constructive solutions

SPECIFICATION METHODOLOGY FOR TREATING HONEY COMB IN THE

CONCRETE STRUCTURE

1. Surface preparation
i. Attention to full and proper preparation of the substrate is essential for complete
adhesion.
ii. The honey combed portion of the concrete shall be completely removed to a proper
geometrical pattern and the dense sound RCC structure shall be kept exposed.
iii. It is recommended to provide a funnel type or chute kind of arrangement from the top
of the affected portion to facilitate the pour of the grout.
iv. All surfaces should be dry and free from contamination such as oil, grease, loose
particles, decayed matter, moss, algal growth, laitance and all traces of mould
release oils and curing compounds.

2. Application of Bonding Agent

i. The bonding agent recommended shall be epoxy based since the bonding efficiency
and compatibility of the reinstatement treatment is very important.
ii. Nitobond EP should be applied on the prepared dry surface after mixing base and
hardener together for 3 to 5 minutes.
iii. The mixed material shall be applied to prepared concrete surface by medium stiff
brush.
iv. Special care shall be taken to ensure that all imperfections are coated, particularly
behind exposed reinforcing bars.
v. The sequence of repair area shall be arranged so that the replacement of micro
concrete or polymer mortar is laid within 6 hours on application of the Nitobond EP
barrier coat.

Fosroc Chemicals
telephone: email:
(India) Pvt Limited ++91 44 6130 4500 enquiryindia@fosroc.com
Hills Centre, Old No.5, New No.9 ++91 44 2493 8994
3rd Cross Street, Jeth Nagar,
Raja Annamalaipuram, ++ 91 44 2493 6641
Chennai – 600028
Registered Office: 41st KM, NH4, Nelamangala Taluk, Bangalore Rural Dist. 562111
www.fosroc.com Corporate Office: Embassy Point, No 150, 2nd Floor, Infantry Road, Bangalore 560001. Telephone : ++91 80 4252 1900
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3. Micro Concrete for Deeper & Wider Honey Comb Repairs

i. Wherever the repair areas are deeper beyond the reinforcement rod and wider, micro
concrete shall be poured instead of trowel applied mortar after application of epoxy
bonding agent, Nitobond EP.
ii. Slurry tight and strong formwork shall be erected and a suitable funnel type
arrangement shall be provided on the top and fixing PVC pipe of 10mm dia with deep
sections beyond the honey comb portions, temporarily on the formwork at 300mm c/c
which shall be removed while the concrete is in plastic state to facilitate grouting in
the later stage.
iii. Renderoc RG, a cementitious micro-concrete shall be mixed to the measured clean
water of 4 litres per 25kg bag of cement and mixed using a normal speed driller of
300 rpm fitted with a paddle
iv. Always add the powder material to the measured water gradually and mix
continuously.
v. Mixing shall be carried out for 3 to 5 minutes to ensure that there is no bleeding or
segregation.
vi. Mixed Renderoc RG shall be poured continuously till the repair area is completely
saturated with micro concrete.
vii. When the micro concrete turns from green stage or plastic stage, nozzle shall be
removed or else saturated micro concrete in the pipe will hinder the flow of grout
later.
viii. The formwork shall be removed after a period of 24 hours and curing shall be done
as per regular practice with water or using membrane curing by applying Concure
WB immediately after de-shuttering.

4. Polymer Modified Mortar for Tiny Patches

i. While the bonding coat attains tacky condition, mix the two component product
Renderoc S2 thoroughly with addition of 3.5 litres of clean water.
ii. The mixing ratio, by volume, should be 3.5 litres of water + 0.25 kg polymer to 25 kg
Renderoc S2.

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iii. In any circumstances the water content should not exceed 3.5 liters. Apply the fully
mixed Renderoc S2 to the prepared substrate, from 5 to 50 mm thickness in single
layer, by steel trowel.
iv. Renderoc S2 is finished by striking off with a straight edge and closing with a steel
float.
v. The polymer mortar should be tightly packed around the packers and ensuring the
mortar should not block inside the packer.
vi. Damp sponges or plastic floats may be used to achieve a desired surface texture, but
care should be taken not to overwork the surface.
vii. Curing shall be done as per regular practice with water or using curing membrane like
Concure WB immediately after surface evaporation of water say after 3 hours from
the time of application.

5. Injection Grouting Treatment

i. Mechanical GI Packers NRV type of minimum 100mm length shall be fixed in the
available cavity of micro concreting using Lokfix S.
ii. The fixed nozzle shall be cleaned with air blower to flush out cement dust and
impurities.
iii. The base and hardener of Conbextra EP 10, low viscous epoxy injection resin grout
shall be mixed mechanically to achieve a homogenous mix.
iv. The mixed material shall be injected in the pre fixed packers by mechanical Injection
pump. The pump pressure shall be maximum of 3 kg/cm², as per site conditions.
v. The Epoxy material shall be injected through the prefixed packers under pressure
using mechanical grout pump to fill all possible pores and gaps left within the
concrete mass.
vi. When the flow of grout stops, or when the grout flows out of the adjacent packers,
mains shall be disconnected, the packers shall be plugged and allowed to set for 24
hours.

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6. Cleaning
i. General cleaning of tools could include N C Thinner or Fosroc Nitoflor Sol,
commercial rotary brush washing using generic soaps and detergents or by manual
brush and detergent cleaning methods.
ii. Care must be taken not to use harsh chemicals or ammonias or cleansers that
contain high levels of acids or alkalis as they may affect the properties of the reinstate
work.

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