BI No.

BI-10-01055-0006
CONTRACT No. 6600036947
AYC Doc. No.<Rev. No.> <Rev.2>

Jazan Refinery & IGCC Industrial Support Facilities

Jazan, Kingdom of Saudi Arabia

Approved Method Statement and Approved Material

Intended to be Use to Repair Large Honeycomb at Building 114

SAUDI ARAMCO APPROVAL STATUS

EAE
Approved
Signature / Date Name / Designation

AL YAMAMA SUBMISSION STATUS

Description Name Designation Signature Date

Prepared by A. Clores QC Supervisor 8/29/2018

Reviewed by M. Tabura QC Manager 8/29/2018

Reviewed by K. Murudkhar QA Manager 8/29/2018

Reviewed by E. Esponosa Safety manager 8/29/2018

Approved by A. Khaseeb Project Manager 8/14/2018

Document No. : <Rev.2> Revision No. : 2 Date : 08. 14. 2018

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CONTRACT No. 6600036947
AYC Doc. No.<Rev. No.> <Rev.2>

Document Issue Purpose

>
√ For Approval For Information For Construction

INDEX

1. Concrete Defects Report / Assesment

1-1 Incidence
1-2 Observations
1-3 Photos

2. Proposed Repair Procedure

2-1 Proposed Repair Material
2-2 Repair References
2-3 Tools / Equipments
2-4 Preparations
2-5 Repair Execution by Non-Shrink grout Applications

3. Quality Control
4. Material Handling and Storing
5. Health, safety and Environment
6. Attachments

Document No. : <Rev.2> Revision No. : 2 Date : 08. 14. 2018

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CONTRACT No. 6600036947
AYC Doc. No.<Rev. No.> <Rev.2>

1. CONCRETE DEFECTS REPORT / ASSESSMENT

1-1 INCIDENCE:
On night of 24th day of May, 2018, the AYC Concrete Pouring Team has done the
concrete casting on suspended slab and beams covering Grid Lines 17a-24a / A.2-D.1 at
building 114 (Generator Room-Laboratory Facilities). After few days from casting,
removal of formworks has been started from underside of slabs and sides of beams.

1-2 OBSERVATIONS:
After the full removal of formworks, concrete defects were observed along the perimeter
of the slab with varying depths and degree of defects from 20 mm on concrete surface to
400 mm penetrating within heavily steel congested areas within sections of columns-
slab-beam. There were no observed severe defects within the interior and under-slab
areas.

1-3 PHOTOS

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CONTRACT No. 6600036947
AYC Doc. No.<Rev. No.> <Rev.2>

Document No. : <Rev.2> Revision No. : 2 Date : 08. 14. 2018

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 BI No. BI-10-01055-0006
CONTRACT No. 6600036947
AYC Doc. No.<Rev. No.> <Rev.2>

Document No. : <Rev.2> Revision No. : 2 Date : 08. 14. 2018

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CONTRACT No. 6600036947
AYC Doc. No.<Rev. No.> <Rev.2>

POSSIBLE CAUSES:
Mortar or concrete fails to fill voids between coarse-aggregate particles. Some defects were found to be
minor, while some locations may be structural and require repair. Voids form when concrete fails to fill
areas in a form, typically those under deep placements, or that are heavily reinforced. Voids are almost
always structural defects requiring repair. Causes of honeycomb and voids were observed to be due to the
insufficient consolidation, and improper placing practices.

2. PROPOSED REPAIR PROCEDURE

A previously approved Method of repairing large honeycombs and concrete defects were
adopted and improved to fit the required repair for this specific location of building 144

2-1 Proposed repair material:

SIKA GROUT 114 - For repairs with 75mm maximum thickness
SIKACRETE 114 - For large concrete defects requiring formwork,
SIKACETE 114 shall be used as per product description and
uses
2-2 Repair References:
SIKA GROUT 114 Data Sheet
SIKACRETE 114 Data Sheet
SAER 5803 (Concrete Repair Manual)
SAES-Q-001 – Criteria for Design and Construction of Concrete Structure
ACI 546R Section 5.6.2

2-3 Tools / Equipment:

Conventional tools as recommended by SIKA GROUT 114 / SIKACRETE 114 or other
equipment (such as electric chipping guns, air compressors) found necessary to
complete the work procedure.

2-4 Preparations:
2-4-1 Isolate the affected area by removing layers of honeycombing or defective
concrete until suitable concrete is exposed.
2-4-2 Locations having concrete defects penetrating 300 or more from beam sides
must be opened until at the top to be able to remove segregations and do the
grouting in a vertical pouring position ensuring that grout can penetrate
completely on the defective part..

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2-4-3 Reinforcements on broken edges of slab shall be made exposed in order to be

embedded in the newly poured non-shrink grout.

2-4-4 Concrete surface should be clean, sound and free from oil, grease, cement
laitance and all loosely adhering particles.
2-4-5 Damaged Coating on reinforcing bars during chipping operations shall be
touched up by approved touch-up material.
2-4-6 Wet the cleaned area prior to applying non-shrink grout. Absorbent surfaces
should be saturated and let it stay as per the Standard requirement.
2-4-7 Formwork shall be required in applying the repair material for large and deep
concrete defects.

2-5 Repair Execution by Non-Shrink Grout Application:

2-5-1 Material mixing, application and curing shall be done in accordance with the
SIKA GROUT 114 and SIKACRETE 114 product instructions.

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2-5-2 Depending on the application requirement, the below consistency can be

considered on Sika Grout 114

2-5-3 For repairs on large and deep concrete repair, Sikacrete is recommended.
2-5-4 For minor surface repairs on sides of beams and within the concrete cover (as
shown below), Plastic consistency of Sika grout 114 (as shown on product
mixing ratio) is recommendable. Application can be done similar to
plastering.

2-6 Quality Control:

 Non-Shrink grout shall be carried out as per SAES-Q-001;
 SATIP-Q-010-01
 SAIC-Q-1048 & SAIC-Q-1019
 Cube samples shall be provided for Compressive Strength Testing and
verification
 In-place testing as per ACI 546R Section 5.6.2 shall be conducted to
determine that the identified condition is no longer present after repair using
Ultrasonic Pulse Velocity Test.

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2-7 Responsibilities:
 Construction Manager – To organize his team and
equipments for proper execution of the concrete repair.
 Site Engineer – To supervise the workers and ensure that repair will be
executed as per the approved procedure.
 QC Inspector – To monitor the work and ensure that the repair was executed
as per the approved procedure and facilitate work inspections.
 QC manager- shall monitor and guide the overall repair process.

2-8 Workforce
 A team of Masons and labours that is sufficient enough to execute the work
at the utmost expected time shall be assigned.

2-9 Material Handling and Storing:

 Handling and storing shall be as per recommendation by the SIKA
GROUT 114 and SIKACRETE 114 product instructions.

2-10 Health, Safety and Environment:

 Health, Safety and Environment issues shall be guided by AYC safety
procedures ARAMCO Standard.
 Work area to be kept clean, safe and easily accessible
 Appropriate PPE shall be worn at all times
 Observe safety on working on heights, proper fall protection shall be provided
when required
 Safety talk shall be conducted to remind the workers about the risk involved
before commencing the activity

2-11 Attachments:
 Material Approval for Sika Grout 114 and Sikacrete
 ITP & Checklists

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CONTRACT No. 6600036947
AYC Doc. No.<Rev. No.> <Rev.2>

“Possible Causes” were corrected noting Review Comments #3

2
“Preparations” item 2-4-2 responded Review Comments #2
3
“Quality Control” added In-place testing as per ACI 546R Section 5.6.2 as noted in Review Comments #4

Document No. : <Rev.2> Revision No. : 2 Date : 08. 14. 2018

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