001-PQP SUBSTATION CRACK REPAIR PLAN.pdf

Pearl GTL Project

LINDE ENGINEERING

Contractor Project No: 5887 Shell Project No: HP-3000-QAT

Project Document Number: T- 4.234.581 Project Rev.: A Page 2 of 99

Purchase Order Number:

2MH127

N/A Tag/Item Number(s):

ASU Unit(s):

Z PCWBS:

QATAR SHELL GTL PROJECT (PEARL) C2 AIR SEPARATION UNITS CONSTRUCTION

D A 15.05.08 Ready for Construction SB AB AG RFC

C O 14.04. 08 Issued for Company comments SB UA ZG ICC

B 08.04.08 Issued for Review SB UA ZG IFR

A 06.04.08 Issued for Internal Review SB UA ZG IIR

GAMA Rev.

Project Rev Date Description

Prepared By

Checked By

Approved By Status

No. No. ORIGINATOR

LINDE ENGINEERING AG

Document Title:

SUBSTATION CRACK REPAIR PLAN

Document No.

GAM REP QAC GTL 001 D LOC470

Contractor

Gama Qatar Co. W. L. L. Org.

Code Doc. Type

Disc. Code

Geogr. Area

Seq. No

Rev. No Vendor Code

Project Document Number: T- 4.234.581 Rev No: A

Doc. Title : GAM-REP-QAC-GTL-001 SUBSTATION CRACK REPAIR PLAN

Date : 15.05.2008 Rev-D

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TABLE OF CONTENTS

1. SUB STATION TIE BEAM CRACK LOCATIONS5

2. METHOD STATEMENT FOR REPAIR OF CONCRETE WORKS.62

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1. SUB STATION TIE BEAM CRACK LOCATIONS

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2. METHOD STATEMENT FOR REPAIR OF CONCRETE WORKS

Pearl GTL

Project

LINDE ENGINEERING

Contractor Project No: 5887 Shell Project No: HP-3000-QAT Project Document Number: T- 4.234.073 Project Rev.: C Page 1 of 36

SUPPLIER/VENDOR DOCUMENTATION

Purchase Order Number: 2MH127

Equipment Description: N/A

Vendor/Supplier Code: Vendor/Supplier Name: GAMA QATAR CO. W. L. L. LOC470

Document Title: METHOD STATEMENT FOR REPAIR OF CONCRETE WORKS

Vendor/Supplier Revision: F

Vendor/Supplier Doc Number: GAM-MTS-CIV-GTL-011

Tag/Item Number(s): SEE NEXT PAGE

Unit: SEE NEXT PAGE PCWBS: SEE NEXT PAGE

Vendor/Supplier Checked By

Initials / Signature

Vendor/Supplier Prepared By Initials / Signature

Vendor/Supplier Approved By Initials / Signature Vend/Supp

Revision Date SB UA ZG 30.03.2008

Status of Submission (tick applicable box before submission) Final: X For Review/Info: Certified: As-Built:

Purchaser signature below does not indicate responsibility or liability for accuracy or completeness of this document, nor does it alter any contractual terms or conditions or relieve the Supplier/Vendor of his contractual obligations.

PURCHASER AREA BELOW Contractor Contract Number: PI 092 Contractor Name: LINDE Contractor Doc. No: GAMAC-0100-C-PC 1006 Contractor Rev no: 4.0 (If applicable)

Contractor Initials / Signature

Date signedReview Code and Status

No Comments. ACCEPTED. Work May Proceed. Code 1

Comments As Noted. Incorporate Comments, Revise and Resubmit. Work May Proceed. Code 2

REJECTED. Incorporate Comments, Revise and Resubmit. Work May NOT Proceed. Code 3

Code 4 Not Reviewed. Work May Proceed.

Pearl GTL Project

LINDE ENGINEERING

Contractor Project No: 5887 Shell Project No: HP-3000-QAT

Project Document Number: T- 4.234.073 Project Rev.: C Page 2 of 36

Purchase Order Number: 2MH127

N/A Tag/Item Number(s):

ASU Unit(s):

Z PCWBS:

QATAR SHELL GTL PROJECT (PEARL) C2 AIR SEPARATION UNITS CONSTRUCTION

F C 30.03.2008 Ready For Construction SB UA ZG RFC

E B 23.03.2008 Ready For Construction SB UA ZG RFC

D A 23.02.2008 Ready For Construction SB UA ZG RFC

C O 09.12.2007 Issued for Company comments SB AU/MC ZG ICC

B 23.11.2007 Issued for Review AU/MC ZG IFR SB

A 20.11.2007 Issued for Internal Review AU/MC ZG IIR SB

Approved By

GAMA Project Rev Rev. Date Description

Prepared By

Checked By Status

No. No. ORIGINATOR

Document Title:

LINDE ENGINEERING AG

METHOD STATEMENT FOR REPAIR OF CONCRETE WORKS

Document No.

GAM MTS CIV GTL 011 F LOC470

Contractor

Gama Qatar Co. W. L. L. Org.

Code Doc. Type

Disc. Code

Geogr. Area

Seq. No

Rev. No Vendor Code

Project Document Number: T-4.234.073 Rev No:C

Doc. Title : GAM-MTS-CIV-GTL-011 MS FOR REPAIR OF CONCRETE WORKS Date : 30.03.2008 REV. F

T-4.234.073 Rev. C

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TABLE OF CONTENTS

1. PURPOSE ____________________________________________________________________ 6 2. SCOPE _______________________________________________________________________ 6 3. HSSE ________________________________________________________________________ 6 4. REFERENCES ________________________________________________________________ 7 5. DEFINITIONS ________________________________________________________________ 7 6. RESPONSIBILITY _____________________________________________________________ 8

6.1. Site Manager ____________________________________________________________________ 8 6.2. Civil Works Manager_____________________________________________________________ 8 6.3. Site Engineer____________________________________________________________________ 8 6.4. Work Supervisor ________________________________________________________________ 8 6.5. QA/QC Officer / Inspector ________________________________________________________ 9

7. EQUIPMENT & MANPOWER __________________________________________________ 10 7.1. Equipment _____________________________________________________________________ 10 7.2. manpower _____________________________________________________________________ 10

8. METHOD OF EXECUTION ____________________________________________________ 11 8.1. General ________________________________________________________________________ 11 8.2. Pre-Commencement Works _____________________________________________________ 11 8.3. Start of repair __________________________________________________________________ 11 8.4. Materials_______________________________________________________________________ 11 8.5. Mixing _________________________________________________________________________ 11 8.6. Extend of Repair _______________________________________________________________ 11

9. CRACKS_____________________________________________________________________ 13 9.1. Technical Description of Crack Type _____________________________________________ 13 9.2. Crack Type (1) Deep crack run across whole surface ____________________________ 13 9.3. Crack Type (2) Crack near the anchor bolts _____________________________________ 13 9.4. Crack Type (3) Crack reaching to box-outs______________________________________ 13 9.5. Crack Type (4) General cracks _________________________________________________ 13 9.6. Crack Type (5) Hairline cracks _________________________________________________ 13 9.7. Selection of Suitable Crack Repair Method _______________________________________ 14 9.8. Method (A) Epoxy resin injection_______________________________________________ 14 9.9. Method (B) V-cut and Repair Mortar ____________________________________________ 14

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9.10. Method (C) Surface application of Repair Mortar ________________________________ 14 9.11. Method (D) Not to be repaired__________________________________________________ 15 9.12. Repair Methods ________________________________________________________________ 15

10. REPAIR OF HONEYCOMBS &SURFACE IMPERFECTIONS _____________________ 16 10.1. Material________________________________________________________________________ 16 10.2. Minor Honeycombs _____________________________________________________________ 16 10.3. Major honeycombs _____________________________________________________________ 16 10.4. Curing _________________________________________________________________________ 17

11. QUALITY ASSURANCE______________________________________________________ 18 12. ATTACHMENTS____________________________________________________________ 18

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1. PURPOSE

This document describes the methods proposed to be used for the concrete repair activities that will be carried out as part of ASU Construction Works of Qatar Shell GTL Plant (Pearl) in Ras Laffan Industrial City of Qatar including similar works in TSF Area.

2. SCOPE This method statement covers methods for Concrete repair works.

3. HSSE All works shall be in compliance with the State of Qatar laws and regulations, Ras Laffan Industrial City and international standards/codes, and Company and Contractor requirements and instructions. All personnel will go through Gama, Linde and Company Safety Induction courses as well as other trainings as identified by their supervisor. A Job Safety Analysis (JSA) specific for this work including a Risk Assessment is prepared and attached herein. Such JSA addresses the hazards associated with each task within the scope of this Method Statement and introduces the controls that will be implemented to reduce the associated risks to acceptable levels. The JSA will be used by the Site Supervisor as the basis of his TSTI / TSTO and Toolbox Talks. All personnel will have PPE required for their specific tasks in addition to the minimum PPE (coveralls, safety goggles, safety shoes, high-visibility vests, gloves) at site at all times as required. In the event of a release, fire or explosion, employees will secure their area and evacuate to the nearest muster point. Once all employees are evacuated the supervisor will conduct a headcount to verify all employees are out of harms way. The supervision will report this to Contractor. Emergency Contact numbers for Company, Contractor and Gama will be posted onsite. All vehicles and equipment used for the subject work will be inspected and certified as required. Drivers and operators will be competent and will have attended all required trainings set forth in project procedures and specifications.

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4. REFERENCES

Qatar Construction Standard DEP 34.19.20.31- Reinforced Concrete Foundations and Structures

(Amendments T.13.376.358G-Clause 3.24)

ASTM 546 Concrete Repair Guide Vendor Specifications

Other specifications and procedures of Contractor, Company and RLIC.

5. DEFINITIONS Company : QSGTL or its PMC Contractor : Linde Engineering AG Subcontractor : Gama Qatar Co. W. L. L. Contract : QSGTL Pearl Plant C2 ASU Construction Works QCP : Quality Control Procedure ITP : Inspection and Test Plan QA/QC : Quality Assurance / Quality Control JSA : Job Safety Analysis

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6. RESPONSIBILITY

6.1. SITE MANAGER

The site manager will provide inputs to the project execution plan to ensure that strategies & philosophy are properly addressed.

6.2. CIVIL WORKS MANAGER

The Civil Works Manager is responsible for the overall management of the project construction team to ensure that safe and effective operations are conducted and properly documented.

6.3. SITE ENGINEER

He will be overall responsible for safe execution of the whole job including:

Confirming the installation location from schedule of approved construction drawings. Organizing of equipments and tools needed for the job. Assigning skilled personnel for the job. Sequence of activities to be carried out for the work as per this method of statement. Conduct inspection and surveillance. Notify to Contractor engineer for inspection as applicable. Ensure all Contractor and Company regulations are followed. Ensure all personnel involved are in safe working condition.

6.4. WORK SUPERVISOR

He will be responsible for safe execution of the following activities:

Conduct TSTI with the concerned work force prior to start the work. Ensure that relevant work permits for the job are obtained prior to start the work. Conduct daily toolbox talks for the entire work force prior to start day work. Assigning a competent work crew for specific activities, details of activities and task

information will be given to the work crew.

Organizing tools and equipment needed to the work site. Inspection and supervision of work. Ensure all Contractor and Company safety regulations are followed as applicable.

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6.5. QA/QC OFFICER / INSPECTOR

He will be responsible for:

Assurance of approved methods and materials are being used and conformance of the specifications.

Stage inspections and surveillance in accordance with ITP and assurance of quality of work as per specification and erection procedures.

Incoming material inspection and review of test certificates.

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7. EQUIPMENT & MANPOWER

All equipment will be inspected and approved by the Contractor, when required, and all personnel will be inducted and trained before and during mobilization.

7.1. EQUIPMENT

Disc cutter : 1 Electric/pneumatic breaker or hammer and chisel : 1 Wire brush: : 1 Measuring jug: : 1 Slow speed drill (400 or 500rpm): : 1 Mixing paddle : 1 Suitably sized mixing vessel : 1 Trowel : 1 Wooden float : 1 Steel or plastic finishing float or sponge : 1 Injection machine : 1 High speed percussion drill : 1 Hand held angle grinders : 2

7.2. MANPOWER

Civil Foreman : 1 Safety Officer : 1 QA/QC Technician : 1 Mason : 2 Helper : 2

If the above-listed equipment or manpower proves not sufficient for the timely completion of the facilities and project; additional will be provided to complete the works on time and in line with rules, regulations and specifications of Contractor, Company and RLIC.

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8. METHOD OF EXECUTION

8.1. GENERAL

This chapter explains the methods to be used for the execution of repairing concrete cracks.

8.2. PRE-COMMENCEMENT WORKS

Prior to work commencement, the existing structures and installations will be checked by means of As-Built Drawings issued by the Contractor or the Company. The locations of such installations will be marked at site and posted with signs. After the area has been barricaded. The Repair area will be covered from direct sun light. The barricades for such activities will be temporary.

8.3. START OF REPAIR

The Repair application only performed after curing period finished as per T.13.376.358E-SEC-9.0

8.4. MATERIALS

Fine mortar incorporating polyvinyl acetate (PVA)/Renderoc BF/ Renderoc Sxtra fillers shall be used for sealing minor cracks (w0.3mm), which do not require structural bonding. Low viscosity epoxy injection resins shall be used for cracks which require structural bonding (BASF Master Flow 648 CP)

8.5. MIXING

Renderoc BF and Renderoc Sxtra are to be mixed as per Manufacturer Recommendation. The Mixing Shall be in compliance with T.13.376.358E.

8.6. EXTEND OF REPAIR

Renderoc BF can be used up to 5mm only .Renderoc Sxtra recommended limits for a Single applications are Minimum applied thickness : 5mm

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Overhead sections : up to 25mm thick Vertical sections : up to 35mm thick Small pockets or horizontal : up to 100mm thick Maximum length : up to 3m Note: If the Repair area exceeds 2.5m2, consideration should be given to the use of mass fill by means of either Renderoc SPxtra* spray applied motar or Renderoc LAXtra* micro concrete. Water Addition=3.0 litres per 20kg bag Under no circumstances should part bags be used or additional water is employed. Either of these two actions will adversely affect material performance, automatically invalidating Fosroc's standard product guarantee.

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9. CRACKS

9.1. TECHNICAL DESCRIPTION OF CRACK TYPE

Technically unfavourable conditions considering the function of concrete in general can be considered as follows (number in corresponds with the number in Fig.-1), and all root cause of cracking shall be verified jointly by Company and Contractor's Engineers. Crack repair can be done only after inspection.

9.2. CRACK TYPE (1) DEEP CRACK RUN ACROSS WHOLE SURFACE

Cracks, which run across the whole top surface and continue to the side surface, and appear to be penetrated through the structure till the certain depth, are apparently detrimental in terms of durability. If the concrete structure is subject to dynamic force continuously, those cracks are also considered to threaten the structural integrity.

9.3. CRACK TYPE (2) CRACK NEAR THE ANCHOR BOLTS

Cracks, which are located in the vicinity of structural elements to transmit forces such as anchor bolt, are considered to be associated with durability problem of the rebar inside and the structural elements themselves. Additionally, if the anchor bolts continuously transmit dynamic forces generated by the machinery, these cracks will also be associated with structural deterioration due to vibration.

9.4. CRACK TYPE (3) CRACK REACHING TO BOX-OUTS

Cracks, which run into any opening, box-out, projected/deflected parts and appear to be penetrated to some depths. These cracks shall likely be associated with the durability problem.

9.5. CRACK TYPE (4) GENERAL CRACKS

General cracks on surface with or without a regular pattern, probably caused by lack of compaction and corresponding settlement, shrinkage force (autogeneous, drying) or thermal gradient (if it is located near the anchor bolts or so, refer to crack type (2)). These cracks will reduce the concrete cover and resistance to chloride penetration and potentially increase the risk of rebar corrosion. However, if the crack width is narrow and crack depth is limited to surface, its effect on the durability is negligible and thus considered not to be a technical problem, but might be a problem in terms of aesthetics.

9.6. CRACK TYPE (5) HAIRLINE CRACKS

Hairline cracks, of which width is not more than 0.3 mm, are shallow surface cracks in most of the cases and have negligible effects in terms of durability, and not a technical problem, but might be a problem in terms of aesthetics.

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9.7. SELECTION OF SUITABLE CRACK REPAIR METHOD

All the cracks are to be logged photographed jointly inspected by Company and Contractor's Engineers and Repair is to be done as per following procedure. The following three types of crack repair method or no action shall be applied depending on the nature of each crack.

9.8. METHOD (A) EPOXY RESIN INJECTION

This method is to inject low viscosity epoxy resin (having bonding feature) into the crack with low pressure. This method shall be applied for cracks, which require structural bonding in order to eliminate the risk potentially threatening the structural integrity. Types of cracks fall in this category are types (1) and (2) cracks on the concrete structures, which are subject to continuous dynamic load, or vibration. If the crack width is more than 0.3mm under this condition, the crack is assumed to be deep and this repair method (A) shall apply. If the crack width is not more than 0.3 mm, it is not to be repaired basically (category (D)). However, based on the properties of the crack, if the crack is estimated to widen in the future, for example due to vibration effect, repair method (C) category may be applied. If the crack is judged to cause significant effects on structural performance, the epoxy injection described here, i.e. repair method (A) shall be applied.

9.9. METHOD (B) V-CUT AND REPAIR MORTAR

This method is to V-cut and to seal the crack with repair mortar. This method shall be applied for cracks, which does not require structural bonding, but require sealing in order to prevent potential chloride migration. Types of cracks fall in this repair category are types (1), (2), (3) and (4) cracks and the width of the crack is more than 0.3mm.

9.10. METHOD (C) SURFACE APPLICATION OF REPAIR MORTAR

This method is to coat concrete surface with filler. This method shall be applied for cracks, which require only sealing as the same, as (B). Types of cracks fall in this repair category are types (1), (2), (3) and (4) cracks and the width of the crack is not more than 0.3mm. This is only for aesthetics and where vibration is expected. In this range of width, the depth of the crack is, in most of the cases, limited to the surface, and the expected length change in the vicinity of the crack in the future is not large and could be withstood by the repair mortar applied at the surface.

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9.11. METHOD (D) NOT TO BE REPAIRED

Types of cracks fall in this category are type (5), which does not require structural bonding, and the width of crack is not more than 0.3mm. This type of cracks is not to be repaired. The crack types and selection of crack repair methods explained above are summarized in Fig. -1.

Fig. -1 Schematic Diagram of cracks Patterns and Repair Methods Classification

9.12. REPAIR METHODS

Repair methods shall be in accordance with manufacturer recommendation. For further details of Product Data Sheet (PDS) and Material Safety Data Sheet (MSDS) for the material to be used not be examined.

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10. REPAIR OF HONEYCOMBS &SURFACE IMPERFECTIONS

10.1. MATERIAL Fine mortar incorporating polyvinyl acetate (PVA)/Renderoc BF filler for filling blowholes and minor honeycombs. Renderoc SXtra - Shrinkage compensated Fine mortar incorporating polyvinyl acetate (PVA)/Renderoc BF repair mortar for repair of major honeycombs and voids, both are approved by Company and Contractor.

10.2. MINOR HONEYCOMBS

After completion of curing period, surface holes shall be inspected as per T.13.376.358E Sec 3.24. Minor voids in below ground concrete shall have the concrete surface fully coated with the specified concrete coating; brush application shall be used to ensure full coating of the void surface. A minor void is defined as a surface defect which is enclosed by a 50mm diameter circle within which the concrete cover is not reduced by more than 10mm Minor voids in above ground concrete shall be filled with fine mortar incorporating polyvinyl acetate (PVA) Renderoc BF. Substrate surface shall be cleaned, roughened to remove loose particles and sound concrete shall be exposed. The area of application shall be free from dust, loose particles, oil, grease and any other contamination. All application with Renderoc BF shall be as per manufacturers technical data. Mix proportions shall be ensured during process. Mixing Water for Renderoc products shall be as per Clause 3.13 of T-13.376.358.The quantity of water added to dry Renderoc material shall comply with Manufacturers Recommendations. As soon as the mortar starts to set, the surface shall be smoothened to a final finish. The surface shall be cured as per manufacturers technical data.

10.3. MAJOR HONEYCOMBS

After removal of forms, surface holes shall be inspected and major honeycombs, voids and defective concrete shall be marked and substrate preparation shall be done, only after full curing completed accordance with T-13.376.358E. Approval will be taken from the client for repair. The particular area shall be repaired by Renderoc SXtra and then covered by polyethylene sheeting, taped down at the edges. After Rendoroc SXtra finally sets one day after repair- polyethylene sheeting shall be removed and curing shall be continued as usual for the whole structural member. Substrate surface shall be clean and free from dust, loose particles, oil, grease and any other contamination.

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Honeycombs or otherwise defective concrete shall be outlined with a minimum 10mm saw cut and such concrete shall be removed to sound concrete. If the defective concrete extends to reinforcement, corroded reinforcement shall be fully exposed in the repair area, which may require further break out of concrete beyond the original repair area. A clear gap of at least 20mm shall be created behind the rear face of reinforcement, such that a gloved hand can comfortably reach behind the main bars. Rebar shall be cleaned to a uniform bright condition by the use of a blast media. Anti-corrosion primer shall be applied to reinforcement. Self sacrificing anode shall be placed if Renderoc BF & Renderoc SXtra used. The saw cut edge of the repair shall be roughened to provide a good mechanical key at the substrate interface. The substrate surface shall be soaked with clean water and excess water shall be removed, leaving the substrate in saturated surface dry condition. Bonding agent shall be applied. Mix proportions shall be ensured during process as per Manufacturer's Instructions. After mixing Renderoc SXtra, it shall be applied to the substrate by trowel or gloved hand, thoroughly compacting on to the primed substrate. Renderoc SXtra is finished by striking off with a straight edge and closing with a steel or plastic float. Water can be drawn to the surface if overworking with the float occurs, and an unsightly finish may result. Damp sponges or plastic floats may be used to achieve a desired surface texture but care should be taken not to overwork the surface. The surface shall be cured as per manufacturers technical data.

10.4. CURING Curing will be done as per Manufacturer recommendation.Renderoc BF generally needs to be protected by polythene sheets .In Hot & windy climate shall be coated with Nitocote PE 135.Nitocote PE 135 need not removed for further surface coating as per Manufacturer recommendation. Curing with damped Hessian is to be done for one day. This coating can be done after one day in wet damped surface also.

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11. QUALITY ASSURANCE A Quality Assurance System will be operated conforming to related standards. Controls and checks will be established and documented in Concrete Repair form -GAM-QCR-QAC-GTL-010.Repaired surface Inspection will be offered to client. All deficiencies will be logged, photographed and repaired. Repair of concrete will be Hold point in ITP T.4.234.075. Separate Repair Log sheet will be maintained.

12. ATTACHMENTS

JSA RENDEROC BF RENDEROC SXTRA NITOCOTE PE 135 REPAIR LOG MASTERFLOW 648 CP COATING LETTER GAM-QCR-QAC-GTL-010

SUBSTATION CRACK REPAIR PLAN.docMS-REPAIR OF CONCRETE WORKS.doc