CONSTRUCTION JOINTS IN IN-SITU CONCRETE METHOD STATEMENT

CONSTRUCTION JOINTS IN IN-

1.

SCOPE

The scope of this procedure outlines methods to be used for constructing effective and
durable

construction

joints

in

accordance

with

the

contract

specifications.

2.

PROCEDURE

.1

In some cases CLIENT shall have to prepare shop drawings proposing location and

type of construction joints and obtain approval from the Consultants representative
before

.2

Horizontal

proceeding

with

the

work.

Surfaces:

Laitance on the surface must be removed from the concrete in order to ensure that a
good bond will be achieved when fresh concrete will be placed against it. Following
methods may be used for removing laitance from the top of walls and columns unless
specified otherwise in the contract:

i)

Washing

and

Brushing:

The easiest way is to brush off the

laitance while the concrete is still
fresh

but

Brushing

has
shall

stiffened
be

slightly.

commenced

between one to two hours after

placing of concrete. Site operatives shall have brushes with soft and hard bristles so that
it can be used depending upon stiffness of concrete. Care shall be taken that the
brushing shall not be harsh which will dislodge the coarse aggregates. In case laitance
has

ii)

hardened

but

is

Air

still

green,

wire

and

brush

should

Water

be

used.

Jet:

Laitance can be removed by directing a jet of air and water onto it. This method can be
used up to six hours after placing or possible longer but the site operative must make his
own judgement while adopting this method. This operation must not start too soon
because

iii)

it

Mechanical

might

dislodge

coarse

aggregate

particles.

Scabbling:

If laitance is too hard to be removed by wire brushing, mechanical scabbling can be tried
using small percussion power tools. This method can be applied after 3 days when
concrete has hardened sufficiently. Care shall be taken not to weaken the coarse
aggregates.

iv)

Abrasive

Blasting:

Wet or dry abrasive blasting can be used to expose the aggregate but special safety
precautions

.3

shall

be

taken

while

using

sand.

The most appropriate time for treating the joints is a matter of judgement, because it

depends on the rate of setting and hardening (which is itself dependent on the
temperature

.4

of

the

concrete).

Where there is likely to be even a short delay before placing the next concrete pour,

protruding reinforcement should be protected. Before the next pour is placed, rust, loose
mortar

or

.5

Vertical

i)

Stop

other

contamination

should

be

removed

from

the

bars.

Surfaces:

Ends/Expanded

Metal

Mesh:

Vertical joints in walls, beams and slabs are usually formed at a stop end in the formwork.
Stop ends shall be located where the reinforcement is least dense. Holes for
reinforcement in stop-ends are a potential weakness because grout loss can occur. In
lightly reinforced sections and where starter bars are acceptable, this problem is
frequently avoided by bending bars so that they run along the inner face of the stop-end.
When the stop-end is removed, the bars are cut out and straightened. However, the
cutting out and straightening can damage the concrete and cause local loss of bond with
the bar, especially if this is carried out within 48 hours of placing the concrete.

Proprietary stop-ends have been developed which overcome this problem by encasing
the bent bars in expanded plastic foam. The foam can easily be removed and the bars
strengthened by means of a steel tube. Take particular care not to use impact to
straighten

bent

steel

at

stop-ends

as

this

can

cause

brittle

fracture.

Permanent forms of expanded metal are increasingly employed, particularly in deep

slabs. The concrete surface produced by such system is very irregular and does not
normally require any surface preparation. Where a very high workability mix is being
used (slump greater than 200mm) with expanded metal formwork, care should be taken
to

avoid

over

ii)

Formwork:

vibration

at

the

joint

as

this

may

cause

grout

loss.

Formwork for subsequent concrete pours must be accurately aligned and well fixed so
that there is no grout leak which results into discoloration and honey combing. Strips of
foam rubber or polyurethane unless specified otherwise can be fixed around the edge of
the

hardened

.6

prepared

joint.

The methods explained previously i.e. washing and brushing, mechanical scabbling

and abrasive blasting can also be used in case of vertical joints. However special care
shall

be

taken

not

to

damage

the

leading

edges

(leave

margin).

.7

Watertight

Construction:

i)

In watertight construction unless specified otherwise, flexible waterbars of specified

details can be used. Care shall be taken while concreting so that all waterbars are
securely

tied

to

avoid

its

folding

during

concreting.

.8

Cold

i)

Cold joints normally occur during the concreting operation when a delay in placing

adjacent

ii)

Joints:

concrete

has

occurred

and

earlier

concrete

placed

has

stiffened.

A simple test can be used to determine whether concreting can proceed. Embed the

poker vibrator into the existing concrete to examine the condition of concrete. Where the
action of the poker has left a distinct hole, concreting operations should not continue. In
this case the joint face can be prepared by one of the methods described above for

horizontal

construction

the

joints.

.9

Placing

i)

Particular care as explained below shall be taken while placing and compacting new

concrete

ii)

on

Fresh

or

Concrete:

against

the

old:

Any dirt or dust from the surface of the hardened concrete shall be removed

preferably with a compressed air hose. As a safety precaution site operatives must wear
safety goggles. This cleaning shall be done before new formwork is fixed because not
only access be easier than but also dirt might otherwise stick to the new formwork.

iii)

While fixing a new formwork extra dirt is created which can be cleaned after

removing a stop end which will make it easy to be swept or blown away.

.10

i)

Joint

Sealing:

Where the structural component containing the joint is to be exposed to the external

environment, the joint has to be sealed to prevent ingress of water. For type and method
of application refer to the contract specifications and/or manufacturers instructions.

3.

DOCUMENTATION

Following documentation and forms may be maintained as a minimum pending on

Project

Quality

Plan

i)

Contract

and/or

i)

Manufacturers

test

requirements

approved

certificates

(in

and

contract

workshop

case

of

specification.

drawings.

sealants

and

waterbars).

iii)

Request

for

Consultants

consent/approval.

The above referenced documentation where appropriate will be retained in the HEE
archive

for

the

prescribed

period

of

time.