METHOD STATEMENT

METHOD STATEMENT

Scope of Work:

Possibilities of repair/restoration work during operational and non-operational condition shall be

finalized after confirmation of structural designer for the stability at present condition.

Specific methodology shall be developed jointly with civil structural designer of client

All the bulged related / affected areas shall be removed immediately till

loose material and clean properly.

Member which have severely damaged moving cracks in particular side of structure needs to be

stabilized with Low Viscous Epoxy Injection Grouting having high strength to address the

honeycombing and voids.

Loose cover concrete shall be replaced by high strength fiber based non shrink polymer modified

concrete.

Additional cover concrete shall be provided by high strength non shrink polymer modified concrete

(micro concrete) wherever applicable.

External surface of foundations, exposed to chemical environment should also be treated with at the

Protective coating.
METHOD STATEMENT

Standard Structural Repair Specification

CONTENTS: -

1. Purpose

2. Controlling Specification

3. Recommended System

4. Procedure

6. Inspection

7. Documentation
METHOD STATEMENT

1. PURPOSE

The purpose of this procedure is to establish, monitor and control all activities to execute repair and
rehabilitation of concrete structure including, inspections & execution without any safety hazard. This
procedure is exercised in order to meet requirements specified in drawings, project specifications and up to
satisfaction level of client & consultant.

2. MATERIAL
.
Sr.No. Nature of work Specification Details Product Name

Removal of loose / unsound material

Surface preparation ---
from surface

Cracks Treatment

Structural crack repair by Epoxy Application of Injection Grouting with

SHALIGROUT EI
Injection Grouting Epoxy Injection

Failure (Structural) cracks / Patch Repairs

Rust Convertor for Steel to increase the Rust Convertor application on rusted
SHALIRPRIME RC
life steel bar

Anti-corrosive coating for corroded Cleaning of corrosion deposits and

reinforcement bars and other steel application of Epoxy based anti- SHALIPRIME ZnR
members corrosive coating to bar

Bonding agent for bonding old concrete

Surface preparation and application of
and repair materials for structural SHALIBOND CONCRETE
Epoxy based bonding agent.
members.

Application of pre packed high strength

Patch repairs on concrete substrates SHALIFIX FRM 40
cementitious repair materials.

Repair of damaged reinforced concrete

elements like beams, columns, wall, etc. Flowable Repair mortar for Damaged
SHALIFIX MC
where access is restricted and reinforced concrete members
compaction is not possible

Concrete Protection against chloride Attack

Moisture Insensitive Coal Tar Epoxy

Protective Coating SHALIPOXY CTE 303 - MI
Based Protective Coating
METHOD STATEMENT

3. CONTROLLING SPECIFICATION
I) Manufacturers Specification
II) Standard – BS EN 1504 – 9; 2008 - 11

4. PROCEDURE

This Method Statement Proposal is intended to supplement STP Data Sheets.

Substrate Preparation: -

Reinforcement Steel and Cleaning of Reinforcement

Reference – EN 1504 Standard Part -7 (Principle No.11 – Control of Anodic Areas)

ShaliPrime RC

A) Surface preparation

Methods for removing rust and corrosion scale from the reinforcement exposed after cutting back and
preparing the concrete shall be subject to acceptance by the Engineering-charge.

The steel shall be cleaned manually with wire brush / emery paper or by sand blasting (wherever permissible)
to a bright steel finish.

Clean all exposed reinforcement, which is to remain in the completed Works to a bright finish including behind
the bars. Do not leave the bars exposed for more than three hours after cleaning.

B) Application

Application of two coats of ShaliPrime RC on affected surface by brush after allowing it to settle down the
entrapped air post stirring it slow speed stirrer

The rusty surface will change its colour after 15 – 30 minutes.

METHOD STATEMENT

C) Defective Reinforcement

Unless otherwise directed by the Engineer-in-charge, replace all reinforcing bars, which have corroded to the
extent of 1/3 of original bar diameter or more, as these shall be deemed defective over the affected length.
Either cut out the defective portion or clean it as specified. For links, binders or stirrups, leave not less than 12
diameters or 120mm, whichever is the greater, of unaffected reinforcement projecting from sound concrete.
Unless otherwise directed by the Engineer-in-charge or shown on the Drawings, expose longitudinal bars to
leave an unaffected length of bar projecting from sound concrete, either side of the defective portion, in
accordance with the lap length requirement.

D) Replacement or Additional Reinforcement

Unless otherwise directed by the Engineer-in-charge, replace or supplement all defective reinforcing bars with
bars of the same type and diameter exposed from the original construction. Lap the replacement bars to the
existing reinforcement for the projecting lengths in accordance with the lap length requirement. All
replacement reinforcement shall be adequately fixed and tied in position such that it will not be displaced
during subsequent repair works. Do not weld the reinforcement unless otherwise agreed. Unless otherwise
directed by the engineer-in-charge or shown on the drawings the cover to the replacement or supplementary
reinforcing bars shall be the same as the cover provided in the original construction.

Mode of Measurement:

Unit for Measurement: Kgs of steel used

Anti-corrosive treatment with Epoxy - Zinc based materials.

Reference – EN 1504 Standard Part -7 (Principle No.11 – Control of Anodic Areas)

ShaliPrime ZnR

The material shall be a two component cold cure, epoxy resin blend with zinc powder. which resists corrosion
by forming and impermeable barrier between the metal and atmospheric moisture, ShaliPrime® Zn R provides
METHOD STATEMENT

corrosion protection through tiny electrical cathodic cells formed by interaction of zinc with steel surface
within the confines of the repair location.

Application Methodology:

The application of ShaliPrime ZnR - Epoxy Zinc Primer based corrosion protection layer must take place as
soon as possible to a cleaned steel surface including replaced reinforcement also not later than 3 hours.

Apply two full and unbroken coats of the material by brush making sure that the back of the exposed steel
reinforcing bars is also properly coated (on bone dry first coat.)

Allow to dry fully before continuing further treatments.

Mode of Measurement: Sq. mtr.

Bonding coat of Epoxy based materials for repairs

Reference – EN 1504 Standard Part -3,4 (Principle No. 3 & 4 – Concrete Restoration)

ShaliBond Concrete –

Material Properties:

100 % reactive, solvent free Epoxy based bonding agent for concrete / mortar. The bonding agent must be
capable of providing excellent bond to concrete, masonry, stone work, plaster etc.

Application Methodology

Bonding Coat.

The Base and Hardener must be mixed thoroughly with stirrer to get a homogeneous mix.

Apply one coat on a well prepared and cleaned concrete substrate.

The material should be applied using squeegee or brushes by scrubbing it well into the substrate.
METHOD STATEMENT

The applied material should not be allowed to dry.

The quartz sand should be sprinkled when the bond coat is still tacky to avoid debonding before application of
repair mortar / micro concrete.

Mode of Measurement: Sq. mtr.

Patch repairs of Beams and Columns

Reference – EN 1504 Standard Part -3,4 (Principle No.3,4 & 6 – Concrete Restoration)

ShaliFix FRM 40

Material Properties:

The polymer modified cement mortar used for patch repairs shall be of structural grade supplied as single
component system. The material should be non-shrink, crack and water resistant. Site batching of polymer
mortar should be strictly avoided.

Application Methodology

Mixing

ShaliFix FRM 40 must be mixed mechanically. For this, heavy-duty slow speed drill with spiral mixing paddle or
forced action mixer can be used.

Add 2.0 – 2.4 litres (for 30 kgs) of water into the mixer. Start the mixer and add the powder rapidly and
continuously. Mix for 3 minutes until homogeneous and lump free mix is obtained.

Add balance 2.8 - 3.0 litre of water, if necessary, to get the desired consistency. Mix further for 1-2 minutes.
Under no circumstances excess water should be added. Little extra water may be required in hot climatic
conditions.
METHOD STATEMENT

If ambient temperature is >30°C, use chilled water for mixing and store unused product in the shed. For better
results maintain the mixed temperature of product within 5 - 35°C.

Application

After mixing, ShaliFix FRM 40 can be sprayed or trowel applied. When applying by hand, it must be forced
tightly into the substrate to ensure complete contact with the pre-wetted substrate.

In situations where reinforcement steel is countered, the mixed material should be placed behind the bars
tightly and then subsequent thickness should be built.

High Thickness can be built in a single layer where heavy reinforcement is not encountered. For more
thickness allow first layer to dry sufficiently before applying next layer.

Leveling and initial finishing should be carried using a wooden or plastic float. Final finishing should be carried
out using a steel float.

Mode of Measurement:

Cum or Sq. mtr of particular thickness.

Low Viscous two component Epoxy injection for injection grouting of Honeycombs/ Voids / Cracks etc.,

Reference – EN 1504 Standard Part -2,5 (Principle No.1 & 4 – Protection against Ingress and Structural
Strengthening)

ShaliGrout EI

Material Properties

Solvent free crack injection material composed of very low viscous liquid epoxy resin & amine hardener
system. ShaliGrout EI is used to seal & inject cracks in concrete floors, walls & structures because it provides
deep penetration, shrink free solid mass, strong bonding inside the cracks and excellent resistance to honey
combing & chemicals
METHOD STATEMENT

Application Methodology:

A) Injection grouting

Remove loose and unsound material from the sides of the cracks at least 5 mm on either side surface must be
strong, dry, clean & free from dust, oil, grease, curing compounds, coatings & other loose materials.

open the cracks & clean by blow of oil free air to ensure complete removal of dust & loose particles & Drill
holes into the crack of diameter higher than the grouting nipples up to a depth of at least 1/3rd of structural
member.

Insert injection nipples / nozzles in to the drill holes at the intervals along the length of each crack or pre -
defined area. The distance between each nipple will depend on width & depth of voids/ crack. Spacing should
be close enough to ensure that the resin penetrates along the voids/ cracks till the next point of injection.

The surface of the cracks in between the nipples should be sealed with ShaliDamit Fast Setting Repair
compound about 30-40 mm wide & 2-3 mm thick band. In case the crack is through & through of a wall or
slab, cracks at both the sides must be sealed in similar fashion. First fix the nozzles in the front portion crack,
and then fix the nozzles at midway points of the front nozzles. This ensures complete filling of grout into crack
& surrounding areas.

The repaired work shall be allowed to cure for at least 8 hrs. at 35°C, at low temperature of 5-12°C curing time
is extended and the applicator must ensure that the surface sealant has adequately cured prior to continuing
the work

One end of the injection hose shall be attached to the lowest nipple on vertical cracks or to either end of the
horizontal cracks. alternative methods of resin injection are currently in use; they include the system where
injection nipples are bonded to the substrate

Thoroughly mix the entire hardener and base resin contents until the liquids become clear

ShaliGrout EI epoxy injection grout should be used with standard injection equipment having closed
containers. The injection pressure should be at least 0.2 n/mm2 (2 bar).

Only mix sufficient resin that can be used within the pot life of the materials.

after completion of the injection work, the injection system shall be allowed to cure for 24 hours and shall be
left undisturbed for this time

Mode of Measurement: Kg of ShaliGrout EI

METHOD STATEMENT

Restoration of Distressed R C Members by Micro Concrete Encasement

Reference – EN 1504 Standard Part -3,4 (Principle No.3,4 & 6 – Concrete Restoration)

Product: ShaliFix MC

Material Properties

ShaliFix MC is a ready to use dry powder which requires only addition of clean water at site to produce a free
flowing non shrink repair micro concrete. It is composed of good quality cement, properly selected aggregates
& additives. It is used & designed for repairing of damaged reinforced concrete elements like columns, beams
& structure where the areas are restricted or not easily accessible for proper placement of concrete using
vibrator ShaliFix MC has excellent flowability, workability & proper particle size to reach small & congested
reinforcement

Application Methodology:

A) Formwork and shuttering

Slurry tight and strong form work shall be provided. The shuttering for encasement shall be kept ready such
that the formwork shall be placed in position and fixed such that the Micro concrete can be poured into the
formwork within the overlay time of the bonding agent.

Adequate supports shall be provided for the formwork.

Care should be taken to ensure leak proof shuttering. Under no circumstance the slurry shall flow out of the
shuttering during pouring of micro concrete.

B) Mixing of micro concrete

ShaliFix MC, a cementitious, non-shrink micro concrete shall be mixed using the appropriate water powder
ratio as mentioned in the product data sheet.

The mixing shall be done mechanically and under no circumstance hand mixing shall be done.

Mixing shall be carried out for 3 to 5minutes to ensure that homogeneous mix is obtained without any
bleeding or segregation.

In hot climate ice cooled water shall be used to maintain the temperature of mixed material.

If the encasing thickness is more than 100 mm, add stone aggregates max. 8 – 10 kg per bag of micro concrete
to the mixed micro concrete directly into the mixer hopper. The stone aggregates must be graded 5 - 12 mm
and down and shall be clean, washed and dried.

Mix first micro concrete with recommended dose of water for about 3 minutes in mixer and then pre weighed
stone aggregates into the mixer. Mix further for about 2 minutes till lump free mix is obtained.

Allow the mix couple of minutes to let the entrapped air escape.

Do not add extra water than mentioned in the product data sheet.

C) Pouring of micro concrete

METHOD STATEMENT

The mixed ShaliFix MC shall be poured into the formwork using a suitable funnel or through a hose pipe. It
must be poured from one end only.

A suitable hopper / funnel arrangement shall be made at site to facilitate the pouring operations.

The pouring operation shall be continuous and it shall not be stopped unless the job is completed.

To achieve this, sufficient mixers / drilling machines and work force shall be arranged at site.

D) Deshuttering

The shuttering from the sides of the R C members shall be removed after a period of 24 hours. However, the
formwork of the soffit shall be retained and removed after 3 days.

E) Curing

All the repaired and encased area shall be fully cured as per standard concrete practices.

Curing compound shall be used for effective curing of sides and soffits of beams.

Note: If a curing compound is applied, care shall be taken to ensure that proper surface preparation is carried
out so as to remove any traces of curing compound on the surface. If this is not done, it may lead to debonding
of any protective coating applied on top.

Mode of Measurement:

Cum or Sq. mtr of particular thickness

 METHOD STATEMENT

Protective Coating on Repaired Concrete Footing Surface.

Reference – EN 1504 Standard Part - 2 (Principle No. 8 & 9 – Cathodic Control and Increasing Resistivity)

ShaliPoxy CTE 303 - MI

Material Properties

ShaliPoxy® CTE 303 MI is two component moisture insensitive, liquid epoxy resin based coating suitable for
application over damp concrete (green concrete) and moist metal surfaces. This material is also suitable to
apply where the RH is more than 85%. It is composed of epoxy resin, special type of hardener, and additives. It
has excellent moisture insensitive characteristics and cures over damp concrete surface prior to any other
applications.

Surface Preparation:
Remove dust, dirt, unsound plaster, flakes, oil, grease or other loose foreign particles corrosion deposits &
algae etc. by wire brush and Roughen the surface by mechanical means or compressed air to improve bonding.
Clean the surface by vacuum or water washing. Allow the surface to dry excess water
Ensure the ambient temperature is not less than 10°C and not more than 50°C at the time of coating.
.

Application of ShaliPoxy CTE 303 - MI:

Apply first coat of ShaliPoxy® CTE 303 MI after stirring with slow speed mixer on the prepared surface by
brush / roller / spray and allow it to touch dry for 4 hrs. (depending on ambient condition)
If required, apply second coat of ShaliPoxy® CTE 303 MI as above as per the technical data.

Mode of Measurement: Sq. mtr.

8. INSPECTION

All the stage wise inspection shall be carried out as per approved Manufacturers’ specification.

Product Range
Waterproofing and Insulation | Road Surfacing | Sealants and Additives | Pipeline Coating | Epoxy Flooring
Protective / Anti-Corrosive Coating | Grouts / Admixtures | RestoFix- Repair/Rehabilitation
Other Construction Chemicals