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TABLE OF CONTENTS

Section Description

1 Introduction

2 Organization and Responsibilities

3 Inspection and Assessment of PC Box Girder

4 Typical Defects and Definition

5 Detailed Inspection and Repair Procedures

6 Health, Safety, and Environmental Plan

7 Attachments

Attachment No. 7-1 – Manual for the Evaluation and Repair of

Precast, Prestressed Concrete Bridge Products,
Precast/Prestressed Concrete Institute (PCI), MNL-137-06-E

Attachment No. 7-2– Causes, Evaluation, and Repair of

Cracks in Concrete Structures, American Concrete Institute
(ACI), ACI-224.1R-07

Attachment No. 7-3 – Inspection and Test Plan (ITP)

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1.3 References

The following technical specifications are taken into consideration for the repair of PC Box Girders.

 Particular Specification – Contract RA/214

nd
 AASHTO (2004) LRFD Bridge Construction Specifications 2 Edition, 2009 Interim Revision
 Approved Detailed Design Drawings
 Approved Shop Drawings
 Precast/Prestressed Concrete Institute (PCI), Manual for the Evaluation and Repair of Precast,
Prestressed Concrete Bridge Products, MNL-137-06-E
 American Concrete Institute (ACI) ACI 224.1R-07, Causes, Evaluation, and Repair of Cracks
in Concrete Structures
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2. ORGANIZATION AND RESPONSIBILITIES

The Contractor intends to organize, deploy, and provide at site the following key staff and personnel
for the proper management and implementation of the works, in order to achieve the objectives of this
method statement, requirements of the construction drawings, construction programme and
specifications of the project.

2.1 Project Manager

 Over-all CONTRACTOR’s Representative to direct, manage, coordinate and supervise all

CONTRACTOR’s personnel assigned at the project site.
 Responsible for the over-all management of all construction activities including all related HSE
and Quality Control activities at the project site.

2.2 Construction Manager

 Responsible for developing, arranging, and managing all construction teams at the project site
necessary to undertake and implement all the construction works/activities including all related
HSE and quality control activities at the project site.
 Responsible for the proper implementation of all site execution plans for the timely and
successful completion of all construction works/activities and related HSE and quality control
activities at the project site.
 Report to the Project Manager the status and progress of all construction works/activities and
related issues/concerns that require actions/solutions.

2.3 Construction Engineer

 Report to the construction Manager the status and progress of all construction works/activities
and related issues/concerns that require actions/solutions.
 Responsible for the coordination and control of all Contractor’s works/activities at the project
site to ensure compliance and conformance with execution plan, HSE Plan, quality plan, and
related project requirements
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2.4 QA/QC Manager

 Responsible for the proper implementation and management of all Quality Assurance and
Quality Control Plan for all construction works/activities and related project requirements
 Responsible for the developing, arranging and managing of the QA/QC Team at the project
site necessary to undertake and implement QA/QC Plan in coordination with all construction
works/activities undertaken by the construction team.
 Responsible for the review/approval of all QA/QC inspection reports, Nom-
Compliance/Conformance (NCR) Reports and Quality Records.

2.5 QA/QC Engineer

 Performs daily inspection activity in accordance, compliance and conformance with the
requirements of the QA/QC Plan for project.
 Establish and maintain adequate inspection records including ITP inspection reports as well as
Issue NCRs and verified the corrective actions taken by the construction teams.
 Reports to the QA/QC Manager all QA/QC activities works/activities requirements, status,
progress and issues/concerns that requires actions/solutions.

2.6 HSE Manager

 Responsible for the proper implementation and management of all HSE plan for all
construction works/activities and related project requirements.
 Responsible for developing, arranging, and managing HSE Teams at the project site
necessary to undertaken by the construction team.
 Responsible for the review/approval of all HSE inspection reports and related HSE Records.

2.7 Environmental Manager

 Responsible for the preparation of project’s occupational safety and health plan, and its
supporting procedures;
 Ensure the full and correct implementation of the project’s occupational health and its
supporting procedures through:
- Daily presence at the operation sites.
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- Provide required training and TBT to the project team as planned and where needed.
- Ensure the full implementation of the project environmental and social management plan.
- Participate in the coordination process with the relevant government agencies to insure
the full and correct implementation of the aforementioned plan.

2.8 HSE Engineer

 Closely monitor all HSE inspectors at site and convey all instructions made by HSE Manager.
 Check all the PTW (Permit to Work) System is in place for all construction works/activities,
including its documentations, and relevant safety measures/policies to be implemented at the
project site.
 Inform the HSE Manager immediately upon the occurrence of accident/incident.

3. INSPECTION AND ASSESSMENT OF PC BOX GIRDER

As with any manufacturing process, casted PC Box Girder shall be inspected and assessed
for damage or defects that include (but not limited to) CPF-related defects, honeycombs,
spalls and voids, cold joints and cracks. The inspection and assessment of PC Box Girder
shall conclude and result into one of the two (2) categories:

1. PC Box Girder that can be accepted without repair; and,

2. PC Box Girder that can be accepted with repair;

For the flowchart of Repair of PC Box Girder, refer below diagram.

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4. TYPICAL DEFECTS AND DEFINITION

Table 3-1 below tabulates the definition of defects for the PC Box Girder.

Table 3-1: Definition of Defects for the PC Box Girder

Defects and Damage Description Photographic Illustration

1. CPF Related Defect This defect occurs with

the removal or
displacement of CPF
Liner during concreting.

2. Air Pockets This defects are small,

regular or irregular
cavities resulting from
entrapment of air
bubbles on the surface
of vertically formed
concrete during
placement and
consolidation. Air
Pockets can be
categorized as Blow
Holes, Bug Holes, and
Pin Holes.
3. Honeycombs This defect occurs due
to inadequate
consolidation of
concrete. Concrete
Segregation is also
considered as minor
honeycomb. This defect
occurs when some sizes
of aggregates separates
for the cement mortar in
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Defects and Damage Description Photographic Illustration

isolated locations with

corresponding
deficiencies of these
materials in other
locations.

4. Spalls and Voids This defect is similar to

honeycombs to the
extent are larger size
and dimensions.
Damage during lifting,
transportation and
deshutting are
categorized under the
spalls and voids.
5. Cold Joints This defect is a plane of
weakness in concrete
caused by an
interruption or delay in
the concreting operation.
It occurs when the first
batch of concrete has
begun to set before the
next batch is added, so
that the two batches do
not intermix.

6. Cracks This occurs from a

number of causes. The
size of the crack is
important in evaluating
the significance of the
crack and the action that
must be taken to repair
the crack.
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5. DETAILED INSPECTION AND REPAIR PROCEDURES

Generally, the detailed procedures for inspecting, identifying, recording, and classifying defects shall
follow the procedures at Section 3 (Inspection and Assessment of PC Box Girder) and Section 4
(Typical Defects and Definitions).

5.1 Inspection, Identification, Recording, and Classification of Defects

The following procedures are to be followed for the inspection, identification, recording, and
classification of defects for the PC Box Girder:

a) Inspection of Defects for the PC Box Girder shall be undertaken thereafter the PC Box
Girder is in place at the Repair Area or Stock Yard Area of the Casting Yard. Through the
issuance of a RFIT, the Contractor and the Consultant shall conduct a joint-inspection to
identify, record, and classify the defects found to a given PC Box Girder.

b) Identification and classification of the found defects shall be in accordance with the Manual
for Evaluation and Repair of Precast Prestressed Concrete Bridge Products of PCI (MNL-
137-06-E), American Concrete Institute (ACI) 224.1R-07, or as per Section 4 of this
Method Statement. The identification and classification of the found defects shall be
agreed both by the Contractor and Consultant, in order to determine the corresponding
repair procedure requirements.

c) Recording of found defects shall be undertaken through photographs, video, and to the
corresponding Mapping of PC Box Girder Form.

5.2 Detailed Repair Procedures

After the inspection, identification, recording, and classification of found defects, the repair
procedure shall be agreed both by the Contractor and the Consultant. Table 5-1 below, tabulates
the defects, and the corresponding repair procedures/guidelines (but not limited) are enumerated.

Table 5-1: Table of Identified Defects

Defects General Repair Guideline/Procedures
Requirements
1. CPF Related Defect Chipping and Application of Mortar, or per  Per Chapter 4 (Method of Patching),
approved repair material procedures and Method B (Mortar Patch Method),
guidelines Manual for the Evaluation and Repair of
Precast, Prestressed Concrete Bridge
Products, Precast/Prestressed Concrete
Institute, MNL-37-06-E
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Defects General Repair Guideline/Procedures

Requirements
2. Air Pockets Blow Holes - Application of Mortar
Bug Holes - Application of Mortar
Pin Holes - Application of Mortar
Or per approved repair material procedures
and guidelines
 Per Chapter 4 (Method of Patching),
Method A (Mortar Patch Method), Manual
for the Evaluation and Repair of Precast,
Prestressed Concrete Bridge Products,
Precast/Prestressed Concrete Institute,
MNL-37-06-E

3. Honeycombs Chipping and Application of Mortar  Per Chapter 3, Standard Repair

Or per approved repair material procedures
and guidelines
Procedure No. 5 (Honeycomb or Void in
Web), Manual for the Evaluation and
Repair of Precast, Prestressed Concrete
Bridge Products, Precast/Prestressed
Concrete Institute, MNL-37-06-E

4. Spalls and Voids Chipping and Application of Mortar  Per Chapter 3, Standard Repair
Procedure No. 3 (Non-confined Bearing
Or per approved repair material procedures Area Spall) and 4 (Spall or Void in the
and guidelines Bottom Flange with Exposed
Prestressing Strand), Manual for the
Evaluation and Repair of Precast,
Prestressed Concrete Bridge Products,
Precast/Prestressed Concrete Institute,
MNL-37-06-E

5. Cold Joints V-Cutting and Application of Mortar  Per Chapter 4 (Method of Patching),
Method B (Mortar Patch Method),
Or per approved repair material procedures Manual for the Evaluation and Repair of
and guidelines Precast, Prestressed Concrete Bridge
Products, Precast/Prestressed Concrete
Institute, MNL-37-06-E

6. Cracks For Crack Widths  Per Chapter 3, Standard Repair

>0.15mm, Epoxy Injection Procedure No. 10, Manual for the
Evaluation and Repair of Precast,
Or per approved repair material procedures Prestressed Concrete Bridge Product,
and guidelines Precast/Prestressed Concrete Institute,
MNL-37-06-E
For Crack Widths
<=0.15mm  Per Chapter 5 (Epoxy Injection), Manual
V-cutting and Application of Mortar for the Evaluation and Repair of Precast,
Prestressed Concrete Bridge Product,
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Defects General Repair Guideline/Procedures

Requirements
Or per approved repair material procedures Precast/Prestressed Concrete Institute,
and guidelines MNL-37-06-E

 Per Chapter 3 (Method of Crack

Repairs), Causes, Evaluation, and
Repair of Cracks in Concrete Structures,
American Concrete Institute 224.1R-07

5.2.1 CPF Related Defects

The following detailed procedures are to be followed for the repair of CPF related defects
in the PC Box Girder:

a) Chip out the CPF related defects by hand chisel, and spray water on the chipped
area.
b) Mix the components of the approved repair mortar.
c) Fill the CPF related defects with the approved repair mortar with a hand trowel.
d) Cure the applied mortar for at least three (3) hours, and then rub sandpaper until
leveled.

5.2.2 Air Pockets

The following detailed procedures are to be followed for the repair of Air Pocket (blow
holes, bug holes, pin holes) defects in the PC Box Girder:

a) Clean and spray water on the air pocket defects.

b) Mix the components of the approved repair mortar.
c) Fill the air pocket defects with the approved repair mortar by a hand trowel.
d) Cure the applied mortar for at least three (3) hours, and then rub sandpaper until
leveled.

5.2.3 Honeycombs

The following detailed procedures are to be followed for the repair of Honeycombs
(including concrete segregation) defects in the PC Box Girder:

a) Cut and Chip out the honeycombed area until sound concrete is detected.
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b) Blow away dust, clean the chipped area by spraying water, and dry the chipped
area.
c) Apply bonding agent if it is required for the approved mortar.
d) Mix the components of the approved repair mortar with water.
e) Patch the area repeatedly with the approved repair mortar.
f) Apply curing compound.
g) Grind the patched area until leveled.

5.2.4 Spalls and Voids

The following detailed procedures are to be followed for the repair of Spalls and Voids
(including minor breakage) defects in the PC Box Girder:

a) Cut and chip out the breakage area, blow away dust, clean the chipped area by
spraying water, and dry the area.
b) Install forms and seal all forms tightly.
c) Apply bonding agent if it is required for the approved mortar.
d) Mix the components of approved repair mortar with water.
e) Pour or grout the repair mortar into the forms sealed tightly.
f) Apply curing compound.
g) Grind the area until required shape is attained.

5.2.5 Cold Joints

The following detailed procedures are to be followed for the repair of Cold Joint defects in
the PC Box Girder:

a) Conduct v-cut on the cold joint area until sound concrete is detected.
b) Blow away dust, clean the chipped area by spraying water, and dry the chipped
area.
c) Mix the components of the approved repair mortar with water.
d) Patch the area repeatedly with the approved repair mortar.
e) Apply curing compound.
f) Grind the patched area until leveled.

5.2.6 Cracks

The following two tables represent the criteria for crack classification and each
corresponding repair works.
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Table 5-2: Horizontal Cracks – Near lifting zone, inside box girder, top of bottom slab, top
slab.

Crack Width Action Required

<0.15mm No action required ACI 224R-19

≥0.15mm ~ <0.30mm
Cut and fill with Epoxy Mortar
≥0.30mm ~ <0.50mm
≥0.50mm Shall be referred to the
Consultant for detailed
investigation

Table 5-3: Non Horizontal Cracks – Near Diaphragm – outside& inside, through cracks

Crack Width Action Required

<0.15mm No action required ACI 224R-19

≥0.15mm ~ <0.25mm Cut and fill with Epoxy Mortar
≥0.25mm ~ <0.50mm Cut and fill with Epoxy Mortar +
EPLV injection
≥0.50mm Shall be referred to the
Consultant for detailed
investigation

5.3 Exposing of Embedded Items

Embedded items such as electrical conduits, drainage pipes, ventilation holes, drainage spouts,
shall be exposed by carefully chipping the excess concrete.
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6. HEALTH, SAFETY AND ENVIRONMENTAL PLAN

The Contractor will comply and conform to the Health, Safety, and Environment (HSE) requirements
of the project. In general, the execution of the works, the Health and Safety Plan of the project per
Doc. No. RA214-00-HAS-HS-PLN-000002-A2, shall be generally followed. In this section the
Contractor will specify all HSE measures applicable for the works.

7. ATTACHMENTS

7.1 Attachments

The following attachments shall form an integral part of this method statement and are mutually
explanatory of each other.

NO. DESCRIPTION REMARKS

Manual for the Evaluation and Repair of Precast,
Prestressed Concrete Bridge Products,
7-1 Precast/Prestressed Concrete Institute (PCI),
MNL-137-06-E

Causes, Evaluation, and Repair of Cracks in

Concrete Structures, American Concrete Institute
7-2
(ACI), ACI-224.1R-07

7-3 Inspection and Test Plan (ITP)

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Attachment 7-1: Manual for the Evaluation and Repair of Precast, Prestressed Concrete
Bridge Products, Precast/Prestressed Concrete Institute (PCI), MNL-137-06-E
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Attachment 7-2: Causes, Evaluation, and Repair of Cracks in Concrete Structures, American
Concrete Institute (ACI), ACI-224.1R-07