LG 50

BAR BENDING & CONCRETING
Level-II
Learning Guide-50
Unit of Competence: Repair and Rectify
Concrete Structures
Module Title: Repairing and Rectifying Concrete
Structures
LG Code: EIS BBC2 M14 1019 LO2-LG-50
TTLM Code: EIS BBC2 1019 TTLM 1019v1
LO2 Carry out minor repairs
Instruction Sheet Learning Guide #50
Page 1 of 49 Federal TVET Agency Author/Copyright Learning Guide for Bar Bending & Version -1
Concreting Level II October 2019
This learning guide is developed to provide you the necessary information regarding the
following content coverage and topics:
 Applying concrete staining agent
 Repairing effects of dusting
 Repairing damaged or blistered concrete
 Grinding/topping techniques
 Repairing mortars and self-leveling floor compounds
 Applying sealers and colored paints
This guide will also assist you to attain the learning outcome stated in the cover page.
Specifically, upon completion of this Learning Guide, you will be able to:
 Repair .Color variations by the application of a concrete mark agent
 Repair the effects of dusting by the correct application of an appropriate surface
hardener/dust constraining agent or removal of the weak top layer
 Repair damage concrete either by grinding or covering
 Apply repair mortars and self-leveling floor compounds according to
manufacturers’ specification
 Apply Cover and colored paints to concrete surfaces in accordance with
manufacturers’ specification
Learning Instructions:
1. Read the specific objectives of this Learning Guide.
2. Follow the instructions described below
3. Read the information written in the information
4. Accomplish the “Self-check ‘’below
5. Accomplish the ‘’operation sheet’’ below ‘’ below
6. If you earned a satisfactory evaluation from the “Self-check
7. Do the “LAP test” below
Information sheet 1 Applying concrete staining agent

2.1 Applying concrete staining agent
Concrete Acid Stain is not an over coat, but is an opaque, penetrating color that
permanently changes the appearance of the concrete. Areas where debris remains on
the surface will likely not accept the stain leaving color imperfections on the floor,
particularly mastic, dry wall mud and paints
Concrete Acid Stain is a water-based liquid bearing minerals and acid. The acid stain
penetrates the pores of the concrete forcing a chemical reaction between the muriatic
acid and the available lime in the surface. Once acid stained, the color of the concrete is
permanently altered. When sealed with an appropriate concrete sealer and for indoor
applications, sealed and waxed, acid stain produces the unique, variegated finish
associated with this process.
 Applying the Stain
Safety First! Remember to use goggles, gloves and a dust mask while
working with concrete acid stain. A respirator may be required for applications
with poor ventilation. The appearance of the finished product is very much
influenced by the manner in which the acid stain is applied. We recommend
spraying the stain on the surface using an all-plastic pump sprayer. If a
darker, more even tone is desired, brush the acid stain into the surface using
consistent circular strokes. If using a brush, spray on a second coat to
eliminate any brush strokes on the surface unless that is the desired finish.
Though new concrete may not always require a second coat of acid stain,
older concrete does require two coats of stain for complete coverage. For a
more diffuse look, spray the stain onto the surface without brushing.
Keep in mind that it is your responsibility, as the stain applicator, to
make sure the slab is ready to accept the stain, whether you poured the
concrete or not. Take the time to look at the batch tickets to see what's in the
concrete mix,
and always do a sample prior to stain installation to ensure that the color is as
anticipated.
Tools and Materials
An example of tools and materials needed:
• Pressure Washer water fan tip
• Acid Resistant Gloves
• Goggles
• Clean Plastic Bucket
• Hand Pump Sprayer
• Nylon Brush (Acid Resistant Non-colored)
• Lambs wool Applicator (Smooth Floor, Custom Work)
• Baking Soda
Before You Begin this work
A fan tipped pressure washer can ensure the concrete is thoroughly clean and free of
dirt or debris. Surrounding areas, landscaping, and adjacent surfaces should be
protected. Prior to making stain applications, precautions should be taken to prevent
water penetration into the concrete from any source. Newly placed concrete should be
sufficiently cured to allow the concrete to become reactive, a minimum of 14 days.
Step 1: The Look Staining is caused by a chemical reaction with the surface of cured
concrete to produce unique and permanent color effects. Concrete chemical stains
create uneven, variegated or translucent color patterns. The result is unique to each
concrete surface and cannot be duplicated with other coloring materials. Concrete
stained color effects vary in intensity over color-hardened concrete, newer concrete,
concrete with high cement contents, and overlay toppings.
Figure 2.1.concrete stain color
Step 2: Equipment Brushes for applying the stain should be of professional quality,
long-handled or hand-held, with uncolored, acid-resistant nylon bristles of medium
stiffness, having the ability to hold liquids. Do not use rollers or mops because they
cannot effectively scrub the stain solution into the surface. A hand-pump sprayer may
be used to transfer the stain solution to the surface in larger areas. For cleaning, a stiff-
bristled bassine or nylon scrub brush is recommended.
Figure 2..2 equipment

Step 3: Determine Color Verify and approve suitability and appearance, by creating
test sections prior to general application of the chemical stain. Apply the Chemical stain
using the desired stain colors, preparation and application equipment, and staining
techniques. Copper Patina, Fern Green, and Weathered Bronze are best suited for
interior use and when used in an exterior application must be protected from constant
weathering.
Figure 2.3 stain types of color
Step 4: Apply Stain A minimum of two separate stain applications is normally required
over concrete. Chemical stains should be applied full-strength (undiluted). Coverage
rate is approximately 75-100 square feet per gallon for two applications. The surface
should be divided into small work sections using walls, joint lines, or other stationary
features as natural stopping point
Figure 2.4 applying stain
Step 5: Stain Reaction Chemical stain normally fizzes while reacting. If fizzing does
not occur, the surface has not been adequately prepared or the concrete is not
sufficiently reactive to be chemically stained. Keep the brush in constant contact with
the surface and in continuous motion. Whether the Stain solution remains wet or dries
on the surface, it should be allowed to remain in contact with the concrete until the
desired effect is obtained, a minimum of 4 hours.
Figure 2..5 brushing
Step 6: Neutralizing the Stain All unreacted stain residue must be neutralized and
then completely removed prior to sealing. A solution of baking soda (sodium
bicarbonate) and water, using 1-pound baking soda per 5 gallons of water, can be used
to neutralize the residual stain acid. The solution should be applied until it stops fizzing.
After neutralization, the surface should be rinsed thoroughly with clean water several
times to remove soluble salts.
Figure 2.6 Neutralizing the Stain

Step 7: Seal the Concrete All chemically stained surfaces must be protected from
traffic until they are sealed. The surface should be sealed as soon as possible after the
surface is neutralized and dry. Failure to completely remove all Stain residues and rinse
the surface clean prior to sealing will result in performance problems with the sealer.
figure 2.7 Seal the Concrete
Step 8: Maintenance A maintenance application of sealer should be made periodically

as the sealer is worn off the surface. It is not necessary to strip the previously applied
sealer.
Figure 2.8 applied sealer.
Self check 1 Written test
Direction: multiply chose item

Instruction I chose the correct answer
1.________is a water-based liquid bearing minerals and acid repairing material
A. Concrete Acid Stain B. concrete binding material C. mortar ingredient
2. which of the following use for working Concrete Acid Stain tools and equipment
A Pressure Washer water fan tip B Acid Resistant Gloves
C. Goggles D Clean Plastic Bucket E all
3. The surface should be sealed as soon as possible after the surface is neutralized and
dry.
A. Seal the Concrete B. Neutralizing the Stain C. Stain Reaction
Key answer
1.______________________
2.______________________
3.______________________
Note:
 Satisfactory rating – above 8points
 Unsatisfactory - below 8 points
Operation sheet 1 Applying stain concrete structure
PROCEDURE
Step 1 Identifying repairing wall or floor
Step 2 Select proper repairing material
Step 3 Select properly hand tools and equipment
Step 4 use safety tools properly
Step 5 Clean and Prepare work area
Step 6 Determine Color
Step 7 Apply Stain
Page 10 of Federal TVET Agency Author/Copyright Learning Guide for Bar Bending & Version -1
49 Concreting Level II October 2019
Information sheet 2 Repairing effects of dusting
2.2 Repairing effects of dusting

What is Dusting?
A dusting floor surface is marked by an accumulation of fine material requiring to be
swept up after the floor has been used. A hand rubbed over the surface of a dusting
floor will be coated with a fine powder.
What causes Dusting

Dusting is caused by the wearing surface being weak and the matrix not properly
bonding the fine aggregate particles. The major causes are:
 Inappropriate concrete specification for the required strength and abrasion
resistance.
 The addition of water in excess of that required by the mix design. This generally
increases bleeding which results in more water and fines at the surface of the
slab and ultimately in a weak, permeable surface layer with low wear resistance.
 Premature finishing. If finishing operations are performed while bleed water is on
the surface, the water will be worked back into the surface layer of the concrete
producing a very high water-cement ratio and, therefore, a low strength surface
layer.
 Excessive use of water during finishing. Spraying the surface with water during
finishing to facilitate either the movement of the trowelling machine from one area
to another, or to wet a surface that has not been adequately protected against
hot or drying conditions and allowed to dry out, may have the same effect as
premature finishing.
 Rainwater. Rainwater falling onto the surface before the concrete has achieved
final set may also have the same effect as premature finishing.
Construction dust is not just a nuisance; it can seriously damage your health and
some types can eventually even kill. Regularly breathing these dusts over a long time
can therefore cause life-changing lung diseases.
This sheet tells employers what they need to know to prevent or adequately control
construction dust risks.
It also provides advice for safety representatives and workers.
Construction dust
This is a general term used to describe different dusts that you may find on a
construction site. There are three main types:
 silica dust – created when working on silicacontaining materials like concrete,
mortar and sandstone (also known as respirable crystalline silica or RCS);
 wood dust – created when working on softwood, hardwood and wood-based
products like MDF and plywood;
 lower toxicity dusts – created when working on materials containing very little or
no silica. The most common include gypsum (eg in plasterboard), limestone,
marble and dolomite.
Health risks
Anyone who breathes in these dusts should know the damage they can do to the
lungs and airways.
 The main dust-related diseases affecting construction workers are:
 lung cancer;
 silicosis;
 chronic obstructive pulmonary disease (COPD);
 asthma.
Some lung disease, like advanced silicosis or asthma,can come on quite quickly.
Figure 2.1 Common tasks like cutting can create very high dust levels
However, most of these diseases take a long time to develop. Dust can build up in the
lungs and harm them gradually over time. The effects are often not immediately
obvious. Unfortunately, by the time it is noticed the total damage done may already be
serious and life changing. It may mean permanent disability and early death.
Construction workers have a high risk of developing these diseases because many
common construction tasks can create high dust levels. Over 500 construction workers
are believed to die from exposure to silica dust every year. The amounts needed to
cause this damage are not large. The largest amount of silica someone should be
breathing in a day after using the right controls is shown below next to the penny.
Figure 2.2 Your maximum daily silica exposure is tiny when compared to a penny
Control the dust

Stop or reduce the dust
before work starts, look at ways of stopping or reducing the amount of dust you
might make. Use
different materials, less powerful tools or other work methods. For example you
could use:
the right size of building materials so less cutting or preparation is needed;
 silica-free abrasives to reduce the risks when blasting;
 a less powerful tool – eg a block splitter instead of a cut-off saw;
 a different method of work altogether – eg a direct fastening system.
Even if you stop some dust this way, you may do other work that could still
produce high dust levels.
In these cases the most important action is to stop the dust getting into the air.
There are two main ways of doing this:
 Water – water damps down dust clouds. However, it needs to be used correctly.
This
means enough water supplied at the right levels for the whole time that the work is
being done. Just wetting the material beforehand does not work.
Figure 2.3 Water suppression on a cut-off saw

On-tool extraction – removes dust as it is being produced. It is a type of local exhaust
ventilation (LEV) system that fits directly onto the tool. This ‘system’ consists of several
individual parts – the tool, capturing hood, extraction unit and tubing. Use an extraction
unit to the correct specification (ie H (High) M (Medium) or L (Low) Class filter unit).
Don’t just use a general commercial vacuum.
Figure 2.4 Wall chasing using on-tool extraction
Other controls
depending upon the work you are doing you may have to combine these
measures with other controls.
 Think about:
 limiting the number of people near the work;
 rotating those doing the task;
 enclosing the work to stop dust escaping. Use sheeting or temporary screens;
 general mechanical ventilation to remove dusty air from the work area (eg in
enclosed spaces such as indoors);
 selecting work clothes that do not keep hold of the dust.
You also need to make sure workers are doing the job in the right way and are
using controls properly. Train workers:
 about dust risks and how this can harm their health;
 how to use the dust controls and check that they are working;
 how to maintain and clean equipment;
 how to use and look after RPE and other personal protective equipment (PPE);
 what to do if something goes wrong.
You may already have the right controls in place, but are they all working
properly? Check the controls work by:
 having procedures to ensure that work is done in the right way;
 checking controls are effective. Does the work still seem dusty? You might need
to carry out dust exposure monitoring;
 involving workers. They can help identify problems and find solutions;
 maintaining equipment:
follow instructions in maintenance manuals;
 regularly look for signs of damage.
 Make repairs; replace disposable masks in line with manufacturer’s
recommendations;
 properly clean, store, and maintain nondisposable RPE. Change RPE filters as
recommended by the supplier;
 carry out a thorough examination and test of any on-tool extraction system at
least every 14 months.
supervising workers. Make sure they:
 use the controls provided;
 follow the correct work method;
 attend any health surveillance where it is needed.
You may have to put a health surveillance programme in place. You may need
advice for this from an
occupational health professional.
Repair of Dusting Surfaces
Repair of dusting floors is difficult; it is best to avoid or minimize the risk by adopting the
techniques outlined above. Recommended repair methods include:
 Application of a chemical surface hardener or dust inhibitor. In the majority of
cases, dusting can be rectified by the use of a surface hardener such as sodium
or fluoro silicate. These products react with the calcium hydroxide in the concrete
to produce additional cementitious compounds. They should be applied only to
concrete that is at least 28 days old. Some surface hardeners may restrict future
application of finishes. Surface hardeners should be applied in accordance with
the manufacturer’s recommendations. Note that they will not improve the
appearance of the surface if it has been affected by the loss of the surface layer
through wear.
 Grinding the surface. In more severe cases, the complete removal of the weak
surface layer with a concrete grinder may be required. This will alter the
appearance by leaving a smooth ‘polished’ concrete surface having the
aggregate visible. Note that the depth of the weak surface layer does not
increase with time, so grinding back to sound concrete of adequate strength can
be an effective solution.
 Applying a topping. The weak surface layer could be removed by scabsbling and
replaced by a topping. If levels need to be maintained, a number of proprietary
 topping products that bond to the existing concrete can be placed at thicknesses
of about 10 mm. If levels are flexible, a 70- to 80-mm-thick unbonded topping
(overlay) on the existing floor can be used.
 In some domestic applications, installation of a floor covering such as carpet or
tiles may be a cost effective solution. The concrete surface should be checked
for adequate strength if the floor covering is to be bonded to it.
Direction multiple choose item

1. Caused by the wearing surface being weak and the matrix not properly bonding the
fine aggregate particles.
A. cracking B. Dusting C painting D.mixing
2. Created when working on silica containing materials like concrete, mortar and
sandstone
A silica dust B. wood dust C. toxic dust D. none
3. Which of the following the major causes the dust
A. Inappropriate concrete specification for the required strength and abrasion
resistance.
B. The addition of water in excess of that required by the mix design.
C. Excessive use of water during finishing. D. all
4. how to look at ways of stopping or reducing the amount of dust you might make.
A. the right size of building materials so less cutting or preparation is needed;
B. silica-free abrasives to reduce the risks when blasting;
C. a less powerful tool
D. all
Key answer
1._______ 2.________ 3._________ 4____________
Note:
Operation sheet 2 Applying Repair of Dusting Surfaces
PROCEDURE
Step 6 Application of a chemical surface hardener or dust inhibitor
Step 7 Grinding the surface the weak surface layer could be removed by scabbing and
replaced by a topping.
Step 8 Applying repair a topping.
Step 9 clean work area
information sheet 3 Repairing damaged or blistered concrete
2.3 Repairing damaged or blistered concrete

2.3.1,what causes damage to concrete?
So we've done our evaluation and now we are ready to determine what caused the
damage this is often called troubleshooting. Start by thinking about the basic
characteristics of concrete strong in compression, weak in tension. Therefore, a
crack implies that the concrete was in tension. Recognize that the crack is always
perpendicular to the direction of the tension always!
Think of a typical shrinkage crack running diagonally from a re-entrant corner in a

concrete slab. The concrete was shrinking back in each direction from the corner
and that diagonal crack is perpendicular to the direction of shrinkage. Look at a
diagonal crack across the corner of a slab panel where it was run over by
heavytraffic or the sub base was poorly compacted the bending force created
tension across the top of the slab. Take a saltine cracker and bend down the corner
it breaks in a diagonal line exactly the same as a concrete slab. I guess you could
think of a concrete slab as nothing more than a big cracker!
Here are a few typical concrete problems and their causes:
 Corrosion of reinforcing steel: Steel rebar is protected inside concrete because

the concrete is very alkaline which prevents rust. But if there are chloride ions
present, such as from deicing salts, the chloride destroys the "passivating layer"
of alkalinity around the steel, allowing it to rust. Rust has greater volume than
steel and the expansion presses against the concrete putting it in tension and
causing it to crack and pop off. Chlorides get to the concrete through cracks or by
simply penetrating through the concrete's pore structure.
 Freeze-thaw disintegration: Concrete is porous, so if water gets in and freezes it
breaks off small flakes from the surface. Deicing salts make it worse. This is
typically called scaling and it can occur during the first winter and get worse over
time. When severe, it can lead to complete destruction of the concrete. Proper air
entrainment completely prevents scaling.
Figure 3.1 concrete damaged
Even decorative concrete can suffer damage, and these repairs require special
expertise. Endure Stamped Concrete
2.3.2 Concrete crack repair
Surface preparation and cleaning of the concrete substrate is generally considered
the most crucial step in a concrete repair project. A poorly prepared surface will always
be the weak link in a repair, no matter how good the repair material might be. Surface
preparation includes the removal of damaged and/or deteriorated parts of the substrate
concrete and previously applied coatings, whereas cleaning commonly refers to the
removal of loose particles and contaminants on the surface. Surface cleanliness is also
very important in concrete repairs, as any loose debris, dirt, grease, or other surface
contaminants can act as bond breakers. Obtaining a sound and clean substrate
requires quality workmanship. Findings and recommendations made from research on
bond durability are meaningless unless proper site practices can be ensured.
With low-pressure crack injection, you can permanently repair a basement leak and
foundation crack without high cost and disruptive excavation.
While concrete cracks appear to be typical, it is not recommended that they remain
ignored. Most homeowner’s best identify concrete cracks in their basement, either on
the foundation wall or on the floor. They may also recognize cracks on the garage floor,
patio or in-ground pool.
These cracks typically due to drying shrinkage, thermal movement or other causes
usually are minor and result in few problems. More often than not, a foundation crack
will widen over time and result in water seepage or possibly the loss of structural
integrity. Foundation and slab cracks are not only an eyesore, but they may hinder the
value of the home.
Figure 3.2 concrete crack
Figure 3.3 concrete crack repair
Why Does Concrete Need Repairing?
 Insufficient reinforcement
 Chemical damage
 Excessive loads
 Structural damage
 Fire damage
 Seismic damage
 Blast damage
2.3.3 Concrete repair strategies
Proper maintenance of a concrete structure is essential in order to guarantee the
designed lifetime, since there can be many causes of concrete deterioration. Therefore,
concrete repair is a specialist activity requiring fully trained and competent personnel at
all stages of the process. Unsatisfactory understanding and diagnosis of concrete
deterioration, incorrect repair specifications and choice of repair products/techniques,
and short-term “patch and paint” strategies, have inevitably led to dissatisfaction from
structure owners.
Direction multiple chose item

1. Which of the following the cause of concrete problems

A poor selection of the ingredient B. Corrosion of reinforcement
C. use poor construction method D. all
2._____ is protected inside concrete because the concrete is very alkaline which
prevents rust.
A. Corrosion of reinforcing steel B. Seismic damage
C. Excessive loads D. Insufficient reinforcement
3. Concrete is porous, so if water gets in and freezes it breaks off small flakes from the
surface.
A. Seismic damage B. Excessive loads C. Freeze-thaw disintegration D. none
Key answer
1.________________ 2.________________ 3._______________
Note:
Operation sheet 3 Applying Concrete crack repair
PROCEDURE
Step 6 Grinding or chisel the concrete surface
Step 7 applying repair concrete crack surface
Information sheet 4 Grinding/topping techniques
2.4 Grinding/topping techniques

2.4.1 Topping
 A layer of concrete or mortar placed to form a floor surface on a concrete
base.
 A structural, cast-in-place surface for precast floor and roof systems.
 The mixture of marble chips and matrix that, when properly processed,
produces a terrazzo surface.
Figure4.1 concrete topping
2.4.2 Concrete topping
Please tell me how to correctly prepare and apply a concrete topping. We

recently placed a slab, and then topped it with a mixture of 1 part cement and 3 parts
sand. The slab was given a broom finish before the topping was applied. We did not use
a bonding agent between the slab and the topping. After the topping had been placed,
we were caught in a rain storm and the topping now is sandy and loose. What do you
suggest?
If the topping you applied is loose it should be removed. The old base then
must be roughened before applying another topping which should not be less than 1
inch thick. Instead of using a 1 to 3 sand mix, use a mix consisting of 1 part cement, 1
1/2 parts sand and 2 parts 3/8-inch gravel or stone. After the old base has been
roughened and cleaned, prepare a group of 1 part cement and 1 part water. Mix this to
a creamy consistency and brush it into the base just ahead of placing the new topping.
Be sure that the base concrete is damp so that it will not pull too much water from the
topping mix. Avoid an overly wet mix and excessive troweling. Toweling a wet mix will
bring fine material to the top and this will result in a dusting surface after the concrete
has hardened. Finally, it is most important to prevent the concrete from early drying,
which may cause cracking. Water for curing should be applied to the new concrete as
soon as this can be done without marring the surface. A fog spray is very effective.
1. Grinding:. grind means to abrade, to wear away by friction, or to sharpen. In

manufacturing it refers to the removal of metal by a rotating abrasive wheel. Wheel
action is similar to a milling cutter. The cutting wheel is composed of many small grains
bonded together, each one acting as a miniature cutting point(1).
Surface grinding Grinding flat or plane surfaces is known as surfaces grinding. Two
general types of machines have been developed for this purpose; those of the planer
type with a reciprocating table and those having a rotating worktable. Each machine has
the possible variation of a horizontal or vertical positioned grinding wheel spindle. The
four possibilities of construction
Tool and cutter grinder In grinding tools by hand a bench or pedastal type of grinder is
used. The tool is hand held and moved across the face of the wheel continually to avoid
excessive grinding in one spot. For sharpening miscellananeus cutters a universal type
grinder is used.
Semi-topping shaper cutter are used during gear cutting to generate chamfers on the
tooth tip.
Figure 4.2 Semi-topping area cutter
Not only is it difficult to design and produce these cutters, but it is even more difficult to
ensure that the gear chamfer remains constant throughout the life of the shaper cutter.
It is impossible to guarantee the constancy of the chamfer on the finished gear not only
because of the production tolerances of the teeth (chordal thickness and outside
diameter)
and the shaper cutter itself, but also because of the profile grinding system.
It is well known that the profile is ground according to the angle
There are two recognized grinding systems:
a)- by fixed grinding wheel (nowadays not often used)
b)- by translating grinding wheel.
We will now briefly examine the basic features of these two methods.
a)- By fixed grinding wheel
As can be presumed b the name itself, the wheel axis is maintained immobile in relation
to the shaper cutter and therefore the wheel will generate a tooth root whose profile will
reflect the curve of the wheel’s outside diameter
Figure 4.3 By fixed grinding wheel
b)- By translating grinding wheel

This manufacturing technique gives a rectilinear tooth root to the shaper cutter since the
wheel translates along the direction of grinding (see fig. N°3)
Figure 4.4 wheel translates along the direction of grinding
Direction multiple chose item

1. The mixture of marble chips and matrix that, when properly processed, produces
a terrazzo surface.
A. topping B grinding C. painting D. all
2. If the topping you applied is loose it should be removed or cutting the surface
A. topping B. grinding C. repairing D none
Key answer
1.____________________
2.____________________
Note:
 Satisfactory rating – above 5points
 Unsatisfactory - below 5 points
Information sheet 5 Repairing mortars and self-leveling floor compounds
2.5 Repairing mortars and self-leveling floor compounds

Mortar is a workable paste used to bind construction blocks together and fill the
gaps between them. The blocks may be stone, brick, concrete blocks, cinder blocks, for
maintenance work etc.
• Mortar is mixture of binding material, water and sand. It is similar to concrete but it do
not contains coarse aggregates.
• Mortar becomes hard when it sets, resulting in a rigid aggregate structure.
2.5.1Composition mortar
Modern mortars are typically made from a mixture of
 Fine aggregate,
 Binder such as cement or lime, and
 Water.
Figure 5.1 mortar material
2.5.2 FUNCTIONS OF MORTAR:

• To bind together the bricks or stones properly so as to provide strength to
the structure.
• To form a homogenous mass of the structure so as to resist allthe loads
coming over it without disintegration.
• To provide a weather resisting i.e., a durable layer between the different courses
of masonry in the structure.
• To hold coarse aggregate together in any concrete so as to form a solid mass.
The mortar used in a concrete is termed as matrix.
• To do pointing and plastering to the structure. The mortar used for plastering is
known as plaster.
• To fill up empty joints in brick and stone masonry. The mortar used for such
purposes is a thin liquid mortar which is termed as grout and the process is known
as grouting.
2.5.3 Function of mortar ingredients
 Cement, lime, clay – Binding materials – imparts strength.
 Sand – increases crushing strength of mortar & reduces shrinkage
 Water – lubricated the surfaces of aggregate; spreads the binding material
uniformly so that it can fill the pores in the fine aggregate and cause hydration of
cement and hydraulic lime. (pH should not be less than 6).
MIXING THE MORTAR:
• The sand and the cement have to be by hand or thoroughly mixed in a mechanical
mixer before adding any water
• Do not use dirty water, or water from puddles or ponds, as this could impair the final
strength of the mortar.
• Similarly, keep any sugar- containing liquids, such as soft drinks, well away from the
mix -sugar, even in small amounts, seriously impairs the setting ability of the cement.
Figure .5.2 hand tools
2.5.4 self-leveling floor compounds

Floor Self-Leveling Screed is a cement-based, rapid-hardening, low-shrinkage,
self-leveling 'underlay', used to rectify uneven or damaged concrete and other cement-
based floor surfaces. Produced from carefully selected raw materials for consistency of
product, it only requires the addition of water on site. Application can be by means of
'hand-mix' or by automated pumping equipment - the final floor finish being smooth,
durable and designed to accept various floor coverings such as vinyl sheeting and -tiles,
laminates and marmoleum, rubber floors, carpeting, parquet, epoxy or urethane
coatings and ceramic/porcelain tiles.
Floor Self-leveling Screed should not be applied to exterior surfaces when there is a
risk of rain or frost within six hours after application.
2.5.5 Surfaces preparation

The following minimum curing periods must be observed, before application of this
Screeding compound:
• New concrete floors: 28 days
• New screeds: 28 days
• New brickwork: 14 days
Ensure that all surfaces are clean, dry, sound and free from dust, grease or any
contamination that could impair bonding.
Make good any unsound areas and remove flaky or peeling layers before
screseding tiling. Organic growth must be removed and the spores killed using
household bleach
self-levelling smoothing compounds and repair mortars
Figure .5.3 repair mortar

Substrate flatness is best achieved through the application of a flowable and
cementitious self-leveling underlayment.
self-leveling underlayments
In response to the new subsurface flatness criteria, a number of tile manufacturers
specializing in large format tile materials have embraced these updated floor flatness
requirements, and now include references to the new guidelines in their product
technical data sheets and installation guidelines. It is the responsibility of the architect or
design professional to include these enhanced floor flatness requirements in the project
specifcation. It is equally important for the architect or specifcations writer
to consult with the design/interiors team (and vice-versa) to ensure that the specifc
installation requirements and guidelines for the selected tile for the project are reflected
in the tiling specifcation.
Figure 5.4 self leveling mortar

1. mixture of binding material, water and sand.a workable paste used to bind
construction blocks together and fill the gaps between them.
A. cement B. sand C. Mortar D. concrete
2.which of the following use to Binding material
A. sand B. cement C. concrete D. mortar
3. a cement-based, rapid-hardening, low-shrinkage, used to rectify uneven or
damaged concrete and other cement-based floor surfaces.
A. Floor Self-Leveling Screed B. concrete material C mortar material D. all
Key answer
1.__________________
2__________________
3_________________
Note:
 Satisfactory rating – above 5 points
Operation sheet 4 Repairing mortars and self-leveling floor
compounds
PROCEDURE
Step 1 observe repairing wall or floor
Step 6 prepare mortar
Step 7 applying Repairing mortars and self-leveling floor compounds
Information sheet 6 Applying sealers and colored paints
2.6 Applying sealers and colored paints
2.6.1 Concrete Sealing

Once decorative concrete floors or new concrete colored are finished the best way to
keep them looking great is to seal and protect their surface. Parchem supply some of
the hardest wearing decorative concrete sealing systems in the world.
It is essential that your decorative concrete surface is resealed periodically in order to

lock in the colour, protect the surface from impurities and maintain its glossy appeal.
Your new or resurfaced decorative concrete is treated with an acrylic sealer to help
produce an attractive surface that is easier to clean and maintain than unsealed
concrete. We recommend resealing every 18-24 months as the sealer works by
blocking the pores of the concrete, providing a protective layer that helps stop dirt
becoming ingrained and helps achieve a more consistent look.
Figure 2.6.1 Concrete Sealing
2.6.2 Colored Concrete Sealers
Dramatically improve the appearance of your concrete by adding a Coloured Concrete

Sealer.
The Colored Concrete Sealer system is ideal for colouring and protecting plain
concrete. It is a two part system;
 Part A the color sealer clear base and
 Part B the color tint.
The Color Tint (Part B) is added to the Color Sealer Clear Base (Part A), and then
applied using a roller or soft bristled broom
Using a Colored Concrete Sealer will improve upon existing hard wearing decorative
concrete. Adding two coats of sealer improves abrasion resistance while creating a
barrier between the concrete color and the effects of the harsh Australian climate.

1 Once decorative concrete floors or new concrete colored are finished the best way to
keep them looking great is to seal and protect their surface.
A. Concrete Sealing B. concrete stain C A and B D.all
2. is treated with an acrylic sealer to help produce an attractive surface that is easier to
clean and maintain than unsealed concrete.
A. decorative concrete B. concrete defect C. concrete dust D.all
Key answer
1._______________
2._______________
Note:
 Satisfactory rating – above 5 points
Operation sheet 1
LAP Test 1 Practical Demonstration
Name: _____________________________ Date: ________________

Time started: ________________________ Time finished: ________________
Instructions: Given necessary templates /guide, to perform the following tasks within 60
minutes.
Task1. Clean and Preparation work area?
Task2. Determine the color and repair the concrete stain?
Operation sheet 2
Name: _____________________________ Date: ________________

Instructions: Given necessary templates /guide to perform the following tasks within 50
minutes.
Task2. Grinding the damage surface ?
Task 3.aplying repair a topping ?
Task 4.clean work area ?

Operation sheet 3
Name: _____________________________ Date: ________________

Instructions: Given necessary templates /guide to perform the following tasks within 50
minutes.
Task2. Grinding the damage surface ?
Task 3.repair concrete crack part ?
Operation sheet 4
Name: _____________________________ Date: ________________
Instructions: Given necessary templates /guide to perform the following tasks within
50 minutes.
Task2. Prepare mortar?
Task 3 applying Repairing mortars and self-leveling floor compounds?
Self check 1
Key answer
1.A 2.E 3.A
Self check 2
Key answer
1.B 2 .A 3.D 4. D
Self check 3
Key answer
1.D 2.A 3. C
Self check 4
Key answer
1.A 2.B
Self check 5
Key answer
1.C 2. B 3. A
Self check 6
Key answer
1.A 2. A
Reference
 visit surface preparation at www.directcolors.com

 Toxic woods Woodworking Information Sheet
 WIS30(rev1) HSE Books 2012
 www.hse.gov.uk/pubns/wis30.htm
 www.concrete.net.au
 H. Amstead, P. Ostwald, M.L.Begaman, Manufacturing Processes,(8 Edition)
 Moltrecht, Karl Hans: Machine Shop Practice, 2nd ed. New York: Industrial
Press, 1981, Volume 1, p. 403. 3. El – Hoffy : Advance Machining Process, Mc
Graw Hill Companies, 0.007- 1466940, 2005
 ,SANS 10109-2:2004, Concrete floors. Part 2: Finishes to
concrete floors, Pretoria: Standards South Africa, 2004.
 SANS 10155:1980, Accuracy in buildings, Pretoria:
Standards South Africa, 1980.
 3,SANS 2001-CCI:2007, Construction works. Part CC1: Concrete
works (structural), Pretoria: Standards South Africa, 2007.
 Roberts, R.F. Testing cement-sand screeds using the BRE
screed tester, Wexham Springs: Cement and Concrete
Association, 1986. (C&CA Guide 48.057)
The trainers who develop this Learning Guide are

N0 Name Qualification Region E.mail
1 Tesfaye Assegidew MSC in CoTM SNNPR tesfayeassegidew@gmail.com
2 HabtamuWendmagegn BSc in Civil Eng Dire Dawa Joniyitna9@gmail.com
3 YazachewGeneti MSc in CoTM BGRS 0917858176

4 GebresilasieJemal BSc in Con. Addis Abeba Gebrajemal@gmail.com
Tech
5 Getachew Mohammed MSC in CoTM Amhara Gerimom07@gmail.com
6 KibryisfawTulema BSc in ConTech Somalie kibrutulema@gmail.com

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BAR BENDING & CONCRETING

LO2 Carry out minor repairs

Instruction Sheet Learning Guide #50

Information sheet 1 Applying concrete staining agent

Figure 2..2 equipment

Figure 2.4 applying stain

Figure 2..5 brushing

Figure 2.6 Neutralizing the Stain

figure 2.7 Seal the Concrete

Step 8: Maintenance A maintenance application of sealer should be made periodically

Figure 2.8 applied sealer.

Direction: multiply chose item

2.2 Repairing effects of dusting

What causes Dusting

Control the dust

Figure 2.3 Water suppression on a cut-off saw

Figure 2.4 Wall chasing using on-tool extraction

Direction multiple choose item

Operation sheet 2 Applying Repair of Dusting Surfaces

2.3 Repairing damaged or blistered concrete

Think of a typical shrinkage crack running diagonally from a re-entrant corner in a

 Corrosion of reinforcing steel: Steel rebar is protected inside concrete because

Figure 3.1 concrete damaged

2.3.2 Concrete crack repair

Why Does Concrete Need Repairing?

Self check 3 Written test

Direction multiple chose item

1. Which of the following the cause of concrete problems

2.4 Grinding/topping techniques

Figure4.1 concrete topping

2.4.2 Concrete topping

Please tell me how to correctly prepare and apply a concrete topping. We

1. Grinding:. grind means to abrade, to wear away by friction, or to sharpen. In

Figure 4.2 Semi-topping area cutter

b)- By translating grinding wheel

Figure 4.4 wheel translates along the direction of grinding

Direction multiple chose item

2.5 Repairing mortars and self-leveling floor compounds

Figure 5.1 mortar material

2.5.2 FUNCTIONS OF MORTAR:

Figure .5.2 hand tools

2.5.4 self-leveling floor compounds

2.5.5 Surfaces preparation

self-levelling smoothing compounds and repair mortars

Figure .5.3 repair mortar

Figure 5.4 self leveling mortar

Direction multiple choose item

2.6 Applying sealers and colored paints

2.6.1 Concrete Sealing

It is essential that your decorative concrete surface is resealed periodically in order to

2.6.2 Colored Concrete Sealers

Dramatically improve the appearance of your concrete by adding a Coloured Concrete

Direction multiple choose item

LAP Test 1 Practical Demonstration

Name: _____________________________ Date: ________________

Task1. Clean and Preparation work area?

Task2. Determine the color and repair the concrete stain?

LAP Test 2 Practical Demonstration

Name: _____________________________ Date: ________________

Task1. Clean and Preparation work area?

Task2. Grinding the damage surface ?

Task 3.aplying repair a topping ?

Task 4.clean work area ?

LAP Test 3 Practical Demonstration

Name: _____________ Date:

Name: _____________ Date:

Name: _____________ Date:

Name: _____________ Date:

Time started: ________ Time finished: