Structured Method Statement for Concrete

Repair
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 are 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

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 in 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 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 statements,
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 procedures are followed and strictly adhered to. Supervise the work to ensure that
technical, quality, safety, and purchase order requirements are met; Attend daily site
meetings 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) managers 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 to 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, and workshops 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

All concrete repairs shall be done in accordance with the approved Method Statement
for Repair of Concrete 

Manual chipping of concrete honeycomb prior to 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, and arrange temporary
shading as necessary.

9. Make sufficient material, plant, and labor available to ensure that the application is
a continuous process.

 1.2 Identification of Defects

1. Surface Imperfections a. Blowholes b. Form tie rod/bolt holes, cone holds, and
voids

2. 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, and 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 the edge of the 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 the 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 the 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 the approved primer as per its current
instructions. 
Mixing and Application
a. It is essential that the approved material is thoroughly mixed and that the
temperature of the mixed material should be below the maximum allowable
temperature as per the approved datasheet.
b. Mixing and application shall strictly follow the approved product data.