PLANT LOCATION

JAZAN SAUDI ARABIA

CUSTOMER
SAUDI ARAMCO

JOB

UNIT
240832

PROJECT / UNIT
JIGCC SULFUR RECOVERY UNlT (SRU) - IK-EPC PACKAGE-2

A07

DOC NO.

A07-ZA-E-7002703_BAA

NSH DOC NO.

A07-NSH-MS-CVL-0030

SH. 1 OF 16
SUBCONTRACTOR
NSH CORP.

SUBCONTRACTOR CONTRACT NO.

975964

REV. A

SUBCONTRACTOR PROJECT NO
240832

METHOD STATEMENT
CONCRETE DAMAGED DUE TO FORMWORK
FAILURE @ SUBSTATION SS 007
CAST-IN SITU REINFORCED CONCRETRE WALL
ALONG GRIDLINE 3/A-B

CONTRACT NO. 6600033161

B.I.-10-01525-0002

ISSUED FOR REVIEW

RAMIL
ENGINEERING

ASHOKAN
CONST MANAGER

MOHANAN CM
HSE MANAGER

RAJEEV GEORGE
PROJECT DIRECTOR

14/11/2016

Rev.

Description

Prepared by

Checked by

Reviewed by

Approved by

Date

PLANT LOCATION
JAZAN SAUDI ARABIA

CUSTOMER
SAUDI ARAMCO

PROJECT / UNIT
JIGCC SULFUR RECOVERY UNlT (SRU) - IK-EPC PACKAGE-2

JOB

UNIT
240832

A07

DOC NO.

A07-ZA-E-7002703_BAA

NSH DOC NO.

A07-NSH-MS-CVL-0030

SH. 2 OF 16
SUBCONTRACTOR
NSH CORP.

SUBCONTRACTOR CONTRACT NO.

975964

REV. A

SUBCONTRACTOR PROJECT NO
240832

CONTENTS
1.

PURPOSE

2.

SCOPE

3.

DEFINITIONS

4.

REFERENCES

5.

TOOLS & EQUIPMENTS AND REQUIRED PERSONNEL

6.

ABBREVIATIONS

7.

REPAIR MATERIALS

8.

CONSTRUCTION METHODOLOGY AND SEQUENCE

9.

QUALITY CONTROL & QUALITY ASSURANCE

10.

HEALTH, SAFETY AND ENVIRONMENT

11.

TRAINING

12.

ATTACHMENTS

PLANT LOCATION
JAZAN SAUDI ARABIA

CUSTOMER
SAUDI ARAMCO

PROJECT / UNIT
JIGCC SULFUR RECOVERY UNlT (SRU) - IK-EPC PACKAGE-2

JOB

UNIT
240832

DOC NO.

A07-ZA-E-7002703_BAA

NSH DOC NO.

A07-NSH-MS-CVL-0030

SH. 3 OF 16
SUBCONTRACTOR
NSH CORP.

SUBCONTRACTOR CONTRACT NO.

975964

A07

REV. A

SUBCONTRACTOR PROJECT NO
240832

1. PURPOSE
The purpose of this Method Statement is intended specifically to describe the concrete
repair procedures to be applied for cast-in situ reinforce concrete wall along gridline 3/A-B of
Substation SS 007 of JIGCC SRU Package -2.
Sequence of operation and precautions shall be observed to ensure that concrete repair is
applied in a safe & acceptable manner. Concrete repair work shall be performed in
accordance with the Saudi Aramco Materials System Specification (SAMSS), Standards
(SAES), Procedures (SAEP), Engineering Report (SAER), Typical Inspection Plan (SATIP),
Inspection Checklist (SAIC), project approved IFC Drawings and General Arrangement
Drawings, Manufacturers Manuals, Saudi Aramco Construction Safety Manual, and
documents listed in Section 4 - REFERENCE.

2. SCOPE
This Method Statement is specifically applicable to concrete repair of misaligned or bulging
concrete surface due to concrete formwork support failure, for cast-in situ reinforced
concrete wall along gridline 3/A-B of Substation SS-007, Area A07 Gasification-Sulfur
Recovery Unit (G-SRU) - EPC Package 2, at Jazan Integrated Gas Combined Cycle Project
(JIGCC), Jazan Economic City, Saudi Arabia.

PLANT LOCATION
JAZAN SAUDI ARABIA

CUSTOMER
SAUDI ARAMCO

PROJECT / UNIT
JIGCC SULFUR RECOVERY UNlT (SRU) - IK-EPC PACKAGE-2

JOB

UNIT
240832

A07

DOC NO.

A07-ZA-E-7002703_BAA

NSH DOC NO.

A07-NSH-MS-CVL-0030

SH. 4 OF 16
SUBCONTRACTOR
NSH CORP.

SUBCONTRACTOR CONTRACT NO.

975964

REV. A

SUBCONTRACTOR PROJECT NO
240832

3. DEFINITIONS
CLIENT

SAUDI ARAMCO OIL COMPANY

PROJECT

IGCC PROJECT

CONTRACTOR

SNAMPROGETTI SAUDI ARABIA

SUB-CONTRACTOR

NASSER S. AL-HAJRI CORP. (NSH)

4. REFERENCE
A07-ZA-E-7002107 -_BAA_A_00A - MOS for Concrete Repair Works
SACSM

Saudi Aramco Construction Safety Manual

SAER-5803

Concrete Repair Manual

SAES-H-003

Protective Coating for Industrial Concrete Structure

SAES-H-102

Safety in the Application of Coatings

SAES-Q-001

Criteria for Design and Construction of Concrete

Structures

ACI 308-92

Standard Practice for Curing Concrete.

ANSI/ASSE A10.9

Safety Requirements for Masonry and Concrete Work

Manufacturers Recommendation for Concrete Repair Materials

PLANT LOCATION
JAZAN SAUDI ARABIA

CUSTOMER
SAUDI ARAMCO

PROJECT / UNIT
JIGCC SULFUR RECOVERY UNlT (SRU) - IK-EPC PACKAGE-2

JOB

UNIT
240832

DOC NO.

A07-ZA-E-7002703_BAA

NSH DOC NO.

A07-NSH-MS-CVL-0030

SH. 5 OF 16
SUBCONTRACTOR
NSH CORP.

SUBCONTRACTOR CONTRACT NO.

975964

5. TOOLS & EQUIPMENTS AND REQUIRED PERSONNEL

5.1

5.2

TOOLS & EQUIPMENTS :

Heavy Duty Drill

Masonry Tools

Putty Knife or Pointing Trowel

Chisel

Hammer

Wire Brush

Metal Trowel

PERSONNEL:

Site Engineer

Foreman

Masons

Helpers

Safety Officer

QC Inspector

6. ABBREVIATIONS:
RFI

Request for Inspection

IFC

Issued for Construction

ITP

Inspection and Test Plan

QC

Quality Control

A07

REV. A

SUBCONTRACTOR PROJECT NO
240832

PLANT LOCATION
JAZAN SAUDI ARABIA

CUSTOMER
SAUDI ARAMCO

PROJECT / UNIT
JIGCC SULFUR RECOVERY UNlT (SRU) - IK-EPC PACKAGE-2

JOB

UNIT
240832

A07

DOC NO.

A07-ZA-E-7002703_BAA

NSH DOC NO.

A07-NSH-MS-CVL-0030

SH. 6 OF 16
SUBCONTRACTOR
NSH CORP.

SUBCONTRACTOR CONTRACT NO.

975964

REV. A

SUBCONTRACTOR PROJECT NO
240832

7. PRELIMINARY INVESTIGATION
Preliminary investigations shall been carryout after removal of formwork only by
visual inspection/examining the damaged part of concrete surface due to formwork
support failure or break out of installed tie rod during concrete pouring. The location
and extend of concrete damages shall be identified in the mark-up plan drawing.
7.1

Examining the concrete surface: the extent of damage on concrete surface

due to failure of formwork shall be visually inspected.

7.2

Damage on Concrete:
7.2.1

Misalign/ bulging concrete surface range from +25mm to

+150mm maximum (as per as-built survey report).

7.2.2

Segregation / honeycomb concrete due to loss / leakage of

cement on concrete.

7.3

Root Cause: The formwork had been constructed as per availability of

construction formworks materials. The tie-rod 16 mm diameters used to
hold the formworks against internal pressure of fresh concrete + vibration
are not visually /physically inspected for any change of possible crack or
damages before use.

PLANT LOCATION
JAZAN SAUDI ARABIA

CUSTOMER
SAUDI ARAMCO

JOB

PROJECT / UNIT
JIGCC SULFUR RECOVERY UNlT (SRU) - IK-EPC PACKAGE-2

UNIT
240832

DOC NO.

A07-ZA-E-7002703_BAA

NSH DOC NO.

A07-NSH-MS-CVL-0030

SH. 7 OF 16
SUBCONTRACTOR
NSH CORP.

7.4

SUBCONTRACTOR CONTRACT NO.

975964

Recommendation:

A07

REV. A

SUBCONTRACTOR PROJECT NO
240832

the degree of concrete damages due to failure of

formworks can be repair as per SAER-5803 Concrete Repair Manual and this
MOS by using approved concrete repair materials.

8. REPAIR MATERIALS:
8.1

The following are repair material to be used:

Nitomortar TC2000 or any approved equivalent

Nitomortar FC or any approved equivalent

Renderoc HF or any approved equivalent

Nitobond AR or any approved equivalent

9. CONSTRUCTION METHODOLOGY & SEQUENCE

9.1

Subcontractor shall clearly describe the diagnosis, classification, reason and

extent of repair with supporting documents such as marked-up drawings
indicating the details of repair and detail site survey inspection report showing
the actual location, condition survey at site and final recommendation.

9.2

After Subcontractor/Contractor has made the final investigation on site to

verify which kind of concrete defects are present on the concrete surface as
stated in section 7 PRELIMINARY INVESTIGATION of this method statement,
the proposal of repair then is finalized.

PLANT LOCATION
JAZAN SAUDI ARABIA

CUSTOMER
SAUDI ARAMCO

PROJECT / UNIT
JIGCC SULFUR RECOVERY UNlT (SRU) - IK-EPC PACKAGE-2

JOB

UNIT
240832

DOC NO.

A07-ZA-E-7002703_BAA

NSH DOC NO.

A07-NSH-MS-CVL-0030

SH. 8 OF 16
SUBCONTRACTOR
NSH CORP.

9.3

A07

SUBCONTRACTOR CONTRACT NO.

975964

REV. A

SUBCONTRACTOR PROJECT NO
240832

Concrete Repair Methodology and sequence shall comply with the

requirements of SAER-5803 and A07-ZA-E-7002107_BAA_A_00A - MOS for
Concrete Repair Works

9.4

For MISALIGN / BULGING CONCRETE SURFACE: limited only for concrete

exposure extending outside. Reinforcement steel bars are still in proper
positioned and not taken for consideration.
9.4.1

Surface Preparation:
9.4.1.1

Identify the misalign surface in line with actual / as-built

survey report. The difference alignment to be mark-up
with chalk on concrete surface.

9.4.1.2

Cut the concrete surface by using mechanical grinding

and chipping tools machine. Chipped concrete surface
shall be minus (-) 15 mm minimum thickness for
allowing the finishing materials.

9.4.1.3

After chipping works, the surface shall be clean by

using air blowing or spraying / flashing with water.

9.4.1.4

Used approved bonding agent NITOBOND AR or any

equivalent bonding adhesive materials recommended
by material manufacturer.

PLANT LOCATION
JAZAN SAUDI ARABIA

CUSTOMER
SAUDI ARAMCO

PROJECT / UNIT
JIGCC SULFUR RECOVERY UNlT (SRU) - IK-EPC PACKAGE-2

JOB

UNIT
240832

DOC NO.

A07-ZA-E-7002703_BAA

NSH DOC NO.

A07-NSH-MS-CVL-0030

SH. 9 OF 16
SUBCONTRACTOR
NSH CORP.

9.4.2

SUBCONTRACTOR CONTRACT NO.

975964

A07

REV. A

SUBCONTRACTOR PROJECT NO
240832

Mixing:
9.4.2.1

Mixing of concrete repair materials shall be as per

written instruction from product catalogue / datasheet.

9.4.3

Application:
9.4.3.1

Application shall be based on written instruction from

product catalogue / datasheet.

9.4.3.2

Apply the applicable repair materials as stated in

section 8 into prepared concrete surface when the
bonding agent (adhesive) is in sticky conditioned. Used
metal/steel trowel to spread the repair materials around
the rough damage concrete surface.

9.4.3.3

Check the repaired concrete surface for leveling by

using spirit level

9.4.3.4

Make the surface plain and smooth finish by using steel

/ wooden float.

9.4.4

Water curing is needed for at least 7 days.

PLANT LOCATION
JAZAN SAUDI ARABIA

CUSTOMER
SAUDI ARAMCO

JOB

UNIT
240832

PROJECT / UNIT
JIGCC SULFUR RECOVERY UNlT (SRU) - IK-EPC PACKAGE-2

A07

DOC NO.

A07-ZA-E-7002703_BAA

NSH DOC NO.

A07-NSH-MS-CVL-0030
REV. A

SH. 10 OF 16
SUBCONTRACTOR
NSH CORP.

9.5

SUBCONTRACTOR CONTRACT NO.

975964

SUBCONTRACTOR PROJECT NO
240832

Concrete Repair Honeycomb and Segregation:

9.5.1

Concrete repair due to honeycomb and segregation shall be based on

recommendation

as

per

of

SAER-5803

and

A07-ZA-E-

7002107_BAA_A_00A - MOS for Concrete Repair Works.

10. QUALITY CONTROL AND ASSURANCE

10.1

All stages of work shall be inspected in accordance with the approved Concrete
Repair Procedure.

10.2

Materials receiving inspection shall be done for reviewed and approval, prior to use.
Sample or mock-up shall be provided or prepared by manufacturer representatives
prior to start any repair works. All materials shall be compliance with ASTM or ACI
requirements and approved by Snamprogetti / and Saudi Aramco.

10.3

Only qualified NSH repair crews shall do the repair in concrete defects.
Manufacturers technical support can be obtained on initial application of approved
products to ensure proper use.

10.4

Prior to performing any concrete repair works, the repairing activities shall be
coordinated with NSH QA/QC personnel.

10.5

Documentation, Inspection & Testing records and reports shall be as per documents
listed in Section 3.0 "REFERENCES" and as per SATIP (Saudi Aramco Typical
Inspection Plans), SAIC (Saudi Aramco Inspection Checklists) and SATR (Saudi
Aramco Test Report).

PLANT LOCATION
JAZAN SAUDI ARABIA

CUSTOMER
SAUDI ARAMCO

JOB

PROJECT / UNIT
JIGCC SULFUR RECOVERY UNlT (SRU) - IK-EPC PACKAGE-2

UNIT
240832

A07

DOC NO.

A07-ZA-E-7002703_BAA

NSH DOC NO.

A07-NSH-MS-CVL-0030

SH. 11 OF 16
SUBCONTRACTOR
NSH CORP.

10.6

SUBCONTRACTOR CONTRACT NO.

975964

REV. A

SUBCONTRACTOR PROJECT NO
240832

Contractor shall comply with all mandatory Saudi Aramco Engineering requirements
(MSAERs), project specifications and Quality procedures. In case of conflict between
above standards, most stringent requirements shall govern.

11.

HEALTH, SAFETY AND ENVIRONMENT

11.1

The work shall be executed in accordance with the approved Safety Plan.

11.2

Before starting the work, this work procedure shall be discussed to all personnel
involved.

11.3

Responsible supervisor will monitor all activities during the construction

11.4

Tool Box Talks to be done at the start of each work.

11.5

PPEs safety protection such as wearing of safety helmets, sturdy leather steel toe
cap shoes and eye protection while on site in the execution of work is mandatory.

11.6

MSDS shall be available at each working location and on materials storing area. In
addition to PPEs, rubber gloves and protective chemical clothes shall be provided to
each personnel physically involved in such activities.

11.7

Contractor/Sub-Contractor shall comply with the requirements for controlling safety

hazards associated with the Concrete work as per Saudi Aramco Construction
Safety Manual.

PLANT LOCATION
JAZAN SAUDI ARABIA

CUSTOMER
SAUDI ARAMCO

PROJECT / UNIT
JIGCC SULFUR RECOVERY UNlT (SRU) - IK-EPC PACKAGE-2

JOB

UNIT
240832

DOC NO.

A07-ZA-E-7002703_BAA

NSH DOC NO.

A07-NSH-MS-CVL-0030

SH. 12 OF 16
SUBCONTRACTOR
NSH CORP.

A07

SUBCONTRACTOR CONTRACT NO.

975964

REV. A

SUBCONTRACTOR PROJECT NO
240832

12. TRAINING
12.1

Training shall be organized for Quality Inspection Team and Construction Repair
Team before starting any work in order to follow the manufacturers recommendation
on the proper use of materials.

13. ATTACHMENTS
ATTACHMENT # 1

SAFETY PLAN

ATTACHMENT # 2

MATERIALS DATA SHEET

ATTACHMENT # 3

MARK-UP DRAWING PLAN & PHOTO

ATTACHMENT # 4

Job Safety Analysis & Hazard Risk Assessment

***End of the Document***

PLANT LOCATION
JAZAN SAUDI ARABIA

CUSTOMER
SAUDI ARAMCO

PROJECT / UNIT
JIGCC SULFUR RECOVERY UNlT (SRU) - IK-EPC PACKAGE-2

JOB

UNIT
240832

DOC NO.

A07-ZA-E-7002703_BAA

NSH DOC NO.

A07-NSH-MS-CVL-0030

SH. 13 OF 16
SUBCONTRACTOR
NSH CORP.

A07

SUBCONTRACTOR CONTRACT NO.

975964

REV. A

SUBCONTRACTOR PROJECT NO
240832

ATTACHEMENT # 1
SAFETY PLAN
Tool Box/ Safe Work Plan

Tool box talks shall strictly be observed before starting the work shift to discuss
the Safe Work Plan and other safety concerns for the work.

Tool box talk shall be conducted by the site supervisor with the safety supervisor
assisting and signing the attendance sheet.

Work can only start when all the provisions in the safe work plan are fully
complied, to include all safety precautions needed.

All tool box talk attendance sheets must be turned over for submission to HSE
department.

General Safety Requirements

Personal Protective Equipments

All personnel (workers, drivers, operators, contractor personnel, client personnel)

must wear the project mandatory PPE (long pants, long sleeve shirt, hard hat,
safety dark glass, safety clear glass, safety shoes, high visibility vest, hand
gloves, etc.,).

Special PPE for noise, hand protection, dust pollution, etc. shall be provided to
all concerned workers/ personnel.

Additional PPEs like disposable coverall protective clothing and rubber gloves
shall be used for handling hazardous chemicals as per compliance to
requirement mentioned in MSDS.

All PPE must be inspected prior to use, damage PPE must be replaced.

PLANT LOCATION
JAZAN SAUDI ARABIA

CUSTOMER
SAUDI ARAMCO

PROJECT / UNIT
JIGCC SULFUR RECOVERY UNlT (SRU) - IK-EPC PACKAGE-2

JOB

UNIT
240832

A07

DOC NO.

A07-ZA-E-7002703_BAA

NSH DOC NO.

A07-NSH-MS-CVL-0030

SH. 14 OF 16
SUBCONTRACTOR
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SUBCONTRACTOR CONTRACT NO.

975964

REV. A

SUBCONTRACTOR PROJECT NO
240832

Housekeeping

Unwanted materials / supplies shall be removed from site to ensure clear access
and assigned roads for equipment traffic.

Proper barricading and signage shall be implemented.

Maintain proper access and egress for workers and equipment.

Keep all work areas clean and free of trash.

Empty cans and remaining waste hazardous chemicals shall be separately kept
into designated area provided by SAIPEM and SAUDI ARAMCO. For proper
disposal of Empty cans and Hazardous waste chemical, separate method
statement / procedures shall be submitted for approval from SAIPEM and SAUDI
ARAMCO

Work Environment

Portable toilets provided.

Cool Drinking type water shall be available in all designated drinking station.
Portable Plastic Cooler shall be provided in all working location far from drinking
station.

Refreshment cooler drinks will be provided to all workers during summer season
to minimize the dehydration due to sun or heat exposure.

Proper Rest Shelters with Electric Fan / or Cooler shall be provided at some
designated places.

During high wind where visibility will hamper the operation, Construction and
Safety will advise the workers on approved action to take.

PLANT LOCATION
JAZAN SAUDI ARABIA

CUSTOMER
SAUDI ARAMCO

PROJECT / UNIT
JIGCC SULFUR RECOVERY UNlT (SRU) - IK-EPC PACKAGE-2

JOB

UNIT
240832

A07

DOC NO.

A07-ZA-E-7002703_BAA

NSH DOC NO.

A07-NSH-MS-CVL-0030

SH. 15 OF 16
SUBCONTRACTOR
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SUBCONTRACTOR CONTRACT NO.

975964

REV. A

SUBCONTRACTOR PROJECT NO
240832

Tools and Equipment

All tools shall be inspected and color coded prior to use. Damage and defective
tools shall be returned to materials warehouse / or store.

Electrical tools / equipment must be properly checked and inspected by

designated authorized competent person. All power connection shall be provided
with GFCI / or ELCB.

Operate the tools according to the operational manual provided by manufacturer

and intended purpose only.

Permit to Work

All permits to work required must be valid and approved before the start of the
job.

Permit original copies must be in the site inside the permit box.

All conditions provided in the permit must be compiled and maintained form the
start up to completion of the works.

For night work, workers list shall be attached on all permits.

Electricity

Lighting facility (like tower lights & flashing lights) for night work shall be provided
around the working areas, access passage and all exits.

All electrical energized equipment shall be properly grounded.

Qualified mechanic / electrician shall be deployed during the operation to

respond the need for lighting relocation etc. and also to act as fire watchers.

Panel boards or extension cords used in site shalt be properly checked and color
coded.

To mitigate tripping hazard, power / electrical cables shall be either installed in

PLANT LOCATION
JAZAN SAUDI ARABIA

CUSTOMER
SAUDI ARAMCO

PROJECT / UNIT
JIGCC SULFUR RECOVERY UNlT (SRU) - IK-EPC PACKAGE-2

JOB

UNIT
240832

A07

DOC NO.

A07-ZA-E-7002703_BAA

NSH DOC NO.

A07-NSH-MS-CVL-0030

SH. 16 OF 16
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SUBCONTRACTOR CONTRACT NO.

975964

REV. A

SUBCONTRACTOR PROJECT NO
240832

between scaffold planks or elevated in access / egress portions.

Other Specific Safety Requirements

MSDS: To be provided in the site. MSDS box, site clinic and work site area.

FOR MEDICAL TEAM / FACILITY: On duty certified MOH certified nurse,

certified first aider, ambulance driver, ambulance (to be parked near the work
area during night time).

Working in pair (BUDDY-SYSTEM) is strictly required especially during night

works and some isolated areas.

During Hot Weather conditioned, a prescribed CHECK TIME (CT) schedule must
be observed. Check times are Intervals between working times and rest times.
Construction and Safety will check the workers conditions before re-starting the
work. For day shift check time shall depend on the heat index level.

Provide scaffold planks as required to walk while working on rebars