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Method Statement for Polyurethane (PU) Date: July 18,

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METHOD STATEMENT
FOR
POLYURETHANE INJECTION WORKS
(PU–Injection)

PREPARED BY REVIEWED BY APPROVED BY

Hrvoje
Name: Issam Odeh Rabei El Khatib Raed Ammori
Vucemilovic
Geotunnel QA/QC Construction Project
Position: QA/QC HSE Manager
Manager Manager Manager
Engineer

Signature:

Date:

REVISION HISTORY
Rev No. Issue Date Purpose of Revision
00 July 18, 2023 First Issue
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TABLE OF CONTENTS
1. Purpose and Scope of Work...................................................................................................................................3
1.1 Purpose.........................................................................................................................................................3
1.2 Scope of Work............................................................................................................................................3
2. Health & Safety.......................................................................................................................................................3
2.1 General.........................................................................................................................................................3
2.2 Work Specifics............................................................................................................................................4
2.3 Personal Protection PPE..........................................................................................................................5
2.4 First Aide......................................................................................................................................................6
3. Environmental Issues..............................................................................................................................................6
3.1 Waste Disposal..........................................................................................................................................6
4. Work Performance Sequence and Methodology...................................................................................................7
4.1 Preparation..................................................................................................................................................7
4.2 Sealing of cracks and construction joints.........................................................................................7
4.3 Sealing of precast permanent manhole (sections).......................................................................9
4.4 Sealing of jacking pipe joints..............................................................................................................10
5. Quality Issues........................................................................................................................................................11
6. Resources..............................................................................................................................................................11
7. Definitions.............................................................................................................................................................12
8. Attachments..........................................................................................................................................................13
8.1 Construction Risk Assessment...........................................................................................................13
8.2 Inspection and Test Plan......................................................................................................................15
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1. Purpose and Scope of Work

1.1 Purpose
The purpose of this document is to outline the necessary activities and step-by-step
procedure for the implementation of the waterproofing for the leaking spots, cracks &
construction joints by the use of Polyurethane Injection resin.

1.2 Scope of Work

This method statement describes the flexible sealing of wet cracks, with and without
hydrostatic water pressure in reinforced concrete with polyurethane injection and
acrylic resins. The method statement also includes a chapter on the methods required
for tunnel crown injection with cementitious based injection grouts in dry scenarios
without hydrostatic pressure.
The general Scope of Works includes:
 Mobilization & Demobilization of Injection team to each location
 Supply & Installation of packers.
 Supply, preparation & injection of Polyurethane material.
 Manpower and Equipment per Shift
 Provide Mobile crane.
 Providing Generator & Ventilation System (if required)
 Keep records of PU Injection activities
 Submission of Report
2. Health & Safety
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2.1 General
The following General HSE Procedures shall apply and inspected prior to allow any
Personnel start work on site:
 All employee working on site shall pass the medical examination as per Qatar
rules and also should be examined to detect their adequacy for the critical and
hard work.
 Emergency contacts should be available with every member on site.
 Emergency plan for evacuating injuries shall detail the following:
 The first aid treatment
 Direct reporting to HSE teams
 Contact Ambulance for direct evacuating to hospital (if necessary)
 No “Drugs, Alcohol and Smoking” Policy which will prevent any site member
from entering any part of the site in such case and disciplinary actions will be
applied to anyone who violates this policy up to and including termination
 Site welfare facilities should be prepared and checked before allowing works:
 Shaded area nearby for resting and eating, in which the locations
should be agreed by the Engineer before erection.
 Fresh water filled daily
 Sewage tankers to clear and clean the wastes on daily basis
 Cleaning and inspection will be done and recorded on daily basis
 Main policy for safety measurement is to implement the best practice,
measurement and mitigation to protect all parties in and outside the
working area
 Safety messages, posters and instructions should be published in Arabic, English
and Indian language
  Safety signs shall be illuminated to be clear at Night, checked and reported on
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daily basis
 All machines shall be licensed, checked and tagged before using on site
including (Excavators, Shovels, Trucks, Generators, Pumps, Cranes, Pickups,
etc…)
 Operators, Foremen and the site staff shall be inducted and trained before
allowing them working on site.
 Trained / licensed banks-man shall be provided for every Machinery
 Flagman should accompany any wheel equipment during movement and
mobilization

2.2 Work Specifics

 Work teams performing the sealing works shall access the leaking points at the
tanks wall enter the manholes through established Project confined space entry
procedures that is via confined space permits with entry logging and a tally
board;
 For sealing works of the tanks wall pipelines between any two manholes, exiting
of entrants may occur on the “other end”, in which case the exiting will be
noted on the tally board of another manhole, and remark shall be added on the
entry manhole log to that purpose; the access will be by using a man-basket or
inspected scaffolding ladder/stair entrance.
 Teams working inside the manholes and pipelines shall carry a gas monitoring
device for continuous gas monitoring.
 Sealing works on completed pipelines shall be done for man-entry pipelines.
 All entering staff required to enter tunnels and shafts must have confined space
training accreditation
2.3 Personal Protection PPE
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 Apply the approved and proper safety

measurement, fencing and protect every part of the
works according to the approved HSE Plan.
 All personnel shall wear proper PPE.
 Handling or processing injection products can cause chemical irritation to the
eyes, skin, nose and throat.
 Appropriate eye protection should be worn at all times while handling and
mixing products.
 Safety shoes, gloves and other appropriate skin protection must be worn at all
times.
 Always wash hands with suitable soap after handling products and before food
consumption.
 In addition to protective clothing, it is also recommended to use a barrier cream
on the skin. If any injection resin gets on clothing, remove the garment at once.
The friction of resin-saturated fabric on the skin can cause serious chemical
burns. Wash your exposed skin occasionally during the workday and
immediately if any material gets on it. Avoid using solvents, since they can help
material penetrate into the skin and solvents themselves are aggressive and
harmful to the skin. Avoiding skin contact by keeping tools and equipment clean
is one of the best ways to protect oneself. Despite safety precautions, with any
instances of skin contact rinse immediately with clean warm water and use soap
to thoroughly clean the skin.
 FOR DETAILED INFORMATION REFER TO THE SAFETY DATA SHEET
2.4 First Aide
 Flush eyes with plenty of clean water,
occasionally lifting upper and lower eyelids.
Remove contact lenses immediately. Continue
to rinse eye for 10 minutes and then seek
medical attention.
 Seek immediate medical attention in the event
of excessive inhalation, ingestion or eye contact causing irritation. Do not
induce vomiting unless directed by medical personnel
  Rinse contaminated skin with plenty of water. Remove contaminated clothing
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and continue to rinse for 10 minutes and seek medical attention.
 FOR DETAILED INFORMATION REFER TO THE SAFETY DATA SHEET OF THE
CORRESPONDING PRODUCT!

3. Environmental Issues
There are no major environmental issues expected during the subject works,
apart from the specialized subcontractor cleaning up any work location from
packaging of products they will use. Any liquid wastes that may be present from
tool and pump cleaning processes shall be collected in a bucket (that it the
cleaning shall be done “over” a container such as a bucket) and disposed of in a
closed bucket or drum and be appropriately disposed of at a later point.

3.1 Waste Disposal

 Do not empty surplus material into drains. Dispose
responsibly through a licensed waste disposal contractor in
accordance with legislation and local / regional authority
requirements. Avoid run-off into soil or waterways, drains or
sewers.
 Hardened resins can be disposed of with other
combustible waste in a waste incineration plant. Under no
circumstances burn the resin in an open fire, due to the potentially dangerous
gases which could be released.
 Uncured resin must be disposed of as hazardous waste. It is forbidden to mix it
with conventional waste.
 FOR DETAILED INFORMATION REFER TO THE SAFETY DATA SHEET

4. Work Performance Sequence and Methodology

4.1 Preparation
The sealing material TamPur is not pre-mixed with a catalyst, but is used as a single
component material which can be poured directly into the container of the pressure
pump which will be used for injection sealing. The material is brown liquid.
After use, the pressure pump that was used for injection must be cleaned with TamPur
cleaner or thinner.
Cleaning of the surface helps the technician to identify the exact location and the
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width of the crack to be injected. Sometimes the concrete surface is hidden under a
surface of mineral deposits left from long-term water leakage. Items that obscure the
crack should be removed, because the crack must be seen clearly in order to lay out
the drilling patterns for the injection holes.
The cracks must be free from loose particles, dust, oil, grease or any other
contamination etc.
Mechanical packers used in tunnel crowns must be secured to seal any pre cast or
drilled opening.

4.2 Sealing of cracks and construction joints

Cracks and construction joints are sealed by drilling boreholes at an angle, from
outward into the crack, with the borehole reaching the crack as some point inside the
wall/concrete element. The boreholes are made staggered in so called stitched format.
Borehole diameter shall be 14 mm

Figure 1. Staggered boreholes for cracks

After the borehole has been cleaned of debris, a packer shall be inserted into the
borehole and fixed into it by expansion so as to withstand the pumping pressures.
TamPur is injected under pressure, and with sufficient quantity, through the packer. It
is left for 12 hours to cure. If after 12 hours there is still a leak residue, repeat the
injection action from boreholes close to locations where it still leaks and wait again for
12 hours. The process is repeated until the leak completely stops.
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Figure 2. Borehole reaching the crack inside the wall

 Figure 3. Boreholes for a construction joint
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Upon completion of sealing, the drill holes shall be filled by the approved project
material, and subsequently the GRP liner shall be in-situ re-laminated over the drill
holes.
The packer’s installation locations do not depend on the orientation or size of the
cracks, it should be first installed near the observed leaks. No certain procedure to be
followed (up to down or right to left).
4.3 Sealing of precast permanent manhole (sections)
Sealing of precast permanent manholes or such sections will be done by drilling into
the joint (in the slit between to segments), perpendicular to the wall, until reaching
the rebate of the upper precast element (which should not be drilled). The driller shall
be informed at what depth is the rebate in advance. Borehole diameter shall be 14
mm
If multiple boreholes are required their spacing should be not less than 300 mm.
After the borehole has been cleaned of debris, a packer shall be inserted into the
borehole a fixed into it by expansion so as to withstand the pumping pressures.
TamPur is injected under pressure, and with sufficient quantity, through the packer. It
is left for 24 hours to cure. If after 24 hours there is still a leak residue, repeat the
injection action from the same borehole or by drilling another (according to
judgement) and wait again for 24 hours. The process is repeated until the leak
completely stops.
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Figure 4. Borehole location for sealing of precast manhole

joints
Upon completion of sealing, the drill holes shall be filled with CIKOPatch 2K, and
subsequently the GRP liner shall be in-situ re-laminated over the drill holes.
4.4 Sealing of jacking pipe joints
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The standard jacking pipe joints shall be sealed by drilling a sealing borehole at
position of compressed joint between two pipes. The exact position of the compressed
joint will not be visible, but can be determined by knowing the average spigot length
for given pipe diameter. Borehole diameter shall be 14 mm.

Figure 5. Borehole location for sealing of jacking pipe joints

Table: off-joint measurements and drilling depths for jacking pipes joint leaks sealing
No Pipe Wall Spigot H (mm) D (mm)
. diameters thickness length
(mm) (mm) (mm)
1. 800/1080 140 144 151 40
2. 1000/1285 142.5 144 151 40
3. 1200/1490 145 144 151 45
4. 1600/1940 170 174 181 60
5. 2000/2400 200 174 181 70

After the borehole has to be cleaned of debris, a packer shall be inserted into the
borehole a fixed into it by expansion so as to withstand the pumping pressures.
TamPur is injected under pressure, and with sufficient quantity, through the packer. It
is left for 24 hours to cure. If after 24 hours there is still a leak residue, repeat the
injection action from the same borehole or by drilling another (according to
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judgement) and wait again for 24 hours. The process is repeated until the leak
completely stops.
Upon completion of sealing, the drill holes shall be filled with CIKOPatch 2K, and
subsequently the GRP liner shall be in-situ re-laminated over the drill holes.

5. Quality Issues
The following Quality measurements shall be considered before starting the
Excavation works on site:
Quality Issues Mitigation Actions

a. All site supervision staff shall be aware and well known by

the approved “Project Quality Plan” and its procedures
and instructions
1. Geotunnel Staff
b. Meetings/briefings shall be prepared to train all site staff
to the approved Method and Procedures to followed in the
works

a. Project Quality Plan shall be prepared and submitted for

2. Project Quality Plan approval at the beginning of the project and No works

“PQP” shall start on site till receiving the approval for the “PQP”
b. PQP shall follow the procedures of QCS 2010, Section 1,
Part 8

a. Method Statement for the subject shall be submitted/

3. Method Statement
reviewed/ approved before proceeding with works

a. Sealing boreholes which are drilled through

prefabricated GRP (in case of sealing of jacking pipe
leaks) shall be filled with mortar, but GRP lamination
4. Sealing works
shall additionally be done over the hole, in a patch. In
case of series of boreholes, lamination patching shall
be continuous.
6. Resources
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To ensure correct application of all components please refer to the following

documents of each product component:
 Product Data Sheet
 Safety Data Sheet
 Vehicles for material and equipment transport (pickups)
 Electric pressure pump for TamPur
 Electric hand drill for boreholes
 Paddle mixer
 Auxiliary manual material (cloths, buckets, trowels etc.)

7. Definitions

 PU-Injection
is a water control resins that are used wherever water is a problem and needs
to be controlled or permanently resolved. High Foaming, fast reactive resins are
effective in controlling or stopping difficult water ingress events.
 TAMPUR 130 / TAMKAT 130
is a semi-flexible polyurethane grout that is a single-shot hydrophobic
polyurethane based on MDI in combination with polyether polyols and an amine-
based catalyst.
 TAMPUR 170 LV
is part of our new ECO range and is a two component, low viscosity,
hydrophobic polyurethane injection resin formulated to produce a highly
resilient flexible gasket. TamPur 170 LV is especially suited for elastic
filling/bonding of cracks, joints and voids that exhibit movement and for
injection into injection tubes. It is commonly used as permanent primary
injection and for second pass injection to tighten up.
 NC LACQUER THINNER
is a combination of selected solvents for Nitrocellulose coatings to reduce
viscosity of the product before the application. For cleaning injection pumps
during or directly after the Injection with PU resins.
 Method Statement
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is a document that shall be submitted, reviewed and approved before
proceeding with the works.
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8. Attachments
Date: July 18,
8.1 Construction Risk
Method Statement for Polyurethane (PU) Page 16 of 19
Assessment
2023
Injection Works
Residual
Risk
Ite Who is Action Risk
Activity Hazard and Risk Rating Necessary Control Measures
m at Risk? By Rating
S L R S L R
Applicators and manipulators of
Work with Swallowing, spraying Laborer’s TamPur material to wear obligatory Traffic
TamPur, mixing, into eyes, getting onto , site goggles and full breathing masks, with engineer
carrying, skin, inhalation with staff
1. 4 3 12 fully covering clothes. Forced 4 1 4
pumping consequences as per
MSDS ventilation to be established, where
possible, or smaller fans at application
location.

Work within a Difficult rescue Laborer’s Crane and man-basket at one end of Site
2. confined space procedures in cases , site 4 3 12 tunnel to be on stand-by during the engineer 4 2 8
staff
of emergency work
ROADS AND CM – Project Manager
Project: INFRASTRUCTURE QM – Quality Manager
IN AL EBB & HSEM – HSE Manager
LEABAIB P-01
Assessment Carried Position: Quality Manager
out by:
Assessment Date
Reviewed by: Position: HSE Manager
Approval: Position: Construction Manager
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Hazard 1 2 3 4 5 LEGEND:
Severity Method Statement for Polyurethane (PU) Date: July 18,
Page 17 of 19
First Aid Injury Disablin Permane 2023
Fatal The likelihood of harm may be rated as:
Injection Works
Only Causing g Injury nt Injury
RED – HIGH RISK (Where it is certain that harm occur)
Time Off Disabling
Likelihood of Work Injury YELLOW – MEDIUM (Where harm will often occur)
Occurrence
GREEN- LOW (Where harm will seldom occur)
5
5 10 15 20 25 S = Hazard Severity; L = Likelihood of Occurrence; R = Risk Rating
Inevitable
Rating Description Likelihood of Occurrence
4
4 8 12 16 20
Likely to Occur Very Unlikely to Highly unlikely, but it may occur in exceptional
1
Occur /Rare circumstances. It could happen, but probably never will.
3
3 6 9 12 15 Not expected, but there's a slight possibility it may
2 Unlikely to occur
May Occur occur at some time.

2 May Occur/ The event might occur at some time as there is a history
3
2 4 6 8 10 Possible of casual occurrence.
Unlikely to Occur
There is a strong possibility the event will occur as there
4 Likely to Occur
1 is a history of frequent occurrence.
1 2 3 4 5 Very likely. The event is expected to occur in most
Very Unlikely to Occur Inevitable /
5 circumstances as there is a history of regular
Almost Certain
occurrence.

8.2 Inspection and Test Plan

Project ROADS AND INFRASTRUCTURE IN AL EBB & LEABAIB P-01 ITP No. ALEBBP01-QTC-GEN-TUN-ITP-00028
Employer Public Works Authority / ASHGHAL Rev. 00
Engineer Date 17/07/2023
Inspection Code Inspection Authority
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H – Hold Point: Attendance at the site is mandatory and S – Surveillance Point: Random attendance at site, no signature 1 - Site / Quality Engineer 3 -PMC (the Engineer)
signature of QCE is required on the Work Inspection Request required on the Work Inspection Request (WIR) or its accompanying
including the check sheet (if available) at the time of the documentation.
inspection to release the following work.
W - Witness Point: Attendance at the site is expected by QCE, RP - Record Point: Documentation to be recorded, QCE signature 2 - QCE 4 - Third Party or Testing Agency /
the signature is required on the Work Inspection Request (WIR) required on the Work Inspection Request or its accompanying Lab. or Stakeholder/ Authority
including the check sheet (if available). documentation.
I - Information

Inspection Authority /
Item Test / Inspection Activity Reference / Controlling Acceptance Form of Record / Code
Frequency Remarks
No. Description Document Criteria Verification Document
1 2 3 4

Method Statement for Approved

1. manholes and pipelines Detailed Design Before start of works Approved submittal H RP RP
submittal
sealing works

Method Statement
for manholes and Approved
2. Sealing of manhole leaks Each section of works Approved inspection H W S
pipelines sealing inspection
works

Method Statement
for manholes and Approved
3. Sealing of pipeline leaks Each section of works Approved inspection H W S
pipelines sealing inspection
works
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Inspection Authority /
Item Test / Inspection Activity Reference / Controlling Acceptance Form of Record / Code
Frequency Remarks
No. Description Document Criteria Verification Document
1 2 3 4

Filling up of drill holes with Method Statement

Cikopatch and re- for manholes and Approved
4. Each section of works Approved inspection H W S
lamination over the drilled pipelines sealing inspection
holes works