Operational Instruction No. 02 / 2011 Particular Specifications For Concrete Repair

OPERATIONAL INSTRUCTION
No. 02 / 2011
Particular Specifications for Concrete Repair
Distribution
To all Controlled Document Holders with circulation to all Senior Professional, Professional
Officers and Site Supervisory Staff
Workstage
2, 3, 4, 5 and 6
1.
Revision No.
Effect on Existing Instructions

This instruction is a new document and has no effect on existing instructions.
2.
Effective Date
This instruction takes immediate effect.
3.
Objective
This is to promulgate the following two particular specifications (PSs) for concrete repair works: -
4.
Particular Specification for Concrete Repair by Patch Repair

Particular Specification for Concrete Repair by Chemical Injection
Background
(a)
Patch repair and chemical injection are widely used for concrete repair in both new works and
maintenance projects. To reinforce the General Specification on the technical requirements on these
repair works, the two PSs were prepared for incorporation in the works contract.
(b)
The PSs define the following technical requirements for the concrete repair works: (i)
(ii)
(iii)
(iv)
(v)
5.
6.
Submissions of repair proposal

Materials
Workmanship
Testing
Record of repairs
Application
(a)
The PSs at Annexes 1 and 2 have been endorsed by Technical Information Committee (TIC).
(b)
The PSs provide standard provisions to be used consistently within the Department and shall be
incorporated in the works contract if concrete repair works are required. Project officers may add,
delete or amend the PSs to suit the speciality of their individual projects, but any amendments must be
carefully considered with full justification. The amendments shall also be verified and approved by the
Senior and Chief officers respectively before incorporation into the works contract. In case of technical
issues, CSE/2 may be consulted.
Attachments
Annex 1 -
Annex 2 -
Architectural Services Department

D/QA.170 Operational Instruction 02/11
Page OI 02.11
First Issue Date - 07 : 11 : 2011

Current Issue Date - 07 : 11 : 2011
No. 02 / 2011
ANNEX 1
1.
General
1.1
Repair of Concrete
The Contractor shall carry out patch repairs to concrete with all necessary labour and materials in accordance
with the General Specification for Building (GS) issued by the Architectural Services Department, the
drawings and this Particular Specification (PS).
1.2
Submissions
Before the commencement of the repair works, the Contractor shall submit the following details to the SO for
approval:
(1)
method statement supported by drawings showing different phases of repair works and details of the
Temporary Works to be employed;
(2)
the name and generic system of the proposed materials (including primer, bond coat, mortar, curing
compound, admixtures, etc. hereinafter referred to as the Repair Mortar System (RMS)), in respect of
each class of repair mortar under the Contract. The following information shall be included in the
proposals:
(a)
mix proportion,
(b)
cement content, polymer content, water/cement ratio and aggregate/cement ratio of repair
mortar,
(c)
source of aggregate, cement and polymer,
(d)
results of all the tests as outlined in Clauses 4.1, 4.2 and 4.3 of this PS, and
(e)
application procedures including mixing procedures, substrate preparation, rust cleaning,
application of primer and bond coat, repair mortar application and curing regime;
(3)
if proprietary RMS is used, the product details with relevant test data, details of the repair work, proven
track records of the application in a climate similar to Hong Kong substantiating the proposed RMS
compliance with this PS should be submitted. Information (a) to (d) above is not required;
(4)
name and address of the supplier and manufacturer of the repair materials;
(5)
product information sheets showing compliance with the material requirements of this PS with current
supporting test certificates;
If in the opinion of the SO the RMS proposed by the Contractor does not comply with this PS, the SO may
reject the RMS immediately without any Field Trial Tests as detailed in Clause 4.4 of this PS. The Contractor
shall forthwith submit details of another RMS for approval.
All approved proprietary materials shall be used in accordance with the manufacturer's specifications and
recommendations.
2.
Materials
2.1
Reinforcement Primer
(a)
Cement based reinforcement primers

Cement based primers shall be approved polymer modified cement based corrosion resistant primers.

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No. 02 / 2011
ANNEX 1
(Continued)
(b)
Epoxy based reinforcement primers

Epoxy based primers shall be approved two-component epoxy resin supplied in pre-weighed quantities.
The primer shall have a pot life suitable for the application. It shall be used before the expiry of shelf
life and pot life.
Where zinc rich primers are required they shall contain zinc dust as the pigment in a two-component
epoxy resin binder.
The primer shall be compatible to the approved proprietary repair mortar and bond coat.
2.2
Bond Coats
(a)
Bond coat (cement based)

Cement based bond coat shall be an approved blend of cementitious materials incorporating a polymer
emulsion. The bond coat shall be cement based unless directed otherwise by the SO.
(b)
Bond coat (epoxy based)

Epoxy based bond coat shall be an approved two-component material based on epoxy resin. The bond
coat shall be supplied in pre-weighed quantities and shall be used before the expiry of shelf life and pot
life. It shall have a pot life suitable for the application.
The bond coat shall be compatible to the approved proprietary repair mortar.
2.3
2.4
Cement for Mortar

(1)
Cement, unless otherwise specified, shall be ordinary Portland cement complying with BSEN 1971:2000.
(2)
The cement and its delivery, storage and testing it shall comply with Section 6 of the GS.
Sand for Mortar

Sand shall consist of crushed rock or clean sand complying with Section 6 of the GS.
The chloride content of the sand, expressed as chloride ion content, shall not exceed 0.1 by weight of dry
sand.
Sand shall be suitable for the specified mortar mix.
Sand shall be stored in an approved manner to avoid contamination and to prevent moisture attack.
2.5
Water for Mortar

Water for mortar shall comply with Section 6 of the GS.
2.6
Reinforcement
Dowel bars and replacement reinforcement as required shall be deformed bars and shall comply in all aspects
with Construction Standard CS2: 1995.
2.7
Polymer
(1)
Polymer for use in primers, bond coats or mortars shall be based on one of the following:(i)
styrene butadiene rubber (SBR);
(ii)
acrylic (acrylic styrene copolymer (ASC);
(iii) polyacrylate copolymer (PAC).

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ANNEX 1
(Continued)
2.8
(2)
Polymer shall have a shelf life suitable for shipment, storage and use.
(3)
Polymer shall contain an antioxidant agent and an antifoaming agent. This requirement may be waived
if the Contractor can produce the results of laboratory tests and evidence of previous applications to
show that they are not necessary for a particular brand.
Cement Mortar
Cement mortar shall be a mixture of cement, aggregate and water in approved proportions.
aggregate/cement ratio shall be not less than 3:1 and not greater than 4.5:1.
2.9
The
Polymer Modified Mortar

(1)
Polymer modified mortar shall be a mixture of cement, aggregate, water, polymer and admixtures
(where approved) in approved proportions. The mortar shall have the following properties and
characteristics and be either Prebagged or Site Batched.
Properties
Compressive strength at 28 days in MPa
Minimum tensile strength at 7 days in MPa
Elastic modulus at 28 days in kN/mm2
Minimum bond strength at 7 days in MPa
Cracking during the Coutinho ring test at 7
days (note)
Minimum figg air permeability in seconds
(note)
Class 40
30-60
2.0
15-25
2.0
0
Class 25
20-40
1.5
9-15
1.5
0
200
150
[Note: Coutinho ring test and figg air permeability are described in Clause 4.3 of this PS.]
Polymer modified mortar shall also have appropriate workability and air content. Where high-build
mortar is used, the mortar shall be suitable for applying overhead in thickness of not less than 40 mm.
Where chloride resistant mortar is specified, the chloride diffusion rate shall not more than 510-14m2/s.
(2)
Prebagged polymer modified mortar

The prebagged material shall be a proprietary formulation incorporating cementitious materials,
aggregates and a polymer emulsion.
(3)
Site batched polymer modified mortar

Polymer for polymer modified mortar shall be added in the following minimum quantities unless the
manufacturer recommends otherwise: -
Polymer
Cement : Polymer ratio (by weight)
Styrene Butadiene Rubber (SBR)
12 : 1
Acrylic Styrene Copolymer (ASC)/

Polyacrylate Copolymer (PAC)
20 : 1
Note: The weight of polymer shall not exceed a tolerance of 5%.

The aggregate/cement ratio (by weight) shall not exceed 2.5:1, unless otherwise directed in the RMS or
approved by the SO.

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ANNEX 1
(Continued)
2.10
Shrink Resistant Mortar

Shrink resistant mortar shall be a mixture of cement, aggregate, water and a shrink resistant admixture in
approved proportions used as a dry pack material. The aggregate/cement ratio shall be not less than 3:1 and
not greater than 4.5:1. The mortar shall have the following properties: Properties
Minimum compressive strength at 28 days in MPa
Elastic modulus at 28 days in kN/mm2
Minimum bond strength at 7 days in MPa
Range of unrestrained plastic expansion (ASTM C82701(a)) in percentage
Maximum drying shrinkage at 28 days in mircostrain
2.11
Required Values
40
15-25
2.5
1-4
50
Admixtures
Admixtures for use in any type of mortar may be approved if there are specific benefits to the fresh mortar and
provided that no adverse effects to the hardened mortar shall be made all as in the opinion of the SO. Such
benefits may include plasticity, adhesion to substrate, cohesion or alteration to setting time. The appropriate
admixtures shall comply with the requirements of BS 4887 Pt. 2: 1987, BS 5075 Pt. 1: 1982, BS 5075 Pt. 3:
1985 or other appropriate standards.
2.12
2.13
Curing Compounds
(1)
Curing compounds shall, when applied, become stable and impervious to evaporation of water from
the surface of the mortar within 60 minutes after application. They shall not react chemically with the
mortar to be cured and shall not crack, peel or disintegrate within three weeks after application.
(2)
Curing compounds shall be applied strictly in accordance with the manufacturers instructions and
have a minimum curing efficiency of 75 per cent.
(3)
Curing compounds shall not be used when a further layer of mortar is to be applied or when they may
affect the adhesion of subsequent coatings or finishes.
Dowel Bar Grout

(1)
Grout for dowel bar installation shall be an approved product of epoxy resin, polyesters, or
cementitious based material. The grout shall have non-shrink properties.
(2)
Grout based on epoxy resin or polyesters shall undergo its initial set in less than 2 hours and shall be
thixotropic with a high viscosity at the time of application for all applications except downhand holes.
Only cementitious grout shall be used in fire-prone areas. Cementitious grout shall be one-part
prebagged and chloride free cementitious material.
The Contractor shall submit full details of the proposed dowel bar grout as required under Clause 3.11 of this
PS. Upon instruction of the SO, the Contractor shall carry out a site trial at his own cost, in order to
demonstrate to the satisfaction of the SO that the workability achieved by the grout mix and the proposed
method of installation are suitable for the proper installation of dowel bar prior to the approval of the proposed
material being given by the SO.
2.14
Control Record of Repair Mortar Materials

(1)
Upon request by the SO, the Contractor shall submit to the SO the following documents provided by
the RMS manufacturer for any batch of repair mortar materials:

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ANNEX 1
(Continued)
(a)
(b)
(c)
(2)
3.
production batch record for such batch;

manufacturers factory quality control record stating that the materials supplied have
satisfactorily passed their own tests; and
test certificates by an approved local independent testing laboratory showing that the materials
supplied comply with the requirements of this PS
The Contractor shall allow sufficient time for testing of the materials by the manufacturer in an
approved local independent testing laboratory and shall not use any such materials without the
acceptance of the above documents by the SO.
Workmanship
3.1
3.2
Identification of Areas to be Repaired

(1)
Areas to be repaired shall be identified by the SO. Where required, the Contractor shall mark out the
identified areas of spalled or cracked concrete for repair, for the agreement of the SO, prior to the
commencement of the repair work.
(2)
The Contractor shall inform the SO when further areas of weak or defective concrete are revealed
during the progress of work.
Samples for Standard of Breakout and Cleaning

Before commencement of the patching repairs, one of the defective concrete areas selected by the SO shall be
broken out with the defective concrete removed, and both the underlying sound concrete and reinforcement
shall be prepared to the specified standard. This area shall form a sample for all future patching repairs which
are to be completed as part of the Works.
3.3
Breaking Out and Preparation of Concrete Substrate

(1)
The defective concrete within the identified area shall be hacked back, with light mechanical plant or a
hammer and chiseled to the standard shown in the table below to leave a gap of between 15 mm and 25
mm behind the reinforcement. Where cementitious repair materials are proposed the concrete shall be
hacked back to allow a minimum depth of 10 mm of repair material.
(2)
The perimeter of each broken out area shall be cut to a nominal depth of 12 mm using a disc cutter or
similar. The Contractor shall ensure that no reinforcement is damaged and the disc-cut surface shall be
roughened prior to reinstatement. Feather edges to repair patches shall not be permitted.
(3)
The SO shall be informed in advance when the cleaning of a displaced reinforcing bar will involve the
removal of more concrete than the extent shown on the drawings submitted by the Contractor and
approved by the SO.
(4)
The extent of breakout of defective concrete areas shall be one of the options shown in the table below
as directed by the SO.

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ANNEX 1
(Continued)
Standard of breakout
Option
3.4
Extent of breakout
Cut back all loose or severely cracked concrete until all remaining concrete
appears solidly bonded together and cannot be prised off by hand.
Cut back all loose, visibly cracked or delaminated concrete and any concrete
attached to heavily corroded reinforcement
Cut back concrete until the reinforcement exposed is no more corroded than light
coloured light rust
Cut back concrete until the reinforcement exposed is uncorroded and the
surrounding concrete is alkaline as indicated by an alcoholic solution of
phenolphthalein used in accordance with the test method of BS EN 14630: 2006
Cut back concrete until the reinforcement exposed is not corroded and all
concrete within 20 mm of the bar is not contaminated by chlorides. The chloride
ion content by weight of dust samples shall be determined in accordance with BS
EN 14629: 2007
(5)
Breakout shall not exceed the identified area by more than 1 square metre or by more than 50% of the
identified area (whichever is the smaller) without the approval of the SO.
(6)
Damage to existing reinforcement (especially where embedded in existing concrete) and to adjacent
elements of the building shall be minimized. The exposed concrete surfaces against which mortar or
concrete is to be placed shall be roughened to expose the aggregate and have all loose material
removed.
Preparation of Reinforcement
(1)
The exposed lengths of existing steel which are to be retained shall be cleaned to the standard shown in
the table below as directed in the RMS or by the SO.
Option
Cleaning Method
Standard
Manual wire brushing and

scraping
Remove loose mill scale and rust
Machine brushing, grinding etc.
Swedish Standard SIS 055900 St 2
Machine brushing, grinding etc.
Swedish Standard SIS 055900 St 3
Blast cleaning
Swedish Standard SIS 055900 Sa 2
Care shall be taken to clean the far side of the bar.

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ANNEX 1
(Continued)
(2)
If the reinforcement is not sound, then the reinforcement shall be replaced with replacement steel by
lapping to existing sound steel at both ends. If approved by SO, welding by single flare V-groove weld
is also acceptable.
Lap length and weld length at each end shall be as follows: Diameter of Bar
(mm)
Length of Weld (mm) 1
Length of Lapping (mm)
8
10
12
16
20
25
60
70
80
100
120
140
360
450
540
720
900
1150
Note: 1The minimum lap length shall then be equal to the length of weld plus 25mm.
3.5
(3)
Replacement reinforcement shall be cleaned to the same standard as specified for remaining
reinforcement unless otherwise directed in the RMS or by the SO.
(4)
All weld slag shall be removed by hammer and chisel.
(5)
After breaking out and preparation of concrete and reinforcement, the reinforcement and concrete
substrate shall be brushed with a dry brush to remove all loose dust and dirt.
Notice for Inspection of Works

Immediately after the completion of breaking out, preparation of concrete substrate and reinforcement, the
Contractor shall give notice within a reasonable advance period of time to the SO for inspection and
examination before proceeding to subsequent repair works.
3.6
Prime Coat for Reinforcement

(1)
The reinforcement shall be primed as soon as possible after cleaning. The reinforcement shall be free
from moisture, rust, oil and other contamination before priming. If the preparation work does not
conform to such requirement, then cleaning shall be repeated at the Contractor's own cost.
(2)
Reinforcement shall be primed with a polymer modified cement based primer as shown below (see
Option A). The use of other primers is subject to the approval of the SO (see Option B and C). The
primer shall be applied and cured in strict accordance with the manufacturer's instructions. No solvents
or thinners shall be used unless specifically permitted by the manufacturer.
Option A
Polymer modified cement based reinforcement primer
Unless otherwise recommended by the manufacturer, the primer shall be applied in one 2 mm thick
layer and allowed to cure for 3 hours or as specified by the manufacturer and approved by the SO
before application of the bond coat.
Option B
Zinc rich primer
Unless otherwise recommended by the manufacturer the primer shall be applied in one high build coat
to give a minimum dry film thickness of 125 microns. The primer shall be allowed to cure for 3 hours
or as specified by the SO before application of the bond coat.

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ANNEX 1
(Continued)
Option C
Epoxy reinforcement primer
The primer shall be applied in two coats at the rate recommended by the manufacturer. The second
coat shall be thoroughly blinded with quartz sand to ensure a physical key for the subsequent repair.
The quartz sand blinding shall be kiln dried sand of grain size between 0.4 mm and 0.7 mm.
(3)
3.7
Care shall be taken to ensure that the primer is fully applied on the back of the reinforcement. Any
spillage to the concrete substrate that may adversely affect the bond of the repair material to the
substrate concrete shall be removed.
Bond Coat for Concrete Substrate and Reinforcement

A bond coat shall be applied to the concrete substrate and the primed reinforcement bars as soon as possible
after the reinforcement primer has cured sufficiently as specified in the manufacturer's instructions. 100%
coverage shall be achieved but care shall be taken to avoid covering too large an area at one time to ensure
that the repair material is applied during the open time of the bond coat.
The bond coat shall be polymer modified cement based as shown below (see Option A) and the use of other
bond coats is subject to the approval of the SO (Option B).
Option A
Polymer modified cement based bond coat
The concrete surfaces to which the bond coat is to be applied shall be thoroughly wetted down for about 20
minutes to achieve saturation. The bond coat shall be applied by brush, worked into the exposed concrete
surface and painted onto the reinforcement. The subsequent repair material shall be applied while the bond
coat is still wet or tacky. If the repair material is not so applied then for SBR modified bond coats, the coat
shall be removed and a new coat shall be applied. For acrylic modified bond coats, a second coat shall be
applied.
Option B
Epoxy based bond coat
The concrete surface shall be thoroughly dry, clean and dust free prior to application. The subsequent repair
material shall be applied during the open time of the bond coat. If the repair material is not so applied then
another coat of at least 50% coverage shall be applied, not later than 24 hours after application of the first
coat, at the Contractors own cost. Otherwise the bond coat shall be removed and a new coat applied.
3.8
3.9
Batching and Mixing of Mortar

(1)
Dry mix ingredients for polymer modified mortar shall be weight-batched. The weight batcher shall be
accurate to within 5%. Liquid ingredients shall be volume batched or separately weight batched.
(2)
Mixing shall be carried out in an approved mechanical pan mixer with means to provide folding and
tumbling of the constituent materials for at least two minutes in accordance with the manufacturers
instructions such that all constituents shall be uniformly dispersed throughout the mixture.
(3)
All proprietary materials shall remain in the original packaging until the material is placed in the mixer
immediately prior to application. No omission, addition or alteration shall be made to the material
unless specifically permitted by the manufacturer. Any materials that have become contaminated in
any way shall not be used for the works and must be disposed of off-site.
Application of Mortar

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ANNEX 1
(Continued)
(1)
Repair mortar shall be:Option A

Option B
Option C
Option D
Cement mortar
Polymer modified mortar Class 40 or Class 25
High build polymer modified mortar Class 40 or Class 25
Shrink resistant mortar
The repair mortar shall be polymer modified mortar Class 25 unless directed by the SO.
3.10
(2)
Repair mortar shall be placed so as to produce a dense homogeneous mass and to avoid sags. Where
voids are found in the repair mortar, none of them shall have:
(a)
for void immediately adjacent to the reinforcement :
(i)
any linear dimension greater than 3 mm measured perpendicular from the reinforcement,
and
(ii)
any linear dimension greater than 6 mm measured along or around the reinforcement
provided that primer has been properly applied, and
(iii) the product of all 3 linear dimensions greater than 27 mm3 ;
(b)
for void at any other locations :
(i)
any linear dimension greater than 20 mm, and
(ii)
the product of any 2 linear dimensions greater than 200 mm2, and
(iii) the product of all 3 linear dimensions greater than 800 mm3;
(3)
Each repair mortar coat shall be placed in thickness not less than 10 mm and not greater than 20 mm
unless otherwise recommended by the manufacturer and approved by the SO. Particular care shall be
taken to avoid voids behind the reinforcement.
(4)
Where thickness of more than 20mm is required and unless high build mortar is used, the mortar shall
be built up in layers of 20mm or less (or as approved). A period of 18 to 24 hours or such time as is
recommended by the manufacturer of the polymer additive and approved by the SO shall be left
between applications. Inner layers shall be scored to provide a mechanical key to the next layers and
shall be saturated with water (unless the mortar is specified by the manufacturer as being waterproof).
Where the mortar is applied in several layers and where outer layers extend onto substrate concrete, the
concrete shall have a bond coat as specified in Clause 3.7 above.
(5)
Where mortar with a SBR polymer is used and a total thickness of greater than 100mm is required, at
least 3 days shall elapse before the buildup exceeds 100mm.
(6)
Where practicable, soffit board or side form shall be used for proposed application of the mortar, and
the cost of the boards is deemed to be absorbed in the contract rate. Cover to reinforcement of at least
10 mm shall be provided. Displaced bars shall be tied back to achieve the specified cover.
(7)
The bond between the mortar and substrate concrete aided by the bond coat shall be sufficiently strong
so that the fracture, if pull-off test is performed, shall be in the substrate concrete and not in the joint
with the mortar.
Protection against Risks

Those areas with safety risks consequencing from unfinished repair works not having been or not able to be
immediately removed shall be cordoned off, and appropriate warming sign(s) shall be displayed in the
vicinity. Props, shoring or other measures shall be installed as directed by the SO.
3.11
Installation of Dowel Bar and Grouting

(1)
Holes for the installations of dowel bars into existing concrete shall be carefully drilled. The hole shall
be air blown by a pneumatic device to clean out debris and dust.

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ANNEX 1
(Continued)
3.12
(2)
The dowel bar grout shall be placed at the deep end of the hole in order to avoid the entrapment of air.
(3)
The dowel bar shall be inserted into the grouted hole to the grouted length required. If flow is not
displaced out from the hole then the dowel shall be removed and further grout shall be inserted in the
hole. The installed bar shall be given a turn and then turned back to original position and left
undisturbed for 2 hours or as recommended by the manufacturer of the grout and approved by the SO.
During curing no further grout shall flow out from the hole.
Storage of Materials
All repair materials including sand and cement shall be stored in a proper and approved manner to avoid
contamination, wetness, obstruction and overloading to the building structure. Proprietary materials shall be
stored strictly in accordance with the recommendations and instructions of the manufacturer.
3.13
Curing of Mortar
The repair shall be properly cured by a method as recommended by the manufacturer of the approved RMS or
as approved by the SO.
3.14
Make Good of Repaired Surfaces

Unless otherwise directed by the SO, the Contractor shall make good all repaired surfaces with render or tiled
finish to match existing.
4.
Testing
4.1
General
Unless otherwise approved or specified elsewhere, the Contractor shall employ an approved independent
testing laboratory accredited by the Hong Kong Laboratory Accreditation Scheme (HOKLAS) (the Testing
Laboratory) with the prior approval of the SO to carry out all the tests required in this PS. All test reports
shall be submitted to the SO directly from the Testing Laboratory.
4.2
4.3
Testing of Sand for Mortar

(1)
Sand for mortar shall be sampled in accordance with BS 812: Pt 102: 1989.
(2)
The moisture content of the sand shall be determined in accordance with BS 812: Pt 109: 1990.
(3)
The particle size distribution of the sand shall be determined by dry sieving in accordance with BS 812:
Pt 103 Section 103.1: 1985. The silt, clay and cut fraction of the sand shall be determined by the
sedimentation method in accordance with BS 812: Pt 103 Section 103.2: 1989.
(4)
The water-soluble chloride content of the sand shall be determined in accordance with BS 812: Pt 117:
1988.
Testing for Characteristics of Repair Mortar System

(1)
The tests as detailed in this sub-Clause shall not be required for prebagged polymer modified mortar,
unless otherwise specifically ordered by the SO.

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ANNEX 1
(Continued)
(2)
For site batched polymer modified mortar, if the Contractor submits no test data or in the opinion of the
SO insufficient data to show its compliance with the characteristics as specified in Clause 2.9 above,
the SO may require trials to be carried out on specimens of polymer modified mortar prepared in
accordance with BS 6319: Pt 1: 1983 except that materials moulds and specimens shall be kept at 26oC
1oC and at a relative humidity of 55% 2%. Unless otherwise specified, specimens shall be left in
moulds and covered with polythene for 3 days before demoulding. The following tests shall be
required, unless otherwise agreed by the SO:
(a)
The compressive strength of the mortar specimens shall be determined in accordance with BS
6319: Pt 2: 1983 except that the cube sizes shall be 70 mm. The flexural strength of the mortar
specimens shall be determined in accordance with BS 6319: Pt 3: 1990. The tensile strength of
the mortar specimens shall be determined in accordance with BS 6319: Pt 7: 1985.
(b)
The bond strength of the polymer modified mortar shall be determined using a modification to
the tensile strength test method to BS 6319: Pt 7: 1985 as described below. A high strength
repair mortar briquette specimen shall be made and cured for 28 days. The mortar shall have a
tensile strength in excess of 4 N/mm2 when tested at 28 days to BS 6319: Pt 7: 1985. One half
of the broken briquette shall be returned to the mould and the remaining section of the mould
shall be filled with the repair mortar under test. The repaired briquette shall be cured at a
temperature of 26oC 1oC and 55% 2% relative humidity for 7 days and then tested as
described in BS 6319: Pt 7: 1985. The failure mode and bond strength shall be recorded.
(c)
The modulus of elasticity of mortar specimens shall be determined in accordance with BS 6319:
Pt 6: 1990 and shall be reported as the secant modulus as defined in that standard.
(d)
Shrinkage cracking of polymer modified mortar shall be tested by the Coutinho ring test as
described below. The mould for this test shall be formed from steel to provide an annular
specimen with an inner diameter of 115 mm 0.1 mm. The mortar shall be prepared and mixed
in accordance with the specification and compacted within the mould. Materials, moulds and
specimens shall be kept at a temperature of 26oC 1oC and a relative humidity of 55% 2%.
After 24 hours the outer mould ring shall be removed from the hardened mortar specimen and
the specimen with the inner ring still in place shall be returned to the conditioning environment.
The mortar specimen shall be examined daily until 7 days after casting and then at 14, 21 and 28
days, and any cracking shall be reported.
(e)
Where shrink resistant mortar is specified, the early volume change of shrink resistant mortar
shall be determined by testing in accordance with ASTM Standards C827-01(a) for checking
compliance with limits given in Clause 2.10 of this PS.
(f)
The permeability of the polymer modified mortar shall be determined by the modified Figg air
permeability test described in Cather, R.B., Figg, J.W., Marsden, A.F., and OBrien, T.P.
(1984), Improvements to the Figg method for determining the air permeability of concrete, in
Magazine of Concrete Research 36(129) pp.241-5. The specimen shall be of 100 mm cast cube
conditioned at a temperature of 26oC 1oC and 55% 2% relative humidity and demoulded at
72 hours after casting and kept in the same environment for a further 18 days. The permeability
test shall be carried out after conditioning at 50oC for 14 days.

Page OI 02.11.A.1(xi)

No. 02 / 2011
ANNEX 1
(Continued)
Guidance Note:
The permeability test shall be as below:10mm diameter hole shall be drilled by using a slow-speed hammer drill, preferably fitted with
a depth-stop. The test hole shall be cleaned-out with a stiff brush with an air-line or blowingball to remove drilling dust. It is important for the subsequent seal that the cavity wall should be
thoroughly cleaned. The open-cell foam plastics backing shall be cut from sheet material by
using a cork-borer. It is pressed into the test cavity to the correct depth with a suitably marked
piece of dowel rod. The catalyzed silicon rubber is then careful extruded into the hole by means
of a disposable syringe. When the silicone rubber has set, the hypodermic needle is pressed
through the rubber seal until it penetrates into the test cavity. It shall be inserted a length of
spring-steel wire into the needle before pushing the needle through the silicone rubber. The
bore shall be rod to ensure that no rubber particles have blocked the fine tube. The test
apparatus is then joined to the hypodermic needle via Luer-taper connectors and the assembly
evacuated to rather more than 55kN/m2 below atmospheric pressure. The diaphragm vacuum
valve is then closed. The pressure reading on the digital manometer is monitored and timing is
started when a reading of exactly- 55.0kN/m2 is obtained. The leakage rate of the apparatus
shall be determined by using a hypodermic needle inserted into a piece of set silicone rubber.
The leakage rate shall be at least an order of magnitude less than the measurement values.
For details of the permeability test, the SO can refer to Cather, R.B., Figg, J.W., Marsden, A.F.,
and OBrien, T.P. (1984), Improvements to the Figg method for determining the air
permeability of concrete, in Magazine of Concrete Research 36(129) pp.241-5.
4.4
Field Trial Tests of the Proposed Repair Mortar System

(1)
After the submission of the proposed RMS and upon the instruction of the SO, the Contractor shall
prepare a trial mix on site using the labour, plant and materials intended for the work and carry out an
overhead repair of size 600 mm x 500 mm with approximate depth of patch of 40 mm. The trial repair
shall demonstrate to the SO the following: (a)
the Contractors competence with the use of the proposed RMS;
(b)
the effectiveness of the quality control procedures proposed for the whole repair process which
include substrate preparation, rust cleansing, primer application, bond coat application, repair
mortar application, curing; and
(c)
the ease of application and the achievable buildup.
(2)
A batch of the repair mortar shall be sampled and the following tests shall be carried out by the Testing
Laboratory, the costs of which shall be included in the Contract and borne by the Contractor: (a)
Compressive strength
Six 70 mm cubes for Compressive strength test, i.e. three at 7 days and three at 28 days.
(b)
Pull-off tests
Two mortar patches at 7 days in accordance with Clause 4.6(2) of this PS.
Should a test result of any above tests fail to meet this PS, all repair patches using the same batch of
RMS shall be deemed not to comply with this PS.
4.5
Works Tests on Fresh Repair Mortar

If directed by the SO, the following works tests on fresh repair mortar shall be carried out during the
application of repair mortar: (a)
Compressive Strength
Two 70 mm repair mortar cubes shall be prepared on site from repair mortar taken from the mixer for
every 5m3 of repair mortar and tested for compressive strength at 28 days, using any one class of repair
mortar or for every week on which repair mortar is being used in the Works or as directed by the SO.
The average of the two cube results shall be taken as the test result.
(b)
Bond Strength at 7 Days

Page OI 02.11.A.1(xii)

No. 02 / 2011
ANNEX 1
(Continued)
Two samples for bond strength test at 7 days shall be prepared on the laboratory for every 5m3 of repair
mortar.
The average of the two sample results shall be taken as the test result.
(c)
Polymer Content
Where site batched polymer modified mortar is used, two fresh repair mortar samples shall be taken to
represent the repair mortar used in the Works for polymer content test in every 5m3 of site mixed repair
for checking compliance with limits given in Clause 2.9 of this PS after making due allowance for the
accuracy of the test method employed in accordance with the method for analysis of Latex Solution as
below:
i)
Mix the sample solution thoroughly by rolling, tumbling or shaking the container for 1 min.
Using a pipette, withdraw about 3 mL and transfer to a flat bottom weighing dish (made of
porcelain, silica or nickel, approx. 60mm in diameter) previously ignited at 550 25oC and
weigh (W) (accurate to 0.1 mg).
ii)
Remove the cover and distribute the latex over the bottom of the dish. This may be facilitated
by carefully adding approx. 1 mL of water to the latex and gently swirling the dish.
iii)
With the dish uncovered, dry the specimen in a vented air oven for 16 hours at 70 2oC.
iv)
Replace the cover, cool in a desiccator to room temperature and weigh (C).
v)
Place the dish in a muffle furnace, and to avoid mechanical loss of material, cover the dish and
raise the temperature slowly to 550 25oC. After 5 minutes at this temperature, remove the
cover and leave the dish in the furnace at this temperature for a further 2 hours.
vi)
Allow the dish to cool to room temperature in a desiccator and weigh. Repeat the ignition,
cooling and weighing until the mass is constant to 0.5mg or less (D) (accurate to 0.1 mg).
vii) Calculation (to the nearest 0.01%)
Polymer content (in percentage) =
viii)
Tests shall be run in duplicate and the results expressed as percentage shall not differ from each
other by more than 0.5%. The average of the two sample results shall be taken as the test result.
Should a test result of any above tests fail to meet this PS, all repair patches using the same batch of RMS
shall be deemed not to comply with this PS. All failed patch repair areas are to be redone by the Contractor at
their own expense and without time extension.
4.6
Testing of Completed Patch Repairs

After completion of Patch Repair, test all patch repairs for voids or delamination by lightly tapping the area
with a wooden mallet or a void detector, at least 3 days after the repair has been carried out. Repairs sounding
hollow which indicates a possible lack of bond or other defects shall be reported. The Contractor shall also
carry out visual inspection for all patch repairs to ensure that the repairs are free from cracks and other
superficial defects.
If directed by the SO, the following tests shall be carried out: (1)
Open-up inspection
The Contractor shall allow an opening of an area measuring 300mm300mm per 25m2 of patch repair
surface area in positions selected by the SO to check compliance with Section 3 this PS.
If any patch is found not in compliance with this PS, the SO may order further open-up inspections. All
such further open-up inspections and subsequent reinstatement regardless of the result of the inspection
shall be at the Contractor's own expense and without time extension.
(2)
Pull-off test - adhesion strength

The adhesion strength of patch repairs shall be determined by the pull-off test as described below.

Page OI 02.11.A.1(xiii)

No. 02 / 2011
ANNEX 1
(Continued)
The bond between the repair mortar and the substrate concrete shall be sufficiently strong so that at
least half of the pull-off test fracture occurs within the substrate concrete, unless the pull-off stress is
not less than 1/3 (or 1/4 for high built mortar in overhead application) of the minimum bond strength of
the repair mortar at 7 days as given in Clause 2.9 of this PS.
The repair area shall be cored to produce a 75 mm diameter core containing the full thickness of the
repair which shall have a minimum age of 7 days and well into the parent concrete. The coring
operation shall minimize damage to the repair material and the parent concrete. A suitable metal plate
shall be glued to the cored repair and this attachment shall be pulled with increasing tensile force using
a specially calibrated device until failure occurs. The force needed to cause failure shall be recorded
and the equivalent stress at failure calculated and reported. The failure surface shall be examined and
the mode of failure reported as either adhesive (at the concrete/repair mortar interfaced) or cohesive
(within the parent concrete or repair mortar). Where both forms of failure occur in a core, an estimate
of the percentage of each shall be made. The core shall be immediately photographed to show the core
and failure surface in close up colour against a contrasting background to the approval of the SO.
Pull-off tests shall be carried out at a rate of at least one per 50m2 of patch repair surface area. Should
any pull-off test result fails, the SO may order further two pull-off tests at any repair location of the
works. All further tests and subsequent reinstatement works regardless of the results shall be at the
Contractor at their own cost and without time extension.
If the further pull-off tests fail to meet this PS, the whole of 50m2 of patch repair area represented by
the test shall be deemed not to comply with this PS. All failed patch repair areas are to be redone by the
Contractor at their own expense and without time extension, including any reinstatement work.
(3)
4.7
Inspection core test

For all patch repairs, 75 mm diameter cores shall be taken at the rate of one per 25m2 of patch repair
surface area in positions selected by the SO to determine repair thickness and quality for checking in
compliance with Section 3 of this PS.
Where instructed by the SO, these cores shall be taken through the repair mortar and passing through a
typical reinforcing bar layer to determine repair quality, possible voids behind the bar and bar cleaning
quality.
All cores shall be drilled in accordance with CS1.
Should any core test inspect fail to meet this PS, the whole 25m2 of repair patches represented by the
test shall be deemed not to comply with this PS. All failed patch repair areas are to be redone by the
Contractor at their own expense and without time extension.
Testing of Grouted Dowel Bar

If directed by the SO, perform pull-out test on grouted dowel bar in accordance with BS 5080: Part 1:1993 at a
repair location of the Works. The dowel bar shall be loaded to test load in one increment at a constant rate.
The load shall be maintained constant for at least 2 minutes and then removed.
Grouted dowel bars shall be selected by the SO and tested by the Testing Laboratory with tensile loading of
1.5 times the working load or other pull-out load as directed by the SO at the rate of at least 1 per 20 nos.
grouted dowel bars. The dowel bar shall be accepted if the maximum load can be maintained for the specified
time without failure.
If any pull-out test result fails, the SO may order further two pull-out tests at any repair location of the Works,
all at the Contractors expense and without time extension.
If the further pull-out tests fail to meet this PS, the whole of designated repair area represented by the test shall
be deemed not to comply with this PS. All failed patch repair areas are to be redone by the Contractor at their
own expense and without time extension, including any reinstatement work.
4.8
Record of Repairs

Page OI 02.11.A.1(xiv)

No. 02 / 2011
ANNEX 1
(Continued)
Within 7 days of the completion of any repair the Contractor shall submit to the SO a record of the repair
carried out. The record shall be in an approved pictorial and written form including photograph of the repair
and giving at least the following information: (1)
General
Repair location (pictorial)
Date and time of repair
(2)
Repair Description
Type of element repaired i.e. beam, wall, etc.
Size and depth of repair
Materials and the batch number used in repair
Type of repair
(3)
Quality Control
Samples taken (if any)
Tests carried out (if any)

Page OI 02.11.A.1(xv)

No. 02 / 2011
ANNEX 2
1.
2.
3.
General
1.1
The Contractor shall carry out repair to cracks in concrete by injection as specified with all necessary labour,
equipment, tools and materials in accordance with the General Specification for Building (GS) issued by the
Architectural Services Department, the drawings, and this Particular Specification (PS).
1.2
Should there be discrepancies between GS and PS, this PS shall take precedence.
1.3
The locations, types and extent of the crack repair by injection are shown on the drawings, or to be directed or
otherwise agreed by the Supervising Officer (SO).
Qualifications
2.1
The Contractor, or its subcontractor if so employed to carry out the repair works, shall have a minimum of 5
years of experience of concrete crack repair by chemical injection.
2.2
The Contractor shall arrange a competent full time site supervisor to supervise the repair works. The site
supervisor shall have a minimum of 3 years of supervision experience of concrete crack repair of comparable
scope by chemical injection.
Submissions
The Contractor shall submit the following details to the SO for approval before the commencement of the repair
works:
a)
Particulars of the Contractor, or its subcontractor if employed, including its experience of concrete crack
repair by chemical injection and job reference in Hong Kong or elsewhere.
b)
Name of the competent full time site supervisor and particulars of his job experience.
c)
Method statement for the repair works together with a proposal of field trial test. The controlling attributes on
suitability and injectability of the proposed injection system shall be clearly stated with range limits for
verification in the field trial and monitoring in the subsequent repair works. These controlling attributes shall
include but not limited to applicable crack width, injection pressure, injection point spacing, volume intake
against time, application temperature and workable time for the injection material.
d)
Name and generic system of the proposed materials, which shall include:
i)
equipment, tools and materials required for the application;
ii)
mix proportions of the proposed materials for injection and surface sealing of cracks;
iii)
application procedures including crack preparation, spacing of injection points, mixing procedures,
injection sequence and curing regime; and
iv)
suitability for injection in wet or dry condition.
e)
Name and address of the supplier and manufacturer of the proposed materials.
f)
Product information sheets with supporting test certificates showing compliance with the material
requirements of Clause 5 of this PS.
g)
Material safety data sheets showing hazards of the materials and control measures.
h)
Proven track record to demonstrate the suitability of the materials for application in Hong Kongs
environment.
i)
Details of temporary works with drawings and calculations.

Page OI 02.11.A.2(i)

No. 02 / 2011
ANNEX 2
(Continued)
j)
4.
An independent testing laboratory accredited by the Hong Kong Laboratory Accreditation Scheme for coring
test, where directed by the SO.
Temporary Works
The Contractor shall provide and maintain all necessary temporary works including temporary support, scaffolding
and working platforms wherever required for the execution of the repair works. The Contractor shall review whether
the affected area shall be cordoned off for the repair works. The Contractor shall remove all the temporary works,
equipment, tools, surplus materials and debris from the premises after completion of the repair works. The affected
areas shall be reinstated to the original condition.
5.
Materials
5.1
Unless otherwise approved by the SO, the epoxy grout for injection shall have the following properties:
Compressive Strength
Tensile Strength at 7 days in MPa:
tested according to ASTM D638-08
not less than the design strength of

the concrete substrate
>48.0 unless for non-load bearing
or minor structural elements as to
be agreed by the SO but shall not
be less than 35.0
or
tested according to BS 6319-7
>15.0
Bond Strength in MPa:

tested according to ASTM C-882
at 2 days (moist cure)
at 14 days (moist cure)
or
tested according to BS EN 12618-2
at 14 days for resin injection systems
at 28 days (moist cure) for cementitious
injection systems
5.2
>2.0
>2.0
Where specified or approved by the SO, the Contractor shall use flexible polyurethane grout, instead of epoxy
resin, for injection, and unless otherwise approved by the SO, the flexible polyurethane grout shall have the
following properties:
Specific gravity at 25oC
Elongation
Bond strength at 24 hours in MPa
6.
>7.0
>10.0
1.1
>34%
>0.28
5.3
The injection materials for repair works shall be solvent free and approved by the SO.
5.4
The proposed materials shall be delivered to the Site in sealed containers with labels intact, and stored
between 4oC and 32oC unless otherwise specified by the manufacturer.
5.5
The proposed materials shall have a pot life suitable for the application.
5.6
All the approved materials shall be used in accordance with the manufacturers specifications and
recommendations.
Test

Page OI 02.11.A.2(ii)

No. 02 / 2011
ANNEX 2
(Continued)
6.1
Material Test
The tests for the material properties shall not be required for pre-packed injection materials, unless otherwise
specifically ordered by the SO.
6.2
6.3
Field Trial Test

6.2.1
After submission of each proposed repair system and upon the instruction by the SO, the Contractor
shall carry out a field trial using the equipment, tools and materials intended for the repair works to a
crack selected by the SO. The controlling attributes as per Clause 3c of this PS shall be measured and
submitted to the SO for record within 3 days of the field trial.
6.2.2
The field trial shall demonstrate to the SO the following:

a)
the Contractors competence with crack repair by injection; and
b)
effectiveness of the proposed repair system.
6.2.3
Coring test for the field trial shall be carried out as per Clause 6.3.1 of this PS within 10 days of the
field trial, where directed by the SO. If test result in coring test is found not satisfactory in
accordance with Clauses 6.3.1 of this PS, the Contractor shall at its own cost carry out another field
trial. The Contractor shall review the repair system and the method statement and submit a revised
proposal addressing the failed aspects to the SO for approval prior to another field trial at location
selected by the SO. The proposed repair system shall be rejected after failing 3 field trials and
another repair system shall be proposed.
6.2.4
The Contractor shall re-inject approved grout at the location where the field trial has been found not
satisfactory.
6.2.5
The Contractor shall not begin the repair works until the test results in the field trial are found
satisfactory.
Coring Test
6.3.1
Where directed by the SO, the Contractor shall employ an approved independent testing laboratory to
take two 50 mm diameter cores through the repaired cracks at locations selected by the SO to
examine the level and quality of material filling. If both cores show more than 95% of the cracked
lengths measured along the core surface are filled with injection grout and that a satisfactory
structural bond is achieved, the repair represented by the cores shall be considered satisfactory. The
structural bond is considered satisfactory if the concrete parts within the core can be cohesively
combined together by epoxy grout. All test reports shall be prepared and be submitted to the SO
directly by the approved testing laboratory. The test report shall assess if the cores satisfy the
requirements of this Particular Specification.
6.3.2
Unless otherwise approved by the SO, cutting of steel bars and/or utility ducts shall not be permitted
during core drilling. The Contractor shall at its own cost use all means including the use of
covermeter and utility detector to check the existence of steel bars and utility ducts.
6.3.3
Concrete core samples shall be extracted using a hand held abrasive cutting barrel fitted to
conventional drilling equipment or a water cooling diamond impregnated core barrel mounted on a
rigid stand, subject to satisfactory demonstration.
6.3.4
The Contractor shall make good to the satisfaction of the SO for the removed-core area.

Page OI 02.11.A.2(iii)

No. 02 / 2011
ANNEX 2
(Continued)
6.3.5
7.
Notwithstanding the acceptance of the field trial, the SO may order additional coring test on the
completed works. The coring test shall be carried out within 10 days upon SOs selection of coring
locations. For any coring test result that fails to comply with Clause 6.3.1 of this PS, the Contractor
shall carry out two further coring test at his own expense and at locations to be selected by the SO. If
any of these further coring tests fails to comply with Clause 6.3.1 of this PS, the Contractor shall
conduct a full review on the quality of all completed repair works and propose verification / remedial
works to the SO for agreement within 1 week.
Workmanship
7.1
Cracks to be repaired are shown on the drawings, or to be directed or otherwise agreed by SO. Where
required, the Contractor shall mark out the locations and extent of the cracks to be repaired for the agreement
of the SO prior to the commencement of the repair works. The Contractor shall inform the SO when further
cracks are revealed during the progress of work.
7.2
Crack Preparation
Unless otherwise approved by the SO, crack shall be thoroughly cleaned and dried. All loose debris shall be
removed by brushing or blowing out with clean compressed air. Where spalling and rusting have occurred, all
defective concrete shall be removed and reinforcing bars be made good before injection. If the crack has
surface water, a repair system suitable for injection in wet condition as specified on Clause 3(d)(iv) of this PS
shall be proposed.
7.3
8.
Injection
7.3.1
The surface of the crack shall be properly sealed with approved compatible material. The injection
points shall be made via injection nipples installed and bonded along the line of the crack with the
approved material. Spacing of the nipples shall ensure uniform penetration and completely filling of
the crack by the epoxy grout. The Contractor shall drill injection holes into the concrete to intersect
the crack in their void areas for injection whenever necessary.
7.3.2
Unless otherwise approved by the SO, device for the injection shall be twin metering pumps,
delivering grout and hardener in a correct proportion through delivery lines to a point close to the
injection nipple. The materials shall be thoroughly mixed continuously in a mixing head and pumped
directly into the crack. Other device for crack injection will be approved when the Contractor can
demonstrate that uniform penetration and complete filling of the crack can be achieved.
7.3.3
When the cracks are vertical or inclined, injection shall normally commence at the lowest point and
work upwards as the injection grout emerges from the next higher injection point. When the crack is
horizontal, injection shall commence at positions approved and proceed along the crack as the
injection grout emerges from the next injection point along the line of the crack. Excess epoxy grout
shall be removed. The above injection operation shall be repeated at the remaining nipples. The
injection points shall be sealed as the work proceeds.
7.3.4
The injection grout shall be cured for a period as recommended by the manufacturer of the proposed
materials.
7.3.5
The Contractor shall not carry out the injection process if the temperature of the concrete is not
within the range of application temperatures as recommended by the manufacturer of the proposed
materials.
Record of Repairs
Within 14 days of the completion of the repair works, the Contractor shall submit a record of repair works carried out
to the SO. The record shall be in an approved pictorial and written form giving at least the following information:
a)
locations of repair;

Page OI 02.11.A.2(iv)

No. 02 / 2011
ANNEX 2
(Continued)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
9.
types of structural element repaired;

the length and width of the crack repaired;
through crack or not;
dry or wet condition;
materials used in repair;
date and time of repair;
maximum and minimum ambient temperatures at the time of repair;
weather conditions, such as rainy and windy;
date of the test done and its result; and
photographic records showing the conditions after marking out but before any repair works, and after
completion of the repair works but before application of finishes.
Finishing
Upon completion of the repair works, injection nipple shall be removed, and the line of the crack shall be ground flat
to give a smooth surface. Plaster, paint or tiles finishes shall be applied to reinstate the surfaces such that they match
the adjacent original finishes and to the satisfaction of the SO.
10.
Safety and Environmental Precautions

10.1
The Contractor shall follow the manufacturers material safety data sheet when using or disposing the
injection grout.
10.2
Grout injection shall be handled by the labourers with appropriate personal protective equipment including
goggles and chemical-resistant gloves and in adequate ventilation condition.

Page OI 02.11.A.2(v)


Operational Instruction No. 02 / 2011 Particular Specifications For Concrete Repair

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Operational Instruction No. 02 / 2011 Particular Specifications For Concrete Repair

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OPERATIONAL INSTRUCTION

Effect on Existing Instructions

Particular Specification for Concrete Repair by Patch Repair

Submissions of repair proposal

Particular Specification for Concrete Repair by Patch Repair

Particular Specification for Concrete Repair by Chemical Injection

Architectural Services Department

First Issue Date - 07 : 11 : 2011

Cement based reinforcement primers

Architectural Services Department

First Issue Date - 07 : 11 : 2011

Epoxy based reinforcement primers

Bond coat (cement based)

Bond coat (epoxy based)

Cement for Mortar

Sand for Mortar

Water for Mortar

Architectural Services Department

First Issue Date - 07 : 11 : 2011

Polymer Modified Mortar

Prebagged polymer modified mortar

Site batched polymer modified mortar

Cement : Polymer ratio (by weight)

Styrene Butadiene Rubber (SBR)

Acrylic Styrene Copolymer (ASC)/

Note: The weight of polymer shall not exceed a tolerance of 5%.

Architectural Services Department

First Issue Date - 07 : 11 : 2011

Shrink Resistant Mortar

Dowel Bar Grout

Control Record of Repair Mortar Materials

Architectural Services Department

First Issue Date - 07 : 11 : 2011

production batch record for such batch;

Identification of Areas to be Repaired

Samples for Standard of Breakout and Cleaning

Breaking Out and Preparation of Concrete Substrate

Architectural Services Department

First Issue Date - 07 : 11 : 2011

Manual wire brushing and

Remove loose mill scale and rust

Machine brushing, grinding etc.

Swedish Standard SIS 055900 St 2

Machine brushing, grinding etc.

Swedish Standard SIS 055900 St 3

Swedish Standard SIS 055900 Sa 2

Care shall be taken to clean the far side of the bar.

Architectural Services Department

First Issue Date - 07 : 11 : 2011

Length of Weld (mm) 1

Length of Lapping (mm)

All weld slag shall be removed by hammer and chisel.

Notice for Inspection of Works

Prime Coat for Reinforcement

Polymer modified cement based reinforcement primer

Zinc rich primer

Architectural Services Department

First Issue Date - 07 : 11 : 2011

Epoxy reinforcement primer

Bond Coat for Concrete Substrate and Reinforcement

Polymer modified cement based bond coat

Epoxy based bond coat

Batching and Mixing of Mortar