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This method statement for the repair of concrete describes the details of rectification for most
common construction defects of concrete structures right after the casting activity and formworks
deshuttering such as concrete cracking (non-structural and structural cracks), honeycombs or
spalling, pinholes and blowholes, form tie rod/ bolt holes, cone holes, and voids. Other severe
defects of concrete such as major deficiencies like exposed rebars and cavities, cold joints, re-
profiling, retrofitting, major cracks, etc. are not covered by this method.
Concrete repair refers to any replacing, restoring, or renewing of concrete or concrete surfaces after
initial placement.
The need for repairs can vary from minor imperfections, such as bolt/pinholes, snap tie holes, or
normal weathering, to major damage resulting from chemical or physical deterioration, water
energy, or structural failure.
I. Description of Works
1. Introduction
This method statement defines the sequence and the control procedures for the repair of concrete
defects which include but not limited to the following:
1. Concrete Cracking (Non-structural and Structural Cracks)
2. Honeycombing or Spalling
3. Pinholes and Blowholes
4. Form Tie Rod/Bolt Holes, Cone Holes and Voids
5. Removal and Repair of Temporary Construction Embedments
2. Definitions
xxxxx Client
xxxxx Project Management
xxxxx Supervising Consultant
SE Site Engineer
QC Quality Control Engineer
SF Site Foreman
PM Project Manager
HSE Manager Health, Safety & Environmental Manager
HSE Officer Health, Safety & Environmental Officer
xxxxx Main Contractor
CEMP Construction Environmental Management Plan
QCP Quality Control Plan
HSE Plan Health, Safety and Environment Plan
Note: All dimensions are in mm unless specified.
3. Reference
Project Specifications
HSE Plan
Company Environmental Management Plan
Approved Repair Materials as attached on Appendix A: Technical Data Sheets
Method Statement for Concrete Works
Material Submittal for Low Viscosity Injection Resin
4. Responsibilities
Project Manager
Responsible for accomplishing the stated project objectives which include creating clear and
attainable project objectives, building the project requirements, and managing the constraints of the
project management triangle, which is cost, time, scope, and quality. The Project Manager shall be
responsible for the 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 all method statement, 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.
Site Supervisor Supervise closely, the activities designated to them and ensure that all instructions
and safety procedure are followed and strictly adhered to. Supervise the work to ensure that
technical, quality, safety and purchase order requirements are met; Attend daily site meeting and
communicate his daily report with the Project/Site Engineer; Participate in the training and
development of his subordinates; Organize with the Project/Site Engineer to ensure the availability
of plant, equipment, and labor to his designated work activities; Closely monitor the usage of
consumables and materials by his crew in order to minimize wastage; Assess the craftsmanship of
subordinates under his control.
HSE Manager
Health, Safety, and Environmental (HSE) manager generally plan, coordinate and implement issues
and directives within the organization. He ensures 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 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.
HSE Officer
Monitor and control all HSE matters related with project team members and contractors in ensuring
that the Project is in compliance with the project requirement i.e. specification, safety code and
other policies/guidelines related to the project. Participate in HSE Risk Assessment and hold the
relevant meeting, workshop internally and with related 3rd parties. Monitor and update the HSE
risks register and ensure all mitigation plans are strictly adhered to throughout the project
execution.
Foreman
Mason
Carpenter
Laborers
II. Concrete Repair
1.1 General
Particular Specifications for Concrete
1. Any defect noticed in concrete shall be rectified by methods approved by the consultant
and client.
2. This method statement shall be adopted when concrete defects are identified at the site
after post-concrete work inspection specifically after stripping of the formed surface.
3. All materials to be used for repair works shall be submitted for approval thru
Material Transmittal.
4. All proprietary materials shall be used strictly in accordance with the
materials manufacturer’s instruction and/or recommendations.
5. Curing for Concrete Patchwork:
Polyethylene or plastic sheets shall be used to cover concrete patchwork. Unless otherwise
specified in the technical data sheets, curing shall be carried out for 2-3 days. If curing
compound/membrane is used, they shall be compatible with the repair products.
6. Store unmixed materials in a cool (preferably temperature controlled)
environment, avoiding exposure to direct sunlight.
7. Keep equipment cool, arranging shade protection if necessary. It is especially important
to keep cool those surfaces of the equipment, which will come into direct contact with
the material itself.
8. Try to avoid application during the hottest times of the day, arrange temporary shading
as necessary.
9. Make sufficient material, plant, and labor available to ensure that the application is
a continuous process.
Honeycombs
a. Honeycomb not exposing rebars;
b. Deep honeycomb exposing rebars
2.1 Honeycombs or Spalling (Reinforcement not exposed and within the cover zone)
The impact from a heavy object, form stripping, poor vibration, use of very stiff concrete is some
of the main causes of this kind of defect.
Surface Preparation
a. Attention to the full and proper preparation of the substrate is essential for complete
repair adhesion.
b. Mark out the affected area, then cut back edge of repair to a minimum depth of 10 mm.
Make several vertical and horizontal cutting for easy breaking of concrete. Break out the repair area
to remove all contaminated or damaged concrete to a minimum depth of 10 mm, up to the pre-cut
edge of the repair.
c. Fully expose any corroded reinforcement in the repair area and continue until un-corroded steel is
reached. It may be necessary to break out the concrete beyond the original repair area in order to
achieve this.
d. Oil and grease deposits are best removed by steam cleaning, detergent scrubbing or the use of a
proprietary degreaser.
e. Fully clean the concrete and steel surfaces to remove laitance, the by-products of corrosion and
other contaminants. This is most effectively achieved by proprietary blast media, with particular
attention required to both the rear face of the bars and the edge of the repair. The steel bars should
be cleaned to a uniform bright condition and the edge of the repair should be ‘roughened’ to
provide a good mechanical key at the substrate interface.
f. Chloride-induced corrosion will further require high-pressure washing with clean water
after blasting to ensure complete removal of the corrosive elements.
Reinforcement Priming
a. Exposed steel reinforcement should be securely held in place to avoid movement
during application, as this will affect the compaction, build and bond of the mortar.
b. Apply one full, unbroken coat of approved primer and allow drying before continuing. If unsure
about continuity of the coating, apply a second coat and allow drying.
Substrate Priming
a. For standard repair conditions, thoroughly soak with clean water and remove excess.
Apply approved substrate primer by scrubbing into the surface and allow becoming tacky.
b. For priming in other conditions, apply approved primer as per its current instructions.
Surface Preparation
a. Attention to full and proper preparation of the substrate is essential for complete repair adhesion.
b. Mark out affected area, then cut back edge of repair to a minimum depth of 10 mm.
c. Break out the repair area to remove all contaminated or damaged concrete to a minimum depth
of 10 mm, up to the pre-cut edge of the repair.
d. Fully expose any corroded reinforcement in the repair area and continue until un-corroded steel is
reached. It may be necessary to break out the concrete beyond the original repair area in order to
achieve this.
e. Oil and grease deposits are best removed by steam cleaning, detergent scrubbing or the use of a
proprietary degreaser.
f. Fully clean the concrete and steel surfaces to remove laitance, the by-products of corrosion and
other contaminants. This is most effectively achieved by proprietary blast media with particular
attention required to both the rear face of the bars and the edge of the repair. The steel bars should
be cleaned to a uniform bright condition and the edge of the repair should be ‘roughened’ to
provide a good mechanical key at the substrate interface.
g. Chloride-induced corrosion will further require high-pressure washing with clean water
after blasting to ensure complete removal of the corrosive elements.
Reinforcement Priming
a. Exposed steel reinforcement should be securely held in place to avoid movement
during application, as this will affect the compaction and bond of the material;
b. Apply one full, unbroken coat of approved priming and allow drying before continuing. If unsure
about continuity of the coating, apply a second coat and allow drying.
Substrate Priming – water (standard repairs)
a. Priming with water should take place after the erection of the formwork.
b. Several hours prior to placing the approved substrate primer, the prepared concrete substrates
should be saturated, by filling the formwork.
c. With clean water. Immediately prior to application of approved substrate primer, any
excess water should be removed via the drainage outlet, leaving the substrate “saturated
surface dry”.
d. Different substrate priming shall be selected and approved depending upon defect like chloride
contaminated concrete etc. Application of the same shall be done in strict accordance with the
manufacturer’s instructions.
Formwork
a. Formwork should be constructed such that the unrestrained surface area of the repair
is minimized.
b. The formwork should be rigid and tight to the substrate to prevent grout loss. Use of
silicone sealant, or similar, is also advised around the edge of the formwork.
c. The internal faces of the formwork should be sealed, using an approved release agent, to ensure
that water is not absorbed from the repair material by the formwork.
d. The formwork should include suitable drainage outlets for pre-soaking and, when filling the repair
‘bottom up’ (e.g. soffit repairs), should further include provision for air-venting to release trapped air
as pouring proceeds.
e. There must be suitable access points to pour or pump the mixed material in place.
Mixing, Placing and Curing
a. It is essential that mixing is done following the approved product data sheet.
b. Limits of the repair geometry should be in accordance with that laid down in the ‘Design criteria’
section of the approved product data sheet.
c. Placement should be a continuous process, to avoid the formation of a ‘cold joint.
d. If placing by the pump, the pipeline should be ‘grouted’ with a rich cement slurry or
mortar, discharging such grout as waste.
e. Pumping of the mixed material should follow immediately after grouting has been carried out.
f. Formwork should be left in place until the cured grouting area has reached a self-
supporting, compressive strength, or as otherwise advised by the Engineer.
g. Immediately after the formwork has been struck, all exposed faces of the repair should
be thoroughly soaked with clean water to remove residual traces of the shutter release agent.
h. At ambient temperatures above 30°C supplementary curing in the form of polyethylene sheeting,
taped down at the edges, must be used.
Cracks
a. The dry/damp crack is identified as per structure elements as below:
b. Cracks equal or larger than 0.20mm on External Walls and Side part of Base Slabs c. On all other
elements i. Non-structural Cracks equal or greater than (>) 0.20mm, but () 0.2mm
d. Wet Cracks: Wet cracks are the type of defects caused by faulty construction work, especially in
waterproofing work.
Surface Preparation
a. Generally, surface preparation includes removal of all loose surface deposited material by wire
brush. The prepared areas must be free of dirt, oil and other contaminants & be thoroughly cleaned
by dry air, oil-free compressed air.
b. Remove from substrate all traces of dust, oil, paint, laitance and other deleterious materials that
might affect subsequent bonding.
c. Mark the defective area, V-cut to a minimum depth (as required by repair material manufacturers)
& break out the repair area to remove all contaminated or damage concrete.
d. Immediately prior to application of repair material, the prepared substrate should be cleaned
by oil-free compressed air.
Priming
Water Priming: Soak the substrate with clean water.
Excess water shall be removed and leave the substrate in a saturated surface dry condition. More
soaking time is required for poor quality concrete.
For large structural repair, soak the substrate for several hours after formworks installation.
Mixing/Application/Finishing/Curing
a. Pre-packed repair materials shall be mixed as per manufacturer’s recommendation.
b. Apply repair material and allow to partly setting before finally trowelling to a smooth finish. In any
case, follow the manufacturer’s manual.
c. Curing not generally required but in extreme drying conditions, must be placed within 30 minutes
after mixing and placement are done in a continuous process to avoid cold joint.
d. Removal and repair of exposed surfaces and curing shall be carried out as per manufacturer’s
recommendation.
e. Thickness applied shall be as per manufacturer product data sheet finish using steel or plastic
float.
f. Damp sponges can also be used to achieve required surface texture.
g. Proper curing by means of wet hessian cloth covered by polythene sheet or use
approved applicable curing materials as per manufacturer’s recommendation.
h. Inspection Request shall be submitted after completion of works.
Crack injection
a. Remove surface laitance and contaminants from a bond 50 mm wide centered on the crack, using
power wire brushing or high-pressure air jetting. Identify the nature of the crack and investigate the
extent and magnitude of the crack by making a V-groove cut 25 mm deep along the crack line.
Remove surface dust & laitance by high-pressure air jetting.
b. Surface cracks extending to bar reinforcement and excess of 0.2 mm in width and 25 mm in depth
shall be injected by a low viscosity epoxy resin.
c. If packers are being used, drill holes along the center of crack to accept the packers. The centers
should be 1-1.5 times the depth of the crack, but not more than 200 mm.
d. Surface Preparation:
1. Clean the surface and remove all traces of dust, oil, paint, curing compounds, grease, corrosion
deposits, algae or any unsound material.
2. The surface should be preferably prepared by using high-pressure water jetting or light abrasive
blasting, followed by thorough washing to remove dust and remaining particles.
3. Oil and grease deposits are best removed by steam cleaning, detergent scrubbing or the use of
a proprietary degreaser.
e. Mixing:
1. The hardener and the base resin should be thoroughly mixed manually until the liquid becomes
clear.
2. Crack injection material should be used with standard injection equipment having closed
containers at an injection pressure of 0.4N/mm² (4 bar).
3. Mix only sufficient material that can be used within the pot life of the material. (Refer
to Technical Data Sheet).
f. Application:
1. Crack injection material should be injected using standard injection equipment having
closed containers.
2. Injection packers should be inserted into the pre-drilled holes at intervals along the length of
the crack. The distance between each packer shall depend on the length and width of the crack.
3. If practical, seal the surface of the cracks between the packers with approved sealer material,
30 to 40 mm wide and 2 to 3 mm thick. Both sides of the cracks, which lead through a wall or slab,
shall be sealed this way. If the water flow is severe the sealer application can be omitted.
4. In case of a wall or slab which is cracked all the way through, packers shall be located on both
sides with those at the back placed at midway points between those at the front.
5. One end of the injection hose shall be attached to the lowest packer on vertical cracks or to
either end of horizontal cracks.
6. Each crack shall be treated in a single continuous operation and sufficient material shall,
therefore, be made prior to the commencement of the work.
7. Remove the packers or nipples and make good any holes or voids with sealer and allow curing.
The sealer can then be ground off or softened with a blowlamp and peeled off. Make sure that it
does not burn.
8. Upon completion of the injection works, the injection system shall be allowed to cure for 24
hours and shall be left undisturbed for this time.
i. Finishing a. Wherever possible unrestrained “shoulders” are to be avoided. These have a tendency
to crack and/or deboned, due to their unrestrained nature; b. The gap between the perimeter
formwork should not exceed 150 mm on the pouring side and 50 mm on the opposite side. It is
advisable where practical to have no gap at the flank sides.
j. Curing On completion of the grouting operation, all exposed areas of grout should be
thoroughly cured. Using approved curing compound, continuous application of water and/or
wet hessian.
k. In summary along with standard practice, methods described by the approved manufacturer shall
be followed in strictly.
V. Drawings, Diagrams, Maps and Survey Data Sketch shall be attached to the submitted INR.