INFRASTRUCTURE AND AREA

DEVELOPMENT CIVIL SERVICES NATIONAL

CO-OPERATIVE HOUSING ENGINEERING SERVICES
SOCIETY PAKISTAN (PVT) LTD.
AT HAWKSBAY KARACHI.
METHOD STATEMENT FOR Document No:SKC-MET-006
Rev : 0
REPAIRS OF BLOWHOLES, Date: 28-09-2020
HONEYCOMBING,
SHRINKAGE CRACKS, and
TIE-ROD HOLES ETC. Page 1 of 13

SEWERAGE, WATER SUPPLY & UNDER GROUND

WATER STORAGE TANKS (PHASE-III)

METHOD STATEMENT FOR

REPAIRS OF BLOWHOLES, HONEYCOMBING, SHRINKAGE CRACKS, & TIE-

ROD HOLES ETC.
 INFRASTRUCTURE AND AREA
DEVELOPMENT CIVIL SERVICES NATIONAL
CO-OPERATIVE HOUSING ENGINEERING SERVICES
SOCIETY PAKISTAN (PVT) LTD.
AT HAWKSBAY KARACHI.
METHOD STATEMENT FOR Document No:SKC-MET-006
Rev : 0
REPAIRS OF BLOWHOLES, Date: 28-09-2020
HONEYCOMBING,
SHRINKAGE CRACKS, and
TIE-ROD HOLES ETC. Page 2 of 13

Revision Record

1. This cover page is a record of all revisions of the document identified above by number and label. All
previous cover pages are hereby superseded and are to be destroyed.

2. The contractor has the full right to modify, amend or change Method Statement and supporting
documents as required or as deemed necessary. All such documents will be submitted to the
“CONSULTANT” for approval.

Prepared Reviewed Approval for Description & page Number of

Rev Date
By by Issuance by Revision
0 28-09-2020 Engr Deppt. Zafar anis First submission, 10 pages
 INFRASTRUCTURE AND AREA
DEVELOPMENT CIVIL SERVICES NATIONAL
CO-OPERATIVE HOUSING ENGINEERING SERVICES
SOCIETY PAKISTAN (PVT) LTD.
AT HAWKSBAY KARACHI.
METHOD STATEMENT FOR Document No:SKC-MET-006
Rev : 0
REPAIRS OF BLOWHOLES, Date: 28-09-2020
HONEYCOMBING,
SHRINKAGE CRACKS, and
TIE-ROD HOLES ETC. Page 3 of 13

CONTENTS

1.0 PURPOSE

2.0 SCOPE

3.0 REFERENCES

4.0 DEFINITIONS AND ABBREVIATIONS

5.0 RESPONSIBILITIES

6.0 MATERIALS

7.0 EQUIPMENT & TOOLS

8.0 SAFETY & HEALTH

9.0 PROCEDURE

10.0 ATTACHMENTS
 INFRASTRUCTURE AND AREA
DEVELOPMENT CIVIL SERVICES NATIONAL
CO-OPERATIVE HOUSING ENGINEERING SERVICES
SOCIETY PAKISTAN (PVT) LTD.
AT HAWKSBAY KARACHI.
METHOD STATEMENT FOR Document No:SKC-MET-006
Rev : 0
REPAIRS OF BLOWHOLES, Date: 28-09-2020
HONEYCOMBING,
SHRINKAGE CRACKS, and
TIE-ROD HOLES ETC. Page 4 of 13

1.0 PURPOSE
 The purpose of this document is to lay down the systematic procedures for the various activities required for REPAIRS OF BLOWHOLES,
HONEYCOMBING, SHRINKAGE CRACKS, and TIE-ROD HOLES ETC. to ensure that all works are carried out in accordance with the approved
construction drawings and contract specification.

SCOPE
2.0
 This procedure is written in order to present the method to be used for repairing concrete defects due to minor plastic and drying shrinkage cracks,
formworks removal, honeycombs, voids, holes, etc., which may appear in the concrete structures. It is intended to serve for all concrete repairs on this
project.

3.0 REFERENCES
 Project Specifications Cast in Place Concrete

Approved shop drawings


Approved steel reinforcement and test results by LABORATORY

Material approval

Mix design and trial mix details. Approved test results by LABORATORY

Contract Drawings

Approved supplier details

Project Quality Plan

Project HSE Plan

Approved method of statement

4.0 DEFINITIONS& ABBREVIATIONS
PM: CONTRACTOR’s Project Manager

CM: CONTRACTOR’s Construction Manager

PE: CONTRACTOR’s Project Engineer

QCE: CONTRACTOR’s Quality Control Engineer

SE: CONTRACTOR’s Site Engineer

QA / QC: Quality Assurance and quality Control

PPE: Personal Protective Equipment

HSE: Health, Safety and Environment

5.0 RESPONSIBILITIES
 Project Manager is responsible for overall project execution, quality and safety. Adopt a leading role with respect to Contractor’s quality and safety
procedures. The PM is responsible for the overall implementation of this method of statement. The Project Manager shall ensure that the key personnel
are well aware of the specifications and method of statement.

 CM / Project Engineer shall arrange all materials, equipment, safety related items and manpower and direct the Site Engineers & Foremen to resort
appropriate action for the smooth execution of the works.

 Safety Engineer shall be responsible for safe working environment & conditions. Coordinate with Site Engineer to identify potential hazards before
works and advise methods of safe working from new developments.
 INFRASTRUCTURE AND AREA
DEVELOPMENT CIVIL SERVICES NATIONAL
CO-OPERATIVE HOUSING ENGINEERING SERVICES
SOCIETY PAKISTAN (PVT) LTD.
AT HAWKSBAY KARACHI.
METHOD STATEMENT FOR Document No:SKC-MET-006
Rev : 0
REPAIRS OF BLOWHOLES, Date: 28-09-2020
HONEYCOMBING,
SHRINKAGE CRACKS, and
TIE-ROD HOLES ETC. Page 5 of 13

 Surveyor shall be responsible for setting out for levels, layout, and lines & establish top levels. Ensuring setting out books are properly maintained and
filed when completed. To coordinate with the CONSULTANT surveyor in determining coordinates, levels, and limits.

 QA/QC Engineer shall be responsible for ensuring that execution of works are complying with approved method statement; specifications, approved
shop drawings and ensure ITR are submitted based on ITP requirements.

 Site Engineer shall ensure that all works are carried out according to approved shop drawings. He shall direct the surveyor for the setting out lines &
levels in concurrence from the Construction Manager/Senior Civil Engineer.

 MEP Coordinator / Engineer shall be responsible for proper execution of MEP works involved before, during and after the works.

6.0 MATERIALS

As per the approved material submittal.


SBR.

NON SHRINK GROUT.

7.0 EQUIPMENTS & TOOLS

Air compressor

Hand tools, hand saw, wire cutter, brush,

Line dory, Mixing drums and buckets

Slow speed drill

Mechanical mixer machine

Measuring tapes

Tamper

Shovel

Wooden Float

Power float

Water pump and PVC flexible hose for curing


The capacity / size of the above tools and equipment shall be judged in accordance with site
conditions, requirements, and availability at the time of execution

8.0 SAFETY & HEALTH

Consultant HSE guidelines and management plan shall be strictly adhered during the substructure concreting works.
Safety of the personnel and properties is to be given prime importance and all the works to be carried out without causing any accidents or property damages.
Concrete works involves the following activities.
1. Shuttering and
2. Fabricating and fixing reinforcement steel.
3. Transportation of concrete.
 INFRASTRUCTURE AND AREA
DEVELOPMENT CIVIL SERVICES NATIONAL
CO-OPERATIVE HOUSING ENGINEERING SERVICES
SOCIETY PAKISTAN (PVT) LTD.
AT HAWKSBAY KARACHI.
METHOD STATEMENT FOR Document No:SKC-MET-006
Rev : 0
REPAIRS OF BLOWHOLES, Date: 28-09-2020
HONEYCOMBING,
SHRINKAGE CRACKS, and
TIE-ROD HOLES ETC. Page 6 of 13

4. Placing concrete at site

5. De-shuttering
6. Curing
Adequate access and egress should be provided to the site for work. All the personnel should wear basic personnel protective equipments. All the equipments,
tools and tackles being used for the work should be in good working condition and maintained. All the personnel will be provided with toolbox talk on the
procedures to execute the work safely.
Necessary risk assessment of the activities is reflected in the enclosed risk assessment.

9.0 PROCEDURE
General:
Request for Inspections and Approval (RFIA)
All repairs shall be conducted by trained masons under the direction of foremen.
The following RFIAs shall be raised:
RFIA-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.
RFIA-2 Inspection of repaired concrete: Raised after the repair work is complete and the concrete has been refurbished.
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:
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 be done.

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.
 INFRASTRUCTURE AND AREA
DEVELOPMENT CIVIL SERVICES NATIONAL
CO-OPERATIVE HOUSING ENGINEERING SERVICES
SOCIETY PAKISTAN (PVT) LTD.
AT HAWKSBAY KARACHI.
METHOD STATEMENT FOR Document No:SKC-MET-006
Rev : 0
REPAIRS OF BLOWHOLES, Date: 28-09-2020
HONEYCOMBING,
SHRINKAGE CRACKS, and
TIE-ROD HOLES ETC. Page 7 of 13

Cracks:

There are three common types of cracks for new concrete.

The first type take place during formworks removal, the concrete edges are broken, peeled,
1.
or cracked during the formwork removal
.
The second type is Plastic cracks which appear in the surface of fresh concrete during its
2.
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
.
Third type is random-drying shrinkage cracks, which appear as random cracks in the top
3.
surface of concrete due to rapid hardening of concrete in hot weather.
Voids or Hole

Holes: The surface defects in walls, foundations, columns and beams is not more than 25cm
4.
depth or concrete cover.
Void through structure: Defects to all structural elements to a minimum depth of 10mm.
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, however since the hole caused has to be rectified it si covered in this
method statement
Classification of the Types of Defects

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

For Minor Defects such as shrinkage cracks, blowholes and minor honeycombs, the QC
6.
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.
 INFRASTRUCTURE AND AREA
DEVELOPMENT CIVIL SERVICES NATIONAL
CO-OPERATIVE HOUSING ENGINEERING SERVICES
SOCIETY PAKISTAN (PVT) LTD.
AT HAWKSBAY KARACHI.
METHOD STATEMENT FOR Document No:SKC-MET-006
Rev : 0
REPAIRS OF BLOWHOLES, Date: 28-09-2020
HONEYCOMBING,
SHRINKAGE CRACKS, and
TIE-ROD HOLES ETC. Page 8 of 13

For Major Defects such as structural cracks, major honeycombs, deep holes, larger voids,
7.
etc. the QC Engineer shall issue an internal NCR to the site Engineer and copies shall be
forwarded to PM/CM. In accordance to section , an 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.
IMPORTANT: All deep surface cracks should be investigated to ensure that the structural
8.
integrity of the element is not compromised. In such cases a third party recommendation for
the repair can be obtained.

1.1. Repairs of various defects.

General Surface Preparation

All surface preparation shall be done as per manufacturer’s recommendation. In general,

9.
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.
All prepared areas should be thoroughly soaked with clean water immediately prior to
10.
repairing product application; any residual surface water should be removed prior to
commencement.

1.1.1. 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.
 INFRASTRUCTURE AND AREA
DEVELOPMENT CIVIL SERVICES NATIONAL
CO-OPERATIVE HOUSING ENGINEERING SERVICES
SOCIETY PAKISTAN (PVT) LTD.
AT HAWKSBAY KARACHI.
METHOD STATEMENT FOR Document No:SKC-MET-006
Rev : 0
REPAIRS OF BLOWHOLES, Date: 28-09-2020
HONEYCOMBING,
SHRINKAGE CRACKS, and
TIE-ROD HOLES ETC. Page 9 of 13

2. The approved material 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 covering the work with properly secured wet Hessian and plastic sheeting.

1.1.2. 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. The 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.

1.1.3. 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 mortar. The defective concrete is to be removed. The
edges perpendicular to the concrete surface shall be cut by angle grinder or by chiselling
process. In case of exposed existing steel reinforcement, a minimum distance of 20 mm
behind the rebar is required. Bonding agent is applied and as per section 7.1 RFIA-1 shall be
raised.
2. Care shall be taken to ensure that the mixture is homogeneous and thoroughly blended as
described in the manufacturer data sheet.
3. The mixed product will be poured on the prepared area continuously to reduce the time
between successive batches. 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.
 INFRASTRUCTURE AND AREA
DEVELOPMENT CIVIL SERVICES NATIONAL
CO-OPERATIVE HOUSING ENGINEERING SERVICES
SOCIETY PAKISTAN (PVT) LTD.
AT HAWKSBAY KARACHI.
METHOD STATEMENT FOR Document No:SKC-MET-006
Rev : 0
REPAIRS OF BLOWHOLES, Date: 28-09-2020
HONEYCOMBING,
SHRINKAGE CRACKS, and
TIE-ROD HOLES ETC. Page 10 of 13

4. The repaired area must be protected from wind by using polyethylene sheet.

1.1.4. 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 substrata. 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 in clause 7.9.

1.1.5. Tie Rod Holes

1. Remove the PVC cone and the PVC sleeve 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 SBR bonding agent.
5. Start mixing by pouring hardener B into base A, the two components must be well mixed to
ensure proper chemical reaction. Use a slow speed drill fitted with suitable paddle to mix the
product at low number of turns (200 – 300 rpm).Mix for few minutes till a homogeneous
mixture is obtained, then add component C (filler/aggregate) and mix for 2 – 3 minutes until
you get a uniform colour mixture. NON SHRINK GROUT GP is supplied in a pre-measured
packing. Partial mixing should not be allowed under any condition.
6. Use a small trowel or a smaller rod shall be used to fill the hole with the non-shrink epoxy
grout mortar (Ep grout GP) to its full capacity.
 INFRASTRUCTURE AND AREA
DEVELOPMENT CIVIL SERVICES NATIONAL
CO-OPERATIVE HOUSING ENGINEERING SERVICES
SOCIETY PAKISTAN (PVT) LTD.
AT HAWKSBAY KARACHI.
METHOD STATEMENT FOR Document No:SKC-MET-006
Rev : 0
REPAIRS OF BLOWHOLES, Date: 28-09-2020
HONEYCOMBING,
SHRINKAGE CRACKS, and
TIE-ROD HOLES ETC. Page 11 of 13

1.1.6. 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.
4. Bonding slurry mixture consists of approved bonding agent; 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.
 INFRASTRUCTURE AND AREA
DEVELOPMENT CIVIL SERVICES NATIONAL
CO-OPERATIVE HOUSING ENGINEERING SERVICES
SOCIETY PAKISTAN (PVT) LTD.
AT HAWKSBAY KARACHI.
METHOD STATEMENT FOR Document No:SKC-MET-006
Rev : 0
REPAIRS OF BLOWHOLES, Date: 28-09-2020
HONEYCOMBING,
SHRINKAGE CRACKS, and
TIE-ROD HOLES ETC. Page 12 of 13

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

10.0 ATTACHMENTS

 Data sheet of SBR

 Data sheet of Non shrink Grout.