Bahrain Precast Concrete Co. W.L.L.

Quality System
Section 25 Method statement
25.2 Method statement for Repair of HCS cracks 04 September, 2011Page 1 of
4

25.2 Method Statement for Repair of HCS Cracks

INDEX

1.0 INTRODUCTION

2.0 SCOPE OF WORK

3.0 LOCATION OF WORK

4.0 REFERENCES

5.0 RESOURCES

5.1 Manpower
5.2 Materials
5.3 Machinery and tools

6.0 WORKS PROCEDURE

6.1 Repair Method for Grey Concrete

7.0 SAFETY
Bahrain Precast Concrete Co. W.L.L.

Quality System
Section 25 Method statement
25.2 Method statement for Repair of HCS cracks 04 September, 2011Page 2 of
4

1.0 INTRODUCTION
This Method Statement accounts for the repair of Cracks on Hollowcore slabs (HCS)

2.0 SCOPE OF WORK

Describes the procedure and quality control related to the repair of cracks on
Hollowcore slabs

3.0 LOCATION OF WORK

Applicable for all BPC Sites

4.0 REFERENCES
4.1 Layout Drawings
4.2 Shop Drawings
4.3 BPC Design Handbook volume 1

5.0 RESOURCES

5.1 Manpower
5.1.1 Foreman
5.1.2 Mason

5.2 Materials
5.2.1 Primer ISOPRIME30-S (Isola Chemicals Laboratory) or equivalent
5.2.2 Bonding Mix- Epoxy repair Mortar ISOPOX OH (Isola Chemicals
Laboratory)or equivalent (e.g. NITOMORTAR by Fosroc)
5.2.3 SICO grout powder.
5.2.4 Water

5.3 Machinery and Tools

5.3.1 Steel Trowel
5.3.2 Paint Brush
5.3.3 Two small pieces of steel plate or plywood for mixing the primer and epoxy bond.
5.3.4 Bucket for mixing the grout.

6.0 WORKS PROCEDURE

6.1 Hairline crack with width of 0.25 mm or less (top or bottom).

 All area to be repaired shall be marked out.
 The entire length of the crack to notched out “V” shape at about 3mm
deep and cleaned with a steel brush.
 Prepare the primer as per instructions and apply a thin layer of primer in
the crack area. Wait for about 15 minutes to dry the primer and then
apply the second layer.
 Wait about 15 minutes for the primer to dry. After the primer has dried,
prepare the bonding mix as per the manufacturer’s instructions. Use the
Bahrain Precast Concrete Co. W.L.L.

Quality System
Section 25 Method statement
25.2 Method statement for Repair of HCS cracks 04 September, 2011Page 3 of
4

steel or plywood plate for mixing the bond. Now fill the crack area with
this mix using the steel trowel.
 Wait for 3-4 hours till the bond has dried and then smoothen the area with
a sand paper.
6.2 Hairline crack with width of more than 0.25 mm (top and bottom).

 All area to be repaired shall be marked out.

 The entire length of the crack to notched out “V” shape at about 6mm
deep and cleaned.
 Prepare the primer as per instructions and apply a thin layer of primer in
the crack area. Wait for about 15 minutes to dry the primer and then
apply the second layer.
 Wait about 15 minutes for the primer to dry. After the primer has dried,
prepare the bonding mix as per the manufacturer’s instructions. Use the
steel or plywood plate for mixing the bond. Now fill the crack area with
this mix using the steel trowel.
 Wait for 3-4 hours and then smoothen the area with a sand paper

6.3 Hairline crack with width of more than 0.25 mm (bottom when roof is
screeded and/or waterproofing is done).

 All area to be repaired shall be marked out.

 The entire length of the crack to notched out “V” shape at about 6mm
deep and cleaned.
 Drill 20-25 mm holes in the HCS from along the crack from ceiling side to
roof side. For slabs upto 4 meters, 2 holes to be drilled and after that
every 2 meters one hole. If water proofing is done then a patch of about
100x100mm will have to be removed.
 Apply a thin layer of primer in the crack area at bottom side. Wait for
about 15 minutes to dry the primer and then apply the second layer.
 Wait about 15 minutes for the primer to dry. After the primer has dried,
prepare the bonding mix as per the manufacturer’s instructions. Use the
steel or plywood plate for mixing the bond. Now fill the crack area with
this mix using the steel trowel.
 Wait for 6-8 hours till crack filling is died out and then smoothen the area
with a sand paper.
 Now prepare the liquid grout SICO as per the manufacturer’s instructions.
Pour the grout from the top holes till the grout over flows from the holes
(we have to fill the core with the grout).
 Clean the overflowed grout.

7.0 SAFETY
 Standard Safety Rules and Regulations are to be observed in the
duration of work.
Bahrain Precast Concrete Co. W.L.L.

Quality System
Section 25 Method statement
25.2 Method statement for Repair of HCS cracks 04 September, 2011Page 4 of
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 Workers are fully equipped with personal protective equipments such as

safety goggles, shoes, helmets, vest and many others as required.
 BPC’s Safety Officer’s presence is to be available whenever required.
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