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    Building 114 Large Honeycomb Rev.02

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    moytabura96
    This document provides a proposed repair procedure for concrete defects found at Building 114 of the Jazan Refinery & IGCC Industrial Support Facilities in Saudi Arabia. Large honeycombing and voids were discovered in concrete slabs and beams after formwork removal. The proposed repair uses Sika Grout 114 or Sikacrete 114 applied according to the manufacturer's instructions. Defective concrete will be chipped away and prepared before applying the repair material. Reinforcement will be exposed and coated areas touched up before application. Formwork will be used for large repairs. The document was prepared by A. Clores and reviewed by several managers before project manager approval.

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    © All Rights Reserved
    Download as DOC, PDF, TXT or read online from Scribd

    Building 114 Large Honeycomb Rev.02

    Uploaded by

    moytabura96
    92 views10 pages
    This document provides a proposed repair procedure for concrete defects found at Building 114 of the Jazan Refinery & IGCC Industrial Support Facilities in Saudi Arabia. Large honeycombing and voids were discovered in concrete slabs and beams after formwork removal. The proposed repair uses Sika Grout 114 or Sikacrete 114 applied according to the manufacturer's instructions. Defective concrete will be chipped away and prepared before applying the repair material. Reinforcement will be exposed and coated areas touched up before application. Formwork will be used for large repairs. The document was prepared by A. Clores and reviewed by several managers before project manager approval.

    Original Description:

    Just a reference for any procedure concerning concrete honeycombing repairs

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    This document provides a proposed repair procedure for concrete defects found at Building 114 of the Jazan Refinery & IGCC Industrial Support Facilities in Saudi Arabia. Large honeycombing and voids were discovered in concrete slabs and beams after formwork removal. The proposed repair uses Sika Grout 114 or Sikacrete 114 applied according to the manufacturer's instructions. Defective concrete will be chipped away and prepared before applying the repair material. Reinforcement will be exposed and coated areas touched up before application. Formwork will be used for large repairs. The document was prepared by A. Clores and reviewed by several managers before project manager approval.

    Copyright:

    © All Rights Reserved
    Download as DOC, PDF, TXT or read online from Scribd
    Download as doc, pdf, or txt
    92 views10 pages

    Building 114 Large Honeycomb Rev.02

    Uploaded by

    moytabura96
    This document provides a proposed repair procedure for concrete defects found at Building 114 of the Jazan Refinery & IGCC Industrial Support Facilities in Saudi Arabia. Large honeycombing and voids were discovered in concrete slabs and beams after formwork removal. The proposed repair uses Sika Grout 114 or Sikacrete 114 applied according to the manufacturer's instructions. Defective concrete will be chipped away and prepared before applying the repair material. Reinforcement will be exposed and coated areas touched up before application. Formwork will be used for large repairs. The document was prepared by A. Clores and reviewed by several managers before project manager approval.

    Copyright:

    © All Rights Reserved
    Download as DOC, PDF, TXT or read online from Scribd
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    You are on page 1of 10

    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

    Page 1 of 10
    BI No. BI-10-01055-0006
    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

    Page 2 of 10
    BI No. BI-10-01055-0006
    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

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

    Page 3 of 10
    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

    Page 4 of 10
    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

    Page 5 of 10
    BI No. BI-10-01055-0006
    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..

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

    Page 6 of 10
    BI No. BI-10-01055-0006
    CONTRACT No. 6600036947
    AYC Doc. No.<Rev. No.> <Rev.2>

    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.

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

    Page 7 of 10
    BI No. BI-10-01055-0006
    CONTRACT No. 6600036947
    AYC Doc. No.<Rev. No.> <Rev.2>

    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.

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

    Page 8 of 10
    BI No. BI-10-01055-0006
    CONTRACT No. 6600036947
    AYC Doc. No.<Rev. No.> <Rev.2>

    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

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

    Page 9 of 10
    BI No. BI-10-01055-0006
    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

    Page 10 of 10

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