Contract No.: Doc. No.

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Rev. No.: Date Issued: 05/18/2021

CONCRETE POURING &

REPAIRING WORKS
METHOD STATEMENT

REVISION HISTORY
Rev. No. Revision Information
Rev. 0 First Issue

Action by Name Designation Signature

Prepared Site Team

Reviewed QA/QC Manager

Approved Project Manager

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TABLE OF CONTENT
1. SCOPE...........................................................................................................................................3
2. PURPOSE......................................................................................................................................3
3. RESPONSIBILITIES......................................................................................................................4
4. EQUIPMENTS AND TOOLS.........................................................................................................4
5. SITE PLANNING...........................................................................................................................7
5.1 PREPARATION...............................................................................................................7
5.2 SITE CLEARANCE..........................................................................................................8
5.3 TRAFFIC MANAGEMENT...............................................................................................8
5.4 PRE-CONSTRUCTION SAFETY MEETING...................................................................8
6. QUALITY PROCEDURES.............................................................................................................9
6.1 INSPECTION OF FORMWORKS ..................................................................................9
6.2 INSPECTION OF REINFORCEMENT..........................................................................10
6.3 INSPECTION OF EMBEDDED ITEMS.........................................................................11
6.4 PRE-PLACEMENT INSPECTION OF CONCRETE......................................................11
7. CONCRETE POURING...............................................................................................................12
8. HOT WEATHER CONCRETE.....................................................................................................17
9. CONCRETE RECEIVING, SAMPLING, FIELD TESTING AND PLACEMENT..........................18
9.1 CONCRETE RECEIVING.......................................................................................................... 19
9.2 SAMPLING OF CONCRETE..................................................................................................... 19
9.3 CONCRETE RECEIVING.......................................................................................................... 19
9.4 CONCRETE RECEIVING.......................................................................................................... 19
10. FORM WORKS REMOVAL..........................................................................................................20
11. CONCRETE REPAIRING..............................................................................................................20
11.1 RESPONSIBILITIES........................................................................................................9
11.2 PROCEDURES/METHOD TO BE EMPLOYED............................................................10
11.3 GENERAL INSTRUCTION ...........................................................................................11
11.4 SUBSTRATE PREPARATION ......................................................................................11

1. SCOPE 

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CEC will execute the construction of concrete structure for NPF Project where required and
shown in the approved construction drawing following the approved design, scope of work, IFC
drawings, and Project specification as required following the structural design criteria and
approved IFC drawings. Quality Procedure is to execute the works following the approved
construction drawings, Project Specification procedure, and other international or national
standards, The works shall be carried out as per the contract specifications and Project Safety
Construction Manual. The procedure shall cover the work and inspection for concrete placement
and finishing of structural concrete works following Project specification and IS applicable codes.

2. PURPOSE
The purpose of this document is to establish the Quality Control Procedure for Placing & Testing
Non-Structural and structural concrete including the inspection, and Concrete Repairing Works
with different kinds of approved repairing materials.

3. RESPONSIBILITIES

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1. The site Engineer shall be responsible for the overall implementation of the Company safety &
Quality Plan and ensure efficient execution of work following Project specifications.

2. QA/QC team shall oversee all the activities, whether all are executed as per the Project Quality
Plan and Specifications.

3. The construction manager shall be responsible to give correct instructions to Supervisor

Implementing the project quality and safety plan.

4. The supervisor shall monitor the execution of all works, Foreman shall lead the workforce and
workmanship during the execution of the work.

5. QC Supervisor shall ensure that all works are carried out as per IFC with Project QC Inspector
for inspection.

6. QC Inspector shall ensure that all works are carried out as per IFC drawings, project
specifications, and standards.

7. Equipment Operator the authorized person to operate any equipment to be used in the project.

8. Helpers /Laborers: Perform tasks involving physical labor at building, assist the skilled workers,
remove the trash, and residual building debris.

9. Assist in constructing and later disassembling reinforcement braces, concrete forms, scaffolds,

and temporary structures.

10. Concrete Batch Plant Supplier

The Plant Manager shall ensure that all necessary equipment pumps and extensions or any
requirements.

4. Equipment and Tools

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All equipment & operators being mobilized shall be approved by concerned personnel before
execution of work.

1. Transit mixer.

2. Concrete pump.

3. Transport vehicle.

4. Electrical Concrete Mixer.

5. Hand Mixer.

6. Water tanker.

7. Concrete vibrators.

8. Power Float.

9. Small Concrete Mixer.

10. Hand Shevel.

11. Mason / carpenter/rebar hand tool.

12. Jackhammer.

13. Loader.

14. Dump truck.

15. Concrete cutter

5. Site Planning

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5.1 Preparation
a. The contractor shall ensure that all gate passes, permits, tools, materials for safety precautions,
manpower, and equipment are available before commencement of work.

b. The Site Team shall make sure that access roads are always clear from any obstruction and the
site is always accessible.

5.2 Site Clearance

a. Before commencing the work, the area shall be cleared of all debris, materials, or other
obstructions.

b. It is the responsibility of the Construction team to ensure that the preceding activity is completed.

c. If concrete is required to be done on earlier concrete work, it is the responsibility of the QC

Engineer to approve that concrete had hardened (% Strength) enough to withstand a load of
reinforcement, formwork, fresh concrete, and concrete operations.

5.3 Traffic Management

a. The Site Team with the assistance of the Safety Officers shall coordinate logistics and materials
move through the site following the direction and road signs displayed on site.

b. The required diversion routes shall be marked on drawings including the required traffic signs.

c. The Work Permits and Operator Certificates shall be compiled and files for reference
by authorized personnel.

d. Temporary traffic signs, barriers, and flagmen will be deployed to control traffic flow following
HSE Plan-Traffic Management & Roadwork Construction.

e. Traffic Routing Plan will be submitted before commencing any concreting activity depending
upon each work. The plan should be approved by the engineer before the start of work.

5.4 Pre-construction Safety Meeting

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a. The meeting shall be scheduled before the beginning of the work and before any Sub-contractor
starts on the project.

b. Safety awareness meetings will be conducted every working day morning/every other day to
brief the workforce on the safety prevention measures. The equipment check for safety shall be
recorded/ documented during the daily Safety Awareness Meeting.

c. Traffic safety will be discussed to emphasize these meetings.

d. Each worker will be instructed to follow specific safety requirements related to his trade. They will
be required to follow installed safety signs, observe barricades and use opens.

e. The contractor Safety Team will perform hazard risk analysis by identifying all steps, hazards
identified in those steps, with a focus on the relationship between the work task, the tools, and
the work environment. After identifying uncontrolled hazards; the Contractor will take steps to
eliminate or reduce them to an acceptable risk level.

f. General contractual Safety, Health, and Environmental requirements.

g. Roles of the contractor, subcontractors, authorized representatives, and all project workers.

6. QUALITY PROCEDURE 

6.1 INSPECTION OF FRAMEWORKS BEFORE CONCRETING

a. Construction & erection of formwork shall comply with the project specifications and shall as what
is shown in the issued for Constructions and shall Section or Site Engineer shall be frequently
made to verify the work is being done as Project Quality Plan & Procedure.

b. Concrete in contact with soil shall be protected by placing polyethylene sheet or 50mm thick lean
concrete and shall be placed beneath the concrete structure.

c. All formwork materials are inadequate condition, constructed from sound material of sufficient
strength, properly braced, strutted, and shored to ensure rigidity throughout the placing and
consolidation of the concrete without visible deflection.

d. All formwork shall be watertight to prevent grout loss.

e. Formwork shall be constructed to provide the correct shape, line, and dimensions of the concrete
shown on the IFC drawings.

f. The formwork surface is thoroughly cleaned of all dirt, mortar, and foreign matter and coated with
a Release agent.

g. Tie-rods and support systems are satisfactory.

h. Surveyor's checks completed and within tolerances.

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i. The area is adequately cleaned out.

j. Final inspection by the Civil Quality Control Inspector for the formwork erection shall be done at
the Pre-Placement inspection before placement of concrete.

6.2 INSPECTION OF REINFORCEMENT.

a. Fusion bonded Epoxy Reinforcing Steel Storage, cutting, bending & fixing shall comply with
Project Specification and applicable international standard. The Civil Quality Control Inspector
shall conduct inspections during the pre-placement of concrete and installation of the
reinforcements.

b. Reinforcing steel shall be accurately placed following the placement drawings and shall be
adequately secured and held in position.

c. Reinforcing, including tendons and post-tensioning ducts, shall be accurately placed and
adequately supported before concrete is placed.

d. Lap splices shall be following the placement drawing.

e. Concrete cover to reinforcement shall be as approved specifications.

6.3 INSPECTION FOR EMBEDDED ITEMS 

a. All Embedded items shall be placed as per the approved drawings and Project Specifications.
The Site Engineer shall check the placement and positions of all embedded items against the
current construction drawing and shall also be responsible for rechecking the positions of the
embedded items to assure no displacement has occurred. 
b. Embedded items such as Anchor Bolt, water stop, conduits sleeves, blackouts, inserts, and other
embedded item if any shall be as what is specified in the issued for construction drawings,
identified, positioned, and secured, and shall be as per the joint type and joint movement
requirements and must be securely positioned in the forms to prevent deflection and
misalignment during the concrete placement as per approved specs.
c. The Quality Control Inspector shall inspect at the Pre-Placement inspection for concrete, the
embedded items, if required, are completed.
d. The contractor shall be responsible and ensure in all trades (electrical, mechanical, etc.) specific
embedded items are coordinated and cleared by respective trades or discipline before pouring.

6.4 PRE-PLACEMENT INSPECTION OF CONCRETE 

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a. Pre-placement Inspection Request for Concrete Structures shall be submitted by the site
Engineer to the Quality Control Department when the installation of the steel reinforcement,
formwork & embedded items are completed. Upon receiving the RFI, assigned Civil Quality.
b. Control Inspector shall initially check the relevant work, If the work is not satisfactory, the Civil
Quality Control Inspector shall inform the Site Engineer by notifying the reason for of rejection of
the work and return the RFI form to the Section or Site Engineer for rectification of the defect.
c. After the Civil Quality Control Inspectors' initial check confirms that the works comply with the
requirements, then he shall submit to the "Project Representative a duly filled in RFI in Form, in
24 hours' notice.
d. Construction Contractor's Civil Quality Inspector shall then accompany Project Representative to
inspect jointly the work and release for concrete placement by signing the box provided on the
relevant 'ITP/Checklist'.
e. Wall or Column form should not be closed until the Construction Contractor Civil Quality Control
Inspector and Project Representative have inspected the steel reinforcement and embedment
items.
f. Cleaning of the wires nails and bolts of wood shall be checked before concrete placement.
g. The QA/QC Inspectors are also required to inspect to verify items, which affect their trades are
completed before placement of concrete.
7. CONCRETE POURING
a. Cleaning of tie wires, nails, bits of wood, and cleaning of windblown sand shall be checked by
the QC Inspector before placing concrete.
b. Concrete shall be placed as per the requirement of Project Specification and Reference
Standards.
c. A minimum of two concrete vibrators/pumps shall be on-site for each concrete placement,
flexible hoses to be used for concrete placement of walls.
d. Concrete shall be placed in horizontal layers not exceeding 450mm in depth.
e. As per Standard, Concrete shall not be dropped freely where reinforcing will cause neither
segregation nor where it would fall freely for more than 1 meter.
f. Civil QC Inspector shall notify the Site or Section Engineer in charge to hold work and
implement an immediate correction in case of any unacceptable operation before concreting.
g. Equipment made of aluminum alloys shall not be used for pump lines, tremies, or chutes to

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discharge concrete from a truck mixer.

h. Concrete shall not be placed before a recorded pre-placement inspection and authorization to
proceed.
i. Vibrators shall not be used to move concrete inside forms.
j. Concrete shall be deposited as near as possible in its final position to avoid segregation due to
re-handling or flowing.
k. Concrete shall be placed on a clean surface, standing water shall be removed before placement
of concrete.
l. No concrete in periods of dust storms.
m. Special care is required against drying winds.
n. Records of delay due to dust storms to be prepared.
o. Sketches showing concrete pump allocation/traffic management plan will be prepared for each
pour & will be monitored by Safety Officer for safe movement.
p. Level pads with cement mortar top levels of the concrete will be established before the
inspection.
q. The Contractor shall assess the weather conditions immediately before pouring concrete into
watertight concrete structures and shall if necessary, either suspend placing of watertight
concrete or carry out place during the late afternoon or evening if the weather is considered to be
too hot and/or sunny.
r. Records showing date, time, temperature, and weather conditions will be established for each
concreting.
s. Concrete Curing to be as per ACI308.

8. Hot weather concrete

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As per ACI 305, Accordingly, considerations shall follow.

9. Concrete Receiving, Sampling, Field Testing, and Placement

9.1 CONCRETE RECEIVING 

a. The approved 3rd Party Field Technician shall monitor concrete receiving and obtain a copy of all
concrete delivery notes to fill in the relevant information on the approved form.
b. Registration of each truck by QAQC Engineer at the site.

9.2 SAMPLING OF CONCRETE 

a. The approved 3rd Party Field Technician shall obtain samples from different batches of concrete
samples of fresh concrete shall normally be obtained from the chute of the truck mixer during
discharge.
b. Concrete samples set of four (4) cylinders shall be taken for every 115 cum, marked with the
concrete placement card number and the casting date for each cylinder sample of the set.
c. The sample is to be transferred to the laboratory for curing and testing as per the testing
requirement.

10. FORMWORKS REMOVAL

Removing of forms shall be as per ACI301 and to consider the following points:
a. Do not remove forms or bracing until the concrete has gained sufficient st4rength to carry its
weight and imposed loads.
b. Loosen forms carefully. Do not wedge pry bars, hammers, or tools against finish concrete
surfaces scheduled for exposure to view.
c. Store removed forms in a manner that surfaces to be in contact with fresh concrete will not be
damaged. Discard damaged forms.

11. Concrete Repairing Works

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The procedure for repairing the concrete works according to a type of defect observed, per the
manufacturer’s requirements.

1.1. RESPONSIBILITIES
1. The Project Manager is overall responsible for the implementation of this method statement and
to ensure that his team of engineers and foreman are aware of this method statement and the all
resources – human, material, and equipment are available to carry out the work as planned and
without any delay.

2. The Site Engineer is responsible to ensure that the work as per the approved repair drawings,
method statements, and all necessary inspections have been carried out. He is also responsible
to ensure adequate equipment for mixing and application before start repair.

3. QA/QC Engineer is responsible to ensure work has been done as per the method statement and
Pre-repair inspections are carried out by the CONTRACTOR and CONSULTANT.

4. The Safety Engineer is responsible to ensure that all safety precautions are in place and that all
personal on-site are using the required Personal Protective Equipment – Helmet, Gloves, Shoes,
and Coveralls.

1.2. PROCEDURE / METHOD TO BE EMPLOYED

This method statement describes in detail for rectifying the defect type for different types of repair as
follows:

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Type ID Type of Repair Proposed Material

Type-1 Blowhole on the surface of concrete AS PER APPROVED MATERIAL

Type-2 At Cracks on surface AS PER APPROVED MATERIAL

Type-3 At Bulging area after chipping AS PER APPROVED MATERIAL

Type-4 Chamfer / Edges broken AS PER APPROVED MATERIAL

Type-5 Insufficient Cover AS PER APPROVED MATERIAL

Type-6 Exposed Rebar AS PER APPROVED MATERIAL

Type-7 Slight Honeycomb AS PER APPROVED MATERIAL

Type-8 Honeycomb to rear of rebar AS PER APPROVED MATERIAL

Type-9 Small voids AS PER APPROVED MATERIAL

Type-10 Void through structure AS PER APPROVED MATERIAL

Other cases to be checked and agreed upon with the
Type-11 AS PER APPROVED MATERIAL
consultant

1.3. General Comments

1. CONTRACTOR has to maintain Concrete Defect Repair Log to ensure that only approved
materials shall be used on-site for agreed repair types, with CONTRACTOR and CLIENT
Representative.
2. The works shall be performed as mentioned in this procedure and the quality assurance
requirements shall be consistent with the relevant sections of the Quality Management System
Manual.
3. Manufacturer’s recommendation to be complied with at the site.
4. Work shall not proceed without formal approval by the Engineer.
5. Before commencement of the work, ascertain the nature and location of all existing services on-
site by a visual survey.
6. If any protection, rerouting, termination or removals of services are required for the smooth
progressing of work, it will be discussed and written approval will be obtained from Employer as
appropriate.

1.4. Substrate Preparation

1. Mark out the area requiring the chipping.
2. The perimeter of the area should be sawed cut with a grinder to a depth of 10mm and the edges
cut as neatly as possible keeping the sides square. Feather-edging is not permitted and a
minimum thickness of 10mm must be maintained over the whole repair area.

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3. Depth of chipping of bulged concrete shall be decided considering the alignment, structure
element’s size as per design and approval of the Engineer.
4. Chipping shall be performed using electrically operated concrete breaker of Hilti, Bosch, etc. with
the pointed chisel of the appropriate capacity. Heavy-duty machinery or jackhammers should not
be used to avoid damage to the structure element by excessive hammering. For removing a very
thin surface electrically operated scrabbling hammers may be used.
5. Chipping shall continue to achieve the required decided depth.
6. The substrate shall be prepared to a rough surface.
7. The prepared surface must be sound, dense, and free of all oil, grease loose and fractured
aggregate, or other contaminants that could impair adhesion.
8. Thoroughly saturate the surface of the concrete to provide a saturated surface dry condition. Any
surface water should be removed using an oil-free compressed air jet.

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