This article is about Extension of Existing Concrete Structure Method Statement & Procedure. Following topics to be discussed.
- PURPOSE
- SCOPE
- OBJECTIVE
- DEFINITIONS
- REFERENCE
- RESPONSIBILITIES
- MATERIALS
- MATERIAL STORAGE
- PROCEDURE
- QUALITY CONTROL AND INSPECTION PLAN
- CONFLICTS & DEVIATIONS
- JOB SAFETY ANALYSIS
Extension of Existing Concrete Structure Method Statement & Procedure
1. PURPOSE
This method of statement is prepared to describe work procedure for extension of existing hardened concrete work to achieve required dimension of structure due to design change.
2. SCOPE
This method statement is prepared for extension work of existing hardened concrete work (foundation/pedestal/etc.) by using injection mortar system and hammer drilled holes at Naphtha Processing & Aromatics Complex project (JRTP).
3. OBJECTIVE
To ensure execution of extension of hardened concrete work will meet with all quality and safety requirements of Saudi Aramco under the above Referenced project.
4. DEFINITIONS
- Owner / Company : SAUDI ARAMCO
- Project : Jazan Refinery & Terminal Project – Naphtha Processing & Aromatics Complex EPC-12
- Prime Contractor : JGC Arabia
- Main Contractor : DAEWOO Engineering &
- Sub-contractor : ALFANAR Construction
- Method Statement : A written document that gives specific instructions on how to perform a work related task safely or safe operation plan using tools and equipment.
5. REFERENCES
The latest revision of COMPANY’s Project Specifications shall be used as references and shall be the part of this Method of Statement during work execution.
- SAUDI ARAMCO ENGINEERING STANDARDS (SAES)
- SAES-M-100 Saudi Aramco Building Code
- SAES-Q-001 Criteria for design and construction of concrete structures
- SAES-Q-005 Concrete Foundations
- SAES-Q-007 Foundations and supporting structure for heavy machinery
- SAUDI ARAMCO MATERIAL SYSTEM SPECIFICATIONS
- 09-SAMSS-097 Ready mixed Portland cement concrete
- 09-SAMSS-106 Epoxy coating of steel reinforcing bars
- INTERNATIONL STANDARDS & SPECIFICATIONS
- ACI 117 Standard Specifications for Tolerances for Concrete Construction and Materials
- ACI 318M Building Code Requirements for Reinforced Concrete
- ACI 347 Guide to Formwork for Concrete
- SAUDI ARAMCO INSPECTION TEST PLAN & CHECK LIST
- SATIP-Q-001-02 Cast in Place Portland cement concrete
- All relevant Saudi Aramco Inspection Checklist as mentioned in SATIP-Q-001-02
- PROJECT SPECIFIC REFERENCES
Method of Statement for concrete work
6.0 RESPONSIBILITIES
6.1 Site Manager
The Site Manager shall ensure compliance by all foremen, labors and other craftsmen to the requirements of this procedure. He shall observe and implement proper execution of the work and responsible for implementation of HSE on the site.
6.2 Site Engineer
The Site Building Engineer has the overall responsibility for the implementation of work as per Approved drawings. He shall arrange the manpower, equipment and materials required for the Implementation of the works, coordinate with HSE Officer and QA/QC Site Manager involved in tasks in accordance to the method statement.
6.3 Safety Supervisor
The Safety Supervisor shall ensure that all workers are in compliance with the requirements of the safety manual. He is responsible for monitoring the work area for any unsafe conditions and make corrective actions where necessary.
6.4 Site Supervisor / Foreman
The Site Supervisor and/or Foreman are solely responsible in assuring that all materials installed permanently and works being implemented are in conformance with specifications and manufacture’s recommendation.
6.5 QC Manager
He will ensure all the material & method statement is approved prior to start of work. He will explain QC requirement for work to PM, site representative & QC supervisor/inspector by coordination with them. He will ensure that all workers are trained and skilled & if required he will arrange training for them. He will ensure that all work is inspected and accepted as per Aramco requirement & SATIP. He will identify any potential nonconformance & suggest preventive action to eliminate occurrence of nonconformance.
6.0 QC Inspector
The QC Inspector is responsible to conduct daily surveillance and inspections as necessary in accordance with this procedure and project quality requirement. Prepare quality control records and documentation to secure completion of activity for final acceptance and handover.
7.0 MATERIALS
- Injection Mortar – HILTI HIT-RE 500.
- Bonding Agent – Fosroc NitoBond.
- RE-Bar.
- Concrete – 28 MPA (Al Hadi concrete batching plant – JEC).
8.0 MATERIAL STORAGE
Materials shall be stored in original packing in accordance with manufacturer’s instructions and recommendations and Saudi Aramco standards requirements.
9.0 PROCEDURE
-
Pre-pouring Activities
- Survey points shall be marked for extension of existing hardened concrete foundation as per approved revised IFC & & FCS.
- All rebars shall be exposed in identified concrete area by chipping the concrete using medium duty jack hammer.
- Exposed rebar shall be properly cleaned to remove concrete laitance and any unwanted foreign particles.
- Touch paint shall be applied on clean exposed rebar with approved material.
- Loose concrete from proposed extension area shall be removed and site shall be clean with air pressure or water jetting.
- If required and mentioned in revised approved IFC/FCS drawing, compaction test shall be perform on proposed extension area subgrade and lean concrete/polyurethane sheet shall be laid as per requirement.
- Rebar anchoring holes of required size and at required spacing as mentioned in approved IFC/FCS drawing shall be drilled in existing concrete with HILTI rotary (refer page 43 of attached material datasheet)
- Cleaning of holes shall be done with compressed air as described on page 44 of attached material datasheet.
- Required size of rebars shall be fixed in holes with injection mortar HILTI RE 500 as per manufacturer recommendation.
- After fixing rebars, formwork shall be done as per approved revised IFC & FCS drawings.
- Again Cleaning of extension area shall be done with air pressure or water jetting as per requirement.
- Prior to concrete pouring approved quality concrete bonding agent shall be applied on existing concrete as per manufacture’s requirement.
-
Concrete Pouring
- All concrete pouring and testing/sampling activities shall be as per approved method of statement for concrete pouring and Saudi Aramco specifications.
-
Post pouring Activities
- Concrete post pouring activities e.g. Curing, formwork stripping, coating & final acceptance shall be done as per approved MOS and Saudi Aramco specifications.
10.0 QUALITY CONTROL AND INSPECTION PLAN
All the activities shall be inspected as per SATIP-Q-001-02 and the result of inspection shall satisfy COMPANY specifications (including related International standards/ codes). Request for inspection for each activity shall be raised as required in relevant SATIP.
11.0 CONFLICTS AND DEVIATIONS
Any conflicts between this specification and other applicable Saudi Aramco Materials System Specification (SAMSSs), Engineering Standards (SAESs), Standards Drawings (SASDs) or industry standards, codes, and forms shall be resolved in writing by the company through the Manager, Consulting Services Department. For any predefined waiver, request shall be raised before one month prior to start work.