Doc No : KAK-ANA-CFS-CMS-0002

METHOD STATEMENT Rev No : A02

FOR Date : 28-July-2018
CONCRETE WORKS Page No : 1 of 10

METHOD STATEMENT FOR CONCRETE WORKS

KAK-ANA-CFS-CMS-0002 rev.A02

Client : Saudi International Petrochemical Company (SIPCHEM)

Project Name : SIPCHEM CO2 Feed System Project

Project Location : Saudi Aramco Shell Refinery (SASREF) Plant, Jubail

Contract No : 7600000196

A02 28-Jul-18 Revised as per comments ARB

A01 21-Jul-18 Revised as per comments ARB
A00 30-Jun-18 First Submission ARB
Prepared Checked Approved HSE Approved
Rev Date Description (ANABEEB)
(KAK) (GAS) (GAS) (SASREF)
 Doc No : KAK-ANA-CFS-CMS-0002
METHOD STATEMENT Rev No : A02
FOR Date : 28-July-2018
CONCRETE WORKS Page No : 2 of 10

TABLE OF CONTENTS:
1.0 SCOPE ……………………………………………………………………………………….…………………………………… 03

2.0 PURPOSE …………………………………………………….…………………………….……………….………………….. 03

3.0 REFERENCES …………………………………………………………………………………….………………………..…. 04

4.0 WORK EQUIPMENT …………………………………..………………………………………………………………….. 04

5.0 WORK MATERIALS …………………………………………………..……………………………………………………. 04

6.0 DUTIES & RESPONSIBILITIES…………………………………….…………………………………………………….. 05

7.0 WORK PROCEDURE ……………………………………………….……………………………………….……………… 07

8.0 SAFETY PRECAUTIONS…………………………………………..………………………..……………………………… 10

 Doc No : KAK-ANA-CFS-CMS-0002
METHOD STATEMENT Rev No : A02
FOR Date : 28-July-2018
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1.0 SCOPE

This method statement covers all required activities for concrete works part of the scope of work.
Methodology statement includes formworks, reinforcement, anchor bolts and embedment installation,
concrete pouring, curing activities and waterproof coating.

Structures covered in this methodology include all concrete foundation of structures, equipment pads,
slabs and paving specifically for the following:
1. Compressor shelter structure foundation and grade slab
2. Compressor equipment pad with sleeper foundations
3. Cooler fin fans structure foundation
4. Knock-out drum Equipment foundations
5. Dehydration system equipment pad with sleeper foundations
6. Dehydration system shelter structure foundations
7. Pipe rack equipment foundations
8. Pipe support and sleeper foundations
9. Oil cooler structure foundation
10. Lube oil system pad
11. Ladder foundations
12. Paving slab
13. Transformer equipment and shelter foundation
14. Corridor area pipe support

2.0 PURPOSE

The methods and sequence of activities contained in this document shall serve as guidance and
reference to ensure proper execution of all related activities are in accordance with contract requirement,
safety & quality assurance. This method statement shall detail the work and concerns that is to be given
attention in each area or work as to the following:

2.1 Survey for location, layout and marking for required sizes and orientation of foundations
2.2 Pre-pour job steps and check-ups for both on-site and pre-cast concrete foundations
2.3 Waterproofing of concrete foundations
2.4 Identify and conduct Inspection points and testing of concrete samples
2.5 Concrete pouring by mobile telescopic boom pump
2.6 Implementation of safety measures, PPE’s and compliance to HSE procedural requirements
2.7 Identification and preparation of required manpower, equipment and materials for all of the above
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METHOD STATEMENT Rev No : A02
FOR Date : 28-July-2018
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3.0 REFERENCES

3.1 PROJECT PROCEDURES

GAS-PMT-1701-0002 - Project Technical Specifications and Project Standards
GAS-SIPCHEM-CO2-QA-PQP-001 - Project Quality Plan
GAS-SIPCHEM-CO2-PSP-001 - Project Safety Plan

3.2 STANDARDS AND SPECIFICATIONS

00-SR-00-SS-005 - SIPCHEM Concrete Construction

00-PQ-00-ML-001 - SIPCHEM Acceptable Manufacturer’s List
ACI-304R - Guide for Measuring, Mixing, Transporting, and Placing Concrete
ACI- 305R - Hot Weather Concreting
ASTM-A615/A615M - Standard Specification for Deformed and Plain Carbon Steel Bars for
Concrete Reinforcement
ASTM-A775/A775M - Standard Specification for Deformed and Plain Carbon Steel Bars for
00-SR-00-SS-006 - SIPCHEM Precast Concrete
ASTM C39/C39M - Standard Test Method for Compressive Strength of Cylindrical Concrete
Specimens
OSHA 29 - OSHA Safety and Health Regulations for Construction

4.0 WORK EQUIPMENT

4.1 Hand tools
4.2 Concrete mixer/s
4.3 Concrete Pump/s
4.4 Concrete Vibrator
4.5 Hand trowel / float

5.0 WORK MATERIALS

5.1 Formwork wood, boards
5.2 Reinforcing steel bars
5.3 PVC conduits and fittings
5.4 Anchor bolts, embedded plates
5.5 Bonding agents
5.6 Polyethylene Sheets
5.7 Hessian cloth
5.8 Waterproof coating
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6.0 DUTIES & RESPONSIBILITIES

6.1 GAS Management

 Obtain all necessary site clearance for construction, MOCs, site takeover permits, etc.
 Ensure availability of approved and required site procedural requirements
 Ensure that project requirements and scope are fully communicated to sub-contractor
 Make available the required IFC drawings prior to start of activity and that any revisions to
approved drawings are promptly communicated to sub-contractor
 Shall oversee overall site management to ensure that responsibilities are well covered and
performed by the project organization
 Shall ensure availability of sub-contractor’s personnel, equipment and service provider’s access
to site to avoid work interruptions due to this

6.2 KAK Project/ Construction Manager

 Shall ensure that contractual obligations are satisfied and satisfactorily performed
 Ensure that all instructions and requirements from main-contractor are within project scope of
work and agreed terms of contract
 Shall ensure timely and keen planning activities in-line with project schedule
 Ensures that key site personnels assigned on project performs their duties required
 Shall intermediate and link between departments to have a clear and continuous communication
for safety, quality and construction team
 Shall take responsibility and accountability for decisions made, interpretations of instructions
from Client and deviations from work program considering risks and opportunities available
 Ensures availability of materials, personnel and equipments required for in all stages of the
project.
 Shall serve as only direct link to main contractor representative for all communication and
instruction to be passed to down-line of the organization.

6.3 KAK Workgroup Supervisor

 Ensures all workgroup are having most recent revision of IFC drawings on the site
 Ensures implementation of work procedures between disciplines and workgroups
 Ensures materials, equipment and manpower required on all open & on-going work fronts are
sufficient and made available

6.4 KAK Quality Supervisor

 Coordinates and informs workgroup supervisors of all inspection and hold-points on open & on-
going work activities
 Ensures all required inspections are promptly inform main contractor of the same
 Coordinate with third party inspection and ensure availability of technicians
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METHOD STATEMENT Rev No : A02
FOR Date : 28-July-2018
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6.5 KAK Safety Supervisor

 Ensures safety procedures are in place and being strictly implemented
 Ensures all safety facilities, PPE and equipments are made available in a continuous basis
 Ensures Site safety and work permit requirements are satisfied and complied
 Oversee implementation of confined space procedures

6.6 KAK Vendor/Supplier on site

 Shall ensure compliance to Site safety procedures
 Shall ensure equipments brought on-site are inspected and well-conditioned to work.
 Shall ensure that all concrete mix delivered are in accordance to approved mix design
 Shall ensure that all aggregates and materials used in production of concrete are compliant to
relevant international standards and Client specifications
 Shall ensure that hot-weather concreting considerations are in place and are being implemented
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7.0 WORK PROCEDURE

7.1 CONCRETE WORK PREPARATION FOR ON-SITE POURS

7.1.1 After excavation and earthwork preparations are made available, deliver required materials
on work area.
7.1.2 Substrate soil or plain concrete shall be clean of deleterious materials.
7.1.3 When concrete structure is casted on soil, soil compaction test verifications shall be checked
by field density test to be conducted by third party inspector.
7.1.4 Concrete constructed above ground shall be prepared by providing a safe working platform
(i.e. scaffolding)
7.1.5 Bottom level of concrete to be constructed shall be in accordance to IFC drawings.
7.1.6 Layout and dimensions of concrete shall be verified by survey.

7.2 FORMWORK, REBARS AND EMBEDMENT INSTALLATION FOR BOTH PRE-CAST AND ON-SITE POURS

7.2.1 Install formworks in accordance to layouts verified to IFC drawings dimensions.

7.2.2 Ensure all formworks used are of standard quality and made rigid by providing bracing and
necessary supports to restrain forms from any movement or displacement during concrete
pouring.
7.2.3 All pre-formed reinforcing rebars shall be installed on pre-pared formworks and provide PVC
spacers to maintain concrete cover of rebars from edge of concrete. PVC Spacers shall be
made of 2” to 3” diameter cut PVC pipe to the required concrete cover of steel in accordance
to IFC drawings.
7.2.4 Damaged coating of FBECRs shall be repaired on site after installation by paint touch-up using
the same material used for coating. Coated tie-wires shall be similarly touched up to cover
plain wires cut on ends.
7.2.5 All embedment shall be installed (i.e. pvc conduits, anchor bolts, weld pads, etc) in
accordance to drawings for construction. All embedment shall be provided with proper
support to maintain their location during concrete pouring activities.
7.2.6 All anchor bolt, embedded plates, angle bars, electrical conduit and waterstops shall be
inspected by respective discipline prior to allowing the pour.
7.2.7 Where required, a 25mm pvc chamfer strips shall be provided on formwork edge/corners
especially for concrete structures exposed to physical and/or mechanical contact.
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7.3 METHOD OF POURING

Two methods of pouring will be adapted for concrete pouring activities. For all pre-cast
concrete, direct pouring by chute from mixer trucks will be implemented. Concrete pours on
site will be performed either by direct chute pouring or by using concrete pump with
telescopic boom.

7.3.1 Chute pouring shall be performed where structure to be poured can be easily accessed by
mixer trucks. In this way, concrete will flow through the chute and disposed on prepared
formwork. It shall be ensured that the chute edge will not be 1.0m higher than the point
where concrete will be disposed to avoid segregation of aggregates with the concrete due to
impact if chute is at very high position.
7.3.2 Pump pours shall be used for most of the structures poured on-site. When using telescopic
boom driven concrete, operator shall be wary of all overhead obstructions which may be
disturbed by the boom. It shall also be checked that the concrete is not released above 1.0m
higher than its of point of disposal to avoid aggregate segregation. The person directing the
pour at the end of the telescopic hose should ensure the height of concrete fall and no
person is directly in front where concrete is being released. After pouring, on one location,
operator shall ensure that hose is emptied or in vacuum before transferring the boom into
other spot or location so as to avoid any damage caused when concrete will spill out of the
hoses while it is on the air and moving to another location.

7.4 CONCRETE POURING

7.4.1 Upon receiving of concrete on-site, fresh concrete testing shall be performed by third party
inspector to verify conformance to specifications and standards.
7.4.2 Concrete disposal from batching time shall not exceed 90mins. When it is not possible to
reach the site from the batching plant within the allowed 90mins duration, retarding agents
can be mixed with concrete under approval of client representative.
7.4.3 Concrete slump, temperature and aggregate sizes shall be physically verified on site prior to
pouring. Non-conforming concrete batch shall be rejected under discretion of client
representative.
7.4.4 Concrete shall be disposed not more than 1.2m high to avoid free-fall impact which may
affect consolidation of concrete aggregate on the forms.
7.4.5 Fill concrete into formworks to required level of concrete. Vibrators shall be sued to aid
consolidation of concrete and remove trapped air voids.
7.4.6 Cold joints shall be avoided on foundation structures and therefore required quantity of
concrete shall be delivered on the site without stoppage.
7.4.7 Top level of concrete shall be prepared to require finishing in accordance to IFC drawings. All
surfaces which will receive coating shall be float finished while surfaces which will require
cladding or tiles may be trowel finished.
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7.4.8 During pouring of concrete, workers should not be directly in physical contact with the
cement mixture. The workers working on the disposal point of concrete shall wear a face
shield.
7.4.9 Pump operation shall be with full caution to avoid hitting any other structures or equipment
on the site. Pump hoses shall be secured firmly by the worker to avoid letting the pump hose
freely jerking and hitting workers or equipments adjacent to the site.
7.4.10 Immediately upon concrete pouring completion, verify all embedment are in-place and did
not move from location. Any adjustments required may be performed while the concrete is
still in liquid state.
7.4.11 Upon consolidation, wet hessian cloth will be installed over new concrete to avoid rapid
evaporation.
7.4.12 Excess concrete on the site shall be cleaned off before drying.

7.5 FRESH CONCRETE TESTING

7.5.1 Perform inspection with client QA/QC prior to concrete pouring to verify all installations are
correct in accordance to drawings and specifications.
7.5.2 Once all inspections are performed and satisfactory to the requirements, prepare the site for
concrete pouring.
7.5.3 Cold joints between concrete pouring shall be applied with concrete bonding agent to
increase bond between hardened concrete and fresh concrete.
7.5.4 Discontinuous concrete especially on expansion or control joints shall be provided with filler
or expansion boards prior to concrete pouring. A total of 7 concrete sample cylinders shall
be taken from concrete batch. 6 cylinders shall be laboratory cured and 1 sample will be field
cured. 3 cylinders will be crushed at 7-days maturity period and the rest of samples shall be
crushed at 28 days maturity period. Concrete samples should not display compressive
strength not less than design strength.

7.6 CURING, SURFACE PREPARATION AND COATING

7.6.1 Concrete shall be cured continuously within a period of 7 days or as client requires.
7.6.2 Concrete shall be wet with potable water at least 2 times a day during favorable weather.
Frequency of curing will be increased during hot and humid weather.
7.6.3 Removal of forms can be performed immediately after concrete consolidation or in
accordance to SIPCHEM requirements.
7.6.4 All surface irregularity found after removal of formwork shall be immediately repaired with
approved repair compound.
7.6.5 Dry the surface of concrete after the curing period in preparation for coating or further
installation/construction work.
7.6.6 Apply 2 coats of waterproof coating material approved by Client. Ensure no pinholes or
bubbled voids on the surface being coated. Such non-uniformity shall be touched-up with
same coating material.
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7.6.7 Waterproof coating shall cover all surface exposed to earth extending to surfaces 300mm
above grade level.

8.0 SAFETY PRECAUTIONS

1.1 All workers shall provide with PPE (Personal Protective Equipment) and shall be worn every time they
entering the site. Safety Supervisor shall ensure all the workers wear all the safety equipment
provided.
1.2 Safety Supervisor shall ensure that the activity carried out in a safe manner.
1.3 All workers shall fully support and actively participate in all safety related activities and comply with all
practicable safety measures.
1.4 All workers shall be advised to report any accident or injury to supervisor and proper treatment to be
obtained.
1.5 The safety supervisor shall ensure that workers understand the safety regulations and explain in detail
in particular hazards, where the workers are working and the precaution to be taken their safety.
1.6 All workers shall ensure that all tools and equipment machinery are in good condition to avoid any oil
leakage that could harm to environment.
1.7 Domestic and construction waste from construction area must be collected into centralized garbage
bin and disposed at the designated area.
1.8 Movement of concrete mixers and pumps on the site shall be made in safe manner such that no
accident will be incurred. Flagman shall be available at all times to guide movement of heavy and
mobile equipments.
1.9 All mobile and engine operated equipments shall be inspected by Safety officer on the site. These
equipments should not display any signs of oil or fuel leaks to avoid cases of fire and spillage on the
site.
1.10 The working area where mobile equipments will work shall be barricaded to avoid access of persons
not involved with the site activity.