Method statement for tie rod hole filling


  • Method Statement for the Repair of Concrete
  • RiveStop System
  • CONSTRUCTION CHEMICALS – PRODUCT RANGE – CONCRETE REPAIR SYSTEMS
  • Types of Form Ties Used in Formwork
  • Tie rod hole sealing with Polyurethane Expanding Foam spray
  • Method Statement for the Repair of Concrete

    ReCon GP — Polymer modified, fibre reinforced, cementitious structural repair mortar Repair of honeycombs, blowholes, tie rod holes and damages in concrete structures. ReCon HS — High strength, fibre reinforced cementitious structural repair mortar Repair of honeycombs, blowholes, tie rod holes and damages in concrete structures. ReCon 35LW — Repair of honeycombs, tie rod holes and damages in concrete structures Concrete repair in vertical and over head locations.

    ReCon 75LW — Light weight high build cementitious repair mortar Concrete repair in vertical and over head locations. ReCon MC40 — Shrinkage compensated polymer modified micro concrete Repair of large sections, encasement of structural elements, difficult access locations, pile head, concrete floor reinstatement, architectural waterproof screed, etc. ReCon Zinc — Zinc rich anti corrosive primer Anti corrosive protective coating over steel reinforcements and metal surfaces of concrete structures in aggressive environments.

    ReCon ST — Aluminum rich anti-corrosive primer Anti corrosive protective coating over steel reinforcements and metal surfaces of concrete structures in aggressive environments. ReCon LVE — Low viscosity epoxy resin for crack injection Crack injection in structural members such as columns, beams, foundations, walls, decks and water retaining structures.

    ReCon PU F — Polyurethane crack injection flexible foam To stop flowing water temporarily through concrete cracks, rock faults, soil stabilisation,etc. ReCon PU R — Polyurethane crack injection resin system To seal moving and non moving cracks in concrete structures such as water tanks, basement wall, slab, roofs, masonry, etc.

    ReCon PTE — Epoxy pile encapsulation system Encapsulation of pile top to provide water tightness, pourable epoxy patch repair material, etc.

    ReCon ME — Epoxy mortar Epoxy bedding for repair of horizontal surfaces such as industrial floors, bridge decks, patch repair works, airport runways, manhole benching, etc. ReCon Plate CFL — Carbon fibre laminates Strengthening of structural elements such as column, beam, slabs specifically where improvement to shear strength and deformation properties are required. In this section.

    RiveStop System

    Threaded Tie 1. Flat Tie Flat tie is a thin flat steel plate which contains hole at each end. These holes are used to lock the flat tie in forms using wedge and pin.

    These are preferred for prefabricated modular form panels and for light duty purposes. These are for one time purpose only since they cannot be removed from hardened concrete. They are removed by braking and to facilitate braking, a notch is provided at a predetermined distance from its ends. To prevent turning of tie while braking, holes may be provided in its middle portion. Fig 2: Flat Tie System 2. Loop Tie Loop tie is single metal bar which ends are looped to provide space for locking systems such as wedge and pin.

    These are also preferred for prefabricated modular form panels and for light duty purposes. Loop tie cannot be removable from hardened concrete hence, it contains weaker cross section. To prevent turning against braking, some part of the middle portion is crimped. Fig 3: Loop Ties 3.

    Fiberglass Tie Fiberglass ties are newly developed tie system which are made of glass fibers and resin materials. These are available in longer lengths and can be cut into required sizes easily.

    These ties are fixed to the form panels using gripper and tie wedge arrangement. After hardening of concrete, the ties can be cut at the surface level of hardened concrete. So, the hole will disappear.

    They are available in so many colors and capable of carrying higher loads than flat, loop and snap ties. Fig 4: Fiberglass Tie System 4. Snap Tie Snap tie is a single rod which ends contain enlarged button or loop to facilitate the use of suitable tie holders.

    Plastic cones or metal washers or pins are attached to these ties to use them as form spreaders and also to prevent water leakage from concrete. Snap ties cannot be removed completely from the hardened concrete hence, they contain weaker cross sections which are easy to snap. The breaking of tie should be done after complete hardening of concrete otherwise they do not break and turn inside the wall by spanning the concrete.

    To prevent turning, while making these ties a portion of the tie at required distance is crimped or weakened to ease snapping of tie. Fig 5: Snap Tie System 5. Taper Tie Taper tie contains a tapered rod which is threaded at both ends. After placing in forms, these ends are locked by using wing nuts and washer system.

    They are available in standard lengths of 34 in to 60 in. So, required wall thickness can be obtained using different lengths of taper ties. The diameter of taper tie is gradually reduced from larger threaded end to small threaded end. Tapered ties can be removed completely after hardening of concrete and can be reusable.

    For easy removal, taper tie must be coasted with grease before installation. Fig 6: Taper Tie System 6. Threaded Tie Threaded Tie contains a metal rod which is completely threaded from one end to the other end. It is fixed to the forms using nuts and washer on each end.

    It can be removed from hardened concrete if plastic sleeve is provided around it. After hardening, the sleeve is bonded with concrete and threaded tie can be removed and reused. It can be used for higher loads, but in such case two nuts on each end are preferred. Fig 7: Threaded Tie System Internal Disconnecting Type In this type of ties, the tie member contain threaded ends so, the external members can be removed without any breaking or pulling.

    Internal disconnecting ties are classified into two types as follows. She-Bolt Tie Coil Tie 1. She-Bolt Tie She-bolt tie system contains one inner tie rod and two she-bolt members. Both ends of inner tie rod are threaded up to some distance. She-bolt contains one normal threaded end and one tapered end with threaded hole. The taper end is placed internally into the forms and tie rod is screwed into the threaded holes of she-bolts on both sides.

    External threaded ends of she-bolts are used to secure the forms by wing nut and washer arrangement. After hardening of concrete, the inner tie rod remains in concrete and she-bolts can be removed and reused.

    Fig 8: She-bolt Tie 2. Coil Tie Coil tie contains two members, inner tension member and external holding member. Inner tension member consists of two helical coils welded to the ends of two or four steel struts. This member remains in concrete after hardening. External holding member consist of two bolts which are screwed into the coils on both ends and these bolts are supported by washer and wale arrangement.

    These bolts can be removed after hardening and reused. Two strut coil is used for medium works and four strut coil is used for heavy works.

    If required, plastic or wood cones can be provided at each end of the coil to act as form spreaders. If the thickness of wall is too large, two inner members connected by threaded rod can be used. Flat tie.

    Fig 3: Loop Ties 3. Fiberglass Tie Fiberglass ties are newly developed tie system which are made of glass fibers and resin materials. These are available in longer lengths and can be cut into required sizes easily. These ties are fixed to the form panels using gripper and tie wedge arrangement. After hardening of concrete, the ties can be cut at the surface level of hardened concrete. So, the hole will disappear. They are available in so many colors and capable of carrying higher loads than flat, loop and snap ties.

    Fig 4: Fiberglass Tie System 4. Snap Tie Snap tie is a single rod which ends contain enlarged button or loop to facilitate the use of suitable tie holders. Plastic cones or metal washers or pins are attached to these ties to use them as form spreaders and also to prevent water leakage from concrete. Snap ties cannot be removed completely from the hardened concrete hence, they contain weaker cross sections which are easy to snap. The breaking of tie should be done after complete hardening of concrete otherwise they do not break and turn inside the wall by spanning the concrete.

    To prevent turning, while making these ties a portion of the tie at required distance is crimped or weakened to ease snapping of tie. Fig 5: Snap Tie System 5. Taper Tie Taper tie contains a tapered rod which is threaded at both ends. After placing in forms, these ends are locked by using wing nuts and washer system. They are available in standard lengths of 34 in to 60 in. So, required wall thickness can be obtained using different lengths of taper ties.

    The diameter of taper tie is gradually reduced from larger threaded end to small threaded end. Tapered ties can be removed completely after hardening of concrete and can be reusable.

    For easy removal, taper tie must be coasted with grease before installation. Fig 6: Taper Tie System 6. Threaded Tie Threaded Tie contains a metal rod which is completely threaded from one end to the other end. It is fixed to the forms using nuts and washer on each end. It can be removed from hardened concrete if plastic sleeve is provided around it. After hardening, the sleeve is bonded with concrete and threaded tie can be removed and reused. It can be used for higher loads, but in such case two nuts on each end are preferred.

    Fig 7: Threaded Tie System Internal Disconnecting Type In this type of ties, the tie member contain threaded ends so, the external members can be removed without any breaking or pulling. Internal disconnecting ties are classified into two types as follows.

    In case of a wall or slab which is cracked all the way through, packers shall be located on both sides with those at the back placed at midway points between those at the front. One end of the injection hose shall be attached to the lowest packer on vertical cracks or to either end of horizontal cracks.

    Each crack shall be treated in a single continuous operation and sufficient material shall, therefore, be made prior to the commencement of the work. Remove the packers or nipples and make good any holes or voids with sealer and allow curing.

    CONSTRUCTION CHEMICALS – PRODUCT RANGE – CONCRETE REPAIR SYSTEMS

    The sealer can then be ground off or softened with a blowlamp and peeled off. Make sure that it does not burn. Upon completion of the injection works, the injection system shall be allowed to cure for 24 hours and shall be left undisturbed for this time. Crack Repair by Gravity Feed: a. Clearly, mark the cracks to be repaired. Rake the crack to widen it to minimum 5mm wide and 10 mm deep.

    Use a stopper on both sides of the crack using a sealant or cement sand mortar or sealant to create a reservoir. After preparing the surface, mix Crack injection material as per the instructions is given in the product datasheet.

    Allow sealer to cure for minimum 12 hours. Pour the mixed material within the pot life of the resin over the top of the crack and allow it to penetrate. Keep filling the cracks until they will no longer accept resin. For flood coat applications, distribute the resin evenly over the surface initially and then puddle the resin over the cracks.

    On smooth surfaces, use wire brush or rollers to promote penetration. Inspect the filling. Look for signs of penetration such as air bubbles escaping from the cracks as the resin displaces the air. Twenty to 30 minutes should be a minimum. Also, be aware that several minutes may pass before resin has fully penetrated tight cracks and more resin may still be required. Once all cracks have been filled to refusal, remove the excess surface resin with a flat rubber squeegee.

    Make sure that the substrate surface must be free from oil, grease or any loosely adherent material; a. If the concrete surface is defective or has laitance, it must be cut back to a sound base; b. Bolt holes or fixing pockets must be blown clean of any dirt or debris c.

    The underside of the base plate should be clean and free from oil, grease, rust, scale or other loosely adherent material; b. It may be necessary to provide air pressure relief holes to allow venting of any isolated high spots; c. If leveling shims are to be removed once the approved grout has hardened, then they should be pretreated with a thin layer of grease. Formwork — General 1. Before fixing any formwork, ensure that the area to be grouted is clean. The formwork itself must be constructed to be leak proof, to prevent any possible grout loss.

    This can be achieved by using a foam rubber strip or mastic sealant beneath the formwork, and at any joints in the formwork. It shall, however, also be provided with drain holes and plugs. The formwork should also be constructed in such a way as to keep the final, unrestrained surface area of the grout to a minimum, to avoid problems with cracking at a later stage.

    It should be fixed in such a way as to allow easy stripping, without causing damage or distress to the grout — particularly if this is to be done whilst the grout is still green. All dirt and debris to be removed from the grout area before the last piece of formwork are fixed, to facilitate pre-soaking. Formwork — Geometry a. Pouring side: Set up so that grout will be poured the shortest distance across the base plate. Erected a maximum of mm from the base plate edge.

    Erected a minimum of mm higher than the underside of the base plate. Open Side: Set up directly opposite the pouring side. Erected a maximum of 50 mm from the plate edge.

    Types of Form Ties Used in Formwork

    Erected a minimum of 25 mm from the underside of the plate. Flanking Sides: Set flush with the plate edge. Pre-Soaking a. All concrete surfaces within the formwork area should be saturated with clean, fresh water for several hours prior to grouting. Immediately before grouting takes place, any free water should be removed.

    Particular care should be taken to blow out all bolt holes and pockets. Mixing a. Mixing shall be done as per approved repair material technical data sheet. Placing 1. It is essential that the machine mixing capacity, material supply, and labor availability is adequate to enable the grouting operation to be carried out continuously.

    This may require the use of a holding tank, with provision for gentle agitation to maintain fluidity; 2. Immediately prior to placement, the mixed grout should be briefly agitated to release any surface tension. Placing shall be done depending upon the thickness of filling referring to approved product data. Any bolt pockets must be grouted prior download studocu files free grouting between the substrate and the base plate.

    Continuous grout flow during the grouting operation is essential. Sufficient grout must be available prior to start, and time taken to pour a batch must be regulated to the time taken to prepare the next one. The mixed grout should be poured only from one side of the void to eliminate the entrapment of air or surplus pre-soaking water.

    The grout head must be maintained at all times so that a continuous grout front is achieved. When the grout reaches the open side of the formwork and rises above the underside of the base plate, pouring should continue slowly down the length of the base plate until completed. Finishing a. The gap between the perimeter formwork should not exceed mm on the pouring side and 50 mm on the opposite side.

    It is advisable where practical to have no gap at the flank sides. Curing On completion of the grouting operation, all exposed areas of grout should be thoroughly cured.

    In summary along with standard practice, methods described by the approved manufacturer shall be followed in strictly. Filling of Core Holes a.

    Prepare the core hole by removing dust, loose particles, grease, oil and traces of foreign materials which may affect the adhesion of the mortar on the concrete.

    Wash the area with water by copiously spraying just a few hours before the application of the mortar. At the time of application, the area should be free from water but still damp. Place the approved micro-concrete or approved repair material inside the hole by gravity pouring and use a trowel for better finishing.

    Upon filling the hole, the surface should be kept moistened by curing it with cool water for 3 days. Protect the surface from wind or excessive heat or properly secured plastic sheeting during the curing period. Note: These steps are for guidelines only. This is most effectively achieved by the use of proprietary blast media, such that the fine aggregate is exposed but not polished.

    Where preparation techniques result in voids of greater than 10 mm depth, alternate method and material shall be used as an approved material datasheet. Immediately prior to the application of approved material, the prepared substrate should be blown clean with oil-free compressed air. Substrate priming shall be done following the procedure mentioned in an approved material-technical datasheet. Removal and Repair of Construction Temporary Embedments All temporary construction embedments such as temporary mechanical or electrical sleeves, block-outs, etc.

    After removal of any temporary embedments, remove any loose areas, laitance and any foreign materials that will affect the bonding of repaired materials. If the embedded item reached the location of reinforcement, ensure to remove any rust formation not only on the exposed surface but also on the rear side of the reinforcement bars. Apply corrosion treatment prior to start the repair.

    Proceed on the application of approved suitable materials as required. Curing shall be done as per the approved curing process or as recommended by the manufacturer.

    Risk Assessment Please refer to the attached document in Appendix B. Permit and Licensing Requirements Necessary permits shall be obtained. Safety Helmet with Company Logo b. Safety Boots c. High Visibility Vest d. Safety Goggles e. Face Mask f.

    Hand Gloves g. Coveralls Information to Personnel a. Safety Induction b. Job training c. Toolbox talks e. Banksman, wearing distinctive vests, shall be assigned to help operators maneuver their equipment. The equipment operators shall possess the required licenses and certificates. Generated dust shall be controlled by periodic water spraying. All working activity shall comply with Client Safety Procedure. First Aid Material. Schedule the project in logical steps and budget time required to meet deadlines.

    Inspect and review projects to monitor compliance with building and safety codes and other regulations. Site Engineer The Site Engineer shall evaluate the number of materials consumed by each trade to be compared against planned quantity.

    Site Foreman A construction foreman is responsible for supervising the workers and also doing actual construction work. The foreman monitors employees to ensure that the work is done efficiently and within quality standards.

    Tie rod hole sealing with Polyurethane Expanding Foam spray

    HSE Engineer The Safety Engineer shall be full time at the site and shall frequently visit all the ongoing works at site. All safety violations and on-conformance of the HSE Plan shall be registered and immediate action shall be done in coordination with the Site Engineer. HSE Officer Monitor and control all HSE matters related with project team members and contractors in ensuring that the Project is in compliance with the project requirement i.

    Participate in HSE Risk Assessment and hold a relevant meeting, workshop internally and with related 3rd parties. Monitor and update the HSE risks register and ensure all mitigation plans are strictly adhered to throughout the project execution.


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