HONEYCOMBED CONCRETE PREVENTIVE MEASURES

What is Honeycomb?
Honeycombing refers to voids in concrete
caused by the mortar not filling the spaces
between the coarse aggregate particles in
concrete surface or inside the concrete mass
where the concrete could not reach. They look
like Honey bees nest.
It usually becomes apparent when the
formwork is stripped, revealing a rough and
stony concrete surface with air voids between
the coarse aggregate on concrete surface. But
Honeycombs inside concrete can be detected
by advanced techniques like ultrasonic test
etc.,

Honeycomb in concrete wall

Honeycomb in concrete wall

HONEYCOMBED CONCRETE PREVENTIVE MEASURES

Risk associated with Honeycomb

According to Honeycomb depth and extent
may reduce the both structural strength and
durability performance of concrete.
Aesthetic look of concrete surface will be
affected.

Root Cause for Honeycomb

Inadequate concrete compaction. (Vibrator not
used properly).
Inappropriate vibrator needle used for concrete
compaction.
Holes or gaps in the form work allowing some of
the mortar to drain out of the concrete.
Required Cover not maintained between the
reinforcement and shutter.
Concrete placing method / Concrete pouring height
increases the risk of segregation.

Root Cause for Honeycomb Cont...

Places like junction of beam to beam to

column and to one or more beams are the
typical spots where honey combs are
observed. This is due to jumbling of
reinforcement of beams and column rods at
one place; special attention is required at
such place during concreting and vibrating.
Use of very stiff concrete (this can be avoided
by controlling water as per slump test).

Practices to Minimise the occurrence of Honeycombed

concrete

To Minimise the incidence of Honeycombed

Concrete:
Ensure the concrete is fully compacted. Use appropriate
concrete vibrator according to concrete wall size / gap
between the reinforcement.
Holes or gaps in the form work to be closed by foam
sheet to avoid the slurry leakage.
Ensure the reinforcement layout and the section shape
will permit the concrete flow around the reinforcement
and completely fill forms.
Reduce Concrete pouring height by extending the
concrete pump hose to place the concrete as near as
possible to its final position.

Practices to Minimise the occurrence of Honeycombed

concrete Cont....

To Minimise the incidence of Honeycombed

Concrete:
Proper shuttering material to be used.
Shutter release agent to be applied.
Concrete pouring shall be done layer by layer.

Different Dia. Of Vibrator Needles

Proper Vibration

Use of Vibrator

HONEYCOMB REPAIRING METHOD

According to the extent and depth of the Honeycombed
area the following Approved materials to be used as per
Engineers instructions.
1. Polycrete FC
2. Polycrete ST
3. Polycrete MC
. Chip off the affected area to expose sound concrete by
means Mechanical equipment.
. Chipped off surface shall be cleaned by air compressor
or with water spray.
. Just prior to the application repaired material, apply
Bonding agent (Polybond AC) on the repair surface and
allow concrete to absorp the bonding agent.

HONEYCOMB REPAIRING METHOD Cont...

Mechanical mixing of Polycrete ST/MC should
be done as per manufacturers data sheet.
Apply mixed material onto honeycombing
surface. The material should be placed within
30 minutes of mixing, in order to gain the full
benefits of fluidity and expansion, which will
fill all the voids.
Once repaired surface dried, immediate curing
is to be done with water spraying, wet hessian
cloth/polythene sheet or a curing compound
for minimum period of 72 hours.

Concrete Wall Without any defects