The method statement for anti-carbonation coating defines the control procedures, and technical details covering surface preparation, pre-application, during the application, and completion of the application method, to achieve the optimum performance for the specified anti-carbonation treatment used in concrete substrates.
What is the anti-carbonation coating?
Anti-carbonation coating is a surface treatment primarily used to protect the concrete substrates from the ingress of contaminants such as carbon dioxide (in reinforced-concrete construction, the chemical reaction between carbon dioxide in the air and calcium hydroxide and hydrated calcium silicate in the concrete is known as neutralization), chlorides, acid gases, water sulfates, and sulfur dioxide.
This protection extends the design life of a reinforced concrete structure. Such a barrier prevents further corrosion of steel reinforcement and subsequent spalling of the surrounding concrete.
Table of Contents
Method Statement For Anti-Carbonation Coating
I. Description of Works
1. Introduction
This Method Statement defines and describes the control procedures, and technical details covering surface preparation, pre-application, during the application, and completion of the application, to achieve the optimum performance for the specified Anti-Carbonation Coating using xxxxx (or equivalent approved material) for (Name of Project).
2. Definitions
SE Site Engineer
QC Quality Control Engineer
SF Site Foreman
PM Project Manager
SA Site Agent representative from the Lab
HSE Manager Health, Safety & Environmental Manager
HSE Officer Health, Safety & Environmental Officer
PS Project Specifications
CEMP Construction Environmental Management Plan
QCP Quality Control Plan
HSE Plan Health, Safety, and Environment Plan
GWL Ground Water Level (meter)
NGL Natural Ground Level (meter)
Note: All dimensions are in mm unless specified.
3. Reference
Technical Data Sheets
HSE Plan
CEMP
Material Approval Submission for Anti-Carbonation System
4. Responsibilities
Project Manager
Responsible for accomplishing the stated project objectives, including creating clear and attainable project objectives, building the project requirements, and managing the constraints of the project management triangle: cost, time, scope, and quality.
The Project Manager shall be responsible for ensuring that the Project Quality Plan and the Inspection and Testing procedures, method statement, HSE safety, and all contractual documentation are maintained up to date and accessible to all parties.
Construction Manager
Responsible for overall construction activities ensuring that the method statement for anti-carbonation coating, quality, and safety procedures are implemented and required approval permits are obtained.
Site Engineer
Supervise operations in accordance with the approved Method Statement, shop drawings, specifications, material submittals, and schedules to achieve the acceptance of the project deliverables.
QA/QC Engineer
QA/QC Engineer is responsible for ensuring work has been done per the approved method statement; inspections are done as per Quality Control Procedure and QA/QC Checklist.
Chief Surveyor /Land Surveyor
Per the approved shop drawings, carry out a pre-construction survey to fix the locations and corresponding elevations.
Ensure quality and compliance during phases of surveying works and the regular checking of the surveying equipment or periodic calibration from a third party.
Ensure the validity and the serial number of calibration certificates are available and posted on the survey equipment.
Ensure proper safety guarding of surveying equipment.
To maintain the records of all surveying equipment handled.
Scaffolding Manager /Supervisor
Ensuring safe access is provided for scaffolders to work.
Ensuring all his Foremen, Team Leaders, and workers conform to site safety regulations and are Third Party Certified (TPC).
Ensuring that all scaffolds are erected according to site scaffold procedures.
Ensuring scaffold schedules are met and still working within the site safety regulations.
Ensuring that material and workers are available to meet the site scaffolding requirements.
Ensuring all documentation adheres to Tool Box Talks, Harness Inspection, Site Request System, Scaffolding Tagging System, and Safety reports.
Survey Aide
Maintain and use Surveying equipment. Assist Surveyors in taking measurements, record measurements manually or electronically, and peg out boundaries.
HSE Manager
Health, safety, and environmental (HSE) managers generally plan, coordinate, and implement organizational issues and directives.
They ensure safe environmental working conditions for all employees.
HSE Engineer
Ensure enforcement of safety procedures in accordance with the approved HSE Plan.
Will be closely monitoring the site engineer’s strict implementation of the MS and Painting Risk Assessment, the use of proper tools and equipment to maintain safety, certifications of equipment and their adherence to safety regulations, reporting of any unsafe work, or stopping work that does not comply with ES&H procedures.
First Aider
The first aider responds promptly when requested, operates with competence, knows how to secure additional help when needed, reports incidents and actions taken, and complies with requirements for certification.
5. Interfacing with Other Operations
Concrete Works
6. Duration, Phasing with the Subcontractors
The work is indeterminate but shall not critically affect the progress of works.
7. List of Subcontractors
Subcontractor/Supplier:
xxxxx
II. Resources
1. Plant, Equipment, and Tools
| Description | No. of Units | Application |
| Wire brush, sand paper, Carborandum stone etc. | 1 | Surface Preparation |
| Water Jetting Equipment / Grinder | 4 | Surface Preparation |
| Roller, Scraper, Spray Equipment, Compressor | 1 | Application of Paint |
| WFT Gauge – preferably Aluminum | 1 | Film Thickness Reading |
| Moisture Meter | 1 | Moisture Reading |
| PosiTector 200 DFT Meter | 1 | Coating DFT Measuring |
| Dew Point Meter | 1 | Dew Point Reading |
2. WorkForce
| Designation | No. of Persons |
| Site Engineer | 1 |
| QA/QC | 1 |
| Land Surveyor | 1 |
| Survey Aide | 1 |
| HSE Engineer | 1 |
| First Aider | 1 |
| Scaffolding Team | 1 team |
| Helper | 2 |
| Painter | 1 team |
3. Light Tools
| As per the Site Requirement | No. of Units | Application |
| Hand Tools | As per the Site Requirement | For Construction |
| Power Tools | As per Site Requirement | For Construction |
III. Materials
Approved Anti Carbonation Coating/Paint
Repcoat Primer (example/replace it with the equivalent approved material)
Repcoat (example/replace it with the equivalent approved material)
IV. Site Planning
The duration of work shall be indeterminate but will not critically affect the progress of the project.
a. Preparation
Permits from the concerned authority shall be obtained prior to starting work at the site.
The contractor shall ensure that all gate passes, permits, tools, materials for safety precautions, manpower, and equipment are available before the commencement of work.
The Site Team shall ensure that access roads are always clear from any obstruction and that the site is always accessible.
Provision of access and egress such as ladders, steps, ramps, or other safe means of egress and be within a reasonable distance and must be extended at least 1.0 m above the ground.
b. Site Clearance
Before the commencement of the activity, the work area shall be cleared of all debris, materials, or other obstructions.
c. Traffic Management
With the assistance of the Safety Officers, the Site Team shall coordinate logistics and materials movement through the site following the direction and road signs displayed on site. The required diversion routes, including the required traffic signs, shall be marked on drawings.
The Work Permits and Operator Certificates shall be compiled and filed for reference by authorized personnel.
d. Pre-construction Safety Meetings
The meeting shall be scheduled prior to the beginning of the work and before any Subcontractor starts on the project.
General contractual safety, health, and environmental requirements.
Traffic safety will be discussed to emphasize these meetings.
Roles of the contractor, subcontractors, authorized representatives, and all project workers.
Accident reporting requirements.
Specific details of the work to be performed along with the use of personal protective equipment.
V. Procedure – Method Statement for Anti-carbonation coating
Repcoat is a one-component water-based acrylic elastomeric protective and carbonation coating system. This product has excellent concrete protection properties that protect concrete against concrete carbonation, moisture, chloride attack, UV degradation, minor cracks, etc. and is ideal for concrete bridges.
V.1 Scope of Work
The scope of work includes the detailed requirement for preparing and applying all products to be used in the specified coating system.
Proposed System:
Repcoat Primer (full coat) (example/replaced it with the equivalent approved material)
Probuild PF200 (touch up) (example/replaced it with the equivalent approved material)
Repcoat (full coat) (example/replaced it with the equivalent approved material)
Repcoat (full coat) (example/replaced it with the equivalent approved material)
V.2 Substrate / General Requirements
All painting shall be strictly carried out in accordance with the project specifications and manufacturer’s recommendations.
The contents of the safety data sheets are to be briefed to the operating staff and ensured that they understand the risks and are clear on the required/necessary control and PPE measures.
A program and sequencing have to be done by the construction team for the painting of the different areas to ensure that structures can be coated in a continuous operation with paint from the same batch.
The surface to be coated shall be in ready condition. All necessary repairs to exposed concrete surfaces are to be completed well in advance of the painting to ensure repairs/curing agents have completely dried out.
The substrate shall be fully cured before starting any painting work.
The substrate should have enough strength to carry out painting work. A scratch with a metallic nail should not produce a deep impression.
The substrate should be free from oil, grease, and other chemical impurities.
No application of the coating in the works shall be undertaken until trials have been completed and site samples are approved.
Areas/items that need protection adjacent to the painting area shall be masked off.
No coating will be performed during sandstorm/ windy, rainy, and similar climatic conditions. If it begins to rain while the coating application, the coating job has to be stopped, and the affected area has to be repainted later.
The substrate’s Moisture content must be less than 4% when tested with a moisture meter.
The substrate should be sound, clean, and free from dust & flaking materials. All holes and deep cracks should be filled with suitable fillers. Remove any traces of oil, grease, chemical contaminant, mold & algae, and treat with a suitable anti-fungicide or bleach solution.
V.3 QA / QC
Ensure a dry, clean, and sound substrate.
Measure the moisture content in the substrate and ensure that it does not exceed 4% (when tested with a calibrated moisture meter).
Use a WFT gauge at regular intervals to control the wet film thickness during all stages of the application procedure. Dry film thicknesses can be converted from the wet readings using the following formula; (WFT X V.S %) / 100 = DFT.
DFT will be tested using the PosiTector 200 to ensure the DFT 300 micron for the full system.
Ensure sufficient ventilation during and immediately after painting.
Avoid painting if the substrate temperature is above 55 °C.
Avoid painting if the relative humidity % where the painting is taking place is above 85%.
On exterior areas, avoid painting during windy and rainy conditions.
V.4 Surface Pre-treatment
Any traces of oil and grease are to be thoroughly removed with a suitable emulsifier to be applied using a stiff brush, and once removed, the area shall be freshwater rinsed, ensuring all traces of residues are removed.
V.5 Surface Preparation
All surfaces should be mutually inspected before starting the painting works to ensure that all surfaces are ready and suitable for applying the protective coating.
The substrate will be kept dry, clean, and free from any laitance, wax, grease, dirt, oil, or any materials that could affect the bond.
All cracks and unsound concrete will be repaired before starting the application by using approved repair materials.
All blowholes & minor imperfections will be repaired.
On new cementitious substrates, leave for 14 days before coating. If in doubt, leave for up to 30 days to cure before coating fully.
All surfaces should be applied by high water jetting to make them ready for the primer coating.
V.6 System Application
V.6.1 Primer Coat
Substrate temperature, moisture content, and relative humidity should be tested and recorded before the start of the primer application if the concrete substrate age is less than 14 days.
Repcoat Primer Siloxane Acrylic Primer is ready to use a material that requires thorough stirring with a mixing stick prior to application. Repcoat Primer is a ready-for-use, single-component primer based on a silane/siloxane and an acrylic resin providing protection from rebar corrosion, efflorescence, freeze-thaw damage, water penetration, oil penetration, mold, and mildew.
Apply evenly by use with brush or textured roller at a rate of Horizontal application: 0.2 – 0.4 litre/m² (or 2.5-5 m²/liter) & Vertical application: 0.1 – 0.2 liter/m².
We should wait for a minimum of 12 hours after priming and before the application of Repcoat.
The primed substrate should be sound, dry, clean, and free from dust or other contamination.
V.6.2 Top Coat
Sufficient materials, equipment, and labor will be arranged for each independent application area.
We can apply Repcoat within temperature (5°C – 38°C).
A first coat will be applied by an airless spray machine with a coverage of 0.3 liters/m² to achieve 150-micron dry film thickness.
We should wait at least 2 to 4 hours at 35°C and 4 to 6 hours at 25°C from the application of the first coat at the same rate.
A second coat will be applied at a right angle to the first coat by an airless spray machine with a coverage of 0.3 liter/m² to achieve 150-micron dry film thickness.
If the overcoating time (8 hours) is exceeded, the first coat will be abraded with sandpaper before applying the second layer.
Total dry film thickness will be kept at 300 microns.
Two coats should always be used on dark, full heavy textured surfaces and when full carbonation protection is required.
V.7 Storage of coating materials
All material delivered to the site must be stored in accordance with local regulations and the manufacturer’s recommendations. It is recommended to store all paint material in shaded, dry, cool, and well-ventilated stores that are away from heat, ignition, and sunlight sources. Containers must be kept tightly closed. Storage area conditions at temperatures between 10°C to 35°C. The shelf life of 12 months from the date of manufacture in proper store condition. For further information, please consult the separate material safety data sheets.
V.8 General Notes
Care should be taken to remove masking tape immediately after each coat without allowing the paint to dry.
All corners/edges should be rounded off properly with the roller before allowing each Repcoat coat to dry.
Before the application of each coat, ensure that all dust and other surface contaminants on the previous coat are removed.
Please refer to the provided technical data sheet for each product to be used, following the recommendations within.
VI. Risk Assessment
Please refer to the attached document in Appendix A.
VII. Permit and Licensing Requirements
Refer to Appendix B for Permit to Work.
VIII. Drawings, Diagrams, Maps, and Survey Data
Please refer to the Method Statement content.
IX. Pre-Start Safety Briefing Arrangements
Refer to Risk Assessment in Appendix A.
1. Protective and Safety Equipment
All workers involved shall be equipped with adequate PPE as stated below:
a. Safety Helmet with Company Logo
b. Safety Boots
c. High Visibility Vest
d. Safety Goggles
e. Hand Gloves
f. Coveralls
g. Safety Harness
2. Information to Personnel
a. Safety Induction
b. Job training
c. Notices/Memos
e. START Card
3. Special Safety Requirements
a. All necessary personal/protective equipment (PPE), as well as harness, be provided.
b. Banksman, wearing distinctive vests, shall be assigned to help operators maneuver their equipment.
c. The equipment operators shall possess the required licenses and certificates.
d. Generated dust shall be controlled by water spraying.
e. The project safety officer and the project zone site engineer are responsible for ensuring that all operations are carried out with due regard to the safety of all project personnel & property.
f. All working activity shall comply with Client Safety Procedure.
g. First Aid Material.
h. General management of protection/operation hazards is to be observed.
i. In the case of working at night, please refer to Method Statement for Night Works (Reference no.:xxxx)
- Emergency Procedures – sample here
- Emergency Contact Numbers -sample here
XI. Environment and Quality Issues
1. Precautionary Measure
All precautionary measures shall be briefed to all workers prior to commencing activity.
2. Disposal Requirements
All waste shall be disposed of as per the Construction Environmental Management Plan and as per Government approved disposal areas.
3. Inspection, Test, and Sampling
Request for Inspection and Testing will be submitted prior to and after the execution of works.
4. Quality Assurance Requirements Table
Refer to Project Quality Plan
a. Project Specifications
XII. Attachments
1. Reference Documentation
Project Specifications
2. Appendices
Appendix A: Risk Assessment for Anti-carbonation Coating Application
Appendix B: Permit to Work
Appendix C: Inspection and Test Plan
Appendix D: Material Technical Data Sheet
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