CONTRACT N UNIT N

STAR-C-01 000
CONTRACTOR DOC No.
STAR RAFNER, A.. 2248-000AEE0230005514 SH/OF
AEGEAN REFINERY PROJECT STAR DOCUMENT No.
(ARP) 000AEE0230005514 1/7
SUBCONTRACTOR DOCUMENT No.

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METHOD STATEMENT FOR

CONCRETE REPAIRING

0 27-01-2016 ISSUED FOR REVIEW MY OD EG

REV. ISSUE DATE REASON FOR ISSUE PREPARED BY CHECKED BY APPROVED BY
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CONCRETE REPAIRING

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INDEX

1. PURPOSE.....................3

2. REFERENCES.................................................................................................................3

3. SURFACE PREPERATION....................................................................3

4. INVESTIGATION AND EVALUATION OF DAMAGED CONCRETE SURFACES ........ 4

5. CONCRETE REMOVAL ..................................................................................................5

6. TREATMENT APPLICATION....5

7. SAFETY CONTROL .........................................................................................................5

8. ATTACHMENTS........................................................................................................8
 STAR RAFNER, A.. CONTRACT N
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1. PURPOSE

The main purpose of this method statement is to outline repair procedure of structural concrete works
for all building works in compliance with all the required specifications, standards and proper
construction procedures.

2. REFERENCES

Manufacturer Instructions (BASF Master Emaco S488&N900 Technical Data Sheet)

Contractor Doc No. 2248-000-A-EE-01960620 (Concrete Repair Procedure)

3. SURFACE PREPERATION

The purpose of Surface preparation shall be done in accordance with the materials manufacturers
recommedation as indicated in this method of statement,technical data sheet as per attachment.
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4. INVESTIGATION AND EVALUATION OF DAMAGED CONCRETE SURFACES

Before performing repairs on damaged or defected surfaces a visual inspection of the exposed
concrete on site should be performed.

Category Surface Defect Classifications Illustration Treatment Material

a. Surface defect Master
Spalling up to 5mm Emaco N900
(Surface voids b. Surface defect Master
1 or irregularities / up to 5mm-80mm Patching Emaco S488
honeycomb / or up to rebar
cone holes) surface

Flowable
Grout : Sika
Severe Voids Surface defect 212
2 and until exposed Grouting
Honeycombs rebars

a. Hairline / N/A
Shrinkage Cracks No Repair
width up to
0,15mm
3 Cracks b. Crack width V cut and Master
from 0,15mm to sealing Emaco N900
0,30mm
c. Crack width V cut and Master
over 0,30mm sealing Emaco S488
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5. CONCRETE REMOVAL

All weak, damaged and easily removable concrete should be chipped away. Classification of
concrete removal method to be applied.

5.1 Impacting Method (for honeycombed and exposed rebar)

-Generally employ the repeated striking of a concrete surface with a mess to fracture and spall the
concrete
-Hand-held breaker
- Using hand-held breaker or chipping hammer for removal of unsound concrete.
-Steel chisel and hammer
- Dismounting unsound and loose concrete and trimming the repaired surface

5.2 Grinding (for abrupt or gradual irregular surfaces)

- Rubbing carborundum on gradual irregular surfaces

- Using grinding machine with concrete grinding disc
- By bush-hammering

5.3 Cutting

Method applicable for making cutouts through concrete members and amploy full depth primeter cuts
to disjoint concrete or removal as a unit: using concrete wheel cutter.

6. TREATMENT APPLICATION

Mixing, application and curing shall be done inn accordance with the manufacturers recommedation
as indicated in this method statement technical data sheets as shown in attachments1-2 and 3

7. SAFETY CONTROL

Prior to commencement of the Works, 2N will ensure that technical specifications of each product
was carefully carried out to avoid any problem at site.
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7.1 Safety Inductions

All workers will be inducted from both ILK and TSGI about General HSE Rules.

TBT will be given to all workers. Repairing workers will receive specific training about applying
manufacturers materials.

7.2 Usage Of PPEs

All workers will use proper PPES at all times.

Following PPEs will be use during this work

1. Safety Helmet
2. Safety Shoes
3. Safety Glasses
4. Reflective Vest
5. Suitable Working Gloves
6. Safety Harness (if necessary)
7. Ear Plug (if necessary)
8. Dust Mask (if necessary)

Additional safety protective equipment shall be issue when and as required.

7.3 Works At Heights

All platforms and scaffolds will be equipped with solid decks free of openings and provided with the
standard guard rail systems regardless of height.

All scaffolds will be erected by trained personnel; certified scaffold construction material will be used
and will be green tag.

The ladder will have the right inclination and will be secured at the upper ends, sticking out 1 m.
(minimum) above the securing point.

If the work places are higher than 1,8 m, the worker will wear a safety harness with double lanyard
attached to a fixed part.

Safety harness will be controlled periodic and color coded.

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Workers will be trained in fall hazard recognition and this procedure.

TR's works at height procedure will be followed.

Temporarily stored materials on the work locations at height will be protected.

7.4 Working With Electrical Equipment

All electrical equipment will be periodically checked and color coded.

It will be ensured that electrical panel will be properly grounded.

During rainy or snowy weather conditions electrical equipment will not be used or protected.

Electrical panels will be locked to ensure that unauthorized personnel will not use it.

Necessary warning sign will be placed or electrical panels.

Plugs of extension cables will be protected from dust and severe weather conditions.

8.0 ATTACHMENTS

8.1 Data Sheet for Basf MasterEmaco S488

8.2 Data Sheet for Basf MasterEmaco N900
8.3 Data Sheet for Sika Grout 212
MasterEmaco N 900

(Formerly known as Emaco 90)

 Product Data Sheet
Edition 02.2014/v1
CSC Master FormatTM 03 62 13
SikaGrout 212

SikaGrout 212
High Quality, Well Proven, Versatile and Non-Shrink,
Cementitious Grout
Description SikaGrout 212 is a non-shrink, cementitious grout with a unique two-stage shrinkage
compensating mechanism, compensating for shrinkage in both the plastic and the
hardened states. It is non-metallic, contains no chlorides and may be placed at
various consistencies ranging from dry pack to fluid by simply adjusting the quantity
of mixing water.
A sulphate resistant grade, SikaGrout 212 SR, and a silica fume modified grade,
Construction

SikaGrout 212 HP, are also available (see separate Product Data Sheets).
Where to Use On grade, above and below grade, interior and exterior applications.
Structural grouting of column base plates, machine base plates, anchor bolts,
bearing plates, bridge seats, precast wall panels.
On grouting projects where ability to adjust consistency and achieve accelerated
strength development is required.
Advantages Pre-blended for easy application and maximum field control. Just add water, mix
and place.
Versatile, can be applied in any consistency from dry pack to fluid by varying water
content.
Reducing water content accelerates strength development and ultimate compressive
strength values.
Non-corrosive does not contain chlorides.
Formulated with inert, non-reactive aggregates to eliminate potential Alkali-
Aggregate Reactivity (AAR).
Excellent pumpability - does not segregate even at high flow; no build-up on
equipment hopper.
Low heat development.
Superior freeze/thaw resistance.
Ministry of Transport Ontario approval for use in grouting bridge bearings as well as
anchor bars. (Reports MI-110, MI-120 respectively).
Product qualified by The Road Authority (TRA).
Meets Ontario Hydro specification M-690-87 for pumping through grout pump and
hoses for a distance of up to 60 m (196 ft).
Ministre des Transports du Qubec acceptance for grouting anchor bolts and
reinforcing dowels in concrete.
Approved by the Alberta Ministry of Transportation.
Product recognized by the British Columbia Ministry of Transportation (BC MoT).
Meets H. A. Simons grout specification 1S-05.01 for grout types 1, 2a, 2b, 2c, 3 and 4.
Meets ASTM C1107 for Grade C type grouts.
Technical Data
Packaging 25 kg (55 lb) bag
Colour Concrete Grey
Yield Approx. 13 L (0.46 ft3) per bag of fluid grout
Shelf Life 12 months in original, unopened packaging. Store dry, ensuring that
product is not exposed to rain, condensation or high humidity. For best
results, condition product at 18 to 29C (65 to 84F) before using.
Mix Ratio 4.6 L (1.21 US gal.) water/bag max.
Properties at 23C (73F) and 50% R.H.
SikaGrout 212 (tested at water/solids ratio of 0.18 by weight)
Aggregate grading ASTM C136 100% passing 2.5 mm (3/32 in)
Flow cone CAN/CSA A23.2-1B 25 - 35 sec
Set time ASTM C 403 Initial 5 hrs
Final 6 hrs 30 min
Compressive Strength, MPa (psi)
CAN/CSA A23.2-1B* W/S = 0.18
[4.6 L (1.21 US gal.)/bag]
1 day 26 (3770)
3 days 42 (6095)
7 days 48 (6965)
28 days 56 (8125)
* Fluid consistency compressive strengths are given as minimum guidelines. Pourable and dry pack consistencies will easily
exceed these values.

SikaGrout 212
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03 62 13 NON-METALLIC, NON-SHRINK GROUTING
 *Compressive Strength ASTM C109, MPa (psi)
(SikaGrout 212 tested with Sikacem Accelerator)
Temperature Dosage 24 hrs 2 days 3 days 28 days
0C (32F) 1 bottle (150 mL) 2 (290) 13 (1932) 24 (3550) 41 (5946)
10C (50F) 1 bottle (150 mL) 18 (2624) 33 (4855) 40 (5756) 48 (6960)
23C (73F) 1 bottle (150 mL) 37 (5366) 42 (6070) 45 (6461) 56 (8125)
*All moulds, mixing tools and powder components were pre-conditioned to the test temperatures. Prepared test specimens were
cast and then cured at the indicated test temperatures until the time of testing.
Liquid/solids ratio (water + Sikacem Accelerator/SikaGrout 212) = 0.18; [4.6 L (1.21 US gal.) of liquid per 25 kg (55 lb) bag of
SikaGrout 212].
SikaGrout 212
Freeze/thaw durability ASTM C666, Procedure A
Relative dynamic modulus 101.9%
Durability factor 101
No significant change to specimen
Anchor Bolt Grouting Applications
Water/solids ratio 0.166
Mix water 4.15 L (1.1 US gal.)
Pull-Out Results [38 mm (1.5 in) diameter hole]
Hole depth, mm (in) Load failure, kN (lbf) Comments
125 (5) 78.6 (17 670) Concrete block split in half
190 (7.5) 108.2 (24 324) Concrete block split in half
250 (10) 126.4 (28 416) Concrete block split in half
(Data based on results obtained from pull tests on 15 M, epoxy coated rebars grouted into 30 MPa (4350 psi),
80 10 mm slump, 6 1% air entrained concrete block)
Construction

Product properties are typically averages, obtained under laboratory conditions. Reasonable variations can be expected
on-site due to local factors, including environment, preparation, application, curing and test methods.
How to Use
Surface All grease, oil laitance, ice or snow and foreign deposits shall be removed from all surfaces
Preparation with which the grout will come in contact.
The concrete foundation shall be roughened to the extent that it does not present a smooth
surface, which would impede the bond of the grout to the foundation. All dust and loose
particles shall be removed by sandblasting, high pressure waterblasting or other suitable
means.
Concrete foundations less than 28 days old shall be kept wet for at least 12 hours, and
older foundations for a minimum of 24 hours before placing grout. All free-standing water
shall be removed from concrete surfaces prior to grouting. All items to be grouted into
place shall be properly positioned and anchored prior to grouting except for anchor bolts
and dowels, which may be placed into the fresh grout if job conditions permit and at the
discretion of the engineer in charge. For grouting of base plates the formwork used to
contain the grout shall be constructed in a workmanlike manner and caulked to prevent
leakage of grout. Provisions shall be made at the high points for air to be vented as it is
displaced by grout.
Mixing Mix using a heavy duty low-speed drill (300 - 450 rpm) and mixing paddle or in a grout
mixer. The size of the mixer should be appropriate to the volume of grout required. Use a
minimum amount of water consistent with placeability requirements. After all dry product
has been added to the water, continue mixing for 3 minutes. For application greater than
150 mm (6 in) in thickness, add up to 12 kg (26.5 lb) of 10 mm (3/8 in) coarse aggregate.
The aggregate must be non-reactive (reference ASTM C1260, C227, and C289), clean,
well graded, saturated surface dry, have low absorption, high density and comply with
ASTM C33, size number 8 per table 2.
Application The prepared grout may be pumped or transported to the forms in buckets or wheelbarrows
and deposited without delay. External vibration and agitation of the grout in the forms is
permitted. Grout having been prepared but not placed within 1 hour after preparation shall
be discarded. Prepared grout shall be agitated until use. Several hours after placement of
grout (depending on ambient temperatures) forms may be removed and exposed grout
shoulders may be trimmed or shaped to desired finish.
Curing As per ACI 308 recommendations for cement concrete, curing is required. To achieve
performance consistent with Technical Data, curing must be provided by recognized curing
methods, such as wet burlap covered with white polyethylene film, misting with water, or
approved water-based curing compound, such as Sika Florseal WB 18 & 25. Curing
must commence immediately after placing and finishing. Protect freshly applied grout from
direct sunlight, wind rain and frost.
Clean Up Clean all tools and equipment immediately after use with water. Once hardened, material
can only be removed manually or mechanically. Wash soiled hands and skin thoroughly in
hot soapy water or use Sika Hand Cleaner towels.

SikaGrout 212
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03 62 13 NON-METALLIC, NON-SHRINK GROUTING
 Limitations Important: protect stored material from exposure to rain, condensation and high humidity as
moisture may penetrate packaging, causing lumps.
For best results, condition product to 18 to 29C (65 to 84F) prior to mixing and installation. Lower
temperatures may result in slower strength development and longer cure times.
Maintain wet grout, ambient and substrate temperatures between 5 - 32C (41 - 89F) for a period
of 72 hours after placing, unless using Sikacem Accelerator in mix (refer to Technical Data
section).
SikaGrout 212 must be protected from freezing during setting.
Minimum application thickness (neat without additional aggregate): 25 mm (1 in).
Maximum application thickness (neat without additional aggregate): 150 mm (6 in). Thicker
applications are possible with the addition of suitable aggregate. Please contact Sika Canada
Technical Services.
For anchor bolt/dowel grouting, hole diameter should be 25 mm (1 in) greater than bar diameter.
Anchor bolt/bar holes should be pre-dampened for a period of 1 hour prior to grouting. Holes must
be in saturated surface dry (SSD) condition at time of grouting.
Do not use as a patching or overlay mortar or in unconfined areas.
Use only potable water.
Extending with aggregates will reduce compressive and flexural strengths. Dimensions and grading
of aggregates will influence effect on physical properties; pre-testing is recommended.
Health and Safety For information and advice on the safe handling, storage and disposal of chemical products,
Information users should refer to the most recent Material Safety Data Sheet containing physical,
Construction

ecological, toxicological and other safety-related data.

KEEP OUT OF REACH OF CHILDREN

FOR INDUSTRIAL USE ONLY

The information, and in particular, the recommendations relating to the application and end-use of Sika products, are given in
good faith based on Sikas current knowledge and experience of the products when properly stored, handled and applied under
normal conditions, within their shelf life. 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 recommendations, or from any other advice offered. The
proprietary rights of third parties must be observed. All orders are accepted subject to our current terms of sale and delivery. Users
should always refer to the most recent issue of the Product Data Sheet for the product concerned, copies of which will be supplied
on request or can be accessed in the Internet under www.sika.ca.

Sika Canada Inc.

Head Office Other locations
601 Delmar Avenue Toronto
Pointe-Claire, Quebec Edmonton 1-800-933-SIKA An ISO 9001 certified company
H9R 4A9 Vancouver www.sika.ca Pointe-Claire: ISO 14001 certified EMS

SikaGrout 212
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Construction

SikaGrout 212
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03 62 13 NON-METALLIC, NON-SHRINK GROUTING