QATAR MALL

GRAND ZONE - SCHOOL AND RESIDENTIAL

Method Statement for Concrete Repair

PROJECT NAME
GRAND ZONE-SCHOOL & RESIDENTIAL
CONTRACTOR’S NAME:
AL ALI ENGINEERING W.L.L.
CONSULTANT’S NAME:
KEO INTERNATIONAL CONSULTANTS
CLIENT’S NAME:
QATAR MALL
DOCUMENT NO:
GZ-AAE-MST-CIV-0004 Rev 3

Name Position Signature Date

Prepared By: Engr. Marivic Mousa QA/QC Engineer 15 December 2019

Reviewed By: Engr. Mohammad Abdelfattah QA/QC Manager 15 December 2019

Approved By: Engr. Mohamed Hussein Project Manger 15 December 2019

Revision History:
Revision Revision Date Revision Description
th
0 28 October 2019 First Issue-Revise and Resubmit
1 24 November 2019 Second Issue-Revise and Resubmit
2 15 December 2019 Third Issue- Issued for Approval
3 8 February 2020 Fourth Issue- Issued for Approval

GZ-AAE-MST-CIV-0004 Rev 3
Method Statement for Concrete Repair
This document is the property of Al Ali Engineering Co. W.L.L. who will safeguard its rights according to the civil and penal provisions of the law.
 QATAR MALL

GRAND ZONE - SCHOOL AND RESIDENTIAL

TABLE OF CONTENTS:

1 SCOPE AND PURPOSE................................................................................................................................................. 4

1.1 SCOPE ......................................................................................................................................................................... 4

1.2 PURPOSE ..................................................................................................................................................................... 4

2 DEFINITIONS .............................................................................................................................................................. 4

3 REFEENCES ................................................................................................................................................................. 4

4 RESPONSIBILITIES ................................................................................................................................................. 5

5 REPAIR MATERIALS USE ............................................................................................................................................. 8

6 SAFETY REQUIREMENT AND EMERGENCY PROCEDURE.............................................................................................. 9

6.1 EMERGENCY RESPONSE PLAN ...............................................................................................ERROR! BOOKMARK NOT DEFINED.

6.2 MEANS OF COMMUNICATION .......................................................................................ERROR! BOOKMARK NOT DEFINED.
Call-Out Protocol ............................................................................................................ Error! Bookmark not defined.
EMERGENCY Call-Out Protocol ...................................................................................... Error! Bookmark not defined.

7 TOOLS PLAN AND EQUIPMENT .................................................................................................................................. 9

8DELIVERY AND STORAGE ........................................................................................ ERROR! BOOKMARK NOT DEFINED.

9 WORK FLOW CHART................................................................................................................................................. 18

10 CONCRETE REPAIR (METHODOLOGY) ..................................................................................................................... 18

10.1 REQUEST FOR INSPECTIONS AND APPROVAL (INR) ............................................................................................................. 18

10.2 TYPES OF DEFECTS ....................................................................................................................................................... 18
10.2.1 Blowhole ......................................................................................................................................................... 18
10.2.2 Honeycomb ..................................................................................................................................................... 19
10.2.3 Cracks: ............................................................................................................................................................. 19
10.2.4 Voids or Hole ................................................................................................................................................... 19
10.2.5 Tie rod holes. ................................................................................................................................................... 19
10.2.6 CORROSION DAMAGE CONCRETE ................................................................................................................................. 20
10.3 CLASSIFICATION OF THE TYPES OF DEFECTS ....................................................................................................................... 20
10.4 REPAIRS OF VARIOUS DEFECTS........................................................................................................................................ 20
10.4.1 General Surface Preparation ........................................................................................................................... 20
10.4.2 Minor repair for Pinholes, minor surface imperfections and shrinkage cracks ............................................... 20
10.4.3 Honeycomb ..................................................................................................................................................... 21
10.4.4 Major repair using formworks....................................................................................................................... 21
10.4.5 Major repair without formworks .................................................................................................................... 22
10.4.6 Tie Rod Holes ................................................................................................................................................... 23
10.4.7 Repair of unformed surface ........................................................................................................................... 23
10.4.8 Crack.............................................................................................................................................................. 24
10.5 CONCRETE CURING ...................................................................................................................................................... 24

11 APPENDICES ........................................................................................................................................................... 25
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Method Statement for Concrete Repair
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 QATAR MALL

GRAND ZONE - SCHOOL AND RESIDENTIAL

11.1 HAZARD IDETIFICATION AND RISK ASSESEMNT ................................................................................................. 25

11.2 INSPECTION TEST PLAN ...................................................................................................................................... 25
11.3 CHECKLIST .......................................................................................................................................................... 25
11.4 Project Emergency flow chart ............................................................................................................................ 25

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Method Statement for Concrete Repair
This document is the property of Al Ali Engineering Co. W.L.L. who will safeguard its rights according to the civil and penal provisions of the law.
 QATAR MALL

GRAND ZONE - SCHOOL AND RESIDENTIAL

1 Scope and Purpose

1.1 SCOPE

This Method Statement, (MS) details the sequence and activities to be followed for the concrete
repairs during the construction activities for the MALL OF QATAR – GRAND ZONE, SCHOOL
&RESIDENTIAL, QATAR PROJECT. It defines personnel responsibilities and activities related to proper
concrete repairs.

1.2 PURPOSE

The purpose for this method statement is to define and document the responsibilities of Key Project
Personnel responsible for the activities listed within this MS and the method required for properly
performing the work in keeping with this MS, Project Specification, Industry and Code Standards to
meet project and quality objectives and maintain good workmanship practices.

2 DEFINITIONS

PM Project Manager
CM Construction Manager
QC Quality Control
SE Site Engineer
CS Chief Surveyor
HSE Health, Safety and Environment
ITP Inspection and Testing Plan
HRA Hazard Identification & Risk Assessment
Consultant KEO
Contractor Al Ali Engineering Co.

3 REFEENCES

 Specifications :QCS 2014 :Section 5 – Concrete, Section 1 Part 10 and Section 11Part 1 and 2
 Specifications: Project technical specification – Volume II – Division 03.
 Manufacturer Recommendation: for each approved repair material.
 Material Approval Ref. No.
 ASTM 546 Concrete Repair Guide
 PLN-HSE-0001
 Drawing and Layout Plan
 ITP

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Method Statement for Concrete Repair
This document is the property of Al Ali Engineering Co. W.L.L. who will safeguard its rights according to the civil and penal provisions of the law.
 QATAR MALL

GRAND ZONE - SCHOOL AND RESIDENTIAL

4 RESPONSIBILITIES
 Serves as a full-time representative of the contractor to the Client
1 Project Manager
and its representatives.
 Ensures that his team of Engineers and Foreman are aware of this
method statement and all resources- manpower, material and
equipment are available to carry out the work as planned and
without any delay.
 Guides, orient, organize and monitor the various professional
people working on the project.
 Communicates and specifies clearly the tasks and the
contributions of each project members.

 Implement and oversee the works on daily basis.

2 Construction Manager  Prepare and monitor detailed resource plans and schedules.
 Delivering the overall works in a safe and timely manner,
ensuring conformance with the approved design. Leading the
team of engineers and surveyors, guiding them in the delivery
of the works. Acquire, allocate and maintain resources.
 Implement and audit all safety, environmental and quality
requirements for the work.
 Report on all aspects of site progress, site issues and incidents
to the Project Manager.
 Reporting to Project Manager
3 Site Manager  Ensures that his team of Engineers and Foreman are aware of
this method statement and all resources- manpower, material
and equipment are available to carry out the work as planned
and without any delay.
 Guides, orient, organize and monitor the various professional
people working on the project.
 Communicates and specifies clearly the tasks and the
contributions of each project members.

 To inspect and ensure the processing works are carried out to

4 Site Engineer the required contract specifications.
 Responsible for the execution and supervision of works.
 He will liaise with the Construction Manager and submit the
progress report on daily/weekly basis. He will also be
responsible for follow up of the H&S implementation.
 Responsible for the material processing schedule, technology
(including quality and safety) and organized the
implementation of the material processing code, specification,
regulations, check and supervise the compliance of code.

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Method Statement for Concrete Repair
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 QATAR MALL

GRAND ZONE - SCHOOL AND RESIDENTIAL

 Inspect and ensure the processing works are carried out to the
5 QA/QC Inspector required Quality specifications and all MEP and relevant
clearances are signed-off.
 Compile quality dossier in a timely manner.
 .Administers the HSE programs on the project
6 HSE Manager  Audits HSE programs and site conditions at all work sites
 Oversees incident investigations and conducts investigations of
incidents that could result in litigation
 Develops and presents recommendations and advises all levels of
management to ensure the balance between productivity and
the safety of team members, subcontractors, and visitors

 Creates and establishes project HSE programs to address

program gaps
 Advises, consults, guides, and assists sectors, divisions, regions,
or corporate departments in HSE matters
 Provides guidance to management through the interpretation of
HSE Practices and Procedures, legislation, and regulation
 Maintains records, reports, and documents required to meet
corporate and regulatory requirements
 Advice site staff and personnel on matters related to health,
7 HSE Officer safety and environmental issues
 Ensure a high standard is maintained on site in accordance with
HSE Policy and the project HSE management plan
 Support the Site Engineer/Foreman but shall not be responsible
for the management of HSE-Critical Activities, which will be all
the time the responsibility of the line for which HSE officer
provide quality and timely HSE advice.
 Monitor and report all discrepancies in relation to the Project
HSE Management Plan to the Project HSE Manager and the area
in-charge.
 Inspect the workplace to identify potential hazards and report
the findings with recommendations for corrective actions to the
Safety Officer and area in-charge
 Investigate accidents/ incidents and dangerous occurrences and
forward report to the Project HSES Manager
 Keep all safety records required for the project
 Take appropriate action to stop work if there is any imminent
danger to life and property
 Checking the accuracy of the set-out and survey as- built
8 Land Surveyor before the progression of the subsequent works.
 Setting out all planned works.
 Monitoring the works being carried to ensure they are at the
correct levels and measurements.
 Maintaining documents relevant to alignment and height
control of the works As-Built Drawings.

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Method Statement for Concrete Repair
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 QATAR MALL

GRAND ZONE - SCHOOL AND RESIDENTIAL

 Conducting task briefing for operatives on daily basis prior to

9 Site Foremen commencing the task.
 Conducting TBT for work force.
 Ensure safety control measures are provided and in place prior
to deploying operatives to commence the task
 Monitoring work area and explaining work descriptions to the
labor.
 Lead and direct people, equipment and resources in the
construction of roads.
 Ensure sufficient deployment and productivity of work crews.
 Carry out their work under direct supervision by their Foreman.
10 Masons  The workforce to attend a daily Tool Box Talks, morning task
briefs prior to starting any new works, EHS (Environmental
Health Standard) plans and Policies.
 The workforce shall receive a full Project briefing and site rules
induction prior to commencing any work on site.

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Method Statement for Concrete Repair
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 QATAR MALL

GRAND ZONE - SCHOOL AND RESIDENTIAL

5 MATERIALS USE
5.1 Repair Material Use
 Repair materials will be supplied from Construction Chemicals supplier approved by KEO.
 Manufacturer’s instructions shall be followed in preparing, mixing, and applying repair as
described.
 Technical data sheets and job references for these products to be submitted in a separate
transmittal for approval by KEO.

Category Surface Defect Classifications Illustration Material

a. Surface defect up to Master Emaco N907
10mm or equivalent
Spalling (Surface Voids or b. Surface defect from Bonding Coat:
I Irregularities lHoney 10mm ~ 50mm or up to MasterBrace 1414
Comb/Cone Holes rebar surface Repair Mortar:
MasterEmaco S488 or
equivalent
a.Surface Defect ( 40mm Flowable Grout:
and above) MasterEmaco S466, or
Severe Voids and Honey equivalent
II
Comb b.Surface Defect Until EMACO S423 NT or
expose rebars (25mm- equivalent
150mm )
a.Hairline /Shrinkage N/A
Cracks width up to
0.15mm

b. Crack width from Sealing:

0.15mm to 0.30mm MasterEmaco N907
III Cracks
Injection:
MasterInjet1315,
Master brace ADH
c. Crack over 0.30mm and
2200 or Equivalent
above

Category Surface Defect Classifications Illustration Material

IV
Corrosion damage EMACO S42 NT,
concrete Further Corrosion Surface EMACO S43 NT,
Cracks Emaco Nanocrete AP (
Primer) or equivalent
V Eventual Spalling
Corroded Bar Exposed

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Method Statement for Concrete Repair
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 QATAR MALL

GRAND ZONE - SCHOOL AND RESIDENTIAL

5.2 TOOLS PLAN AND EQUIPMENT

All equipment will be inspected and approved respectively and all personnel will be inducted and trained
before and all personnel will be inducted and trained before and during mobilization.

Category Equipment Quantity

Concrete Cutter
Hand Chipping or Chisel
Hammer
I & II
Grinder
Water Jet
Mixing Paddle AS required in actual site
Crack and Scale condition
II Grinder
Mixing Paddle
Crack and Scale
Grinder
III
Mixing Paddle
Injection Machine

5.3 Material For Tie rod Hole Flag

Description No. of Units

DK Sealing Cone DW 15/55 As per Project Requirements

SK Sealing Ring UNI DW 15 As per Project Requirements

Tube rough 22, L = 2.0 m As per Project Requirements

DK Concrete Cone UNI 58/52 As per Project Requirements

DK Cone Pliers 58 As per Project Requirements

DK Cone Spanner UNI As per Project Requirements

Sealing Compound-2, 5 kg pack As per Project Requirements

GZ-AAE-MST-CIV-0004 Rev 3 Page 9 of 25

Method Statement for Concrete Repair
This document is the property of Al Ali Engineering Co. W.L.L. who will safeguard its rights according to the civil and penal provisions of the law.
 QATAR MALL

GRAND ZONE - SCHOOL AND RESIDENTIAL

6 DELIVERY, STORAGE, AND HANDLING

 Material shall be delivered to site by truck or any proprietary vehicle that material shall reached on
site undamaged.
 Make sure that material is sealed with labels indicating the manufacturer name, trade mark, date of
manufacture and expiry.
 Material shall be stored in a safe material storage with shade and or at the area out of direct sunlight.

7 SAFETY REQUIREMENT AND EMERGENCY PROCEDURE

7.1 SPECIFIC HEALTH & SAFETY REQUIREMENTS & PRECAUTION MEASURES
The works shall be carried out in compliance with the applicable HSE legal and contractual requirements as
well as Health and Safety Plan.

Any emergency situations that may occur on site shall be dealt following the procedures, responses and
controls as described in the Emergency Preparedness and Response Plan.

The significant HSE hazards and risks related to the works covered by this document have been identified,
and documented in “Risk Assessment”.

The environmental hazards and risks shall be identified and documented in accordance with the
Environmental Risk Assessment Plan.

The identified hazards and associated risks and mitigation controls shall be communicated to the workforce
through registered Pre-task briefings at the beginning of each shift.

Daily task Briefing shall be performed by site supervisor / Foreman prior to commencement of works.

7.2 Personal Protective Equipment

The minimum PPE as per the project HSE Plan that all personnel involved in the works will wear are:

 Safety Helmet

 Safety Shoes

 High Visibility Vest

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Method Statement for Concrete Repair
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 QATAR MALL

GRAND ZONE - SCHOOL AND RESIDENTIAL

 Overall

 Protective eye wear (glasses)

 Respiratory Mask

 Hand Gloves / Rubber Gloves

Personnel not directly involved in physical work, who are visiting the site must also wear all the required
personal protective equipment at any time they are outside of their vehicle, with the exception of gloves,
which are discretionary. Personnel who are visiting the site but not leaving the PPE “free” designated areas
which, if present on the site, will be clearly defined and barriers by signs (typically around the offices and
car park), are not required to wear PPE (but it is recommended, especially protective eye wear).

7.3 Manpower
Safety and Health induction shall be conducted by AAE Health & Safety Department prior to
commencement of works to each person involved in works. All operators involved in the works execution
and the workers undertaken critical tasks shall be competent and certified to undertake the works. The
drivers shall hold a valid Qatari license. All workers will receive a daily briefing about the works they are
to undertake that day.

All personnel shall wear the required Personal Protective Equipment (PPE) in accordance with the Health
and Safety Plan.

The Site Engineer is responsible for the job and will be present at site during working hours and a Safety
Officer as well to monitor all activities.

Any incident, injury and near miss will be reported immediately to the Safety Department and Site
Manager. The welfare facilities (see Health and Safety Plan) for the site works including drinking water
cooler, shaded area, workers toilet blocks, dedicated smoking area, emergency standby vehicle will be
established prior to commence the works.

7.4 Plant and Equipment

All plant and equipment shall be inspected by the Plant & Equipment department prior to start the work.

Before use of any tool, inspection and color coding is mandatory to ensure smooth execution of works.

The AAE subcontractor will also practice a daily visual inspection to all plant and equipment. A pre-shift
visual inspection must be contacted and recorded as per the equipment checklist.

The following will be ensured as a minimum:

All equipment shall have valid certificate and inspections.

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Method Statement for Concrete Repair
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 QATAR MALL

GRAND ZONE - SCHOOL AND RESIDENTIAL

Plant/ machine operators will have all round 360o visibility at all times.

Regular maintenance of plant will be carried out as per manufacturer recommendation.

Plant movement and operation will be coordinated and managed to ensure safe and efficient operation.
All persons on site will be briefed on the hazards of working adjacent to traffic or in the vicinity of moving
plant/ equipment & instructed to maintain eye contact at all times with machine / vehicle operators.

No sleeping or resting will be allowed underneath stationary plant/ equipment or vehicles.

7.5 Access / Egress on Work Site

Only authorized personnel will be permitted to enter the work site. Upon arrival at site the following
checks will be made and any non-compliance will result in that person being prevented from entering
the work site:

Evidence of receiving site specific safety induction (register of attendance/ helmet sticker)

All staff shall have their ID card with them at all times, as evidence of site induction and competencies.

Appropriate Personal Protective Equipment (PPE)

At the end of each working day all access to the work site will be secured. A night time patrol will ensure
that the work area is secure and that safety precautions are in place. The following will be ensured as a
minimum:

Access / egress routes shall be clearly defined by designated walkways/ traffic routes/ loading-unloading
areas, signage/barriers & lighting.

Access / egress routes will not be blocked as a result of the work.

Vehicle traffic routes will be maintained as two-way street or as per project requirement.

7.6 Emergency Preparedness

All accidents/incidents and near misses shall be reported immediately to site management.

In the event of a serious accident the area will be segregated off and a full investigation will be carried
out with initial report submitted within 24 hours.

AAE personnel will meet the emergency services at the site entrance and escort them to the scene of
the accident.

Emergency contact numbers shall be displayed in notice boards and prominent locations all around the
work area.

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Method Statement for Concrete Repair
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 QATAR MALL

GRAND ZONE - SCHOOL AND RESIDENTIAL

Fire extinguishers shall be provided in fire points provided around the work area, site office and welfare
area.

Mobile Plant and Equipment will have fire extinguishers fixed in place.

Smoking will only be allowed in designated areas. Trained first aiders will be available on site and first
aid kits available in the site offices. Engineer, Supervisor and Foremen shall be supplied with complete
set of First Aid Kit to be kept inside their vehicle in order to give immediate treatment in case of accident
happen.

7.7 Medical / First Aid Facilities

Prior to the commencement of work, confirmation will be made that all appropriate and required first
aid facilities and trained first aid personnel are available on the site and if necessary, shall be made
available for prompt attention to the injured person.

For minor injuries, RIC vehicle assigned to the job site will be used for transporting injured persons to
the first-aid station. If the person needs transportation to hospital, an ambulance will be required.

7.8 Emergency Contact Numbers

The emergency contact numbers list shall be kept up to date at all times and shall be displayed on site
at such locations so as to be readable by all personnel.

PROJECT EMERGENCY CONTACT NUMBERS

DESIGNATION NAME CONTACT NO.

PROJECT MANAGER ENGR MOHAMMED HUSSEIN 74400515

SITE MANAGER ENGR QAZI MOHSIN 55137852
CONSTRUCTION MANAGER ENGR.ABOEL NASR 30482292
CONSTRUCTION MANAGER ENGR FARUQ SAYED 30128028
CONSTRUCTION MANAGER ENGR AHMAD FAWZY 77999693
H.S.E. MANAGER MR. SAJI NAIR. 33359838
HSE COORDINATOR MR NASEEF ELKHEDR 70502922
H.S.E. SUPERVISOR MR SANMI AKINOLA 66412772
H.S.E. SUPERVISOR MR. FAHMY ELSAYED 77334043
H.S.E. SUPERVISOR MR RASHEED BELLO 55171827
LOGISTIC COORDINATOR MR MOHD BARAKAT 50650621
LOGISTIC OFFICER MR MURAD SHAKIL 55161820
HR OFFICER MR MUSHAMMER ALI 70570521
SECURITY SUPERVISOR [DAY] MR SATWANT SIGN 66952028
SECURITY SUPERVISOR [NIGHT] MR ABDUL MAJID 55165631
DOCTOR DOCTOR MOHAMMED 55434048
NURSE MR. PRATHAB BABU 70929897
EXTERNAL
POLICE POLICE ALFAZAA 999
ASSISTANCE

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Method Statement for Concrete Repair
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CIVIL DEFENSE FIRE CIVIL DEFENSE 999

CONTROL
EMERGENCI
AMBULANCE ES / E.M. H.M.C. - E.M.S. 999 /

HOSPITAL HAMAD MEDICAL CTR. 44392222

8 ENVIROMENTAL:
8.1 Control Measures
The Environmental control measures will be taken to avoid any leaks, and wastes to Environment which can
pollute the Environment. The Environmental aspects will be assessed to control them.

a) Noise Control:
In case of high noise workers will be given hearing, protection devices and efforts will be done to reduce the
noise by taking engineering control.

i. To adequately define the noise problem and set a good basis for the control strategy, the following
factors should be considered|:

 Type of noise
 Noise levels and temporal pattern
 Frequency distribution
 Noise sources (location, power, directivity)
 Noise propagation pathways, through air or through structure
 In addition, other factors have to be considered: for example, numbers of exposed workers, type of
works, etc. If one or two workers are exposed, expensive engineering measures may not be the most
adequate solution and other control options should be considered; for example, a combination of
personal protection and limitation of exposure.
ii. General source Noise Control can involve:

 Maintenance of equipment (replacement/adjustment of worn/loose parts, balancing, lubrication)

 Substitution of materials
 Substitution of equipment
 Substitution of parts of equipment
 Change of work methods
 Substitution processes
 Substitution of Mechanical Power Generation and transmission equipment
 Replacement of worn moving parts
 Minimising the number of noisy machine running at any time

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Method Statement for Concrete Repair
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 QATAR MALL

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b) Dust Control:
 Regular dust suppression on exposed bare ground, and other areas
 Susceptible to dust generation is required.
 During high windy weather conditions, the work may be suspended
 Temporarily to prevent contributing dusty conditions on site.
 Mandatory use of dusk mask inside the working zone areas.
 Vehicles transporting materials should maintain speed limit of less than 10km/hr.

c) Spill Response
In case of any spillage, the operator doing the work will be responsible for managing the spill, spill kit will be
used to remove the spilled material.

Waste Management of Hazardous Material:

For hazardous material, competent persons after taking all PPEs will collect the waste and it should be
disposed of using a specific standard. For collection of waste there will be separate bins as well for
segregation. The site team including subcontractors shall implement the following general environmental
control measures:

a) Waste shall be placed in the waste skips and wheelie bins provided;

b) Risk due to chemical spillage or such other contaminants are treated as soon as possible;

c) Material containers will be inspected for leaks on arrival on Site;

d) For static equipment drip trays are mandatory.

Awareness will be provided to all workers about hazardous material. Awareness about MSDS will be
imparted to all workforce to know the hazardous associated with different material and how to control it.

d) Waste Management:
The environmental manager in coordination with the health and safety manager shall ensure that the tool
box talks include aspects of the environment particular to the work execution and waste management will
be:

a) Waste Reduction:

 Reduce waste generation and disposal.

 Select materials with increase product life reducing overall amount of material sent to
dumpsite/landfill.
b) Waste Reuse:

 Reuse waste resources without further manufacturing.

 Review policies on disposal of obsolete
c) Waste Recycle:
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Method Statement for Concrete Repair
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 Turning waste resources into similar or different products.

 Increase staff awareness in order to maximize co-mingled recycling and avoid contamination of
recycling bins.
d) Disposal:


Spill kit should be provided

All static equipment’s should be provided with drip tray

Training should be provided to control leakage from equipment’s

All hazardous waste should be kept separately in red colored skips and disposal by approved
hazardous waste management agency.
 All waste will be segregated into different skips provided at the site.
 All waste will be collected from site in a separate labelled bin from where it will be disposed-off
as per legal compliance.
 All waste generated such as concrete debris, shutters shall be disposed as per project
Environmental and waste management plan.
 Hazardous waste shall be collected from site on daily basis and should be kept separately in waste
collection area and will be disposed-off as per legal local regulations.
e) House Keeping:

 Good Housekeeping of the workplace will be maintained after periodically cleaning the area and
every possible effort will be done to make the environment neat and clean.

9. Site Planning
Refer to approved baseline schedule for the duration of cementitious waterproofing works.

9.1 Preparation
Contractor shall ensure that all gate passes, permits, tools, materials for safety precautions, manpower and
equipment are available before commencement of work.
The Site Team shall make sure that access roads are always clear from any obstruction and site is always
accessible.

9.2 Site Clearance

Before commencing the work, the area shall be cleared of all debris, materials or other obstructions.
Required levels are to be confirmed and verified by Site Engineer and QC Engineer before commencing the
work. It is the responsibility of the CM to ensure that any preceding activity is completed.

9.3 Traffic Management

Other than some special cases no special traffic management plan is required.
Special cases can be identified on individual bases and related actions can be taken accordingly.

9.4 Pre-construction Safety Meetings

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The meeting shall be scheduled prior to the beginning of the work and before any main
contractor/subcontractor starts on the project. Safety awareness meetings will be conducted every working
day morning/every other day to brief the workforce in the safety prevention measures. The
equipment check for safety shall be recorded/ documented during the daily Safety Awareness Meeting.
Traffic safety will be discussed to emphasize these meetings.
Each worker will be instructed to follow specific safety requirements related to his trade. They will be
required to follow installed safety signs, observe barricades and use opens.
Contractor Safety will perform hazard risk analysis by identifying all steps, hazards identified in those steps,
with a focus on the relationship between the work task, the tools, and the work environment. After
identifying uncontrolled hazards; Contractor will take steps to eliminate or reduce them to an acceptable risk
level.
General contractual Safety, Health, and Environmental requirements.
Roles of the contractor, subcontractors, authority representatives and all project workers.
Accident reporting requirements.
Specific details of the work to be performed along with the use of personal protective equipment.
Emergency procedure.

9.5 Operating Procedures

Site work shall be done as per the ongoing safety procedures being implemented on site. All throughout the
duration of work, the required supervision shall be considered to ensure completion of the activity in a safe
and orderly manner.

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Method Statement for Concrete Repair
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10 WORK FLOW CHART

MAPPING

SURFACE PREPARATION

DEFECT CATEGORY IDENTIFICATION AND

METHOD OF TREATMENT

DEFECT CATEGORY IDENTIFICATION AND

METHOD OF TREATMENT

TREATMENT APPLICATION

CURING

11 CONCRETE REPAIR (METHODOLOGY)- PROCEDURE

11.1 Request for Inspections and Approval (INR)

All repairs shall be conducted by trained masons under the direction of foremen, Site Engr. And CM

The following RFIAs shall be raised:

1. INR-1 Inspection of substrate preparation: It is raised after cleaning of debris and removal of loose
concrete. If hacking or bonding agent application is required it shall be done prior to submitting this
inspection request to the consultants.
2. INR-2 Inspection of repaired concrete: Raised after the repair work is complete and the concrete has
been refurbished.

11.2 Types of Defects

The repair action depends on the depth and type of defected area; the types of concrete surface
defects are classified into the following:

11.2.1 Blowhole
Blowhole (Also sometimes called Pinholes / Bubbles/Bug holes): Blowhole defects are considered
concrete surface defects due to the entrained air bubbles between the concrete and formworks,
with an length less or equal to 10mm and a depth not more than 5mm, this type of defect will be
repaired where the concrete surface is to be finished without plaster so that it is exposed to view. In
the case of plaster, tiling or block work where hacking of the surface is required the repairs shall not

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be done.

11.2.2 Honeycomb
Honeycomb refers to voids left in concrete due to failure of the mortar to effectively fill the spaces
among coarse-aggregate particles. It usually becomes apparent when the formwork is stripped,
revealing a rough and 'stony' concrete surface with air voids between the coarse aggregate.

Honeycombing is caused either by the compaction not having been adequate to cause the mortar to
fill the voids between the coarse aggregate, or by holes and gaps in the formwork allowing some of
the mortar to drain out of the concrete. In some cases, the member shape and detailing/placement
of the reinforcement compounds the effect of inadequate compaction.

11.2.3 Cracks:
There are three common types of cracks for new concrete.

1. The first type take place during formworks removal, the concrete edges are broken, peeled, or
cracked during the formwork removal.
2. The second type is Plastic cracks which appear in the surface of fresh concrete during its plasticity
period and it is usually seen as parallel cracks to each other. The cracks appear generally on the top
of wide surfaces like slabs due to rapid water evaporation and plastic settlement of concrete around
steel bars and rising of bleeding concrete.
3. Third type is random-drying shrinkage cracks, which appear as random cracks in the top surface of
concrete due to rapid hardening of concrete in hot weather.

11.2.4 Voids or Hole

1. Holes: The surface defects in walls, foundations, columns and beams is not more than 25cm depth or
concrete cover.
2. Void through structure: Defects to all structural elements to a minimum depth of 10mm.

11.2.5 Tie rod holes.

Strictly speaking holes due to the use of tie rod used in the use of formwork is strictly not a defect of
the concrete or concreting.

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11.2.6 Corrosion damage concrete

This damage is usually manifested in the form of cracking and spalling of concrete cover, which is
caused by the expansion of the corrosion products around the reinforcement bar.

11.3 Classification of the Types of Defects

The QC Engineer shall determine the defect as “minor” or “major”.

1. For Minor Defects such as shrinkage cracks, blowholes and minor honeycombs, the QC Engineer
shall decide the suitable approved repair material and as per the approved Method Statement,
instruction shall be given to the site Engineer to proceed with the repair work.
2. For Major Defects such as structural cracks, major honeycombs, deep holes, larger voids, etc. the QC
Engineer shall issue an internal NCR to the site Engineer and copies shall be forwarded to PM/CM. In
accordance RFIA shall be raised to the Consultant prior to proceed for the repair works. Approval for
the surface preparation shall be obtained from the Consultant prior to application of bonding agent
and repair materials. Internal NCR shall be closed upon completion of the work and final approval of
RFIA by the Consultant.
3. IMPORTANT: All deep surface cracks should be investigated to ensure that the structural integrity of
the element is not compromised. In such cases a third party recommendation for the repair can be
obtained.

11.4 Repairs of Various defects.

11.4.1 General Surface Preparation
1. All surface preparation shall be done as per manufacturer’s recommendation. In general, the
surface shall be sound, clean and free from any loose materials up to sound concrete and the surface
must be free from oil, grease and dust.
2. All prepared areas should be thoroughly soaked with clean water immediately prior to repairing
product application; any residual surface water should be removed prior to commencement.

11.4.2 Minor repair for Pinholes, minor surface imperfections and shrinkage cracks
The following procedure describes the remedial action to be taken for repairing the minor defected
concrete due for slight honeycomb, pinholes and shrinkage cracks by using the approved material.

1. Prior to starting the application, concrete surfaces shall be prepared and shall be thoroughly soaked
to ensure a saturated but surface dry condition at the time of application.
2. Master Emaco N907 or equivalent will be mixed using a slow speed drill fitted with a suitable
mortar-mixing paddle. In case of small quantities less than 10kg the mixing will be achieved by hand
mixing.
3. The mortar shall be applied by using brush, roller, steel float, spatula or trowel to the previously
prepared substrate ensuring a maximum thickness of 5mm.
4. Where the material is used to fill voids and blowholes the excess shall be scraped off with the edge
of the steel trowel.
5. Good curing is essential particularly in hot or windy conditions. Curing will be performed with
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covering the work with properly secured wet Hessian and plastic sheeting.

11.4.3 Honeycomb
1. The following procedure describes the remedial action to be taken for repairing the defective area
due to honeycomb, pocket, and holes left by tie rod or voids in concrete cover. The preparation of
surface will be achieved by cleaning the surface and remove any dust and unsound material.
Roughen the surface to remove any laitance and expose the fine aggregates. All prepared areas
should be treated with bonding agent (prior to starting the application of the repairing product. As
per Section 7.1 RFIA-1 shall be raised to inspect the preparation.
2. Master Emaco S488 or equivalent patched mortar consists of approved non shrink grout. Mortar will
be applied by trowel into the substrate to ensure high contact with substrata. The final finishing is to
be done by wooden or plastic float.
3. After setting time of mortar, the curing must be started using the same procedure for the existing
concrete as described below.

11.4.4 Major repair using formworks

1. The following procedure describes the remedial action to be taken for repairing the major defected
concrete element due to the existing of honeycomb or voids greater than 40 mm deep by using
formworks and free flowing grout (master emaco s466) or microconcrete (master emaco S423). The
defective concrete is to be removed. The edges perpendicular to the concrete surface shall be cut by
angle grinder or by chiselling process.
2. In case of exposed existing steel reinforcement,
2.1 Corrosion damage shall be identified and defined using a systematic visual survey.
2.2 Reinforcement must be fully exposed, where spalling has occurred until at least 50mm of un-
corroded steel has been revealed and loose rust and scale must be removed from exposed
reinforcement.
2.3 Concrete must be removed around the full circumference of the bars so that the fingers of a
gloved hand can pass behind the steel.
2.4 The condition of the steel should be inspected as necessary.
2.5 EMACO NANOCRETE AP or equivalent primer should be applied to the cleaned steel prior to
repair of the surface of concrete which contaminate from corrosion.
2.6 EMACO S42 NT shall apply for minor Corrosion Surface affected area.
2.7 Care shall be taken to ensure that the mixture is homogeneous and thoroughly blended as
described in the manufacturer data sheet.
2.8 EMACO S43 NT product will be poured on the prepared area continuously. The compaction must
be performed by tapping the formwork slightly with a proper hammer. In case of large-scale
repair, the material will be applied at layers with thickness as per mention in data sheet.
2.9 The repaired area must be protected from wind by using polyethylene sheet.

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11.4.5 Major repair without formworks

1. The following procedure describes the remedial action to be taken for repairing the defected
concrete especially for the overhead repair application due to existing of honeycomb or voids
greater than 40mm deep.
2. The defected concrete to be removed down by hand tools to obtain regular profile with depth not
less than 10mm, the concrete surface to be prepared to provide a rough surface.
3. The unsound concrete particles must be removed by using hand tools, the repaired area to be
cleaned by steel brush and blown by air compressor to clean the dust. Prior to the repairing product
application, all areas should be thoroughly saturated with water prior to applying the repairing
materials. Appropriate quantities suitable to the repairing area are mixed by slow speed drill and
mortar mixing paddle or by hand using a suitable mixing drum or bucket to obtain homogeneous
mixture.
4. The mixed product will be applied by hand trowel and forced tightly into the pre-wetted substrate to
ensure high contact with substrate. The final finishing to be done by wooden or plastic float.
5. After the setting time for repairing mortar, the curing must be started using the same procedure for
the existing concrete.

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11.4.6 Tie Rod Holes

1. Remove the PVC cone along with the tie rod.
2. Insert a wall plug to prevent the grout to flow over from the other side. This is not required for cases
like water tank or retaining wall where a cast-in-tie-rod-connector/ water stop tie rod connector is
used.
3. Clean the hole of any dust or dirt. And ensure the hole is dry.
4. Apply the bonding agent (MasterBrace 1414 or equivalent). Thoroughly stir Part A, add Part B and
blend thoroughly using a slow speed mixer fitted with a suitable paddle.
5. Use a small trowel or a smaller rod shall be used to fill the hole with the non-shrink epoxy grout
mortar (to its full capacity.)

4. Mix Non-shrink grout 5. Press grout mix into recess

11.4.7 Repair of unformed surface

1. Surface defect in concrete which don’t comply with the specified tolerance especially in monolithic
slabs be repaired as follows:
2. To an unformed surface in high areas, it will be corrected by using a grinding machine. To cover the
low defected surface, the area is to be cut out and leave the edges perpendicular to the concrete
surface by angle grinder or similar to obtain regular profile.
3. The unsound concrete particles must be removed by using hand tools. The repaired area must be
blown with air compressor to clean the dust. Prior to product application, all repaired areas should
be thoroughly soaked with water.
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4. Bonding slurry mixture consists of approved bonding agent (MasterBrace 1414 or equivalent);
cement and water will be applied on the pre-wet substrata, prior to application.
5. Mix patching fresh concrete of same materials to provide concrete of the type. The material shall be
applied continuously. After the completion of repairing, the repaired area must be protected from
wind by using polyethylene sheet.

After setting time for repairing material; the curing must be started using the same procedure for the
existing concrete.

11.4.8 Crack
The following procedure describes the remedial action to be taken for Wide Crack defect.
1. Chisel the crack with a hammer and masonry chisel to widen the base of the crack and to dislodge any
loose material from the old concrete.
2. Remove all debris from the crack, using a wire brush. If desired, clean the crack with a pressure washer
or a garden hose and spray nozzle.
3. Remove all water and debris from the crack with a wet/dry shop vacuum or a brush. Work carefully
to remove all dust and grit from the crack. It's OK if the surfaces are wet, but there should be no pools
of water.
4. For the Crack width from 0.15mm to 0.30mm Mix the concrete sealing compound (EMACO N907),
following the manufacturer's directions. And for the Crack 0.30mm above MasterInjet1315, Master
brace ADH 2200, or Equivalent crack injection shall apply following the manufacturer's directions
5. Trowel the compound into the crack. Stab the trowel into the compound to remove air pockets and
help work the patching material deep into the crack. Fill the crack up to the surrounding concrete
surface.
6. Smooth the surface of the patch with the trowel, feathering the compound into the surrounding
concrete.
7. Brush the surface of the patching compound with a dry paintbrush to texture the surface, if desired.
8. Let the compound cure as directed.

11.5 Concrete Curing

1. The repaired area must be protected from premature drying in hot, dry and windy weather, so that
the curing process to be started as soon as possible after formwork removal.
2. Repaired area will be cured by placing wet Hessian cloth (burlap) and cover over with polythene
sheet or by water ponding on the surface and comply with specification section 033000.

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11 APPENDICES
11.1 HAZARD IDETIFICATION AND RISK ASSESEMNT

11.2 INSPECTION TEST PLAN

11.3 CHECKLIST

11.4 Project Emergency flow chart

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Method Statement for Concrete Repair
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