PROJECT / UNIT

Khurais Area Facilities Expansion & Satellite GOSP JOB

Project 032184

PLANT LOCATION
Doc. No. 000-ZA-E-T09410
Khurais– SAUDI ARABIA
General Method Statement for Concrete
Rev. A 15-FEB-18
Protective Coating for Immersion Service APCS-3

GENERAL METHOD STATEMENT for

Concrete Protective Coating for Immersion Service APCS-3

CONTRACTOR review result 1: Approved

by 2: Approved with comments
3: Rejected

Department Date Name Signature

Technical Discipline 1 2 3
Field Engineering Dept. 1 2 3
HSE Dept. 1 2 3
QA/QC Dept. 1 2 3

1: Approved
2: Approved with comments
CONTRACTOR review result 3: Rejected
by Date Name Signature
1 2 3

REV DATE Prepared Checked Checked Approved Approved

Jaycy Yutuc Readolf Fedelin Rubenel Javier Ahmad Shibi Abdullah Hani
A 15-Feb-18
QCDC HSE Mngr. QC Mngr Const.Mngr. Proj. Dir.

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 PROJECT / UNIT
Khurais Area Facilities Expansion & Satellite GOSP JOB
Project 032184

PLANT LOCATION
Doc. No. 000-ZA-E-T09410
Khurais– SAUDI ARABIA
General Method Statement for Concrete
Rev. A 15-FEB-18
Protective Coating for Immersion Service APCS-3

General Method Statement for

Concrete Protective Coating for Immersion Service APCS-3

Issued for Jaycy Yutuc Readolf Fedelin Rubenel Javier Ahmad Shibi Abdullah Hani
A 15-Feb-18
Review QCDC HSE Mngr. QC Mngr Const.Mngr. Proj. Dir.
Rev Description Prepared Checked Checked Approved Approved Date

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 PROJECT / UNIT
Khurais Area Facilities Expansion & Satellite GOSP JOB
Project 032184

PLANT LOCATION
Doc. No. 000-ZA-E-T09410
Khurais– SAUDI ARABIA
General Method Statement for Concrete
Rev. A 15-FEB-18
Protective Coating for Immersion Service APCS-3

Table of Contents

1. PURPOSE-------------------------------------------------------------------------------------------------- 4

2. SCOPE------------------------------------------------------------------------------------------------------ 4

3. DEFINITIONS & ABBREVIATION--------------------------------------------------------------------- 4

4. REFERENCES DOCUMENTS/ DRAWINGS----------------------------------------------------------- 4

5. GENERAL REQUIREMENTS----------------------------------------------------------------------------- 4

6. METHODOLOGY I WORK EXECUTION PROCEDURE--------------------------------------------- 5

7. RESPONSIBILITY------------------------------------------------------------------------------------------ 7

8. LIST OF EQUIPMENT------------------------------------------------------------------------------------ 8

9. QA/QC DOCUMENTATION---------------------------------------------------------------------------- 8

10. APPLICABLE JOB SAFETY ANALYSIS----------------------------------------------------------------- 8

11. ATTACHMENTS------------------------------------------------------------------------------------------- 10

JSA – Job Safety Analysis

IFC – Issued for Construction Drawing (Plot Plan) Sub-Contractor GECAT Scope of
Works

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 PROJECT / UNIT
Khurais Area Facilities Expansion & Satellite GOSP JOB
Project 032184

PLANT LOCATION
Doc. No. 000-ZA-E-T09410
Khurais– SAUDI ARABIA
General Method Statement for Concrete
Rev. A 15-FEB-18
Protective Coating for Immersion Service APCS-3

1. PROJECT DESCRIPTION

This method statement describes the usage and installation of concrete protective coating for
Immersion Service with Coal Tar Epoxy Coating System APCS-3

2. SCOPE

This method statement covers concrete protective coating for Immersion Service with Coal Tar
Epoxy Coating System APCS-3

3. DEFINITION & ABBREVIATION

COMPANY/OWNER: SAUDI ARABIAN OIL COMPANY ("SAUDI ARAMCO"),

CONTRACTOR: SAIPEM
Sub-Contractor: GECAT Limited Company
Method statement: A written document that explains the procedure &execution of work.
IFC: - Issued for Construction Drawings.
PTS: - Project Technical Specification.

4. REFERENCE DOCUMENTS/DRAWINGS

 Gl 2.100, Work Permit System

 SAES-Q-001 Criteria for Design and Construction of Concrete Structures
 SAES-H-003 Protective Coatings for Industrial Concrete Structures
 SAES-H-001 Coating Selection and Application Requirements for Industrial Plants and
Equipment
 SAES-H-101 V Approved Saudi Aramco Data Sheets-Paintings & Coatings
 SAES-H-102 Safety Requirements for Coating Application
 SAEP 316 Performance Qualification Requirement of coating personal
 Material Manufacture's Technical Data
 Construction Safety Manual (CSM)

5. GENERAL REQUIRMENTS

 All surfaces shall be sound, free of grease, oil and any imperfection or any other major
defects. All defects shall be repaired prior applying any paint material.

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 PROJECT / UNIT
Khurais Area Facilities Expansion & Satellite GOSP JOB
Project 032184

PLANT LOCATION
Doc. No. 000-ZA-E-T09410
Khurais– SAUDI ARABIA
General Method Statement for Concrete
Rev. A 15-FEB-18
Protective Coating for Immersion Service APCS-3

 Not suitable for use in direct sunlight

 Suitable for internal painting for below items in Khurais GOSP

6. METHODOLOGY I WORK EXECUTION PROCEDURE

6.1 CONCRETE SURFACE PREPARATION

 Work permits shall be secured prior to commencement of concrete protective

coating for atmospheric service with epoxy primer under APCS-3
 Scour the surface to remove any protrusions and sharp edges by using an abrasive
brick (Carborundum), power grinding, or power brushing. Check the overall surface
soundness by pocked knife across the surface.
 The purpose of surface preparation is to remove laitance, contaminants and others
adhered compounds on the concrete like the curing agents, and to create an
anchoring for coating to be well adhered with the concrete structures.
 Concrete surface shall be prepared for coating after they are adequately cured. The
surface preparation methods of concrete structure can be done by mechanical
cleaning, abrasive blasting, acid etching and water jetting.
 Concrete surface preparation prior to coating application shall include but not
limited to: Repair of cracks, spalls, pop outs, and other irregularities, removal of
surface contaminants that inhibit coating adhesion or induce early coating
deterioration, smoothen the Rough surfaces to improve coating adhesion, and
eliminating and weak surface layers to establish the strong base required for many
coating system.
 After cleaning is completed ensure that surfaces are free of voids which may be
exposed or enlarged during blasting process. Repair the voids if necessary.
 Cracks less than 10mm wide and holes not exceeding 10 mm in diameter shall be
filled using an Approved Epoxy Base material putty/before applying primer I sealer
to the surface.
 Expansion and construction joints shall be cleaned and masked off prior to coating.
When coating application is completed, remove the masking tape for further civil
works by others.
 All voids shall be prepared, primed and filled using the approved suitable and
compatible repairing material.

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 PROJECT / UNIT
Khurais Area Facilities Expansion & Satellite GOSP JOB
Project 032184

PLANT LOCATION
Doc. No. 000-ZA-E-T09410
Khurais– SAUDI ARABIA
General Method Statement for Concrete
Rev. A 15-FEB-18
Protective Coating for Immersion Service APCS-3

 For major repair like (honeycomb-deep cracks exceed 10 mm width) chipping,

cleaning, soaking with water ,and fill with the approved non-shrinkage grouting
material.

6.2 PROTECTIVE COATING APPLICATION

Painting material shall be as per SAES-H-101V APCS-3

 All detailing of the work system shall be carried out in accordance with the
manufactures requirements, and as per the drawing for the project.
 Material receiving shall be done with proper documents, only inspected and
approved batch material shall be used for execution purpose.
 The coating shall be applied after the full curing time of concrete in accordance to
SAES-Q-001. New concrete must have a moisture content of 4% or less before the
coating applications commence.
 The coating personnel shall have on site, all times, the necessary proper calibrated
and maintained testing and inspection instrument, which are available to conduct
test and surveillance of the work.
 Spray/application equipment shall be designed to accurately ratio and apply
specified protective coating materials and shall be properly maintained in proper
working condition.
 Prior to the coating application, dew point and relative humidity shall be measured,
reading shall be every 4 hours. The work shall not proceed if the substrate
temperature shall be less than 3 deg C (5 deg F) above dew point.
 Spray coating shall not be carried out if, adverse weather conditions exist such as,
but not restricted to, the following:
 Wind is strong enough to blow sand, salt spray, or other foreign matter onto
the surface being coated.
 Wind is strong enough to cause dry spray or to otherwise seriously disturb
the spray pattern when application is by spray gun.

 Only SAEP 316 approved applicator will be allowed to perform coating application.
 The protective coating shall be applied directly after the concrete surface
preparation.
 Epoxy coating material shall be applied with uniform appearance and no visible
holes. Dry Film thickness will meet the requirement of SAES-H-101, APCS-3.

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 PROJECT / UNIT
Khurais Area Facilities Expansion & Satellite GOSP JOB
Project 032184

PLANT LOCATION
Doc. No. 000-ZA-E-T09410
Khurais– SAUDI ARABIA
General Method Statement for Concrete
Rev. A 15-FEB-18
Protective Coating for Immersion Service APCS-3

 Protective Coating shall be applied in accordance to the Approved Manufacturer

Instructions and Requirements.
 Health & safety hazards and its mitigation, disposal of the material shall be in
accordance with the attached manufacturer recommendation.

6.3 TOUCH UP AND REPAIR

 Touch up less than 0.1 m2 shall be carried out in accordance to Approved

Manufacturer Instructions and Requirements.
 In case of any repair other than touch up or inadequate coating thickness the
coating shall be removed completely by means of grinding or compatible approved
chemicals.
 The concrete surface shall be prepared and again inspected prior to the application
of concrete Protective coating.

7. RESPONSIBILITY

Project Manager

Project Manager will be responsible For the Overall implementation and monitoring of all
activities in the method of statement for CONCRETE PROTECTIVE COATING

Site Manager

Site Manager will be responsible for the overall direction, monitoring coordination and control
of all the construction activities attached and related to the CONCRETE PROTECTIVE COATING
and overall health and safety standards and procedures.

Site Engineer

Site Engineer will be responsible for the overall implementation and monitoring of all the
activities involved in CONCRETE PROTECTIVE COAINTG including safety measures and mitigation
from his work place. Application for work permits if required prior to commence of any
demolition.

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 PROJECT / UNIT
Khurais Area Facilities Expansion & Satellite GOSP JOB
Project 032184

PLANT LOCATION
Doc. No. 000-ZA-E-T09410
Khurais– SAUDI ARABIA
General Method Statement for Concrete
Rev. A 15-FEB-18
Protective Coating for Immersion Service APCS-3

Supervisor/Foremen

Supervisor/Foremen will be responsible:

 Having knowledge and direction of work's activities and planning at site, and directly
imparted people to do what is the best way to achieve the assigned task.
 Conduct safety briefing prior to commence daily activities and give information and
guidance to newly hired workers.
 Report any incident, accident, unsafe condition and defects in equipment to
immediate superiors.
 Incorporate safety procedures in routine tasks and see that they are obeyed.
 Set a personal example to his people

HSE Officer/Supervisor

Safety Officer/Supervisor will be responsible:

 Review prior to the start of the work Safe Work Plan and work permit
 To implement daily and specific safety program at the work place and ensure all
working activities comply with the established safety rules, regulations and
procedures as safe working practices.
 To provide instructions on task and responsibility for safe and correct working
practices and tool box talk
 Any near miss accidents or incidents should be immediately reported to the Site
manager or project manager and submitting the report recommending actions to be
taken to prevent recurrence.

8. LIST OF EQUIPMENTS

• Air compressor
• Air blower
• Angle grinder( with Buffing wheel)
• Generator
• Electric drill with paddle mixer
• Roller Brush
• Wire Brush
• Scraper
• Filling Knife
• Sand paper 80-100-120
• Cleaning Cloth

9. QA/QC DOCUMENTATION

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 PROJECT / UNIT
Khurais Area Facilities Expansion & Satellite GOSP JOB
Project 032184

PLANT LOCATION
Doc. No. 000-ZA-E-T09410
Khurais– SAUDI ARABIA
General Method Statement for Concrete
Rev. A 15-FEB-18
Protective Coating for Immersion Service APCS-3

All activities will be inspected and certified per SAIC-H-1003 Rev 8 Concrete Coatings Pre-
installation and Final Inspections

10. APPLICABLE JOB SAFETY ANALYSIS

10.1 JSA for Transportation of People inside KHCPF

10.2 JSA for Loading & Unloading Material
10.3 JSA for CONCRETE REPAIR
10.4 JSA for GRINDING
10.5 JSA for CONCRETE PROTECTIVE COATING
10.6 GAP Analysis (to decide if any specific JSA required)
10.7 Safety Requirements

 All the work force must undergo Saipem and Aramco safety induction before
commencement of their work.
 Approved work procedure must be fully understood by working personnel on
site. Copy of work procedure must always be available when needed.
 Work permit must issue prior to start the activity and made available at all
times. All requirements safety precautions and requirements must be put in
place prior to start the activity.
 All personnel at site shall wear appropriate PPE, hard hat, safety shoes, eye
protection, hand gloves and other types of PPE applicable to their specific work.
 Perimeters of work area(s) will be safety taped or barricaded; only authorized
personnel will be allowed access.
 Aramco certified Work Permit Receiver shall be engaged for the permit works.
 Original PTW, Method Statement and Risk Assessment and/ or JSA shall be
displayed at worksite in visible locations.
 Tool Box Meetings shall be conducted and the JSA must be discussed before
starting any activity, or if there are new crew members have joined the team.
Supervisor must ensure the JSA is property understood by all member of the
working crew.
 Gas testing shall be done before starting the work and in regular intervals as
tested in PTW.

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 PROJECT / UNIT
Khurais Area Facilities Expansion & Satellite GOSP JOB
Project 032184

PLANT LOCATION
Doc. No. 000-ZA-E-T09410
Khurais– SAUDI ARABIA
General Method Statement for Concrete
Rev. A 15-FEB-18
Protective Coating for Immersion Service APCS-3

 Appropriate firefighting equipment such as fire extinguisher and fire blankets

are inspected and are made available at all times. Trained fire watch are
stationed at all times.
 All electrical equipment, lifting tools and tackles, etc., shall be inspected, tagged
and coloured code every month.
 After completion of work, Permit shall be handed over to MIS Aramco/ MIS
Saipem with necessary documentation.
 Maintain the necessary standards of cleanliness and tidiness within the
workplace.

 Site Safety Representative shall be present at the job site at all times while
personnel are working.
 Safety Officers shall be assigned to monitor safety condition of the work area,
and are authorized to stop any activities if the conditions at the site changed
such that to continue working would be unsafe.
 No mechanical excavation where U/G utilities is close to less than 3m, only
manual excavation is permitted.
 Heat stress protection.
 Rest shelter shall be provided in designated area.
 Cooling water shall be provided in the cooling water cans.
 Cooling water cans shall be placed in the easy accessible location to all.
 Heat stress protection shall be inducted in the tool box meeting regularly.
 Heat index shall be displaced visible area to understand the requirement of
precaution measure as per Aramco standard.

11. ATTACHMENTS

 JSA – Job Safety Analysis

 IFC – Issued for Construction Drawing (Plot Plan)

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