METHODOLOGY
REPAIR OF HONEYCOMBS
A. Preliminary Works
a. Scheduling of work in coordination with owner’s representative.
b. Installation of the necessary lighting and power outlets.
c. Initial ordering/delivery of materials required.
d. Locate area to be repaired. Hammer sounding is used when locating delamination.
e. Design and install temporary support system prior to any concrete removals.
B. Surface Preparation
a. Remove deteriorated concrete using acceptable methods. Existing concrete
surfaces need to be roughened to a profile necessary to achieve mechanical
interlock.
b. Prepare surface repair boundaries to prevent feather edged conditions.
c. Clean the surface of the exposed reinforcing steel and concrete. Surface cleaning is
critical to achieve an adequate bond between the repair and existing concrete.
d. If there are corroded reinforcing steel bars, these must be applied with rust
converter and epoxy coating to stop corrosion.
C. Grouting and Epoxy Injection
a. Prepare formworks to provide a more uniform surface appearance. Design of forms
must follow standard practice. In addition, forms must accommodate the weight
and pressure of the repair material.
b. Embed several aluminum tubes on strategic places of the cavity. This will serve as
injection ports to ensure that the voids would be completely filled up.
c. Mix a pre-packed set of polyester putty thoroughly and seal the corners to prevent
the epoxy from leaking.
d. Thoroughly mix a set or sets of pre-packed low viscosity epoxy (2-parts base, 1-
part hardener). Then add screened sand to mixture at a ratio of 1:1.5 by volume.
Then pour the mixture from the top of the form and let it flow freely to the prepared
cavity. Consolidation is best achieved with external vibration of the form works.
e. After 24 hours from the last activity, epoxy injection is ready to begin. Mix a set or
sets of low-viscosity epoxy then pump through the aluminum tubes.
f. Remove formworks after 24hours.
D. Cleaning
a. Remove all protruding tubes and excess hardened epoxy grout.
b. In cases where uneven surfaces had resulted due to hardened epoxy and/or putty
sealer, employ a portable grinder to smoothen out the repaired concrete surface.
