Method statement for DIAPHRAGM

WALL REPAIR WORKS

Date: 13-03-2023
Revision: 0

Construction of Approximate Nine (09) km Twin Bored Tunnels from TBM

Retrieval Shaft near Venugopal Nagar Station to Kelly’s Station and Construction
of Diaphragm Walls of Station Box and Entry/Exit Structures of Madhavaram Milk
Colony, Murari Hospital, Ayanavaram and Purasaiwakkam High Road Stations,
including Launching and Retrieval Shafts as required in the above Metro Stations”

PACKAGE: CP30/TU-01

CLIENT: CHENNAI METRO RAIL LIMITED

GENERAL CONSULTANTS: NKAB

CONTRACTOR: TATA PROJECTS LIMITED

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 Method statement for DIAPHRAGM
WALL REPAIR WORKS
Date: 13-03-2023
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Method statement for DIAPHRAGM WALL REPAIR

WORKS

Revision: 0

DISCIPLINE Civil Mechanical Electrical General



Controlled Copy Uncontrolled Copy



Name Designation Signature

Prepared by: Mr. Ashok Kumar Deputy QA/QC Manager

Reviewed by: Mr. P. Velmurugan Chief OHS & E Manager

Reviewed by: Mr. K. Venugopal Chief QA/QC Manager

Approved by: Mr. Mick Jurgen Project Manager

Submitted by:

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 Method statement for DIAPHRAGM
WALL REPAIR WORKS
Date: 13-03-2023
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Table of content

1. Purpose 4
2. Scope of Works 4
3. Roles and Responsibility 4
4. Reference Documents 5
5. Abbreviations 5
6. Materials 5
7. List of Major Plant & Equipment’s 6
8. Methodology for rectification 6
8.1 Concrete Bulging 7
8.2 Honeycombing Concrete 7
8.3 Exposed Reinforcement 10
8.4 Water Leakage 12
8.5 Missing Coupler 13
8.6 Joint Repairs 13
8.7 Cracks 14
9. Quality Control / Quality Assurance 15
10. Health, Safety and Hazard Analysis 15
11. Attachments 16
Proposed material for D wall repair works
Check list
Inspection and Test Plan
Material Data Sheet

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 Method statement for DIAPHRAGM
WALL REPAIR WORKS
Date: 13-03-2023
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1. PURPOSE
This Method Statement describes about the procedure for the rectification work for any defect
in the diaphragm wall at Madhavaram Milk Colony (MMC), Madhavarm High Road(MHR),
Ayanavaram(AYN)& Purasaiwakkam(PWK), including Venugopal shafts and other shafts in
CP30/TU01.

2. SCOPE OF WORKS
The construction execution procedure applied to rectification works to be carried out if
necessary for the diaphragm wall during excavation for station box.
The rectification work shall be categorized based upon type of defects:-
Concrete Bulging
Honey combed Concrete
Exposed reinforcement
Wall Joint repairs
Water leakage repairs
Planting of missing couplers
Cracks

3. ROLES AND RESPONSIBILITY

Project Manager

He is overall responsibility for arranging the resources and required manpower to be work site
and ensuring the correct process.

Station Managers:

He is the responsible for identifying and demarking the defect and manpower for all necessary
resources for this activity

QA/QC Manager:

He is the responsible for ensuring the quality of enduring the method of execution as per
approved method statement and necessary testing arrangements.

Safety Manager:

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He is the responsible for ensuring the safety precautionary measures to be taken at site during
execution as per the site safety plan.

4. REFERENCE DOCUMENTS
Method statement for Diaphragm wall construction
Method statement for Excavation
Project Safety Plan
Project quality Plan

Manufacturer Literature / Recommendations for Repair Material

5. ABBREVIATIONS
CMRL Chennai Metro Rail Limited.
GC General Consultant
TPL Tata Project Limited
QC Quality Control
IS Indian Standard
ITP Inspection & Test Plan
High Yield Strength Deformed bars
HYSD
SOP Standard Operating Procedure
OCS Outline Construction Specification

6. MATERIALS:
Cement OPC 53 Grade
10mm Coarse Aggregate
M.Sand
Water
Admixture
Soidum Slicate
Reinforcement

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Repairing materials as per Manufactures site conditions

7.0 LIST OF MAJOR PLANT & EQUIPMENTS

Drilling Machine

Air compressor

Pneumatic hand breaker

Portable Grouting Pump

Generator

Scaffolding and conventional formwork Shotcrete Machine

Required length of Hose connected to shotcreting Gun
Air Compressor
Transit Mixer
Batching Plant

8.0 METHODOLODY FOR RECTIFICATION

Station Manager shall identify all defects in consultation with the GC representatives based on the
exposure of Diaphragm Wall during excavation. The defects shall be classified as stated below.

Concrete Bulging
Honeycombed Concrete
Water Leakage
Exposed Reinforcement
Joint repair
Coupler dislocations
Cracks

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 Method statement for DIAPHRAGM
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8.1 Concrete Bulging:

 The excess concrete bulging portion shall be smoothly chipped off with the help of chisel
hammer / Chipping machine to the required level.
 After chipping the loose aggregate, Laitance shall be removed and the surface shall be
cleaned.

8.2 Rectification for Honeycombed Concrete

For Repair Area Thickness < 80mm

Where defected area is within reinforcement cover, approximately less than 80mm depth,
troweling method shall be employed with Renderoc S2 or equivalent material.

Surface Preparation:
Concrete surface shall be free from dust, loose aggregates, oil, paint, grease, corrosion deposits
and any other deleterious substances, Surface laitance should be removed by mechanical means.
Oil and grease deposits shall be removed by wire brush/ approved materials. Concrete surface so
treated should be washed with clean water. Smooth substrate must be mechanically roughened
to provide mechanical key.
Priming:
The surface should be thoroughly soaked with cleaned and any excess water and any excess
water must be removed prior to apply one coat of Nitobond primer or equivalent and scrubbing
it well into the surface. Renderoc S2, or GP2, or equivalent can be applied as soon as the primer
becomes tacky.
Mixing:
Care should be taken to ensure that Renderoc S2 or GP2 or equivalent is thoroughly mixed. A
forced action mixture is essential. For normal application, use 3.25 – 3.5 ltr of water for 25kg
bag (or as per the recommendation of Manufactures) of Renderoc S2 or GP2 or equivalent.
Application:
Apply the mix renderoc S2 or GP2 to the prepared surface by gloved hands or trowel. Thoroughly
compact the mortar on to the primed substrate. Renderoc S2 or GP2 can be applied from a
minimum of 5-15mm thickness in smaller packets or with use of formwork. If sagging occurs
during application to vertical face.

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Finishing:
Renderoc S2 or GP2 is finished by striking of with the straight edge and closing with a suitable
hand trowel, or a damp sponge may be used to achieve the desired surface structure.
Curing:
The repair area should be cured immediately by using either the following measures:
 Water curing for 3 days.

 Spray/ apply curing compound in a continuous film over repair area.

For Repair Area Thickness > 80mm to Upto 1m

Where defected area is over reinforcement cover, approximately more than 80mm depth, form
and cast-in place method shall be employed with GP2 or Equivalent Material as the following
procedures.

Surface Preparation:
Cut and clean the concrete surface with mechanical saw and remove any dust, unsound
material, plaster etc. Roughen the surface and remove any laitance by light scrubbing or grit
blasting. The concrete surfaces and exposed reinforcing bars should be thoroughly cleaned with
Wire brush several hours prior to placing of micro concrete- GP2.
Reinforcing steel is exposing and found to have lose rust or corrosion products or is no well
bonded to the surrounding concrete, then concrete removal should continue to create a clear space
behind the reinforcing steel of minimum 12mm(6mm plus the 12.50mm of the maximum size of
aggregate of the repair material).

Reinforcement Priming:
One coat of anticorrosive Primer Nitoprime Zincrich or Master Protect P8100AP or equivalent
material shall be applied on the reinforcing steel. If any discontinuity in the applied film is
noticed, one more coat has to be applied.

Substrate Priming:
The prepared substrate shall be primed using Nitobond or equivalent material

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Formwork:
Slurry tight formwork shall be prepared and placed in position with provision of feed hopper at
the highest point. Formwork shall be coated with mould releasing agent prior to fixing.

Mixing:
Micro Concrete( Cement OPC 53 Grade + 10 mm aggregates + M.Sand + Water) or GP2-should
be mixed with 10mm aggregates and water thoroughly in a forced action mixer of adequate
capacity. The quantity of water required will be generally between 3.75 to 4.0 liters (W/P ratio
of 0.15 to 0.16) per bag of GP2 or equivalent. Add calculated water to the drum and with the
mixer running slowly, empty GP2 or equivalent in to mixer containing water. Mix continuously
for 5 minutes ensuring a smooth and even consistency.

Placing:
The mixed micro concrete should be placed immediately through a chute and from one end to
air entrapment. Place the grout within 20 minutes or as per manufacture recommendations.

For Repair Area Thickness > 1m

For larger cavities more than 1m thickness, same procedure for cleaning, priming and formwork
shall be followed as per the earlier method. The material used for filling shall be of higher or
equivalent grade of concrete .Additional care shall be taken to ensure proper compaction of
concrete.

De-shuttering:
The shuttering should be removed after a minimum period of 24 hours.

Curing:
The repair area should be cured immediately after stripping the formwork by using either the
following measures:
 Water curing for 7 days.

 Spray/ apply curing compound a continuous film over repair area.

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8.3 Exposed Reinforcement:

8.3.1 Repair of Protruding Rebars:

 All protruding rebars shall be identified .Small recess of about 25 to 50mm ( as per site
conditions) shall be made around the protruding Rebar by chipping and bars shall be
trimmed off with cutting wheel.

 Upon cutting the bars, the exposed bar shall be applied with Nito prime /equivalent material
and repaired with Renderoc/GP2.

8.3.2 Repair of Damaged Shear Link Bars:

 The exposed and damaged shear link bars shall be identified and jointly inspected with GC.

 The damaged bars whichever not possible to rectify shall be trimmed using cutting machine.

 The same shall be replaced with new bars by chemical anchoring .Once the bars are fixed
the repair shall be done as per the clause 7.2.

8.3.3 Repair of exposed reinforcement for entire panel surface:

Preparation:
Chip off the loose concrete, clean the concrete surface with and remove any dust,
unsound material, plaster etc. The concrete surfaces and exposed reinforcing bars should be
thoroughly cleaned with Wire brush and water jet prior to placing of Shotcrete.
Cleaned Rebar shall be coated with primer before application of shotcrete.

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Shotcreting Machine

Surface Preparation

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Application of Shotcrete
Mix shall be of wet mix with equivalent or higher grade of concrete and supplied from Batching
plant to the site. During Shotcreting min thickness of 50 to 80mm shall be maintained uniformly
and finished matching to the adjacent surface. Accelerator (Sodium Silicate) percentage shall be
adjusted within 6% to 9 %. Sprayed surface shall be cured for minimum period of 3 days.

Application of Shotcrete

8.4 Rectification for Water Leakage through Diaphragm Wall panel

This rectification procedure applied for surface leakage, joint leakage.

Top Acrylic Gel or Tampur 125 or Equivalent Material for Joint leakage

Top Inject 70 or Tampur 125 or Equivalent Material for Surface Leakage

 Drill a hole of 10-12mm diameter at the bottom most point where water leakage is observed.
For the panel and wet cracks, the hole shall be drilled diagonally 45 degree to intersect both
side of the joint 300mm C/C or as per site conditions.
 Dampness area shall be grouted with cementitious material
 Upon identifying more leakage even after cement grouting ,Install packer into drilled hole
and clean edge of leakage to ensuring that the hole shall be not have any blockage, dust.

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 Install grout pump nozzle onto the packer and inject polyurethane grout with hardened at Max
3 bar pressure. Continue pumping until the grout starts to overflow from the joints or fissures
of the surface to cover all the voids shall be filled with grout materials.
 Cotton wastage shall be inserted into joint to further seal the gap where the grout overflows.
When no water leakage or when pumping pressure build up, pumping shall be terminated.
 The cotton wastage and excess polyurethane grout on the diaphragm wall surface shall be
removed after curing period of 8-10hr from the time of grout.

8.5 Rectification for Missing Couplers:

If any couplers are missing in the diaphragm wall beyond the tolerance as per the approved
drawings in slab, the missing couplers location shall be identified by the respective station
manager in consultation with the GC representative, the joint inspection record shall be
recorded.
 Drill the core required size of hole into the diaphragm wall to the specified depth as per
designer considerations.
 Clean the drilled hole with wire brush or air jet to remove the loose particles inside the hole.
 Chemical anchoring shall be followed as per approved Design recommendations.
 Fill adhesive (Approved from GC) in to hole from bottom upwards/Inside outwards.
 Insert and rotate rebar slowly into the hole and allow the adhesive to cure.
 The pull out test shall be carried out as per Design and Manufacture requirements.

8.6 Panel Joints Repairs:

 Diaphragm wall panel joints of gap more than 75mm shall be repaired as per the following
methodology

 The joint inspection shall be carried out with GC and Panel joints with more than 75mm gap
shall be identified.

 All loose particles in the Panel joints shall be chipped off and protruding Rebars shall be
trimmed with Hand cut machine .The joints shall be cleaned with water jet and sound
concrete to be ensured after cleaning.

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 Surface shall be prepared and treated by applying Bonding agent on the existing concrete
surface. Exposed Rebar shall be treated with Nito Prime or equivalent material .Upon
completion of surface preparation, Steel wire mesh(3mm thick) shall be fixed all along the
joints firmly by nailing into the Diaphragm wall.

 After completion of the above process, the joints shall be covered with formwork and joint
between formwork and D wall shall be sealed to avoid leakage of slurry.

 Once formwork rigidity is ensured, it shall be followed by filling with GP2 grout or
Renderoc Plug or Equivalent material.

8.7 Cracks:

Less than 0.30 mm repairs not required

0.30 to 0.50mm Cracks:

Clean the concrete surface along the crack or joint of any loose or deleterious materials that
might affect adhesion. Any dust shall be blown away with dry compressed air.

 After ensuring the cleanliness of the surface, the entire surface shall be washed with water
and allowed to dry.
 Wedge type cut along the length of the crack to the full depth.
 Prime the crack with a bonding agent like Nitobond AR of FOSROC or Equivalent Material.
 MasterEmaco S488 or Equivalent Material is finished by striking of with the straight edge
and closing with a suitable hand trowel, or a damp sponge may be used to achieve the desired
surface structure.
 On the Completion of repair work, the exposed area is thoroughly cured with CHRYSO
Cure AC or Equivalent Material.

More than 0.50mm cracks:

Separate method statement will submit based on Joint inspection at site

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9.QUALITY CONTROL / QUALITY ASSURANCE

Generally this method statement as well as the relevant works on the site will follow our
Project Quality Assurance Plan.
Material testing as per Approved Inspection & Test Plan (ITP).
Manufacture test certificate provide in each lot of materials received at site
Required tests on site test will be carried out site.

10. HEALTH, SAFETY & HAZARD ANALYSIS:

This will be as per the Risk Assessment for Diaphragm wall works, which is attached along
with this Method Statement.

Safety engineer will ensure that all the personals involved in the construction activity will
strictly adhared to follow the PPE’s at site.

The following PPE’s will used at site

 Safety shoes
 Safety jackets
 Hand gloves
 Gum boots for masons and other labour involved at site
 Safety googles

Access to work area:

Safe access to and out of the area and access passing shall be achieved by appropriate
contribution of scaffolding frames, staircases and aluminium ladders and timber planks.

Lighting

General lighting with an intensity of 100 Lux shall be provided in and around the works area
during the night shift.

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9. ATTACHMENTS

Annexure A Proposed Material used for Repair works

Annexure B Checklist & ITP
Annexure C Material Data Sheet

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Proposed material D wall repair works:

PANEL DEFACTS MATERIAL USED FOR
RECTIFICATION
Reinforcement Coating NitoprimeZincrich/MasterProtect
P8100AP/TamRez Zinc Rich Primer
Bonding Agent in old concrete NitobondEP/SIKA
Hibond/Masterbrace1414
Honeycombing less than 80mm Renderoc S2/ GP2/ MasterEmaco
S488/Sikatop 123 plus

Honeycombing more than 80mm GP2/Sikagrout214in/Powergrout NS2 with

10mm Aggregates. or
Micro Concrete (Cement,10mm Aggregate,
Fine aggregate, Water)

Exposed reinforcement entire panel surface M40 Shotcrete

Panel Joints more than 75mm 3mmwiremeshwith

GP2/Sikagrout214in/PowergroutNS2 with
10mm Aggregates.
Or
Micro Concrete (Cement,10mm Aggregate,
Fine aggregate, Water)
Water Leakages Tampur125/Top Inject 70/ Top Acrylic
Gel/Master roc MP355 2K

Cracks V groove cutting and Renderoc S2/ GP2/

MasterEmaco S488

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