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2755-MCD-CON-CEP-0070 - Concrete Repair Works For Cold Joint
2755-MCD-CON-CEP-0070 - Concrete Repair Works For Cold Joint
CONSTRUCTION EXECUTION
PROCEDURE
CONCRETE REPAIR WORKS
Client:
A 10 Apr 2017 Issue for Review and Approval M. Villaroza P. Rajendra D. Pau
B 09 Jun 2017 Issue for Review and Approval M. Villaroza P. Rajendra D. Pau
C 10 Jul 2017 Cast back repair method included M. Villaroza P. Rajendra D. Pau
This document remains the property of McConnell Dowell Corporation. Its contents are confidential and shall not be
reproduced, destroyed or given away without the express, written permission of McConnell Dowell Corporation. The electronic
version of this document in MMS Database on designated server(s) is the Master Copy and is a controlled document. Unless
specifically noted thereon, other copies of this document are uncontrolled. Based on MMS Template MMS # 600-J001-100
Rev11 25Mar2015.
CONSTRUCTION EXECUTION PROCEDURE
2755-MCD-CON-CEP-0034
REVISION C
DATE 10 JULY 2017
TABLE OF CONTENTS
1 PURPOSE 3
2 scope 3
3 ACRONYMS 3
4 RESPONSIBILITIES 4
5 REFERENCES 4
6 CONSTRUCTION METHODOLOGY 5
6.1 summary 5
6.2 work method 6
6.3 MATERIAL DATA SUMMARY 10
6.4. permits 10
7 ACTIVITY SCHEDULE / MILESTONES 12
8 CONSTRUCTION RESOURCES 12
8.1 KEY PROJECT PERSONNEL 12
8.2 personnel & Training Requirements 12
8.3 Subcontractors & Suppliers 13
8.4 Plant & equipment 13
APPENDIX A: QA / QC Documents
i. Request for Inspection – Notification 017-F002-2755
ii. Concrete Repair Checklist F028-600-2755
iii. Summary list of Approved Material Submission (MAR)
APPENDIX B: JSEA
1 PURPOSE
The purpose of this Construction Execution Procedure (CEP) is to identify and provide
specific requirements and procedure for most types of concrete repairs. It also details the safety
measures required to ensure that the works are conducted in accordance with the client’s safety
requirements.
However due to the nature of the works, this CEP may be altered to suit the work. In such an
event the client will be informed either verbally or in writing.
2 SCOPE
The scope of work applicable to this Construction Execution Procedure outlines the repair works
for unsound concrete in the Permanent Reinforced Concrete Structure and Patching of
Formwork Tie-rod Cone Holes
3 ACRONYMS
The scope of work applicable to this Construction Execution Procedure outlines the repair
works for unsound concrete in the Permanent Reinforced Concrete Structure and Patching of
Formwork Tie-rod Cone Holes.
CEP Construction Execution Procedure
COP Code of Practice
ENV Environment
EPI Environmental Protection Instruction
IFC Issued for Construction
ITC Inspection and Test Checklist
ITP Inspection and Test Plan
JSEA Job Safety and Environmental Analysis
OHS Occupational Health and Safety
PEP Project Execution Plan
SOP Safe Operating Procedures
SWI Safe Work Instructions
SWMS Safe Work Method Statement
4 RESPONSIBILITIES
Responsibility Who
5 REFERENCES
Particular Specification
Other(s), specify:
Project Documents
6 CONSTRUCTION METHODOLOGY
6.1 SUMMARY
Repair procedures have been prepared for eight possible types of repair to precast units
and cast in situ works as listed below. The damaged area will be repaired using one of
the products, which has been specified for each area.
5. Cone Holes
Remove plastic cones.
The surface must be free from standing water, oil and grease. Dust, dirt and
other foreign particles must also be removed.
Wet the surface and apply the mortar ‘Sto Crete NSG / NSG-S’.
‘Sika ANTISOL – S’ or ‘Stocryl SCC Supreme’ curing compound is then used.
Use a breaker to remove all the unsound concrete. Continue hacking until sound
homogeneous concrete is reached.
Clean-off the prepared area with water to remove all dust. Remove all rust from
exposed rebar using wire brush.
Apply reinforcement protection primer ‘Fosroc Nitoprime Zincrich’ to the exposed
reinforcement
Wet surface with water but ensure there is no free surface water before
application of bonding agent ‘Fosroc Nitobond AR’.
Put up formwork at the affected area to hold repair materials in shape if
necessary.
Flow the repair mortar ‘Sto Crete NSG/ NSG-S from one side only to avoid air
entrapment’.
‘Sika ANTISOL – S’ or ‘Stocryl SCC Supreme’ curing compound is then used.
All works will be performed in accordance with the manufactures
recommendations.
Apply ‘Stocryl SCC Supreme’ curing compound with a paint brush after removing
the formwork
D. Cast Back Method. (Honeycomb / Other Defects more than 200mm deep)
Use marker pen to draw a line around the defective area.
Saw cut 5 to 10mm deep along the marked line to avoid feathered edges.
Use a breaker to remove all the unsound concrete. Continue hacking until sound
homogeneous concrete is reached.
Clean-off the prepared area with water to remove all dust. Remove all rust from
exposed rebar using wire brush.
Pre-wet the substrate surface to saturate and clear any excess water.
Apply Fosroc Nitobond AR’ or Stocrete SBR-HD bonding agent to the substrate.
Fix the surface to be concreted with a funnel top edge (as necessary). Formwork
to be higher than the surface to be repaired. All edges to be made leak-proof
using sponge in between the formwork and the concrete surface
Cast back with Approved Concrete Mix Design or approved NSGrout
Leave to cure until concrete / NS Grout is set, before removing the formwork
Use a grinder to remove excess concrete on top part and sides and make
surface even
Apply Stocryl SCC-Supreme curing compound with a roller or spray after
removing the formwork
Cracks in the precast wall panels and Cast-in Situ with widths of 0.30mm and above
shall be repaired using UNIFOR “UF Grout” for dry Crack Repair by Epoxy Injection as
per the following procedure:
Surface Preparation. Remove dust particles , laitance with wire brush and or
using compressed air.
Sealing of Surface and Adhesive of Plug. Seal crack at lengths, stopping at
intervals of 300mm for plug adhesion using UF seal (Interval length depends on
crack and depth).
UF Seal Curing. Allow UF Seal to cure. 9refer to material specifications).
Installation of Injector. Install injector by screwing onto the plugs.
UF Grout Injection. Inject UF grout into container using grease/ footpump. Stop
when pressure indicator rises to 3.kg/cm2. Proceed to next injector
UF Grout Curing. Allow UF Grout to cure.
Finishing. Remove injector and grind off sealing material.
6.4. PERMITS
Permit-To-Work (Lifting, Hot Work Permit, Working at Height) of McConnell Dowell as and when
required.
8 CONSTRUCTION RESOURCES
8.1 KEY PROJECT PERSONNEL
The Project Manager or Construction Manager or delegate will appoint a Supervisor to oversee
each or a few related activities. It will be ensured that the Supervisor will be experienced in the
associated work, will be able to read drawings, be competent in reporting, and be conversant with the
technical, safety and environmental specifications, guidelines or requirements.
Table 7A Personnel requirements
Function / Role Name Contact Details
All equipment shall be operated by suitably qualified and experienced personnel. Specialised
labour requirements for the works will involve:
Table 7B Personnel & Training requirements
Function / Role Qualification / licence Activity specific Training
Required Required
Skilled Supervisor Work at height Certificate Work at height training
Plant and equipment associated with the works will be in good working order and have the
capacity to safely and efficiently do the work required. The type, size and number of machines used will
depend on the quantity of material, scheduling and access restrictions. Necessary plant inspections and
operator competency assessments will be undertaken as part of the Project Safety Management Plan.
The following list outlines the plant and equipment expected for the associated scope:
Person or organisation
ITP Number Title / scope responsible for
preparation
Development
JSEA/SWMS Title / Activity description (What) Due By
Responsibility (Role)
Implementation Responsibility
Aspect (What) Control (How)
(Role/Subcontractor)
Erosion and
Not applicable
Sediment control
PEP Noise Management Plan
Noise ECO
K044-Exposure to Noise
Supress with water
Dust ECO / Supervisor
PEP Safety management plan
Note: the above list is not intended to be exhaustive, and is limited to the scope of work as identified at
the time of the Risk Register Workshop.
11 HAZARDOUS MATERIAL /
SUBSTANCES
Table 12A Hazardous materials / Substance list
Fosroc Nitoprime Zincrich Refer to submitted SDS via Material Approval (MAR)
Davco Grout 280 Refer to submitted SDS via Material Approval (MAR)
Note: the above list is not intended to be exhaustive, and is limited to the scope of work as identified at
the time of the Risk Register Workshop.
12 APPENDICES
APPENDIX A: QAQC Documents
i. Request for Inspection – Notification 017-F002-2755
ii. Concrete Repair Checklist F028-600-2755
iii. Summary list of Approved Material Submission (MAR)
APPENDIX B: JSEA
APPENDIX A
QA / QC Documents
APPENDIX B