CONCRETE REPAIR METHOD STATEMENT No.

CFC/DTC/CA007/ST/MST/200106
Department :QC Rev. 01
Title :Concrete Works Date : 15.06.19

METHOD OF STATEMENT
Repair of Concrete

REVISION HISTORY

0 Revision 0 15.06.2019

Rev. Revision information Date

Originated by Reviewed by Approved by

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CONCRETE REPAIR METHOD STATEMENT No. CFC/DTC/CA007/ST/MST/200106
Department :QC Rev. 01
Title :Concrete Works Date : 15.06.19

Eng. Mostafa Attalla Eng. Alaa Soliman

Repair of Concrete
1.0 OBJECTIVE

1.1 To outline the method statement for rectification of Loose Concrete and
honey combs. To define the requirement and describe the procedure for
Concrete Repair of AL-Futtaim Oriana 4 Villas Development’ Phase 1&2-New
Caro Project – New Cairo (Tender Number: CA007P01)

2.0 SCOPE

 Applicable to the entire project. The scope of this Method Statement covers the repair
of reinforced concrete.
 These works include the following: Working with concrete structures members after
striking for the form work.
 This Method Statement covers repair material, specified in the Contract documents,
recommended by manufacturer and approved by consultant prior to installation.

3.0 REFERENCE

3.1 Project Approved Drawings.

3.2 Project Specifications, Division 03, Section 33000 .

3.3 Tender documents.

3.4 E.C.P (203,1109, 1450, 1658, 373)

3.5 British Standards BS (812 , 5328)

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CONCRETE REPAIR METHOD STATEMENT No. CFC/DTC/CA007/ST/MST/200106
Department :QC Rev. 01
Title :Concrete Works Date : 15.06.19

3.6 American Society of Testing and Material (ASTM C 94 , ASTM C 494 , ASTM C 1059 ).

4.0 Procedures

4.1. Control of materials

4.1.1 Testing and quality control of manufacturing point are carried out by approved
supplier.
4.1.2 Upon receipts material on site, Q.C. Eng. Of the contractor will inspect the
production date of the material & the expired date.
4.1.3 Q.C. Eng. will follow its storage, application, work procedure, and curing.

4.2. General:
4.2.1 All materials must be as per specification and approved documents.

4.2.2 Workmanship

4.2.2.1Surface Preparation:

 Surface to be probably prepared. Remove all loose aggregates & adhering

particles - including concrete debris attached to the exposed reinforcement -
until clean & sound concrete is exposed. The affected defective area is
cleaned, brushed, hammered or chiseled to remove all the loose concrete and
small particles such as sand. Remove cement paste.

 Identify the loose concrete and honey combs areas of the defective areas.
Concrete surfaces should be sound, clean and free from oils, grease or
surface contaminants. All Surface defects must be fully exposed.
 Demolishing any loose concrete, blowholes, voids & honey combs to reach for
sound concrete surface. To ensure good bonding between the concrete and
the repair material, all the concrete dust that is left over is then washed away
with water or blown away using compressed air.

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CONCRETE REPAIR METHOD STATEMENT No. CFC/DTC/CA007/ST/MST/200106
Department :QC Rev. 01
Title :Concrete Works Date : 15.06.19

 Non shrink grout Sikagrout 200 is then mixed according to the supplier’
instructions. Using a masonrying trowel a layer of the non-shrinkage grout is
then applied onto the surface of the affected areas.

 Level the surface according to the required shape and finishing. The affected
area shall be brushed / toweled smooth.

 The repaired area will harden after about 4 to 5 hours.

4.2.2.2. Sequencing

 Cleaning steel dowels to remove rust.

Sound concrete surfaces to be washed thoroughly using grout with adding
SikaLatex.
 Using (Sika Zinc rich-1) as a protective coat for steel bars (If applicable).
 Repair the defected areas with Sika grout 200 with adding Sika Latex for
bonding the existing concrete with repair grout. Approved Sika grout 200 is used
for the zones where the dimensions of the damaged concrete are less than 60 mm
thick.
 Repair will be carried out on layers depends on repair thickness.
 Cement slurry to be made with Sika Latex & Sika grout 200 to make fair face
finish.
 Concrete substrates should be pre-soaked with water prior of application.
 Casting non-shrinkage grout as Sikagrout-200 for large cavities grouting
projects. Apply the grout into the shuttered area in accordance to the
manufacturer’s application instruction. Formwork is erected on 3 sides (and is
prepared for the fourth). Plastic mortar is rammed into place, to fill all voids.
Without a delay, a vertical or sloping form is fixed on the fourth side; the grout
is placed and is consolidated.
 Compressive Strength of grout is more than the compressive strength of the
element structure. External vibrator mounted on the shuttering may be used.
 Volume of water must always be within the limits as stated in our technical data
sheet. Mixing with water should continue until a uniform, lump free consistency
is obtained. We can add an adhesive material like Sika Latex to improve the
bonding between the old concrete & the fresh concrete.
 Sikagrout-200 should be left to stand after final mixing for 5 minutes allowing
any entrapped air to dispel. Prepare and use-up the mix within the pot life.

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CONCRETE REPAIR METHOD STATEMENT No. CFC/DTC/CA007/ST/MST/200106
Department :QC Rev. 01
Title :Concrete Works Date : 15.06.19

 We can use Master Emaco S 488 as high strength, non-shrink, cementations'

mortar as an alternative product from BASF.
 In the zones where the dimensions of the damaged concrete are less than 20
mm thick, we can use portand cement or Sika Rep or Masterflow 544M
 In the zones where the dimensions of the damaged concrete are greater than
20 mm thick, we can use Sika Rep or Masterflow 544M.

 In the zones where the dimensions of the damaged concrete are greater than
60 mm thick, we can use Sikacrete 114 or Master Emaco S 466 as micro
concrete for grouting and repairing.
 After placement of grout, Exposed surface should be fully cured to keep moist
for achieving its initial setting. This will prevent early drying shrinkage and help
to develop strength, durability and other desired properties.
 For best moist cure immediately after mortar reaches initial set (typically1-2
hours depending on ambient temperatures), continue moist curing for minimum
48 hours.

5. PERSONAL RESPONSIBILITIES

A full and detailed description of the roles and responsibilities of all DETAC
staff is included within the Project Quality Plan. For the works as covered by
this method statement, the following personnel have specific duties.

5.1 Technical office Engineer : specific responsibility include :

 Responsible for ensuring that the various submittals are timely

undertaken (materials, method statements, workshop drawings,
subcontractors issues, technical issues)

 Responsible for quotations as required (materials, subcontractors).

 Responsible for ensuring RFI’s are timely undertaken on behalf of

DETAC.

 Responsible for the distribution of documents within DETAC site

personnel.

5.2 Site Engineer : specific responsibility include :

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CONCRETE REPAIR METHOD STATEMENT No. CFC/DTC/CA007/ST/MST/200106
Department :QC Rev. 01
Title :Concrete Works Date : 15.06.19

 Ensuring that the project is managed in a safe manner and meets

the requirements of the project documentation.

 Ensuring that subcontractors and suppliers achieve the on-site

required standards.

 Shall refer to the QC Department and the HSE Department for

advice and guidance when required.

 Shall ensure that operatives comply with the relevant method

statements, Toolbox Talks and general site briefings.

5.3 HSE Site representative: specific responsibility include :

 Assisting in the production of any health, safety and environmental

documents.

 Monitoring the implementation of health, safety and environmental

requirements.

 Undertaking audits and ensuring that corrective and preventive

actions are taken where required.

 Liaison with the senior site staff on health, safety and

environmental related matters.

5.4 QC Site representative(s) specific responsibility include :

 Carrying out phased inspections as required.

 Preparation of the ITP.

 Ensuring that all required tests are performed and are in

compliance with appropriate specifications.

 Maintaining a record of all QC activities on site.

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CONCRETE REPAIR METHOD STATEMENT No. CFC/DTC/CA007/ST/MST/200106
Department :QC Rev. 01
Title :Concrete Works Date : 15.06.19

 Controlling and ensuring all measuring and test equipment on site

is properly calibrated.

 Controlling all non-conforming products or workmanship, and

implementing the required preventive actions.

 Ensuring that corrective and preventive actions are taken when

required.

6. Equipment

Hand tools

 Brush.

 Hammer & Chisel.

 Electrical Breaker.

 Plain Water.

 Trowel.

 Loader.

 Water Tank.

 Source of electricity.

 Formwork.

7. Materials

 Approved Sika Zincrich-1.

 Sika Latex to improve adhesion and water resistant properties.

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CONCRETE REPAIR METHOD STATEMENT No. CFC/DTC/CA007/ST/MST/200106
Department :QC Rev. 01
Title :Concrete Works Date : 15.06.19

 Approved Sika Rep or Masterflow 544M as for layer thickness less than 2cm.
Approved Sikagrout 200 or Eamaco 88 for the zones where the dimensions of the
damaged concrete are less than 60 mm thick.
 Approved Sikacrete 114 or Eamaco 66 as micro concrete for grouting and repair.
for the zones where the dimensions of the damaged concrete are larger than 60
mm thick.

8. Safety Precautions:

 Ensure implementation of all safety measures according to HSE

plan and monitor that everybody aware of its proper
implementation.
.
 Wearing P.P.E (Personal Protective Equipment) to avoid injuries.

 Head protection will be worn on job sites when there are

potentials of falling objects.

 Eye protection will be worn when there are potentials of hazards

from flying objects or particles, such as when grinding, chipping,
burning and welding, etc.

 Protective footwear shall be worn to protect from falling objects.

 Protective gloves or clothing shall be worn when required to

protect against a hazard.

 Project Safety Plan shall be strictly enforced at all times. All works
shall be regularly monitored to ensure full compliance.

 Routine access and egress will be provided for materials and

operatives at all times. Where emergency routes are required,

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CONCRETE REPAIR METHOD STATEMENT No. CFC/DTC/CA007/ST/MST/200106
Department :QC Rev. 01
Title :Concrete Works Date : 15.06.19

these shall be determined and arranged and instructions given

prior to commencement of the works.

 Ladders with handrails will be made to give proper and safe

access to the bottom of excavation and take all necessary steps to
prevent public to open excavation.

 Barricade the excavation area with warning tapes and install

Safety signs and notices to create Safe Working area.

 During manual excavations ensure that the workers are equipped

with Safety Shoes, Coverall, Safety Helmets and Safety Hand
Gloves and Goggles where required.

 Tools and equipment will be inspected periodically by the

Contractor to ensure that remain in proper working order and
calibration certifications is current.

 Provide additional lighting facility for the excavation sub-contractor

to carryout works in poor daylight.

 All implemented safety measures are adequate to maintain the

safe working on site.

 Inspect all site activities and train safety persons to prevent

accidents.

 Establish first aid station and maintain adequate first aid supplies.

 Undertaking audits and ensuring that corrective and preventive

actions are taken where required.

 Ensure the site is clean and tidy.

 All internal scaffolding shall be checked by the safety inspectors,

where the works are unsafe and may cause injury to persons or
damage to property, works shall be stopped until scaffolds are
rectified to a reasonable stability. For scaffolds above 3 M high 2
Planks shall be used to reach high levels.
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CONCRETE REPAIR METHOD STATEMENT No. CFC/DTC/CA007/ST/MST/200106
Department :QC Rev. 01
Title :Concrete Works Date : 15.06.19

 All safety and health regulations shall be strictly followed and any
case of disregarding the safety procedures to be immediately
reported to safety office and construction manager.

9. Inspection:
 Hold Point for Repair.

 ITP for repair of concrete.

10. Submittals

 Approved Material.

11. STORAGE OF MATERIALS:

 Repair materials which obtain approval from the engineer are stored away from
moisture. Store out of direct sunlight, clear of the ground, on pallets protected
from rainfall. Avid excessive compaction. Storage life is approximately 18 months
when stored as above in original sealed bags.

 In the event that any materials for use in this chapter deteriorate and become
unusable due to inadequate and poor storage they shall be removed from site as
instructed by the Engineer.

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