ให้ ผวิ เรี ยบดูเรี ยบร้ อย

ใช้ Lanko 731 ซ่อม โดยการอุดให้นูน

ออกมา

(This is completed the step of repair concrete)

รู ปที่เสร็จเรี ยบร้อยแล้ว

Page 13 of 13 IBC-MS.C0-40-1304.04-4800-013 Rev.F1