Method of Statement for Concrete Repair

Concrete repair is the process of rectifying damaged concrete areas, usually these damages can happen if various factors such as water, corrosion, physical impact or some other factor. so , its should be necessary repaired at on time otherwise theses corrosion or damages will continue spread to other areas.
Following steps are involved in concrete repair work.

Process of concrete Repair

1. Inspection & Identification of Defective Areas
2. Surface Preparation & Necessary arrangement
3. Chipping the old concrete in defected areas
4. Steel preparation and Anti-corrosion coating on steel
5. Steel Anchoring
6. Shotcrete

1. Inspection & Identification of Defective Areas

• Conduct an visual inspection of the concrete structure to identify visible cracks, corrosion, sapling, or other signs of damage.
• If needed make an required test like Non-Destructive Testing to identify the defected areas

2. Surface Preparation & Necessary arrangement

• Mark an defected areas prior to chipping
• Arrange an necessary arrangements such as Safety, scaffolding, required tools and machineries.
• Clean the surface and remove the dust prior to chipping work

3. Chipping the old concrete in defected areas

• Setting-Out, Alignment, Verticality, Elevation, and required rebar’s anchoring locations & spacing shall be in accordance as per project specification.  
• Concrete chipping of the Columns & ceiling & other vertical structures and Floor surface will be carried out using jack hammers, drilling tools & breakers to achieve a good bond between old and new concrete as per required thickness and to remove all the segregated, damaged, or deteriorated concrete until a sound homogeneous substrate has been reached.
• After chipping the concrete The Surface should be rough and properly cleaned using compressed air to remove loose / chipped materials.  
• The surface should be cleaned from dust, oil, grease, corrosion deposits, or any other containments that could impair the adhesion of the repair mortar.

4. Steel preparation and Anti-corrosion coating on steel

• Break along corroded steel bars in the repair area until the non-corroded bright steel observed, it may necessary to break out the concrete beyond original repair area in order to achieve
• If the defected areas are big, clean the reinforcement steel using an sand blasting technique.
• If the defected areas are small, clean reinforcement steel using an steel brush
• All cleaned steel reinforcement should be primed with (Anti-corrosion) zinc-rich epoxy coating 

5. Steel Anchoring

• Rebar anchoring installation carried out should be as per approved location and properly fixed and inspected by the consultant prior for additional rebar installation.
• Drilled holes are filled with epoxy or grout before anchoring the new reinforcement steel bar.
• Install the required reinforcement rebar as per approved structural drawing.
• Ensure all required rebar spacing, lapping, covering shall be carried out as per approved drawings.

6. Shotcrete 

• Prepare an levelling & make an curing before applying the shotcrete
• Prepare the shotcrete mixture as per project specified mix design.
• Apply the bonding agent on steel before applying the shotcrete used for good adhesion between the new shotcrete layer and the existing concrete.
• Apply shotcrete (sprayed concrete) using a high-pressure hose to the prepared surface. This can be done in layers, ensuring even coverage and proper compaction
• Finishing: Make an good finish on the shotcrete surface using trowels and other required tools.
• Continue curing for 7 to 28 days to ensure the concrete reaches its full strength