10 Powerful Steps for a Complete Method Statement of Concrete Works
Discover a detailed method statement for concrete works in 10 powerful steps, with real site scenarios, troubleshooting tips, and quality control procedures for flawless results.
Concrete is the backbone of modern construction. From the foundations of a residential villa to the towering columns of a bridge, concrete provides the structural strength and durability needed for long-lasting projects. But achieving quality concrete is not just about pouring cement and water into a mold — it’s about planning, sequencing, and controlling every step of the process.
This is where the method statement comes in. A method statement for concrete works is more than a procedural formality; it is a blueprint for execution that ensures compliance with specifications, safety regulations, and quality standards. In this detailed guide, we present 10 powerful steps for preparing and executing a complete method statement for concrete works, backed by real site scenarios, practical tips, and troubleshooting solutions.
The purpose of the method statement is to outline a clear, step-by-step approach to carrying out all concrete-related activities — from preparation to curing — in line with approved drawings, technical specifications, and recognized standards such as ACI 301 and BS EN 206.
Site Experience: On a Riyadh high-rise project, a lack of detailed scope in the method statement caused confusion about curing responsibilities. The curing was delayed, resulting in shrinkage cracks that needed costly repairs. A clear scope would have assigned this task explicitly to the site team, preventing the problem.
Tip: Always attach extracts of relevant clauses to the method statement’s appendix. It saves time during inspections when disputes arise about slump tolerances or curing durations.
3. Responsibilities
Clear responsibility allocation avoids delays and errors.
Typical roles and duties:
Project Manager: Oversees execution plan, ensures resources are available, and liaises with the client.
Construction Manager: Manages site operations and coordinates suppliers.
Site Engineer: Checks formwork, reinforcement, and embedded items before pouring.
HSE Manager: Implements and monitors safety compliance.
QC Engineer: Oversees quality inspections, testing, and documentation.
Foreman: Directs the crew, ensuring smooth workflow.
Workers: Execute tasks following safety and quality guidelines.
Practical site note: For large pours — such as raft foundations — assign two supervisors: one for pump coordination and one for vibration/compaction control. This split avoids overlooked areas and ensures uniform compaction.
4. Materials and Equipment
4.1 Materials
Cement: Must meet ASTM C150 specifications, fresh and stored in dry, moisture-proof conditions.
Water: Potable and free of harmful salts or chemicals.
Admixtures: ASTM C494-compliant, with consultant approval.
Reinforcement: ASTM A615 or equivalent, with mill certificates.
4.2 Equipment
Transit mixers for ready-mix deliveries.
Concrete pumps or crane buckets for placement.
Vibrators (poker for deep sections, surface for slabs).
Steel/aluminum/timber formwork.
Curing sheets, hessian cloth, or spray-applied curing compounds.
Site Experience: In a bridge deck pour, having only two vibrators for a large crew caused poor compaction in certain areas. The honeycombs had to be repaired with epoxy grout — costing time and money. Always have backup vibrators on site.
5. Site Preparation
Proper site preparation is one of the most critical stages in the concrete construction procedure. A well-prepared site not only speeds up the pouring process but also reduces the risk of defects, rework, and structural weaknesses. Site preparation involves much more than simply setting up formwork and reinforcement — it is about ensuring every element is ready for a smooth, uninterrupted pour.
Site Preparation – Concrete Works
5.1 Formwork
Formwork acts as the mold that shapes the concrete until it gains sufficient strength to be self-supporting.
Alignment and Level: The formwork must be precisely aligned and leveled to the dimensions indicated on the approved shop drawings. Even a few millimeters of deviation can cause uneven slab thickness or misaligned columns.
Sealing: All joints, corners, and panel connections must be completely sealed to prevent grout leakage. Unsealed joints lead to surface defects, honeycombing, and weak edges.
Strength and Stability: The formwork should be designed to withstand concrete pressure, vibration forces, and construction loads without shifting. This includes bracing for lateral stability and providing adequate support spacing to prevent bulging.
Surface Condition: Check that the contact surfaces are smooth, free from sharp protrusions, and coated with an approved form release agent to facilitate easy removal.
5.2 Reinforcement
Reinforcement steel is the structural backbone of concrete and must be installed exactly as per the design.
Cleanliness: Bars must be free of rust, oil, mud, or any substance that can affect bonding. Use a wire brush or compressed air to clean surfaces before inspection.
Placement: Ensure correct bar spacing, lap lengths, and cover as specified in drawings and standards like ACI 318.
Tying and Stability: Bars should be tied securely with binding wire at intersections and supported on spacers or chairs to maintain the required cover during pouring and vibration.
Embedded Items: Anchor bolts, sleeves, and other embedded components must be fixed firmly to prevent displacement.
5.3 Release Agents
Release agents prevent concrete from sticking to formwork, ensuring a clean finish.
Application: Apply a thin, even coat over all contact surfaces. Over-application can cause staining or surface dusting on hardened concrete.
Type Selection: Use a release agent compatible with both the formwork material and the intended concrete finish — for example, chemical release agents for steel formwork and oil-based for timber.
Timing: Apply before reinforcement installation to avoid contaminating steel bars, which could affect bonding.
5.4 Access Routes
Smooth and unobstructed access for concrete delivery vehicles and pumping equipment is essential for continuous placement.
Path Clearance: Remove debris, loose materials, and equipment from access roads and work areas.
Load Capacity: Ensure the ground or temporary platforms can support the weight of loaded transit mixers (often over 25 tons).
Pump Setup Area: The pump truck requires a stable, level platform with enough clearance for outriggers and boom movement.
5.5 Weather Check
Weather plays a decisive role in concrete quality.
Rain: Heavy rain during pouring can wash out cement paste from the surface, causing laitance and reduced strength.
Wind: High wind increases evaporation, leading to plastic shrinkage cracks.
Heat: Excessive heat accelerates setting time, making finishing and compaction more difficult.
Cold: Low temperatures slow hydration and can cause freezing in fresh concrete.
Always consult a reliable weather forecast before scheduling the pour and have contingency measures ready, such as shading, windbreaks, heaters, or cooling water.
5.6 Troubleshooting Tip
Even the smallest gap in formwork can cause grout leakage, leading to surface defects, honeycombing, or weakened concrete edges. Always:
Inspect all joints visually and by pouring water to detect leaks.
Seal gaps with expanding foam, mastic sealant, or mortar before pouring.
Recheck seals after reinforcement adjustments.
5.7 Field Example
On a commercial slab pour in Riyadh, improperly supported rebar sagged during pouring, reducing cover at the bottom layer. This led to early corrosion signs within two years, requiring partial replacement and epoxy coating. Proper chair spacing would have prevented this
6. Concrete Placement Procedure
The concrete pouring method is a critical stage in the overall concrete construction procedure. Mistakes during placement can lead to costly defects such as honeycombing, segregation, or cold joints, which can compromise the durability and strength of the structure. This stage should be executed with careful preparation, continuous supervision, and adherence to approved standards.
Concrete Placement Procedure
6.1 Pre-Pour Checks
Before the first cubic meter of concrete is placed, pre-pour inspections must confirm that everything is ready:
QC Approval: Obtain written approval from the quality control engineer confirming that the formwork, reinforcement, embedded items, and access arrangements comply with approved drawings and specifications.
Slump Test: Conduct a slump test (ASTM C143) to verify that the delivered mix has the correct workability for the element being poured. Slump results must be within the approved tolerance, ensuring proper compaction without segregation.
Surface Preparation: Check that formwork and reinforcement are clean, free from debris, and pre-wetted if needed in hot climates to prevent rapid water absorption from the concrete.
6.2 Placement
The goal during placement is to deliver and distribute concrete efficiently, maintaining uniform quality throughout the element:
Proximity to Final Position: Discharge concrete as close as possible to its final location to minimize re-handling, which can cause segregation and loss of workability.
Layer Thickness: Place concrete in horizontal layers not exceeding 450 mm in depth. This allows proper vibration and bonding between layers.
Free Fall Limits: Avoid free fall greater than 1.5 meters, as excessive drop height can separate the coarse aggregates from the mortar, leading to uneven texture and reduced strength. For taller elements like columns, use drop chutes or tremie pipes to control the fall.
Continuous Flow: Ensure the pouring sequence is uninterrupted to avoid cold joints. This requires proper coordination between the batching plant, delivery trucks, and pump operators.
6.3 Compaction
Proper compaction eliminates air pockets and ensures a dense, durable structure:
Poker Vibrators: Insert vibrators vertically into the concrete, ensuring that the vibrator tip penetrates slightly into the previous layer to blend layers together.
Overlap Zones: Each insertion point should overlap the previous one by about 50% to guarantee complete coverage.
Withdrawal Speed: Withdraw vibrators slowly and steadily to prevent the formation of voids or air pockets along the insertion path.
Vibration Time: Typically 5–15 seconds per insertion, depending on the mix’s workability and element size — avoid over-vibration, which can cause segregation and bleeding.
6.4 Field Experience
In one basement wall pour on a commercial project in Riyadh, a pump blockage delayed placement for 45 minutes midway through the pour. This created a visible cold joint line. The team minimized structural impact by applying epoxy bonding agents to the joint surface and placing a high-slump mix for the adjoining section. While the repair met structural requirements, the event highlighted the importance of standby equipment, backup pumps, and pre-pour contingency planning to avoid interruptions.
7. Curing and Protection
Curing is one of the most important yet often overlooked stages of the concrete construction procedure. It is the process of maintaining adequate moisture, temperature, and time after placement to allow proper hydration of the cement. Without proper curing, even the best concrete mix can fail to reach its design strength, durability, and resistance to cracking.
Concrete Cracks
7.1 Importance of Curing
The hydration of cement — the chemical reaction between cement particles and water — produces the binding compounds that give concrete its strength. If the concrete dries out too early, hydration stops prematurely, leaving unreacted cement particles and creating a weaker, more porous structure. Poor curing can result in:
Reduced compressive and flexural strength.
Increased permeability, leading to faster reinforcement corrosion.
Surface defects such as dusting, scaling, and crazing cracks.
7.2 Duration
The curing period depends on the type of cement and environmental conditions:
Ordinary Portland Cement (OPC): Minimum 7 days of continuous curing in moderate temperatures.
Rapid-Hardening Cement: Minimum 3 days, as it gains strength faster but still requires moisture for proper hydration.
Hot and Dry Climates: Curing may need to extend beyond the minimum period due to rapid evaporation.
Cold Weather: Longer curing is often required because low temperatures slow the hydration process.
7.3 Curing Methods
Several methods can be used, depending on site conditions and the type of concrete element:
Water Ponding: Creating a shallow pool of water on horizontal surfaces like slabs to keep them continuously moist.
Wet Coverings: Using hessian cloth, burlap, or mats soaked in water and laid over the surface. They must be kept wet at all times.
Plastic Sheeting: Covering surfaces with polyethylene sheets to trap moisture. Edges should be sealed to prevent wind from lifting the sheets.
Curing Compounds: Applying a spray-on membrane-forming compound that seals moisture inside the concrete. This method is especially useful when water curing is difficult.
Sprinkling/Misting: Regular spraying of water over the concrete surface to replenish moisture — common in hot and windy conditions.
7.4 Protection Measures
Curing is not only about keeping the concrete wet — it’s also about protecting it from adverse environmental effects:
Sunlight: Direct sun can cause rapid surface drying and thermal gradients that lead to cracking. Shade cloths or temporary shelters can help.
Strong Winds: Wind accelerates evaporation; windbreaks or barriers should be installed around the pour area.
Freezing Temperatures: In cold weather, insulation blankets or heated enclosures may be necessary to prevent early freezing, which can permanently damage fresh concrete.
7.5 Field Example
In a major project in Abu Dhabi, high desert winds during the curing period rapidly evaporated surface moisture from a freshly poured suspended slab. This resulted in fine surface cracks within hours of placement. For subsequent pours, the contractor installed temporary windbreaks around the perimeter and used a light misting system to keep the surface damp. This simple adjustment eliminated the problem in later stages.
8. Safety Measures
Concrete works involve a combination of heavy materials, powerful machinery, chemical exposure, and often challenging environmental conditions. This makes safety a critical part of the method statement for concrete works. A safe working environment not only protects personnel from injury but also ensures that operations proceed without costly delays or legal consequences.
8.1 Personal Protective Equipment (PPE)
All workers involved in concrete works must wear appropriate PPE at all times:
Helmets: To protect against falling objects or accidental impact with equipment.
Safety Glasses or Goggles: To guard against splashes of wet concrete, which can cause severe eye irritation or burns.
Gloves: Alkaline-resistant gloves to protect skin from cement’s caustic effects.
Safety Boots: Steel-toe, slip-resistant footwear to protect from heavy impacts and provide stability on wet surfaces.
High-Visibility Vests: Especially important in busy sites with moving vehicles and equipment.
Dust Masks or Respirators: Required when handling dry cement to prevent inhalation of fine particles, which can cause respiratory issues.
8.2 Safe Handling of Concrete
Chemical Exposure: Wet concrete is highly alkaline and can cause chemical burns. Workers should avoid prolonged skin contact and wash off splashes immediately with clean water.
Manual Handling: Bags of cement and formwork panels can be heavy. Use mechanical lifting aids where possible to prevent back injuries.
Mixing and Pouring Equipment: All moving parts (e.g., mixer drums, pump hoppers) should have safety guards in place.
8.3 Worksite Organization
Access Control: Only authorized personnel should be allowed within the pour zone during operations.
Clear Pathways: Keep routes for concrete trucks, pumps, and wheelbarrows unobstructed.
Housekeeping: Remove debris, tools, and unused materials to prevent tripping hazards.
Lighting: Adequate lighting must be provided for night pours or shaded areas.
8.4 Electrical Safety
Many concrete tools (e.g., vibrators, saws) are electrically powered:
Use weatherproof connections and cables rated for site conditions.
Keep electrical lines elevated or routed away from wet areas.
Regularly inspect cables and plugs for damage, replacing any defective components immediately.
8.5 Working at Heights
When placing concrete for elevated slabs or formwork:
Install guardrails, toe boards, and safety nets as needed.
Workers must use full-body harnesses anchored to approved points.
Ladders and scaffolding should be secured and inspected daily.
8.6 Environmental Hazards
Weather: High winds can cause formwork instability, while extreme heat can lead to heat exhaustion in workers. Implement weather monitoring and stop work if conditions become unsafe.
Noise: Prolonged exposure to pumps, vibrators, and mixers can damage hearing; provide ear protection in high-noise zones.
8.7 Field Example
During a large slab pour in Riyadh, a worker without gloves handled wet concrete for over 30 minutes. By the next day, he had developed severe chemical burns requiring medical treatment and time off work. This incident prompted the contractor to strictly enforce PPE requirements and add pre-pour safety briefings for all workers handling cement.
9. Quality Control and Testing
Quality control (QC) in concrete works ensures that the final structure meets the strength, durability, and appearance requirements set out in the project specifications. Testing begins before the concrete is poured and continues during and after placement. A robust QC process helps detect issues early, avoiding costly repairs and delays.
9.1 Pre-Pour Quality Checks
Before any concrete is placed, the QC team should:
Verify formwork alignment, stability, and cleanliness.
Check that reinforcement steel matches approved shop drawings in size, spacing, and placement.
Confirm that embedded items (anchor bolts, sleeves, inserts) are fixed in the correct locations.
Ensure that mix design approval is on file and the batch plant has received the correct proportions.
9.2 On-Site Testing During Placement
Slump Test (ASTM C143)
Measures the concrete’s workability.
The acceptable slump range is typically 75–125 mm for general reinforced concrete, but project specs may vary.
Too low a slump can make placement difficult; too high may indicate excess water or incorrect admixture dosage.
Temperature Check (ASTM C1064)
Ensures concrete is delivered within the specified temperature range, often between 10°C and 32°C.
High temperatures can reduce workability and accelerate setting; low temperatures slow hydration.
Air Content Test (ASTM C231)
Used for air-entrained concrete in freeze-thaw climates to ensure adequate air void spacing.
Typical range: 4–8% depending on the exposure class.
Visual Inspection
Monitor for signs of segregation, bleeding, or improper compaction during the pour.
9.4 Post-Pour Testing
Compressive Strength Test (ASTM C39)
Samples are cast in cubes or cylinders during pouring.
Common testing ages: 7 days (to check early strength) and 28 days (for final design strength).
Failure to meet target strength may trigger an investigation and remedial measures.
Surface Finish Inspection
Check for honeycombing, surface voids, or form tie defects after stripping formwork.
Measure dimensions and tolerances to confirm compliance with specifications.
Core Sampling (if needed)
If there are doubts about in-situ concrete quality, core samples can be extracted and tested for compressive strength.
9.5 Acceptance Criteria
Concrete should be accepted only if:
All test results fall within the limits specified in the project specifications and relevant standards.
No visible defects compromise structural integrity or aesthetics.
Any non-conformities are documented and approved by the consultant after corrective actions.
9.6 Field Example
On a high-rise project in Jeddah, several 28-day strength tests showed results 10% below the specified 35 MPa requirement. Investigation revealed that drivers were adding water at the site to ease pumping without QC approval. The contractor enforced a strict no water addition policy, trained pump operators to manage pressure without diluting the mix, and introduced spot checks during unloading. Strength results returned to acceptable levels in subsequent pours.
10. Environmental Considerations
Concrete works, if not managed properly, can have significant environmental impacts. These range from polluting waterways with cement slurry to generating excessive waste and increasing carbon emissions. A comprehensive method statement must address how the construction team will minimize environmental harm while complying with relevant laws, client sustainability policies, and recognized environmental management systems such as ISO 14001.
10.1 Control of Concrete Waste and Wash Water
Concrete Washout Areas: Designate contained washout pits or tanks for cleaning transit mixer chutes, concrete pumps, and other tools. These must be located away from drains, waterways, and sensitive soil areas.
Containment: Wash water from concrete equipment is highly alkaline (pH 11–13) and can harm aquatic life and soil structure. Containment prevents contamination.
Recycling: Where possible, wash water should be filtered and reused for cleaning purposes instead of being discharged.
10.2 Dust and Particulate Control
Dry Cement Handling: Minimize dust when loading, transporting, or storing cement by using sealed silos or covered bags.
Mixing Areas: Where manual mixing is unavoidable, locate it in sheltered areas and provide dust masks to workers.
Sweeping Practices: Avoid dry sweeping; use wet sweeping or vacuum systems to reduce airborne dust.
10.3 Noise Control
Equipment Selection: Use low-noise pumps, vibrators, and generators, especially during night pours or near residential zones.
Barriers: Install temporary sound barriers around noisy equipment.
Scheduling: Schedule high-noise activities during daytime hours to minimize community disturbance.
10.4 Material Efficiency and Waste Reduction
Accurate Batching: Follow approved mix designs closely to avoid producing excess concrete.
Return Concrete Management: Coordinate with batching plants to reuse or recycle returned concrete in non-structural elements where permitted.
Formwork Reuse: Maximize reuse of formwork materials (timber, steel, aluminum) to reduce waste generation.
10.5 Sustainable Practices
Low-Carbon Mixes: Use supplementary cementitious materials (SCMs) like fly ash, slag, or silica fume to replace a portion of Portland cement, reducing CO₂ emissions.
Local Sourcing: Source aggregates and other materials from nearby suppliers to cut transportation emissions.
Energy Efficiency: Use energy-efficient batching plants and machinery where possible.
10.6 Spill Prevention
Chemical Storage: Store admixtures and curing compounds in bunded areas to contain leaks.
Refueling: Conduct refueling of machinery in designated areas with spill kits on hand.
10.7 Field Example
On a large infrastructure project in Eastern Province, a mixer truck was washed directly onto bare soil, causing cement slurry to flow into a nearby drainage ditch. This resulted in a fine from the environmental authority and required costly cleanup. After the incident, the contractor implemented dedicated lined washout pits and trained all drivers on environmental compliance, avoiding further violations.
11. Deliverables and Documentation
Provide:
Approved method statement and risk assessment.
Material submittals and approvals.
Test reports and inspection records.
As-built drawings.
Photo documentation of works.
12. Troubleshooting Common Issues
Problem
Cause
Solution
Honeycombs
Poor vibration
More vibrators, trained operators
Cold joints
Pour delays
Bonding agents, better sequencing
Surface cracks
Poor curing
Increase curing time, use curing compounds
Low strength
Excess water
Enforce mix control
Conclusion
A detailed and enforceable method statement ensures that concrete works are safe, durable, and defect-free. By following these 10 powerful steps, backed by field experience, you can guarantee the success of projects ranging from small-scale residential work to massive infrastructure pours.
