METHOD STATEMENT FOR

CONCRETE REPAIR WORK

DOCUMENT No :
KNPCC-10/CONCRETE REV. No: R0 DATE: 20-08-2022 PAGE1 OF 13
REPAIR/1

METHOD STATEMENT FOR CONCRETE REPAIR

Contract Package KNPCC-10 :- Construction of Residential, Non-Residential and Institutional buildings at Polytechnic College
Campus, Gurudev Chauraha, GT Road, Kanpur and Multi Storied Officer's Colony of Uttar Pradesh Metro Rail Corporation inside
Kanpur Metro Depot, GT Road, Kanpur including Architectural finishes, Plumbing Drainage, External Development and E&M
Works"

APPROVED BY
REV DATE PREPARED BY CHECKED BY UPMRC
REPRESENTATIVE
Anshul Mr. Rajesh
Bipin Singh Keshav Chaturvedi
Katiyar Singh

20-08-
R-0
2022

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 METHOD STATEMENT FOR
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CONTENTS:

Sr. No. ITEM DESCRIPTION PAGE No.

1 PURPOSE 3

2 SCOPE 3

3 RESPONSIBILITY 3-4

4 REFERENCE DOCUMENT 4

5 MAJOR RESOURCES TO BE DEPLOYED 4

6 MATERIAL 5

7 METHODOLOGY 5-12

8 QUALITY ASSURANCE & CONTROL 12

9 SAFETY GENERAL POINTS 12

10 ENVIRONMENTAL REQUIREMENT 13

11 FORMATS AND ANNEXURES 13

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 METHOD STATEMENT FOR
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1) PURPOSE:
This method statement describes methodology for defect identification and repair in the concrete
structures for contract KNPCC-10 project. The objective of this method statement is to clearly
understand the job and procedures of execution along with safety precautions, which are
necessary to avoid any kind of injuries / accidents to personnel or any damage to any
equipment’s or property and maintaining the quality of works.
2) SCOPE:

The purpose of this statement is to identify the defects in the concrete structures and to repair the
same.

3) Responsibility

Reporting structure of personnel involved in concrete production.

Project Manager  Shall report to management (Cluster Head)

 Implementation of SHE standard in all step of activity
Dy. Project Manager.  Shall report to the Project Manager.
 Shall provide all necessary resources to implement this procedure for
concrete placing, compaction and curing
 Implementation of SHE standard in all step of activity
Site-in-Charge/ Engineers  Shall report to Dy. P. Manager.
 Shall be responsible to guide work force for this procedure
 Shall responsible to compliance of PTW system, SOP and SHE
Observation.
 Shall responsible to compliance/implement of environmental
requirement.
Quality Control Manager  Project Manager and responsible for follow the work procedure
 Shall responsible to compliance of PTW system, SOP and SHE
Observation.
Batching Plant Engineer  Shall report to Quality Head and Quality Control Manager
 Shall be responsible for Incoming of Raw material and Concrete
Production
 Shall be responsible to compliance of PTW system, SOP and SHE
Observation.

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Project Environmental  Shall be responsible for Identifying significant aspects of the activity and
Manager ensuring the mitigation Measure with the support of Site Team.\
 Shall be responsible to monitor environmental general requirement.

Safety Incharge / Officer  Shall report to P.M.

 Shall observe all safety aspects in all the activities

4) REFRENCEDOCUMENTS:
 Contract Specifications
 Project SHE Plan
 Material Data Sheet

5) MAJOR RESOURCES TO BE DEPLOYED: As per site condition and requirement

4.1 Equipment’s:

Sr.no Equipment Qty

1 Grout pump 01 no
2 Pressure Grout pump 01 no
3 Groove cutting Machine 01 no
4 Drilling machine 01 no
5 Compressor 01 no

4.2 Manpower to be deployed:

S.no Category No’s

1 Project Manager 01 No
2 Sr. Engineer 01 No
3 Site Engineer 01 No
4 QA/QC Engineer (Field and Lab) 01 No
5 Safety supervisor 01 No
6 Surveyor 01 No
7 Supervisor 01 No
8 Electrician 01 No

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6) MATERIALS:

Sl.
Name of Work Brand / Source
No.
BASF,FOSROC, SIKA, and any
1 High Strength low viscous grouts approved brand
BASF,FOSROC, SIKA, and any
2 Bonding Agent approved brand
BASF,FOSROC, SIKA, and any
3 Filler Materials approved brand
BASF,FOSROC, SIKA, and any
4 Epoxy Resins
approved brand
BASF,FOSROC, SIKA, and any
5 Non-Shrinkage Grouts
approved brand

Note-
 Vishnu Saran & Co. /GC Approved material only shall be used for repairing work.
 Material Storage Shall be as Per Manufacturer Guidance.
 MTC to be Submitted Prior to using the Chemicals.

7) METHODOLOGY:

The following are the possible defects that could be encountered in the concrete structures.
 Bulged concrete
 Grout loss
 Honeycomb
 Exposed Reinforcement bars
 Air bubbles on concrete surface
 Cracks on concrete
 Broken Edges & Surface damages

7.1 Bulged Concrete: Bulging in concrete takes place due to displacement of formwork.
Identification: Site engineer will inspect the exposed concrete after striking off of formwork or
exposure of the surface by excavation. Site engineer will mark such defect on the plan and at
site.

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Surface preparation: The bulged area on concrete surface shall be hacked with chisel to
required line, level. All dirt, dust shall be cleaned with brush and water.
Repairing: Hacked area will be patched up with cement: sand mortar of proportion 1:4. On the
completion of patch up work, the exposed area shall be thoroughly cured. After completion of
repairing work, Line and Plumb/Level to be checked as per Concrete Outline drawing.

7.2 Grout Loss: Exposed aggregate surface created by exits of cement slurry/grout mortar from
the gaps off formwork due to excessive vibration, unsealed joint off formwork during pouring of
concrete. Grout loss is such defect in which segregation of aggregates from mortar takes place but
sufficient bonded to still exist.
Identification: Site Engineer will inspect the exposed concrete surface immediately after striking
off of work or exposure of the surface by excavation, if surface is intact by gently tampering by
steel object and it found aggregates can’t be loosed off the surface easily and its spreads within
the cover of reinforcement bar. Site engineer will mark such defects on the plan and at site.
Surface preparation: The concrete surface is cleaned and free from dust/oil/grease etc.by using
broom or wire mesh by scrubbing vigorously.
After removal of loose particles surface is washed with water.
Repairing: Patch up is done at cleaned surface with non-shrink Grout conbextra GP2 (Fosroc)
/SikaGrout-214 or equivalent. The material mixing shall be as per manufacturer recommendation.
On the completion of patch up work exposed area shall be thoroughly cured.

7.3 Honeycomb: It is due segregation of aggregates and mortar into the concrete. Honeycomb
creates in structures due to mainly improper compaction in terms of excessive/insufficient
vibration at the time of placing of concrete or several grout loss. Honeycomb creates in to two
types.
a) Minor Honeycomb: Minor honeycomb is those which create small void within the cover of
reinforcement.
b) Major Honeycomb: Major honeycomb is those defects which extend beyond the
reinforcement bar and create big void on the surface.
Identification: Site/Qc Engineer will inspect the exposed concrete surface immediately after
striking off of work or exposure of the surface by excavation, if surface found voids, segregation
of aggregate in concrete, easily removal of aggregate by gently tampering the surface by metal

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object. Site/QC engineer will mark such defects on the plan and at site.
Surface Preparation:
a) Minor Honeycomb: All loose particles from exposed surface shall be removed by gently
tapping on it. After removal of all loose aggregate, dust, dirt etc. by wire/Soft brush then surface
will be cleaned with Water.

b) Major Honey comb: The loose aggregate that are exposed shall be removed by gently
tapping on it. After removal of all loose aggregate, dust, dirt etc. by wire/Soft brush then surface
will be cleaned with Water.

Repairing:
a) Minor Honeycomb: Patch up is done by using conbextra GP2 (Fosroc) / SikaGrout-214 or
equivalent on the cleaned surface. The material mixing shall be as per manufacturer
recommendation. On completion of the patch up work, exposed area is thoroughly cured.

b) Major honeycombing: All loose material shall be removed & cleaned thoroughly. Then a
coat of Epoxy Resin Bonding Agent such as “Sikadur 32 LP” of SIKA or “Nitobond EP” of
FOSROC shall be applied on the old concrete. Then the area shall be rebuilt by using same
concrete mix. On completion of the repairing operation, exposed areas is thoroughly cured.
In case, depth of treated area is more than 30 mm, nozzle shall be left in fresh concrete for
injection of grout, in future. Cement grout shall be used for this purpose.

7.4 Exposed Reinforcement Bars: Reinforcement bars exposed is mainly due to improper /
insufficient cover block placement at the time of fixing of reinforcement bars, loose formwork
erection (Mortar flows through the gap off formwork).
Identification: Site/QC Engineer will inspect immediately after removal of formwork or exposure
of surface by excavation if any exposed reinforcement bars found in to the structures they will
mark such defect on plan and at site.
Surface Preparation: Concrete is chipped off up-to 25mm behind the reinforcement for the area
where there is exposure of reinforcement bars takes place. Remove all loose particle, dust etc.
with clean water.

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Repairing: The exposed rebar is treated by coating with cement slurry. The patch up work is
carried out using non shrink grout conbextra GP2 (Fosroc) / SikaGrout-214 or equivalent. The
material mixing shall be as per manufacturer recommendation. The finishing of surface is beyond
the reinforcement forming a smooth curvature. On the completion of patch work, the repaired
area is thoroughly cured.

7.5 Air bubbles on concrete surface: The inner face of elements, especially at the bottom slab
(covered by Inner Form) concentration of air bubbles is likely to be more. These spots shall be
filled up by a homogeneous mix of Cement, sand (passing through 1.18 mm sieve), a bonding
agent namely “Sika Latex” of SIKA or equivalent shall be used. Proportion of Cement &Sand

shall be 1:2 to 1:3. Sika Latex & water will be added at 1:6 ratios by volume. This shall be added
to the mix to form a paste. This paste shall be applied on air bubbles by trowel.

7.6 Cracks: Any crack noticed shall be investigated and will be repaired after it is confirmed that
it is not a structural crack. In case of structural cracks, separate methodology will be adopted for
repair / rehabilitation after approval from Vishnu saran & co.

Surface cracks: Despite taking utmost care during curing, the concrete surface may develop
certain Cracks. This cracks being very fine in nature, cannot be filled up by any kind of grout
material. To prevent these types of cracks delayed finishing shall be done. To prevent ingression
of water, moisture this can be covered by a thin layer of Cement slurry with bonding agent
(Sika Latex” of SIKA or equivalent shall be used).

Cracks less than 0.2 mm width: Cracks shall be marked. A groove of 10 mm shall be made
along with the crack and same shall be coated with bonding agent (Sika Latex” of SIKA or
equivalent shall be used). After application of bonding agent, groove shall be filled by using non
shrink grout conbextra GP2 (Fosroc) / SikaGrout-214 or equivalent.

Cracks More than 0.2 mm width: Such Cracks shall be repaired using Epoxy grouting ie.
Sikadur 52, Sikadur 53 or equivalent by fixing nozzle at regular intervals depends up on site

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condition.
Grouting Procedure:-

a. Surface Preparation :- Crack location shall be identified and marking shall be done. Remove
all grease, oil, dust, residual curing compound, Mould release agent or other contaminant
that could impair adhesion of the injection ports. Clean the area of all loose particles and
dust by means of oil free compressed air or wire brush.

b. Drilling of Holes:-Nozzle holes shall be drilled at 45° angle to the concrete surface, at
appropriate spacing (as per condition) along the length of the crack . Holes will be drilled
next to the crack with a diameter of about 10 to 14mm (depending on injection port to be
used) and depth ranging from 40mm~50mm, where injection port will be inserted .Holes

will be provided on both the sides of crack in a staggered pattern and distance of one hole
to the crack shall be about 15 mm.

c. Fixing of Nozzles:- NRV (Non returning Valve) Nozzle of MS, 100mm length & 10-12 mm
diameter shall be fixed in Hole as given in Fig-1 and tightened and Epoxy based material
( Sikadur-31 or Equivalent) shall be used for packing of nozzles. Allow the Mix to cure before
injecting. Grouting shall be done after 24 hours of Nozzle Fixing. Nozzle projection length
shall be 30-40 mm from Concrete Surface.

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Fig-1
Fixing of
Nozzle

Crack

300-900 MM

Nozzle
20-30 MM

d. Grouting of Chemical:-Grouting of chemical shall be done by high pressure injection pump.

 Sufficient working platform shall be provided for fixing the grouting machine.
 Grouting Machine shall be fixed perpendicular to the Nozzle.
 Material shall be mixed as per technical data sheet. Care shall be taken that the material is
consumed in its pot life as mentioned in the technical datasheet.
 Chemical shall be taken in Grout pump hopper
 Hose pipe shall be fixed in nozzle and chemical shall be injected in crack through nozzle.
 When chemical injecting getting hard. Hose pipe shall be fixed in another nozzle.

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 Grouting shall be carried out typically around 5 bar pressure, depending of the viscosity
of the epoxy resin.
 After Grouting excess chemical shall be wiped off and surface shall be clean.
 After Grouting, Grouting Pump shall be cleaned with the use of thinner or Equivalent.
 The similar process will be carried out for all the ports installed.
 After curing time (as mentioned in technical data sheet) of grouting, Nozzle shall be cut
using grinding Machine and surface of structure shall be cleaned & smoothly finished.
Surface shall be matched as per approved concrete outline drawing to avoid offset
&bulging.

7.7 Broken Edge & Surface damage: During de-molding or handling the elements
sometimes the edges & surface may get damaged & thus its aesthetics gets affected.
For rebuilding the broken edge or damaged surface ,the affected area is to be cleaned
throughly and then 3
–component Epoxy Resin Mortar, namely “Sikadur 41” of SIKA or equivalent product of
different make shall be applied by trowel. Before application of this the surface may be
primed by a coat of “Sikadur 31”. However, this product can be used only after concrete
attains an age of 6 weeks or more. In case of early requirement, a cohesive mix of
Cement, Sand, a bonding agent namely “Sika Latex” of SIKA or equivalent product of
other manufacturer & water shall be used. Proportion of Cement & Sand will be 1:4 and
that of Cement &Sika Latex will be 5:1. In case of depth of treatment / repairing is more
than 10 mm, stone aggregates of smaller size (passing through 6.3 mm sieve) shall be
used along with sand. Before application of the mix, the area should be thoroughly
cleaned. Mix application shall be done by trowel.
Note: Prior permission shall be obtained from respective Vishnu Saran & Co /GC in-
charge/ executive before rectification works and suitability of repair materials/ chemicals
& their application methodology may be discussed case to case.
 Curing of any type of repair shall be done by using curing compound. If the Crack width
is more than 0.2 mm prior to apply the works, Designer Concurrence shall be required.
 All defect shall be listed and mapped include crack and all defect should be checked and
repaired by Contractor at present Vishnu Saran & Co /GC, especially crack developing
should be monitored as a record.

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 Cube shall be casted as and when required. Cube size will be as following-
 With agg mix 100*100 mm size cube mould shall be use

 Without agg mix 75*75 mm size cube Mould shall be use

8) QUALITY ASSURANCE AND QUALITYCONTROL

 Ensure that all materials to be used are approved materials.
 Ensure that the required materials are approved from consultant prior to
execution of work.
 All works shall be carried out following to the related method statement and
approved by consultant.
 All manpower that carrying out the works shall be adequately trained and
equipped with the required PPE against the work hazards.
 Required maintenance shall be done frequently to the works related
equipment.

9) SAFETY GENERAL POINTS

 Relevant Work permit formats & Safety checklists incorporating all the risks related to
PLASTERING should be prepared and attached with the MS.
 Activity specific Safety checklist should be prepared and attached with the document.
 All the machineries related to plastering should have operator’s competency certificate, ‘Green tag’ /
fitness certificate and valid TPI.
 All the scaffoldings should be of sound materials free from any physical damage / defects.
 All the scaffoldings erected at site (either for temporary or permanent structure) must be in
compliance with 3rd party approved drawing. The drawing must consider the safe access/egress and
fall protection arrangement at height.
 Relevant Work permit formats & Safety checklists incorporating all the risks related to plastering
should be prepared and attached with the MS.
 Activity specific Safety checklist should be prepared and attached with the document.
 All concerned drawings related to plastering should be prepared and attached with the MS.
 All the machineries related to formwork should have operator’s competency certificate, ‘Green
tag’ / fitness certificate and valid TPI.
 All the scaffoldings shall be erected under the supervision of ‘3rd party certified scaffolder’.
 All the erected scaffoldings must be checked / inspected after every erection / modification / shifting
by certified scaffolder and necessary ‘Scaffolding tag’ should be issued.
 No bamboo / timber scaffold along with bamboo ladder shall be allowed / permitted at site at any
circumstances.
 Temporary working platform should be fully decked with fall protection arrangement like hard
railing to be provided.
 Standard ladder with handrail must be in place for access / egress.
 All the ladders (any length) must have hand railing at both sides along the ladder length and in
compliance with standard. Ladder should be made of sturdy material which will prevent from
sagging. Any checklist should be in proper format.

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 MSDS of all the chemicals related to plastering should be attached with the document.
 No welding activity shall be allowed in wet condition.
 Good housekeeping to be maintained in & around the work location.
 All the electrical safety measures should be checked and maintained on regular basis.
 Sufficient illumination should be ensured while working in dark hours.

10)ENVIRONMENTAL General Points

 All the environment norms and precautions shall be taken as per condition of contract on Safety,
Health and Environment Vol. 7 Part IV for each activity before commencing.
 Vehicles / tracks shall be kept moist to prevent flying of dust particles with the vehicle movement.
 Environmental Monitoring for fugitive dust emission and its control measures.
 Waste oils/waste lubricants /spent oil /waste grease /paints and thinners will be collected in
separated labelled containers and sent to the collection agency.
 Solid waste generated by various process during the construction phase will be segregated such that
no hazardous toxic waste will mix with solid waste.
 The wastewater from construction area / P&M workshop /runoff from approach road storm water
will be collected in a collection pit and its will be disposed of local bodies.
 All vehicle and machineries will be maintained to ensure that that exhaust is in compliances with
vehicular pollution standards.
 Use PPE (Noise plug, N-95 mask etc).
 Water sprinkling shall be practice minimizing particulate emission.
 Carry out environmental training based on ongoing work priorities to train employees and
workforce.
 Identify the significant environment aspect and its control measure shall be monitored.
 C&D waste management and its record for audit purpose.

11) FORMATS &ANNEXURE:

Sr. Description Doc. No.

No.
1 Safety Checklist Form-1

2 Quality Checklist Annexure-1

3 Drawings N/A

4 ITP Annexure - 2

5 HSE RISK ASSESSMENT Annexure - 3

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