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 uproject 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.
c. If sagging occurs on vertical or overhead faces, the compound must be
completely removed.
d. The substrate must be reprised and compounded and then reapplied in layers of
reduced thickness.
e. Multiple layers can also be used to achieve the desired thickness and profile but
care must be taken to ensure consistency of inter-coat bond strength.
f. Where multiple layers are to be applied, the surface of intermediate layers
should be ‘scratch-keyed’ and cured with wet hessian. Further applications of the
fresh compound may be applied once the intermediate layer has reached its initial
set.
g. It can be finished by striking off with a straight edge and closing with a steel or
plastic float. Note that water can be drawn to the surface if ‘overworking’ with the
float occurs, and an unsightly finish may result.
h. Damp sponges or plastic floats may be used to achieve the desired surface
texture, but care should again be taken not to overwork the surface.
i. Curing of repaired areas should be carried out as soon as possible after the
surface has been closed.
j. Approved curing compound should be spray applied in accordance with its
current data sheet instructions.
k. In adverse conditions (e.g. windy conditions or ambient temperatures greater
than 30°C), supplementary curing in the form of polyethylene sheeting taped down
at the edges should be used.
2.2 Honeycombing or Spalling (Reinforcement exposed and beyond cover
zone) Impact, rebar space too close, loss of grout, poor vibration, and low slump
are 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.
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 the 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 the 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 the 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
defects 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 placed 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.

1. orking at night, please refer to Method Statement for Night Works

2. Emergency Procedures The Flow Chart below shows the Emergency Contact No.
during work:

3. Emergency Contact Numbers

Supervision and Monitoring Arrangements
 Construction Manager
He is in charge of all construction activities. Schedule the project in logical steps
and budget the time required to meet deadlines. Inspect and review projects to
monitor compliance with building and safety codes and other regulations.
Site Engineer
The Site Engineer shall evaluate the number of materials consumed by each trade
to be compared against the planned quantity.
Site Foreman
A construction foreman is responsible for supervising the workers and also doing
actual construction work. The foreman monitors employees to ensure that the
work is done efficiently and within quality standards.
QA/QC Engineer
The QA/QC Engineer shall monitor whether the installation works are conforming
to the required quality otherwise he shall notify the Site Engineer should he find
nonconformance to the ongoing activities. The Site Engineer shall immediately
rectify the work to avoid receipt of NCR from the QA/QC Engineer.
HSE Engineer
The Safety Engineer shall be full-time at the site and shall frequently visit all the
ongoing works at the site. All safety violations and on-conformance of the HSE
Plan shall be registered and immediate action shall be done in coordination with
the Site Engineer.
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 a relevant meeting, and
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. Note: Site Engineers / HSE Staff shall have access on-site to
each MS/RA. Consultants will monitor activities on-site based on the MS/RA. XI.
Environment and Quality Issues
4. Precautionary Measure All precautionary measures shall be briefed to all workers
prior to commencing activity
5. Disposal Requirements All waste shall be disposed of as per the Construction
Environmental Management Plan and as per Government approved disposal areas.

VII. Inspection, Test, and Sampling

Request for Inspection and Testing will be submitted prior to and after execution of
works.

VIII.Quality Assurance Requirements Table

Refer to the Project Quality Plan
a. Project Specifications
IX. Attachments
References (attach here)
Documentation (attach here)
Project Specifications (attach here)
Appendices:
Appendix A-Material Technical Data Sheet (attach here)
Appendix B-Risk Assessment
Appendix C-Inspection and Test Plan