Method Statement

Concrete surface reparation at the inlet and outlet structures, tunnel linings
and closure of tie-rod holes.
Rev. 1

Materials:

- Sika Rep.
- Sika Latex.
- Cement ALSABEH PA-L 42.5.
- Sand from site stock.

Equipment:

- Electrical saw with diamond discs.

- Electrical chipping hammer.
- Shovels.
- Trowels.
- Water compressor with flexible pipe.
- Drill with mixing bit.

Reparation of honeycombs and segregation :

1. On exposed surfaces, the perimeter of the repair shall be neatly defined by disc cuts to the depth of
sound concrete and shall be splayed to form a dovetail.
2. Chipping hammers weighing approximately 7 kg or less shall be used to remove the required amount
of concrete. The cavity shall have roughened sides at least to reach sound concrete for the full
perimeter.
3. Surface shall be water blasted to remove the fractured surface and all loose or none dense materials
and dust.
4. Sika Latex shall be diluted with water with a 1:4 ratio and applied to dried surface with brush as
bonding agent.
5. Sika Rep shall be mixed with water to the right proportions recommended by the manufacturer, and
mixed using an electric drill with a mixing bit at low revolution.
6. While the applied bonding agent is still wet, Reparation mortar shall be applied using a trowel. If the
repair is deeper than 1 inch (25 mm), mortar shall be applied in layers no thicker than inch to avoid
sagging and loss of bond.
7. After placing each layer, worker shall wait about 30 minutes before placing the next layer, giving the
preceding layer enough time to harden. Therefore the mortar mix of each layer shall be prepared
separately and applied within setting time.
8. To complete the repair, the voids shall be overfilled slightly then trimmed off with the edge of a steel
trowel, working from the center toward the edges. Extreme care should be taken to avoid impairing
the bond.
9. Placed mortar shall be kept moist by water spraying for at least 72 hours after the repair has taken
place.
10. Repair of all damaged or defective surfaces shall be performed by skilled workmen only, always in the
presence of the engineer unless instructed otherwise.

Closure of tie-rod holes:

1. Holes left by removal of tie-rods or other accessories shall be reamed and cleaned, then filled with dry-
pack. All bulges and other projections on exposed surfaces shall be chipped and ground until a true
smooth surface of matching color and texture is obtained.
2. Dry pack shall be composed of a mix of 1 part of cement, by volume, to 2.5 parts, by volume, of fine
aggregate passing a 1.2mm square sieve, together with sufficient water to produce a mortar which will
just stick together when moulded into a ball by light pressure of the hands and will not exude water,
but will leave the hands damp.
3. Surface finish shall be done using Sika Rep, while dry pack is still fresh.