Doc. No.

: 26071-100-GPP-GCX-00056

Job No. : 26071 Rev.001

CONCRETE REPAIR PROCEDURE

PROJECT : Engineering, Procurement and Construction (EPC) Inside

Battery Limits (ISBL) and Outside Battery Limits (OSBL) for
the Refinery Development Master Plan (RDMP) Project
RU V Balikpapan
LOCATION : Refinery Unit V Balikpapan, East Kalimantan, Indonesia
OWNER : PT PERTAMINA (Persero)

001 11 Mar 2021 ISSUED FOR CONSTRUCTION ANG.H A.ARIFIN Y.D.KIM

000 20 Oct 2020 ISSUED FOR CONSTRUCTION ANG.H A.ARIFIN Y.D.KIM

00A 11 Mar 2020 ISSUED FOR REVIEW DIFY.K A.ARIFIN Y.D.KIM

REV. DATE DESCRIPTION PREPARED CHECKED APPROVED

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REVISION LOG

REV. NO. DATE PAGE DESCRIPTION

00A 11 Mar 2020 - ISSUED FOR REVIEW

ISSUED FOR CONSTRUCTION
000 20 Oct 2020 ALL
- Incorporated with PMC comment
ISSUED FOR CONSTRUCTION
001 11 Mar 2021 ALL
- Incorporated with PMC comment

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HOLD LIST

No. Paragraph HOLD Content

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TABLE OF CONTENTS

1. GENERAL............................................................................................................................ 5

2. DEFINITIONS AND ABBREVIATIONS ........................................................................... 5

3. REFERENCES ...................................................................................................................... 5

4. RESPONSIBILITY ............................................................................................................... 6

5. MATERIALS ....................................................................................................................... 8

6. EQUIPMENT & TOOLS .................................................................................................... 9

7. WORK PREPARATION. .................................................................................................... 9

8. WORK PROCEDURE CONCRETE REPAIR ...................................................................10

9. HEALTH, SAFETY AND ENVIRONMENT CONTROL ................................................21

10. CONCRETE CHIPPING ...................................................................................................21

11. CONCRETE CURING .......................................................................................................22

12. QUALITY...........................................................................................................................22

13. ATTACHMENT ................................................................................................................22

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1. GENERAL
This procedure covers the requirements for construction covering the general sequences for
concrete repair method on the RDMP RU V Balikpapan Project.

SUBCONTRACTOR should read and understand all of the documents. Any conflicts or
inconsistencies between this procedure and codes, standards, drawings, or contract
documents shall be brought to the attention of CONTRACTOR for solution.

2. DEFINITIONS AND ABBREVIATIONS

Owner : PT PERTAMINA (Persero)
Contractor : RDMP Balikpapan JO
Project : Pertamina RDMP RU-V Balikpapan Project
HSE : Health, Safety, and Environment
Work : All work must be done, all materials to be delivered and all
commitments that must be fulfilled by the Contractor under the
contract.
Workplace : Any physical location where work-related activities are carried
out under the control of the organization.
WMS : Work Method Statement

3. REFERENCES
The latest edition of the following specifications, codes and standards shall be applied to this
work:

Specifications Documents

26070-100-3SS-DB02-J0001 Engineering Specification for Concrete Work

26071-100-3SS-E13-00001
26071-100-3SS-E13-00002
26071-100-GPP-GHX-00001
26071-100-GPP-GCX-01004
26071-100-GQI-GCQ-00009
26071-100-G01-GHX-00002
26070-203-G07-GEC-J3001
26071-100-D0-000-00001
Specification for Furnishing and Delivery of Concrete
Specification for Concrete Work and Grout
Work Permit Procedure
Night Shift Work Procedure
Inspection and Test Plan for Civil Works
Project HSE Plan
Approved Brand/Vendor List for civil works
Structural Concrete STD DWG General Notes &
Abbreviation

Codes and Standards

A. ACI (American Concrete Institute) Standards

1. ACI 117 Specification for Tolerances for Concrete Construction and

Materials (ACI 117-10) and Commentary
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2. ACI 211.1 Standard Practice for Selecting Proportions for Normal, Heavy
weight, and Mass Concrete
3. ACI 301 Specification for Structural Concrete for Buildings
4. ACI 308 Standard Practice for Curing Concrete
5. ACI 224.IR Cause, Evaluation, and Repair of Cracks in Concrete
Structures
6. ACI 315 Details and Detailing of Concrete Reinforcement
7. ACI 318/318R Building Code Requirements for Reinforced Concrete and
Commentary (ACI 318R)
8. ACI 347R Guide to Formwork for Concrete

B. ASTM (American society for Testing and Materials)

1. ASTM C1059 Standard Specification for Latex Agents for Bonding Fresh To
Hardened Concrete
2. ACI 315 Details and Detailing of Concrete Reinforcement
3. ASTM C150 Standard Specification for Portland Cement
4. ASTM C173/C173M Standard Test Method for Air Content of Freshly Mixed
Concrete by the Volumetric Method
5. ASTM C1107 Standard Specification for Packaged Dry, Hydraulic-Cement
Grout (Nonshrink)
6. ASTM C928 Standard Specification for Packaged, Dry, Rapid-Hardening
Cementitious Materials for Concrete Repairs
7. ASTM C260/C260M Standard Specification for Air-Entraining Admixtures for
Concrete
8. ASTM C494/C494M Standard Specification for Chemical Admixture for Concrete
9. ASTM A615/A615M Standard Specification for Deformed and Plain Carbon-Steel
Bars for Concrete Reinforcement
10. ASTM C404-2011 Standard Specification for Aggregate for Masonry Grout

C. SNI
1. SNI 15-2049-2004 Semen Portland

4. RESPONSIBILITY
4.1 Project QA/QC Manager
Project QA/QC Manager or his representative is responsible for:
i. Approval of ITP for each discipline of construction activities;
ii. Review of witness/hold points of ITP to verify conformance to the requirements of
specified documents;
4.2 OC QC Lead
OC QC Lead is responsible for:
i. Overall supervision of inspection and test activities by CONTRACTOR and
SUBCONTRACTORs.
4.3 QC Engineer
QC Engineer is responsible for:
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i. Preparation of ITP for each discipline of construction activities;

ii. Maintaining and up date for approved ITP;
iii. Ensuring quality control site surveillance;
iv. Attending witness inspections and tests, in accordance with the approved ITP,
verifying the inspection reports and validating the results;
v. Shall make continually monitoring of the work at site. All QC documentation shall be
managed by the inspectorate and technical clerks assigned by the Quality
department;
vi. Monitoring the timely production of the inspection certificate by Construction
Functions or SUBCONTRACTORs;
vii. Ensuring the proper disposition of the nonconformities, with the assistance of
specialists as required;
viii. Identifying any quality related problems or deviations.

4.4 QC Inspector
QC Inspector is responsible for:
i. Conduct Site Inspection and Test in accordance with approved Inspection and Test
Plan.
ii. Conduct quality control site surveillance
iii. Reporting any quality related problems which is found during site surveillance,
inspection and test including Non-conformances to QC Engineer
iv. Review and document result of inspection and test and update the result in relevant
IT system (CPACE)

4.5 Each Construction Function Representative

Each Construction Function Representative is responsible for:
i. Acknowledgement of ITP including designation of witness/hold points;
ii. Overall supervision the work preparation for inspection and test activities.

4.6 Each Construction Function Engineer

Each Construction Function Engineer is responsible for:
i. Providing timely written notification to IPMT / CONTRACTOR QA/QC for inspection in
accordance with approved ITP;
ii. Performing the inspection pertaining to witness/hold points at appointed time, when
required.

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5. MATERIALS

For concrete materials refer to 26071-100-3SS-E13-00002, Specification for Concrete Work

and Grout.

a. Cement
Portland cement mortar in accordance with ACI 301/ACI 301M-2016, Specification for
Structural Concrete / Specification for Structural Concrete (Metric).

b. Aggregate
- Aggregates shall meet requirement of Specification for Furnishing and Delivery of
Concrete 26071-100-3SS-E13-00001.
- Fine aggregate shall be natural sand having clean, hard, durable, uncoated grains
free from ,lumps, soft or flaky particles, organic matter or other injurious materials.
- Course aggregate shall be washed gravel or crushed stone having clean, hard, strong
and durable particles free of chemicals, coatings of clay or other fine materials that
may affect hydration and bond of the cement paste.

c. Water
Water shall be potable and free from injurious amounts of oil, acid, alkalis, organic
materials, or other deleterious substances.
Admixtures shall not be used without prior approval.

d. Concrete Reinforcement

e. Material for Grouting SIKA as listed on AB-VL Civil.

Material for Grouting to be used for concrete repair shown in table below:

Table 1. Material for Repair

Parts Description
SIKA Bond NV or Equal To glutinous old concrete to new fresh
concrete. As bonding agent for concrete
and mortar
SIKA Separol 10 or Equal To release agent for wooden formwork.
Number of lifts is substantially increased.
SIKA Antisol E-White or Equal To protect newly concrete surfaces to form
a thin film barrier against premature water
loss.
Sikadur 31 CF or Equal To use concrete repair mortar and
adhesive. (Corner and edges, Holes and
void filling, vertical and overhead use)
SIKA Grout 215 or Equal To use grouting over a wide range.
(Anchor bolts, cavities, gaps and
recesses)
Sikadur 32 or Equal To use for material seal after do injection
method repair.
Sikadur 752 or Equal To use for material injection method
repair, used to repair major crack defect.
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*Note: If any others non categorized material will be used and / or provided by unlisted
ABVL vendor, Contractor shall submit MAR to IPMT Engineering for review and approval.

6. EQUIPMENT & TOOLS

Table 2. Equipment & Tools
No. Equipment Name Function
1. Concrete Cutter Repair Works
2 Electric Mixer Repair Works
3. Concrete Grinder Repair Works
4. Chipping Machine Repair Works
5. Water Jet Repair Works
6. Injection Machine Repair Works
7. Air Compressor Cleaning Works
8. Brush Clean Works
9. Water Truck Curing
10. Generator Providing Power
11. Drill Machine Repair Works
12. Other

7. WORK PREPARATION.
7.1. General
Before commencement of work, Below Safety requirements shall be done by authorized
person on site.
1. All the personnel working in the field will be given relevant safety orientation training
and formal site induction. All the personnel will be made aware of safety procedures
and requirements to be ensured on the entire task to be executed on site.
2. Daily toolbox tasks will be held at the site prior to commencement of work activities. All
the personnel working in the site shall wear the appropriate PPE.
3. Isolate the work area with warning tape and warning signs in order to control access to
the work area by unauthorized workers.
4. Proper barricading must be provided and maintained around working area at all times.
5. Ensure that all equipment such as excavator, cranes, mixer trucks and etc. shall have
valid 3rd party inspection certificate which has been issued by the approved 3rd party
agency.
6. Inspection of all equipment shall be carried out by the CONTRACTOR inspector prior
to start activities for color coding materials and equipment inspection control and
operator and / or construction supervisor shall conduct daily inspection for all
equipment to ensure good equipment conditions at site.
7. Housekeeping shall be carried out in proper way and the Waste shall be disposed in
the designated place allocated by CONTRACTOR.
8. Job risk assessment shall be done daily by supervisor and workers and potential
hazards shall be highlighted during Tool Box Meeting.
9. Dust shall be kept at a minimum level by use of water or other safe mean.

7.2. Work Permit (PTW: Permit to Work)

1. To start the work CONTRACTOR will follow approved permit to work procedure along
with the approved WMS (Work Method Statement), Risk Assessment (or Job Safety
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Analysis) and the related drawings showing the working proposal shall be submitted to
OWNER
2. Before work starts, ensure that all work permits have been obtained from OWNER for
brownfield, from SHRP for Greenfield.
3. Permit Box shall be available & all the permits shall be displayed in the Permit Box on
site.

7.3. Hand tools and equipment

1. All tools and equipment shall be in good working condition.
2. Operators shall be instructed and trained in the safe use of the equipment.
3. All trucks must be mechanically checked prior to entering the site using HSE Pre-
Inspection check list.
4. All heavy machineries must be Third Party Certified according to safety regulation.

7.4. Emergency Response Plan (ERP)

1. Emergency Response Plan must be available and all personnel acquainted with the
relevant provisions and know what to do in case of any emergency.
2. CONTRACTOR shall have suitably trained fire watch man among his crew at all times
during onsite operations.
3. The CONTRACTOR shall display emergency evacuation procedures at strategic
locations on the site and ensure arrangements are in place to call for outside help if
need to assist in any emergency associated with the Work on Site.
4. CONTRACTOR shall at all-time keep updated with list of addresses and telephone
numbers of the CONTRACTOR and OWNER staffs who are responsible for organizing
emergency responses at Site

8. WORK PROCEDURE CONCRETE REPAIR

8.1 Notified Repair
IPMT shall be notified for any defect prior to repair work. QC from Contractor and
Owner must be discussing first to analysis category of defect. Contractor must repair
based on defect category method.
Contractor shall be notified to IPMT for any defect finding after formwork removal.
Concrete repair subject for Owner approval shall be follow as mention on 26071-100-
GQI-GCQ-00009ITP for Civil and Contractor shall be initiated NCR to eliminate
recurrence events.

8.2 General Concrete Surface Preparation

1. Conduct the surface preparation on area which will be repaired. The substrates
must be sound, dry, clean and free from laitance, ice, standing water, grease, oils,
old surface treatments or coatings and loosely adhering particles to achieve a
laitance and contaminant free, open textured surface.
2. Chip first whole repair area which are considered unsound and unfree from
laitance.
3. Other area could be considered/checked using a hammer, listen the sound of
concrete. Dense concrete and undressed concrete sound different.

8.3 Honeycomb
Honeycombs definition, are voids left in concrete due to failure of the cement mortar to
effectively fill all the spaces between the coarse aggregate particles.
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Primary causes of voids or honeycombs in reinforced concrete:

1. Rebar Congestion - if rebar is placed too close together or too close to form work it
will trap the larger pieces of aggregate while the mortar in the mixture mayor may
not pass through.
2. Mix Design - Improper mix design can lead to low workability, early stiffening or an
aggregate that is too large to properly consolidate the concrete for a given
application.
3. Lift Depth - When single concrete placements or "lifts" are too deep, proper
vibration can become very difficult or impossible. Excessive lift depths can also
allow too much freefall of the concrete that can create a separation of the cement
mortar and aggregate as the aggregate impacts the reinforcing steel when falling
through the forms.
4. Inadequate Vibration - When the concrete is properly vibrated it acts more like a
liquid allowing it to better settle in the form, consolidate around the reinforcement
and completely fill the forms

Honeycomb type:
1). Shallow Honeycomb
Minor structural defect, show in figure 1.

Figure 1. Visual of Shallow Honeycomb

Repair Shallow Honeycomb:

a. Removal of the unsound material can be accomplished using typically with
chipping machine or suitable tools.
b. Prepare a vessel to mix component A & B from “Sikadur 31 CF” or equal and an
electric mixer at least 300 rpm with paddle/stirrer. Paddle/stirrer are possible to be
modified by ourselves on site using remain of rebar on site. Mixing at least 3
minutes. Use a spatula to apply “Sikadur 31 CF” or equal.
c. Maximum thickness per application is 20 mm
d. “Sikadur 31 CF or equal” will be set final in 4 hours.
e. Apply “Antisol E White” (White Pigmented Polyolefine Base Curing Compound) or
equal on whole surface of “Sikadur 31 CF or equal”.
f. This material is applied by patching system (no need formwork).
g. Sikadur 31 CF will reach the Compressive Strength of 60-70 MPa at 7 days with
temperature of curing +30˚C.

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Figure 2. Repair Procedure for surface honeycomb

2). Deep Honeycomb

Major structural defect, show in figure 3.

Figure 3. Visual of Deep Honeycomb

Repair Deep Honeycomb:

a. Prepare formworks on repair area, make sure around of whole formworks
have no leakage and supported very well. SIKA Separol 10 or equal suitable
to minimize the leakage around formworks.
b. Whole repair area must be saturated surface dry.
c. Prepare a vessel to mix “SIKA Grout 215 or equal”. Pour 4 liters of water into
the vessel then pour half of “SIKA Grout 215 or equal”. Water to be used in
mixing grout shall conform of requirements Standard Specification for
Furnishing & Delivery of Concrete 26071-100-3SS-00001.
d. Mix them using an electric mixer at least 300 rpm with paddle/stirrer.
Paddle/stirrer are possible to be modified by ourselves on site using remain of
rebar’s on site.
e. Pour remain of “SIKA Grout 215 or equal” into the vessel then mix them at
least 3 minutes.

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f. The thickness of grout repair is more than 100 mm, use ice water to mix them
to eliminate the temperature rise.
g. Place “SIKA Grout 215 or equal” from one side to avoid air trapped. Maintain
the head box 150 mm – 200 mm. Do not vibrated.
h. Initial Setting Time of “SIKA Grout 215 or equal” is 4 – 8 hours.
i. Compressive Strength of “SIKA Grout 215 or equal” will be 63,7 MPa at 28
days.
j. Apply “Antisol E White or equal” (White Pigmented Polyolefin Base Curing
Compound) on whole surface of “SIKA Grout 215 or equal”

8.4 Tie Rod Installation

Tie Rod used to strength formwork from pressure of fresh concrete casting, however tie
rod must be taken out from concrete as formwork. Take out tie rod must be cut
minimum 5 cm from surface of concrete. Then, it will cause hole/cavity to the fresh
concrete. Show in Figure 4.

Figure 4. Tie Rod Installation

Repair Tie Rod Installation:

1. Cut appear rebar from surface concrete, cut until 5 cm depth from the surface of
concrete.
2. Prepare a vessel to mix “SIKA Grout 215 or equal”. Pour 4 liters of water into the
vessel then pour half of “SIKA Grout 215 or equal”.
3. Mix them using an electric mixer at least 300 rpm with paddle/stirrer. Paddle/stirrer
are possible to be modified by ourselves on site using remain of rebar’s on site.
4. Pour remain of “SIKA Grout 215 or equal” into the vessel then mix them at least 3
minutes.
5. Place “SIKA Grout 215 or equal” from one side to avoid air trapped. Maintain the
head box 150 mm – 200 mm. Do not vibrate!
6. Initial Setting Time of “SIKA Grout 215 or equal” is 4 – 8 hours.
7. Compressive Strength of “SIKA Grout 215 or equal” will be 63,7 MPa at 28 days.

8.5 Crack Defect

The quality of concrete structure structures is highly dependent on achieving a hard
and durable surface that is flat, relatively free of crack, and at proper grade of
elevation. Properties of the surface are determined by the mixture proportions and the
quality of the concreting and jointing operations. Failure to address this issue can
contribute to undesirable characteristic in the wearing surface such as cracking.

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The proper repair of cracks depends on knowing the causes and selecting the repair
procedures.

It is important to identify the primary concern in regard to any cracking. The main
concerns are whether the cracks are affecting structural integrity as a result of reduced
durability.
Building cracks are most common problem found, We all love to have a house which
structurally safe and beautiful but it is not so easy, one has to overcome natural
calamity, soil failure, construction faults, improper design, and inadequate joints
causing’s to develop cracks on the building. Though the cracks in concrete cannot be
prevented entirely but they can be controlled by using adequate material and technique
of construction and specific design criteria. On timely identification of such cracks and
adopting preventive measure are essential.

When structural cracks occur comprehensive mitigation shall conduct to determine the
root cause of damage. Contractor shall be prepare root cause and explain more detail
e.g. incorrect design, faulty construction, overloading, etc. If any design impact
contractor shall issued Design Change Notice (DCN).

Primary causes of crack in reinforced concrete:

1. Plastic Shrinkage – when moisture evaporates from the surface of freshly placed
concrete faster than it is replaced by bleed water, the surface concrete shrink. Due
to restraint provided by the concrete below the drying surface layer, tensile
stresses develop in the weak, stiffening plastic concrete, resulting in varying depth
of crack.
2. Settlement – after initial placement, vibrations, and finishing, concrete has a
tendency to continue consolidated. During this period the plastic concrete may be
locally restrained by reinforcing steel, a prior concrete placement, or formwork.
This local restraint may result in void and/or cracks adjacent to restraining
elements.
3. Drying shrinkage – the loss of moisture from the cement paste constituent. This
moisture induced volume changes are a characteristic of concrete.
4. Thermal stresses – temperature differences within a concrete structure may be
caused by portions of the structure losing heat of hydration at different rates or by
the weather conditions cooling or heating one portion of the structure to different
degree or at different rate than another portion of structure.
5. Poor construction practices – a wide variety of poor construction practices can
result in cracking concrete structures.

Crack type:
1). Minor crack defect, show in figure 5.

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Figure 5. Visual Minor Crack Defect

Repair Minor Crack Defect:

a. Clean the cracks from dirt, oil, grease or frost standing water.
b. Prepare a vessel to mix component A & B from “Sikadur 32 or equal” and an
electric mixer at least 300 rpm (max 600) with paddle/stirrer until the material
becomes smooth in consistency.
c. After finish mixing, apply directly to the prepared substrate by brush, roller or spray
on crack surfaces.
d. Ensure that it is well brushed in to get smooth surfaces after repair.
e. Pour new concrete within specified open time, as long as material is still tacky.
This step if necessary when the inspector didn’t accept the result of repair.

2). Major crack defect, show in figure 6.

Figure 6. Visual Major Crack

Repair Major Crack Defect:

a. Clean the crack from all contaminated material such as oil, grease, dirt or fine
particles of concrete prevent. Blown out using compressor to provide surfaces of
crack to be air-dying.
b. Surface cracks should be sealed to keep the epoxy from leaking out before it has
gelled.
c. Install the ports for do injection work.
d. Drilled holes-fitting inserted used in conjunction with V-grooving of the cracks.
Drill a hole into the crack, approximately ¾ in below the apex of the V-grooved
section into which a fitting such as a pipe nipple or tire valve stem is bonded with
an epoxy adhesive.
e. Prepare a vessel to mix component A & B from “Sikadur 752 or equal” and an
electric mixer at least 300 rpm (max 600) with paddle/stirrer until the material
becomes smooth in consistency.
f. For vertical crack, pumping epoxy into the entry port at the lowest elevation until
the epoxy level reaches the entry port above.
g. For horizontal cracks, injection should proceed from one end of the crack to the
other in the same manner. The crack is full if the pressure can be maintained.
h. Seal parts and cracks with “Sikadur 32 or equal” after cured inject with steady
pressure.
i. Remove the surface seal after the injected epoxy has cured, the surface seal
should be removed by grinding or other means.

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8.6 Spalling/ Scalling Defect

Show in figure 7.

Figure 7. Spalling/ Scaling Defect

Repair Spalling/ Scaling Defect.

1. Remove the concrete at the spalled areas to expose the corroded steel bars.
2. Scrape and clean the exposed steel bars and use a wire brush to remove the rust.
3. Apply two coats of anti-rust paint to the steel bars
4. Before patching the area, apply a sika bond NV or equal to the affected surface to
ensure proper adhesion
5. Patch up the hacked area using polymer modified cement mortar

8.7 Cold Joint,

Show in figure 8

Figure 8. Cold Joint

Repair Process:
1. Chipped the surface to open crevice with unstable concrete on the edges
2. Cleaning thoroughly the construction joint by means of air compressor and
ensuring all loose materials and dirt are removed.
3. Water jet the surface of the construction joint prior to commencement of the next
pouring
4. After that, pour Material for a Sika Bond NV or equal into the area and prepare
concrete to fill back.

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5. The cold joint line between the old and new concrete will be v-cut approximately
30~50mm depth and grouted with the suitable materials (as bonding material and
curing compound) under the conditions of Temperature limitation and Relative
humidity limitation in compliance with the vendor’s instructions

8.8 Defects due to Poor Formwork Installation

Formwork installation errors include misalignment, movement, loss of support, failure of
forms that can lead to cracking and structural failure, Show in figure 9

Figure 9. Defect due to poor formwork installation

Settlement cracks develop due to concrete settlement caused by the loss of support
during construction. Inadequate formwork support and premature removal of formwork
are the major causes of loss of support during construction.

Repair Process:
1. Defects due to formwork placement mistakes can be repaired with surface grinding
to maintain the verticality of the structure if the error is minor.
2. In case of major error, the concrete member shall be repaired by removing the
concrete in the defective area
3. Prepare formworks on repair area, make sure around of whole formworks have no
leakage and supported very well.
4. After that, pour Material for a sika bond NV or equal into the area and prepare
concrete to fill back.

8.9 Bugholes
Bugholes or surface voids are small regular or irregular cavities formed due to the
entrapment of air bubbles in the surface during placement and consolidation. Show in
figure 10.

Figure 10. Bugholes

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Bugholes are considered as defects if their width and depth exceed 3.81cm and
1.27cm respectively.

Prevention:
1. The surface of the formwork is rough or adheres to debris, and the concrete
surface is damaged when the formwork is removed.
2. The formwork is not watered or watered enough, and concrete loose too much
water, form pits.
3. Formwork isolation reagent is unevenly painted, and the surface of concrete bonds
with the formwork, resulting in bugholes.
4. There are gaps between the formworks.
5. The concrete is loosed, and the bubbles are stop on the surface of the formwork to
form pits.

Repair Process :
Preparing concrete with original concrete mixing ratio, repairing the bugholes after the
bugholes is well watered.

8.10 Abrasion Erosion Damage

Concrete structures that transport water containing silt, sand, gravel, or rock, or water
at high velocities, are subject to abrasion damage. Abrasion-erosion damage results
from the grinding action of silt, sand, and rock. Show in figure 11.

Figure 11. Abration Erosion Damage

Repair Process:
Abrasion damage is the best repaired with silica fume concrete or polymer concrete
with higher quality. These materials have shown the highest resistance to abrasion
damage in laboratory and field test. The polymer concrete will enhance concrete
abrasion resistance. If the damage does not extend behind reinforcing steel or at least
6 inches into the concrete, the silica fume concrete should be placed over a fresh
epoxy bond coat.

8.11 Void (Air trap) under embedded plate

A type of concrete defect throughout which small air bubbles are trapped under
embedded plate.

Repair Process :
1. Indicate and make sure position of Void area on Embedded Plate.

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2. Drill some point the concrete beside Embedded Plate near void area. Drill the
concrete at several marked points.
3. Clean the borehole from dust and debris with a manual hand pump, It is very
important to do so that Sika Grout can stick firmly and work properly.
4. Blow the holes using a hand air pump to ensure the empty space on bottom of
embedded Plate is connected between the boreholes. This is important to ensure
that there is no vacuum (dead end) bottom of the embedded plate. so that it can be
ascertained that all the void gaps have been filled with Sika Grout's cement.
5. Install 1” plastic hose that fits standing over each hole this is done as air flow and
overflowed when casting of Sikadur-752 is done.
6. Make a mixture of Sikadur-752 according to the manufacturer's specifications
7. At this step there are 2 options:
- Cast Sikadur-752 into one hole for access, so that it flows naturally to fill the
other hole. If the flow is not smooth, it will be assisted by pressure using a
manual tool.
- Cast the Sikadur-752 into one hole for access, Place the small hose into the end
of the sealant gun, then insert the small hose into the gap. Press the sealant
gun with slowly pressure so that SIKA flows to fill the void and other holes.
- Make sure that when casting Sikadur-752 Material, the material has overflowed
in the other holes. this indicates that the gap under the Embedded Plate is
completely filled.
8. Finish

8.12 Finishing Concrete Surface after repair.

After repair concrete mortar better used to finish the surface of concrete. Curing also
needed (If the crack is major) to get maximum strength of repaired concrete.

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Job No. : 26071 Rev.001

Concrete Repair Flow

Subcontractor Contractor IPMT
Start Rejected

Preparation for Procedure, Mitigation of Defect also

Method, Material, Tools and
Equipment before conduct the
repair
Procedure, method, tools and
review method, tools and
material certificate follow as per
material certificate follow as
specification
per specification

Rejected
Identification, marking and
surface preparation of defect
area as per repair sequence Approved
such as material, drill, v-cut,
chip, mixing, injection and Rejected
cleaning.

Conduct the inspection for Conduct the inspection for

repair concrete as per work repair concrete as per work
step and ITP as Hold Point step and ITP as Hold Point

Prepare RFI for repair concrete

with detail defect area before
and during of Work step Rejected

Rejected

Conduct the inspection to

ensure sequence of repair
concrete before injection or Approved
concrete such us drill hole, v-cut,
formwork, mixing homogenious
material, power and speed
Rejected

Ensure application for Injection is Approved

started at the first packer using
the lowest pressure
setting of the pump also for
cleaning and curing.

Review the quality document

report for repaire concrete
Ensure for setting time, curing
before formwork removal was
achieve and follow requirement Review the quality document
of specification and subbmit the report for repaire concrete
document report with
attachment maximum two days
after application
Rejected

Approved
Finish

Close out action and acceptance of concrete repair subject for Owner approval as mentioned
on 26071-100-GQI-GCQ-00009 ITP for Civil.

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Job No. : 26071 Rev.001

9. HEALTH, SAFETY AND ENVIRONMENT CONTROL

a) All members who will involve into the work execution team shall obey Pertamina RU-V
safety requirement, and ensure that the activities would be conducted with the safety
manners.
b) The following condition is general safety requirement during work execution.
c) All working activity inside project site area shall be covered by proper work permit, and
shall be daily updated. “No Permit – No Work”.
d) Ensure that workers are in a good and health condition, before commencing work
activities.
e) To wear standard minimum of Personal Protective Equipment (PPE) i.e. Coverall, Safety
Helmet, Safety Shoes, Safety Glasses, hand glove properly.
f) In such case of working at special condition, additional PPEs are required, i.e. masker,
face shield, ear plug/muffler, full body harness.
g) To conduct safety toolbox meeting prior work, in particularly to remind the underground
existing facility such as, instrument and electrical live cables. In this case, manual
excavation is recommended.
h) The tools and equipment that will be utilized during work execution shall be in good
condition and have been pass the safety inspection by HSE Department.
i) To obey and follow the HSE requirement
j) Observe and Report to the competent person for any unsafe condition at around the
working areas. To follow the applicable Procedure and standard safety during work
execution

10. CONCRETE CHIPPING

Chipping or breaking concrete often is the first step in a demolition or repair project.
Chipping stage:
- Preparation
Before concrete chipping works started, prepare the equipment like jack drill, angle grinder,
air compressor, etc. Check and ensure that all equipment in a good condition to be used.
Ensure that all manpower is used PPE for protection
- Concrete Chipping
Concrete chipping is one of the important processes on concrete repair works. Contractor
shall chip the concrete defects/finding and continue to repair concrete based on the defects.
Light chipping to be conduct using angle grinder and if the concrete surface to be chipping
is thick, we can chip it using jack drill. Chipping the concrete which in unsteady condition.
Concrete chipping result shall be checked by supervisor, QC and CONTRACTOR to ensure
that the chipping works in accordance with IFC Drawing
- Cleaning
After concrete chipping work has finished, clean the concrete surface all loose particles,
dust and all of surface dirt. Ensure that all loose particles of chipping concrete thoroughly
removed by using air compressor or brush along the chipped area

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Job No. : 26071 Rev.001

11. CONCRETE CURING

Waterproof Paper or Plastic Membrane shall conform to ASTM C171 or SNI 2847.2013.
Liquid Membrane Curing Compound shall conform to ASTM C309.

12. QUALITY
a) All exposed concrete surface shall be free from mud, oil or other nonmetallic coating that
adversely affect with material used.
b) All used material shall be following the specification of material check first by QC
CONTRACTOR.
c) QC ensure of concrete repair as per method statement and by visual check there is no
crack after repaired.

13. Attachment List

1. Attachment 1
2. Attachment 2
3. Attachment 3

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Job No. : 26071 Rev.001

Attachment 1 - Concrete Pouring Release Report

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Job No. : 26071 Rev.001

Attachment 2 – Fresh Concrete Test Report

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Job No. : 26071 Rev.001

Attachment 3 – Compressive Strength Test Report

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