J&P Document number:

M ET H O D CP 300(a)-QCP-007
S T AT E M E N T
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J&P–AVAX S.A. J.V. 10

Document Title:

METHOD STATEMENT
REPAIR OF CONCRETE STRUCTURES

Issue Date : 09-07-2005

Revision Date: 09-07-2005 Revision No. : 03

Issued By : QA/QC Engineer:

Approved By : Deputy Project Manager:

Approved By : Senior Project Manager:

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1. SCOPE

This Method Statement includes the activities involved in the repair of

concrete structures to ensure that the works and materials conform to
the requirements specified in the Contract (IFC) drawings and Project
Specifications.

2. FIELD OF APPLICATION

This Method Statement specifically applies to repair of tie rod holes,

cracks, pinholes, spalls, blow holes/honeycombs/bolt pockets, irregular
areas requiring chipping and areas with loose aggregates to be removed
on all horizontal, vertical and overhead concrete structures of the
Hospital and the Oval Parking.

A dedicated group of skilled workforce shall be assigned for the mixing

and application of all repair materials.

2.1 Repair of Tie Rod Holes for Water Tank Walls

2.1.1 Materials

A. Masterflow® 544 (Product Data Sheet attached)

High Strength, Non-shrink Cementitious Mortar
Supplier: degussa - MBT

B. Concresive® 1414 (Product Data Sheet attached)

Epoxy Bonding Agent for Concrete Repairs,
Bonding Concrete to Concrete, Steel & Granolithic
Toppings
Supplier: degussa - MBT

2.1.2 Repair Procedure

A. All PVC cones shall be removed.

B. All laitance, weak or friable concrete, if any, shall be

chipped out of the cone portion of the holes to
expose a rough, sound surface.

C. The repair surface must be pre-wetted to thoroughly

dampen the concrete, but any free surface water
must be removed before the application of
Concresive® 1414 Epoxy Bonding Agent. If
necessary, oil-free compressed air shall be used to
blow out holes. The concrete should have cured
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until the shrinkage and moisture movement is low.

D. Mix Concresive® 1414 Epoxy Bonding Agent as per
manufacturer’s recommendation then apply it to the
cone-shaped portion of the hole (both sides of the
water tank walls) using a clean, short haired
paintbrush or a laying-on towel.

E. Close one end of the tie rod hole with suitable form
material. Formwork shall be secured to prevent
movement and leakage during the placing of
grout/mortar.

F. Mix Masterflow® 544 High Strength, Non-shrink

Cementitious Mortar in accordance with
manufacturer’s recommendation until a dry-pack
consistency is achieved. Retempering of mortar
shall not be allowed.

G. Place the mortar by trowel or other suitable means

in layers that will ensure complete penetration inside
the hole. Use of a blunt stick for layer compaction
may aid in securing that all voids will be fully filled-
up.

H. Finish off the surface to match the surrounding

concrete.

I. Immediately after Masterflow® 544 mortar finishing,

all exposed repaired surfaces shall be covered with
clean damp hessian and shall be kept continuously
moist for at least 7 days.

2.2 Repair of Tie Rod Holes for All Other Walls

2.2.1 Materials

A. Site Mixed Mortar (see attached extract from ACI

301M)

B. Rheomix® 141 (Product Data Sheet attached)

Multi-purpose Admixture for Cementitious Systems
Waterproofs & Improves Mortar
Bonding Agent
Supplier: degussa - MBT

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2.2.2 Repair Procedure

A. All PVC cones shall be removed.

B. All laitance, oil, grease or mould oil shall be

removed from the repair surface using wire brush.
All weak or friable concrete, if any, shall be chipped
out of the cone portion of the holes to expose a
rough, sound surface.

C. The repair surface shall be saturated but free of

surface water.

D. Prepare the bonding slurry consisting of 1 ½ to 2

parts cement to 1 part Rheomix ® 141, mix to a lump-
free, creamy consistency.

E. Apply the bonding slurry to the cone-shaped portion

of the hole (both sides of the wall) using a stiff
brush, work the bonding slurry well into the damp
surface, ensuring that no pinholes are visible. The
bonding slurry shall not be applied in thickness
more than 2mm. If a second coat is necessary, it
must be applied after the first coat is touch dry. The
second coat must be applied at right angles to the
first to ensure complete coverage.

F. Close one end of the tie rod hole with suitable form
material. Formwork shall be secured to prevent
movement and leakage during the placing of mortar.

G. Mix dry the repair mortar using the same materials

as concrete to be patched without the coarse
aggregates plus Rheomix® 141 for 2 minutes, then
slowly add water until a stiff consistency is
achieved. Do not use more than 1 part cement to 2-
½ parts sand by damp loose volume.

H. Place the mortar by trowel or other suitable means

over the wet bonding slurry and inside the hole in a
manner that will ensure complete penetration. Use

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of a blunt stick for layer compaction may aid in

securing that all voids will be fully filled-up.

I. Finish off the surface to match the surrounding

concrete.

J. Moisture cure the repaired surface for 24 hours then

allow to dry out slowly.

2.3 Repair of Fine Cracks (<0.30mm), Pin Holes & Bolt Pockets of
Horizontal, Vertical and Overhead Concrete Structures

2.3.1 Materials

A. Concresive® 2200 (Product Data Sheet attached)

High Strength, Non-flow, Epoxy Bedding and Repair
Mortar
Supplier: Master Builder Technologies (MBT)

2.3.2 Repair Procedure

A. Determine areas to be repaired by visual inspection.

B. Highlight/mark all areas that needs repair.

C. Remove all loose particles, laitance, dust and

grease etc. prior to application of Concresive ® 2200.

D. Apply to the required level the readily mixed mortar

(Concresive® 2200) to the repair areas by knife,
trowel, spatula or scraper whichever means suits
each particular repair. A minimum solvent maybe
used to aid workability.

E. Finish smooth the surface using a paintbrush dipped

in Cleaning Solvent No. 2.

2.4 Repair of Cracks (>0.30mm); Spalls, Blow Holes (depth  10mm

i.e. cosmetic repairs), Irregular Areas Requiring Chipping and
Areas With Loose Aggregates to be Removed for Horizontal,
Vertical and Overhead Concrete Structures

2.4.1 Materials

A. Same mix concrete used (Re-concreting) without

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the coarse aggregates (max. aggregate size 

12.50mm)
* For wide and deep surface repairs

B. EMACO® R907 (Product Data Sheet attached)

Two Component Polymer Modified Fairing Coat and
Reprofiling Mortar
Supplier: degussa - MBT
* For surface repairs  10mm deep (see attached
letter from degussa; Ref. No.: MBT/TR881/05)

2.4.2 Repair Procedure

A. Determine areas to be repaired by visual inspection

and hammer sounding.

B. Highlight/mark all areas where concrete quality is

suspect.

C. Cut the perimeter of the marked areas (except

surface cracks) to a depth of 10mm using a suitable
tool, keeping the sides as square as possible to
avoid feather edging.

D. Remove all loose, cracked or friable concrete in the

area until sound concrete appears. Ensure that the
surface is laitance, oil and grease free,
uncontaminated and it is left in rough condition.

E. Surface should be thoroughly soaked prior to re-

concreting or application of EMACO ® R907 Two
Component Polymer Modified Fairing Coat and
Reprofiling Mortar. Surface/standing water shall be
removed.

F. Use forms as necessary for wide and deep surface

repairs.

G. Mix EMACO® R907 Two Component Polymer

Modified Fairing Coat and Reprofiling Mortar in
accordance with manufacturer’s recommendation.

H. Place the same mix concrete (ready-mixed) used

without the coarse aggregates (max. aggregate size
 12.50mm) observing proper concreting procedure
for wide and deep concrete repairs or apply
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EMACO® R907 Two Component Polymer Modified

Fairing Coat and Reprofiling Mortar by steel trowel
for  10mm deep surface repairs.

I. Trowel finish the surface of the repair mortar to

make it match the surrounding concrete. Final
finishing by trowel shall be done after leaving the
applied mortar for a short time.

J. For re-concreted surface, curing shall start

immediately after its initial set and removal of forms.
Curing shall be by moisture retaining cover.

For EMACO® R907 Two Component Polymer

Modified Fairing Coat and Reprofiling Mortar
repaired surface, curing is generally not required. It
only needs to be covered during hot weather to
prevent rapid drying.
K. For surface cracks, cut a V-shaped groove along
the line of crack, clean the surface, remove all loose
concrete, dirt dust, laitance, oil and grease, soak the
surface thoroughly then apply EMACO ® R907 Two
Component Polymer Modified Fairing Coat and
Reprofiling Mortar. Finish off the surface by trowel.

L. Where reinforcement is encountered, the cut should

be deepened at least 15mm beyond the steel bar for
the reception of the repair concrete/mortar. Wire
brush the steel to remove contaminates, rust and
loose millscales.

2.5 Repair of Blow Holes/Honeycombs (deeper than 10mm)

2.5.1 Materials

A. EMACO® S88C T (Product Data Sheet attached)

Shrinkage Compensated, Polymer Fibre Reinforced,
Thixotropic Repair Mortar
Supplier: degussa - MBT

2.5.2 Repair Procedure

A. Determine areas to be repaired by visual inspection.

B. Cut the perimeter of the marked areas to a depth of

10mm using a suitable tool, keeping the sides as
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square as possible to avoid feather edging.

C. Remove all loose, cracked or friable concrete in the

area until sound concrete appears. Ensure that the
surface is left in rough condition.

D. Thoroughly saturate the repair surface to provide a

saturated surface dry condition. It shall be free from
surface water.

E. Mix EMACO® S88C T Shrinkage Compensated,

Polymer Fibre Reinforced, Thixotropic Repair Mortar
mechanically in accordance with manufacturer’s
recommendation until the required consistency is
achieved.

F. Apply EMACO® S88C T Shrinkage

Compensated, Polymer Fibre Reinforced,
Thixotropic Repair Mortar by trowel or by hand.

G. When the placed repair mortar has stiffened to the

point where finger pressure lightly marks the
surface, do the final trowel finish.

H. Curing shall start immediately after finishing by

placing a wet hessian over the repaired surface then
covering it with plastic sheet.

I. Where reinforcement is encountered, the cut should

be deepened at least 15mm beyond the steel bar for
the reception of the repair mortar. Wire brush the
steel to remove contaminates, rust and loose
millscales.

3. CURING

Potable water shall be used for curing the repaired areas/surfaces. It

shall not contain impurities in the amount to cause discoloration of the
concrete and shall meet the requirements of QCS Section 5 Part 4.
Moisture retaining cover curing shall be applied to all repaired
areas/surfaces if and when required. This will be done by placing a strip
of wet absorbent material over the repaired surface/area, maintaining it
continuously wet & covering it with polyethylene sheet to aid in the
retention of moisture. This shall be done for a minimum period of 7 days.

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It should be noted that immediate and appropriate curing is very

important for a successful and durable repair.

4. REFERENCES

4.1 Project Specifications

Section 03300 Cast-in-place Concrete

4.2 AC1 301 Standard Specifications for Structural Concrete

Chapter 5.3.7 Repair of Surface Defects

4.3 Qatar Construction Specifications

Section 05 Part 16 Repair of Concrete

5. MATERIAL SUBMITTAL

5.1 Portland Cement Type I (OPC) CP300(a)-MS-03/004

5.2 Concresive® 2200 (Product Data Sheet attached)

High Strength, Non-flow, Epoxy Bedding & Repair Mortar

5.3 Masterflow® 544 (Product Data Sheet attached)

High Strength, Non-shrink Cementitious Mortar
Supplier: degussa - MBT

5.4 Concresive® 1414 (Product Data Sheet attached)

Epoxy Bonding Agent for Concrete Repairs, Bonding Concrete to
Concrete, Steel & Granolithic Toppings
Supplier: degussa - MBT

5.5 Rheomix® 141 (Product Data Sheet attached)

Multi-purpose Admixture for Cementitious Systems
Waterproofs & Improves Mortar
Bonding Agent
Supplier: degussa - MBT

5.6 EMACO® R907 (Product Data Sheet attached)

Two Component Polymer Modified Fairing Coat and Reprofiling
Mortar
Supplier: degussa - MBT

5.7 EMACO® S88C T (Product Data Sheet attached)

Shrinkage Compensated, Polymer Fibre Reinforced, Thixotropic
Repair Mortar
Supplier: degussa - MBT

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S T AT E M E N T
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6. REVISIONS

Rev. 3 Date: 09-Jul-05

F-P.810/1-0