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1. EMPLOYER
NWSDB CENTRAL PROVINCE
SRI LANKA
NATIONAL WATER SUPPLY AND
DRAINAGE BOARD
MAIN CONTRACTOR
OTV
VEOLIA WATER TECHNOLOGIES
GREATER MATALE WATER SUPPLY SCHEME
SRI LANKA
METHOD STATEMENT FOR HONEYCOMBS REPAIRING
A Bharatha
REV /DATE/ PREPARED CHECKED APPROVED DESCRIPTION
Format :
A4
This document is the intellectual property of
the relevant issuer. It shall not be
reproduced, used or disclosed other than
with the document issuer’s acceptance.
For Employer Approval :
□ Approved □ Comment □ Rejected
Date:
Name:
Signature:
Page 1 of 23
Sub-Contractor
Document Reference :

2. GREATER MATALE WATER SUPPLY SCHEME
SRI LANKA
METHOD STATEMENT FOR HONEYCOMBS REPAIRING
Page: 2 of 10
Date: 16/12/2018
Rev: 1
TABLE OF CONTENTS
Section Description
1. PURPOSE
2. SCOPE
3. DEFINITIONS
4. REFERENCES
5. RESPONSIBILITIES
6. MATERIALS
6.1 Microcrete
6.2 Non-Shrink Cementitious Grout
6.3 Epoxy bonding agent
6.4 Silicon Sealant
7. MOBILIZATION OF WORKFORCE & EQUIPMENT
7.1 Construction Plant & Equipment
7.2 Manpower
8. WORKING METHODS / PROCEDURES
8.1 Surface Preparation
8.2 Identify the type ofhoneycombs
8.3 Formwork for the deep honeycombs
8.4 Mixing ofbinding agent
8.5 Mixing ofgrout
8.6 Placing of grout
8.7 Curing
9. INSPECTION, TESTING & QUALITY CONTROL
10. SAFETY & SECURITY
9.1 General Provisions
9.2 Safety Action Plan
11. ATTACHMENTS

3. GREATER MATALE WATER SUPPLY SCHEME
SRI LANKA
METHOD STATEMENT FOR HONEYCOMBS REPAIRING
Page: 3 of 10
Date: 16/12/2018
Rev: 1
1. PURPOSE
The purpose of this Method Statement is to create awareness of common tasks involved in repairing of
honeycombs and ensure the execution is in full compliance with Project Specifications & Standards,
Drawings and other related international Standards & Specifications including HSE requirements. This
Method Statement shall be communicated and be understood by all personnel associated with the task
before commencing the activity.
2. SCOPE
In general sub-contractor shall receive client approval for manufacturer of material, and shop drawings
prior to start repairing. Approved materials shall be verified upon received at site. honeycombs repairing
procedure shall be in accordance with this Method Statement.
There are two types to be repair
1. Shallow honeycombs (d < 50 mm, rebar not exposed)
2. Deep honeycombs ( d ≥ 50 mm, rebar exposed)
1. d <50 mm 2. d ≥ 50 mm

4. GREATER MATALE WATER SUPPLY SCHEME
SRI LANKA
METHOD STATEMENT FOR HONEYCOMBS REPAIRING
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Date: 16/12/2018
Rev: 1
3. DEFINITIONS
NWSDB : National Water Supply and Drainage Board
CONTRACTOR : OTV Veolia
SUB-CONTRACTOR : China Eleventh Chemical Construction Co. Ltd.( ELECO)
PROJECT : Greater Malate Water Supply Scheme
CMS : Construction Method Statement
QA / QC : Quality Assurance & Quality Control
HSE : Health Safety & Environment
PPE : Personnel Protective Equipment
RA : Risk Assessment
4. REFERENCES
- Specification for civil engineering works – NWSDB/SBD/Plant & Design – Build: Specification
- Material Technical Data sheet of non-shrink grout / Mapefill GP
- Material Technical Data sheet of X – Roc Epoxy Bond
- Material Technical Data sheet of X – Roc MicroCrete
- ITP & Check lists for grout works
5. RESPONSIBILITIES
- Responsibilities for ensuring that the steps in this procedure shall be carried out are specified at
relevant steps in the procedure:
 Site Manager
 Construction manager
 QA/QC Engineer
 Site Engineer
 HSE officer
 SK

5. GREATER MATALE WATER SUPPLY SCHEME
SRI LANKA
METHOD STATEMENT FOR HONEYCOMBS REPAIRING
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Date: 16/12/2018
Rev: 1
6. MATERIALS
All Material listed below shall be approved and inspected by NWSDB prior to use at site.
6.1 MICROCRETE
-X-Roc MicroCrete is a single component, shrinkage compensated, fluid micro concrete
manufactured from selected cements, aggregates and additives. It can be used at a wide range
of workability’s. When used as a fluid micro concrete it is self-compacting. It has exceptional
resistance to carbonation, chloride ingress, sulphate attack and freeze thaw attack.
-Physical Properties
Compressive strength Mpa(psi) 70(101150) [28 days]
Initial set < 1 hour at 25°C
Final set < 24 hours at 25°C
Initial expansion < 4% within 24 hours
Expansion(3-28 days) < 0.4%
6.2 NON-SHRINK CEMENTITIOUS GROUT
-Mapefill GP is a pre-blended powdered grout based on high strength cement, 1mm diameter graded
aggregates and special additives with an expansive agent
-Physical Properties
Compressive strength Mpa > 8
Initial set 7 hrs.
Final set 8 hrs.
Volume expansion (ASTM
C827)
1%
Color Grey
6.3 EPOXY BONDING AGENT (PRIMER)
- X-Roc EpoxyBond is an epoxy bonding agent used to bond fresh concrete to hardened
concrete or steel. It can also be used to protect reinforcing steel from corrosion, and as an
anti-chloride barrier and primer for concrete repair.

6. GREATER MATALE WATER SUPPLY SCHEME
SRI LANKA
METHOD STATEMENT FOR HONEYCOMBS REPAIRING
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Date: 16/12/2018
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-Physical Properties
Compressive strength Mpa 60
Application temperature 5 - 35°C
Pot life
6 hrs. - 20°C
3 hrs. - 30°C
Maximum overlay time
24 hrs. - 20°C
12 hrs. - 30°C
6.4 SILICON SEALANT
7. MOBILIZATION OF WORKFORCE AND EQUIPMENT
7.1 CONSTRUCTION PLANT & EQUIPMENT
 Air Compressor
 Grinder
 Chipping hammer
 Chisel
 Carpentry / Masonry Tools
 Wire brush
7.2 MAN POWER
 Site / QC Engineer
 Foremen
 Carpenters
 Masons
 Helpers

7. GREATER MATALE WATER SUPPLY SCHEME
SRI LANKA
METHOD STATEMENT FOR HONEYCOMBS REPAIRING
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Date: 16/12/2018
Rev: 1
8. WORKING METHODS / PROCEDURES
8.1 Surface Preparation
Visible separation shall be identified and marked. The defect shall be grooved “V” shape by
routing to a minimum depth of 10 mm and if found loose concrete, continued up to sound
concrete. Prepared surfaces must be clean, sound, and free from dust and shutter release
oils after chipping. Concrete surfaces must be thoroughly pre-wetted but excess surface water
(free water) must be removed prior to placing the grout. Always ensure that the shutters are
watertight and sealed to prevent suction of water from the product.
8.2 Identify the type of honeycomb
- After the preparation of surface, if the depth of concrete hole below 50mm. (Figure: 01)
It was shallow honeycomb. For this type grouting
 X – Roc Epoxy Bonding agent
 Mapefill GP non shrink grout
these two materials were used. Mixed grout can directly apply to the cleaned surface
using spatula or mason trowel.
- If the depth above the 50mm and exposed rebar, (Figure: 02) it was deep honeycomb.
For these type of grouting.
 X – Roc Epoxy Bonding agent
 X – Roc Microcrete
These two materials were used. Other than that this type of grouting may need formwork
with the chute.

8. GREATER MATALE WATER SUPPLY SCHEME
SRI LANKA
METHOD STATEMENT FOR HONEYCOMBS REPAIRING
Page: 8 of 10
Date: 16/12/2018
Rev: 1
8.3 Formwork for the deep honeycomb holes
- The wall shall equipped with chute to
facilitate proper pouring of grout as shown
in the figure
- Make sure the water tightness of the
formwork before the pouring of grout, any
spaces gaps or holes shall be sealed with
silicon sealant.
8.4 Mixing of binding agent
The hardener ‘Part B’ into the base ‘Part A’ and mix using a slow speed drill (350rpm) with an Mixer
Paddle for 3 minutes, or until both components have fully dispersed and are uniform in colour. Be
sure to rotate the mixer throughout the drum. Mix only full packs.
8.5 Mixing of grout
1. Mapefill GP grout
Pour 80% of the required mixing water into a suitable rust free container and slowly add a 25 kg
bag of MAPEFILL GP. Add the remaining water to achieve the desired mortar consistency (water
ratios are 4 litres for ‘pumpable’ consistency; 4.5 for ‘pourable’ consistency). Mix for 1-2 minutes
with a low speed mechanical mixer, then check that the mixture is well blended by removing any
powder left on the sides of the mixer. Re-mix for another 2-3 minutes. Larger quantities can be
mixed in a grout mixer.
The mix obtained remains workable for about 1 hour at +20°C. Application: Pour the MAPEFILL
GP mix from one side only into the prepared cavity or shutter in a continual flow in order to prevent
the entrapment of air bubbles.
Consumption: 13.5 litres per 25 kg bag.
2. X-Roc MicroCrete grout
Add X-Roc MicroCrete to water and mix for at least five minutes using an X-Calibur approved forced
action mechanical mixer.

9. GREATER MATALE WATER SUPPLY SCHEME
SRI LANKA
METHOD STATEMENT FOR HONEYCOMBS REPAIRING
Page: 9 of 10
Date: 16/12/2018
Rev: 1
8.6 Placing of grout
1. For the shallow honeycomb
- After cleaned the grouting area, apply single coat of epoxy bonding agent by brush, ensure
uniform coating is achieved and no ponding occurs
- Pour Mapefill GP from one side only in a continual flow encouraging the discharge of
air bubbles using spatula or mason trowel.
2. For the deep honeycombs
- After cleaned the grouting area, apply single coat of epoxy bonding agent by brush, ensure
uniform coating is achieved and no ponding occurs
- Mixed grout should be poured into the cavity at one point only to avoid entrapping air with the
use of chute for pointing grout
- The formwork should include drainage outlets for pre-soaking and, if beneath a soffit,
provision for air release
- Immediately after mixing, pump or pour the X-Roc MicroCrete into the formwork. No
vibration is required when X-Roc MicroCrete is used in a fluid condition
-
8.7 Curing
Grout surfaces should be protected from wind or high temperature, which can cause rapid
drying. Cover the surface with damp sacks (hessian). Do not allow the sacks to dry out.
Curing to be continued for minimum 3 days. Leave formwork in place until the compressive
strength has reached 20 MPa. WB or water soak/ polythene wrap. Curing to be continued
for minimum 3 days.

10. GREATER MATALE WATER SUPPLY SCHEME
SRI LANKA
METHOD STATEMENT FOR HONEYCOMBS REPAIRING
Page: 10 of 10
Date: 16/12/2018
Rev: 1
9. INSPECTION, TESTING & QUALITY CONTROL (QA/ QC)
- Inspection shall be accordance with approved ITP & Checklist
- Temperature shall be maintained at manufacture recommended limits, ice or chilled water shall
be need as necessary
- Sample of grout shall be taken, size 100mm x 100mm molds to verify the compressive strength
of grout
- An RFI shall be raised 24 hrs. in advance prior to executing the activity
10. SAFETY& SECURITY
10.1 General Provisions
Protection and safety shall be in accordance with Project Safety Manual and ELECO Safety Manual
approved by OTV / NWSDB. ELECO shall provide temporary fence, barricades, lights and any other
preventive measure according to the approved Safety Manual for personnel safety during
construction. Directions given in manufacture’s MSDS shall strictly followed.
10.2 Safety Action Plan
Where applicable, Permit to Work will be obtained prior to starting the works.
Workforce and supervisors shall be aware of common risks that could be encountered during the
activities associated with masonry works.
Necessary warnings, suitable barricades, proper access, shall be established.
PPE for workers are mandatory.
Site Engineer and General Foreman shall arrange all necessarysafety requirements at site and they
will ensure workplace is safe.
Safety Inspector shall ensure that all safety measures are implemented at workplace and
workers/staff are aware of safety risks.
11. ATTACHMENT
Annex 1: Risk Assessment