ENVIRONMENTAL MANAGEMENT SYSTEM MANUAL

1. General

1.1. Company Profile

(Provide general background information on COMPANY NAME. Describe the nature and products / services of COMPANY NAME’s business)

1.2. Purpose of this Manual

This Manual defines the Environmental Management System (EMS) of COMPANY NAME’s activities and contains:

• The Environmental Policy;
• Statements of responsibility and authority;
• An overview of the company’s environmental procedures and controls;
• The identification of the resources and training allocated to management, performance of work and verification activities including internal audit;
• The appointment of the Environmental Management Representative (EMR); and
• The arrangement for periodic management reviews

The purpose of this Manual is to demonstrate that this EMS meets all ISO 14001:2004 requirements and provide guidance and direction for the implementation and operation of the EMS to all personnel including all relevant documents.

1.3. Scope of EMS

The scope of the EMS applies to the (BUSINESS ACTIVITIES) related to the (PRODUCTS / SERVICES) provided / undertaken by COMPANY NAME. Also the locations and areas to be covered in the EMS.

2. Policy

Environmental Policy (Briefly describe your company profile and scope of your Environmental Management System) The Company is committed to protecting the environment of the Earth. To minimize environmental impacts concerning our activities, products and services, we shall:- Comply with applicable legal requirements and other requirements to which the Company subscribes which relate to its environmental aspects. Prevent pollution, reduce waste and minimize the consumption of resources. Educate, train and motivate employees to carry out tasks in an environmentally responsible manner. Encourage environmental protection among suppliers and subcontractors. The Company is committed to continual improvement of environmental performance. This Policy will be communicated to all staff, contractors and suppliers, and be available for the public. Endorsed by: Signature: Date:

3. Organization

3.1 Organization Chart

(Insert Company Organizational Chart – be sure to identify major staff and their role in EMS development and implementation)

3.2 Responsibility

(Define the role and responsibilities of the staff / function / department involved in the EMS such as top management, Environmental Management Representative, Deputy Environmental Management Representative, Environmental Management System Committee and Management Review Committee.)

3.2.1 Top Management

(Top Management)is responsible for:

1. endorsing the environmental policy;
2. ensuring appropriate resource allocation to enable the effective operation and continual improvement of the EMS.

3.2.2. Environmental Management Representative (EMR)

The (Position) is the appointed EMR and has the responsibility and authority for:

1. Ensuring that EMS requirements are established, implemented and maintained in accordance with the ISO 14001 standard;
2. Ensuring that sufficient resources are allocated for the proper implementation of the environmental policy and the EMS;
3. Regularly reviewing the policy and the effectiveness of the EMS, and ensuring that the necessary changes are made.

EMR is also the Chairman of the EMS Committee and has the responsibility and authority for :

1. Leading the EMS Committee to establish and implement the EMS according to ISO 14001 standard, and monitoring the performance of the EMS;
2. Coordinating internal EMS audits to ensure the EMS has been properly implemented and maintained;
3. Handling and investigating nonconformity and ensuring corrective and preventive action has been taken to mitigate any impacts caused;
4. Reporting on the performance of the EMS to the top management for review and as a basis for improvement of the EMS.

The EMR, the DEMR, the EMS Committee and (Top Management) shall undertake the EMS management review annually to ensure top management commitment and integration of the EMS with business strategies for its implementation and continual improvement.

3.2.3. Deputy Environmental Management Representative (DEMR)

The (Position) is the appointed DEMR and has the responsibility and authority for:

1. Assisting the EMR to ensure the EMS is effectively implemented and maintained in accordance with ISO 14001 standard;
2. Assuming the responsibility and action of the EMR when the EMR is unavailable

3.2.4. Environmental Management System Committee (EMS Committee)

This committee is responsible for:

1. The establishment and implementation of the EMS;
2. The establishment and review of objectives, targets, and programmes;
3. Ensuring the effective implementation of environmentally-related operational controls and programmes;
4. The internal communication of environmental matters between management and employees; and promoting environmental awareness among company staff;
5. The review of complaint records, nonconformity, corrective action and preventive action reports and the adoption of preventive actions as necessary;
6. Providing leadership in the pursuit of environmental issues;
7. Any other EMS activities that are assigned by the EMR;
8. Holding regular meeting (at approximately three-month intervals.

3.2.5. Management Review Committee

The Committee systematically examines the EMS to ensure the suitability, adequacy and effectiveness of the EMS. The Committee comprises of the (Top Management), EMR, DEMR, and designated Function / Departmental Managers.

3.2.6. Function / Departmental Manager

The Function / Departmental Managers are responsible for:

1. Establishing controls for the identified significant environmental aspects for his/her function team / department according to procedures and instructions;
2. Ensuring that the EMS is properly implemented and that environmental matters are properly handled at all stages;

3.2.7. All Employees

All employees are responsible for:

1. Working in accordance with the documented environmental procedures and instructions, specific responsibilities defined in individual procedures and instructions; and
2. Reporting problems or deviations associated with environmental issues and the EMS to the EMS Committee.

4. Environmental Management System Requirements

The EMS of COMPANY NAME is developed to manage significant environmental aspects so as to limit their impacts on the environment. The EMS is established in accordance with ISO 14001:2004 , and is described in this section. Procedures for each component is given in the relevant Environmental Procedures (EPs) listed in Appendix A.

4.1. Environmental Management System Documents

The purposes of these EMS documents are as follows:.

Environmental Policy	Describes the intention and principles to be adopted in relation to environmental performance, including but not limited to legal compliance, continual improvements and pollution prevention.
Environmental Management System Manual (EMS Manual)	Describes the environmental management system and outlines how the requirements of the International Standard (ISO 14001) are achieved.  A cross-reference of the ISO 14001 clauses to the sections of this Manual is listed in Appendix A.
Objective(s) *	The overall environmental goals that COMPANY NAME set to achieve.
Target(s) *	The set of measurable performance requirements that COMPANY NAME establishes to achieve the objectives.
Programme(s) *	The programme and schedule which COMPANY NAME implements to achieve the objectives and targets.
Environmental Procedures (EPs)	Define the roles, responsibilities, and actions to be taken to ensure that activities are performed and the EMS implemented in accordance with the environmental policy and the requirements of ISO 14001.  A cross-reference of the ISO 14001 clauses to the EPs is listed in Appendix A.
Register of Environmental Aspects	Compiles the environmental aspects that are derived from the activities and services of COMPANY NAME. The register also denotes the significance of the environmental aspects and the respective operational controls for significant environmental aspects.
Register of Legal and Other  Requirements	Compiles the legal and other requirements, which include legislation, codes of practice, regulatory and non-regulatory guidelines that are applicable to COMPANY NAME.
Environmental Instructions (EIs)	Describe which and how activities should be performed to manage significant environmental aspects and to achieve the EMS ISO 14001 requirements.
Environmental Forms/Records	Record information for the audit trail and the assessment of environmental conditions and performance.

* Objectives and Targets, and associated Programmes are provided as a single document.

4.2. Environmental Policy

(ISO 14001 Standard Clause 4.2)
The environmental policy of COMPANY NAME is included in Section 2 of this document. It outlines the environmental commitments of COMPANY NAME with respect to its operations, activities, and overall environmental performance. During the development of this policy, the appropriateness to the nature, scale and environmental impacts of COMPANY NAME activities, products and services has been considered. The policy is endorsed by the (Top Management) and the policy shall be reviewed during the management review meeting.
The policy shall stipulate the commitments of COMPANY NAME to continually improve its environmental management and prevention of pollution. COMPANY NAME is also committed to comply with applicable legal requirements and other requirements to which COMPANY NAME subscribes which relate to its environmental aspects. The environmental policy shall provide a framework for setting and reviewing objectives and targets, and must be maintained, implemented and communicated to all employees of COMPANY NAME and its contractors. This policy shall be available to the public.

4.3. Planning

COMPANY NAME shall follow a “plan-do-check-act” process to facilitate continual environmental performance improvements. The planning process includes the identification and updating of COMPANY NAME’s Register of Environmental Aspects, and the Register of Legal and Other Requirements. Together with COMPANY NAME’s environmental policy, COMPANY NAME’s objectives and targets are established, and appropriate programmes are formulated to achieve the objectives and targets.

4.3.1. Environmental Aspects

(ISO 14001 Standard Clause 4.3.1)
The planning process commences with the identification and updating of environmental aspects. In order to evaluate the impacts of its activities to the environment, COMPANY NAME shall establish, implement and maintain a procedure to identify the environmental aspects of its activities, products or services that it can control and those that it can influence taking into account planned or new developments, or new or modified activities, products and services. These aspects, inclusive of those arising from works carried out by contractors, are registered in the "Register of Environmental Aspects". COMPANY NAME shall ensure that all environmental aspects that may pose significant impacts to the environment are under control and prioritised for improvements. COMPANY NAME shall keep this information up-to-date. Relevant procedure : EP-01 Identification of Environmental Aspects and Significance Evaluation

4.3.2. Legal and Other Requirements

(ISO 14001 Standard Clause 4.3.2)
COMPANY NAME shall establish, implement and maintain a procedure to identify and maintain access to legal requirements that are relevant to the company, as well as other requirements that the company subscribes to which relates to the company’s environmental aspects. COMPANY NAME shall identify all relevant regulations, codes of practice and guidelines that are applicable to the environmental aspects of its activities, products and services, and record this information in the Register of Legal and Other Requirements.COMPANY NAME shall keep this information up-to-date. Relevant procedure : EP-02 Review of Legal and Other Requirements

4.3.3. Objectives, Targets and Programme(s)

(ISO 14001 Standard Clause 4.3.3)
Based on the environmental policy and significant environmental aspects, environmental objectives and targets shall be established, implemented and maintained at each function and level within COMPANY NAME. Programmes are established, implemented and maintained for achieving its objectives and targets. When establishing and reviewing its objectives, COMPANY NAME shall take into consideration the legal and other requirements, significant environmental aspects, technological options, financial/operational/business requirements, and the views of interested parties, and ensure that the objectives and targets are consistent with the environmental policy, including commitment to pollution prevention, to compliance with applicable legal requirements and other requirements, and to continual improvement. The programmes designate the responsibility for achieving objectives and targets at each function and level of the company, together with the means and time frame by which they are to be achieved. The (Top Management) shall approve the objectives, targets and programmes proposed by the EMS Committee before implementation. The EMR shall ensure that the objectives and targets are measurable if possible, and that the progress towards achieving the objectives and targets is continually monitored and reviewed. The achievement of objectives, targets and programmes shall be reviewed by the EMS Committee every 3 months. The EMR shall lead the EMS Committee in revising the objectives, targets and programmes as necessary. COMPANY NAME shall ensure that the programmes are amended as appropriate for new projects and new or modified activities, products or services in order to ensure that environmental management applies to such projects and activities. In the event that objectives and targets in the programmes are not met, the EMR shall revise the programme as necessary and maintain documented evidence / records for the actions taken to mitigate the problems. The EMR shall also maintain obsolete objectives, targets and programmes as an EMS record for three years.

4.4. Implementation and Operation

The implementation of the EMS requires COMPANY NAME to clearly define roles, responsibilities and authorities of key personnel, commit to staff training, maintain effective communication channels, adopt effective document and operational controls, and maintain sufficient awareness on emergency preparedness among the staff.

4.4.1. Resources, Roles, Responsibility and Authority

(ISO 14001 Standard Clause 4.4.1)
Top management of COMPANY NAME shall commit to provide resources (including human resources and specialized skills, organizational infrastructure, technological and financial resources) essential to the implementation and control of the EMS. The roles, responsibilities and authorities of key personnel shall be defined, documented, and communicated in order to facilitate effective environmental management. COMPANY NAME has appointed the (Position) as the Environmental Management Representative (EMR), and the (Position) as the Deputy Environmental Management Representative (DEMR) for the implementation and maintenance of the EMS. Their EMS responsibilities are described in section 3 of this manual.

4.4.2. Competence, Training and Awareness

(ISO 14001 Standard Clause 4.4.2)
COMPANY NAME shall ensure all persons performing tasks for it or on its behalf, whose work may have a significant impact on the environment, are competent on the basis of appropriate education, training and/or experience, and shall retain associated records. COMPANY NAME will need to ensure that all people performing tasks for or on behalf of the organization, which includes contractors, sub-contractors, temporary staff and remote workers, have had an appropriate assessment for their potential to cause a significant environmental impact and the associated competence required. COMPANY NAME shall establish, implement and maintain procedures to identify the training needs associated with its environmental aspects and its EMS, and develop programmes to ensure awareness and competence, at each relevant function and level, by addressing:

• The roles and responsibilities in achieving conformity with the environmental management system;
• The importance of conformity with the environmental policy, the procedures & the requirements of the structured EMS;
• The significant environmental aspects and related actual or potential impacts associated from their work activities and the environmental benefits of improved personal performance;
• The potential consequences of departure from specified operating procedures;

Relevant procedure : EP-03 Training

4.4.3. Communication

(ISO 14001 Standard Clause 4.4.3)
For internal communication, the EMR shall ensure information regarding the EMS (such as the policy, objectives, targets and programmes) and environmental performance is readily available to employees on notice board, or is published on the intranet or newsletters. Employees with enquiries / complaints regarding to the EMS and/or environmental issues of COMPANY NAME shall inform their Function / Departmental Manager. The designated member of EMS Committee representing each division shall maintain a log for the relevant enquiries / complaints. Depending on the nature and scope of the enquiry / complaint, the EMR shall determine the corresponding action and maintain relevant records to demonstrate the response / corrective actions taken. For external communication, the environmental policy is available at the office and company web page. All internal and external enquiries / complaints / communications shall be discussed and reviewed during the EMS Committee meeting and the decision shall be recorded on meeting minutes. The EMS Committee may discuss and decide whether to communicate externally about its significant environmental aspects, the decision shall be documented in the meeting minutes. If the decision is to communicate, the EMS Committee shall establish and implement a method(s) for this external communication, e.g. publish environmental report. Relevant procedure : EP-07 Enquiry / Complaint / Nonconformity Handling.

4.4.4. Documentation

(ISO 14001 Standard Clause 4.4.4)
The Environmental Management System documentation encompasses four levels as described below:

• The first level is the Environmental Management System Manual (this document) which includes COMPANY NAME’s environmental policy (specifying the principal objectives and environmental commitments of COMPANY NAME), and a broad description of how COMPANY NAME addresses the ISO 14001 requirements. The EMS Manual serves as an interface to interpret the relationship between COMPANY NAME’s EMS and the ISO 14001 Standard. An individual document of Objectives, Targets and Programmes is developed based on the company’s environmental policy. It demonstrates the company’s environmental commitment on continual improvement in environmental performance.
• The second level is the Environmental Procedures (EPs), which include all procedures that COMPANY NAME shall follow as specified in the ISO 14001 Standard. These procedures provide a detailed description of the EMS elements and define who should do what, how and when. Appendix A shows the relationship between various environmental procedures and the ISO 14001 Standard clauses. Register of Environmental Aspects, and Register of Legal and Other Requirements are derived from the procedures and act as the foundation of the EMS which the company subscribed to.
• The third level is the Environmental Instructions (EIs), which are operational control procedures or instructions, with defined responsibilities, to control the identified significant environmental aspects associated with COMPANY NAME’s operations and activities.
• The fourth level is Environmental Records, which arise from the implementation of the Environmental Management System Manual, Environmental Procedures and Environmental Instructions. Environmental Records include various checklists, reports and meeting records, etc, as defined in each Environmental Procedure and Environmental Instruction.

4.4.5. Control of Documents

(ISO 14001 Standard Clause 4.4.5)
The essences of EMS documentation controls are:

• They shall be reviewed, revised as necessary and approved for adequacy by authorized personnel;
• That current version of relevant documents shall be available at all locations where operations essential to the effective functioning of the environmental management system are performed;
• That documents of external origin determined by the organization to be necessary for the planning and operation of the EMS are identified and their distribution controlled;
• Obsolete documents shall be promptly removed from all points of issue and use, or are otherwise assured against unintended use; and
• Any obsolete documents retained for legal and / or knowledge preservation purposes shall be suitably identified.

COMPANY NAME shall ensure that documentation is legible, dated (with dates of revision) and readily identifiable, maintained in an orderly manner, and retained for a specified period. COMPANY NAME shall establish, implement and maintain a procedure for the creation and modification of the various types of documents and the respective responsibilities for such creation and modifications.
Relevant procedure : EP-04 Control of Documents

4.4.6. Operational Control

(ISO 14001 Standard Clause 4.4.6)

• COMPANY NAME shall establish, implement and maintain operation control procedures to manage its significant environmental aspects.
• COMPANY NAME shall ensure that all operations and activities, carried out by COMPANY NAME’s employees or contractors, that are associated with the significant aspects are properly controlled, and that appropriate operational control procedures, in terms of Environmental Procedures (EPs) and Environmental Instructions (EIs), are communicated to personnel whose tasks may result in significant environmental aspects.
• COMPANY NAME shall influence its staff and contractors by communicating its environmental policy and other relevant EPs and/or EIs to them.

4.4.7. Emergency Preparedness and Response

(ISO 14001 Standard Clause 4.4.7)

• COMPANY NAME shall establish, implement and maintain a procedure to identify potential emergency situations and responses to such situations in order to prevent and/or mitigate environmental impacts that may associate with them.
• COMPANY NAME shall review and revise its emergency preparedness and response procedures, in particular after the occurrence of accidents or emergency situations
• COMPANY NAME shall also periodically test the procedure and the preparedness where practicable.

Relevant procedure : EP-05 Environmental Emergency Preparedness and Response

6.0. Appendix

• Appendix 1 : Monthly Office Inspection Checklist (EF-EI01-01)

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ENVIRONMENTAL OFFICE PRACTICE

1. Purpose

This instruction outlines the practices to be adopted for controlling environmental impacts of office activities under the scope covered by the EMS.

2. Scope

This instruction is applicable to the operations in the office.

3. Procedure

3.1. General Responsibility

The Administration Manager shall ensure all relevant staff under the scope of the EMS are aware of and adopt the procedures described below in Section 3, and maintain relevant records for monitoring and demonstrating compliance accordingly.

3.2. Resource Utilization

3.2.1. Paper Saving

• Use both sides of paper
• Use suitable font size / shrinkage mode to minimise pages,if possible;
• Use electronic media for circulation / communication, to minimize using paper;
• Without unnecessary cover page. (e.g. fax)

3.2.2. Materials Re-use and Conservation

• Choose proper sized for packing goods;
• Choose waste papers as fillers for packing and/or reduce using fillers, if possible.
• Handle and store materials carefully to reduce breakage and wastage.
• Reuse boxes /fillers /other materials for packaging /storage /delivery

3.2.3. Water Conservation

• Report leaking faucet or pipe to the relevant authority.
• Turn off the tap when not in use.

3.2.4. Electricity Conservation

• Set energy saving mode where possible; for computers, the idle automatically mode is 20 minutes or less.
• Set room temperature range from 20° C to 25.5° C. The ideal optimal temperature is 25.5° C.
• Switch off unnecessary lighting; and /or
• Switch off power supply when they are not in use; and /or
• Switch off all power supply in the area while leaving.

3.2.5. Stationery Conservation

• Use environmental friendly stationery.
• Reuse cord binder, envelopes and other materials until worn out.
• Reuse stationery as far as possible.

3.3. Green Pantry

• Use reusable cutleries, cups and glasses.
• Use environmental friendly cleaning products (e.g. biodegradable or phosphate free detergent, refillable soap, etc.)
• Reuse stationery as far as possible.

3.4. Handling of Office Wastes

3.4.1. General Refuse

• Establish waste segregation with separately allocated containers (e.g. paper, toner cartridge) to facilitate recycling of general solid wastes.

3.4.2. Toner Cartridge Recovery

• Collect spent toner cartridges and pick up by the appropriatecontractor for recycling.

3.4.3. Waste Paper Recycling

• Do not place contaminated items (e.g. food contaminated papers) and non-recyclable paper (e.g. carbon paper, plastic laminated paper) in the designated containers.

3.4.4. Waste Computers and Accessories

• Collect and reuse waste computer accessories in other computers or systems wherever practicable.

3.4.5. Batteries Collection

• Encourage the use of rechargeable batteries;
• Collect spent batteries for recycling / proper disposal.

3.5. Indoor Air Quality

• Place large-leafed green plants in appropriate office areas where possible.
• Encourage staff to keep small green plants.
• Implement a no smoking policy within the general office or restrict smoking to a separately ventilated smoking area.

3.6. Collection and Records

• Dispose of refuse in appropriate containers for regular collection by collectors to prevent odour.
• Maintain records of waste disposed and recycled for different types of wastes.
• Arrange pest control, ventilation system and carpet cleaning on a regular basis.

4.0. Monitoring and Checking

1. For procedures outlined in Section 3, the Administration Department or his / her delegate shall:

• Check monthly by visual inspection to ensure that the procedures described above are followed by staff; and complete the Monthly Office Inspection Checklist;
• Where a major nonconformity is identified, corrective actions shall be defined and implemented in accordance with EP-07 Enquiry/ Complaint/ Nonconformity Handling.

5.0. Record

Record Description	Record Location/ Retention Responsibility	Minimum Retention Time
Monthly office inspection records (EF-EI01-01)	Admin Officer	3 years
Paper purchasing and consumption records	Admin Officer	3 years
Electricity / water consumption records	Admin Officer	3 years
Waste disposal and recycling records	Admin Officer	3 years

6.0. Appendix

• Appendix 1 : Monthly Office Inspection Checklist (EF-EI01-01)

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JSA 02 FOR MECHANICAL EXCAVATION

• Ensure the area to be excavated is declared EOD cleared.
• Locate underground / aboveground services referring to the site map / drawing. 
• Endorsements in Excavation Notification from the concerned Teams for the services in the area to be excavated.  
• Hold pre-job safety meeting 
• Get authorization for Hot Work Permit 
• Conduct Toolbox Talk

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JSA-01 MANUAL EXCAVATION

Pre - work 

• Ensure the area to be excavated is  cleared.
• Locate underground / aboveground services referring to the site map / drawing. 
• Endorsements in Excavation Notification from the concerned Teams for the services in the area to be excavated.  
• Hold pre-job safety meeting 
• Get authorization for Cold Work Permit 

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METHOD STATEMENT FOR WELDING IN WORKSHOP

1.     Purpose

The purpose of this methodology is to provide a systematic control and direction for the activity for the fabrication and welding of piping and structure at Safwan. This method statement provides the expectation to execute work in safe, eco-friendly manner and in compliance to the Client HSE and Quality requirements.

Download link given in the bottom

2 Scope

This procedure is applicable for fabrication in Safwan yard for the Construction works for All Project.

3 References 

Specification for material and fabrication requirement for CS piping and equipment in sour service.

Technical specification for piping system

Specification for welding and welding inspection of shop and field fabricated carbon steel process and utility piping

ASME B 31.3 Process piping

DEP 31.38.01.31 Shop and Field fabrication of piping

AWS D1.1 Structural welding code

DEP 34.28.00.31A Structural steel works

4 Definitions

• QHSE                  Quality, Health, Safety & Environment   
• QCI                      Quality Control Inspector
• ITP                       Inspection and Test Plan
• WPS                    Welding Procedure Specification
• NDT                     Non-destructive testing
• PWHT                  Post Weld heat treatment

5 Responsibilities

In addition to the regular work as per Job description/ regular practice the following activities shall also be carried out.

5.1 Project / Mechanical engineer 

Mechanical engineer is responsible to ensure that this procedure is Understood and is being implemented by his subordinates.

5.2 Supervisor/ Foreman

• Ensure that welding equipment, baking oven, quiver is in good condition.
• Ensure welding is done as per the approved WPS and approved for Construction drawing.
• Ensure that weld maps / spool drawings are available.
• Coordinate with QC personnel to study the cause of any reported weld 
• Defects and arrange to take corrective and preventive action.
• Adhere to the QHSE requirements.
• Comply with PTW requirements.

5.3 QC Inspector

• Carry out the inspection as per the Inspection and test plan.
• Approving/ rejecting the item based on inspection.
• Submitting the quality records to the client and getting their approval.
• Responsible to keep records of all inspection related activities.
• Adhere to the QHSE requirements.

5.4 HSE Officer

• Advice the construction crew on HSE aspects and ensure the safety of them.
• Arrange through Job performer for tool box talk covering risk assessment in language understandable by workers.
• Cross checking certified material devices and equipments are used.
• Do weekly, monthly HSE audit.
• Ensure appropriate safety measures are taken as per the risk assessment and control document.
• Adhere to the HSE plan and HSE requirements.

6      Procedure

6.1 General

• Prefabrication will be done at Safwan workshop. Prefabricated spools will be painted with two layers of coating and transported to site for field welding.
• Fabricated spools shall be carefully transport to site. The transported spools will be tied down with ample support to prevent any damage. Tie downs shall be nylon straps and chains shall not be used. By this way it is ensured that no damage is done to painting during transportation to site.
• Ensure no damage is done to painting during transportation to site.
• Whenever the pipes are cut the heat no: shall be transferred to the cut pieces for traceability by paint / permanent marker. Welding shall be done as per the approved procedure, specification and approved for construction drawing.
• Welding machine, ovens and etc. shall be maintained in good condition.
• Approved welders for the particular WPS shall be used for welding.
• Welded surfaces shall be clean and free from grease, oil, paint or other foreign material which are detrimental to welding. 
• Bevels shall be as per the WPS and cleaned for minimum 1” from the welding.
• Peening shall not be performed at any time.
• Tack weld not incorporated in the final weld shall be removed by grinding or other mechanical means. 
• Welding consumables shall be issued, received and handled in accordance with the approved method statement.
• All tools used for working on stainless steel shall be those designated for stainless steel work.
• All flange face shall be protected with plywood / suitable means from mechanical damages during handling or storage. 
• End caps of pipes will be kept in place during storage, moving, fabrication and Erection activities, except when the joint end is actually being worked upon. Flanges and open ends shall be protected at all times. 
• Such protection shall be removed only to permit work to be performed as part of a fabrication or inspection process, after which they shall be again re protected.

6.2 Weather protection:

When the weather does not permit satisfactory workmanship welding shall not be done. On site in windy condition the pipe ends shall be closed to prevent through draughts during welding. Suitable covering using tarpaulin & etc. shall be provided. Welding shall not be done when the weld surface is wet / when the area is exposed to rain / strong windy condition. 

6.3 Weld Identification:

• Each weld shall be uniquely identified with the joint no: and welder number.
• After completing the weld, the welder shall mark the joint no: & welder no: near the weld using paint or indelible crayon.
• After welding each spool, the line no, spool no & etc shall be marked / tagged on the spool and stocked over wooden sleepers or other suitable material above ground.

6.4 Non Destructive Testing:

Non-destructive testing shall be done as per the approved procedure using approved sub-contractor.

6.5 Alignment Circumferential welds.

• Butt weld alignment shall satisfy the requirement of ANSI B 31.3 and conditions stated below.
• Internal misalignment of pipe work shall not exceed 1.6 mm in order to facilitate welding of the root pass. 
• When a GTAW process is to be used maximum misalignment shall not exceed 0.8 mm. If there is excess misalignment tapering of the internal dia of the thicker member to a taper of 1:4 shall be done. 
• Ensure minimum wall thickness is maintained.
• If misalignment up to 3.2 mm exists, internal grinding or machining may be conducted to improve root alignment, provided the taper doses not exceed 1 in 4 maximums and the minimum required wall thickness is maintained.  
• Misalignment correction shall be done using suitable clamps and heavy hammering or heating of the pipe shall not be done.

6.6 Weld separation

6.6.1 Circumferential welds (Girth welds):

For nominal size of 75mm & above the minimum distance shall be 75 mm. For lesser pipes the minimum distance shall be 4 times of the wall thickness or one pipe dia whichever more is. Welds lesser than the above limit shall be done with the approval of the client and may require PWHT solely at the discretion of the company.

6.6.2 Branch / Nozzle / attachment welds.

Branch / nozzle and other pressure attachment welds shall have minimum 3” 
distance to adjacent pressure welds. Non pressure containing attachment welds shall be separated by 2” from adjacent pressure containing welds. 

6.6.3 Longitudinal seams 

Longitudinal seams of adjacent pipes shall be separated by at least 4”.

6.7 Pre-heating, Interpass temperature, PWHT:

Preheating shall be done as per the WPS if high pre heat temperature is specified or else minimum preheat for CS upto 19mm thick is 21°C and > 19mm thick CS is 100 °C. When the base material is below 21 deg C, the material shall be heated to 50 deg C prior to welding. The heating shall be done gradually and uniform manner. The preheat temperature shall be held at least five minutes before welding is commenced & shall be checked using temperature indicating crayons. 
Preheating shall be done by using propane torches or by electric resistance and the use of oxy-acetylene torch is not allowed. A minimum width of 3” on both side of the joint shall be preheated. Interpass temperature shall be as per the WPS. If any post weld heat treatment is required as per the WPS the same shall be carried out as per the temperature specification in the WPS. Controlled heating and cooling shall be as per the WPS. The temperature recorded chart shall be submitted to the client for approval. PWHT shall be performed on carbon steel piping if the wall thickness exceeds 19.05 mm.

6.8 Weld sequence:

The weld bead sequence shall be as per the approved WPS. The welding shall be cleaned of all flux, slag and spatter by wire brush, grinding and hand chipping after each pass. The welder shall visually check the welding after every pass for any defects and if any defects found it shall be removed or repaired before the next pass. If any crack is found it shall be informed to the inspector and with his knowledge rework shall be done. After completing welding the adjacent surfaces shall be cleaned of all spatters, slag, flux & etc.

6.9 Welding interruption:

Welding for each pass shall be continuous without interruption other than changing electrodes or filler wires or allow welder for changing their position. Specifically root run and hot pass shall be done without interruption. If there is interruption the following action shall be taken. 

• If only 25 % of the weld grove has been deposited, then the weld shall be cutout & recommended for a new preparation. Otherwise the welding shall be recommenced as mentioned below.
• The weld shall be allowed to cool slowly to room temperature. This can be done by wrapping the weld with insulation and allowing the joint to cool in still air. 
• MPI to be carried out prior to welding.
• The weld shall be preheated.

7 Repair welding:

• Any defects which require repair shall be entirely removed to sound metal. Metal Shall be removed 1” on both side of the defect without substantial removal of the Base metal.
• By grinding, the metal shall be removed and the grove shall be smooth without any undercut. Visual examination and magnetic/dye penetrant test shall be done on the grove. 
• If repairs are done after hydrotest / PWHT the same shall be repeated after repair. Welding repair shall be done only twice. Even after second repair if the weld is not acceptable the weld shall be removed, re beveled and re welded.
• Same NDT technique & acceptance criteria for the original weld shall be done after repair welding.

8 Resources 

• Welding machine
• Grinding machine
• Preheating torches with propane gas cylinders
• Holding ovens/baking ovens
• PWHT equipment
• Hiab, Crane
• Cutting tools
• Generator

9 HSE Requirements

• Basic PPE.
• Fire extinguishers.
• First Aider with first aid kit shall be available.

10 QA/QC requirements & attachments

Quality shall be maintained by ensuring the systematic implementation of this procedure and ensuring quality records are prepared as per the ITP.
Records:

• Piping daily fabrication report P002: MFM 12-M/1-P002
• Fabrication control sheet P003: MQM/P3-005
• Welding electrode control sheet M15: MFM 12-M/1-M15

11 Emergency contacts

The following shall be the contact number in case of any emergency.

• Project Manager
• Mechanical Engineer     
• QA/QC Engineer    
• CM                   
• HSE                          
• Control room

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METHOD STATEMENT FOR CONCRETE CASTING

1.SCOPE

The scope of this method of statement is to cover concrete works activity which includes (Formwork installation, rebars supply and installation, concrete supply and placement, water proofing, etc.) d supply for cast in situ Concrete in the project. In accordance with contract requirements and approved project specification, project safety procedure and approved issued for construction drawings.

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2. PURPOSE

The method statement shall address the precedence of physical operations applicable for the supply and placing Structural / nonstructural Concrete on the project. 

This Method Statement is to ensure that concrete works activity will be expedite in an efficient and safe manner in accordance with all relevant contract documents, (Specification and Drawing) and international accepted methods, utilizing proven methods and procedures, as detailed herein and was implemented on previous projects.

This Method Statement is for submittal to Consultant / Employer for their concurrence.

This Method Statement will, if deemed necessary, be revised as and when required to accommodate circumstantial requirements that cannot be foreseen at this page.

3. REFERENCES

• Project Standard Specification for CONCRETE WORK.
• 25457 – 0000 – 3PS – DB00 – 0001 Rev. 001 for Concrete Work
• 25457 –0000 – 3PS -  DB01 – 0001 Furnishing and Delivering Ready- Mix Concrete
• 25457 -  0000 -  3PS – DG01 – 0001 Reinforced steel, Embedded items and Miscellaneous Concrete Accessories. 
• EN 206-1 Concrete specification, performance, production and conformity.  
• EN 12620 –Aggregates for Concrete.
• ENV 13670 Execution of Concrete Structures
• ACI 347 Guide to Formwork for Concrete
• ACI 305.1 Specification for Hot Weather Concreting

4. RESPONSIBILITIES:

• Project Director / Project Manager have the responsibilities for overall the project activities including safety measures.

4.1. Project Engineer / Construction Manager (Civil)

In charge shall be responsible for coordination and supervision of construction works (activities) and construction groups, ensuring that works is done as per project specification and approved drawings, and all safety measures are implemented, of site construction and report to construction manager civil.

4.2. Site Engineer / Site General Foreman 

General Foreman Shall be supervising closely that activities designated to them ensuring that all instruction are followed are strictly adhered to, (this may involve providing alternative access routes for moving Traffic with Traffic Signs if necessary are in place prior to commencing the work, safety procedures of the project are strictly followed.
The SE shall be responsible for the following:

• To ensure construction is carried out to the required Project Specifications and drawing as well as in accordance with the approved ITP’s and QCP’s and to this method statement.
• To ensure that the surveyor has completed setting out with reference points complying with the approved for construction drawings.
• Ensure that all parties who are required to make any kind of test / inspection are suitably informed as to the overall program of the works and daily inspection testing requirements.
• Ensure checking and performing the concreting as per the Specification.
• The QC Engineer or his designee (QCI) shall be responsible for the following:
• Review all relevant documentation and test reports issued by parties involved (SE, Lab Tech (ITL Laboratory), Surveyor and QC Inspectors) and submit records to consultant.
• Ensure that all discipline activities that require to be inspected in the concreting operation has been inspected and approved.
• Organized and allocate inspection works to the Quality Control Inspectors (Civil).
• To issue NCR’s / DR’s, when and where required and to check that the construction department provides timely appropriate corrective and preventive action.
• The QCI shall be responsible for:
• Sign off and obtain signatures from the Consultant on the forms and verifying documents as required.
• Accompany the Consultant Supervision representative if required, to carry out inspections and release of hold points
• Identifying and reporting to the QA/QC Mgr. any non-conformances 
• Keeping a daily log of all the inspection Request submitted by the SE.
• Carry out statistical analysis of the inspection and test result to improve quality control operation on site, to verify testing compliance and to advise the SE of the results.
• Filling and compiling controlled copies of all test reports under the supervision and instructions of the QC Engineer.
• The Lab Tech shall be responsible for:
• Sampling and conducting field testing according to the instruction of the consultant and QC Manager and in accordance with the Specifications.
• The ITL (Independent Testing Laboratory) to ensure that the required numbers of samples are taken from concrete works for the evaluation of quality and Durability of Concrete works. 
• The Laboratory technician / Engineer shall be responsible to test all concrete aggregates constituent for quality ensuring it complies with specifications requirements and abide with the frequency stipulated in the specification.
• Ensure that all tests required specified for fresh concrete Production is completed.
• Issuing, reviewing / interpreting all laboratory test result report in timely manner, submitting it to QC department keeping records in laboratory for consultant Reference.
• Compilation and filling all laboratory Test Forms / RFI for Certification submitting all records to QC department.
• Scaffolding Supervisor: To ensure that all scaffolding system has been erected accordingly to safety and requirements.
• Safety Inspector: To ensure all safety precautions has been taken into consideration before commencing the concrete works.
• All equipment should be inspected by Bechtel inspector and should have entry pass before working on site.
• All heavy equipment operators such as excavator’s cranes, forklift, etc, should have third party license. 

5. EQUIPMENTS:

• Concrete Mixing and Transport equipment
• Ready Mix Concrete Batching Plant
• Transport Mixer
• Concrete Pump
• Hoses / Concrete shoots
• Concrete buckets
• Air Compressor
• Survey Equipment
• Level
• Total Station (Surveying instrument for checking the levels & distances)
• Masonry Accessories
• Wheel Barrows
• Concrete Vibrators

6. MATERIAL:

• Form Plywood
• Timber
• Scaffolding

7. SHOP DRAWINGS.

Approved / Issued for Construction Drawings

8. PROCEDURE

8.1. Excavation and Backfilling

• All the areas where excavation is required, the surveyor will give the information to the excavation foreman to start the excavation to the levels indicated in the IFC drawings. 
• After the excavation is completed, the surveyor will check the final grade of the excavation and the grade will be adjusted accordingly.
• Compaction shall be completed and shall be tested by an inspection company (Independent third Party laboratory).
• Slight trimming will be carried out when & where required before the placing of polyethylene plastic sheet.
• Concrete blinding will be carried out where indicated in IFC Drawings.
• Polyethylene plastic thickness to comply with the project specifications.
• Cast in situ elements shall be constructed in accordance with IFC drawings and line with project specification.
• MEP and Civil insert will be in place.
• Surveyor shall mark the location of structural member (foundation, wall, Column, etc.) as per approved drawings.
• Excavation shall be carried out up to bottom level of blinding, leveled, sprayed with water, compacted and tested as per relevant specification and approved drawings.
• Erect formwork for blinding with concrete mix class C12/15.
• Allow the concrete blinding to be hardened and cured as per relevant specification.
• Apply approved protective coating / Damp proofing or water proofing membrane on top of blinding as per specification and approved drawings.
• In specific condition and coordination with consultant when concrete workability is not meeting prevailing placement condition, re tempering of concrete with admixture shall be carried out.
• On specific areas where rate of concrete placement is to be very slow Dry mix concrete will be delivered to site. Water and Concrete admixture meeting concrete mix design requirements will be mixed on small batches using small site Mixers, the same site mixers will be used for Cement plaster.
• Where construction joints detailed on the drawing, width of concrete element warrant establishment of construction / expansion joints, or concrete placement to be stopped due to an avoidable circumstance on site, Construction joints shall be made, Concrete surfaces will be roughened cleaned to establish a good joint between old and new fresh concrete, QC inspection, Consultant approval is required before concrete placement continue in concrete member.
• On water retaining Concrete Structure and detailed on issued for Construction Drawings, approved water stops will be used as required by the project specifications.
• On concrete slabs and where detailed on drawing, Expansion / Construction joints will be established, the joint will be sealed with approved flexible materials.
• Cleaning of Starter Bars shall be carried out following concrete placement completed in preparation for the next concrete pouring.

8.2. Formwork   

• Concrete placement will not commence before Engineer Approval of Formwork and Rebar Installation.
• The design and construction of formwork shall take account of safety and of the surface finish required. The formwork will be sufficiently rigid and tight to prevent loss of grout or mortar from the fresh concrete and stand concrete Vibration (Excreted Hydro static Pressure) without Movements. Form work and its supports to maintain the correct position and to maintain correct shape and profile.
• The formwork for foundation, beam connection, column neck and manholes etc. will be made of either traditional formwork (plywood and timber and supported by tie rod and steel support) or DOKA system which a combination of DOKA wooden beams, plywood and DOKA steel supports system with tie rod. 
• Molds and formwork shall be prepared according to the IFC drawing.
• Formwork will be placed and aligned fixed to the required dimensions as detailed in issued for construction drawings by the carpentry crew.
• Formwork shall be rigid / sturdy and fixed in such a way to retain the structure member’s dimensions.
• QC Inspector will check the formwork installation and safety officer to ensure safety of the work.
• Before placing the steel reinforcement, an approved form release agent will be applied to the internal face of the formwork.
• For columns, walls shutter will not be closed before QC and consultant releases. 

8.3. Steel Reinforcement:

• Grade of Steel will be as follows:
• B500B for 20mm and larger diameter
• B500C for 16mm and smaller diameter
• Based on the issued bar bending schedule, steel cutting and bending will be carried out either in site fabrication shop / supplier fabrication work shop delivered to site and assembled on site as per approved IFC drawings.
• Reinforcement will be placed above ground not in touch of soil, either using wooden blanks or concrete base to comply with project specification and international accepted procedures.
• Upon the arrival of steel rebar to site fabrication shop, the rebar fabrication crew will cut and bend rebar in accordance with project specification and IFC drawings.
• The rebar will be transferred to site by pick up or trailer and tagged.
• Before placing the fabricated rebar inside the formwork or mold, the formwork shall be clean, blown out by air with air compressor and coated with approved releasing agent.
• Rebar will be placed according to the project specifications and IFC drawings.
• Rebar will be assembled either inside or outside the concrete member, outside assembly steel will be placed by a crane to avoid any disturbance to the water proofing materials / or polyethylene plastic sheet. Additionally, when leveling concrete is provided, rebar mats can be assembled in the place.
• Reinforcement support shall be properly assembled at site: non metallic or plastic concrete spacer shall be used to maintain the cover as required by the specifications.

8.4. Embedded Metals, Anchor bolts:

• All embedded materials items for civil. Mechanical or electrical activities shall be placed / inspected by QC inspectors ensuring materials comply with specifications.
• All embedded items shall be unpainted unless noted otherwise, and free of deleterious materials, such as dirt, grease, and heavy scale.
• Anchor bolts and other embedded items shall be positioned and secured within the tolerances shown on the drawings, in accordance with ENV 13670 and as required by this specification.
• All embedded elements to comply with the project specification and fabricated in accordance with IFC drawings.
• The embedded metals and anchor bolts will be installed in accordance with IFC drawings.
• The QC inspector shall check formwork, rebar steel, embedded metal and anchor bolts prior to concrete placement.
• Section / Site Engineer will submit Request for inspection to QC inspector prior to start site delivery of concrete.
• After the concrete has hardened sufficiently, the exposed portion of anchor bolt shall be cleaned of all concrete and the threads chased. Threads shall then be carefully coated with grease and the washers and nuts installed.

8.5. Concrete Placement:

Stage 1:

• Project Engineer / Section Engineer shall ensure Concrete Grade / Class is approved by consultant / clients, the following concrete grades shall be used:
• All cast in place concrete ------------C30/37
• Precast Members----------------------C40/50
• Blinding concrete-----------------------C12/15
• Misc. Concrete--------------------------C20/25
• The QC inspector ensures that mix Design Proportions / Batch weight available in batching plant.
• Ready mix concrete supplier is aware of project specification requirements for concrete temperature and slump.
• Formwork installed to true lines and levels.
• Reinforcement as per approved drawings and bar bending.
• Embedded elements, inserts, box outs chases, champers, water bars etc. as per approved drawings.
• Surveyor marks the concrete top level on the shutter as per approved drawings.
• Formworks is clean from inside using compressor and magnetic bars used to remove pieces of binding wires.
• Sub- Contractors QC (civil) and company / contractor QCI (civil) shall inspect each member prior to pouring of concrete.
• Structural member is released by QC and consultant.
• Concrete pouring schedule submitted to batching plant.

8.6. Concrete Placement: 

Stage 2:

• Concrete shall be placed at each individual pour location dependent on access and pour configuration either by;
• Direct discharge
• Crane and skip
• Concrete pump
• Chute
• The exact method / procedure for placing concrete shall be decided depending accessibility of structural member on site. 
• All necessary laboratory tools for fresh concrete quality testing shall be available on site prior to pouring of concrete (cube moulds / cylinder mould, slump cone, thermometer etc.) And third party laboratory technician is available at site or Concrete site station (checking temperature, slump air content and fresh concrete density and samples taken as per specifications). Then transit Mixer released to specified Concrete location.
• Place the approved mix concrete into layers 450 mm per layer maximum using one of the above methods.
• Preparation forms, reinforcement, joints and mixing conveying.
• Concrete shall not be dropped from a height exceeding 1.8 meters.
• Expansion / Contraction joints shall be provided as per IFC drawings.
• If the air temperature is less than 30 deg C concrete shall be placed within 90 minutes of the introduction of the mixing water to the cement and aggregates, or cement to aggregates. If the air temperature is greater than 30 deg C mixing time shall be reduced and concrete placed within 60 minutes except when a suitable set retarding mixture is used and slump requirements can be met. The maximum time between batching and placing shall not be exceed 120 minutes in all cases.
• Specific measures taken for minimum dimension of any casting is .80 meters or more.
• Where Kicker is used it shall be at least 70 mm high and carefully constructed.
• Concrete in high temperature (ACI standard 305.1 for hot weather concrete shall be complied with.
• The minimum concrete cover maintained as detailed in specification.
• 75mm for all concrete poured against soil.
• 50mm for all foundation concrete poured against forms.
• 40mm for all other concrete exposed to soil but poured against forms.
• 40mm for all exterior concrete.
• 40mm to principle reinforcement of interior beams and columns.
• 35mm for interior slabs and walls.
• 50mm for columns, beams and walls & other exposed member of Maritime Structures.

8.7. Concrete Compaction:

  Stage 3:

• Full compaction of the concrete shall be achieved throughout the entire depth of the layer using mechanical vibrators.
• Vibration of concrete shall be thoroughly worked against the formwork and around the reinforcement: successive layers shall be thoroughly bonded together during vibration.
• Ensure Reinforcement or form is not disturbed.
• Compaction of concrete shall be carried out by mechanical or electrical vibrators to expel all air bubbles formed during the mixing and casting.
• Immersion vibrators shall be withdrawn slowly to prevent the formation of voids.
• Care shall be taken to avoid over vibration which could cause segregation, surface laitance or leakage through formwork.

8.8. Concrete of Curing 

Curing is the process of maintenance satisfactory moisture content or humid condition in concrete for certain period. Curing is done to complete the hydration reaction, so may continue until the desire properties are developed to a sufficient strength.

8.8.1.  Spraying Water & Curing Compound

• Concrete must cure after concrete casting and finishing in early period of hydration. Water is sprayed on the concrete through a hose or by spray pump of several times during each day to maintain sufficiently moisture for at least 4 days.
• For vertical walls, columns, beams and shear walls, sprinkle water at least times a day for 4 day. This required at least 3 cycles for per day with interval of 4 hours.
• If shortage of water supply, curing compound to be applied on concrete surface using brush or roller as soon as possible after final troweling, it’s to prevent premature water loss due to evaporation. For vertical surfaces, apply immediately after removal of formwork.

8.8.2.  Wet Gunny Bags

• For slab structures, wet gunny bags coverings method of curing is applied. This method can be achieved by applying coverings that are saturated with water. 
• Care should be taken to cover the entire surface with wet fabric, including the edge of slabs. The covering should be kept continuously moist so that a film of water remains on the concrete surface throughout the curing period. 
• Best way is to keep the concrete under wet gunny bags for 4 days and then commence water by way of ponding or spray

8.9. Concrete Repair

8.9.1. General

All concrete repair is a HOLD POINT in the ITP and only proprietary factory made materials approved by the Company shall be used for the repair.
The surface preparation of the concrete to be repaired & the mixing, application & curing of the (proprietary) repair mortars/(micro) concrete shall be as per manufacturers requirements/ recommendations and /or the specifications applicable for concrete shall be followed if specific requirements are not given by the manufacturer (e.g. curing).
All repair areas shall be covered from direct sunlight.
The repair shall only be carried out after the curing has been completed.

8.9.2. Repair of Cracks.

All cracks with a crack width greater than 0.3mm
Note: Cracks with a width exceeding 0.3mm are not confirming to the specification & a Non Conformance Report (NCR) shall be raised.
Open the crack, by chiseling a V –cut, to a depth where the crack visually seems to stop; however the maximum depth for chiseling is 20mm. The crack shall be cleaned with compressed air. Fill the crack up with water and observe whether or not the crack continues by looking for air bubbles in the water due to air escaping out of the crack.
If air bubbles are observed, an approved low viscosity resin shall be poured into the crack as per manufactures recommendation until the crack is fully saturated with the resin. 
Repair / seal the V-cut of the crack, after injection, with an approved shrinkage controlled structural grade cementitious repair mortar system.
If no air bubbles are observed, the V-cut shall only be repaired/sealed as per above. Where detection of a possible continuation of the crack with water filling is not possible (on vertical faces) the crack repair shall be discussed between Company and Contractor, looking for similarities with horizontal cracks in the same area. 
Where similarities are not found and/or agreed the crack shall be deemed to be deep and injected with epoxy and the V-cut further repaired/sealed as per above. All cracks with a crack width between 0.1 and 0.3mm (Only for Non Coated Areas) If the crack is reaching anchor bolts or box-outs, apply the same repair method as for cracks with a crack width of greater than 0.3mm.

8.9.3. Repair of Minor Surface Deficiencies in The Concrete (Air Voids, Etc.)

Surface defects that can be enclosed by a 50mm circle and in which circle the concrete cover is not reduced by more than 10mm are defined as minor surface deficiencies (refer to section 3.24 of T-13.376.358).  These minor voids shall be filled with fine mortar incorporating polyvinyl acetate (approved is Renderoc RF, for a maximum thickness of 5mm).

8.9.4. Repair of Major Surface Deficiencies in The Concrete

Note: Major surface deficiencies are not confirming to the specification and a Non Conformance Report (NCR) shall be raised. Major surfaces deficiencies are deficiencies that cannot be enclosed by a circle of
50mm and/or where the concrete cover has been reduced by more than 10mm and up to the rebar zone (no rebar exposed). Defective concrete shall be removed up to sound concrete. These major deficiencies shall be repaired by an approved shrinkage controlled structural grade cementitious mortar system (approved is Renderoc Sxtra).

8.9.5. Major Concrete Repair 

Note: Major concrete repairs are not confirming to the specification and a Non Conformance Report (NCR) shall be raised.
Areas where after removal of the defective concrete the rebar becomes exposed and/or where the extend of the repair is such that formwork has to be used are defined as Major Concrete Repairs. The defective concrete shall be removed up to sound concrete.
If the defective concrete extends to the rebar a clear gap of at least 20mm shall be created behind the rear face of the rebar, such that a gloved hand can comfortably reach behind the main bars. 
All exposed rebar shall be carefully cleaned by wire brushing before the repair & the concrete faces to be scabbed & wetted as per requirement/recommendation of the manufacturer of the repair micro concrete.

8.10. Curing Compounds

This is the best method of curing. It is suitable for curing horizontal surfaces such as floors, roof slabs, road and air field pavements. The horizontal top surfaces of beams can also be ponded. After placing the concrete, its exposed surface is first covered with moist hessian or canvas. After 24 hours, these covers are removed and small ponds of clay or sand are built across and along the pavements. The area is thus divided into a number of rectangles. The water is filled between the ponds. The filling of water in these ponds is done twice or thrice a day, depending upon the atmospheric conditions. Though this method is very efficient, the water requirement is very heavy. Ponds easily break and water flows out. After curing it is difficult to clean the clay.

9. QUALITY CONTROL 

The work ability of the concrete will be continuously monitored at delivery place before casting. Samples for conducting tests for determining the compressive strength on concrete will be taken according to the specifications.
Concreting will be carried out using the approved design mixes and that specified for the structure. The concrete from approved sources only will be used for all concreting works.
All rebar and forms will be cleaned of debris and foreign materials before pouring.
It will be ensured that the temperature of concrete at the time of placing does not exceed more than 30° C.
The concrete pouring will be done within the initial setting time of the cement. For the purpose of this, the time of batching as marked on the delivery sheet will be considered.
During hot weather, reinforcement temperature will be reduced by shading, water pray before pouring as well as additional crew wiII be engaged to expedite the finishing etc. However preference for night pouring of concrete will be given.
The concrete will then be poured into the mold I form after ensuring that it is free of all foreign materials or debris; the inserts are in place; the re-bars are as per the drawings and all other QC requirements are complied with.
The concrete surfaces will be rendered appropriate finish to eliminate all voids and pits unless specified otherwise in the drawings.
The concrete will be laid in layers not exceeding 300mm in thickness; each layer compacted separately before the next is laid.
At least two vibrators of needle type will be made available at the site, where one of them acts as a stand-by.
In case of mass pouring, the concreting will be done uninterrupted so that cold joints can be avoided. However, in case of slabs/ paving appropriate pre-approved construction joints will be provided. 
For the mass concrete pouring, specific method statement will be submitted. Concrete surface will be finished as per specifications within the initial setting time of concrete. Immediately after finishing surface shall be covered with white polyethylene sheeting which shall be in contact with concrete surfaces to avoid evaporation of moisture content from fresh concrete. Control joints, if any, will be cut within 12 hours after placing of concrete.

10. SAFETY PLAN:

Safety of men and materials is a high priority for Client. All safety measures will be observed during the entire works. Detailed safety measures for every works will be elaborated in the concerned JSA being submitted by electrical safety department to PMT HSE department, however basic account of the safety strategy is given under:

• All the activities will be envisaged a week in advance and job safety requirements will be worked out by analyzing the likely hazards and resorting to preventive.
• Proper housekeeping at the end of the day is a part of the mandatory tasks assigned to workers to avoid accidents due to littered tools and materials.
• Flagmen will be engaged to control the movement of trailers, cranes, pumps and other mobile equipment’s.
• Weekly tool box talk will be conducted and brief safety measures required for the ensuing days will be discussed.
• First aid facility will be available entire the period in the work site.
• The JSA will be submitted separately by the HSSE department.

CONCRETE REPAIR LOG
S.NO	AREA	GRID	CRACKS	REPAIRED	Signature
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