PP14-00-Y-CNL-SAR-004-RA Concrete

11
SAUDI ARCHIRODON LTD. Early and General Civil Works for Riyadh
Integrated Management System PP14 - Combined Cycle Power Plant
Employer Ref. No. PP14-00-Y-CNL-SAR-004 Rev A
Reference No. 11061-PMG-PSP-03-F01 Rev 0
Method Statement for Serial No. 0011
Concrete Repair Works Page Page 2 of 16
Table of Contents

1.0 Purpose and Scope .............................................................................................. 3
2.0 Document Control ............................................................................................... 3
3.0 Reference Documents ......................................................................................... 4
4.0 Responsibility ..................................................................................................... 4
5.0 Materials ............................................................................................................. 5
6.0 Resources ............................................................................................................ 5
7.0 Methodology / Procedure.................................................................................... 6
8.0 Quality Control ................................................................................................... 9
9.0 Health, Safety and Environment ......................................................................... 9
Appendices
Appendix A Fairing Coat for Repair of Pinholes Thickness 3mm - 30mm.

Appendix B Repair of Voids, Honeycombing & Segregated concrete exceeding
10 mm & not more than 75 mm thick.
Appendix C Repair of Voids, Honeycombing & Segregated concrete exceeding
thickness exceeding 50 mm.
Appendix D Job Safety Analysis (JSA).
2
1.0 Purpose and Scope
1.1 This method statement describes the techniques and methods to be implemented and the
resources to be utilized for all the concrete repair / rectification works required in the
construction of the ‘‘Early and General Civil Works at Power Plant PP14 in Riyadh, Saudi
Arabia’’.
1.2 This Method Statement details the method of carrying out repairs works to any concrete, in-
situ or precast that has blown holes, honeycombing or minor surface cracks for all concrete
works wherever required.
2.0 Document Control
2.1 This method statement is a controlled document as required by the system procedure Quality
Planning and it is issued in accordance to the system procedure Control of Documents and
Data. Furthermore, it will be distributed as such to those detailed on the Internal Distribution
of Documents Matrix maintained by the Document Controller.
2.2 Internal distribution of this document will be by the Document Controller, while external
distribution will be via the Secretary.
2.3 The documents govern the preparation, registration, approval, distribution and
amendment/revision of this method statement will be detailed in below paragraphs if necessary.
2.4 This method statement is subject to amendments during the execution of all operations
described above in Paragraph 1.2, as a result either of periodic reviews or whenever
circumstances demand such an action.
2.5 Revisions will be issued in accordance to the system procedure Control of Documents and Data
both whenever the body of the method statement changes and when an appendix is being added
or removed. Revised appendices for substitution will be issued separately and, where
appropriate, will include a separate schedule of contents. Revisions to the text of this document
will be indicated by a black line in the right hand side. Revisions to forms and the like will be
indicated by ‘’clouding’’ the changed information.
2.6 Details of previous revisions will be removed. This document’s revision and appendix issue
status is shown in the Project Register of Management System Documents, a copy of which
may be obtained from the Project Office upon request.
2.7 This document includes all revised versions, will be included in 11061-PMG-PSP-10-F01,
“Deliverables Plan” prepared by the Project Controls Manager and maintained by the
Document Controller.
3
3.0 Reference Documents
3.1 The following documents define the requirements to be employed to demonstrate compliance
of the works defined in this method Statement:
 Specifications / Codes / Standards
Ref. Title
PP1314 - 00 - Y - CI - WP - 301 - Rev - 01 Concrete Technical Specification
NOTE: The design, all materials, constructions and installations, tests and investigations
also on site, shall be as a minimum conform to the latest edition or replacement of the
Codes and Standards listed in alphabetical order in the project Tender Documents, as far
as these standards, codes and regulations are available in English language edition
Add GEMSS-C-15
 Documents
Ref. Title
PMG-PRO-10 Development and Control of Project IMS Documents
and Records
PMG-WI-001 Guidelines to Develop a Method Statement
QLT-WI-002 Codification of IMS Document
QLT-PRO-04 Control of Inspection and Testing of permanent
works
JSP-QM-43-10-001 Inspection Procedure for Civil Works (with ITP)
HSE-PRO-10 HSE Risk Assessment for Activities
11061-PMG-PRO-10-D01 Project Quality Plan
11061-PMG-PRO-10-D02 Project HS Plan
11061-PMG-PRO-10-D03 Construction Environmental Management Plan
PP14-00-Y-CPT-SAR-002 R1 Inspection & Test Plan for civil works
PP14-00-U-CHO-SAR-027 RA Material Approval for Repair Material
PP14-00-U-CHO-SAR-023 RA
Inspection and Test Plan for Concrete Civil Works
11061-QLT-PRO-04-F03
Cast in Place and Precast Elements
4.0 Responsibility Revise revision mark
4.1 The Project Manager is responsible to appoint site supervisory personnel to organize,
coordinate, and oversee the execution of the work detailed in this method statement.
4.2 The Construction Manager is responsible for the organization and coordination of the entire
work detailed in this method statement.
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4.3 The responsible Section Engineer is responsible for the execution of the works detailed in this
method statement. He will be responsible for instructing the Foremen/Superintendent about the
requirements of the contract, including all restrictions, safety regulations, scope of work and
time schedule. In addition, he will be responsible for related logistic matters and all matters
related to HSE and the quality of the works.
4.4 The Site Civil Engineers are responsible to assist the Section Engineer and to ensure that the
construction teams will be provided with the necessary information to execute their work
accurately and effectively.The Superintendent/Foreman is responsible for the day-to-day
implementation and supervision of the works detailed in this method statement.
4.5 Assigned HSE staff is responsible to assist the construction team to develop safe methods of
working and to monitor implementation of the controls as required.
4.6 Assigned QA/QC staff is responsible to assist the construction team to ensure all works comply
with specified requirement and to monitor implementation of the controls as required.
5.0 Materials
5.1 Materials
 All materials to be used in the permanent works will comply with the latest project
specifications and appropriate Material Approvals will be submitted and approved prior to the
incorporation of the materials into the works.
 Quality Control tests will be performed as required by the project specifications to ensure
compliance prior to any materials being incorporated in the works.
 The main items of materials are as follows:
- Sikarep
- Renderoc HS Xtra
- Renderoc TG Xtra
- Renderoc LA Xtra
- Other similar approved materials
6.0 Resources
6.1 Personnel / Workforce :
Description No.
Foremen One
Repair man Two
Helper Three
6.2 Equipment & Tools :
Description No.
Hand Mixer One
Tools As required
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7.0 Methodology / Procedure
7.1 General
Three different methods of repair treatment, are described below. They are
categorized in accordance with the depth of the required repair.
7.2 Method / Procedure

 Type – 1
Sikarep or similar approved fairing coat shall be used for repair of imperfections
up to 5 mm thick & pinholes up to 30 mm thick refer to appendix A for technical
data sheets & manufacturer recommendations.
1. Surface preparation
1.1. The surface of the substrate shall be thoroughly cleaned to remove all traces
of dust or any unsound material which might affect subsequent bond between
the fairing coats.
1.2. The substrate shall further be “roughened” to remove excess laitance, to
expose pinholes & blowholes and to provide a mechanical key for subsequent
application of repair material.
2. Substrate priming
2.1. All prepared areas should be thoroughly soaked with clean, potable water
immediately prior to the application of sikarep or other approved product,
such that the substrate is “saturated surface dry”.
3. Mixing
3.1. Care should be taken to ensure that repair material is thoroughly mixed. In all
cases the powder should be added to the water and mixed strictly in
accordance with the manufacturer’s recommendations.
3.2. The mixing ratio for sikarep, by volume, should be 5 parts of repair
material product to 1 part water.
3.3. For larger volumes of material it will be necessary to mix using a proprietary
forced action mixer, or slow speed drill.
3.4. For each bag of sikarep 4.0 – 4.5 liters of cool, potable water into the mixer
(water quantity may vary slightly according to ambient temperature and
desired consistency of mix).
3.5. The powder will be added to the water and mixing will continue for 5 minutes
until fully homogenous.
4. Application
4.1. The fully mixed fairing coat will be applied to the prepared substrate, by steel
trowel, and allow to partly set before finally trowelling to a smooth finish.
5. Curing
5.1. Curing of sikarep is not generally required. However, under extreme drying
conditions - high temperatures, drying winds, normal curing method will be
applied.
6
 Type – 2
Repair of Voids & Segregated Concrete thickness exceeding 10 mm & not more
than 75 mm thick refer to appendix B for technical data sheets & manufacturer
recommendations.
1. Surface preparation
1.1 The defective area will be marked and the edges will be saw cut to a
minimum depth of 10 mm, angling the blade to create an undercut.
1.2 All contaminated or damaged concrete will be removed to a minimum
depth of 10 mm, up to the pre-cut perimeter of the repair. Should any
reinforcement be exposed, preparation will continue until concrete has been
removed until a 10 mm gap has been created behind the reinforcement.
1.3 A clear gap of at least 20 mm will be created behind the rear face of the
steel reinforcement, such that a gloved hand can comfortably reach behind the
bars.
1.4 Concrete and steel surfaces will be cleaned thoroughly to remove laitance.
The steel bars will be cleaned to a uniform bright condition; and the saw cut
edge of the repair should be “roughened” to provide a good mechanical key at
the substrate interface.
2. Reinforcement priming
2.1 Exposed steel reinforcement, including any replacement reinforcement,
should be securely held in place to avoid movement during application, as this
will affect the compaction, build and bond of the mortar.
2.2 One full, unbroken coat of primer will be applied to the steel within 3
hours of cleaning, and it will be allowed for drying before continuing.
3. Substrate Priming
Similar as described in Type – 1 procedure (Point no: 2).
4. Mixing
5. Application
6. Curing
6.1 Curing of repaired areas will be carried out as soon as possible after the
surface has been “closed”, using regular curing method.
 Type – 3
Repair of Voids & Segregated Concrete thickness exceeding 50 mm – Grinder,
chisel & hand concrete breaker will be used for removing imperfection for
filling voids refer to appendix C for technical data sheets & manufacturer
recommendations.
1.0 Surface preparation
1.1 The affected area will be marked and the edges will be saw cut to a
minimum depth of 10 mm.
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1.2 All contaminated or damaged concrete will be removed to a minimum

depth of 10 mm, up to the pre-cut edge of the repair. Should any reinforcement
be exposed, preparation will continue until concrete has been removed until a
10 mm gap has been created behind the reinforcement.
1.5 The concrete and steel surfaces will be cleaned thoroughly to remove
laitance. The steel bars will be cleaned to a uniform bright condition and the
edge of the repair will be “roughened” to provide a good mechanical key at the
substrate interface.
2.0 Reinforcement priming
3.0 Substrate priming
5.0 Formwork
5.1 Formwork will be constructed such that the unrestrained surface area of
the repair is minimized. The formwork will be rigid and tight to the substrate
to prevent grout loss.
6.0 Mixing
7.0 Application
8.0 Curing
8.1 Formwork will be left in place until the cured Renderoc LAXtra or other
approved product has reached a self-supporting, required compressive
strength or as otherwise advised by the Engineer.
8.2 Immediately after the formwork has been struck, all exposed faces of the
repair will be thoroughly soaked with clean water to remove residual traces of
the shutter release agent. The repair should then be cured.
7.3 Classification of material
Description of Materials Application Details

Sikarep Fairing Coat for Repair of Pinholes Thickness 3mm -30mm.
Renderoc HS Xtra Repair of Voids, Honeycombing & Segregated Concrete

Renderoc TG Xtra exceeding 10 mm & not more than 75 mm thick.
Repair of Voids, Honeycombing & Segregated Concrete

Renderoc LA Xtra
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8.0 Quality Control

8.1 All works will be undertaken in compliance with the quality requirements of the Contract,
and PP14-00-Y-CNQ-SAR-001 Rev A, “Project Quality Plan”.
8.2 All works requiring inspection and testing to demonstrate conformity with requirements
will be undertaken in accordance with PP14-00-Y-CPT-SAR-002 – Rev.1 “Inspection and
Test Plan for Civil Works”.
8.3 Where non-conformities are found/identified, they will be addressed in accordance with
QLT-PRO-05 – Rev.0 “Control of Non-conformities”.
8.4 The quality control activities associated with the works will be conveyed to all personnel
involved in the execution of the works by the Project QA/QC Manager prior to the
commencement of the work.
9.0 Health, Safety and Environment

9.1 HSE Program Overview
The HSE Program will be utilizing steps based on “Plan, Do, Check, and Act”
Principles, as shown below:
9.2 Managing Hazards & Risks

Ref. PP1314-00-Y-UP-WP-018 15. Hazard Identification Program
Ref. PP1314-00-Y-UP-WP-029 6. Managing Hazards & Risk
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9.2.1 Planning & Objectives
The fundamental HSE objective for the Project is to achieve a mutually agreed
target of zero harm to People, assets and the environment, and to maintain the
welfare of all Project personnel by removing or reducing to As Low as Reasonably
Practicable (ALARP) all Occupational Safety, Health and Environmental risks
during all field activities. Specific objectives are:
 To define the methods to be applied for the prevention of incidents and the
improvement of HSE standards.
 To foster the maximum involvement by management and employees in
the prevention of accidents through training, orientation and mutual
consultation, and their actions.
 To record and monitor the effectiveness of the Corporate and Project HSE
Management System by utilizing best-practice methodology and
recognized continuous improvement processes.
 Provide a risk-based HSE management system framework, consistent with
ISO QMS 9001:2008, BS OHSAS 18001:2007, AS/NZS 4801, ISO EMS
14001:4004 and other internationally recognized standards that support
the implementation of Project HSE Policies.
9.2.2 Hazard Identification, Assessment and Control
The Project HSE Management Strategy is to identify hazards and their potential
consequences within the construction environment. This will be achieved by
encouraging the active participation of all personnel in the identification and
continual assessment of hazards to avoid or minimize the risk of the hazard to a
level that is As Low as Reasonably Practicable (ALARP) and/or controlling the
events that could lead to a potentially hazardous situation.
Hazard and risk management techniques, such as HAZIDs, HAZOPs, JSAs, and
START Cards will be used throughout the Project.
 Technical Risks (Safety in Design)

The Technical risks are or may be associated with the construction, engineering
process, facility, operability, and maintainability of the plant.
 Technical Risks (Safety in Design)

The diagram below outlines the five-step process that will be utilized throughout
the construction phase.
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 Project HSE Keys

Project personnel working within the operating facility areas will be required to
use a specifically designed “START Card”. This form of hazard identification
card will be undertaken as a team. A card will be done for each new task and
on each new day. It will be revisited if anything changes. The HSE team will
monitor compliance and quality.
 Job Safety Analysis (JSA)

From a safety perspective, JSA is the most commonly used term and the most
misunderstood within the industry today.
To ensure clarity with regard to this item, this procedure describes JSA in the
context of:
 Tasks that have a history of, or high potential for, injury, near miss or loss-
related Incidents.
 Critical tasks outlines in Company’ Safe Work Procedures or Practices.
 Tasks carried out in new or unusual environments.
 Tasks that have high potential for changing conditions during execution.
 Tasks that are rarely performed in a petrochemical environment.
 Tasks where multiple contractors / subcontractors are required to
sequentially execute an activity.
 Tasks where high ongoing interaction with process operations is required.
 Tasks that have a high potential for impact on the integrity of processing
systems.
 Tasks that need to be performed when a state of zero energy cannot be
achieved.
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9.3 Mandatory Safety Rules

Adherence to critical safety rules is mandatory. Failure to follow these rules
allows the potential for serious injury to people or damage to equipment. As such,
the consequence, after investigation, may result in dismissal from site for the
subcontractor’s employee(s) in violation of the rule. In addition, the employee’s
immediate supervisor will be appropriately disciplined and / or dismissed from
the work site. The following are the contractor.
Mandatory Safety Rules:
1. Always protect against falling where you can fall more than 1.8m (6 ft).
2. Never throw or drop any object or tool from one level to another.
3. Never initiate or participate in any physical altercation (fight).
4. Always adhere to work permit procedure.
5. Never engage in any horseplay.
6. Never tamper, alter or remove any safety device.
7. Always verify and tag and lock all energy isolations.
8. Never wilfully give an unsafe instructions nor allow another person / s to
work in an unsafe manner.
9. Always smoke in designated smoking areas.
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Appendix A
Fairing Coat for Repair of Pinholes Thickness 3mm-30mm
SIKAREP
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Product Data Sheet
Edition: KSA
Rev: 30/11/2013 16:04
SikaRep®
SikaRep®
Multi Purpose, Economical, Patching and Repair Mortar
®
SikaRep is a cementitious, silicafume and polymer containing, one component
Product repair mortar. Suitable for use in tropical and hot climatic conditions.
Description
Uses  For cosmetic or structural repair of deteriorated concrete and mortar.
 SikaRep® can be used on exterior or interior, horizontal and vertical
applications
 Compatible with the properties of typical concretes
 Low water absorption, but vapour permeable
 Non corrosive, non toxic
 Excellent Chloride and Carbonation Resistance
Characteristics /  One component, requires the addition of water only

Advantages  Easy to mix, apply and finish
 Excellent adhesion
 Shrinkage compensated

Tests / Standards Al-Futtaim Tarmac Laboratories, United Arab Emirates
ASTM C109 Compressive strength
ASTM C 348 Flexural Strength
BSEN12390 water Penetration
BS 1881:part 122 Water Absorption
ASTM C 157 Length Change
Product Data
Cementitious, Silica fume, polymer composition
Type
Grey powder
Form
Packaging 25 kg bag
Store in a dry area between 5ºC and 35ºC. Protect from direct sunlight
Storage
Storage Conditions / 12 months minimum from production date if stored properly in original unopened
Shelf-Life packaging
1 SikaRep® 1/4
Technical Data
o
Density at 25 C Approx. 2.0-2.1Kg/Lit (fresh wet density)
Mixing Ratio 4.0-4.5 liter potable water per 25kg bag(16 -18 % water addition )
Setting Time ~45 mins
Compressive Strength
(ASTM C109) 28 days
~ 40(±5) N/mm2
2
Flexural Strength 7-9N/mm (BS 6319-P3)
2
Adhesion Strength ~ 2 N/mm (BS 1881 part 207)
Thickness Minimum 5mm
Maximum 30mm
Yield Approx. 14 Liter per 25 kg bag

2
Modulus of Elasticity Approximately 33,000 N/mm (BS 1881 Part 121)
2
Initial Surface 0.01 ml/(m .sec) (BS 1881 Part 208)
Absorption
O
Temperature Minimum 5 C
O
Maximum 40 C (substrate)
Coefficient of Thermal -6 ○
Approx 13x10 per C
Expansion
System
Information
Application Details
Substrate Preparation
Concrete surfaces should be clean, sound and free from oil, grease, organic growth
& curing compounds.
Metal surfaces (steel and iron) should be free from scale, rust, oil and grease.
Pre wet substrate substrate to a saturated surface dry condition (SSD) prior to
application . Avoid puddles and standing water.
Mechanically prepare concrete surfaces to remove laitance, curing compounds and

other loose materials back to sound concrete, to provide a mechanical key for the
subsequent product.
For large volume repairs to columns, walls or soffits, mark the extremity of the
repair area and saw cut to a minimum depth of 10mm to define the area to be
removed.
Chip out the area within the saw cut back to sound concrete, to a minimum depth of
10 mm ensuring no feather edges and a good mechanical key for the SikaRep® .
If steel reinforcement is exposed, continue to break out the concrete to at least

15mm behind the bars, and mechanically prepare by grit blasting to remove
rust, contamination or other loose material.
2 SikaRep 2/4
Bonding Agent and Steel For standard concrete repair procedures:
Protection
Reinforcing should be treated with a suitable protective coating such as Sika
SikaTop® Armatec® 110 EpoCem.
The concrete bond line should receive an application of a suitable bonding agent,
such as MonoTop® 610 or SikaTop® Armatec® 110 EpoCem, will improve
adhesion on large areas or where particularly dense concrete substrates are
involved.
Application
Instructions
Mixing
Accurately measure 4.0 to 4.5 litres of drinking quality water and place 3.5 to 4.0
litres in a suitable empty container with sufficient volume to accommodate the
mixed material.
Slowly add the powder to the water and mix continuously for 2-3 minutes using a
slow speed drill and clean, rust free, mixing paddle or forced action mixer, until a
homogenous consistency is achieved.
Then add the remaining water and mix for an additional 2 minutes .
DO NOT MIX BY HAND OR PART MIX BAGS!
Application Before applying, let the mixed mortar stand for 2 - 3 minutes after mixing to allow
entrapped air to escape.
Apply SikaRep® while the bonding agent is still wet.
Apply SikaRep® while the bonding agent is still wet. The mortar can be applied by
spatula or trowel. For any thickness greater than 30 mm, SikaRep® must be
applied in several layers. As soon as the mortar has started to set it can be
smoothed by wooden or synthetic float, styrofoam block or sponge. For a very fine
surface finish, Sika MonoTop® 620 / 625 can be applied over the SikaRep®.
Curing Where ambient conditions may lead to rapid surface drying, the use of light water
fogging for 48 hrs or the application on exposed surfaces with Antisol-E Curing
Compound or use other approved
Curing methods such as polyethylene sheeting or wet hessian. (Do not commence
Fogging until final set has been reached).
Cleaning Clean equipment and mixer after application with water. Hardened material can
only be removed mechanically.
Remarks SikaRep® should not be used at temperatures below 5°C. At ambient temperatures
above 35°C, the material should be stored in the shade and chilled water should be
used for mixing. SikaRep® may be overcoated with Sikagard® ElastoColor W,
Sikagard-680 S, Sikagard-550 W Elastic and all SikaRep® and MonoTop®
products.
For additional information on SikaRep® or other repair materials
contact our Technical Services Department
Value Base All technical data stated in this Product Data Sheet are based on laboratory tests.
Actual measured data may vary due to circumstances beyond our control.
Local Restrictions Please note that as a result of specific local regulations the performance of this
product may vary from country to country. Please consult the local Product Data
Sheet for the exact description of the application fields.
Health and Safety For information and advice on the safe handling, storage and disposal of chemical
products, users shall refer to the most recent Material Safety Data Sheet containing
Information physical, ecological, toxicological and other safety-related data.
Do not dispose of into water or soil but according to local regulations.

Ecology
Toxicity
Non-toxic under the relevant Gulf health and safety codes
Transportation
Non-hazardous.
Legal Notes
The information, and, in particular, the recommendations relating to the application
and end-use of Sika products, are given in good faith based on Sika's current
knowledge and experience of the products when properly stored, handled and
3 SikaRep 3/4
applied under normal conditions in accordance with Sika’s recommendations. In
practice, the differences in materials, substrates and actual site conditions are such
that no warranty in respect of merchantability or of fitness for a particular purpose,
nor any liability arising out of any legal relationship whatsoever, can be inferred
either from this information, or from any written recommendations, or from any other
advice offered. The user of the product must test the product’s suitability for the
intended application and purpose. Sika reserves the right to change the properties
of its products. The proprietary rights of third parties must be observed. All orders
are accepted subject to our current terms of sale and delivery. Users must always
refer to the most recent issue of the local Product Data Sheet for the product
concerned, copies of which will be supplied on request
Sika Saudi Arabia Sika Gulf B.S.C.(c) Sika U.A.E.L.L.C.,

P.O. Box-58647, 11583 P O Box15776, P.O.Box 126212,
Riyadh Adliya, Dubai,
Kingdom of Saudi Kingdom of Bahrain United Arab Emirates
Arabia Tel: +973 17735 560 Tel: +971 4439 8200
Tel: +9661-217 6532 Fax: +973 17732 476 Fax: +971 4439 3606
Fax: +966 1 4193607 E Mail: info@ae.sika.com
Info@sa.sika.com sika@sikagulf.com.bh Web: www.sika.com.ae.
www.sika.com.sa Web:www.sikagulf.com
4 SikaRep 4/4
Hand Applied Mortars
Author: Des Smith
Date: 10/12/2013 12:18
Method Statement
For restoring Concrete structures by Hand
Applied Mortars
PRODUCTS:
Sika®Rep LS,
Sika®Rep LWLS,
Sika®Rep,
Sika®Rep HSF-SA
Sika®Top 121
Sika®Top 122F
Sika Technical Service

Saudi Arabia
BU Contractors
Key Words Repairs, mortar, low shrink, performance, confined, concrete, repair, hand,
pouring mortar,
Scope: This method statement describes the step by step procedure for using Trowel
grade applied mortars to restore concrete structures.
Storage Place: Method Statements
:.
The information contained herein and any other advice are given in good faith based on Sika's current knowledge and experience of
the products when properly stored, handled and applied under normal conditions in accordance with Sika's recommendations. The
information only applies to the application(s) and product(s) expressly referred to herein. In case of changes in the parameters of the
application, such as changes in substrates etc., or in case of a different application, consult Sika's Technical Service prior to using
Sika products. The information contained herein does not relieve the user of the products from testing them for the intended
application and purpose. All orders are accepted subject to our current terms of sale and delivery. Users must always refer to the
most recent issue of the local Product Data Sheet for the product concerned, copies of which will be supplied on request.
1/17
Author: Des Smith
Date: 10/12/2013 12:18
Table of Contents:
1. System Description* .................................................................................... 3
2. Products* .................................................................................................... 4
3. Equipment *................................................................................................ 5
4. Safety Measures on site .............................................................................. 6
5. Environment *............................................................................................. 7
6. Preparation ................................................................................................ 8
7. Mixing....................................................................................................... 11
8. Application................................................................................................ 12
9 Inspections Sampling Quality control 15
10. Additional Guidance 17
2
Author: Des Smith
Date: 10/12/2013 12:18
1. System Description*
This method statement describes the system build up using SikaRep LS (Low Shrinkage) Mortars,
SikaRep LWLS, SikaRep, Sikacrete HSF-SA, Sika®Top 121, Sika®Top 122F and Sika® EpoCem® range of
products to restore concrete structures by recasting using mortar (methods 3.2, 4.4, 7.1, 7.2 11.1
and 11.2 of European Standard EN 1504-9). The system build up on the concrete substrate can
consist of a bonding primer, reinforcement corrosion protection layer; pouring mortar, levelling or
smoothing
1.1. Mortar References

This method statement has been written in accordance with the recommendations contained
in European Standards EN 1504: Products and systems for the protection and repair of
concrete structures, and the following relevant parts:
EN 1504 Part 1: Definitions, requirements, quality control and evaluation of conformity
EN 1504 Part 3: Structural and non-structural repair
EN 1504 Part 7: Reinforcement corrosion protection
EN 1504 Part 10: Site application of products and systems, and quality control
of works
1.2. Limitations
Products shall only be applied in accordance with their intended use.
Local differences in product may result in performance variations. The most recent and
relevant local Product Data Sheets (PDS) and Material Safety Data sheets (MSDS) shall
apply.
For specific construction / build information refer to the Architect’s, Engineer’s or
specialist’s details, drawings, specifications and risk assessments.
All work shall be carried out as directed by a supervising officer or a qualified
Engineer.
This method statement is only a guide
3
Author: Des Smith
Date: 10/12/2013 12:18
2. Products*
Sika Product Description
Sika®Rep LS 1-component, Dual Shrinkage controlled, Hand applied
Sika®Rep ready to use repair mortar for filling shallow repair zones
Sika®Rep LWLS
Sika®rep HSF-SA
Sika®Top 121
Sika®Top 122F
Sika® EpoCem® 3-component, ready to use bonding primer (with long

open
time) or reinforcement corrosion protection
2.1. Material Storage

Materials shall be stored properly in undamaged original sealed packaging in dry
cooled conditions. Refer to specific information contained in the product data
sheet regarding minimum and maximum storage temperatures
3. Equipment:
3.1. Hand Tools:
Wire brush Hammer and Application Smoothing Mixing

chisel trowels trowels container
4
Author: Des Smith
Date: 10/12/2013 12:18
3.2. Mixing Tools:

.
Drill and Mixing Double Mixing Paddle Forced Action Pan Mixer large
Paddle for small Medium Quantities quantities
quantities
3.3. Miscellaneous tools

Water Concrete Machine
Spray Removal & Applied
Cleaning Spray
Equipment
Equipment &
(section
Hopper Gun
6.1)
4. Safety Measures on Site *
4.1. Risk Assessment

The risk to health and safety from falling objects or defects in the
structure shall be properly assessed.
Platforms and temporary structures shall provide a stable and safe area
to work. Do not take any unnecessary risks!
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4.2 Personal Protection

Work safely!
Handling or processing cement products may
generate dust which can cause mechanical
irritation to the eyes, skin, nose and throat.
Appropriate eye protection shall be worn at all

times while handling and mixing products.
Approved dust masks shall be worn to protect

the nose and throat from dust.
Safety shoes, gloves and other appropriate skin protection

shall be worn at all times.
Always wash hands with suitable soap after
handling products and before food consumption.
FOR DETAILED INFORMATION REFER TO THE MATERIAL SAFETY DATA SHEET
4.2 First Aid

Seek immediate medical attention in the event of excessive inhalation, ingestion
or eye contact causing irritation. Do not induce vomiting unless directed by
medical personnel.
Flush eyes with plenty of clean water occasionally lifting upper and lower
eyelids. Remove contact lenses immediately. Continue to rinse eye for 10
minutes and then seek medical attention.
Rinse contaminated skin with plenty of water. Remove contaminated clothing and continue to
rinse for 10 minutes and seek medical attention.
5. Environment
5.1. Cleaning Tools / Equipment

Clean all tools and application equipment with water immediately after use. Hardened
material can only be removed mechanically.
5.2. Waste Disposal

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Do not empty surplus material into drains; dispose responsibly through licensed waste disposal
contractor in accordance with legislation and local / regional authority requirements. Avoid runoff
onto soil or into waterways, drains or sewers
6. Preparation
6.1. Concrete Substrate
The concrete substrate shall be in a good sound condition and free from dust, loose
material, surface contamination and materials which reduce bond. Delaminated, weak,
damaged and deteriorated concrete shall be removed by suitable means. If necessary
sound concrete shall also be removed but only as directed by a supervising officer or
qualified engineer.
Methods of cleaning, roughening and concrete removal are summarised as follows:
■ Intended use
□ For certain intended uses
roughening
cleaning
removal
Hammer and chisel ■
Breaker ■ ■
Grit and sand blasting ■ ■
Water Blasting with low pressure (max. 180 bar) ■
Water Blasting with high pressure (min. 600 bar) ■ □
Water Blasting very high pressure (min. 1100 bar) ■
Appropriate tool selection will depend on the type and extent of damage
as well as the substrate quality and shall be agreed with the supervising
officer or qualified engineer.
Note: Hydro-demolition is a preferred fast and effective method of
removing concrete which can produce no micro cracks in the concrete.
As defined in EN 1504-10, water jet categories are as follows:
Low Pressure – Up to 18 N/mm2 (MPa) / 180 bar / ~2,600 PSI

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-Used for cleaning concrete and steel substrate
High Pressure – from 18 to 60 N/mm2 (MPa) / 600 bar / ~8,700 PSI

-Used for cleaning steel substrate and for removal of concrete
Very High Pressure –from 60 to 110 N/mm2 (MPa) / 1100 bar / ~16,000 PSI
-Used for concrete removal when low water volume is available
Where: 1N/mm2 = 10 bar = 145 PSI (lbf/in2)

Concrete removal shall be kept to a minimum and shall not reduce the structural
integrity of the structure. Pneumatic equipment or tools which can damage concrete
due to an intense vibration shall not be used.
The extent of concrete removal shall be in accordance with the chosen principle and
method contained in EN 1504-9. In the case of repair and restoration the depth of
contamination shall be established and taken into account when determining the depth
of concrete removal.
Removal of concrete shall continue to expose full circumference of the
steel reinforcement to a minimum depth of 15 mm behind the back of the
bars.
Breaking out shall continue along the reinforcement until non-corroded
steel is reached as directed by the supervising officer or qualified
engineer.
Edges around the patch repair shall be cut at an angle of >90o to avoid
undercutting and a maximum angle of 135o to reduce the possibility of de-
bonding
Surface of the concrete substrate shall be roughened to 2 mm to increase
bonding which can be tested in accordance with EN 1766 for horizontal
surfaces.
Micro cracked or delaminated concrete including damage caused cleaning, roughening or removal
techniques shall be removed or repaired if they might reduce bond or structural integrity. Micro
cracks can be detected by wetting the surface and allowing it to dry. Dark lines on the dried surface
indicate cracks as they retain the water.
The finished surface shall be visually inspected prior to application and can be tapped lightly using
a metal hammer to detect delaminated concrete. The supervising officer or qualified engineer shall
be informed immediately of any loose, cracked or damaged surfaces. In these circumstances repair
materials shall not be applied without prior written consent of the
supervising officer or qualified engineer.
If a smoothing coat is required the whole application surface shall be
properly prepared. Appropriate cleaning procedures consist of low
pressure water blasting, abrasive grit and sand blasting, or high pressure
water blasting to remove a laitance layer.
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6.2. Steel Reinforcement

The steel reinforcement shall be free from rust, scale, mortar, concrete, dust and other loose and
deleterious material which reduces bond or contributes to corrosion. Tie wire and nails shall also be
removed.
The whole circumference of the bar shall be uniformly cleaned, except where structural
considerations prevent this. Cleaning shall not damage in anyway the structural integrity of the
steel.
Immediately notify the supervising officer or qualified engineer if there is a possibility of damaging
the steel by cleaning.
Exposed bars contaminated with chloride or other deleterious material shall be cleaned by low
pressure water jet (18 MPa) and checked afterwards to ensure the contamination has been totally
removed.
If a reinforcement corrosion protection layer in the form of an active coating (method
11.1 as defined in the European Standards EN 1504-9) is to be applied, then the steel
reinforcement shall be cleaned to Sa 2 defined by ISO 8501-1. If reinforcement corrosion
protection layer in the form of a barrier coating (method 11.2 of EN 1504-9) is to be applied, then
the steel reinforcement shall be prepared to Sa 2½ defined by ISO 8501-1.
Cleaned bars shall be protected against further contamination prior to application of a
reinforcement corrosion protection layer.
Loss of steel-area on reinforcement due to corrosion, or due to any other damage, shall be brought
to the attention immediately of the supervising officer or qualified engineer prior to application.
Any further action such as replacing reinforcement bars shall only be carried in accordance with
the direct instruction of the supervising officer or qualified engineer. The scope of this method
statement does not include any replacement of reinforcement bars.
6.3. Pre-Wetting Substrate

Concrete surfaces shall be saturated with clean water a minimum 2 hours before
application ensuring that all pores and pits are adequately wet. The surface shall not be allowed to
dry before application.
Formwork shall be fixed immediately after pre-wetting to avoid
loss of moisture from the substrate surface. Ensure there is no
standing water on the surface before closing the formwork. The
surface shall achieve a dark matt appearance without glistening
and surface pores and pits shall not contain water.
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6.4. Formwork
Formwork shall be clean and fixed in place as soon as possible after the substrate has been
prepared. If required, release agents shall be applied to the formwork before placing into position.
Do not contaminate the substrate with the release agent and reduce bond of the grout material
from spillage or run-off. Openings in the formwork shall be protected to prevent ingress of debris
or contamination. Formwork shall be watertight and free from obstructions to allow the free flow
of pourable mortar.
Formwork shall be designed to allow the controlled escape of air and water bleed.
7. Mixing
Mixing shall always be carried out in accordance with the recommendations contained in the latest
product data sheet (PDS).
Do not use water beyond the stated maximum and minimum limits. In determining the mixing
ratio the wind strength, humidity, ambient and substrate temperature and shall be taken into
consideration
7.1. One Component Products
Product Procedure
Product Procedure
Place minimum recommended water ratio in mixing container.
Progressively add powder whilst mechanically mixing using low speed
(maximum 500 rpm) electric drill.
Add more water if required to suit the desired consistency and flow
properties but not exceeding maximum dosage.
Mix in total for minimum 3 minutes or until the material is
homogenous.
SikaRep
SikaRep LWLS
SikaRep LS
SikaRep HSF-SA
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7.2 Two component Repair Mortars

Shake thoroughly component A separately
Pour mixed components A into mixing container
and add component C progressively whilst mixing
mechanically using low speed (maximum 500
rpm) electric drill.
Mix for minimum 3 minutes until homogenous.
Sika®Top 121
Sika®Top 122F Do not add water.
7.2. Three Component Products (Primers)

Sikatop® Armatec®
Shake thoroughly component A and B separately
110 EC
Pour component A into component B and shake
thoroughly
Pour mixed components A+B into mixing
container and add component C progressively
whilst mixing mechanically using low speed
(maximum 500 rpm) electric drill.
Mix for minimum 3 minutes until homogenous.
Do not add water.
8. Application
The product and system shall be appropriate for the type of substrate, structure and exposure
conditions which they are required.
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Working space shall be clean and tidy with no obstructions.

Record the substrate, ambient temperature and relative humidity.
Check pot life information on bag or in the product data sheet and
allow for climatic conditions e.g. high / low temperatures &
humidity.
External applications shall be adequately protected. Do not apply
recasting mortar in direct sun, windy, humid or rainy conditions,
do not apply if there is a risk of frost within 24 hours in
unprotected areas.
Make sure blow holes are not obstructed and can allow the
escape of air.
Calculate the required volume for the application and then using
the equation in section 10 of this method statement, calculate
the yield of the product.
Make sure there is enough material on job site to carry out
the work.
8.2. Reinforcement Corrosion Protection

Where a reinforcement corrosion protection is required, apply material to
the whole circumference of the steel reinforcement bar in two layers.
Wait until the first layer has dried before applying the second layer.
Use a mirror to inspect behind the back of the bars to ensure full coverage.
Take care not to splash or apply material on a dry concrete substrate behind the bars.
For small areas use two paint brushes to apply 2 layers and ensure full coverage. For larger areas
use hopper gun aim the spray in different directions to ensue coverage behind the back of the
bars.
Reinforcement should be free from rust, oxides or other deposits on the surface.
As a protection for the reinforcement use Sikatop® Armatec® 110 EC.
Mix Sikatop® Armatec® 110 EC according to the instructions given in the Technical Data Sheet.
Apply the slurry in two coats, each coat at a thickness of approx. 0.5 - 1.0 mm (refer to the Method
Statement of Sikatop® Armatec® 110 EC.
The recasting mortar shall only be applied when the reinforcement corrosion protection is
hardened. Refer to the relevant product data sheet for more information
8.3. Bonding Primer

Refer to relevant repair mortar product data sheet if a bonding primer is
required. If a bonding primer is required, the substrate surface shall be
pre-wetted in accordance with section 6.3.
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Bonding primers can be applied by hand (pressing the material firmly into the surface), using a
brush or using a hopper gun for larger areas.
The repair mortar shall be applied wet on wet to a bonding primer. Ensure the substrate surface is
fully covered behind the reinforcement bars. For large applications use only a bonding primer with
long open time to take into account the formwork construction e.g. Sikatop® Armatec® 110 EC.
Refer to product data sheet for more information.
Application of hand applied Repair Mortar

Whilst the bonding agent is still wet, apply SikaRep® LS by trowel or by
hand tamping the mortar into position to a maximum thickness of 50
mm per application. Ensure good compaction of the repair mortar.
If thickness exceeds 50 mm, apply in several layers. As soon as the
mortar has started to set, it can be smoothened by wooden or synthetic
float, styrofoam block or sponge.
8.7. Curing
Best curing is achieved while the formwork is still in place. As soon as the formwork is removed,
protect the still green material from premature drying. Cure with proper curing methods for 3 days
or spray with appropriate curing compound once any surface water has evaporated. Curing
methods include jute and water, plastic sheets
or other suitable membranes
8.8. Smoothing / Levelling Mortars

Smoothing mortars can be applied by hand, by hopper gun or by
mechanical spray equipment for large areas. Refer to relevant product
data sheet for further information.
A smoothing coat shall be applied over the whole prepared concrete
surface (including repair and non-repaired areas). Any laitance layer on
the surface shall be removed (section 6.1) and surface pre-wet in
accordance with section 6.3.
Smoothing coats may be hand, using notched trowel, or by spray applied.
Refer to relevant product data sheet for further information.
Use a toothed trowel to apply the mortar onto the surface in a vertical
direction. Hold the trowel at an acute angle to the surface and use
different size toothed trowels to regulate the application thickness.
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Toothed Approximate application thickness

trowel size o o
30 C 45 C
10mm ~5.0mm ~7.0mm

5mm ~2.5mm ~3.5mm
2mm ~1.0mm ~1.5mm
When 1st layer is hard, apply the second layer between the vertical lines.
The hardness can be tested by the ease at which a finger nail can be
inserted into the mortar.
Finish surface with damp sponge, wooden or plastic float after material has
set. Do not add apply additional water on the surface as this will cause
discoloration and cracking.
8.9. Application Limits

Do not apply a flowable mortar/grout as a patch repair or overlay in unconfined areas
(horizontal, free applications)
Avoid application in direct sun and/or strong winds.
Do not add water over the maximum recommended dosage.
Always check the material’s pot life and adjust for climate conditions.
Temperature of the repair mortar and substrate shall not differ significantly.
9. Inspection, Sampling, Quality Control

As part of “Good Practice” the grouting contractor shall provide a QC report containing
the following recommended data. For more detailed information refer to EN 1504-10
Annex A, or any other local standards or legislation which may apply.
9.1. Substrate Quality Control - Before and After Preparation

The following checks should be carried out before and after preparation.
Characteristic References Frequency Parameters

Cleanliness of Visual After preparation & No contamination,
concrete immediately before loose particles or
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application defects
Cleanliness of Steel DIN EN ISO After preparation & No rust, scale or
bars 8501-1 immediately before contamination.
application [Grade Sa 2 or SA 2
½ for methods 11.1or
11.2]
Delaminating Hammer After preparation No delaminating
concrete Sounding concrete
Roughness Visual or EN After preparation Minimum roughness
1766 on 2 mm (repair area)
horizontal No laitance layer
surfaces (smoothing mortars)
Surface Tensile EN 1542 After preparation >1.0 N/mm² for
strength of the works structural repair
substrate
Table 2 QC summary before and after preparation
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10. Performance Testing

The following can be used to check the adequacy of the application.
characteristic References Frequency Parameters

Compressive strength EN12190 3 prisms per batch Within PDS limits
on 40x40x160 prisms
Cracking Visual 28 days after No cracking on
application application
Presence of voids/ EN 12504-1 After application No delaminating
Delamination Hammer concrete
sounding or
*ultrasonic
testing
Adhesion Bond *(pull EN 1542 Min 3 on a test area Within PDS limits
off)
11.1.Yield
The yield of a product can be determined from the following equation (assuming no wastage).
When calculating the required consumption on job site allow an additional
10% of material to maintain pressure head on the grout flow. Remember to calculate
the required volume to the top of the base plate.
Equation: yield (litres) = (weight of powder (kg) + weight of water (kg))

density of mixture (kg/l)
Given: weight of water 1 litre = ~1 kg
Example:
Calculate consumption of a bag weighing 25 kg mixed with 3.2 litres of water, when
the density of the fresh material is 2.3 kg/l.
1 bag of 25 kg yields: (25 + 3.2) = 28.2 kg
28.2kg/2.3 = ~12.3 litres of flowable mortar
Therefore, the number of bags required for 1m3 of grout will be:
No of bags required per 1m3= (1/yield) x 1000
(1/12.3) x 1000 = ~81 bags
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11.2.Consumption
Consumption of a product can be calculated as follows:

Calculate how many kg of powder is required to cover a 40 mm thick application over
an area 2 m2 (assuming no wastage)
Weight of mixed mortar (kg) = volume (m3) x density (kg/m3)
= (2 x 0.04) x 2300 (for NON-lightweight mortars)
= 184 kg (total)
Less weight of water;
If water to powder mixing ratio = *12.0% then;
Required weight of powder = 184 x (100-12.0)/100
= ~ 162 kg powder (or minimum 7 x 25 kg bags)
Disclaimer
The information contained herein and any other advice are given in good faith based
on Sika's current knowledge and experience of the products when properly stored, handled and applied under normal
conditions in accordance with Sika's recommendations. The information only applies to the application(s) and product(s)
expressly referred to herein and is based on laboratory tests which do not replace practical tests. In case of changes in
the parameters of the application, such as changes in substrates etc., or in case of a different application, consult Sika's
Technical Service prior to using Sika products. The information contained herein does not relieve the user of the products
from testing them for the intended application and purpose. All orders are accepted subject to our current terms of sale
and delivery.
Users must always refer to the most recent issue of the local Product Data Sheet for the product concerned, copies of
which will be supplied on request.
Sika Saudi Arabia Sika Gulf B.S.C.(c) Sika U.A.E.L.L.C.,
P.O. Box-58647, 11583 P O Box15776, P.O.Box 126212,

Riyadh Adliya, Dubai,
Kingdom of Saudi Arabia Kingdom of Bahrain United Arab Emirates
Tel: +9661-217 6532 Tel: +973 17735 560 Tel: +971 4439 8200
Fax: +966 1 4193607 Fax: +973 17732 476 Fax: +971 4439 3606
Info@sa.sika.com E Mail: sika@sikagulf.com.bh info@ae.sika.com
Web: www.sika.com.sa Web:www.sikagulf.com Web: www.sika.ae
17
Appendix B
exceeding 10 mm & not more than 75 mm thick
RENDEROC HS Xtra
RENDEROC TG Xtra
14
TECHNICAL SUBMITTAL
PRODUCT NAME : Renderoc HS Xtra
constructive solutions
Technical Datasheet
Renderoc HS Xtra constructive solutions
Shrinkage controlled, cementitious high

specification repair mortar system
Uses Properties
Renderoc HSXtra is suitable for hand and spray application The following typical results were obtained at a water
for repairs where high load bearing is required. Typical powder ratio of 0.18.
applications would include, but not be limited to, the
following: Test method Typical results
Drying shrinkage to ASTM
 Vertical and overhead repairs to restore ‘covercrete’. C157-93 7 days: < 300 micro-strain
28 days: < 500 micro-strain
 General concrete and masonry repairs. Permeability: < 5 mm
(DIN 1048 Part 5)
 Voids greater than 10 mm deep. 2
Flexural strength: >13 N/mm at 28 days
 Repairs to honeycombing. (BS 6319 Part 3)
2
Tensile strength: > 6 N/mm at 28 days
 Larger scale repairs where formwork cannot be erected. (BS 6319 Part 7)
2
Compressive strength: 60 N/mm at 7 days
Advantages 1 2
(BS 1881 Part 116 ) 80 N/mm at 28 days
Renderoc HSXtra features Dimensional Stability Water absorption: < 2%
Technology - a new materials technology which controls
the rate of drying shrinkage such that, when used correctly: (BS 1881 Part 121)
Rapid chloride permeability: < 500 columns
i. The dimensions of the repair remain stable; and thus (AASHTO 277-93)
ii. Eliminating failure, due to shrinkage cracking. Note 1: 100 mm cubes, water cured at 25 C.
o
This in turn leads to a series of associated benefits:

Technical support
 Cost effective - shrinkage control enables repairs to be Fosroc offers a comprehensive range of high performance,
completed ‘right first time’. high quality products suitable for use within all aspects of
the concrete repair and protection industry. In addition, the
 Enhanced durability – works in tandem with extremely company offers a technical support package to specifiers,
low permeability to prolong effective working life. end users and contractors, as well as on-site assistance.
 Compatibility – aligns performance closer than ever Design criteria

before, to that of host concrete.
Dimensional stability Technology is a major step forward
 User friendly – specifically developed to provide an in the general compatibility of repair mortar systems with the
easy-to-apply product, suitable for local conditions. host concrete, and the control of shrinkage in particular.
Attention to the basic design criteria given below should

 Definable performance – positive benefits are easily
ensure that the full benefits of this technology are gained in
demonstrated via a single, simple measurement.
use:
Description (i) Recommended limits for a single application are:
Renderoc HSXtra is supplied as a ready to use blend of dry Minimum applied thickness: 10 mm
powders, which requires only the addition of clean water to Overhead sections: up to 50 mm thick
produce a highly consistent repair mortar suitable for Vertical sections: up to 75 mm thick
structural concrete and masonry repairs. Renderoc HSXtra Small pockets or horizontal: up to 100 mm thick
may be hand applied or sprayed with suitable equipment, Maximum length: up to 3 m
please see application method statement for details.
Page 1
Renderoc HS Xtra
2
Note: If the repair area exceeds 2.5 m , consideration Storage
should be given to the use of mass fill by means of
either Renderoc LAXtra spray applied mortar or Shelf life
Renderoc LAXtra micro-concrete.
Renderoc HSXtra has a shelf life of 12 months if kept in a
dry environment, in its original, unopened packing. If stored
(ii) In situations where a substrate/repair barrier is in conditions of high humidity and/or temperature, the shelf
required, or enhanced bond strength/working life will be reduced.
time is required, or where the substrate is likely
to be permanently wet or damp (e.g. seawalls, Standard compliance
quays etc.), Nitobond EP epoxy bonding agent
should be used. Renderoc HSXtra repair mortar system complies with the
following international standards:
(iii) Water addition = 3.6 litres per 20 kg bag.
ASTM C-157-93 : Test for drying shrinkage
DIN 1048 Part 5 : Test for permeability
Under no circumstances should part bags be used or BS 1881 part 121 : Test for water absorption
additional water be employed. Either of these two actions
will adversely affect material performance. Precautions
Application instructions Health and safety
Renderoc HSXtra should only be mixed and applied in strict Renderoc HSXtra contains cement powders which, when
accordance with the product Method Statement, a copy of mixed with water or upon becoming damp, release alkalis
which may be obtained from your nearest Fosroc office. which can be harmful to the skin.
During use, avoid inhalation of the dust and contact with the
Estimating
skin or eyes. Wear suitable protective clothing – eye
protection, gloves and respiratory equipment (particularly in
Supply confined spaces).
Renderoc HSXtra: 20 kg bags The use of barrier creams to provide additional skin
protection is also advised. In case of contact with the skin,
Yield rinse with plenty of clean water, then cleanse thoroughly
with soap and water.
Renderoc HSXtra: 10.7 litres per 20 kg bag
In case of contact with eyes, rinse immediately with plenty
Limitations of clean water and seek medical attention immediately – do
not induce vomiting.
 Renderoc HSXtra should not be used when the Fire
o
ambient temperature is below 5 C and falling.
Renderoc HSXtra is non-flammable and thus presents no
 Renderoc HSXtra should not be part mixed, nor fire hazard.
part bags used.
For further information, please refer to the product Material
 Renderoc HSXtra should not be exposed to Safety Data Sheet for Renderoc HSXtra.
running water either during application or prior to
final set.
Important note:
Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions
for the Supply of Goods and Services, copies of which may be obtained on request. Whilst Fosroc endeavours to ensure that
any advice, recommendation, specification of information it may give is accurate and correct, it cannot, because it has no direct
or continuous control over where or how its products are applied, accept any liability either directly or indirectly arising from the
use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.
Fosam Company Limited

Telephone: +966 2 637 5345 Fax: +966 2 637 5891 email: fosam@fosroc.com
Head Office
Post Box 11081 Regional Offices
Jeddah Sales Office Tel: (02) 608 0999 Fax: (02) 638 0693 Yanbu Tel: (04) 322 4280 Fax: (04) 391 2980
Jeddah – 21453
Jeddah Showroom Tel: (02) 665 0187 Fax: (02) 667 4844 Makkah Tel: (02) 542 0869 Fax: (02) 542 0869
Saudi Arabia Riyadh Tel: (01) 482 9303 Fax: (01) 482 7562 Medinah Tel: (04) 855 0091 Fax: (04) 855 0047
Dammam Tel: (03) 814 1282 Fax: (03) 814 1581 Jubail Tel: (03) 362 3904 Fax: (03) 362 3875
www.fosroc.com Khamis Mushayt Tel: (07) 250 0469 Fax: (07) 250 0469 CSD Tel: (02) 608 0999 Fax: (02) 638 0693
Registered Office: Industrial Area, Phase 4, Road No. 414, Street No. 407
Page 2 FO SA/RENDEROC HSXTRA/05/A
Material Safety
Datasheet
SAFETY DATA SHEET
1: IDENTIFICATION OF THE SUBSTANCE / PREPARATION AND OF THE COMPANY /
UNDERTAKING
Product Name: RENDEROC HSXtra
Application: Shrinkage controlled, cementitius repair mortar
Company: Fosam Company Limited
Address: Jeddah Industrial Area, Phase 4, Road 414, Street 407, P.O. Box 11081, Jeddah
Telephone: (02) 637 5345 (4 Lines) Fax (02) 637 5891
2: COMPOSITION/INFORMATION ON INGREDIENTS
Composition: portland cements, silica sands, inorganic fillers, additives, limestone aggregate
Hazardous Ingredient(s) Symbol Risk Phrases Other Information %
Cement (OPC) Xi R36/37/38 Cas No: 65997-15-1 >25 <50
All constituents of this product are listed in EINECS (European Inventory of Existing Commercial Chemical Substances)
or ELINCS (European List of New Chemical Substances) or are exempt.
Refer to Section 8 for Occupational Exposure Limits.
3: HAZARDS IDENTIFICATION
Irritating to eyes, respiratory system and skin
IRRITANT
4: FIRST AID MEASURES
Eyes: Irrigate immediately with copious quantities of water for several minutes. Obtain medical attention
urgently.
Skin: Wash immediately with copious quantities of water. Remove contaminated clothing immediately.
Obtain medical advice if skin disorders develop.
Inhalation: Remove from exposure, rest and keep warm and obtain medical attention urgently.
Ingestion: Wash out mouth with water. Do NOT induce vomiting. Obtain medical attention.
5: FIRE FIGHTING MEASURES

Suitable Extinguishing Media: None, not flammable.
Special Exposure Hazards: None.
Special Protective Equipment: None.
6: ACCIDENTAL RELEASE MEASURES
Personal Precautions: Wear rubber boots in addition to the recommended protective clothing.
Environmental Precautions: Prevent entry into drains, sewers and water courses.
Decontamination Procedures: Avoid the creation of dust in atmosphere. Gather into containers. Residues may
be flushed to drain with large volumes of water.
7: HANDLING AND STORAGE
Handling: Avoid creating dust. Avoid breathing dust. In case of insufficient ventilation, wear suitable respiratory
equipment. Avoid skin and eye contact.
Storage: Store in cool, dry area.
Issue No: 01 Date: 15.01.99 RENDEROC HSXtra Page: 1 of 3

8: EXPOSURE CONTROLS/PERSONAL PROTECTION
Occupational Exposure Limits:-
Substance 8 Hour TWA STEL Source/Other Information
silica, amorphous: EH 40
total inhalable dust 6 mgm -3 -----
respirable dust 3 mgm-3
portland cement: EH 40
total inhalable dust 10 mgm-3 -----
limestone EH 40
total inhalable dust 10 mgm-3 ----
respirable dust 5 mgm -3 ----
Engineering Control Measures: Atmospheric levels of dust must be maintained within the Occupational
Exposure Limit. Where mechanical methods are inadequate or impractical,
appropriate personal protective equipment must be used.
Personal Protective Equipment: Impervious gloves (eg PVC). Goggles / Safety glasses. Approved dust mask.
Change contaminated clothing immediately and clean before re-use.
9: PHYSICAL AND CHEMICAL PROPERTIES
Physical State: Granulated powder.
Colour: Grey.
Odour: Odourless.
pH(working dilution): >12
Boiling Point/Range (°C): Not applicable.
Melting Point/Range (°C): Not applicable
Flash Point (closed, °C): None.
Autoflammability (°C): Not determined.
Explosive Properties (%): Not known.
Relative Density (at 20°C): 1.20

Water Solubility: Insoluble.
10: STABILITY AND REACTIVITY

Stability: Stable.
Conditions to Avoid: Exposure to air. Contamination with water.
Materials to Avoid: Strong acids.
Hazardous Decomposition Products: None.
11: TOXICOLOGICAL INFORMATION

Health Effects
On Eyes: Irritating and may injure eye tissue if not removed promptly.
On Skin: Irritation. See "chronic" effects.
By Inhalation: Irritating to respiratory system. Inflammation of the nasal mucous membrane by exposure to cement
dust.
By Ingestion: May cause irritation of mouth, throat and digestive tract.
Chronic: Cement, cementitious grouts and mortars are known to cause both irritant and allergic contact
dermatitis. Prolonged skin contact can result in chemical burns.
12: ECOLOGICAL INFORMATION

Environmental Assessment: Little detailed information is available on the ecological effects of this product, but
its overall environmental impact is not regarded as significant
Mobility: Insoluble in water.
Issue No 01 Dae: 15.01.99 Product Name: Renderoc HSXtra Page 2 of 3

Persistence and Degradability: Not readily biodegradable.
Bioaccumulative Potential: Not expected to be bioaccumulative.
Ecotoxicity: Not expected to be ecotoxic to fish/daphnia/algae.
13: DISPOSAL CONSIDERATIONS
Disposal must be in accordance with local and national legislation.
Unused Product: Dispose of in an approved manner.
Used/Contaminated Product: As for Unused product.
Packaging: The method of disposal must be acceptable to the local authority.
14: TRANSPORT INFORMATION
This product is NOT classified as dangerous for transport.
15: REGULATORY INFORMATION

Hazard Label Data:-
Named Ingredients: cement powders
Symbol(s): Xi
Risk Phrases: Irritating to eyes, respiratory system and skin.
Safety Phrases: Do not breathe dust
Avoid contact with skin and eyes
In case of contact with eyes, rinse immediately with plenty of water and seek medical advice
Wear suitable protective clothing, gloves and eye/face protection
EC Directives: Dangerous Substances Directive, 67/548/EEC and adaptations.
Dangerous Preparations Directive, 88/379/EEC.
Safety Data Sheets Directive, 91/155/EEC.
Statutory Instruments: Chemicals (Hazard Information and Packaging for Supply) (Amendment) Regs. 1996 (SI
1092).
Health & Safety at Work, etc. Act 1974.
Control of Substances Hazardous to Health Regs. 1994 (SI 3246).
Codes of Practice: Waste Management. The Duty of Care.
Guidance Notes: Occupational skin diseases: health and safety precautions (EH 26).
Dust in the workplace: general principles of protection. (EH44).
Occupational exposure limits (EH 40).
The above publications are available from HMSO
16: OTHER INFORMATION
The data and advice given apply when the product is used for the stated application or applications. The product is not sold as suitable for any other
application. Use of the product for applications other than as stated in this sheet may give rise to risks not mentioned in this sheet. The product should
not be used other than for the stated application or applications without seeking advice from Fosroc Ltd.
If this product has been purchased for supply to a third party for use at work, it is the purchaser's duty to take all necessary steps to secure that any person
handling or using the product is provided with the information in this sheet.
It is the responsibility and duty of the employer to inform employees and others who may be affected of any hazards described in this sheet and of any
precautions which should be taken.
This sheet does not constitute or substitute for the users own assessment of workplace risk, as required by other health and safety legislation.
Further copies of this Safety Data Sheet may be obtained from Fosroc Limited.
Date Printed 05/01/1999 SDS Reference: 2370/1 RENDEROC HSXtra
Supersedes issue no: 01 dated:05.01.1999
Sections updated/revised - no(s): 1 . 8.
Issue No: 01 Dat 15.01.99 RENDEROC HSXtra Page: 3 of 3

Method Statement
method statement constructive solutions
Renderoc HSXtra
Section A : General Comments
High temperature working
It is suggested that, for temperatures above 350C, the following guidelines are adopted as good
working practice:
(i) Store unmixed materials in a cool (preferably temperature controlled) environment, avoiding
exposure to direct sunlight.
(ii) Keep equipment cool, arranging shade protection if necessary. It is especially important to
keep cool those surfaces of the equipment which will come into direct contact with the material
itself.
(iii) Try to avoid application during the hottest times of the day, arrange temporary shading as
necessary.
(iv) Make sufficient material, plant and labour available to ensure that application is a continuous
process.
Equipment
It is suggested that the following list of equipment is adopted as a minimum requirement
Protective clothing : Protective overalls

: Good quality gloves, goggles and face mask
Preparation equipment : Marker chalk or pen
: Disc cutter
: Electric or pneumatic breaker
: Wire brush
: Proprietary blasting equipment
Application equipment : Any suitable wet or dry spray equipment may be
used.
Application - points of note

Fosroc operates a policy to encourage the use, where possible, of approved or licensed applicators.
This ensures that repairs are completed satisfactorily so that the long term performance of the
materials is assured. For contractors who wish to apply the materials themselves Fosroc is also able
to offer technical assistance and training, either on-site or at its Training Centre in Jeddah.

Head Office telephone: fax: email:
PO Box 11081
+966 (2) 637 5345 +966 (2) 637 5891 fosam@fosroc.com
Jeddah – 21453
Saudi Arabia
Certificate number IND93024
www.fosroc.com Registered Office: Industrial Area, Phase 4, Road No. 414, Street No. 407
Section B : Application Method

Attention to full and proper preparation of the substrate is essential for complete repair
adhesion.
1.1 Mark out affected area, then cut back edge of repair to a minimum depth of 10 mm.
1.2 Break out the repair area to remove all contaminated or damaged concrete to a minimum
depth of 10 mm, up to the pre-cut edge of the repair.
1.3 Fully expose any corroded reinforcement in the repair area and continue until uncorroded
steel is reached. It may be necessary to break out the concrete beyond the original repair
area in order to achieve this.
1.4 Oil and grease deposits are best removed by steam cleaning, detergent scrubbing or the use
of a proprietary degreaser. The effectiveness of decontamination should be assessed by a
pull-off test.
1.5 Fully clean the concrete and steel surfaces to remove laitence, the by-products of corrosion
and other contaminants. This is most effectively achieved by proprietary blast media; with
particular attention required to both the rear face of the bars and the edge of the repair. The
steel bars should be cleaned to a uniform bright condition; and the edge of the repair should be
‘roughened’ to provide a good mechanical key at the substrate interface.
1.6 Chloride induced corrosion will further require high pressure washing with clean water after
blasting to ensure complete removal of the corrosive elements.
2.1 Exposed steel reinforcement should be securely held in place to avoid movement during
application, as this will affect the compaction, build and bond of the mortar.
2.2 Apply one full, unbroken coat of Nitoprime Zincrich and allow to dry before continuing. If
unsure about continuity of the coating, apply a second coat and allow to dry.
3.0 Substrate priming (wet spray only)
3.1 The substrate should be thoroughly soaked with clean water, and any excess removed
immediately prior to spraying.
3.2 For priming in other conditions, apply Nitobond EP as per its current instructions.
3.3 If in any doubt regarding the most appropriate bonding agent, contact the local Fosroc office.
4.0 Mixing
4.1 For either technique, water addition should not exceed 3.6 litres per 20 kg bag.
Page 2 of 4
5.0 Application
5.1 Suitable wet or dry spray equipment may be used.
6.0 Multiple layers

6.1 Although not generally recommended as common practice, it may be necessary (e.g. machine
breakdown or blockage) to stop work before completing the repair. In such cases it will
become necessary to adopt an intermediate layer.
6.2 If an intermediate layer is to be used, care must be taken to ensure consistency of the intercoat
bond strength.
6.3 The surface of the intermediate layer should be ‘scratch-keyed’ and cured with wet hessian.
6.4 Subsequent application of fresh Renderoc HSXtra may commence once the intermediate layer
has reached its initial set
7.0 Finishing
7.1 Renderoc HSXtra is finished by striking off with a straight edge and closing with a steel or
plastic float. Note that water can be drawn to the surface if ‘overworking’ with the float occurs,
and an unsightly finish may result.
7.2 Damp sponges or plastic floats may be used to achieve a desired surface texture, but care
should again be taken not to overwork the surface.
8.0 Curing
8.1 Curing of repaired areas should be carried out as soon as possible after the surface has been
‘closed’.
8.2 Rendercure should be spray applied in accordance with its current data sheet instructions.
8.3 In adverse conditions (e.g. windy conditions or ambient temperatures greater than 300C),
supplementary curing in the form of polythene sheeting, taped down at the edges, should be
used.
9.0 Cleaning
9.1 Renderoc HSXtra should be removed from tools, equipment and mixers with clean water
immediately after use. Cured material can only be removed by mechanical means.
9.2 Nitoprime Zincrich and Nitobond EP can only be removed from tools and equipment using
Fosroc Solvent 102.
Page 3 of 4
Section C : Approval and variations
This method statement is offered by Fosroc as a ‘standard proposal’ for the application of Renderoc
HSXtra. It remains the responsibility of the Engineer to determine the correct method for any given
application.
Where alternative methods are to be used, these must be submitted to Fosroc for approval, in
writing, prior to commencement of any work. Fosroc will not accept responsibility or liability for
variations to the above method statement under any other condition.
Page 4 of 4
Test Reports
Appendix C
RENDEROC LA Xtra
15
TECHNICAL SUBMITTAL
PRODUCT NAME : Renderoc LA Xtra
Technical Datasheet
Renderoc LA Xtra constructive solutions
Shrinkage controlled, fluid micro-concrete

for structural repairs of all types
Uses Properties
Renderoc LAXtra is suitable for mass infill to structural The following typical results were obtained at a water
repairs in all types of load-bearing situation. Typical powder ratio of 0.133.
Repairs to columns suffering from major loss of section. C157-93 7 days: < 300 microstrain
28 days: < 500 microstrain
Soffit repairs where heavy load-bearing is required. Permeability:
(DIN 1048 Part 5) < 10 mm
Repairs to restricted access areas, where use of hand Flexural strength:
2
applied mortars would prove impractical. (BS 6319 Part 3) > 9 N/mm at 28 days
Tensile strength:
2
Repairs requiring high fluidity e.g. heavily congested (BS 6319 Part 7) > 5 N/mm at 28 days
2
steel or repairs into re-entrant angles/concealed voids. Compressive strength: > 39 N/mm at 3 days
1 2
(BS 1881 Part 116 ) > 45 N/mm at 7 days
2
Any repairs requiring significant levels of load-bearing. > 60 N/mm at 28 days
Water absorption:
Advantages (BS 1881 Part 121) < 2%
o
Renderoc LAXtra features Dimensional Stability Note 1: 100 mm cubes, air cured at 25 C.
Technology - a new materials technology which controls
the rate of drying shrinkage such that, when used correctly: Design criteria
i. the dimensions of the repair remain stable; and thus
Dimensional stability Technology is a major step forward
in the general compatibility of repair mortar systems with the
ii. eliminating failure, due to shrinkage cracking.
host concrete, and the control of shrinkage in particular.
This in turn leads to a series of associated benefits:
Attention to the basic design criteria given below should
Cost effective - shrinkage control enables repairs to be use:
completed ‘right first time’.
(i) Renderoc LAXtra is designed for large volume repairs,
Enhanced durability - works in tandem with extremely typically in excess of 50 mm deep. The product can
low permeability to prolong effective working life. be applied in sections generally between 50 and 200
mm thick, greater thicknesses may be achievable,
Compatibility - aligns performance closer than ever depending upon repair configuration and location
before, to that of host concrete. together with the volume of reinforcing steel. Consult
the local Fosroc office for more information.
User friendly - specifically developed to provide an
easy-to-apply product, suitable for local conditions.
(ii) In situations where a substrate/repair barrier is
required, or enhanced bond strength/working time is
Definable performance - positive benefits are easily required, or where the substrate is likely to be damp
demonstrated via a single, simple measurement. (e.g. seawalls, quays etc.), Nitobond EP epoxy
bonding agent should be used.
Description
(iii) Water addition = 2.7 litres per 20 kg bag.
Renderoc LAXtra is supplied as a ready to use blend of dry
powders and selected aggregates, which requires only the Under no circumstances should part bags be used or
addition of clean water to produce a highly consistent, fluid additional water be employed. Either of these two actions
micro-concrete suitable for all load-bearing situations. will adversely affect material performance, automatically
invalidating Fosroc’s standard product guarantee.
Page 1
Renderoc LA Xtra
Instruction for use Standard compliance
Renderoc LAXtra should be mixed and applied in strict Renderoc LAXtra repair micro-concrete system complies
accordance with the Product Method Statement, a copy of with the following international standards:
which may be obtained from your nearest Fosroc office.
DIN 1048 Part 5 : Test for permeability
Estimating BS 1881 part 121 : Test for water absorption
Supply
Precautions
Renderoc LAXtra: 20 kg bags
Health and safety
Yield
Renderoc LAXtra contains cement powders which, when
Renderoc LAXtra: 9.8 litres per 20 kg bag mixed with water or upon becoming damp, release alkalis
which can be harmful to the skin.
Limitations During use, avoid inhalation of the dust and contact with the
Renderoc LAXtra should not be used when the ambient protection, gloves and respiratory equipment (particularly in
o
temperature is below 5 C and falling. confined spaces).
The use of barrier creams to provide additional skin

Renderoc LAXtra should not be part mixed, nor part bags protection is also advised. In case of contact with the skin,
used. rinse with plenty of clean water, then cleanse thoroughly
with soap and water.
Renderoc LAXtra should not be exposed to running water
either during application or prior to final set. In case of contact with eyes, rinse immediately with plenty of
clean water and seek medical advice. If swallowed seek
medical attention immediately - do not induce vomiting.
Water ponding is not recommended for curing.
Fire
Storage
Renderoc LAXtra is non-flammable and thus presents no
Shelf life fire hazard.
Renderoc LAXtra has a shelf life of 12 months if kept in a For further information, please refer to the product Material
dry environment, in its original packing. If stored in Safety Data Sheet for Renderoc LAXtra.
conditions of high temperature and/or humidity, the shelf life
may be reduced to as little as 4 months.
Important note:

Telephone: +966 2 637 5345 Fax: +966 2 637 5891 email: fosam@fosroc.com
Head Office
Jeddah Sales Office Tel: (02) 6080999 Fax: (02) 635 3330 Yanbu Tel: (04) 322 4280 Fax: (04) 391 2980
Jeddah – 21453
www.fosroc.com Khamis Mushayt Tel: (07) 250 0469 Fax: (07) 250 0469 CSD Tel: (02) 6080999 Fax: (02) 635 3330
Page 2 FO SA/REMDERPCLAXTRA/06/05
Material Safety
Datasheet
SAFETY DATA SHEET
UNDERTAKING
Product Name: RENDEROC LAXtra
Application: Shrinkage controlled, fluid micro-concrete
IRRITANT
urgently.

Issue No: 01 Date: 15.01.99 RENDEROC LAXtra Page: 1 of 3

limestone EH 40
Colour: Grey.
Odour: Odourless.


Stability: Stable.

Health Effects
dust.

Issue No 01 Dae: 15.01.99 Product Name: Renderoc LAXtra Page 2 of 3


Hazard Label Data:-
Symbol(s): Xi
1092).
Date Printed 05/01/1999 SDS Reference: 2370/1 RENDEROC LSXtra
Issue No: 01 Dat 15.01.99 RENDEROC LAXtra Page: 3 of 3

Method Statement
method statement constructive solutions
Renderoc LAXtra
It is suggested that, for temperatures above 35°C, the following guidelines are adopted as good
working practice:
(ii) Keep equipment cool, arranging shade protection if necessary. It is especially important to
keep cool those surfaces of the equipment, which will come into direct contact with the material
itself.
necessary.
process.
Equipment
: Disc cutter
: Electric/pneumatic breaker or hammer and chisel
: Wire brush
Mixing equipment : Measuring jug
: 1 KW slow speed drill, 400 or 500 rpm
+ Fosroc MR3 mortar mixing paddle
+ suitably sized mixing vessel, for single bag mixing or
: Proprietary forced-action mixer, for multiple bag mixing
Application equipment : Formwork
: Pouring equipment

Fosroc operates a policy to encourage the use, where possible, of approved or licensed applicators.
This ensures that repairs are completed satisfactorily so that the long-term performance of the
materials is assured. For contractors who wish to apply the materials themselves Fosroc is also able
to offer technical assistance and training, either on-site or at its Training Centre in Jeddah.

PO Box 11081 +966 (2) 637 5345 +966 (2) 637 5891 fosam@fosroc.com
Jeddah – 21453
Saudi Arabia
www.fosroc.com

adhesion.
1.1 Mark out affected area, then cut back edge of repair to a minimum depth of 10 mm.
1.2 Break out the repair area to remove all contaminated or damaged concrete to a minimum
depth of 10 mm, up to the pre-cut edge of the repair.
1.3 Fully expose any corroded reinforcement in the repair area and continue until uncorroded steel
is reached. It may be necessary to break out the concrete beyond the original repair area in
order to achieve this.
1.4 Oil and grease deposits are best removed by steam cleaning, detergent scrubbing or the use
of a proprietary degreaser. The effectiveness of decontamination should be assessed by a
pull-off test.
1.5 Fully clean the concrete and steel surfaces to remove laitence, the by-products of corrosion
and other contaminants. This is most effectively achieved by proprietary blast media; with
steel bars should be cleaned to a uniform bright condition; and the edge of the repair should be
„roughened‟ to provide a good mechanical key at the substrate interface.
1.6 Chloride induced corrosion will further require high pressure washing with clean water after
blasting to ensure complete removal of the corrosive elements.
2.1 Exposed steel reinforcement should be securely held in place to avoid movement during
application, as this will affect the compaction and bond of the material.
2.2 Apply one full, unbroken coat of Nitoprime Zincrich and allow drying before continuing. If unsure
about continuity of the coating, apply a second coat and allow drying.
3.0 Substrate priming - water (standard repairs)

3.1 Priming with water should take place after erection of the formwork.
3.2 Several hours prior to placing the Renderoc LAXtra, the prepared concrete substrates should
be saturated, by filling the formwork with clean water. Immediately prior to application of
Renderoc LAXtra, any excess water should be removed via the drainage outlet, leaving the
substrate “saturated surface dry”.
4.0 Substrate priming - Nitobond EP (non-standard)
4.1 This should be completed before erection of the formwork, and application of Nitoprime
Zincrich.
4.2 Mix Nitobond EP in accordance with its current data sheet instructions.
Page 2 of 4
4.3 An unbroken coating of primer must be achieved - apply two coats. Each coat should be well
„scrubbed‟ into the prepared substrate, the first coat being allowed to gel before application of
the second coat.
4.4 The primed substrate should then be left for one hour before proceeding with further
application of the repair material
NOTE If in any doubt regarding the most appropriate priming for a particular repair, contact the local
Fosroc office.
5.0 Formwork
5.1 Formwork should be constructed such that the unrestrained surface area of the repair is
minimised.
5.2 The formwork should be rigid and tight to the substrate to prevent grout loss. Use of silicone
sealant, or similar, is also advised around the edge of the formwork.
5.3 The internal faces of the formwork should be sealed, using Reebol release agent, to ensure
that water is not absorbed from the repair material by the formwork.
5.4 The formwork should include suitable drainage outlets for pre-soaking and, when filling the
repair „bottom up‟ (e.g. soffit repairs), should further include provision for air-venting to release
trapped air as pouring proceeds.
5.5 There must be suitable access points to pour or pump the mixed material in place.
6.0 Mixing
6.1 It is essential that Renderoc LAXtra is thoroughly mixed and that powder is always added to
the water.
6.2 Measure out 2.7 litres of cool, potable water, into the mixing apparatus. (It is suggested that
the temperature of the water should not exceed 200C, so that the temperature of the final
mixed material is not greater than 300C).
6.3 With the mixing apparatus in operation add one full 20kg bag of Renderoc LAXtra and mix for 3
to 5 minutes until a smooth, even consistency is obtained.
7.0 Placing
7.1 Limits of the repair geometry should be in accordance with that laid down in the „Design
criteria’ section of the current product data sheet.
7.2 The material should be placed within 30 minutes of mixing, in order to gain the full benefits of
fluidity and expansion, which will fill all the repair voids.
7.3 Placement should be a continuous process, to avoid the formation of a „cold joint‟.
7.4 If placing by pump, the pipeline should be „grouted‟ with a rich cement slurry or mortar,
discharging such grout as waste.
7.5 Pumping of the mixed material should follow immediately after grouting has been carried out.
Page 3 of 4
8.0 Curing
8.1 Formwork should be left in place until the cured Renderoc LAXtra has reached a self-
supporting, compressive strength of 10 N/mm2, or as otherwise advised by the Engineer.
8.2 Immediately after the formwork has been struck, all exposed faces of the repair should be
thoroughly soaked with clean water to remove residual traces of the shutter release agent. The
repair should then be sprayed with Rendercure.
8.3 At ambient temperatures above 300C supplementary curing in the form of polythene sheeting,
taped down at the edges, must be used.
9.0 Cleaning
9.1 Renderoc LAXtra should be removed from tools, equipment and mixers with clean water
immediately after use. Cured material can only be removed by mechanical means.
Fosroc Solvent 102.

This method statement is offered by Fosroc as a „standard proposal‟ for the application of Renderoc
LAXtra. It remains the responsibility of the Engineer to determine the correct method for any given
application.
Where alternative methods are to be used, these must be submitted to Fosroc for approval, in
writing, prior to commencement of any work. Fosroc will not accept responsibility or liability for
variations to the above method statement under any other condition.
Page 4 of 4
Test Reports
TECHNICAL SUBMITTAL
PRODUCT NAME : Renderoc TG Xtra
Technical Datasheet
Renderoc TG Xtra constructive solutions
Shrinkage controlled, vertical and overhead

cementitious repair mortar
Uses Properties
Renderoc TGXtra is suitable for hand application to repairs The following typical results were obtained at a water
where light to medium load bearing is required. Typical powder ratio of 0.18.
C157-93 7 days: < 300 micro-strain
Vertical and overhead repairs to restore ‘covercrete’.
28 days: < 500 micro-strain
Permeability:
General concrete and masonry repairs. (DIN 1048 Part 5) < 10 mm
Flexural strength:
Voids greater than 10 mm deep. (BS 6319 Part 3) 2
> 6.5 N/mm at 28 days
Tensile strength:
Repairs to honeycombing. 2
(BS 6319 Part 7) > 2.5 N/mm at 28 days
2
Compressive strength: 35 N/mm at 7 days
1 2
Larger scale repairs where formwork cannot be erected. (BS 1881 Part 116 ) 40 N/mm at 28 days
Water absorption:
Advantages (BS 1881 Part 121) < 2%
o
Renderoc TGXtra features Dimensional Stability Note 1: 50 mm cubes, air cured at 25 C.
Technology - a new materials technology which controls the
rate of drying shrinkage such that, when used correctly: Standard compliance
i. The dimensions of the repair remain stable; and thus Renderoc TGXtra repair mortar system complies with the
following international standards:
ii. Eliminating failure, due to shrinkage cracking.
This in turn leads to a series of associated benefits: DIN 1048 Part 5 : Test for permeability
BS 1881 part 121 : Test for water absorption
Cost effective - shrinkage control enables repairs to
be completed ‘right first time’. Design criteria
Enhanced durability – works in tandem with extremely Dimensional stability Technology is a major step forward
low permeability to prolong effective working life. in the general compatibility of repair mortar systems with the
host concrete, and the control of shrinkage in particular.
Compatibility – aligns performance closer than ever
before, to that of host concrete. Attention to the basic design criteria given below should
User friendly – specifically developed to provide an use:
easy-to-apply product, suitable for local conditions.
(i) Recommended limits for a single application are:
Definable performance – positive benefits are easily
demonstrated via a single, simple measurement. Minimum applied thickness : 10 mm
Overhead sections : up to 50 mm thick
Description Vertical sections : up to 50 mm thick
Small pockets or horizontal : up to 100 mm thick
Renderoc TGXtra is supplied as a ready to use blend of dry Maximum length : up to 3 m
powders, which requires only the addition of clean water to 2
produce a highly consistent, lightweight repair mortar suitable Note: If the repair area exceeds 2.5 m , consideration
for general purpose concrete and masonry repairs. should be given to the use of mass fill by means of either
Renderoc SPXtra spray applied mortar or Renderoc LAXtra
micro-concrete.
Page 1
Renderoc TG Xtra
(ii) In situations where a substrate/repair barrier is required, Storage
or enhanced bond strength/working time is required, or
where the substrate is likely to be permanently wet or Shelf life
damp (e.g. seawalls, quays etc.), Nitobond EP epoxy
bonding agent should be used. Renderoc TGXtra has a shelf life of 12 months if kept in a dry
environment, in its original, unopened packing. If stored in
(iii) Water addition = 3.6 litres per 20 kg bag. conditions of high humidity and/or temperature, the shelf life
may be reduced to as little as 4 months.
Under no circumstances should part bags be used or
additional water be employed. Either of these two actions will
adversely affect material performance, automatically Precautions
invalidating Fosroc’s standard product guarantee.
Health and safety
Instruction for use Renderoc TGXtra contains cement powders which, when
mixed with water or upon becoming damp, release alkalis
Renderoc TGXtra should be mixed and applied in strict which can be harmful to the skin.
accordance with product method statement, a copy of which
may be obtained from your nearest Fosroc office. During use, avoid inhalation of the dust and contact with the
Estimating protection, gloves and respiratory equipment (particularly in
confined spaces).
Supply
The use of barrier creams to provide additional skin
Renderoc TGXtra: protection is also advised. In case of contact with the skin,
20 kg bags
rinse with plenty of clean water, then cleanse thoroughly with
soap and water.
Yield
In case of contact with eyes, rinse immediately with plenty of
Renderoc TGXtra: 12.7 litres per 20 kg bag clean water and seek medical advice. If swallowed seek
medical attention immediately - do not induce vomiting.
Limitations
Fire
Renderoc TGXtra should not be used when the ambient
o Renderoc TGXtra is non-flammable and thus presents no fire
temperature is below 5 C and falling.
hazard.
Renderoc TGXtra should not be part mixed, nor part

bags used. For further information, please refer to the product Material
Safety Data Sheet for Renderoc TGXtra.
Renderoc TGXtra should not be exposed to running
water either during application or prior to final set.
Water ponding is not recommended for curing.
Important note:

Head Office Telephone: +966 2 637 5345 Fax: +966 2 637 5891 email: fosam@fosroc.com
Jeddah – 21453 Jeddah Sales Office Tel: (02) 608 0999 Fax: (02) 638 0693 Yanbu Tel: (04) 322 4280 Fax: (04) 391 2980
www.fosroc.com Khamis Mushayt Tel: (07) 250 0469 Fax: (07) 250 0469 CSD Tel: (02) 608 0999 Fax: (02) 638 0693
Page 2 FO SA/RENDEROC TGXTRA/05/A
Material Safety
Datasheet
SAFETY DATA SHEET
UNDERTAKING
Product Name: RENDEROC TGXtra
Application: Shrinkage controlled, vertical and overhead repair mortar
IRRITANT
urgently.

Issue No: 01 Date: 15.01.99 RENDEROC TGXtra Page: 1 of 3

limestone EH 40
Colour: Grey.
Odour: Odourless.


Stability: Stable.

Health Effects
dust.

Issue No 01 Dae: 15.01.99 Product Name: Renderoc TGXtra Page 2 of 3


Hazard Label Data:-
Symbol(s): Xi
1092).
Date Printed 05/01/1999 SDS Reference: 2370/1 RENDEROC TGXtra
Issue No: 01 Dat 15.01.99 RENDEROC TGXtra Page: 3 of 3

Method Statement
Method statement constructive solutions
Renderoc TGXtra
It is suggested that, for temperatures above 35°C, the following guidelines are adopted as good
working practice:
(ii) Keep equipment cool, arranging shade protection if necessary. It is especially important to keep
cool those surfaces of the equipment, which will come into direct contact with the material itself.
necessary.
process.
(v) Where mixing water is required in the application of a product, it is advised to maintain such
water at a maximum of 20°C
Equipment
: Disc cutter
: Electric/pneumatic breaker or hammer and chisel
: Wire brush
: Proprietary blasting equipment
Mixing equipment : Measuring jug
: 1 KW slow speed drill, 400 or 500 rpm
+ Fosroc MR4 mortar mixing paddle
+ suitably sized mixing vessel, for single bag mixing or
: Proprietary forced-action mixer, for multiple bag mixing
Application equipment : Hand application trowel
: Wooden float
: Steel or plastic finishing float & Finishing sponge
PO Box 11081
+966 (2) 637 5345 +966 (2) 637 5891 fosam@fosroc.com
Jeddah – 21453
Saudi Arabia
www.fosroc.com Registered Office: Industrial Area, Phase 4, Road No. 414, Street No. 407
Fosroc operates a policy to encourage the use, where possible, of registered applicators, since the
long term performance of the materials is dependent upon proper application. For contractors who
wish to apply the materials themselves Fosroc is also able to offer technical assistance and training,
either on-site or at its Training Centre in Jeddah.
adhesion.
1.1 Mark out the defective area, then saw cut the edge of the repair to a minimum depth of 10 mm,
angling the blade to create an undercut.
1.2 Break out the repair area to remove all contaminated or damaged concrete to a minimum depth
of 10 mm, up to the pre-cut perimeter of the repair.
1.3 Fully expose any corroded reinforcement in the repair area and continue until non corroding
steel is reached - it may be necessary to break out the concrete beyond the original repair area
in order to achieve this. Ensure that a clear gap of at least 20 mm is created behind the rear
face of the steel reinforcement, such that a gloved hand can comfortably reach behind the bars.
1.4 Oil and grease deposits are best removed by steam cleaning, detergent scrubbing or the use of
a proprietary degreaser. The effectiveness of decontamination should be assessed by a pull-off
test.
1.5 Fully clean the concrete and steel surfaces to remove laitence, the by-products of corrosion and
other contaminants. This is most effectively achieved by the use of proprietary blast media; with
steel bars should be cleaned to a uniform bright condition; and the saw cut edge of the repair
should be „roughened‟ to provide a good mechanical key at the substrate interface.
1.6 Chloride induced corrosion will further require high pressure washing with clean water, after
blasting, to ensure complete removal of the corrosive elements.
2.1 Exposed steel reinforcement, including any replacement reinforcement, should be securely held
in place to avoid movement during application, as this will affect the compaction, build and bond
of the mortar.
2.2 Apply one full, unbroken coat of Nitoprime Zincrich to the steel within 3 hours of cleaning, and
allow to dry before continuing. If unsure about continuity of the coating, apply a second coat and
allow to dry.
3.0 Substrate Priming
This can be broadly classified as : (i) standard priming conditions where a standard acrylic primer can
be used, or (ii) non standard priming conditions (i.e. where the substrate is contaminated with
chlorides or is immersed) where an epoxy based bonding agent/isolator is required. If in any doubt
regarding the most appropriate primer, contact the local Fosroc office
3.1 Standard priming conditions
a) Thoroughly soak with clean water and remove excess, leaving the substrate in “saturated
surface dry” condition.
b) Apply Nitobond AR by scrubbing into the surface and allow to become tacky (typically 10 to
15 mins after application).
c) If the primer is too wet, or has dried, Renderoc TGXtra will not adhere properly.
3.2 Non-standard priming conditions
a) Thoroughly clean the substrate to remove all traces of contamination.
b) Mix Nitobond EP in accordance with its current data sheet instructions.
c) An unbroken coating of primer must be achieved - apply two coats. Each coat should be well
„scrubbed‟ into the prepared substrate, the first coat being allowed to gel before application of
the second coat
d) The primed substrate should then be left for one hour before proceeding with further
application of the repair material
4.0 Mixing
4.1 Only full bag mixing is permissible. Do not part mix, nor add further water to the mixed material
in order to prolong workability. Either of these actions will result in an incorrect water-powder
ratio, and will compromise final material performance.
4.2 It is essential that Renderoc TGXtra is thoroughly mixed and that the temperature of the mixed
material should not be allowed to exceed 300C.
4.3 For each 20Kg bag of Renderoc TGXtra to be mixed, measure out and place 3.6 litres of cool,
potable water, into the mixing vessel (it is suggested that the temperature of the water should
not exceed 200C, so that the final temperature of mixed mortar is not greater than 300C).
4.4 Always add the powder to the water. With the mixer in operation add the full 20kg bag of
Renderoc TGXtra, or multiples thereof, and mix continuously for 5 minutes until fully
homogenous, using :
(a) a 1 KW, slow speed drill (400/500 rpm) + Fosroc MR4 mortar mixing paddle, for single
bag mixing, or
(b) a forced action, proprietary mixer for multiple bag mixing
NOTE : Free-fall mixers must not be used for mixing.
5.0 Application
5.1 Apply mixed Renderoc TGXtra to the substrate by trowel or gloved hand, thoroughly compacting
onto the primed substrate, whilst the primer is still tacky. Ensure that mortar is applied around the
exposed steel reinforcement, compacting fully at the rear face.
5.2 Thickness of application should be in accordance with that laid down in the „Application
criteria’ section of the current product data sheet.
5.3 If sagging occurs on vertical or overhead faces, the Renderoc TGXtra must be completely
removed. The substrate must be reprimed and Renderoc TGXtra then reapplied in layers of
reduced thickness.
6.0 Build-up
6.1 Build-up of Renderoc TGXtra is best achieved using a „wet on wet‟ technique.
6.2 Multiple layers can also be used to achieve the desired thickness and profile; but care must be
taken to ensure consistency of intercoat bond strength.
6.3 Where multiple layers are to be applied, the surface of intermediate layers should be „scratch-
keyed‟ and cured with wet hessian. Further applications of fresh Renderoc TGXtra may be
applied once the intermediate layer has reached its initial set.
7.0 Finishing
7.1 Renderoc TGXtra is finished by striking off with a straight edge and closing with a steel or
plastic float. Note that water can be drawn to the surface if „overworking‟ with the float occurs,
and an unsightly finish may result.
7.2 Damp sponges or plastic floats may be used to achieve a desired surface texture, but care
should again be taken not to overwork the surface.
8.0 Curing
8.1 Curing of repaired areas should be carried out as soon as possible after the surface has been
„closed‟, using Rendercure.
8.2 Rendercure should be brush or spray applied as per its current method statement.
8.3 In adverse conditions (e.g. windy conditions or ambient temperatures greater than 300C),
supplementary curing in the form of polythene sheeting, taped down at the edges, should be
used.
9.0 Cleaning
9.1 Nitobond AR, Rendercure and Renderoc TGXtra should be removed from tools, equipment and
mixers with clean water immediately after use. Cured material can only be removed by
mechanical means.
Fosroc Solvent 102.
This method statement is offered by Fosroc as a „standard proposal‟ for the application of Renderoc
TGXtra. It remains the responsibility of the Customer to determine the correct method for any given
application. Where alternative methods are to be used, these must be submitted to Fosroc for
comment, in writing, prior to the commencement of any work..
Appendix D
Job Safety Analysis (JSA)
16
JOB SAFETY ANALYSIS
SEC PP14 PROJECT
Date: 2/7/2015
Job Description Concrete Repair Works JSA # #. 0007
Location RPP14 SITE
Permit Required
Attached
Documents
Contractor Endorsements
SAFETY REVIEW CONSTRUCTION SUPERVISOR REVIEW CONSTRUCTION MANAGER REVIEW
I have reviewed and agreed with all steps in this JSA I have taken the people doing the job through this JSA I have reviewed and agreed with all steps in this JSA
Print Name: Gomaa Mahrous Print Name: Print Name:
Position HSEM Position Position
Sign Sign Sign
Date 4/7/2015 Date Date
WPECC Endorsements
SAFETY REVIEW CONSTRUCTION SUPERVISOR REVIEW CONSTRUCTION MANAGER REVIEW
I have reviewed and agreed with all steps in this JSA I have taken the people doing the job through this JSA I have reviewed and agreed with all steps in this JSA
Print Name: Print Name: Print Name:
Position Position Position
Sign Sign Sign
Date Date Date
Note:
1. All JSA must be reviewed and approved by WP Construction and HSE.
2. JSA must be discussed by Supervisor with all crew members prior to start of the job.
3. Every member of the work crew/team must sign off on the JSA form to acknowledge awareness & participation
JOB SAFETY ANALYSIS
SEC PP14 PROJECT
Job Description: Concrete Repair works Page : 1 of 1 JSA # #. 0007
Location RPP14 SITE Date 2/6/2015
Area Coordinator:
Supervisor:
A. Sequence of Job Steps B. Potential Hazards C. Mitigating Steps
1- Surface preparation 1- Lack of Access and Egress

Safe access (Ladder / Platform with Handrail / scaffold ) to be provided
where work is required
Access to be secured to avoid falling.
Ladder to have suitable angle and sufficient length above the surface
(4:1).
Ladders to be in good working condition and color coded.

2.- Electrical shock due to defective electrical tools Electrical tools to be in good working condition
Tools to be inspected prior each use and color coded by technician
Cables passing through to be raised at least 2 Meters. / Burred

3.- Injury due to lack / improper PPE Heavy Duty gloves to be used while grinding
Face shield to be used while repairing works to protect from foreign

objectives
Dust mask / respiratory protection to be worn where dust is created.
Grinders / hammers / chisels to be inspected and color coded
safety guard and dead man switch to be in place all time

4- Slip, Trip and Fall Maintain good standards of Housekeeping
Anti slippery shoe to be worn and extra careful to be taken while

walking on wet surface
Falling protection to be provided above 120 CM. and working at height
requirements @ 1.8 M
JOB SAFETY ANALYSIS
SEC PP14 PROJECT
Job Description: Concrete Repair works Page : 1 of 1 JSA # #. 0007
Location RPP14 SITE Date 2/6/2015
Area Coordinator:
Supervisor:
A. Sequence of Job Steps B. Potential Hazards C. Mitigating Steps
2- Mixing and application of Chemicals 2.1- Hazards of Exposing to chemicals

MSDS for each used material to be available at store
COSHH Ass. To be prepared and available along with material at work

area.
COSHH to be briefed to employees exposed to chemical
Suitable Fire extinguisher to be available.

Rubber Gloves, chemical goggle and disposable coverall to be
worn.
Suitable respiratory protection to be worn as per MSDS.
Area to be barricaded and required signs to be in place.
Eye wash to be available where chemical works.
Chemical to be temporarily stored with drip tray
Fall face with respirator protection / have face respirator with

face shield to be worn.
3- Curing Slip and fall In addition to above extra carful to be taken while walking on
wet surfaces
Opening not to be covered to avoid stepping over then fall
No walking nearby any edge to avoid slip and fall except if there
is protection
4- Waste disposal Storage and waste disposal Residual material / waste from work to be stored in designated
area as per Haz. / none Haz.
Waste to be segregated as per waste type
Area for waste storage to be prepared as per HSE-WI-008

Waste to be Transported , Disposed as per Country rules and
regulation and according to HSE requirements.
Records of training and disposal to be kept within HSE Office
for evidence
JOB SAFETY ANALYSIS
SEC PP14 PROJECT
JSA # #. 0007
Employee Acknowledgement
Note: Every member of the work crew/team must sign off on the JSA form to acknowledge awareness & participation
Team Member Name Signature Date Team Member Name Signature Date

PP14-00-Y-CNL-SAR-004-RA Concrete

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11

Appendix A Fairing Coat for Repair of Pinholes Thickness 3mm - 30mm.

1.0 Purpose and Scope

2.0 Document Control

3.0 Reference Documents

4.0 Responsibility Revise revision mark

7.0 Methodology / Procedure

7.2 Method / Procedure

1.2 All contaminated or damaged concrete will be removed to a minimum

7.3 Classification of material

Description of Materials Application Details

Renderoc HS Xtra Repair of Voids, Honeycombing & Segregated Concrete

Repair of Voids, Honeycombing & Segregated Concrete

8.0 Quality Control

9.0 Health, Safety and Environment

9.2 Managing Hazards & Risks

9.2.1 Planning & Objectives

9.2.2 Hazard Identification, Assessment and Control

 Technical Risks (Safety in Design)

 Technical Risks (Safety in Design)

 Project HSE Keys

 Job Safety Analysis (JSA)

9.3 Mandatory Safety Rules

Characteristics /  One component, requires the addition of water only

Yield Approx. 14 Liter per 25 kg bag

Mechanically prepare concrete surfaces to remove laitance, curing compounds and

If steel reinforcement is exposed, continue to break out the concrete to at least

Do not dispose of into water or soil but according to local regulations.

Sika Saudi Arabia Sika Gulf B.S.C.(c) Sika U.A.E.L.L.C.,

Sika Technical Service

4. Safety Measures on site .............................................................................. 6

9 Inspections Sampling Quality control 15

10. Additional Guidance 17

1.1. Mortar References

Sika® EpoCem® 3-component, ready to use bonding primer (with long

2.1. Material Storage

3.1. Hand Tools:

Wire brush Hammer and Application Smoothing Mixing

3.2. Mixing Tools:

3.3. Miscellaneous tools

4. Safety Measures on Site *

4.1. Risk Assessment

4.2 Personal Protection

Appropriate eye protection shall be worn at all

Approved dust masks shall be worn to protect

Safety shoes, gloves and other appropriate skin protection

FOR DETAILED INFORMATION REFER TO THE MATERIAL SAFETY DATA SHEET

4.2 First Aid

5.1. Cleaning Tools / Equipment

5.2. Waste Disposal

FOR DETAILED INFORMATION REFER TO THE MATERIAL SAFETY DATA SHEET

As defined in EN 1504-10, water jet categories are as follows:

Low Pressure – Up to 18 N/mm2 (MPa) / 180 bar / ~2,600 PSI

-Used for cleaning concrete and steel substrate

High Pressure – from 18 to 60 N/mm2 (MPa) / 600 bar / ~8,700 PSI

Where: 1N/mm2 = 10 bar = 145 PSI (lbf/in2)

6.2. Steel Reinforcement

6.3. Pre-Wetting Substrate

7.1. One Component Products

7.2 Two component Repair Mortars

7.2. Three Component Products (Primers)

Working space shall be clean and tidy with no obstructions.

8.2. Reinforcement Corrosion Protection

8.3. Bonding Primer