Method of Statement For Internal External Oil Water Tanks Repairing and Coating System

Plant Doc Disc.
Doc Rev
METHOD OF STATEMENT No. Index Code Type No.
FOR INTERNAL & 769 A CI PL A
EXTERNAL OIL WATER
TANK REPAIR CI-769-PL-0039
BI-11-19034 (GCP’s)
BI-11-20034 (PWIS)
Jafurah Gas Compression Plants (GCPs) and
Produced Water Injection Station (PWIS) (Package-1)
JAFURAH GAS COMPRESSION PLANTS (GCPs) AND PRODUCED WATER INJECTION STATION
(PWIS) (PACKAGE-1)
CONTRACT No.: 6600050508 (IK)

BI-11-19034 (GCP’s); BI-11-20034 (PWIS)
DOCUMENT REVIEW STATUS

DOCUMENT SUBMISSION STATUS SAUDI ARAMCO PROJECT MANAGEMENT
TEAM
FIRST SUBMISSION ☐ APPROVED

☐ RESUBMISSION WITH
☐ COMMENT AS NOTED. WORK MAY
PROCEED SUBJECT TO
INCORPORATED COMMENT COMPLIANCE WITH COMMENTS
☐ REJECTED. REVISE AND RESUBMIT

☐ RETAINED FOR INFORMATION
DOCUMENT
COMPANY
CATEGORY
 REVIEW
Position Name Signature
☐ INFORMATION
Date
Issued for
A 31-JUL-2022 DIPANKAR M O P SINGH D. MANIMARAN
Review / Approval
REVIEWED BY APPROVED BY
PREPARED BY
REV. ISSUE DATE DESCRIPTION (CONSTRUCTION (CONSTRUCTION
(CIVIL ENGINEER)
SUPERVISOR) MANAGER)
Page 1 of 19
Plant Doc Disc. Doc Rev
EXTERNAL OIL WATER
BI-11-19034 (GCP’s)
BI-11-20034 (PWIS)
METHOD OF STATEMENT FOR INTERNAL & EXTERNAL OIL WATER

TANK REPAIR
Revision History
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EXTERNAL OIL WATER
BI-11-19034 (GCP’s)
BI-11-20034 (PWIS)
Rev. No. Date Revised Pages Revision Description
A 31-JUL-2022 NA Issued for Review / Approval
Page 3 of 19
METHOD OF No. Index Code Type No.
STATEMENT FOR 769 A CI PL A
INTERNAL & CI-769-PL-0039
EXTERNAL OIL WATER
TANK REPAIR
Jafurah Gas Compression Plants (Package-01)
INDEX
SR NO DESCRIPTION PAGE NO
1 PURPOSE 5
2 SCOPE 5
3 DEFINITIONS 5
4 ORDER OF PRECEDENCE 5
5 APPLICABLE CODES AND STANDARDS 5,6
6 OTHER REFERENCE 6
6 APPLICABLE PROCEDURE 6
7 REQUIRED EQUIPMENT AND TOOLS 7
8 RESPONSIBILITY 7-9
9 HEALTH, SAFETY & ENVIRONMENT 9-11

10 CONSTRUCTION METHODOLOGY 11-13
11 REPAIRING PROCEDURE 13-16
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1 PURPOSE
The purpose of this method statement is to define the requirements and execution methodology for
internal and external oily water holding tank concrete repair works at OWIS as per COMPANY
specifications for construction of JAFURAH GAS COMPRESSION PLANTS (GCPs) and PRODUCE WATER
INJECTION STATION (PWIS)
2 SCOPE
This procedure describes the methodology and steps for the concrete repair works to the project work
at project site for Jafurah Gas Compression Plants –Package 1.
3 DEFINITIONS
Company : Saudi Arabian Oil Company (Saudi Aramco).
SAPMT : Saudi Aramco Project Management Team.
Contractor : L&T Hydrocarbon Saudi Company.
SAPID : Saudi Aramco Project Inspection Division.
Work : All work and services to be performed by the Contractor.
Pursuant to the Contract.
4 ORDER OF PRECEDENCE
The order of precedence for drawings, specifications and standards for the FACILITIES shall be as
follows (As per Schedule B Attachment I Clause 1.5)
1) FACILITIES Specifications
2) Preliminary Design (Drawings and Reports)
3) Project Standard
In case of any conflict between ISO 9001 and Schedule “Q”, the requirements specified in Schedule
“Q” shall have precedence.
The effective standards cutoff date shall be May 24, 2019.
5 APPLICABLE CODES AND STANDARDS
The facilities will be designed to meet the requirements of Saudi Aramco Standards, International/
industry standards. The Saudi Aramco Engineering Standards (SAES), Saudi Aramco Engineering
Procedures (SAEP) and Saudi Aramco Material System Specifications (SAMSS) will be followed.
Saudi Aramco Standards & Feed Documents
SAEP-302 : Waiver of a Mandatory Saudi Aramco Engineering Requirements.

SAEP-385 : Preservation of Project Material & Equipment.
SAEP-1152 : Approval Procedure for Ready Mixed concrete Mix Design
SAER-580 : Concrete Repair Manual
SAEP-1150 : Inspection Coverage on Project
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SAES-Q-001 : Criteria for Design and Construction of Concrete Structure

SAES-Q-005 : Concrete Foundation
SAES-Q-012 : Criteria for Design and Construction of Precast and Preparation
Concrete Structure
SAES-Q-009 : Concrete Retaining Wall
SAES-M-100 : Saudi Aramco Building Standards
09-SAMSS-097 : Ready Mix Concrete
Schedule “Q”
6 OTHER REFERENCE
ISO 9001:2015 : Quality Management System

PIP STS03001 : Plain and Reinforced Concrete Specification
ASTM C136 : Sieve Analysis of Soil
ASTM D422 : Particle Size Analysis of Soil
ASTM D2922 : Standard Test Methods for Density of Soils and Soil-Aggregate in
Place by Nuclear Methods (Shallow Depth)
ASTM D4253 : Test Methods for Minimum Index Density of Soil Using a
Vibratory Table
ASTM D4254 : Minimum Index Density and Unit Weight of Soil and Calculation of
Relative Density
ASTM D4318 : Liquid Limit, Plastic Limit and Plasticity Index of Soil
American Concrete Institute (ACI)
ACI 228 : In-Place methods to Estimate the strength of concrete

ACI 308 : Guide to Curing of Concrete
ASTM C136 : Specifications for Structural Concrete
ACI 350.5 : Specification for Environmental Concrete
ACI 305 : Specification for Hot Weather Concreting
ACI 562 : Code Requirements for Evaluation, Repair, and Rehabilitation of
Concrete Building
ACI 224.1R : Causes, Evaluation and Repair of Cracks in concrete structures
ACI 546 R : Guide to Concrete Repair
7 APPLICABLE PROCEDURE
PROCEDURE NO. DESCRIPTION
QM-769-PL-2251 Project Quality Management Plan

QM-769-PL-2253 Non-conformance Procedure
QM-769-PL-2298 Procedure for Concrete Repairs
CI-099-PL-0021 Material handling, issuing and storage procedure
QM-769-PL-2311 Personnel Qualification procedure for Concrete Repair
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8 REQUIRED EQUIPMENT AND TOOLS
 Wire Brush
 Hammer and Chisel
 Applicable Trowel
 Air Compressor/Blower
 Chipping bit with hammer & Chisel
 Smoothing Floats
 Mixing container
 Drill and mixing paddle
 Other necessary hand tools
 PPE’s
9 RESPONSIBILITY
The following list comprises the minimum responsibilities for each designated person that will be involved
in this activity/procedure:
9.1 Construction Manager

The Construction Manager is in charge for all the works carried out at site and he is reporting to the
Project Manager. He is responsible for overall Work Production and completion of all the work
activities of this project. He liaison with all parties involved for the effective execution of project in
compliance with the safety and engineering procedures, standards, codes, and specifications.
Ensure implementation of Project Execution Plan and availability of resources well in advance. He
coordinates with client and leads the construction team. The Construction Manager is in charge of
construction site team and leads all discipline all discipline construction leads. He ensures that all
site works are achieved as planned ensuring compliance to safety and quality requirements
9.2 Construction Supervisor
Construction Engineer / Supervisor shall ensure that all works are carried out as per approved
drawings, project specifications & requirements. Construction Supervisor shall ensure that the work is
covered with valid work permits from Issuing authority, wherever applicable, and all permit/safety
requirements are strictly followed. He shall ensure conducting regular tool box talks explaining the
hazards associated with the work and the mitigation measures.
9.3 QC Manager :
QC Manager is reporting to QA Manger. He is overall responsible for implementing and ensuring

compliance of this procedure at site. He ensures that all resources required for implementing this
procedure are mobilized in time. He ensures that quality meeting is carried out prior to start of this
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work and team has understood the requirements. Evaluates the non-conformance reported by
supervisor/inspector and categorizes it to major / minor / moderate prior to submitting of NCR to QA
Manager. Upon rectification of non-conformities evaluates the relevant inspection record and
forward the compliance report to QA manager.
QC Manager is authorized to take actions on inspectors if inspectors have willfully violated the
requirements.
9.4 Quality Control Supervisor
QC Supervisor shall report to the QC Manager and shall be responsible for Implementation &
monitoring of Project Quality Plan requirements and assure compliance. He will do the Periodic
review of PQP for its adequacy and provide information to QC Manager He is responsible to
generate new work procedures, ITP & record forms at site for any additional activities identified / as
required and monitoring, revision, if necessary, of all contract’s specific procedures, work
instructions, ITPs. Ensure relevant reports / Documents are generated as per the procedure / ITP
and Check that approval of all necessary documentation has been obtained and the inspection
formats properly filled, signed off by concerned people. He will Co-ordinate with Company and Sub-
contractors and supervises all the inspection carried out by Inspectors and Technicians. He will
check daily inspection reports for correctness & completeness and ensure that inspection / testing
Equipment are with valid calibration. He is responsible for maintaining & update all quality related
records / documents at site. He has the overall control, supervision, & implementation of contract
quality & technical problems, resolution of quality problems and Prepare QA reports to include in
monthly Quality report.
9.5 Quality Control Inspector
QC Inspector shall report to the QC supervisor. He is responsible for Implementation and

supervision of related procedure. He will Check survey, lay out marking and civil materials and
review material test certificates. He will Check levels, width of trench and monitors excavation,
padding & backfilling. Report any Non-conformity to QC Supervisor / Manager
Co-ordinating with client inspector for inspections. Checking As built mark ups for correctness. Co-
ordinate with third party lab agencies and to raise request for inspection (RFI) after verification of
the activities involved are completed. They are responsible for the preparation and submittals of all
the QC records.
9.6 Safety Supervisor
The Safety Supervisor checks the risks/hazards for each particular activity and analyzes the
procedure in performing the works to be completed. To ensure compliance of all personnel for their
safety requirements by wearing proper Personal Protective Equipment (PPE), proper use of lifting
equipment (crane) & devices including the condition and proper setting, personnel qualification and
certificate, and the necessary work permit is available. The Safety Supervisor verifies the
installation of safety tools and abiding to the Safety Procedures. He checks areas for likely unsafe
conditions and coordinate with the Site Superintendent & Supervisors in ensuring that work is
carried out in compliance to the Project Safety Plan.
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9.7 Testing Laboratory Technician
The Laboratory Technician is the representative of the SAUDI ARAMCO approved Independent
Laboratory and shall be responsible for inspection and field testing, material sampling and related
laboratory works as required by specifications and in accordance with the approved International
Standards.
9.8 Concrete finisher
The duty of the concrete finisher is to prepare surfaces such as roads, curbs, floors, and sidewalks
by pouring, leveling, and smoothing concrete. He is responsible for Cutting expansion joints with a
power saw, aligning forms to required depth and pitch, directing concrete casting, prepping and
cleaning surface areas, and completing moldings with a variety of hand-held and power tool.
10 HEALTH, SAFETY & ENVIRONMENT
 Prior to commencing with any work on site, work permits to be obtained, wherever
applicable and available on site always.
 All safety precaution in line with Material safety data sheet to be followed.
 Vehicles to be maintained in good condition as per approve HSE procedure.
 Vehicles must have backup alarms, No set up work behind equipment operator.
 Make available of water, fluids and insulated tents/shelters or toilets for the employees in
close proximity to work location.
 Local law work hours to be complied especially with Midday break rules and Ramadan
month procedures as per government directives.
 Barricades, sign boards must be installed at the work site and at the temporary access
road
 Works shall be carried out according to Safe Construction Practices.
 All personnel involved in works shall be aware of Safety requirements of the project. The
site shall be kept clean and in tidy conditions.
 All access / exit points to work areas shall be maintained free from obstacles, materials,
and equipment.
 Vehicles and Equipment shall be inspected by authorized inspection personal.
 Contractor shall maintain good housekeeping at all the times.
 Equipment shall be inspected by approved third party agency for 3rd party certification.
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 Equipment’s lifting tools and tackles shall have the certification by third party and
operators shall have valid KSA / approved third party license.
 For excavation which shall not satisfy width and depth ratio shall be treated as Confined
Space, necessary Permit shall be obtained prior to work start.
 Use of ladders or stairs shall be used for access.
 Barricades should be placed approx. 1.0 m away from the edge of the excavation.
Excavated material should not be stocked less than 1.0 m from the end of the
excavation.
 Do not drive nearer than 3m around the excavation.
 Always wear mandatory PPE.
 Gas testing in regular intervals if required as specified by PTW, fire extinguisher should
be present during hot work at site all the time.
 Stop blocks to be fitted when tipping into excavation to prevent vehicles from falling in.
 Make sure that excavations do not undermine the footings or scaffolds or the
foundations of nearby buildings or walls.
 During the hours of darkness any excavations openings or obstructions near or on
roadways and walkways must be indicated by enough warning lamps and whether day
or night, barricaded and protected in accordance with the excavation procedure.
 Platforms, walkways, and pedestrian crossovers must be of sufficient width 90cm
minimum with handrail and toe boards.
 Mitigation measures identified in the job safety analysis shall be in place, prior to
commencement of works at site.
 Safety toolbox talks shall be carried out by the supervisor on daily basis prior to the start
of the job at all work locations, as per approved HSE Plan.
 Work Site Engineer/Supervisor shall be always available on site.
 Certified first aider shall be always available on site.
 Plastic bags or food packets/cans shall never be thrown around but shall be contained in
appropriate skips, placed at work locations.
 Wastes segregation at source to be practised. Disposal records to be maintained.
 Daily check shall be carried out for exposed trench sections, and it shall be ensured that
proper barricade and warning signs are in place.
 List of emergency contact telephone numbers shall be displayed to all site locations.
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 All work shall be stopped in case of any incident, and it shall be reported to HSE
Manager, Project Manager, Construction Manager and COMPANY immediately. Work
shall proceed only after investigation & corrective actions are in place to the satisfaction
of COMPANY.
 HSE Engineer / Manager shall conduct periodical audit and report to the project
manager for corrective actions.
 Prior approval shall be obtained from COMPANY, if works are to proceed beyond the
normal working hours.
 Emergency Response Plan is to be made available at site. In case of emergency for
communication with workforce emergency siren / whistle shall be used.
 Job Performer shall be responsible for supervising all work archives at location. If Job
Performer has to leave work location all work must be stopped in accordance to PTW
requirement.
11 CONSTRUCTION METHODOLOGY
11.1 General
 Company Approved Material shall be used for repair works
 Mock up training to be conducted and qualified repair personnel shall perform repair
works
 Material shall be stored as per manufacturer recommendation and in line with CI-099-
PL-0021 Material handling, issuing and storage procedure
11.2 Repair Material & Mortars.
 a repair system essentially consists of four components, namely repair mortar, bond coat,
steel primer and surface coating. Each of these components influence the properties of the
total repair system. Incompatibility, either physical, thermal or chemical, between the repair
component of repair system.
 There are many repairs mortar are available. Some important characteristics of a repair
mortar are good bond to substrate, movement characteristic compatible with substance, low
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permeability, alkali passivation of rebar, structural strength, durability of freeze and weather,
and easy application.
 Service type of repair mortars, such as cementitious mortars, resin-based repair mortars,
and polymer modified cementitious mortars are available for repair work particularly patch
work.
11.2 Cementitious repair mortars.
 The deterioration reinforced concrete should be repaired with impermeable alkaline cement-
based materials closely material in properties to the parent concrete.
 Cementitious mortar or resin mortar and they have thermal expansion and movement
characteristic more characteristic more compatibility with the concrete substances however
the resin-based mortar are preferred in area subjective to chemical attach, when thin section
have to be applied or a rapid strength gain in required. Sometime chemical mortar are
modified by the additional or additives, such as silica fume or polymer, to improve the
properties.
11.3 Polymer Modified Cementitious Mortars.
Polymer latexes are often added to cement mortars. Such mortars afford the same alkaline
passivation protection of the steel as conventional cementitious materials and can readily be
placed in a single application at 12 to 15 mm thickness that gives adequate protective cover.
The polymer latex acts in several ways:
(a) It functions as a water reducing plasticizer, producing a mortar with good workability and
lower shrinkage at lower water/cement ratios.
(b) It improves the bond between the repair mortar and the concrete being repaired,
providing, of course, that they are applied and used properly.
(c) It reduces the permeability of the repair mortar to water, carbon dioxide, and oils, and it
also increases its resistance to some chemicals.
(d) It acts, to some degree, as an integral curing aid; but in drying conditions, very careful
curing is still essential.
11.4 Resin-Based Repair Mortars.

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Unlike cement-based repair mortars, whose high alkalinity helps prevent reinforcement corrosion by
passivation, resin mortars provide protection by encapsulating the steel reinforcement with an
impermeable 'macro' coating which exhibits excellent adhesion to both the steel and the concrete
substrate. This protective mortar/coating will give good long-term protection to the steel at a
thickness far less than is possible with the cementitious repair materials. Epoxy resin mortars are
most widely used in concrete repairs. Polyester resin and acrylic resin-based mortars are also used
generally for patch repairs where very rapid development of strength is required. Polyester and
acrylic mortars with high elastic modulus and rigidity are not suitable for larger repairs because of
dangers of shrinkage and subsequent cracking or debonding. However, those with low elastic
modulus are capable of absorbing these stresses and have been used to a limited extent in rapid
setting repair mortars. Epoxy resin mortars are also available which can give excellent handling and
curing characteristics at high ambient temperatures. Mortar systems based on lightweight fillers are
available which can be applied up to 30 mm thickness in a single layer on soffits and vertical faces
without problems
11.5 Sprayed Concrete.
Sprayed concrete is a mixture of cement, aggregate and water projected at high velocity from a
nozzle into place against an existing structure or formwork where it is consolidated by its velocity to
produce a dense homogenous mass. Sprayed concrete is placed either by the dry or wet process.
Unite and shotcrete are variously used to refer, respectively, to sprayed concrete where the
aggregate is less than 10 mm, and 10 mm and upwards maximum size. They also apply
respectively to dry process and wet process sprayed concrete.
11.6 Injection Grout.
Cracks in reinforced concrete greater than approximately 0.3 mm require sealing/injection to

prevent ingress of moisture, oxygen, carbon dioxide, chloride and sulphate and other corrosive
chemicals, or to protect the integrity of the structure. Cracks wider than about 1 mm in the upper
surfaces of slabs etc. can often be sealed by brushing dry cement followed, if necessary, by light
spraying with water. For cracks wider than about 2 mm it may be preferable to use a cement and
water grout.
Low-viscosity liquid polymers can be used in a similar way to cement grout. Some of these
materials will penetrate cracks down to about 0.1 mm width but, in general, the repair will not be
structural. It will seldom be necessary to seal cracks narrower than this. When it is necessary to
ensure, as far as possible, that the sealant penetrates to the full depth of a crack, injection of
polymer grout under pressure is the method most commonly used.
12 REPAIRING PROCEDURES
➢Internal surface of concrete walls for tanks
As the internal concrete walls of water-retaining structures will be subjected to water pressure on a
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continuous basis, Master Builders recommend using epoxy-based mortars Master Brace ADH 2200
for thickness ranging from 0-5mm and Masteremaco S488 or for thicknesses> 10mm. mortars are
specifically designed for vertical and overhead applications. They exhibit excellent chemical and
mechanical resistance and form an impervious layer thereby providing all round protection to
concrete and rebar.
Application Guidelines for MasterBrace ADH 2200 (0-5mm thickness)
Master Brace ADH 2200 is a solvent free, non-slumping, fast-curing, epoxy-based repair mortar.
suitable for bedding, gap filling and concrete repair applications. It is resistant to oils, greases,
petroleum, salts, many acids and alkalis, and other aggressive media usually encountered in water
retaining structures.
Substrate preparation
➢ The concrete surface to be repaired should be dry, and free dust, loose concrete and curing
compound or any other contaminant that could impair adhesion.
➢ Cement laitance shall be removed by wire brushing, chipping, or light grinding.
Application
➢ Mix base (Part-A) and reactor (Part-B) components of Master Brace ADH 2200 for 2-3 minutes
until we get a uniform streak free colour and good mortar consistency.
➢ The epoxy mortar (Master Brace ADH 2200) shall be applied on the prepared surface thoroughly
using a steel trowel.
➢ Master Brace ADH 2200 shall be pressed well into the surface and compacted to ensure positive
and permanent adhesion.
➢ Use a steel trowel to finish to the desired level.
Note:
Master Brace ADH 2200 is a self-curing mortar and requires only 24 hours of self-curing prior to
overcoating with approved protective coatings.
Application Guidelines for Master Emaco S 488 (10-50mm thickness)
Master Emaco S 488 is a cementitious prebagged ready-to-use structural repair mortar in powder
form. When mixed with the correct amount of water, it produces a thixotropic, high strength repair
mortar, reinforced with acrylic polymer fibres. It possesses excellent bond characteristics to steel
reinforcement and to concrete It has low permeability and is extremely durable making it highly
suitable for repairs in marine environments.
➢ The concrete surface to be repaired should be dry, and free dust, loose concrete and curing
compound or any other contaminant that could impair adhesion.
➢ Cement laitance shall be removed by wire brushing, chipping or scabbling.
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➢ The edges of all repairs shall be cut by angle grinder or similar to produce a regular profile with a
minimum depth of 10mm. No feather edges can be expected in such repair works.
➢ Where the removal of damaged concrete exposes the steel, further breaking out to expose the
full circumference of the steel is essential. A minimum of 20mm behind the steel is required
➢ Apply epoxy-based bonding agent Master Brace ADH 1414 on the prepared concrete surface.
When Master Brace ADH 1414 is used as a bonding agent, it prevents migration of chloride or
sulphate soluble salts.
Application
➢ Pour the required amount of mixing water into the mixing drum. Start the mixer and add the
MasterEmaco S 488 powder rapidly and continuously. Mix for 3 to 4 minutes after all the powder
has been added until mortar is homogeneous and lump free.
➢ Apply Master Emaco S 488 on the prepared surface whilst the bonding agent MasterBrace ADH
1414 is still tacky. (2-8 hours).
➢ Master Emaco S 488 can be applied via hand, spatula, or trowel.
Note:
1. Master Emaco S 488 shall be cured for a minimum of 7 days using water curing or suitable curing
compound. The applied repair mortar (Master Emaco S 488) can be coated after a minimum of 14
days.
2. MasterEmaco S 488 can be suitably applied in thicknesses up to 50mm in one layer on vertical
applications.
3. In case of higher thicknesses (>50mm) install multiple layers of MasterEmaco S 488.
Cracks and cold joints on wall
➢ Internal surface of concrete walls
As the internal concrete walls of Water tanks structures will be subjected to water continuous basis,
Master Builders recommend using a low viscosity epoxy-based crack injection resin _Master Inject
1315for deep static cracks.
Surface cracks/ non penetrated cracks shall be filled using Master Brace ADH 2200.
Application Guidelines for MasterBrace ADH 2200 (for non-penetrated cracks)
Master Brace ADH 2200 is a solvent free, non-slumping, fast curing, epoxy-based repair mortar
suitable for bedding, gap filling and concrete repair applications. It is resistant to oils, greases,
petroleum, salts, many acids and alkalis, and other aggressive media usually encountered in water-
retaining structures.
➢ Chase the crack using a chisel to make V shape the cracks at the surface or use an angle
grinder to open the crack.
➢ Wire brush the crack, then blow dust and debris from the crack.
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➢ All loose particles, laitance, dust, and grease etc.; must be removed prior to application of Master
Brace ADH 2200.
Application
➢ Mix base (Part-A) and reactor (Part-B) components of Master Brace ADH 2200 for 2-3 minutes
until we get a uniform streak free colour and good mortar consistency.
➢ Using a spatula or putty knife apply Master Brace ADH 2200 into the routed-out crack, forcing the
material into the concrete surface.
➢ Smooth off the surface with the spatula or putty knife.
➢ To fill blow holes etc. in concrete prior to overcoating, tightly trowel the prepared surface with
Master Brace ADH 2200.
➢ Master Brace ADH 2200 shall be pressed well into the surface and compacted to ensure positive
and permanent adhesion.
Note:
Master Brace ADH 2200 is a self-curing mortar and requires only 24 hours of self-curing prior to
overcoating with approved protective coatings.
Tie-rod holes filling on concrete walls
Tie rod holes shall be filled by using with the combination of Master Flow 544 and Master Brace
ADH 2200.
Application Guidelines
➢ Remove the PVC conduit (if possible) from the tie rod hole using a pointed chisel.
➢ The cone shaped surfaces shall be roughened using a pointed chisel.
➢ Once the preparations completed, clean the surface using clean/ potable water.
Application
➢ Fill the tie-rod sleeve holes with Master flow 544. A steel rebar (with smaller diameter than tie rod
hole) or wooden rod shall be used to ensure the complete filling of the tie rod holes inside the
concrete wall.
➢ Mixing: First dry mix contents of bag, then thoroughly mix with the specified amount of water. The
specified amount of water (4. 0 Lit / 25kg)
➢ Application of Master flow 544 shall be continued on the cone shaped surface leaving 1 to 2 mm
below concrete level. Leave 7 days for self-curing.
➢ Once the Master flow 544 is cured, apply Master Brace ADH 2200 over the cured Master Flow
544 to fill the remaining 1 to 2 mm depth. Please ensure the application of Master Brace ADH 2200
overlaps 5 CM on the concrete surface around the cone shaped surface. This is to eliminate any
water seepage through the tie rod holes.
➢ Allow minimum 7days curing prior to the application of protective coating.
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Note: After finish all repairs for internal tanks should start to fill tank by water 1m height per day to start leak
test for tank.
In case any leakage appears in external walls we will use injection system Master inject 1335 &Master
Inject 1320
Injection system Masterinject 1335 & Masterinject 1320
The specification for the pressure grouting works involves identification of leakages and
rectification/ arresting leakages to the fullest satisfaction of the customer, consultant, and client.
Surface Preparation:
➢ Attention to the full and proper preparation of the substrate is essential for complete repair
adhesion.
➢ If water permits, clean the surface adjacent to the cracks and remove all traces of dust, oil, paint,
curing compounds, grease, corrosion deposits, algae, or any unsound material.
➢ The surface should be preferably prepared by using an air blower and sandpaper if water
permits.
Application of Masterinject 1335
➢ Identify and Mark the leakage location.

➢ Drill the hole to accommodate the injection plug/ packer. The diameter of the hole shall be as per
injection packer size.
Packer for injection
➢ Clean the hole with an air blower.

➢ Injection packers should be inserted into the pre-drilled holes at intervals along the length of the
crack. The distance between each packer shall depend on the length and width of the crack.
Spacing normally would be between 100 mm-500 mm.
➢ Packer shall be inserted along the crack/ 45 Deg to the crack or as per suit to site condition.
➢ If practical, seal the surface of the cracks between the packers with a band of Master brace adh
2200 , 30 to 40 mm wide and 2 to 3 mm thick. Both sides of the cracks which lead through a wall or
slab shall be sealed this way. If the water flow is severing the Master brace adh 2200 application
can be omitted.
Mixing
➢ The accelerator/ hardener and the base resin should be thoroughly mixed manually and placed
in a closed container. While mixing, care should be taken to exclude moisture as much as possible.
➢ Master inject 1335 should be injected using standard injection equipment.
➢ One end of the injection hose shall be attached to the lowest packer on vertical cracks or to
either end of horizontal cracks.
Page 17 of 19
EXTERNAL OIL WATER
TANK REPAIR
➢ Pressure shall be slowly applied by gently squeezing the gun trigger until resin stops flowing or
starts to flow out of the joint or next packer.
➢ Pressure shall be removed from the gun and injection shall continue on to the next
location/packer.
➢ Each crack shall be treated in a signal continuous operation and sufficient material shall there
fore be made prior to the commencement of the work.
➢ Observe for few hours, if need re-inject Master inject 1335. If leakage is under control/arrest,
continue with the application of Master inject 1320.
➢ Clean the injection machine and accessories with thinner.
Application of Master inject 1320
➢ After running water under control by applying Master inject 1335

➢ Master inject 1320 should be injected through a pre-inserted plug/ packer using standard
injection equipment having closed containers.
Mixing
The accelerator/hardener and the base resin should be thoroughly mixed manually and placed in a closed
container. While mixing, care should be taken to exclude moisture as much as possible.
Each crack shall be treated in a signal continuous operation and sufficient material shall therefore be made
prior to the commencement of the work. One end of the injection hose shall be attached to the lowest
packer on vertical cracks or to either end of horizontal cracks.
Pressure shall be slowly applied by gently squeezing the gun trigger until resin stops flowing or starts to
flow out of the joint or next packer.
Pressure shall be removed from the gun and injection shall continue on to the next location/packer.
Continue as above at all injection points and then allow curing for at least 6 hours.
Injection packers shall be removed, and the concrete surface shall be cleaned using a wire brush.
Clean the injection machine and accessories with thinner.
Repairing of drilled hole:
➢ Remove the projected part of the injection plug/packer by suitable means.

➢ Clean the loose particle and MASTER EMACO deposition from the concrete surface.
Stages of Application repairing and coating system
1. The area to be repaired should be marked on on the structure, and subject to revision based on
conditions found as breaking out proceeds.
2. The edges of all repairs area shall be cut by angle grinder to produce a regular profile with a minimum
depth of 20mm. No feather edges will be accepted in any repair work.
All contaminated, decayed and spalled grout/concrete shall be broken out using pointed mechanical
chisels. The use of blunt scrabbling hammers which can fracture aggregate, but leave it in place, is not
permitted.
3. The prepared surface shall be sound, dense, free of all oil, grease, loose and fractured aggregate, or
other contaminants that could impair adhesion.
Page 18 of 19
EXTERNAL OIL WATER
TANK REPAIR
4. Using a short haired brush Master Brace ADH 1414 shall be applied to the prepared surface ensuring
total coverage of the substrate and paying special attention to the saw cut edges of the parent concrete.
5. Master Emaco S488 shall be used in trowel application for small and local repair area.
6. Remove from Tie rod the plastic area in 5 cm depth and inject using Master Flow 544.
7. Surface preparation using hand grinder with diamond disk to remove all lose concrete.
8. Hair cracks repair: opening all hair cracks using cutting disk by grinder and opening in V shape.
9. Clean the crack and fill using Epoxy Putty Master Brace A DH 2200.
10. Repair all pinholes using Master Brace A DH 2200.
11. Follow the leak test procedure for the Tank.
12. In case any leakage appears in the surface start to use injection system Master inject 1335 and
Masterinject 1320.
13. After inspection of leak test that we don’t have any leakage from any points in the tank.
14. Remove all water from the tank and sanding all the surface using hand grinder.
15. Apply approved protective coating system.
.
➢ External surface of concrete walls

As the external surface of concrete walls of water-retaining structures will be follow method of statement of
Master seal 550 application.
Enclosed
➢ Technical datasheets
Page 19 of 19

Method of Statement For Internal External Oil Water Tanks Repairing and Coating System

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Method of Statement For Internal External Oil Water Tanks Repairing and Coating System

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CONTRACT No.: 6600050508 (IK)

DOCUMENT REVIEW STATUS

FIRST SUBMISSION ☐ APPROVED

☐ REJECTED. REVISE AND RESUBMIT

METHOD OF STATEMENT FOR INTERNAL & EXTERNAL OIL WATER

Rev. No. Date Revised Pages Revision Description

A 31-JUL-2022 NA Issued for Review / Approval

5 APPLICABLE CODES AND STANDARDS 5,6

7 REQUIRED EQUIPMENT AND TOOLS 7

9 HEALTH, SAFETY & ENVIRONMENT 9-11

5 APPLICABLE CODES AND STANDARDS

Saudi Aramco Standards & Feed Documents

SAEP-302 : Waiver of a Mandatory Saudi Aramco Engineering Requirements.

SAES-Q-001 : Criteria for Design and Construction of Concrete Structure

ISO 9001:2015 : Quality Management System

American Concrete Institute (ACI)

ACI 228 : In-Place methods to Estimate the strength of concrete

PROCEDURE NO. DESCRIPTION

QM-769-PL-2251 Project Quality Management Plan

8 REQUIRED EQUIPMENT AND TOOLS

9.1 Construction Manager

QC Manager is reporting to QA Manger. He is overall responsible for implementing and ensuring

9.4 Quality Control Supervisor

QC Inspector shall report to the QC supervisor. He is responsible for Implementation and

9.7 Testing Laboratory Technician

9.8 Concrete finisher

10 HEALTH, SAFETY & ENVIRONMENT

11.2 Repair Material & Mortars.

11.2 Cementitious repair mortars.

11.3 Polymer Modified Cementitious Mortars.

11.4 Resin-Based Repair Mortars.

11.5 Sprayed Concrete.

11.6 Injection Grout.

Cracks in reinforced concrete greater than approximately 0.3 mm require sealing/injection to

➢Internal surface of concrete walls for tanks

Application Guidelines for MasterBrace ADH 2200 (0-5mm thickness)

Cracks and cold joints on wall

➢ Internal surface of concrete walls

Application Guidelines for MasterBrace ADH 2200 (for non-penetrated cracks)

Tie-rod holes filling on concrete walls

Injection system Masterinject 1335 & Masterinject 1320

Application of Masterinject 1335

➢ Identify and Mark the leakage location.

Packer for injection

➢ Clean the hole with an air blower.

Application of Master inject 1320

➢ After running water under control by applying Master inject 1335

Repairing of drilled hole:

➢ Remove the projected part of the injection plug/packer by suitable means.

Stages of Application repairing and coating system

➢ External surface of concrete walls

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