APS LANKA (PVT) LTD

Ref No. : MS / PLU / BIATO /

Rev :000
001
METHOD STATEMENT Date :
Page No. : Page 1 of 10
05/03/2010

Contract: APS/ELE/S/BIATO/026

Works : Repair of Honeycombed Concrete (Except Repair of Tunnel Lining

Concrete)

Amendment Record

Rev. No. Description of Amendment

Complied by : Reviewed (Quality) by: Reviewed (Safety) by: Approved by :

___________________ ____________________ ___________________ ___________________

(Section Manager) (Project Quality Engineer) (Project Safety and (Project Manager)
Environmental Engineer)
 APS LANKA (PVT) LTD
Ref No. : MS / PLU / BIATO /
Rev :000
001
METHOD STATEMENT Date :
Page No. : Page 1 of 10
05/03/2010

Contract: APS/ELE/S/BIATO/026

Works : Repair of Honeycombed Concrete (Except Repair of Tunnel Lining

Concrete)

1. General
This method statement describes for the installation of sewer piping system and waste
water piping system

2. Extent of Works
This method statement covers the followings:-
Manufacturing details of septic tank and soakage pit
Method of construction of sewer disposal system
Method of construction of waste water disposal system

3. References Documents
1. Shop drawing of sewer and waste water system
2. Guaran

4. Investigation of Honeycomb

Honeycomb will be caused by some reasons such as followings.

(1) Segregation of coarse aggregate in the concrete due to free fall from pipe or hitting to
the reinforcing bars during placing.
(2) Segregation of coarse aggregate in the concrete due to long transportation by concrete
pump with long pipe arrangement.
(3) Lack or improper compaction by vibrator.
(4) Placing of concrete into the water pool which is made by rain water, washing water,
bleeding water, etc.
(5) Leakage of mortar from the opening or gap of formwork.

Honeycomb shall be investigated by the concrete engineer in the presence of the Engineer
when it is found.
Location, size, and assumed reason of the honeycomb shall be recorded in the
investigation sheet.
 APS LANKA (PVT) LTD
Ref No. : MS / PLU / BIATO /
Rev :000
001
METHOD STATEMENT Date :
Page No. : Page 1 of 10
05/03/2010

Contract: APS/ELE/S/BIATO/026

Works : Repair of Honeycombed Concrete (Except Repair of Tunnel Lining

Concrete)
 APS LANKA (PVT) LTD
Ref No. : MS / PLU / BIATO /
Rev :000
001
METHOD STATEMENT Date :
Page No. : Page 1 of 10
05/03/2010

Contract: APS/ELE/S/BIATO/026

Works : Repair of Honeycombed Concrete (Except Repair of Tunnel Lining

Concrete)

Mortar leaking from

the joint of pipes
Concrete fall
freely or hitting
rebar

Case (1) Case (2)

Concrete is
poured into
Vibrator can not
the water
reach to the
Bleeding water pool
corner

Case (3) Case (4)

 APS LANKA (PVT) LTD
Ref No. : MS / PLU / BIATO /
Rev :000
001
METHOD STATEMENT Date :
Page No. : Page 1 of 10
05/03/2010

Contract: APS/ELE/S/BIATO/026

Works : Repair of Honeycombed Concrete (Except Repair of Tunnel Lining

Concrete)

Mortar leak out

from the gap or
opening of the
formwork

Case (5)
 APS LANKA (PVT) LTD
Ref No. : MS / PLU / BIATO /
Rev :000
001
METHOD STATEMENT Date :
Page No. : Page 1 of 10
05/03/2010

Contract: APS/ELE/S/BIATO/026

Works : Repair of Honeycombed Concrete (Except Repair of Tunnel Lining

Concrete)

Selection of Repair Method

Honeycombed concrete shall be replaced with mortar, concrete or epoxy resin as

specified hereafter or as otherwise directed by the Engineer. Generally repair method will
be selected in accordance with the flowchart shown below.
The repairs of honeycomb on the tunnel lining shall be carried out in accordance with
another Method Statement of MS/C11/700/005 which was submitted with the letter of
MNJV/0288/TR/JP dated 08th February 2010.

Start

Depth of honeycomb

Less than 60mm 60 to 200mm More than

200mm

Epoxy Mortar Cement Mortar Class A Concrete

Coating with Epoxy with Epoxy
Bonding Bonding

General Flowchart for the selection of repair method

 APS LANKA (PVT) LTD
Ref No. : MS / PLU / BIATO /
Rev :000
001
METHOD STATEMENT Date :
Page No. : Page 1 of 10
05/03/2010

Contract: APS/ELE/S/BIATO/026

Works : Repair of Honeycombed Concrete (Except Repair of Tunnel Lining

Concrete)

6. Repair of Honeycomb

6.1 General

Repairs shall be performed by skilled workmen and the Contractor shall inform the Engineer before
starting the repair work. Materials, procedures and operations used in the repair of concrete, and
also the finished work, shall be done in accordance with the orders and instructions of the Engineer.

6.2 Repairs with Class A Concrete

Where the depth of damage is more than 200 mm, the repair shall be made by first saw-cutting a
grove 4 cm deep around the perimeter of the damaged area. Then the damaged concrete shall be
removed by light weight jackhammer and the resulting surface shall be cleaned by chisel and
compressed air to receive the epoxy-bond coat.

Damp or wet areas shall be dried with a propane torch immediately before applying the bonding
agent to prepare a surface warm to the tough.

Epoxy boding agent Sikadur 32 or Sikadur 32LP will be applied on the cleaned surface of
concrete.

After the application on the clean and dry surface, and while still in a tacky stage, the bonding agent
shall be overlaid with the repair concrete.

The repair concrete shall be of Class A with plastic to stiff consistency or as otherwise directed by
the Engineer.

If the bonding agent has set before applying the concrete, it shall be removed by additional
chiseling.
 APS LANKA (PVT) LTD
Ref No. : MS / PLU / BIATO /
Rev :000
001
METHOD STATEMENT Date :
Page No. : Page 1 of 10
05/03/2010

Contract: APS/ELE/S/BIATO/026

Works : Repair of Honeycombed Concrete (Except Repair of Tunnel Lining

Concrete)

6.3 Repairs with New Mortar

Where the depth of damage is between 60mm and 200 mm, the repair shall be made by first saw-
cutting a grove 4 cm deep around the perimeter of the damaged area. Then the damaged concrete
shall be removed by light weight jackhammer and the resulting surface shall be cleaned by chisel
and compressed air to receive the epoxy-bond coat.

Damp or wet areas shall be dried with a propane torch immediately before applying the bonding
agent to prepare a surface warm to the tough.

Epoxy boding agent Sikadur 32 or Sikadur 32LP will be applied on the cleaned surface of
concrete.

After the application on the clean and dry surface, and while still in a tacky stage, the bonding agent
shall be overlaid with the repair mortar.

The repair mortar shall be of dry pack mortar with plastic to stiff consistency using same materials
of existing concrete or as otherwise directed by the Engineer.

If the bonding agent has set before applying the concrete, it shall be removed by additional
chiseling.
 APS LANKA (PVT) LTD
Ref No. : MS / PLU / BIATO /
Rev :000
001
METHOD STATEMENT Date :
Page No. : Page 1 of 10
05/03/2010

Contract: APS/ELE/S/BIATO/026

Works : Repair of Honeycombed Concrete (Except Repair of Tunnel Lining

Concrete)

6.4 Repairs with Epoxy mortar Coating

Where the depth of damage is less than 60mm, the repair shall be made by first saw-cutting a
grove 3 cm deep around the perimeter of the damaged area. Then the damaged concrete shall be
removed by light weight jackhammer and the resulting surface shall be cleaned by chisel and
compressed air to receive the epoxy-mortar coat.

Damp or wet areas shall be dried with a propane torch immediately before applying the bonding
agent to prepare a surface warm to the tough.

Epoxy mortar Sikadur 53UF will be applied on the cleaned surface of concrete.
 APS LANKA (PVT) LTD
Ref No. : MS / PLU / BIATO /
Rev :000
001
METHOD STATEMENT Date :
Page No. : Page 1 of 10
05/03/2010

Contract: APS/ELE/S/BIATO/026

Works : Repair of Honeycombed Concrete (Except Repair of Tunnel Lining

Concrete)

7. Hazard/Risk Assessment

We shall take all necessary precautions against risks of injury or loss of life to any person
employed on the Works or to employees of the Employer and the Engineer or to visitors or
to persons having good and sufficient reasons to be around the Works, and to this end we
shall properly safeguard the Works to the satisfaction of the Engineer.

Safety officer shall introduce initiation of measures for the prevention of accidents and the
enforcement of ass safety rules and regulations.

The following safety measures are to be followed.

Personnel who are assigned to the works shall wear basic safety protection equipment.
These shall consist of but are not be limited to safety helmets, dust masks, safety boots,
safety gloves.
Any kind of machinery for repair work and other related operations shall be checked the
fitness for the work before assigned. Only authorized personnel shall be allowed to operate
machinery. In addition, unauthorized personnel shall not be allowed to enter the working
areas.

Repairing area and accesses shall be provided lighting to ensure that security and safe
working conditions.

8. Environmental Precaution

Every possible measure will be taken to minimize the damagers to the environment when
carrying out the repair works. The environmental consideration shall comply with
Environmental Management Plan.