Handbook CPWD NoPW

HANDBOOK ON
REPAIR AND REHABILITATION

OF
RCC BUILDINGS
PUBLISHED BY
DIRECTOR GENERAL (WORKS),
CENTRAL PUBLIC WORKS DEPARTMENT,
GOVERNMENT OF INDIA, NIRMAN BHAWAN.
CPWD Handbook on Repairs and Rehabilitation of RCC Buildings
© Copyright by Director General Works {DG(W)},
Central Public Works Department (CPWD) ,
Government of India, New Delhi.
CPWD, its authors, editors and engineers, apply diligence and judgment in locating and using reliable sources
for information published, practices and beliefs. However, CPWD makes no express or implied warranty or guarantee
in connection with the content of the information contained herein, including the accuracy, correctness, value,
sufficiency, or completeness of the data, methods and other information contained herein. CPWD makes no express
or implied warranty of merchantability or fitness of a particular purpose. CPWD shall have no liability to any customer
or third party for any loss, expense, or damage including consequential, incidental, special or punitive damages,
including lost profits or lost revenue, caused directly or indirectly by any error or omission, or arising out of, or in
connection with, the information contained herein.
All rights reserved.
No part of this publication can be reproduced, stored in a retrieval system, or transmitted in any form or by any
means without written permission DG (W), CPWD.
First published in 2002
Published by : Director General Works {DG(W)}, Central Public Works Department (CPWD),
Government of India, New Delhi.
The book Printed in India
At Government of India Press, Mayapuri, New Delhi
The CD containing the Electronic version of the book has been created by
Kshitiz Enterprises, New Delhi-110049
Ph: 91+11+4624018 • e-mail : [email protected]
FOREWORD
CPWD, with a glorious history of more than 100 years in the field of built environment, is playing
a lead role in our country in dissemination of knowledge relating to practices in building industry for
engineering profession. It is actively involved in the development of infrastructure for the country and has
to its credit successful completion of a large number of prestigious projects including bridges, flyovers,
airports, roads and other buildings of national importance. CPWD publications are being used profusely
by both public and private sector and they are reckoned as standard engineering practices. A vast
number of technical publications have been released for the benefit of engineering community. Some of
these are:
1) Manual on Planning and Design of Reinforced concrete multi-storeyed buildings – Vol. –I
and Vol. –II. - 1976
2) Maintenance from Approach, Cause and Effect Study by Shri K S Narayanan
3) A Report of Documentation on Fire, Assessment of Damages and Repair of Vigyan Bhawan,
New Delhi - 1993.
4) Guidelines and Space Standards for Barrier Free Built Environment for Disabled and
Elderly Persons, 1998
5) Manual on Rainwater Harvesting, 2002
Buildings and other structures have a certain useful life, which depends on the specifications adopted.
The large number of monuments, which are cherished heritage structures have stood well over a period
of time. But some of these have shown signs of distress due to age, aggressive natural environment/
industrial pollution etc. Further, distress gets aggravated due to overloading/ misuse of buildings. A few
buildings have also failed due to faulty design / construction. Thus, Repairs & Rehabilitation of buildings
are of vital importance. The experiences gained by CPWD and other organisations in Repairs &
Rehabilitation of RCC Buildings are presented in this Handbook. A panel of experts drawn from gov-
ernment departments, scientists, research organisations and consultants has ensured that the handbook
will provide expert guidance in Repair & Rehabilitation work. An attempt has been made to compre-
hensively cover all aspects related to repair, rehabilitation and strengthening of RCC buildings at one
place. I am sure this handbook will serve as a ready reference guide to all practicing civil engineers,
academicians and students.
The initiative and efforts of Shri A K Sharma, Superintending Engineer and his team in Repairs &
Rehabilitation Unit under the guidance of Dr A.V.Chaturvedi, ADG (Training) & Shri R Subramanian,
Chief Engineers of CDO are commended. I express my appreciation for Shri S. L. Karunakaran,
Chairman and all members of the Expert Committee for their valuable contribution in bringing out this
handbook, which is first of its kind dealing with the vital area of Repair & Rehabilitation.
(ER. KRISHAN KUMAR),

Director General (Works)
CPWD, Govt. of India.
EXPERT COMMITTEE
Chairman : Shri S L Karunakaran, Consultant to Govt of India and ADG(Retd.),

Central Public Works Department, New Delhi
Member Secretary : Shri A K Sharma, Superintending Engineer, Repairs & Rehabilitation Unit, Central
Design Organisation, Central Public works Department, New Delhi.
Members :
1. Dr C Rajkumar, Advisor, National Council of Cement and Building Materials, Ballabgarh
2. Dr K Mani, Scientist, Structural Engineering Research Centre, Chennai
3. Dr L K Aggarwal, Head, OBM Division, Central Building Research Institute, Roorkee
4. Dr N S Rengaswamy, Scientist(Retd), Central Electro-Chemical Research Institute, Karaikudi,
Tamilnadu
5. Dr S K Sharma, Superintending Engineer, Central Public Works Department, Indore
6. Dr S Srinivasan, Scientist (Retd), Central Electro-Chemical Research Institute, Karaikudi, Tamilnadu
7. Dr Yogendra Singh, Department of Earthquake Engineering, Indian Institute of Technology, Roorkee
8. Shri A K Gupta, Chief Engineer(Civil), Department of Telecom, Mahanagar Telephone Nigam Ltd,
New Delhi
9. Shri D S Sachdeva, Chief Engineer, Central Public Works Department, Siliguri
10. Shri H.S.Bakshi, Consultant, Engineering Development and Consultant, New Delhi
11. Shri J Bhattacharjee, Addl Chief Engineer, Military Engineering Service, Ministry of
Defence, New Delhi
12. Shri M A Jacob, Addl Director General (Retd), Central Public Works Department, Mumbai
13. Shri P C Sharma, Scientist (Retd), Structural Engineering Research Centre, Ghaziabad
14. Shri R N Raikar, Chairman & Managing Director, M/s Structwel Designers & Consultants Pvt Ltd,
Mumbai
15. Shri R Subramanian, Chief Engineer(D), Central Design Organisation, Central Public Works Depart-
ment, N Delhi
16. Shri S P Banwait, Chief Engineer, Public Works Department, Govt of Delhi, New Delhi
EDITORIAL COMMITTEE
Chairman : Shri S L Karunakaran, Consultant to Govt of India and ADG (Retd.) Central Public Works
Department, New Delhi
Members:
1. Dr C Rajkumar, Advisor, National Council of Cement and Building Materials, Ballabgarh
2. Shri P C Sharma, Scientist (Retd.), Structural Engineering Research Centre, Ghaziabad
3. Shri A K Sharma, Superintending Engineer, Repairs & Rehabilitation Unit, Central Design
Organisation, Central Public works Department, New Delhi.
ACKNOWLEDGEMENT
A. Encouragement, Guidance and Support:

Shri Krishan Kumar, Director General (Works); Dr A V Chaturvedi, Addl Director General
(Training); Shri H K Munjal, Addl Director General (TD); Shri Deepak Narayan, Engineer-in-
Chief, PWD, New Delhi.
B. Drafting & finalisation:
Shri A K Sharma, Superintending Engineer, Repairs & Rehabilitation Unit, CDO, CPWD, New
Delhi
C. Technical Support:
Dr V Thiruvengadam, Professor, School of Planning & Architecture, New Delhi;
Shri Manoj K Sharma, Shri Bhagwan Singh, Shri Rajesh Khare, Shri Vasu Dev, Executive Engineers;
Shri Manoj Kumar, Assistant Executive Engineer; Shri Naresh K Sharma, Shri Piyush K Singh,
Shri M C Singhal, Assistant Engineers; Shri Sanjay Bose, Junior Engineer; Repairs & Rehabilitation
Unit, CPWD, New Delhi
D. Sketches:
Shri Mukesh Kumar Sharma, Smt. Bimlesh Kumari Saxena, Draftsman, Repairs & Rehabilitation
Unit, CPWD, New Delhi
D. Secretarial Assistance :
Smt. Aanchal Arora, Stenographer and Ms Rajani Saxena, UDC, Repairs & Rehabilitation Unit,
CPWD, New Delhi
E. Printing & Publication :
Directorate of Printing M/o UD & PA Govt. of India
1 Shri H. A. Yadav, (Director of Printing)
2. Shri A.K. Sinha (Dy. Director of Printing)
3. Shri Joginder Singh (Dy. Director of Printing)
PREFACE
Reinforced cement concrete (RCC) as a construction material has come into use for the last one
century. In India, RCC has been used extensively in the last 50-60 years. During this period, we have
created large number of infrastructural assets in terms of buildings, bridges, sports stadium etc., which
are lifeline for the civilized society. These have been created with huge investment of resources. We
cannot even dream of recreating such assets out of limited national resources. It is, therefore, essential to
maintain them in functional condition. Since, deterioration of RCC is a natural phenomena and has
started exhibiting in large number of structures, a systematic approach is needed in dealing with such
problems. Identification of the causes of deterioration and consequent repair/rehabilitation strategy at
optimum cost needs a scientific evaluation and solution.
It has been observed that the deterioration phenomena of RCC is not realized by majority of
practising civil engineers. As a result, the factors considered necessary for durability of RCC buildings
are many times not given due importance during construction and/or during maintenance. The durability
provisions have been given emphasis in the revised ‘Code of Practice on Plain and Reinforced Con-
crete’ (IS:456-2000). In the international scenario also, deterioration of RCC had been drawing atten-
tion of the practising civil engineers for quite some time. They have accordingly, made certain advance-
ments in the field of protection, repairs, rehabilitation, strengthening and retrofitting of the existing RCC
structures taking advantage of the advancement in the materials science, more particularly the polymer
science. The knowledge in this area among the Civil Engineers, in India is still at infancy stage and needs
development and systematic dissemination. This Handbook is a pioneering attempt with this objective in
view.
CPWD is a leading organisation practising in construction and maintenance of buildings for over a
century. Having faced the problem of deterioration in RCC buildings under its maintenance, the need of
specialised unit in the field of repair, rehabilitation and protection of existing buildings was felt and a unit
was created on 1/1/96. Based on various investigative works carried out by this unit including remedial
measures suggested & adopted for deteriorated buildings and study of literature available on the sub-
ject, this handbook has been prepared. The book covers the subject starting from causes of deteriora-
tion, investigative methods, design principles, selection criteria of repair materials & methods, guidelines
for selection of consultant, short-listing of contractors and preparation of contract documents for repair/
rehabilitation contracts including nomenclature and related specifications of commonly used repair items.
A variety of case studies with photographs have also been included to facilitate the readers to imbibe a
better understanding of the subject.
Initially, the structures deteriorate slowly due to cyclic temperature variations, overloading, physi-
cal causes & aggressive chemical attack due to environment etc. Later on, if not paid due attention,
these deteriorate rapidly and fail to meet the functional requirement for its designed service life. Various
causes of deterioration like original construction defects, chloride induced corrosion, carbonation of
concrete, sulphate attack, cracking due to thermal gradient, plastic shrinkage cracks and foundation
settlement etc. are discussed lucidly with the help of sketches in Chapter-2.
The first step in repairs and rehabilitation is the proper diagnosis for successful rehabilitation works.
Chapter 3 deals with Non Destructive Evaluation (NDE) techniques, laboratory tests and Condition
Survey Techniques. Over forty tests have been enumerated for measurement of different properties
grouped in four categories as given below:
a) Corrosion of embedded steel,
b) Concrete quality, durability and deterioration,
c) Concrete Strength
d) Structural Integrity
Details of commonly used tests for Non Destructive Evaluation (NDE) like Rebound hammer test,
Ultrasonic Pulse Velocity (UPV) test, Capo / Pull out test, Core test, Chloride test, Carbonation test,
pH measurement, Resistively test, Differential Thermal Analysis (DTA), etc have been dealt with. Sym-
bols for recording distresses on building plans and worksheets have been given. Proforma for scientific
analysis, planning and documentation has been developed which will go a long way in grouping / classi-
fication of damages. These in turn are useful tools in selection of the appropriate repair technique.
Chapter 4 deals with the analysis and design of repairs, which are quite different from the original
design. For this purpose, repairs have been classified as active or passive depending upon the relieving
or non-relieving of existing stresses & strains before carrying out the repairs. The types of stresses
acting on the interface of substrate and repairs have been briefly discussed for a designer not to loose
sight off during structural evaluation.
The compatibility of repair material with the parent material is an essential requisite for successful
repairs. Chapter 5 covers cements, admixtures, additives, polymers and epoxies in detail specifying
wide and varied application with their advantages as well as limitations. Attempt has been made to guide
the readers to select the right type of material for a specific job. The directory of Indian manufacturers
of repair materials and testing laboratories has been included for information of users.
The methods available for repair, rehabilitation and retrofitting are many. The chapter-6, which is
on ‘Repair, Rehabilitation and Retrofitting Methods’ gives guidelines for selection of method from vari-
ous repair options available to suit the performance requirement of repair system. More than twenty
techniques for dealing with various types of distresses and other situations have been described. These
generally cover concrete, RCC structural members like slabs, beams, columns, and foundations, repairs
of cracks, strengthening of masonry, surface protection, reinforcement etc.
As the structural repairs have to be generally investigated by the consultants and executed through
contractors, foolproof contract documents are basic necessity. Chapter-7 ‘Guidelines for Special Con-
ditions of Contract’ gives information for engagement of consultant and short-listing of contractors and
also gives the checklist, so that none of the salient points are missed while preparing the contract/tender
documents.
Chapter-8 and Chapter-9 give the nomenclature and related specifications of more than seventy
items generally used in repairs and rehabilitation works. These have been grouped under ten subheads.
The specifications are given in easy to follow step-by-step format for their fail-safe execution/applica-
tion in the field.
An expert group in the field of repairs, rehabilitation and retrofitting, consisting of over fifteen
experts drawn from Government and Non Government practising engineers/designers/consultant/lead-
ing scientists was constituted for finalisation of this Handbook drafted by the Repair & Rehabilitation
Unit of CPWD. This was done with a view to ensure that all aspects required are covered in such a
Handbook in a lucid form for reference and adoption.
It is hoped that this handbook, which covers A to Z of Repairs and Rehabilitation, will be of
immense use for the student community, Academicians, consultants, practising professional engineers /
scientists involved in planning, design, execution, inspection and supervision, for proper Repair and
Rehabilitation Management of Buildings.
The time for preparation of the book was rather tight and hence the aspect of retrofitting could not
be dealt in detail. Since the subject is rather nascent in the country, it is proposed to update the Hand-
book every 3 to 5 years. If the readers wish to share their typical experiences in the form of case studies,
they are welcome for inclusion in the updated versions. Comments and suggestions for improvement are
welcome from the readers and users.
A K SHARMA R SUBRAMANIAN
Superintending Engineer Chief Engineer (Design)
Repairs & Rehabilitation Unit, CDO, Central Designs Organisation,
CPWD, New Delhi CPWD, New Delhi
S L KARUNAKARAN, CHAIRMAN
Expert Committee, CPWD
CONTENTS
❐ CHAPTER 1.................................................................... I-1 to I-4

Introduction
❐ CHAPTER 2................................................................ II-1 to II-18
Causes of Deterioration and Durability Aspects
❐ CHAPTER 3............................................................... III-1 to II-52
Condition Survey & Non-destructive Evaluation
❐ CHAPTER 4............................................................... IV-1 to IV-6
Structural Analysis and Design
❐ CHAPTER 5............................................................... V-1 to V-49
Selection of Repair Materials for Concrete
❐ CHAPTER 6............................................................. VI-1 to VI-38
Rehabilitation and Retrofitting Methods
❐ CHAPTER 7...........................................................VII-1 to VII-88
Guidelines for Framing Terms and Conditions
for Repair & Rehabilitation Works Contracts
❐ CHAPTER 8 ...................................................... VIII-1 to VIII-24
Schedule of Special Items for
Structural Repair Work
❐ CHAPTER 9 ......................................................... IX-1 to IX-105
Specifications for Structural Repair Work
❐ CHAPTER 10 ............................................................ X-1 to X-81
Case Studies
❐ GLOSSARY ................................................................ G-1 to G-4
CHAPTER 1
INTRODUCTION
PAGE NO.
1.1 An Overview of Present Repair Practices I-1
1.2 Distress Identification I-2
1.3 Repair Management I-3

INTRODUCTION
1
INTRODUCTION
The whole professional life of engineers is based on team work rather than on personal competitiveness
…Freeman Dyson
Concrete construction is generally expected to give trouble free service through out its intended
1
design life. However, these expectations are not realized in many constructions because of
structural deficiency, material deterioration, unanticipated over loadings or physical damage.
Premature material deterioration can arise from a number of causes, the most common being
when the construction specifications are violated or when the facility is exposed to harsher
service environment than those expected during the planning and design stages. Physical
damage can also arise from fire, explosion – as well as from restraints, both internal and
external, against structural movement. Except in extreme cases, most of the structures require
restoration to meet its functional requirements by appropriate repair techniques.
1.1 An Overview of Present Repair Practices

Since 1950s, the construction activity in India has been increasing geometrically without
matching increase in the availability of quality inputs, in terms of materials and skilled
workmen. The gap between the quality planned and the quality achieved continues to
become wider. The factors contributing to damages/distresses in buildings have, thus,
become intrinsic right from the construction stage. Often these are concealed under
external renderings and the defect takes time to manifest itself.
Construction documents contain adequate specifications and instructions required to
execute quality works. However, they remain as written document without achieving
the desired level of results, because of lack of understanding of their significance by
the field engineers. Standard cube test results are taken as a measure of quality in the
construction. Whereas the factors such as method of placing, compaction and curing
of concrete, which have significant influence on the quality achieved in the hardened
concrete, are given scant attention. Many a times, the quality of concrete as placed and
hardened in position has no correlation to the cube test results, which are used for
quality control measures.
Procedures, mandatory or otherwise, for periodic inspection of buildings and structures
and documenting defects, like cracks, excessive deflections, corrosion of reinforcement
etc., in logical manner, and recording of structural repairs already carried out, are
generally not followed or maintained. In some buildings, only visual inspection is
carried out for preparing maintenance budget estimates and this exercise is often left to
the engineers who have no experience in such problems.
Central Designs Organisation I-1

HANDBOOK ON REPAIRS & REHABILITATION OF RCC BUILDINGS
Concrete constructions require proper care in the form of regular maintenance. Buildings
remain for several years without getting due attention. Water stagnation, paint pealing,
plaster break- off, fungus growth, cracking of external rendering and cover
concrete are common and widespread. Penetration of moisture into reinforced
concrete components promotes corrosion process and further damages the concrete
cover.
The engineers responsible for maintaining buildings often begin repair activity without adequate
understanding of the factors responsible for the defects. The repairs strategy adopted is
replacement of damaged materials without dealing with the real problems. Many engineers
unintentionally attempt treating the symptoms, instead of dealing with the cause and effect
phenomenon. Such an approach may offer a quick action with minimum inconvenience to the
1 occupants. But in this process, there is a strong possibility that the source and cause for the
distress remain unattended and continue to cause problem even after the superficial repairs
have been executed. If structural defects are dealt with in this fashion, it remains only as
defects camouflaged beneath finishes, which gives a false sense of safety to the occupants
allowing the problem to continue without getting treated. A rational approach to any repair
and rehabilitation work is to consider the source of the problem and the symptoms together.
1.2 Distress Identification

Before attempting any repair procedure it is necessary to have a planned approach to
investigate the condition of concrete and reinforcement. While the diagnosis of damage
or deterioration in some cases is reasonably straightforward, it may not be so in many
cases. Particularly difficult are cases in which the cause and effect phenomenon cannot
be readily explained or when prognosis in terms of long-term performance of restored
structure is to be made.
This will require a thorough technical inspection and an understanding of the behaviour
of the structural component, which is being repaired. Inspection calls for detailed
mapping of affected areas, documentation of type and location of symptoms and their
history and photographic evidences. It may also include the environmental factors,
which are likely to accelerate the damage process. Existence of concealed ducts, water
lines, wet areas require special attention. Some areas impose severe limitations on
access to damaged areas. A comprehensive inspection data helps in making an effective
strategy for repair and rehabilitation.
Non-destructive evaluation (NDE) of concrete and components are well known and
extensively used. While they are very good tools for establishing quality levels in new
constructions, applying these techniques to damaged structures requires certain level
of experience and understanding of limitations of these methods. Solving the problem
successfully is entirely dependent on the ability of a team of experts engaged to do this
job. Both field and laboratory tests are available. It is important to select the appropriate
Non Destructive Evaluation (NDE) techniques and location of investigation. This is a
specialised job and requires sophisticated instruments and trained personnel. A single
technique may not be adequate and a combination of techniques has to be adopted to
get a truly representative data on the condition of the building.
I-2 Repairs & Rehabilitation Unit

INTRODUCTION
Concrete normally provides excellent protection to reinforcing steel. Notwithstanding this, a

large number of cases have been reported in which corrosion of reinforcement has caused
damage to concrete structures within a few years from the time of construction. One of the
most difficult problems in repairing a reinforced concrete element is to handle corrosion
damage. Reinforcement corrosion caused by carbonation is arrested to a great extent through
repairs executed in a sound manner. However, the treatment of chloride-induced corrosion is
more difficult and more often the problem continues even after extensive repairs have been
carried out. It invariably re-occurs in a short period of time. Repairing reinforcement corrosion
involves a number of steps, namely, removal of carbonated concrete, cleaning of reinforcement,
application of protection coat, making good the reduced steel area, applying bond coat and
cover replacement. Each step has to be executed with utmost care. When chlorides are
present in concrete, it is extremely difficult to protect reinforcing steel from chloride attack, 1
particularly in cases where chlorides have entered through materials used in construction and
residing in the hardened concrete. For such cases, new technologies are available which
require specialists to execute the job.
1.3 Repair Management

Three distinct stages are to be recognized while taking up a repair job. The first stage involves
documentation of damage, its type and extent, prognosis of repaired structure and
recommendations on repair methodology. For major jobs it will be worth while to engage an
independent consultant to do this job. The second stage requires preparation of detailed
drawings, sketches, execution guidelines and notes, material and works specifications and
tender document. The tender document should adequately cover various elements to the
extent possible. Specific provisions in terms of material specifications should be included. It
should clearly define modalities of payment, works measurements and records. This will
facilitate in receiving a fair and competitive proposal for the repair works. Guidelines prepared
for executing the job should be practical and flexible so as to encourage the ingenuity of the
contractor executing the job. The third stage is actual execution of repairs. This is a specialised
job and those who have the necessary expertise and resources in terms of tools and plants
should be engaged. The supervising engineer should have a good understanding of the
procedures and give an attentive supervision. In some cases it may become necessary to
monitor the effectiveness of repairs by various tests before and after the repairs have been
executed.
Various options in terms of techniques and repair materials are available for executing repair
jobs. Selecting a most appropriate material and repair methodology is very important to
achieve durable, effective and economic repairs. Matching the response of repaired sections
with the main structure is an important task.Compatibility of materials and matching specifications
are essential in any repair job. Just as building durable construction requires understanding of
structural engineering, material science, and environment/ exposure conditions, repair jobs
also require the same level of attention in these areas.
The buildings taken up for repair may have structural deficiency and in such cases it is necessary
to consider provisions for strengthening through bracing and creating alternative load transfer
framing to give additional reserve strength to the structure for adequate safety and serviceability
Central Designs Organisation I-3

response. If this aspect is overlooked, the symptoms are likely to reappear even after repairs
have been carried out.
Familiarity with repair methodology and repair materials is very essential. General civil
en1gineering practice does not offer much scope in this area. The engineer undertaking such
specialised jobs should have good knowledge of new materials, repair methodologies, its
limitation and the fundamentals of structural engineering to ensure safety and serviceability of
the buildings during repair and thereafter.
✯ ✯ ✯
1
I-4 Repairs & Rehabilitation Unit

CHAPTER 2
CAUSES OF DETERIORATION AND

DURABILITY ASPECTS
PAGE NO.
2.0 General: II-1
2.1 Holistic Model of Deterioration of RCC II-2
2.1.1 Model-1 II-2
2.1.2 Model-II II-3
2.1.3 Model-III II-3
2.2 Permeability Of Concrete II-4
2.2.1 Capillary Porosity II-5
2.2.2 Air Void II-7
2.2.3 Micro Cracks: II-7
2.2.4 Macro Cracks: II-8
2.3 Aggressive Deteriorating Chemical Agents II-9
2.3.1 Corrosion of reinforcing bars: II-9
2.3.2 Sulphate Attack: II-12
2.3.3 Alkali Silica Reaction: II-13
2.3.4 Other Causes of Distress: II-13
2.4 Durability Aspects: II-13
Suggested further reading Material and References II-14
Appendix 2.1 II-15

2
CAUSES OF DETERIORATION AND DURABILITY
ASPECTS
All things are hidden, obscure, and debatable if the cause of the phenomna be unknown, but everything is
clear if this cause be known
..Louis Pasteur
2.0 General:
2
Concrete is a composite material that consists essentially of a binding medium, within
which are embedded particles or fragments of aggregates. However in cement concrete,
which is relevant to RCC structures, the binding medium is the mixture of hydraulic cement
and water.
All concrete in service will be subject to chemical and physical changes. A durable concrete
is one in which these changes occur at a rate, which does not detrimentally affect its
performance within its intended life. Leave it to concrete alone, the material remains by and
large durable, but concrete alone cannot be utilised extensively for structural applications. It
is the Reinforced Concrete (RCC), a composite structural material, which is utilised for
variety of structural uses. But, it has been observed that RCC has not proved to be durable
due to large number of factors, including variations in production, loading conditions in service
life and subsequent attack by the environmental factors. However, a well constituted, properly
compacted, and cured concrete used in RCC continues to be substantially water tight and
durable as long as capillary pores and micro-cracks in the interior do not become interconnected
pathways leading to surface of concrete. (Ref Fig 2.1(a) &2.1(b))
Fig 2.1: (a) Porous but Impermeable Structure (b) Porous but Permeable structure
Fig 2.1: Structure of Durable Concrete and Non-durable concrete
Central Designs Organisation II-1

Case studies reported in the literature show that many reinforced concrete structures, within
a life period of 15 years or so, suffered from of durability distress. The external symptom
range from cracking to spalling of concrete, which frequently involved corrosion of
reinforcement. The field cases included in Chapter 10 of this publication give further details
on the magnitude of this problem. In almost all the field cases, penetration of water and /or
aggressive chemicals during the service life of structures, is the primary reason for the problem.
Addressing the issue of deterioration, carbonation, chloride ingress, leaching, sulphate attack,
alkali-silica reaction and freeze-thaw are the known responsible natural causes. Out of these,
the first three can all lead to corrosion of reinforcement. The general approach for durability
is to demand impermeability of concrete as the first line of defence against any of the
deterioration process. Damages due to other natural hazards including fire damage may not
come under this category.
Although it is difficult to generalize the causes of deterioration due to interacting nature of
2 various factors, efforts have been made to group the various types as physical and chemical.
Because the micro-structure of concrete material is continuously changing in response to
penetration of water, CO2, oxygen and aggressive ions at a rate, which is influenced by local
conditions of temperature, humidity and pressure, it would be difficult to make exact quantitative
predictions of cause affecting service-life. Based on this simplification, few holistic models of
deterioration of RCC have been illustrated, which represent a qualitative design approach for
easy understanding of the contributing factors for deterioration and its mechanism.
2.1 Holistic Model of Deterioration of RCC
2.1.1 Model-1
According to this holistic model of deterioration of concrete shown in Fig 2.2, the deterioration
process is considered in two stages. During the first stage, due to loading and weathering
Fig 2.2: Holistic Model-I of Concrete Deterioration from environmental effects

(Source: P.K. Mehta, “Concrete Technology: Last, Present and Future,” SP-144,
American Centre Institute, Detroit, 1994)
II-2 Repairs & Rehabilitation Unit

CAUSES OF DETERIORATION AND DURABILITY ASPECTS
effects (e.g. cycles of wetting & drying, diurnal & seasonal temperature variations, etc) the
voids and micro-cracks in the interfacial zone between the cement paste and coarse aggregate
or reinforcing steel become inter-linked. When the inter-linked network of micro-cracks gets
connected to any cracks present at the concrete surface, this provides the primary mechanism
of fluid transport into the interior of concrete. Once this happens, the penetrability of concrete
increases greatly and the beginning of the second stage during which water, oxygen, carbon
dioxide and acidic ions are able to penetrate easily into concrete. The presence of these
elements facilitates various physical-chemical interactions as a result of which, the material
eventually undergoes cracking, spalling and loss of mass resulting in partial loss of strength
and stiffness.
2.1.2 Model-II
According to this concept as illustrated in Fig. 2.3 there are three stages, namely gradual loss
of water tightness, initiation of damage and propagation of damage. During the stage 1 no 2
noticeable weakening of the material occurs but some protective barrier is being broken
down, such as the depassivation of the reinforcing steel by CO2 or chloride penetration.
While discussing this model, Prof Mehta says that the longevity of stage 1 can be manipulated
through proper attention to the selection of materials, mixture proportions and concrete
processing.
Fig. 2.3: Holistic Model-II of Deterioration of RCC
2.1.3 Model-III
Another model on deterioration of concrete, which is dependent on the important role played
by water cement ratio (W/C), is illustrated in Fig 2.4. This offers an overall view on the
co-existence of the following three principal elements.
(a) Interconnected porosity of Cement paste
(b) Exposure to aggressive agents/chemicals
(c) Intermittent presence of water

In absence of any of these three elements, damage to RCC will not occur. For example, even
in a porous and/or micro cracked concrete, further deterioration can not occur, in absence of
water/moisture even if there is a potential presence of environmental aggressive agent such as
SO4-2 , Cl- , CO2. In absence of water/moisture, these aggressive ions cannot travel, through
inter connected pores. Thus, neither sulphate attack on cement paste nor the corrosion of
steel reinforcement can occur.
Fig. 2.4: Ternary Representation of the Damage to RCC

(Source: M. Collepardi, “A Holistic Approach to Concrete Durability—Role of Superplasticisers”
Proc. of International Syuposium on Concrete Technology for Sustainable Development in
Twenty-First Century, Hyderabad, India, Feb., 1999)
2.2 Permeability Of Concrete

As deterioration process in concrete begins with penetration of various aggressive agents,
low permeability is the key to its durability. Concrete permeability is controlled by factors like
water-cement ratio, degree of hydration/curing, air voids due to deficient compaction,
microcracks due to loading and cyclic exposure to thermal variations. The first three are
allied to the concrete strength as well. The permeability of cement paste is a function of
water-cement ratio. This is well illustrated in Fig 2.5. Beyond 0.55 there is an asymptotic
increase. Given good quality materials, satisfactory proportioning and good construction
practice, the permeability (i.e. ‘Interconnected Porosity’) of the concrete is a direct function
of the porosity and interconnection of pores of the cement paste. Interconnected Porosity is
related to:
1. Capillary Porosity -High w/c ratio

-Inadequate curing
2. Air voids -Improper compaction
3. Micro cracks -Loading effects
-Weathering
-Initial care
-After care
-Secondary effects

4. Macro cracks -Placement,

-Hardening process
-Intrinsic chemical attack
-corrosion of reinforcement
Fig. 2.5: Permeability of cement paste is a function of water-cement ratio
For understanding the permeable character of concrete, it is necessary to understand the

mechanism of formation of pores, capillaries and air voids during hardening process due to
hydration of cement paste. This is better understood by knowing the composition of cement
and resultant hydration products after chemical reaction with water.
2.2.1 Capillary Porosity: The volume of hydrated cement product is significantly higher than
the volume of its constituents (i.e., cement particles and water). As a result of hydration,
increased volume of hydrated gel eventually fills part of capillary pore volume [Fig 2.6 (a)].
This helps in creating discontinuity in capillary pores. Whereas any lessening in the hydration
process will not give the full benefit from this phenomenon.
It can be shown that 100 gm of anhydrous Portland Cement requires about 23 gm
of water (a water/cement ratio of 0.23) after about a month’s hydration under normal
conditions. However, for achieving full hydration as well as to render the mortar/
concrete workable, excess water is required. This extra volume of water entrapped
in the cement paste after completion of hydration leaves interconnected pores,
called capillaries in hardened concrete, which become means of passage for
external/environmental chemicals into the concrete. This porosity is termed as
capillary porosity. The porosity obviously increases with the increase in w/c
ratio [Fig 2.6(b)].
This approach is explained in simplified models in Fig 2.6(a) and 2.6(b) , wherein Case-A
shows changes in permeability for constant w/c ratio under varying degree of hydration &
Case-B indicates change in porosity at complete hydration for varying w/c ratio.
Fig. 2.6(a): Changes in capillary porosity with varying degree of hydration

(Source: Concrete—Microstructure, Properties and Meterials by P. Kumar Mehta & Paulo J.M. Mouterio)
Fig. 2.6(b): Changes in capillary porosity with varying w/c ratio

(Source: Concrete—Microstructure, Properties and Meterials by P. Kumar Mehta & Paulo J.M. Mouterio)

Tables 2.1 and 2.2 illustrate the effect of curing time on capillary pores and the curing time
required for various w/c ratios.
In a well constituted, adequately compacted & cured concrete with low water-cement ratio,
volume of capillary pores gets reduced and become discontinuous due to expansive hydrated
gel, which significantly reduces the permeability.
Table 2.1: Curing Time required Table 2.2: Typical Reduction in

for various water-cement ratios permeability of cement paste with
progress of hydration
Water-Cement Curing Time required (Source: T.C. Powers, L.E. Copeland, J.C. Hayes and
H.M. Mann, J.ACI, Proc. Vol. 5, pp. 285-98, 1954)
Ratio by mass for capillary
discontinuity Age (days) Coefficient of permeability
(x10-11 cm /sec)
0.4 3 days
0.45 7-days Fresh 20,000,000 2
5 4000
0.5 14 days 6 1000
0.6 6 months 8 400
0.7 1 year 13 50
24 10
>0.7 1 year Ultimate 6
2.2.2 Air Voids: Air voids (much larger than capillary pores) form due to inadequate compaction
in the form of discrete air bubbles (as in air entrained concrete) of much larger size than
capillary pores. These air voids may get inter-connected by capillary pores system.
2.2.3 Micro Cracks: During service life of a reinforced structure, it is subjected to various types
of loading conditions (static and/or of cyclic nature) and also exposed to extreme exposure
conditions of temperature variations (diurnal and seasonal). Micro-cracking combined with
capillary porosity is generally responsible for ingress of aggressive chemicals in RCC.
l Cyclic loading: Fig 2.7 illustrates the crack propagation due to cyclic load in tensile
zone of an RCC beam. The crack depths in structural members due to cyclic loading
are higher than due to static loads of same intensity.
Fig. 2.7 Crack propagation in tensile zone of an RCC beam.

l Differential Thermal Exposure: The structural members having different thermal

exposure conditions on the opposite faces, more particularly, those located on the
exterior, are subjected to loading due to temperature gradient within the cross section.
This is due to difference in temperature on the two faces of member during different
times. As a result, tensile stresses in excess of tensile strength of concrete could develop
across the cross section and result in formation of micro cracks. This process is cyclic
due to diurnal and seasonal temperature variation conditions. Cyclic nature of loading
is responsible for further increase as the crack depths propagate deeper with each
cycle. Fig 2.8 illustrates the cyclic process of thermal loading of a structural member.
Fig. 2.8 Cyclic process of thermal loading of a structural member.
l Other causes: Besides above, several other factors and secondary effects would also
cause micro-crack formation, which could be severe in special structures under special
circumstances.
Initial and after care of the structure in the form of periodical painting, also plays an important
role in controlling the adverse effect due to propagation of such micro-cracks.
2.2.4 Macro Cracks: Some minor cracking in concrete structures would occur within the normal
practice. Proper design and detailing coupled with proper construction practice can control
the crack widths. Any crack width, which allows aggressive chemicals to travel freely into the
concrete, is termed as Macro Crack. The threshold limiting crack width has been defined by
various codes of practices for RCC design. These vary from 0.1 to 0.3 mm. Any crack in
concrete, which is wider than this, is likely to cause durability problems. Beeby has showed
from his experimental and theoretical work that the relationship between corrosion and crack
width either does not exist or, if it does, is not a significant factor compared with other
variables such as the amount of cover and the quality of the concrete. Yet many others
consider that even micro-cracking is responsible for easy ingress of aggressive deteriorating
chemicals in to the cover concrete to adversely affect and cause depassivation to initiate

corrosion of embedded steel reinforcement and acelerate the same with development of
macro cracks. Macro cracking in concrete could be due to variety of reasons,
which includes:
- Improper placement of concrete,

- Settlement cracks of fresh concrete,
- Cracking due to - intrinsic sulphate attack,
- alkali aggregate reaction,
- heat of hydration,
- Increased volume of Corroded reinforcement
exerting bursting pressure on concrete.
- Excessive Loading
2
2.3 Aggressive Deteriorating Chemical Agents
The deterioration of RCC is basically related to loss of water tightness of cover concrete and
migration of aggressive chemicals through interconnected porosity, which in turn chemically
attacks on its constituents i.e. hydrated cement gel, aggregate and the reinforcement
as under:
(a) Corrosion of reinforcing bar - Due to carbonation of concrete

- Due to ingress of chloride
(b) Sulphate Attack
(c) Alkali Silica Reaction (ASR)
2.3.1 Corrosion of reinforcing bars: Steel reinforcement in concrete is protected from corrosion
by a combination of
- the formation of a passivating protective layer on steel surface due to chemical reaction
under highly alkaline environment and
- the environmental protection provided by the concrete cover.
The hydration reactions of portland cements release allkalies giving it a high pH in the range
of 12.6 to 13.5. Even though oxygen and moisture may reach the steel surface, it will not
corrode and will remain passive as long as high pH is maintained and the cover concrete is
intact. The two common conditions that lead to the loss of passivity of steel in
concrete are
i. Reduction of alkalinity of concrete surrounding the steel with pH lower than
11 to 11.5
ii. Presence of chemicals (e.g. chloride ions ), which destroy the passivity even while the
alkalinity of surrounding concrete remains high.
Note: Use of rusted reinforcement will promote further rusting since pre rusted
surface will impede the passivation of steel substrate.

The three elements needed (see Fig 2.9) for initiation of the corrosion of reinforcement bars
are:
l De-passivation of Steel
l Oxygen
l Intermittent presence of water i.e. alternate wetting and drying
Fig. 2.9 Corrosion of reinforcement due to environmental elements

(Source: M. Collepardi, “A Holistic Approach to Concrete Durability—Role of Superplasticisers”
Proc. of International Syuposium on Concrete Technology for Sustainable Development in
Twenty-First Century, Hyderabad, India, Feb., 1999)
Carbonation: The alkalinity in concrete is provided by hydroxides of calcium, sodium and

potassium present in the hardened cement gel. Permeation of carbon dioxide into concrete
through interconnected pores and its reaction with these hydroxides causes chemical reaction
as under:
CO2+ H2O = H2CO3(Acid)
Ca(OH)2 + H2CO3 = CaCO3 +2H2O
(Alkali) (Acid) (Salt) (Water)
Because of this reaction, the alkalinity of concrete gets reduced. This process is called
Carbonation of concrete. Carbonation of concrete can be a problem in areas where the
concentration of CO2 is high and relative humidity is moderate (50-60%). Permeable concrete
made with low cement content, high water—cement ratio, and inadequately moist-cured
tend to suffer from serious carbonation even due to diurnal or seasonal temperature variations
[Fig 2.10(a)]. Diffusion of gaseous products from environment (CO2 and O2) cannot occur
or if occurs, at negligible rate in a fully and permanently saturated concrete. On the other
hand, water is also needed for feeding the corrosion process. Therefore, discontinuous i.e.
intermittent exposure to water (rain or wetting/drying cycle due to leakage from toilets) [Fig
2.10(b)] is the most favourable condition for corrosion of reinforcing steel. Once the passive
film is destroyed, the affected portion of reinforcing steel is exposed to action of oxygen and
water; consequently corrosion in reinforcement steel is initiated.
Localised rusting of reinforcement steel is represented as under:
Anode reaction Fe = Fe+++2e-
Cathode reaction O2+2H2O+4e-=4(OH)-(Oxygen is reduced)


Chlorides: These may be present in the fresh mix or may penetrate from external source into
the hardened concrete. Due to the deleterious effect of chlorides on the corrosion protection
of the reinforcement, the chloride content of the mix is limited to certain values in relation to
cement in almost all standards. During use of the structures, chlorides may penetrate into the
concrete from various sources. The most important of these are sea water. Substantially
greater amounts of chlorides may ingress into the hardened concrete via water transport
mechanisms than via pure chloride ion diffusion. The rate of penetration depends both on the
diffusion property of the concrete and on its binding capacity. The composition of binder
plays important role for the penetration resistance of concrete than the amount of cement
used and the water/cement ratio.
The parameters having decisive influence on the chloride-induced corrosion of the reinforcing
steel are : chloride content at the steel surface; C3A content in cement; addition of blast-
furnace slag/fly ash/silica fume in mix; water cement ratio; concrete cover; temperature and
2 relative humidity. The quality of the concrete cover is the dominant influencing variable for the
corrosion rate in the crack zone. This is, however, true only of crack widths up to about
0.4mm. With larger cracks, crack width is of decisive importance, since a different corrosion
mechanism is dominant in this situation. If the renforcement detailing rules given in the codes
are followed, it generally ensures that the crack widths are in the order of 0.3mm or less.
Lower the permeability of cover concrete, longer the time it takes for the penetration and
depassivation of embedded steel to affect the RCC. A corrosion initiation period is thus,
dependent on permeability of cover concrete. Deffusion of air and chloride ions cause
carbonation and depassivation of steel. Oxygen available in the air becomes a feed for the
corrosion process.
Water Acts as electrolyte. A medium for penetration of harmful dissolved
materials
Carbon Dioxide Reduces Alkalinity of concrete – Results in destroying the passive film
on the reinforcing steel reinforcement and thereby corrosion is likely to
initiate.
Chloride Destroys the passive film on reinforcing steel and initiates corrosion of
steel .
2.3.2 Sulphate Attack: The term, sulphate attack, is generally used to mean the deterioration of
concrete as a result of physical-chemical interactions between the minerals in hardened Portland
cement paste and sulfate ions from the environment. Soils containing sulfates of calcium,
sodium, potassium and magnesium are the primary source of sulfate ions in groundwater. A
high sulfate content in water is generally indicative of the presence of magnesium and /or
alkali sulfates. In combination with ammonium, chloride, nitrate and carbonate ions the sulfate
ion attack is more severe.
The sulfate attack on concrete manifests itself in the form of expansion, cracking, loss of mass
and/or disintegration. Expansion and cracking is generally associated with the product ettringite
formed due to reaction between sulphate ions and the hydration products C3A present in
high quantity in Portland cement pastes. The ettringite formation could take place due to
internally present sulphate ions or sulphate entering from external sources. In addition to
ettringite, cement paste subjected to prolonged attack by aggressive sulfate solutions generally

contain gypsum which forms as a result of progressive decomposition of calcium hydroxide

and calcium silicate hydrates. This leads to a reduction of stiffness and strength, with eventual
transformation of the material into a mushy mass.
For improved resistance to sulfate attack, a reduction in the porosity and consequently the
coefficient of permeability, is more important than modification in the chemistry of cement.
Addition of mineral admixtures, such as fly ash, ground blast furnace slag and silica fume have
a beneficial influence on the sulfate resisting behaviour of concrete.
2.3.3 Alkali Silica Reaction: Chemical reactions between aggregates containing certain reactive
constituents and alkalis and hydroxyl ions released by the hydration of cement can have a
deleterious effect on concrete. When the aggregates in cement concrete contain reactive
forms of silica, the phenomenon of chemical reaction is referred to as Alkali-Silica reaction
(ASR). Expansion and cracking, leading to loss of strength, elasticity and durability are among
the physical manifestations of ASR. Amorphous silica, microcrystalline and poorly crystalline
2
silica, fractured or strained quartz and glassy silica are among the commonly known alkali-
reactive forms of silica. Depending on the degree of disorder, porosity, particle size, and
temperature, the dissolution of silica structure will gradually occur, followed by formation of
a swelling-type alkali-silica gel, which can cause considerable expansion on water absorption.
Deleterious expansion from alkali-silica reactions in field takes years to develop. Mineral
admixtures, such as natural pozzolans, fly ash, silica fume, and ground granulated blastfurnace
slag, when used as partial replacement in concrete, can be effective in suppressing the ASR
expansion. Reports in the published literature by many investigators, confirm that, as a result
of ASR, adequately reinforced concrete structures do not suffer any significant deterioration
in mechanical strength. Another point to note is that expansion will not occur unless sufficient
moisture is present in the environment.
2.3.4 Other Causes of Distress: The basic underlying cause of deterioration of RCC are covered
in preceding part of this chapter. There could be a number of other causes like construction
and/or design and detailing deficiencies, material & workmanship deficiencies and the effect
of environment. The deficiencies could be due to extrinsic or intrinsic contributory factors as
explained in Table given in the Appendix 2.1.
2.4 Durability Aspects:

Durability is defined as the continued ability of the structure to withstand the expected wear
and deterioration and perform satisfactorily in the normal operating conditions through out its
intended life without the need for undue maintenance. What is implied is that the designer
should expect certain degree of deterioration during the service life and provide required
design inputs to adequately control it. Design for durability is now highlighted in IS:456-2000
under a specific section. The code emphasizes the perceived concern about the durability of
concrete structures in India with specific design recommendations to deal with corrosion of
reinforcement besides dealing with other types of durability problems.
Based on simplified approach, most of the National codes of practice on concrete construction
include specific clauses for ensuring durability of constructed facilities, addressing the issue
under carbonation, chloride ingress, leaching, sulphate attack, alkali-silica reaction and freeze-
thaw. The first three can all lead to corrosion of reinforcement, which can take place only
when steel reinforcing bars get depassivated due to reduced pH on account of reduction of
alkalinity of pore water of cement gel surrounding it. The alkalinity reserve of concrete is a
function of proportions of hydroxides of Calcium, Potassium and Sodium present in the
hardened concrete matrix, which in turn is directly related to quantity of cement. Higher the
cement content, higher the reserve pH of concrete due to increased quantity of such hydroxides
of Calcium, Potassium and Sodium. It is noteworthy that excessive quantities of cement
content also lead to other related problems due to heat of hydration, shrinkage etc. For this
reason, in the codes, the requirements on durability are expressed in terms of minimum cement
content, maximum water/cement ratio, minimum grade of concrete and minimum cover to
reinforcement. These design parameters are related to specific exposure conditions. The
general approach is to demand impermeability of concrete as the first line of defence against
any of the deterioration process. The parameters mentioned above play a significant part in
enhancing the durability, a comprehensive approach to design reinforced concrete structures
for durability should give equal attention to the type and quality of component materials, the
2 selection of mix proportions, the control of processing conditions. The design and detailing
aspects should aim at minimizing the size and number of joints and cracks due to thermal
gradients, drying shrinkage, creep and loading.
✯ ✯ ✯

SUGGESTED FURTHER READING MATERIAL AND REFERENCES
1. Mehta, P. Kumar and Monteiro,Paulo J.M., CONCRETE-MICROSTRUCTURE,

PROPERTIES AND MATERIALS, Published by :Indian Concrete Institute, Ocean Crest,
35, 3rd Maim Road, Gandhi Nagar, Adyar, Chennai-600020, India.
2. “Causes of distress & Durability Aspects of Concrete Structures” by S. Gopalkrishnan,
Deputy Director & Head, concrete composites Laboratory, SERC, Madras 600113,
presented during advanced cause on “Damage Assessment & Rehabilitation of Distressed
concrete structures” at SERC Madras, December, 10-13, 1996.
3. “Durability of Concrete Structure, Investigation, repair, protection” by CEOFFMAYS.,
Gramfield (U.K.) (First edition 1992 )
4. IS:456-2000 Code of Practice for Plain & Reinforced Concrete 2
5. Concrete Society Technical Report No 26, “Repair of concrete damaged by

reinforcement corrosion” published by “The Concrete Society”, Devon House, 12-15,
Dartmouth Street, London.
6. ACI Manual of Concrete Part I Practice, ACI committee 116.

Appendix 2.1
INTRINSIC & EXTRINSIC CAUSES AND STAGES OF DISTRESS
CAUSE INITIAL DAMAGE STAGE ACCELERATED

OF DISTRESS OF RCC DAMAGE STAGE OF RCC
CONSTRUCTION DEFICIENCY (INTRINSIC)

PHYSICAL:
(a) High w/c Ratio High capillary porosity in cement paste 1. Carbonation reaches reinforcement
which allows the aggressive chemicals level to depassivate steel & initiate
from its environment to penetrate easily corrosion.
and allows the concrete/reinforcement to 2. Increased volume of corrosion
2 get affected at an accelerated rate and product exerts pressure on
initiate the onset of corrosion. surrounding concrete.
3. Increased cracking of concrete
allows easy permeation of
atmospheric gases.
4. Accelerated corrosion to cause
increased cracking, then spalling
of concrete.
5. Corrosion reduces steel bar cross-
section.
6. Corrosion product behind
reinforcement pushes bar outward
to make it buckle and fail in
compression to cause collapse
(b) Inadequate curing -Do-
(c) Poorly Graded
Aggregates Porous concrete due to Air voids and allows Same as above
the aggressive chemicals from its
environment to penetrate easily and allows
the concrete/ reinforcement to get affected
at an accelerated rate and initiate the onset
of corrosion.
(d) Inadequate Porous concrete due to Air voids and Same as above
compaction allows the aggressive chemicals from its
the concrete/ reinforcement to get affected
of corrosion.
(e) Shuttering Joints not Honey combed concrete due to bleeding Same as above
Slurry tight when cement paste is replaced by air voids
near surface and allows the aggressive
chemicals from its environment to penetrate
easily and allows the concrete/
reinforcement to get affected at an
accelerated rate and initiate the onset of
corrosion.
Contd...

Appendix 2.1 (Contd..)

(f) Cover Thickness being Protective cover Thickness against Same as above
lesser external/environmental chemical attack
reduced and allows the concrete/
reinforcement to get affected early.
(g) Wrong placement of Cracking /crushing of concrete to cause Same as above

reinforcement macro-cracking and allows the aggressive
chemicals from its environment to penetrate
easily and allows the concrete/
reinforcement to get affected at accelerated
rate and initiate the onset of corrosion.
CHEMICAL: 2
(a) Chloride infested Depassivation of Steel reinforcement 1. Chloride ion acts as current carrier in
beyond permissible locally and formation of galvanic cells to presence of water and causes
limits either through initiate corrosion of bar localised corrosion of
construction water reinforcement.
and/or aggregates 2. Same as 2-6 above
(b) Sulphate being beyond Formation of C4A3S, an expansive product 1. Bursting force in hardened concrete
permissible limits in to cause disintegration due to bursting causes cracking and disintegration
construction water or force within hardened concrete (a slow of concrete to make it weak in
aggregates or diffusion process ) strength and more permeable
from adjacent 2. Same as Sl no 1 to 6 above
environment
(c) Reactive aggregates Formation of expansive gel around 1. Bursting force in hardened concrete
containing amorphous aggregate particles in presence of water causes cracking and disintegration
silica or strained and disintegration of concrete due to of concrete to make it weak in
Quartz to cause Alkali- bursting force in hardened concrete (a slow strength and more permeable
Silica Reaction (ASR) process ) 2. same as Sl no 1 to 6 above
DESIGN DEFICIENCY (Intrinsic)

(a) Wrong assessment of Deflection, Crushing/ Cracking of same as Sl no 1 to 6 above
design Loads Structural Member allows the aggressive
chemicals from its environment to
penetrate easily and allows the concrete/
reinforcement to get affected at an
accelerated rate and initiate the onset of
corrosion.
(b) Factors like shrinkage, Disintegration of Concrete, shrinkage same as Sl no 1 to 6 above

thermal Movement, cracks allow the aggressive chemicals from
structural behaviour, its environment to penetrate easily and
etc not considered allows the concrete/reinforcement to get
affected at an accelerated rate and initiate
the onset of corrosion.
Contd...

Appendix 2.1 (Contd..)

ENVIRONMENTAL (EXTRINSIC) PHYSICAL:

(a) Heating/ Cooling Surface disintegration and micro- same as Sl no 1 to 6 above
cracking allows the aggressive chemicals
from its environment to penetrate easily
and allows the concrete/reinforcement to
get affected.
( b) Wetting/ Drying Increase in Capillary porosity due to same as Sl no 1 to 6 above

leaching away of water soluble salts results
in depletion of water soluble calcium
2
hydroxide reducing the alkalinity which
further allows the aggressive chemicals
resulting the concrete/reinforcement to get
affected at accelerated rate and initiate the
onset of corrosion.
(c) Abrasion of Surface Surface disintegration and reduced cover same as Sl no 1 to 6 above
thickness allows the aggressive chemicals
and allows the concrete/reinforcement to
get affected at an accelerated rate and
initiate the onset of corrosion.
CHEMICAL EFFECT:
(a) Chloride attack from When chloride ions permeate and reach 1 Chloride ion acts as current carrier
sullage of Toilets, sea reinforcement level, cause local in presence of water and
water, atmospheric depassivation of steel bars and formation causeslocalised corrosion of
gases, acids, etc of galvanaic cells locally and initiate reinforcement.
corrosion 2. Same as S. No. 2 to 6 above.
(b) Sulphate attack from When permeate and react with calcium 1. Bursting force in hardened concrete
soil, sub-soil water, aluminate Hydrate (C-A-H) in cement causes cracking and disintegration
industrial waste/Gases, paste, it forms expansive compound, of concrete to make it weak in
acids, etc which exerts bursting pressure to cause strength and more permeable
disintegration & cracking of concrete up
to depth of permeation to allow the 2. Same as Sl no 1 to 6 above
aggressive chemicals from its
the concrete/reinforcement to get affected
of corrosion.

CHAPTER 3
CONDITION SURVEY & NON-DESTRUCTIVE

EVALUATION
PAGE NO.
3.1 Condition Survey III-1
3.1.1 Definition III-1
3.1.2 Objective III-1
3.1.3 Stages III-1
3.1.3.1 Preliminary Inspection III-2
3.1.3.2 Planning Stage III-4
3.1.3.3 Visual Inspection III-6
3.1.3.4 Field/Laboratory Testing stage III-11
3.1.4 Consideration for Repair Strategy III-13
3.2 Non-destructive Evaluation Tests III-13
3.2.1 Concrete Strength Assessment III-15
3.2.1.1 Rebound Hammer Test III-17
3.2.1.2 Ultrasonic Pulse Velocity (UPV) test III-20
3.2.1.3 Penetration Resistance (Windsor Probe & PNR Tester) III-22
3.2.1.4 Pullout (LOK) Test III-25
3.2.1.5 Core Sampling and Testing III-28
3.2.2 Chemical Tests III-30
3.2.2.1 Carbonation Test III-30
3.2.2.1 Chloride Content III-30
3.2.3. Corrosion Potential Assessment III-31
3.2.3.1 Cover meter survey III-32
3.2.3.2 Half cell potential survey III-32
3.2.3.3 Resistivity Measurement III-35
3.2.4 Fire Damage Assessment III-38
3.2.4.1 Differential Thermal Analysis (DTA) III-38
3.2.4.2 X-ray Diffraction (Xrd) III-38
3.2.5 Structural Integrity/Soundness Assessment III-39
3.2.5.1 Radiography III-39
3.2.5.2 Impact-echo test III-39
3.2.5.3 Dynamic Testing of Structures III-39
3.2.6 Interpretation & Evaluation of Test Result Data III-40
3.3 Conclusion III-42
Appendix 3.1 III-43
Appendix 3.2(A) III-45
Appendix 3.2(B) III-46
Appendix 3.3 III-48
3
CONDITION SURVEY & NON-DESTRUCTIVE
EVALUATION
All things are hidden, obscure, and debatable if the cause of the phenomna be unknown, but everything is
clear if this cause be known
…Louis Pasteur
3.1 Condition Survey:
3.1.1. Definition:
Condition Survey is an examination of concrete for the purpose of identifying and 3
defining area of distress. While it is referred in connection with survey of concrete and
embedded reinforcement that is showing some degree of distress, its application is
recommended for all buildings and structures. The system is designed to be used for recording
the history of the project from its inception to completion and subsequent life.
3.1.2. Objective:
The objective of Condition Survey of a building structure is
a) To identify
- causes of distress and
- their sources;
b) To assess
- the extent of distress occurred due to corrosion, fire, earthquake or anyother
reason,
- the residual strength of the structure and
- its rehabilitability ;
c) To prioritise the distressed elements according to seriousness for repairs and
d) To select and plan the effective remedy.
“Find the cause, the remedy will suggest itself”. Sometimes, the source of the cause of
distress is different than what is apparently seen. It is, therefore, essential that the engineers
conducting condition survey, determine the source(s) of cause so as to effectively deal with
it and minimize their effects by proper treatment.
3.1.3. Stages:
Stages for carrying out Condition Survey, largely depend on field conditions, user habits,
maintenance, etc, and have a direct relation with the pattern of distress, whether localised or
spread over.
Condition Survey of a building/structure is generally undertaken in four different stages to
identify the actual problem so as to ensure that a fruitful outcome is achieved with minimum
Central Designs Organisation III-1

efforts & at the least cost.The four stages of Condition Survey described in
Fig3.1 are:
a) Preliminary Inspection,
b) Planning,
c) Visual Inspection,
d) Field and Laboratory testing
3.1.3.1. Preliminary Inspection:

A. The primary objective of the preliminary inspection is
1. To assess and collect following necessary information for a thoughtful planning before
a condition survey is physically undertaken:
l Background history of the distressed structure
- from the Owners/Clients;
3
- from the occupants of building, general public, etc based on personal
enquiries;
l Notes and records of earlier repairs, if carried out,
l All possible relevant data and information;
ESTABLISH AIMS AND

INFORMATION REQUIRED
STAGE-1
PRELIMINARY DOCUMENTATION
SITE VISIT SURVEY
PRELIMINARY
SITE VISIT
ANALYSIS INTERPRETATION AND REPORTING

SET
STAGE-II INTERPERTATION RULES
PLANNING STAGE FIELD SPECIFICATION
VISUAL INSPECTION
STAGE-III
VISUAL INSPECTION STAGE IS STRUCTURAL

NECESSARY?
NON-DESTRUCTIVE TESTS
STAGE-IV
TESTING STAGE CONCLUSION
ACTION PLAN
Fig.-3.1 Flowchart to illustrate the process of condition survey
III-2 Repairs & Rehabilitation Unit

CONDITION SURVEY & NON-DESTRUCTIVE EVALUATION
l The practical restrictions in conducting field survey and devise methods to

overcome the same;
l The safety requirements for condition survey team;
l Necessary site preparations including access scaffolds, working platforms, etc,
if any;
l The extent and quantum of survey work;
l The approx. time required for survey;
l The requirement of
- field-testing equipments,
- tools for sampling.
2. To advise the client/owner of the building in regard to immediate safety measures, if
considered necessary, to avert any mishap endangering life and structure.
3. To define the scope of work of field investigations in consultation with the
Clients/Owners.
B. Basic Information Gathering: - A programme has to be evolved to obtain as much 3
information as possible about the distressed structure at reasonable cost and in a
reasonable time.Accordingly, the information required from the owner/client has to be
listed out.Even though, many construction details and other related information may not
be available with the owners/clients, yet as much as information and details as possible
be gathered during the Preliminary Site Visit. Before undertaking a Condition Survey of
a building/structure, the following essential information is required and be obtained from
the clients/owners:
a) Period of construction;
b) Construction details including architectural, structural and as built
drawings;
c) Exposure conditions of structure;
d) Designed use vis-a-vis present use of structure;
e) Previous changes in use, if any;
f) Record of structural changes made, if any;
g) Record of first occurrence of deterioration, if any;
h) Details of repairs, if carried out in the past;
i) Reports of previous investigations/condition surveys, if any;
j) Apparent cause of distress, as could be ascertained from the owner/client;
k) Photographs of distressed portions of structure.
A typicalProforma for collection of this information is given in Appendix 3.1. Study of
such details and documents shall be done combined with the preliminary visit.It will give
a fairly good idea of the distressed structure. The history-case file of distressed building/
structure with remedial actions taken in the past is important and more relevant. However,
the information as listed above covering old drawings, record of past repairs/maintenance,
change of use, modifications carried out, though very important, may not be available in
certain cases.
C. Photographic Record: It is always necessary to carry a camera with flash during such
‘Preliminary inspection’ and take necessary photographs of the distressed structure
and its members.

Preliminary Inspection and collection of data would be helpful in planning, the Condition
Survey for field investigations. The symptoms of distress are related with the age of
structure. This allows a reasonably sufficient understanding of the cause of distress for
an experienced Rehabilitation Engineer.Table 3.1 gives such indicative details for
guidance.
Table 3.1: Diagnosis of Defects and Deterioration

(Source: Testing of Concrete in Structures by J H Bungey et al)
Cause Symptoms Age of Appearance

Cracking Spalling Erosion Early Long Term
Structural deficiency Yes Yes Yes Yes
Reinforcement Corrosion Yes Yes Yes
Chemical Attack Yes Yes Yes Yes
Frost Damage Yes Yes Yes Yes
3 Fire Damage Yes Yes Yes
Internal Reactions Yes Yes Yes
Thermal Effects Yes Yes Yes Yes
Shrinkage Yes Yes Yes
Creep Yes Yes Yes
Rapid Drying Yes Yes
Plastic Shrinkage Yes Yes
Physical Damage Yes Yes Yes Yes Yes
3.1.3.2 Planning Stage

Planning stage involves preparation of field documents, grouping of structural members and
classification of damage as under:
i) Preparation of Field Documents:
For condition survey, the following are required to be prepared:
a) Survey objective;
b) Scope of work;
c) Method of survey;
d) The field and laboratory testing requirements and field equipments & tools required
for the same;
e) List of tasks and their sequence for condition survey together with a work
schedule;
f) Required number of photo copy of available drawings;
g) Floor plans based on field measurements;
h) Work sheets and tables for recording in a logical manner all information, test
results including field data gathered;
i) Previous Condition Survey results and Investigation Reports, if any;
j) Maintenance and repair records.

Work Sheets are documents in the form of floor plans, charts and statistical formats to
record relevant data, observations, locations, quality, type and extent of damage etc.
These have to be tailor- made for structural elements i.e. slabs, beams and columns of
the project under investigation. Work Sheets are required for study of damage pattern
and its extent as well as to work out Bill of Quantities of various repair items based on
condition survey. The Work Sheets should contain:
l Plan of building at each floor with suitable grid pattern evolved to identify structural
member in an RCC framed structure
- with each structural element drawn to a convenient scale so as to record the
visual observations on the floor plan itself using suitable notation.
- The typical notations and their details used for recording field observations
on each such plan. (Typical notations are given in Appendix-3.2) Any of the
symptoms that cannot be reflected with notations could also be recorded in
the form of a note.
ii) Grouping of the Structural members: 3
Soon after the preliminary site visit and on perusal of building plans, the structural members
shall be grouped as per their type and based on similarity of exposure conditions for
proper appreciation of the cause of distress. For example in a building subjected to
normal environmental attack, the grouping could be done as under:
a) External columns/beams would be subjected to more severe environmental
attack than the internal structural members of a building and could be grouped in
two broad groups.
b) Even from amongst the external columns, those at corners or projected out are
likely to be exposed more due to adjacent faces being exposed than those not at
corners or un-projected columns. Hence to be grouped separately.
c) The members subjected to dampness/wetting/drying located in or around the
toilet shafts are likely to undergo similar class of distress and be grouped
separately.
d) Structural members with different protective finishes have to be grouped
separately.
For assessment of the behaviour of the group as a whole, test results of RCC members
in each of the groups so formed in a building have to be tabulated together in a Proforma
(Appendix 3.3) for their interpretation.
iii) Classification of Damage :
Based on the preliminary data collected and site visit, the rehabilitation engineer should
freeze the interpretation rules and subdivide the repair classification broadly in to five
classes as ‘Class 0’ to ‘Class 4’ named as Cosmetic Repair, Superficial Repair, Patch
Repair, Principal Repair and Major Repair.The classification given in
Table 3.2, is generally considered sufficient for deciding the ‘Repair Requirements’
for carbonation induced corrosion damaged structure. This is just an indicative
classification and the same may vary from case to case. It should be decided by the
Rehabilitation Engineer before taking up detailed Condition Survey of the distressed
structure in field.

TABLE 3.2 : Classes of Damage and Repair Classification

Class of Repair Classi- General Observations Repair Requirements
Damage fication on the Condition of
Concrete
‘Class O’ Cosmetic Only final finishes Redecoration, if required
disfigured. No
structural distress
observed.
‘Class 1’ Superficial Final finishes/skin alone Superficial repair of slight
damaged. No structural damage to non-structural
cracks observed. Carbo- finishes
nation depths not yet
reached reinforcement
level.
‘Class 2’ Patch Repair Minor structural cracks Non-Structural or minor
3 observed and /or carbo- Structural Repair limited to
nation depths reached crack sealing, restoring the
reinforcement level lost cover concrete, if any,
due to corrosion of
reinforcement. Carbonation
resistant surface protective
coating, shotcrete or other repair
material reinforced with nominal
light steel fabric
‘Class 3’ Principal Repair Spalling of cover con- Strengthening repair to
crete, major structural reinforced concrete in
cracks, including crack- accordance with the load-
ing along reinforcement carrying requirement of the
due to corrosion or member. Concrete strength
otherwise leading to may be extremely low and
substantial reduction reinforcement dia might
of load carrying have been significantly
capacity. reduced requiring check by
design procedure. Make up
reinforcement may have to
be provided in case of
deficiencies due to
deterioration
‘Class 4’ Major Repair Major structural loss Major Strengthening repair
necessitating replace- ignoring the original con
ment of structural crete and reinforcement or
member. demolition and recasting
3.1.3.3 Visual Inspection :

1. Visual examination of a structure is the most effective qualitative method of evaluation of
structural soundness and identifying the typical distress symptoms together with the
associated problems.
2. This provides valuable information to an experienced engineer in regard to its
workmanship, structural serviceability and material deterioration mechanism.

3. It is meant to give a quick scan of the structure to assess its state of general
health.
4. The record of visual inspection is an essential requirement for preparation of realistic bill
of quantities of various repair items.
5. Experienced engineers should carry out this work as this forms the basis for detailing
out the plan of action to complete the diagnosis of problems and to quantify the extent
of distress.
6. Simple tools and Instruments like camera with flash, magnifying glass, binoculars, gauge
for crack width measurement, chisel and hammer are usually needed. Occasionally, a
light platform/scaffold tower can be used for access to advantage.
A. What to look for ?
l Though the record of visual inspection is required to be prepared for the structure
as a whole for working out bill of quantities. But for analysis and identification of
source of cause, focused work could be carried out on selected areas
showing typical defects, but choosing these, as far as possible, from areas with 3
simple access.
l One or more areas, apparently free from defect, would also be examined at this
stage for simple comparison. This is required, because it is frequently found that by
comparing good areas with bad, the reasons for the problems emerge.
l Preparation of good photographic record during such inspection is very
important.
l The commonly observed order of deterioration of RCC structures due to ageing
process is given in Table 3.3.
Table 3.3 : Commonly Observed Order of Deterioration of RCC Building
Commonly Location of RCC component

Observed Order
First Wet / water stagnating areas with RCC elements located on external
direct exposed walls/slabs and frequented with alternate wetting/drying
cycle.
Second Thin exposed non structural RCC elements e.g. chhajjas, railings, facias, fins
etc
Third Terrace RCC slab with ineffective insulation, water proofing and drainage
systems
Fourth Wet areas with RCC elements located on inner unexposed walls and frequented
with alternate wetting/drying cycle
Fifth Beams/columns with one face exposed direct to sun and rain and the other
face unexposed.
Sixth Beams/Columns exposed to rain and sun from all sides.
Last Beams/Columns/Slabs located in the interior of building.
Note : These are indicative and based on assumptions that the quality of concrete is uniformly
good or poor at all locations. May vary upon the degree of exposure, frequency of wetting/
drying cycles.

A.1 Obstructions to Visual Inspection :

1. False ceiling, carpets, recently done paints, patch work repairs of plaster, re-plaster
etc are likely to create obstructions to visual inspection. Such areas should be
analysed and recorded with due care.
2. The access height from within and from outside during this inspection could also be
a major problem.
3. Notes of these obstructions/limitations of visual inspection need to be recorded for
taking into considerations while preparing the work details on repairs/
rehabilitation.
A.2 Structural System :
1. It is necessary that the engineer conducting visual inspection should have necessary
familiarity with its structural system, structural behaviour and serviceability
requirements.
2. One must look for its main framing system, bracings and alike. Thus, he should
3
analyse the basic system bracing, structural stability and soundness of the structural
system.
3. In case of non-availability of structural drawings, the existing framing, bracing and
stiffness provisions have to be recorded during this inspection.
4. Malfunction, if any, due to structural deficiency should be identified with reference
to material distress observed at site.
A.3 Leakage/Seepage due to Ineffective Drainage System :
1. Water stagnating areas in a structure attract dampness, leakage etc and are subjected
to alternate wetting/drying cycle. Such areas are more prone to early corrosion of
embedded steel reinforcement.
2. Concealed water supply and drainage lines are the general source attracting damage
to the structure. Source of leakage/seepage due to concealed services has to be
identified, established and recorded during the inspection.
3. Particularly at terrace floors of the building, dampness due to improper terrace
treatment, its slope or inefficiency of rainwater disposal system may not be noticeable
to the eyes but damage continues till spalling of cover concrete takes place. Hence
efficiency of rainwater disposal system should be carefully examined during such
inspection and a note to this effect be recorded.
4. Discolourations observations made during inspection should be marked on drawings
and also taken as photographic records .
A.4 Types of Cracks and their pattern :
1. It is generally easy to differentiate various types of cracks and relate them with the
cause of distress. The location of cracks and their pattern, etc give the first
indications of the problem
2. Cracking & spalling, cracking & rust staining or rust staining are the visual indications
of the corrosion of steel in concrete structures. Corrosion cracks are quite
characteristic and distinct from those caused by other factors and such cracks run
along the reinforcement location
3. Rust staining in freshly laid concrete is indicative of honeycombed concrete,

which could result in severe rusting and deterioration of concrete at a later

date.
4. Cracks at right angle to main reinforcement are generally associated with structural
deficiency.
5. A mesh pattern of cracks suggests drying shrinkage, surface crazing, frost attack or
alkali-aggregate reaction (Fig 3.2)
Figure 3.3 and 3.4 give typical symptoms of distress due to corrosion of reinforcement in a
concrete slab and beam respectively. Cracking along the bar can be an important indication
that the reinforcements are subjected to corrosion.
Fig.-3.2 Map’ cracking typical of shrinkage crack etc. in concrete
SLAB CORROSION
INITIATION STAINS AND
AS CAST
CRACKS
As cast
RADIAL LONGITUDINAL
FRACTURE POP-OUTS CRACK
DELAMINATION SPALLING EXPOSURE
Fig.-3.3 Typical symptom of corrosion in a reinforced concrete slab

AS CAST INSTALLATION STRAINS

AND CRACKS RADIAL
FRACTURE
POP-OUTS LONGITUDINAL DELAMINATION SPALLING

CRACKS
3
Fig.-3.4 Typical symptom of corrosion in a reinforced concrete Beam
A.5 Colour & texture of concrete surface:

1. The texture of a concrete surface may indicate the possibility of a chemical
attack and associated disintegration by leaching.
2. In fire damaged structure, the colour of the concrete gives an indication
of maximum temperature level to which the surface had been subjected.
B. Worksheet
The visualinspection shall largely cover:
1. Recording of
l Areas of high distress ;
l Cracks & their location ;
l Excessive deflection ;
l Exposure conditions of various distressed areas ;
l Moisture, leakage/ seepage & dampness locations ;
l Abnormal vibrations in structure, if any ;
l Algae, fungus growth and/or efflorescence etc and their locations ;
l Photographic records, and
2. Identifying the areas of immediate concern.
Visual inspection would be documented in the form of Worksheets ,
photographic record etc for reference at a later date. Each worksheet shall :
1. Have unique identification for each of the structural members of the building
covered by it.
2. Essentially cover the following in regard to observed defects:
l Location,
l Classification, and
l The extent of spread.

3. Have notations for recording different types of defects, which could be suitably
evolved by the rehabilitation engineer before taking up the condition survey. The
suggested notations used for recording the defects on Work Sheets are given in
Appendix 3.2
The Worksheets (Fig. 3.5), besides being helpful in analysis for arriving at the cause
of distress, would also be helpful for working out Bill of Quantities at a later date.
All the defects noticed during visual examination are required to be plotted on
Work sheet for a subsequent detailed study in combination with tabulated field &
lab test results in proforma as per Appendix-3.3. This is necessary for determining
the cause of deterioration.
The information obtained from visual inspection will determine whether there is need for
further comprehensive investigation using more sophisticated testing techniques.
Visual inspection is, therefore, the best way of qualitative assessment of any structure.
3.1.3.4 Field/Laboratory Testing stage : 3
Objective :
1. It may neither be feasible nor is the practice to conduct field/laboratory testing on every
structural member in an existing distressed building.
2. The field/laboratory testing of structural concrete and reinforcement is to be undertaken,
basically for validating the findings of visual inspection.
3. These may be undertaken on selective basis on representative structural members from
each of the various groups based on exposure conditions as explained in the preceding
sections.
4. The programme of such testing has to be chalked out based on the record of visual
inspection.
Fig.-3.5 A Typical Work Sheet

Table 3.4 gives the list of test methods that could be deployed for field/Laboratory testing
during the course of investigations. A typical format for tabulation of the field test results/
observation is given in Appendix-3.3. NDE tests are frequently adopted during the process
of condition survey
Table 3.4 : Principal Test Methods

Property under Test Equipment type

investigation
Corrosion of Half Cell potential Electrochemical
embedded Steel Resistivity Electrical
Linear polarization resistance Electrochemical
A.C. Impedance Electrochemical
Cover depth Electromagnetic
Carbonation depth Chemical/microscopic
3 Chloride concentration Chemical/electrical
Concrete quality, Surface hardness Mechanical
durability and Ultrasonic pulse velocity Electromechanical
deterioration Radiography Radioactive
Radiometry Radioactive
Neutron absorption Radioactive
Relative humidity Chemical/electronic
Permeability Hydraulic
Absorption Hydraulic
Petrographic Microscopic
Sulphate content Chemical
Expansion Mechanical
Air Content Microscopic
Cement type and content Chemical/microscopic
Abrasion resistance Mechanical
Concrete strength Cores Mechanical
Pull-out Mechanical
Pull – off Mechanical
Break-off Mechanical
Internal fracture Mechanical
Penetration resistance Mechanical
Maturity Chemical/electrical
Temperature-matched Electrical/electronic
Curing
Integrity and Tapping Mechanical
Performance Pulse-echo Mechanical/electronic
Dynamic response Mechanical/electronic
Acoustic emission Electronic
Thermoluminescence Chemical
Thermography Infra-red
Radar Electromagnetic
Reinforcement location Electromagnetic
Strain or crack measurement Optical/mechanical/electrical
Load test Mechanical/electronic/electrical

3.1.4 Considerations for Repair Strategy :

In the Condition Survey Report, before arriving at the Repair Strategy, it shall include the
following considerations:
1. Identification of the cause of problem and its source is the fundamental to the success or
failure of the repair. A lack of attention at this point can put at risk the whole job.
2. For arriving at an effective and economical solution, systematic documentation of all
observations is essential, which will greatly facilitate in diagnosing and making assessment
of the extent of damage.
3. Available space and accessibility will determine the selection of repair method and
repair strategy.
4. Accessibility to the areas identified for repairs needs consideration.
5. Depending upon the scope and scale of repairs, the repair strategy has to suit and
dovetail the on-going activities in the building.
6. The prioritization of repairs and their sequencing are important components for deciding
the repair strategy. 3
7. Major repair procedure may demand propping the structural members to relieve a part
or full component of the load acting on the member. If the building requires extensive
propping, vacating the building may become the pre-requisite.
8. Safety measures to prevent any immediate major mishap shall be prescribed without
loosing further time.
9. The report should also include requirements on safety measures to be adopted during
execution of repair jobs.
More experienced engineers should look in to special and peculiar distress problems For
example, micro cracking or some other subtle defect could be the cause of carbonation and
corrosion. Carrying out repairs to corrosion distress, missing the main cause, may simply
mean that the problem recurs in a relatively short duration.
3.2 NON DESTRUCTIVE EVALUATION TESTS :

A number of non-destructive evaluation (NDE) tests for concrete members are available to
determine in-situ strength and quality of concrete. Some of these tests are very useful in
assessment of damage to RCC structures subjected to corrosion, chemical attack, and fire
and due to other reasons. The term ‘non destructive’ is used to indicate that it does not impair
the intended performance of the structural member being tested/investigated. The non-
destructive evaluation have been broadly classified under two broad categories viz ‘in-situ
field test’ and ‘laboratory test’. These tests have been put under five categories depending on
the purpose of test as under :
1. In-situ Concrete Strength
2. Chemical Attack
3. Corrosion Activity
4. Fire Damage
5. Structural Integrity/Soundness
Various non destructive evaluation tests commonly used under each of these categories have
been listed out in Table 3.5 as under :

Table 3.5 : Commonly Used NDE Tests

Sl No Test Method Details
A. Insitu Concrete Strength:
1 Rebound Hammer Test A qualitative field test method to measure surface
hardnessof concrete
2 Ultrasonic Pulse Velocity A qualitative field test by measurement of Ultrasonic Pulse
Velocity (UPV)
3 Windsor Probe A qualitative field test for assessment of near surface
strength of concrete
4 Capo/Pull out test -do-
5 a. Core cutting/ sampling
b. Lab Testing of Cores Field cum lab test method for assessing quality of concrete
as under:
- strength
- density
- texture
- permeability
3 6. Load Test A field test for assessing the load carrying capacity within
the limits of elastic deformations
B. Chemical Attack
1 Carbonation Test A field/lab test for assessment of pH of concrete and depth
of carbonation
2 Chloride Test A field/lab Test for assessment of total water/acid soluble
chloride contents
3 Sulphate Test A Lab Test for assessment of total acid/water soluble
sulphate contents of concrete
C. Corrosion Potential Assessment
1 Cover-Meter / Profo-meter A field method for measuring
measurement -thickness of cover concrete
(In-situ Test) -reinforcement diameter
-reinforcement spacing.
2 Half Cell Method A field method for Measuring/ plotting corrosion potential
for assessing probability of corrosion
3 Resistivity Meter A field method for assessing electrical resistivity of
concrete to determine its corrosion resistance
4 Permeability
a. Water
b. Air A field/Lab method for assessment of in-situ permeability
of concrete due to water and air.
D. Fire Damage Assessment
1 Thermo-Gravimetric A laboratory test for assessment of temperature
Analysis (TGA) range to which concrete was subjected to
2 Differential Thermal A laboratory Test for assessment of qualitative
Analysis (DTA) & quantitative composition of sample of concrete
3 X-ray Diffraction (XRD) To determine the extent of deterioration in concrete
subjected to fire
E. Structural Integrity/Soundness Assessment
1 Ultra-sonic Pulse velocity A field method for determination of
Method discontinuities, cracks and depth of cracks
2 Radiography For taking photographs showing details of inside of a
concrete member, where other NDE methods are not suitable
3 Impact Echo Test A field/laboratory test method to detect hidden damage
andits extent.

3.2.1 Concrete Strength Assessment :

A. Objective:
1. Generally, in-situ non-destructive evaluation of concrete is to have an overall idea of the
quality of concrete.
2. In some cases, a sufficiently accurate estimate of quantitative value of concrete strength
is required for assessment of load carrying capacity of a structural member. The need
for such an estimate may arise during evaluation of change in usage of structure,
modification or extension of the original structure or damage due to fire, earthquake,
etc.
3. Core cutting /sampling method, as at sl no 5 in Table 3.5 above, is done by extracting
the concrete cores from the beams/columns/slab or any other structural members to
determine the residual insitu strength, density & porosity /permeability of concrete in
laboratory. This test, being semi destructive, is also time consuming. Hence it is used
selectively in combination with other NDE qualitative test results, so as to validate and
calibrate such other qualitative test methods used more commonly. 3
B. Limitations:
The accuracy is not very high as most of the non-destructive methods of evaluation of
concrete strength are based on indirect measurement of concrete strength.
C. Selection of test, its location and number :
Out of test methods listed above, the choice is usually Schmidt Hammer and UPV for
determining the insitu quality of concrete.The uses of other methods like pull out test/
capo test, windsor probe etc, being either time consuming &/or partially destructive,
have not become popular in India. Hence UPV test has an edge over the Windsor
Probe test & is most commonly employed. This method gives substantially reliable &
adequate data for quality assessment of concrete.
The table 3.6 gives commonly used test methods indicating minimum number of test
readings/samples, the percentage of confidence level, the speed of test, likely damage
to concrete, reliability of strength calculation, and representative-ness of the test.
It would be prudent to have a combination of at least two methods for assessing the
quality of concrete in addition to their correlation with concrete core results.
Table 3.6 : Strength Tests-Relative Merits

Test Mini- Typical Best Cost Speed Dam- Re- Reliability

Method mum Coeffi- 95% of age presen of absolute
number cient of confi- test tatives strength
of read- varia- dence ness correla-
ings tion level tions
General Applications:
Cores 3 10% +10%
Standard
Cores
(100 mm) High Slow Mode- Mode- Good
Smaller 9 15% +15% rate rate
Cores
Contd.....

Table 3.6 : (Contd...)
Test Mini- Typical Best Cost Speed Dam- Re- Reliability

Method mum Coeffi- 95% of age presen of absolute
number cient of confi- test tatives strength
of read- varia- dence ness correla-
ings tion level tions
Pull -out 4 8% +20% Mode- Fast Minor Near Mode-

rate Surface rate
Only
Pull-off 6 8% +15% Mode- Mode- Minor Near Mode-
rate rate Surface rate
only
Break-off 5 9% +20% Mode- Mode- Minor Near Mode-
rate rate Surface rate
only
Internal fracture 6 16% +28% Low Fast Minor Near Mode-
Surface
only
3 Windsor Probe 3 4% +20%
Comparative Assessment:
Ultrasonic Pulse 1 2.5% +20% Low Fast None Good Poor
velocity
Surface hardness 12 4% +25% Very low Fast Un- Surface Poor
likely only
D. Examination of Variability:
1. Variability of test result depends on the NDE test method and shall vary with each
type of method.
2. Obtaining strength of concrete by different methods and studying variability of average
results can lead to wrong conclusions.
3. Insitu strength of concrete in a structural member also varies with the location.
4. Plotted histogram and contours of test results, give better idea of variability of
concrete strength. These help in identifying the concrete from different sources/
batches for working out the coefficient of variation separately.
E. Analysis of Results:
1. The standard charts supplied by manufacturers or available in literature may not be
valid for the site conditions.
2. Calibration curves for concrete strength assessment could be prepared by testing
cores of standard size at a few locations and correlating the results of the other test
methods with the core strengths.
3. Characteristic strength of concrete shall thus, be calculated from such calibration
charts using statistical analysis.Minimum 50 readings are required for calculation of
standard deviation. If the number of readings are not sufficient, the following values
of standard deviation as per table 3.7 may be assumed .
4. The in-situ characteristic strength of the concrete may be obtained by using the well
known relationship

fck = f mean – 1.64 S Where, fck is the characteristic strength of concrete,

f mean is the mean strength and “S” is the standard deviation.
Table 3.7:Typical Values of Standard Deviation of Control Cubes and

In-situ Concrete
Material control and Assumed std. devn. of Estimated std. devn.of

construction control cube(s) , (N/mm2) in-situ concrete cube(s),
(N/mm2)
Very good 3.0 3.5
Normal 5.0 6.0
Low 7.0 8.5
Note : IS-456: 2000, Table 8, gives the assumed values ofstandard deviation for cube testing for
different grades of concrete.Accordingly, highervalues for in-situ testing may be assumed.
3.2.1.1 Rebound Hammer Test : 3
The operation of Rebound Hammer (also called Schmidt’s Hammer) is illustrated in

Fig 3.6. When the plunger of rebound hammer is pressed against the surface of concrete, a
spring controlled mass with a constant energy is made to hit concrete surface to rebound
back. The extent of rebound, which is a measure of surface hardness, is measured on a
graduated scale. This measured value is designated as Rebound Number (a rebound index).
A concrete with low strength and low stiffness will absorb more energy to yield in a lower
rebound value.
INSTRUMENT READY
FOR TEST
BODY PUSHED TOWARDS
TEST OBJECT
HAMMER
IS RELEASED HAMMER REBOUNDS
WINDOW AND SCALE
HAMMER MASS
HOUSING
IMPACT SPRING
PLUNGER
Fig.-3.6 Schematic diagram of operation of the rebound hammer

Rebound or Schmidt Hammer
IS 13311 Pt-2-1992 as well as BS: 6089-81 and BS: 1881:Pt-202 explains the standard
procedure for test and correlation between concrete cube crushing strength and rebound
3 number. The results are significantly affected by the following factors :
a. Mix characteristics :
i. Cement type,
ii. Cement Content,
iii. Coarse aggregate type :
b. Angle of Inclination of direction of hammer with reference to horizontal (Fig 3.7)
c. Member Characteristics,
i. Mass,
ii. Compaction,
iii. Surface type,
iv. Age, rate of hardening and curing type,
v. Surface carbonation,
vi. Moisture Condition,
vii. Stress state and temperature.
Fig.-3.7 Cube Compressive strength is N/mm2 plotted against the rebound number

Since each of these may affect the readings obtained, any attempts to compare or estimate
concrete strength will be valid only if they are all standardized for the concrete under test and
for the calibration specimens.
A. Strength Assessment
This test is conducted to assess the relative strength of concrete based on the hardness
at or near its exposed surface. Carrying of periodic calibration of rebound hammer
using standard anvil is desirable. However for new concrete construction, rebound
hammer is calibrated on concrete test cubes for a given source of constituent materials
(viz. cement, sand and stone aggregate), this calibration data can be used with reasonable
accuracy in arriving at equivalent in-situ cube strength of relatively new concrete ( i.e.
not more than three months old concrete). This calibration exercise may be carried out
in a concrete lab by casting cubes of designed mix and testing these under controlled
condition with rebound hammer as well as test to destruction in compression. Calibration
graphs then can be drawn. Large number of readings are desirable to reduce the effects
of variability in readings due to various localised as well as instrument factors. This 3
method may give highly erroneous results for concrete whose surface is exposed to
atmosphere for longer periods say more than three months. This is due to hardening
of concrete surface due to carbonation, which may cause overestimation as much as
50% for old structure.Hence Strength assessment by Rebound Hammer Test should
generally be restricted to relatively new structures only.
B. Survey of Weak & delaminating Concrete
As the test requires a flat surface and large number of readings to reduce variability, this
test is not generally suitable for use on spalled concrete surfaces of distressed structures.
However, comparison of Rebound numbers, which indicate the near surface hardness
of the concrete, will help to identify relative surface weaknesses in cover concrete and
also can be used to determine the relative compressive strength of concrete.
Locations possessing very low rebound numbers will be identified as weak surface
concrete and such locations will be identified for further investigations like corrosion
distress, fire damage and/or any other reason including original construction
defects of concrete. This survey is to be carried out on each identified member in a
systematic way by dividing the member into well-defined grid points. The grid
matrix should have a spacing of approximately 300mmx 300mm. Table 3.8 gives
guidelines for qualitative interpretation of rebound hammer test results with reference
to quality.
Table-3.8: Quality of Concrete from Rebound Values

Comparative Hardness
Average Rebound Quality of Concrete

>40 Very Good
30-40 Good
20-30 Fair
<20 Poor and/or delaminated
0 Very Poor and/or delaminated

3.2.1.2 Ultrasonic Pulse Velocity (UPV) test

Ultrasonic scanning is a recognised non-destructive evaluation test to qualitatively assess
the homogeneity and integrity of concrete. With this technique, following can be assessed.
1 Qualitative assessment of strength of concrete, its gradation in different locations of
structural members and plotting the same
2 Any discontinuity in cross section like cracks, cover concrete delamination etc
3 Depth of surface cracks.
Ultrasonic Pulse Velocity instrument
This test essentially consists of measuring travel time, ‘T’ of ultrasonic pulse of
50-54 kHz, produced by an electro-acoustical transducer, held in contact with one surface
of the concrete member under test and receiving the same by a similar transducer in contact
with the surface at the other end. With the path length, ‘L’ (i.e. the distance between the two
probes) and time of travel, T the pulse velocity (V = L/T) is calculated (fig 3.8). Higher the
elastic modulus, density and integrity of the concrete, higher is the pulse velocity.The ultrasonic
pulse velocity depends on the density and elastic properties of the material being tested.
Though, pulse velocity is related with crushing strength of concrete, yet no statistical correlation
can be applied.
The pulse velocity in concrete may be influenced by :
a) Path length
b) Lateral dimensions of the specimen tested.
c) Presence of reinforcing steel
d) Moisture content of the concrete.
The influence of path length will be negligible provided it is not less than 100 mm when 20 mm
size aggregate is used or less than 150 mm for 40 mm size aggregate. Pulsevelocity will not
be influenced by the shape of the specimen, provided its least lateral dimension (i.e. its dimension
measured at right angles to the pulse path ) is not less than the wavelength of the pulse
vibrations.For pulse of 50 Hz frequency, this corresponds to a least lateral dimension of
about 80 mm. The velocity of pulses in a steel bar is generally higher than they are in concrete.For
this reason, pulse velocity measurements made in the vicinity of reinforcing steel may be high
and not representative of the concrete.The influence of the reinforcement is generally small if
the bars run in a direction at right angles to the pulse path and the quantity of steel is small in

Fig.-3.8 Method of propogating and receiving pulses
relation to the path length.The moisture content of concrete can have a small but significant
influence on the pulse velocity. In general, the velocity is increased with increased moisture
content, the influence being more marked for lower quality concrete.
Measurement of pulse velocities at points on a regular grid on the surface of a concrete
structure provides a reliable method of assessing the homogeneity of the concrete.The size of
the grid chosen will depend on the size of the structure and the amount of variability encountered.
Table 3.9 : General Guidelines for Concrete Quality based on UPV

(Source: Indian Concrete Journal, June 1998)
Pulse Velocity Concrete quality

> 4.0 km/s Very good to excellent
3.5-4.0 km/s Good to very good, slight porosity may exist.
3.0- 3.5 km/s Satisfactory but loss ofintegrity is suspected
<3.0 km/s Poor and loss of integrity exist
Table 3.9 shows the guidelines for qualitative assessment of concrete based on UPV test
results. To make a more realistic assessment of the condition of surface concrete of a structural
member, the pulse velocity values can be combined with rebound number. Table 3.10 shows
the guidelines for identification of corrosion prone locations by combining the results of pulse
velocity and rebound numbers.

Table 3.10 : Identification of Corrosion Prone Location based

on Pulse Velocity and Hammer Readings
Sl.No. Test Results Interpretations

1. High UPV values, high Not corrosion prone
rebound number
2. Medium range UPV Surface delamination, low quality of surface
values, low rebound numbers concrete, corrosion prone
3. Low UPV, high rebound Not corrosion prone, however, to be confirmed
numbers by chemical tests, carbonation, pH
4. Low UPV values, low Corrosion prone-requires chemical and
rebound numbers electrochemical tests.
Detection of defects
3 When an ultrasonic pulse traveling through concrete meets a concrete-air-interface, there is a
negligible transmission of energy across this interface so that any air-filled crack or void lying
directly between the transducers will obstruct the direct beam of ultrasound when the void
has a projected area larger than the area of transducer faces.The first pulse to arrive at the
receiving transducer will have been diffracted around the periphery of the defect and the time
will be longer than in similar concrete with no defect.
Estimating the depth of cracks.
An estimate of the depth of a crack visible at the surface can be obtained by measuring the
transit times across the crack for two different arrangements of the transducers placed on the
surface. One suitable arrangement is one in which the transmitting and receiving transducers
are placed on opposite sides of the crack and distant from it. Two values of ‘x’ are chosen,
one being twice that of the other, and the transmit times corresponding to these are measured.An
equation may be derived by assuming that the plane of the crack is perpendicular to the
concrete surface and that the concrete in the vicinity of the crack is of reasonably uniform
quality.It is important that the distance ‘x’ be measured accurately and that very good coupling
is developed between the transducers and the concrete surface. The method is valid provided
the crack is not filled with water.
3.2.1.3 Penetration Resistance (‘Windsor Probe’ and ‘PNR Tester’)

This technique offers a means of determining relative strengths of concrete in the same structure
or relative strength of different structures. Because of the nature of equipment, it can not, and
should not be expected to yield absolute values of strength. ASTM C-803 gives this standard
test method titled, “ penetration resistance of hardened concrete”.
‘Windsor Probe’, as commercially known, is penetration resistance measurement equipment,
which consists of a gun powder actuated driver, hardened alloy rod probe, loaded cartridges,
a depth gauge and other related accessories. In this technique, a gunpowder-actuated driver
is used to fire a hardened alloy probe into the concrete. During testing, it is the exposed length
of probe, which is measured by a calibration depth gauge. But, it is preferable to express the
coefficient of variation in terms of the depth of penetration as the fundamental relation is
between concrete strength and penetration depth.
The probeshown in fig. No. 3.9 has a diameter of 6.3 mm, length of 73 mm, and conical point
at the tip.The rear of the probe is threaded and screwed into a probe-driving head, which is
12.6 mm in diameter and fits snugly along with a rubber washer into the bore of the driver. As
the probe penetrates into the concrete, test results are usually not affected by local surface
conditions, such as texture and moisture content. However, damage in the form of cracking
may be caused to slender members. A minimum edge distance and member thickness of 150
mm is required. It is important to leave 50mm distance from the reinforcements present in the
member since the presence of the reinforcing bars within the zone of influence of the penetrating
probe affects the penetration depth.
A pin penetration test device (PNR Tester), which requires less energy than the Windsor
Probe System, is given in Fig no 3.10.
Fig.-3.9 Windsor Probe
Fig.-3.10 PNR Tester

Being a low energy device, sensitivity is reduced at higher strengths. Hence, it is not recommended
for testing concrete having strength above 28 N/sqmm. In this, a spring-loaded device, having
energy of about 1.3% of that of Windsor Probe, is used to drive 3.56 mm diameter, a pointed,
hardened steel pin in to the concrete. The penetration of pin creates a small indentation (or hole)
on the surface of concrete. The pin is removed from the hole, the hole is cleaned with an air jet
and the hole depth is measured with a suitable depth gauge. Each time a new pin is required as
the pin gets blunted after use.
The strength properties of both mortar and stone aggregate influence the penetration depth of
the probe in a concrete, which is contrastingly different than cube crushing strength, wherein
the mortar strength predominantly governs the strength. Thus, the type of stone aggregate has
a strong effect on the relation of concrete strength versus depth of penetration as given in
Fig no 3.11
Fig.-3.11 Effect of aggregate type on relationship between concrete strength and

depth of probe penetration
For two samples of concrete, with equal cube crushing strength, penetration depth would be
more in the sample with softer aggregate than the one with harder aggregates. Correlation of
the penetration resistance to compressive strength is based on calibration curves obtained
from laboratory test on specific concrete with particular type of aggregates. Aggregate
hardness is determined from standard samples provided along with the instrument. Aggregate
size in the mix, also influences the scatter of individual probe readings. This technique offers
a means of determining relative strengths of concrete in the same structure or relative strength
of different structures. Because of the nature of equipment, it can not, and should not be
expected to yield absolute values of strength. This test is not operator independent although
verticality of bolt relative to the surface is obviously important and a safety device in the
driver prevents, if alignment is poor.
It is claimed an average coefficient of variation for a series of groups of three readings on
similar concrete of the order of 4% may be expected.It has been observed that ± 20%
accuracy may be possible in strength determination of concrete. Fig 3.12 explains the
approximate shape of failure during the test.

Fig.-3.12 Approximate shape of failure zone in probe penetration test
3.2.1.4 Pullout (LOK) Test

The fundamental principle behind pull out testing with LOK-test and CAPO test is that test
equipment designed to a specific geometry will produce results (pull-out forces ) that closely
correlate to the compressive strength of concrete. This correlation is achieved by measuring
the force required to pull a steel disc or ring, embedded in fresh concrete, against a circular
counter pressure placed on the concrete surface concentric with the disc/ring.
For hardened concrete, an expandable steel ring is used instead. This ring expands to fit a
specially drilled hole and routed recessin the concrete. The first method, shown in figure 3.13
using the cast in steel disc, is called LOK test. The second method , shown in figure 3.14
using expandable ring, is called CAPO- test (i.e. Cut And Pull Out Test) The diameter of
Fig.-3.13 LOK test insert

Fig.-3.14 CAPO test testing principle
both the disc and ring is 25mm. The distance to the concrete surface is also 25mm. The inner
diameter of the counterpressure is 55mm.
The relationship between the pull-out force Fu in KN and compressive strength fc in MPa is
given in figure 3.15
Fig.-3.15 Typical Pull out force Calibration Chart

By measuring the pull-out force of a cast-in disc or expanded ring, the compressive strength
of in-situ concrete can be determined from the relationship in figure 3.16 to a great degree of
confidence.
Fig.-3.16 Pull off force compressive strength relationship
The Pullout Test produces a well-defined failure in the concrete and measures a static strength
property of concrete. The equipment is simple to assemble and operate.
As the insert is pulled out, a roughly cone shaped fragment of the concrete is extracted. The
compressive strength, which is considered as an indicator of quality, is obtained from the
calibration curves, prepared based on laboratory and field tests conducted on concrete cubes
and pull out samples cast with various grades of concrete. In the test assembly, the embedment
depth and the insert-head diameter have to be equal with inner diameter of the reaction ring
could vary between 2 to 2.4 times the diameter of the insert-head. The apex angle of the
conic frustom defined by the insert-head diameter and the inside diameter of the reaction ring
can vary between 54O to 70O. The compressive strength can be considered as proportional
to the ultimate pullout force. The reliability of the test is reported as good.
Since, the embedment depths of the commercially available metallic inserts is of the order of
25 to 30 mm, the test results cover a small portion of the near surface concrete located
adjacent to the fractured surface and below the reaction ring. Thus, due to the inherent
heterogeneity of concrete, typical average within-batch coefficient of variation of such pullout
tests has been found to be in the range of 7 to 10% which is better than that of the standard
cube/cylinder compression test. It is superior to rebound hammer and Windsor probe test
because of greater depth of concrete volume tested. This test is not affected by, by type of
cement and aggregate characteristics. However, this test is not recommended for aggregate
size beyond 38 mm. The major limitation with this test is that it requires special care at the
time of placement of inserts to minimise air voids below disc besides a pre-planned
usage.

Pull out tests are used to:

i) Determine in-situ compressive strength of the concrete.
ii) Ascertain the strength of concrete for carrying out post- tensioning operations.
iii) Determine the time for removal of forms and shores based on actual in-situ strength
of the structure.
iv) Terminate curing based on in-situ strength of the structure.
Here item no (i) only are of relevance for residual strength assessment of old & distressed
structures. It can be also used for testing repaired concrete sections. These tests are divided
under the following two categories:
a) Embedding an insert into the fresh concrete while casting and then pulling out with a
jack (LOK test- LOK meaning “punch”) after hardening after a specified
period.
b) Insert fixed into a hole drilled into the hardened concrete and then pulling out with a
jack (CAPO test- cut and pull out).This second method offers greater flexibility for
3
conducting in-situ tests on hardened concrete of existing structures and is explained
above in detail.
After the concrete has fractured by this test, the holes left in the surface are first cleaned of the
dust by a blower.It is then primed with epoxy glue and the hole is filled with a polymer-
modified mortar immediately thereafter and the surface is smoothened.
3.2.1.5 Core Sampling and Testing

While rebound hammer, Capo/Pullout, Windsor probe and ultrasonic pulse velocity tests
give indirect evidence of concrete quality, a more direct assessment on strength can be made
by core sampling and testing. Cores are usually cut by means of a rotary cutting tool with
diamond bits. In this manner, a cylindrical specimen is obtained, usually with its ends being
uneven, parallel and square and sometimes with embedded pieces of reinforcement. The
cores are visually described and photographed, giving specific attention to compaction,
distribution of aggregate, presence of steel etc. The core should then be soaked in water,
capped with molten sulpher to make its ends plane, parallel, at right angle and then tested in
compression in a moist condition as per BS 1881: Part 4: 1970 or ASTM C 42-77. The core
samples can also be used for the following:
Instrument showing core cutting

Concrete Core
l Strength and density determination

l Depth of carbonation of concrete
l Chemical analysis 3
l Water/gas permeability
l Petrographic analysis
l ASHTO Chloride permeability test
The strength of a test specimen depends on its shape, proportions, and size. The influence
of height/diameter (H/D) ratio on the recorded strength of cylinder is an established
fact. Strength of cores have to be related to the standard cylinder strengths i.e. for H/D
ratio of 2. Thus, core should preferably have this ratio near to 2. For values of H/D
between 1 and 2, a correction factor has to be applied. Cores with H/D less than 1
yield unreliable results and BS 1881: Pt 4: 1970 prescribes a minimum value as 0.95.
The same Standard specifies the use of 150 mm or 100 mm cores. However, cores as
small as 50 mm are also permitted in other standards. Very small diameter cores exhibit
more variability in results than larger dia cores, hence their use is generally not
recommended. The general rule adopted for fixing the core size, besides the H/D ratio,
is the nominal size of stone aggregate and the dia should be not less than 3 times the
maximum size of stone aggregate. For diameter of core less than 3 times the size of
stone aggregate, an increased number of cores have to be tested.
Following are the factors, which affect the compressive strength of extracted concrete
cores:
l Size of Stone Aggregate: If the ratio of dia of core to maximum size of stone
aggregate is less than 3, a reduction in strength is reported. For concrete with 20
mm size aggregate, 50 mm dia core has been tested to give 10% lower results than
with 100 mm dia cores.
l Presence of transverse reinforcing Steel: It is reported that the presence of
transverse steel causes a 5 to 15% reduction in compressive strength of core. The
effect of embedded steel is higher on stronger concrete and as its location moves
away from ends i.e. towards the middle.However, presence of steel parallel to the
axis of the core is not desirable.
l H/D Ratio: This has already been discussed above. However, its value should be
minimum 0.95 and maximum as 2. Higher ratio would cause a reduction in strength.

l Age of Concrete: No age allowance is recommended by the Concrete Society as

some evidence is reported to suggest that in-situ concrete gains little strength after
28 days. Whereas others suggest that under average conditions, the increase over
28 days’ strength is 10% after 3 months and 15% after 6 months. Hence it is not
easy to deal the effect of age on core strength.
l Strength of Concrete: The effect in reducing the core strength appears to be higher
in stronger concretes and reduction has been reported as 15% for 40 MPa concrete.
However, a reduction of 5 to 7 % is considered reasonable
(concrete society Tech Report no. 11 “Council Core Testing for Strength”- The
Concrete Society, 1987 )
l Drilling Operations: The strength of cores is generally less than that of standard
cylinders, partly as a consequence of disturbance due to vibrations during drilling
operations. Whatever best precautions are taken during drilling, there is always
arisk of slight damage.
l Site Conditions vis a vis Standard Specimens: Because site curing is invariably
3
inferior to curing prescribed for standard specimens, the in-situ core strength is
invariably lower than the standard specimen taken and tested during concreting
operations.
3.2.2 Chemical Tests:

Chemical analysis of concrete can provide extremely useful information regarding the cause
of causes of failure of concrete.The tests most frequently carried out are listed below :
1. Depth of carbonation 4. Sulphate content
2. Chloride content 5. Type of cement
3. Cement content 6. Alkali content
3.2.2.1 Carbonation Test

This test is carried out to determine the depth of concrete affected due tocombined attack of
atmospheric carbon dioxide and moisture causing a reduction in level of alkalinity of concrete.A
spray of 0.2% solution of phenolphthalein is used as pH indicator of concrete. The change
of colour of concrete to pink indicates that the concrete is in the good health, where no
change in colour takes place, it is suggestive ofcarbonation-affected concrete.The test
is conducted by drilling a hole on the concrete surface to different depths upto cover concrete
thickness, removing dust by air blowing, spraying phenolphthalein with physician’s injection
syringe and needle on such freshly drilled/ broken concrete and observing the colour change.
The depth of carbonation is estimated based on the change in colour profile.The pH value
can also be determined by analyzing samples of mortar collected by drilling from the site,
dissolving the same in distilled water and thereby titration in laboratory.
3.2.2.2 Chloride Content

Chloride content can be determined from broken samples or core samples of
concrete.Primarily, the level of chloride near the steel-concrete interface is of prime importance.
Chlorides present in concrete are fixed (water insoluble) as well as free (water soluble).
Though it is the water soluble chloride ions, which are of importance from corrosion risk

point of view, yet total acid soluble (fixed as well as free) chloride contents are determined
and compared with the limiting values specified for the concrete to assess the risk of corrosion
in concrete. The total acid soluble chlorides are determined in accordance with IS: 14959
Part III 2001, whereas for assessment of water soluble chlorides the test consists of obtaining
the water extracts, and conducting standard titration experiment for determining the water
soluble chloride content and is expressed by water soluble chloride expressed by weight of
concrete or cement. The method gives the average chloride content in the cover region.Further,
a chloride profile across the cover thickness will be a more useful measurement as this can
help to make a rough estimate on chloride diffusion rate. One recent development for field
testing of chloride content includes the use of chloride ion sensitive electrode.This is
commercially known as “Rapid chloride test kit-4”. The test consists of obtaining powdered
samples by drilling and collecting them from different depths (every 5 mm), mixing the sample
(of about 1.5 gm weight) with a special chloride extraction liquid, and measuring the electrical
potential of the liquid by chloride-ion selective electrode.With the help of a calibration graph
relating electrical potential and chloride content, the chloride content of the samples can be
3
directly determined.
Based on the chemical analysis, corrosion-prone locations can be identified as per the
guidelines given in Table-3.11.
Table-3.11 : Guidelines for Identification for Corrosion

Prone Locations based on Chemical Analysis

1. High pH values greater than 11.5 and very low No corrosion
chloride content
2. High pH values and high chloride content greater Corrosion prone
than threshold values (0.15 percent
by weight of cement)
3. Low pH values and high chloride content increased risk of
(greater corrosion prone than threshold values of corrosion
chloride 0.15 percent by weight of cement
3.2.3 Corrosion Potential Assessment:

1) Cover-Meter/ Non-destructive method for
Profo-meter measuring
(In-situ Test) - thickness of cover concrete
- reinforcement diameter
- reinforcement spacing.
2) Half Cell Method Non-destructive method for
(In-situ Test) measuring/ plotting corrosion potential for
assessing probability of corrosion
3) Resistivity Measurement Non-destructive method for assessing
(In-situ Test) electrical resistivity of concrete

4) Permeability Assessment of in-situ

a. Water permeability of concrete due to
b. Air water and air.
(In-situ Test)
5) Initial Surface An indicator of surface permeability
Absorption
(Lab Test)
Half-Cell Potential measurement method is used for finding out the status of corrosion actively
in the embedded steel.
3.2.3.1 Cover meter survey
The necessity to provide adequate cover thickness to control corrosion needs no emphasis.A
cover thickness survey is useful to determine existng cover thickness in a specific location,
where a damage has been identified and elsewhere, for comparison on the same structure.The
3
cover thickness can be measured non-destructively using commercially known cover meters.
The cover meters are also used to identify the location and diameter of rebar.COVERMASTER
and PROFOMETER are the commercially available instruments, which are used to measure
the cover thickness and rebar size. Table 3.12 shows how the cover meter readings are to be
interpreted for corrosion assessment.
Cover meter or Profometer
Table 3.12 : Interpretation of Cover Thickness Survey

1. Required cover thickness and good Relatively not corrosion prone
quality concrete
2. Required cover thickness and bad Corrosion prone
quality cover concrete
3. Very less cover thickness, yet good Corrosion prone
Quality cover concrete
3.2.3.2 Half cell potential survey

Corrosion being an electrochemical phenomenon, the electrode potential of steel rebar with
reference to a standard electrode undergoes changes depending on corrosion activity.

A systematic survey on well-defined grid points gives useful information on the presence or
probability of corrosion activity.The same grid points as used for other measurements, namely,
rebound hammer and UPV could be used for making the data more meaningful.The common
standard electrodes used are:
i) Copper - Copper sulphate electrode (CSE)
ii) Silver - Silver chloride electrode (SSE)
iii) Standard Calomel electrode (SCE).
The measurement consists of giving an electrical connection to the rebar and observing the
voltage difference between the bar and a reference electrode in contact with concrete surface.
[Fig 3.17(a)] Generally, the voltage potential becomes more and more negative as the corrosion
becomes more and more active. However, less negative potential values may also indicate
the presence of corrosion activity, if the pH values of concrete are less.
Fig.-3.17(a) Half Cell Potential Test
The general guidelines for identifying the probability of corrosion based on half-cell
potential values as suggested in ASTM C 876 are given in Table 3.13
Table 3.13 – Corrosion Risk by Half Cell Potentiometer

Probability of Half Cell Potential Reading Range

Corrosion being Cu-CuSO4 Silver-Silver
active Electrode Chloride
Electrode
>95 percent More negative than More negative
– 350 mV than – 700 mV
50 percent - 200 to - 350 mV - 500 to - 700 mV
<5 percent More positive than More positive than
– 200 mV – 500 mV

In any case, the technique should never be used in isolation, but should be coupled with
measurements of chloride content of the concretes and its variation with depth and also the
cover to the steel and the depth of carbonation.
l However, a systematic “potential mapping survey” is considered to be more useful for
on-site identification of the Corrosion State of rebars.This will facilitate setting out potential
profile or potential contour.A typical potential contour is shown in fig 3.17 (b) and (c).
Initially when potential surveying was introduced as per ASTM C876, each reading
was interpreted in isolation and the numerical value was directly correlated to the degree
of corrosion.Subsequently, this approach was realised to be erroneous because non-
corroded steel can exhibit a wide range of potential values.It is now realised that potential
values should be assessed, not in isolation, but as a group and the inter-relationship
of the potentials within that group should form the basis for interpretation.Analysis
of potential contour will generally consist of Identifying the locations with accumulated
potential lines indicating to the corroding areas beneath.
3
(b) Shaded Mapping (c) Contours Plot

Fig.-3.17 (b) & (c) Typical Half Cell Potential Coutours
l Locating at a glance, the anodic areas identified by the gathering of isopotential lines
having more severe potential gradient.
l Ascertaining whether or not a structure is actively corroding.
It is necessary to realise certain important parameters (listed below) which influence the
measured potentials of the reinforcement.
i) The potentials of a rebar measured on the surface of, or within concrete may not be a
true representation of the value at the surface of the steel
ii) The physical i.e. moisture content and chemical state of concrete i.e. presence of
electrolyte ions can result in wide variation.
iii) The ohmic drop due to electrical resistance of the concrete also can induce variations
iv) With increasing concrete cover, the potential values at the concrete surface over actively
corroding and passive slab become similar.
3.2.3.3 Resistivity Measurement

Resistivity Mapping:
The electrical resistance of concrete plays an important role in determining the quality of
concrete from the point of view ‘corrosion susceptibility potential’ at any specific location.
This parameter is expressed in terms of “Resistivity” in ohm-cm.
For general monitoring, a resistivity check is important because long-term corrosion can be
anticipated in concrete structures where accurately measured values are below 10,000 ohm-
cm.Further, if resistivity values fall below 5,000 ohm-cm, corrosion must be anticipated at a
much earlier period (possibly within 5 years) in the life of a structure. Table 3.14 indicates the
general guidelines of resistivity values based on which areas having probable corrosion risk
can be identified in concrete structures. 3
Table-3.14 : Corrosion Risk from Resistivity

Resistivity ohm cm. Corrosion Probability

Greater than 20,000 Negligible
10,000 – 20,000 Low
5,000- 10,000 High
Less than 5,000 Very High
The principle of resistivity testing in concrete is similar to that adopted in soil testing.However,
when applied in concrete, a few drawbacks should be realised.The method essentially consists
of using a 4- probe technique in which a known current is applied between two outer probes
100 mm apart and the voltage drop between the inner two elements at 50 mm spacing, is
read off allowing for a direct evaluation of resistance R.Using a mathematical conversion
factor, resistivity is calculated as per principle of four probe resistivity testing is illustrated in
Fig 3.18.
Fig.-3.18 Resistivity meter (4 probe system)

The following drawbacks are important to note while analysing and interpreting the resistivity
values:
l The value obtained represents only the average evaluation over the depth regulated by
the chosen probe spacing and not that of concrete at steel interface
l The resistivity of concrete varies with varying moisture conditions
l The instrument should have adequate ‘IR’ drop compensation for measurement.
Table 3.15 gives some guidelines for a qualitative identification of corrosion prone areas
based on combined results of half-cell potential and resistivity.
Table 3.15 : Corrosion Probability based on Resistivity and Potential Mapping
1. High resistivity greater than 10,000 ohm - cm No active corrosion-
and low potentials – more positive than – relatively cathodic
200 mV (CSE)
3
2. Low resistivity below 10,000 ohm – cm and Initiation of corrosion
potentials between – 200 m V to -350 mV activity – relatively
(CSE) anodic
3. Low resistivity about 5,000 ohm – cm and Presence of corrosion
potential – 200 mV to -350 mV (CSE) activity – anodic
4. Low resistivity below 5,000 ohm cm and High intensity of
potential more negative than – 350 mV (CSE) corrosion – fully
anodic
5. Higher potential gradient and high conductivity High rate of corrosion
Measurement of corrosion rate:

In reinforced concrete structures, determination of actual rate at which the reinforcement is
corroding assumes larger importance since the laboratory results are not directly applicable
to field conditions.Another form of the polarisation method has been developed and is known
as “Linear Polarisation Resistance” (LPR) method for the on-site study of corrosion rates of
steel in concrete.The fundamental principle of linear polarisation is based on the experimentally
observed assumption that for a simple model corroding system, the polarisation curve for
few millivolts around the corrosion potential obeys a quasi-linear relationship .The slope of
this curve is the so-called polarisation resistance “Rp”. (ICJ 98, JUNE, 1998)
Rp =(DE/DI)DE0
From this slope, the corrosion rate can be determined using stern- Geary equation
I = B/R
corr p
Where, B is a constant which is a function of the Tafel Slopes and ba, bc, and determined
from the formula given below:
B = [ba. bc/ 2.3(ba + bc)]
The value of B usually lies between 13 and 52 mV depending on the passive and active
corroding system.For on-site measurements, the testing system consists of a potentiostat,
counter electrode, reference electrode and the reinforcement as working electrode.This system
is schematically illustrated in Fig 3.19.

Fig.-3.19 Resistivity testing for concrete
A typical plot of linear polarisation curve is shown in Fig.3.20.

It is necessary that for measurements i n concrete, the potentiostat should have electronic
ohmic compensation(IR drop) or otherwise, the value is to be obtained by calculation or
separate experiments.
Fig.-3.20 Linear Polarisation Curve

3.2.4 Fire Damage Assessment:

1. Differential Thermal Assessment of qualitative & quantitative
Analysis(DTA)(Lab Test) composition of sample of concrete
2. X-ray Diffraction To determine the extent of deterioration
(XRD)(Lab Test) in concrete subjected to fire
3.2.4.1 Differential Thermal Analysis (DTA)

DTA is used to study the physical and chemical changes that occur in a material when it is
heated so as to characterise the material. It is concerned with the rate of change of temperature
of a sample as it is heated at a constant rate of heat flow.
The principle on which DTA is based is that when a material is slowly heated, its temperature
rises but when the material undergoes any endothermic reaction viz. losing water,
losing CO2, change in crystalline structure or decomposition, its temperature remains
constant.
3
The results of DTA are presented in the form of DTA curves. The sample and an inert material
are heated in separate crucibles and the difference of temperature between the two is recorded
by means of thermocouples which generates an electrical signal whenever there is a temperature
difference between the reference and the sample. When there is no endothermic reaction in
the sample, there would not be any difference of temperature between the reference and the
sample and hence, no electrical signal would occur. Any endothermic change would create a
thermal differential and hence an electric pulse. The occurrence of this pulse appears as a
peak in the DTA curve which is a plot.of temperature versus electrical signal generated.
Advantage of DTA over TGA is that the changes not involving weight loss can also be detected.
By comparing the DTA curve of a sample with that for known compounds, qualitative
composition of the sample can be judged. Quantitative composition of the sample can also
be judged by measuring the size of the peak in the DTA curve. The peak size is directly linked
with amount of heat involved in a transition.
If a concrete sample is analysed, endothermic peak due to Calcium hydroxide is found at
500°C. The peak due to conversion of silica occurs at 570°C. When various fire damaged
samples of concrete are subjected to DTA, the presence of peak at 500°C indicates that
Calcium hydroxide is present and that the sample has not been subjected to temperature
more than 500°C. If peak of 570°C only is present, it means that silica conversion had not
occurred in the sample and it was not subjected to temperature more than, 570°C. If no
peak is there, it means that sample was subjected to temperature exceeding 570°C.
3.2.4.2 X-ray Diffraction (Xrd):

X-ray diffraction technique is based on the principle that a crystal of a substance has a unique
diffraction pattern; When monochromatic X-ray beam falls on a crystal it gets reflected by
the various crystalline planes. Interference occurs among the various reflected beams resulting
in a diffraction pattern consisting of dark and bright fringes depending upon the phase difference
among the interfering beams.
A crystal whose composition is unknown can be identified by obtaining its diffraction pattern
and comparing it with diffraction patterns of already identified crystals. The diffraction pattern

of a single crystal consists of a number of single spots but when powder sample is used, the
diffraction pattern consists of a series of diffraction lines.
By this technique the size of crystal planes the molecular structure of the sample can be
determined. It can also be found whether the sample is a single compound or consists of
more than one compound. In case of polymers, degree of crystallinity can be found because
the noncrystalline portion will scatter the x-ray beam to give a continuous background while
the crystalline portion will give discontinuous diffraction pattern.
As regards to the assessment of fire damage, X-ray diffraction can be used to determine
the extent of deterioration in concrete that has been subjected to fire. The temperature
to which the damaged concrete has been subjected to can be determined by this method:
3.2.5 Structural Integrity/Soundness Assessment
3.2.5.1 Radiography:
This technique enables to take a photograph showing details of the inside of a concrete 3
member. It is used to determine the location and size of reinforcement, to check for the
existence of voids and areas of poor compaction in concrete where other NDE test methods
are not suitable, such as massive old concrete structural units when being assessed for structural
safety. It is also used for checking for voids in the grouting in prestressing ducts.
BS 1881: Part 205 gives detailed information/ recommendation for radiographic inspection
of concrete.
The method uses sources of gamma rays for concrete up to about 500 mm thick and above
this thickness, the standard recommends the use of high-energy X rays.
Due to the inherent danger of using gamma rays and high energy X rays, the use of this
method is confined to investigation which justify the cost of the special precautions which
have to be taken.
3.2.5.2 Impact-echo test:

Most recent Non-destructive evaluation technique based on use of transient stress waves,
has been used for detecting flaws in many different types of structures including plate like
structures, such as bridge decks, slabs and walls beams and columns, layered structures and
hollow cylindrical structures. To detect hidden damage and determine the extent of damage
inside a concrete cross section (delamination, Honey-comb, cracks etc.)
3.2.5.3 Dynamic Testing of Structures :

The dynamic characteristicsof structures depend on its stiffness and mass.Frequency of
a structure gives a good indication of deterioration or improvement of its stiffness.The
dynamic testing of a structure before and after repairs will give an idea of the deterioration
of structures and effectiveness of the repairs.The different techniques available for dynamic
testing of structures are following:
1. Frequency Shift : The method is based on the comparison of the natural frequency of
the damaged structure with the undamaged structure.In the absence of the knowledge
of the natural frequency of the undamaged structure an estimate has to be based on

theoretical computations.Care should be taken for the effect of non-structural members

on the frequency. The frequency being a global property of a structure, this method
cannot be used for locating the damage.
2. Mode-Shape Change : The change in mode shape is more sensitive to damage than
the frequency. The damage location using mode-shape can be done without a prior
knowledge of the undamaged structure or the theoretical calculations (West, 1984 ).An
alternative to mode shape is to use derivatives of mode shapes such as curvature.
3. Change in Dynamically Measured Flexibility : The flexibility matrix of a structure can be
synthesized using the frequency and mode shape in various modes.The flexibility matrix
of the damaged structure compared with that of undamaged structure can indicate the
damage. The same comparison before and after the repairs will indicate the effectiveness
of repair.
In addition to the above-mentioned techniques a few techniques are available for
continuous/periodic health monitoring of a structure. The problem with the dynamic
3 testing is the absence of the knowledgeof the undamaged structure.However, the
testing can be very; useful in assessing the effectiveness of repairs, as the testing
can be done before and after the repairs.
3.2.6 Interpretation and Evaluation of Test Result Data
3.2.6.1 Establishing the problem, the probable causes and factors influencing the deterioration re-
quires careful studies and analysis of the information gathered in the investigation stage which
should be tabulated on a specific proforma to be prepared depending on the type of test
data, information available for analysis.
3.2.6.2 This usually involves proposing a hypothesis and testing the resultant scenario against the
observed facts. Two or three such hypothesis and scenario may be looked at and tested for
their veracity against the available facts. Examination of available facts
often reverse the need for further investigation to resolve the unanswered questions
3.2.6.3 Interpretation of test results.

Based on UPV Results:
a) Uniformity of ultra-sonic pulse velocities throughout the structure indicates that
the concrete is likely to be of a uniform quality.This is a rare phenomenon in a poorly
constructed building.However, uniformly low value would indicate low strength of
concrete.
b) If the pulse velocities vary from one zone to another of a structure, but are reasonably
uniform within each zone, there is probably a variation in the quality of concrete from
one batch of concrete to the other that was used in construction.
c) If the pulse velocities vary randomly over a wide range throughout thestructure, the
quality of concrete is not necessarily the only suspect. The very likely cause could be
poor concreting, inadequate and non-uniform compaction, addition of extra water on
site in uncontrolled quantities, and other construction related errors could lead to highly
variable concrete.

d) Stripping of the plaster and exposing the concrete surface may visually indicate the poor
quality of concrete by way its appearance.Segregation, honeycombing, loose concrete,
powdery surface, cracks and presence of foreign material, one or all of them, may
become visible when the plaster is stripped.
e) Micro cracking to various degrees in an under-designed or an over loaded structure in
which there are zones of high-sustained stresses may also cause high variation in pulse
velocities.A check of the actual loads on the structure and structural calculations will
reveal zones of high-sustained stresses in the structure.Low pulse velocities have
sometimes been mistakenly attributed to poor quality of concrete in the structure, though
in reality low pulse velocities had been caused by micro cracking.
The engineer assessing the structure sometimes faces a dilemma when he is presented with a
report on tests with many inconsistencies and unacceptable results.The fault may or may not
lie with the testing agency.The following are some of the inconsistencies, which may make the
test report inconclusive.
1) Low pulse velocities are accompanied by high core strengths; 3
2) Low probe penetrations are accompanied by low core strengths;
3) High core strengths are accompanied by low pulse velocities and high probe penetrations;
4) Other variations of the above;
5) Unacceptably low correlation coefficient.
The problem may arise due to inaccuracies in testing such as the following;
1) Inappropriate surface preparation for the non-destructive evaluationtests.
2) Applying too thick a coupling medium, which separates the surface of concrete from its
contacting transducer, in the case of ultrasonic tests. For this reason, repeated readings
of the transit time should be made while allowing the couplant to become thinly spread
until a minimum value of the transit time is obtained.
3) Failing to detect reinforcement bars and ensuring that they do not lie in the path of the
ultrasonic pulse, or ensuring that the presence of any steel is accounted for;
4) Measuring pulse velocities in zones of tensile stress or zones where compressive stress
is too high for the quality of concrete; the influence is significantif the compressive stress
is higher than 60 percent of the ultimate strength of the concrete;
5) Failing to ensure that the drill is kept rigidly positioned during coring, otherwise badly
ridged or cored surfaces may be obtained with possible reduction in measured strength;
6) Failing to ensure that apparatus used in the various tests are performing satisfactorily;
7) Errors in measurements
It may not be possible to obtain sensible correlation curves for reasons other than
testing procedures such as the following:
1) Poorly constructed structure with pockets of weak concrete, voids, cracks and foreign
material scattered all over the structure;
2) Poorly designed and badly detailed structure with varying degrees of micro cracking
and deterioration.
While it may be possible to get good correlation under controlled conditions in the laboratory,
or for the concrete in a well designed and well constructed structure, it is often a problem in
badly designed and badly constructed structures with highly varying conditions within the
structure.
If the irregularities in test results are due to the testing procedure, these can be corrected and
tests repeated.If the irregularities are due to other reasons, the assessor has to use a lot of
judgement. He may decide to carry out a lot more tests on the critical members of the
structure before coming to a conclusion on the condition of the structure.
3.3 Conclusion
In majority of cases, the causes of particular problem could be traced to the following, singly
or in combination
1) Lower cover thickness over steel
2) Permeable cover concrete
3) High chloride levels
4) Alternate wetting and drying
It will be thus clear that the approach that should be adopted to control the future deterioration
of concrete will depend on which of the above causes (or combination of causes) applies.
3 The range of remedial solutions can vary from the minimal (patch repair of areas actually
spalling) to the drastic (crust out completely & reinstate)
It is essential that all possible factors be noted during an investigation, so that unusual features
of the environment or the concrete can be identified and the necessary solution sought.
✯ ✯ ✯

APPENDIX-3.1
Proforma For Planning Condition Survey Of Structure

Data- sheet
date :
Important
For proper investigation & selection of correct repair systems, it is desirable to furnish all possible
information in detail as correctly as possible.
A. DATA
1. Name of the Project :

a. Estimated cost :
b. Location :
3
c. Plinth area of Building :
2. Year of Construction :
3. Use of the Building
a. Designed Use :
b. Present Use :
c. Any other change in Bldg use :
d. Brief background history,
if change in building use is involved :
4. a. Structural changes made in the past :
b. If so, details of Changes carried out :
5. Year of first distress noticed :
6. Nature of distress noticed
a. Any previous investigation done in the past :
b. If so, copy of results of such investigation :
7. Any repair to concrete undertaken in the past. :
a) If so, provide details
1. Year of carrying out repairs
2. Type of repairs
3. Efficacy of repair
4. Cost of repairs
8. Any investigation done in past
a) If so, copy of the results of such
investigation :
9. Type of cement used (OPC/PPC)/ :
SRC/ any other in original
construction)

10. Type of steel reinforcement used

(Mild steel/Cold twisted steel/TMT
/any other steel ) :
11. Source of water used for original construction
(Municipal water/Local bore well / Any
other source) :
12. Chemical analysis results of water
used for construction :
pH Value :
Chloride ppm :
Sulphate ppm :
13. Source of sand and chemical analysis,
if any, in regard to Chloride/
3 Sulphate contents :
14. Source of coarse aggregate including
type of rock :
15. Photo of defective portions, if any :
16. Set of architectural drawings
(to be enclosed) :
17. Set of structural drawings :
(to be enclosed)
18. Details of any protective
treatment used ( during or
after construction) :
B. TECHNICAL COMMENTS ON NATURE OF DISTRESS
1. Executive Engineers :
2. Superintending Engineers :
3. Chief Engineers :
Signature of Engineer-in-Charge

APPENDIX-3.2(A)

APPENDIX 3.2 (B)

APPENDIX 3.2 (B)

Repairs & Rehabilitation Unit III-48
Group of
Exposure
Member no.
member
Spread sheet
Bldg Identification
reference No.
Location of structural
Velocity km/sec
Qualitative Grading
UPV meter
Rebound Numbers
as recorded
Rebound Index
Qualitative Grading
Schmidt Hammer
Core Crushing
strength
Equivalent
cube strength
Crushing Strength
Qualitative Grading
Core
Density
% age of standard
Concrete Strength Assessment
density
A. Concrete Strength assessment
Core Test
Density Test
Qualitative
Grading
3
Typical Format for analysis of field test results
Visual
observation
of core
Qualitativ
Examination
e Grading
Petrographic
General observation
including
priorisisation based
on distress/deterioration
Reasons for distress with
justification
Recommendation
APPENDIX 3.3
III-49 Central Designs Organisation
Group of Exposure
Member No
Bldg
member
Work
structural
Location of
Identification
Sheet
Specified
Thickness (mm)
Actual
Cover
Measured
Concrete
Thickness (mm)
Depth of
Carbonation
measured (mm)
Whether
reinforcement
needs to be
exposed all
Carbonation Depth
around
Potential
Readings as
observed
Number of readings
falling in Ranges A,B&C
C=?
B=?
-do-
A=?
Ranges are
‘C’=>(-)350mV
Probability of
corrosion
‘B’=(-)200mv to (-)350 mV
Measured
H
Value
cover
‘A’=0 to (-) 200mV concrete
Total Chlorides
B. Corrosion Assessment
(% by weight of
Corosion Assessment
Cement)
Concrete
3
Total Sulphate
Typical Format for analysis of field test results
(% by weight of
Cement)
Half Cell Potential Test P of Chemical Test Results of
Original Bar Dia (Do)

Measured Bar Dia (D2)
% age Reduction of
X-sectional area
Diameter
Whether addl reinforcement Reduction of Bar
required (Y/N)?
General Observation including
priorisisation based on distress/
deterioration distress/
deterioration
I Recommendations
Reasons for distress with
justification
CONDITION SURVEY & NON-DESTRUCTIVE EVALUATION APPENDIX 3.3
1. (————) Corrosion of Reinforcement in concrete construction, edited by ALAN

R.CRANE Society of Chemical Industry, industry, London, Publishers - Ellis Horwood
Ltd., First Edition, 1979
2. (————) Corrosion of Steel in Concrete, edited by Schiessel P. Report of the Technical
Committee, 60-CSC, Rilem, published by Chapman and Hall 1988.
3. (————) MALHOTRA V.M. Testing hardened concrete non-destructive methods.
The lowa State University Press, AMES, IOWA and ACI, Detroit, Michigan 1976,
Chapter 2, p 21.
4. (———) Operation Manual, Rapid chloride test kit, German instrument, Emdrupvej
102 DK-2400, Copenhagen NV, Denmark
5. Corrosion of Reinforcement in Concrete, edited by PAGE CL. TREADWAY, K.W.J
3
and BOMFORTH P.B. Society of Chemical industry Elsevier Applied Science, May
1990
6. Standard test method for half cell potentials of reinforcing steel in concrete, ASTM C
876-80, American Society of Testing materials.
7. FELIV J.A. GOSALEZ and ANDRADE,M C.Polarisation resistance measurements
in large concrete specimens mathematical solution for a undirectional current distribution,
Materials and Structures, RILEM V-22 1989, pp 199-205
8. BIS: 6925 : 1973 Methods of test for determination of water soluble chlorides in concrete
admixtures.
9. IS: 1311: 1992 (Pt I) – Methods of non destructive testing of concrete : Pt I. Ultrasonic
Pulse Velocity
10. IS: 13311: 1992 (Pt II) - Do - Pt II. Rebound hammer
11. IS : 3085 : 1965 (Methods of test for permeability of concrete & cement mortar.
12. IS: 5536 : 1969 Specification for constant flow type air permeability apparatus (Lea
and Geary)
13. Paper on “Guide for evaluation of concrete Structures prior to Rehabilitation” reported
by ACI committee 364 published in ACI Material Journal- September/October, 1993
14. Repair, protection and water proofing of concrete structures, Third editions By P. H.
Perkins, 15. Concrete society Refrence.(as mentioned on page 15 under “Age of
Concrete” ).—rnr
15. Dhir,R.K., 1990,”Concrete Research :An International Perspective”, Seminar on
Durability of Concrete, pp. 1-7, IIT, Madras,April.
16. Escalante,E., EFFECTIVENESS OF POTENTIAL MEASUREMENTS OF ES-
TIMATING CORROSION OF STEEL IN CONCRETE, Corrosion of Reinforce-
ment in Concrete, Edi. by C.L.Page., K.W.J.Treadway., and P.B.Bamforth, Publ.by
Elsevier Science Publishers Ltd, England , 281-292, 1990

17. Loto,C.A., Odumbo,E.T., ELECTROCHEMICAL POTENTIAL MONITORING

OF CORROSION AND COATING PROTECTION OF MILD STEEL
REINFORCEMENT IN CONCRETE , Corrosion, Vol.45, No.7, 553-557, 1989
18. McDonald,D.B., Pfeifer,D.W., Krauss,P., Sherman,M.R., TEST METHODS FOR
NEW BREEDS OF REINFORCING BARS, Corrosion and Corrosion Protection
of Steel in Concrete,Edi. by R.N.Swamy , Publ. by Sheffield Academic Press Ltd,
Sheffield, U.K , Vol.2 , 1155-1171, 1994
19. Rengaswamy, N.S., et al, 1985, “Durability of Reinforced Concrete Structures– 25
Years of R&D Work at Central Electrochemical Research Institute, Karaikudi”,
Proceedings of Workshop on Corrposion of Builoding Materials in Fertilizer & Chemical
Industries, pp. 20-31, May,Roorkee.
20. Naish,C.C., Harker,A., Carney,R.F.A., CONCRETE INSPECTION: INTERPRE-
TATION OF POTENTIAL AND RESISTIVITY MEASUREMENTS, Corrosion of
Reinforcement in Concrete, Edi. by C.L.Page., K.W.J.Treadway., and P.B.Bamforth 3
, Publ. by Elsevier Science Publishers Ltd, England , 314-332, 1990
21. Bhaskaran Rao, M.V., et al, 1987,”A Review of the Investigation and Evaluation of
Corrosion in Concrete Structures”, Indian Highways, Vol.15, No.1,pp.22-23, January.
22. Atimtay,E., and Ferguson, P.M., 1973,”Early Chloride Corrosion of Reinforced
Concrete –A Test Report”,,Title No.70-55, American Concrete Institute Journal,
pp.606-622, September.
23. Dhir, P.K. et al, 1989, “Near – Surface Characteristics of Concrete Prediction of
Carbonation Resistance”, Magazine of Concrete Resistance, 41(148), pp. 137-143,
Septemper.
24. Dhir, R.K., et al, 1989, “Near Surface Characteristics of Concrete:Intrinsic Permeability”,
Magazine of Concrete Research,Vol.41 (147), pp. 87-97, June.
25. Mani, K. and George, Z., 1981, “Experimental Techniques for Assessment of Corrosion
of Embedded Steel in Concrrete in Marine Environment”, Indian Conference on Ocean
Engineering,pp.V-34 to V-42,IIT, Madras.
26. Mehta,P.K., 1980, “Performance Tests for Sulphate Resistance and Alkali-Siliea
Reactivity of Hydraulic Cement”, Proceedings of the International Conference on
Durability of Building Materials and Components, ASTM STP 691,336-345.
27. Rangaswamy, N.S. et atl, 1979, “Surface Potential Measurements on Reinforced Cement
Concerete”,, Transactions of the SAEST, Vol.14, No.2, pp.85-91.
28. Feldman, R.F. and Ramachandran, V.S., 1980,” New Accelerated Method for Predicting
Durability of Cementitious Materials”, Durability of Building Materials and Components,
ASTM STP 691,pp.315-325.
29. ACI Journal Committee 201, 1977, “Guide to Durable 162, Sluijter, W.L. et al,
“Potentiodynamic Polarization Curves and Steel Corrosion”,, pp. 1-13, Heron Germany.
30. IS:6009:1987, Method for Evaluation of Results of Accelerated Corrosion Tests, pp.36,
BIS, New Delhi.

31. Malhotra, V.M., 1988,”In-Situ/Nondestructive Testing of Concrete: A Review”, Pro-
ceedings of Second International Colloquium on Concrete in Developing Countries – A
Joint Indo-CanadianColloquium, pp. 27-30, Bombay, January.
32. ASTM B 117-57 T, Salt Spray (Ffog) Testing.
33. IS:3025, 1964, “Determination of pH value (Hydrogen Ion Concentration),pp.16,Sec.8,
BIS, New Delhi.
34. IS:3085, 1965, “Method of Test for Permeability of Cement Mortar and
Concrete”, pp.3-10 ,BIS, New Delhi.
35. Malhotra, V.M., “In Situ Nondestructive Testing of Concrete – A Global Review”, SP
82-1, pp. 1-16, ACI, USA.
36. Nuffield, E.W. 1966, “X-Ray Diffraction Methods”, pp. 114-115, John Wiley and
Sons, Inc, New Delhi.
37. Rengaswamy, N.S. et al, 1966,”Measurements of Electrical Resistance of Concrete
Structures”,,The Indian Engineer, pp. 1-4, June.
38. Rengaswamy, N.S. et al, 1986, “Non- Destructive Testing of Concrete by Electrical
Resistivity Measurements”, Indian Concrete Journal, pp. 23-26, January.
39. Tamura, H. et al, “Nondestructive Method of Detecting Steel Corrosion in Concrete”,
SP-82, ACI, pp. 689-702, Detroit, USA.
CHAPTER 4
STRUCTURAL ANALYSIS AND DESIGN

PAGE NO.
4.1 General: IV-1
4.1.1 Reserve Strength IV-1
4.1.2 Analysis necessary to Identify Critical Section IV-1
4.1.3 Active and Passive Repairs IV-2
4.1.4 Modeling of Repaired Composite Structure IV-2
4.2 Structural System & Its Validation IV-2
4.3 Mechanical Properties of Materials IV-2
4.4 Evaluation of Damage to Concrete/Reinforcement IV-4
4.5 Service Loads Including Due to Change of Building use IV-4
4.6 Evaluation of Building Configuration IV-4
4.7 Analysis and Design IV-4
4.8 Load Tests for Flexural Members IV-5
Suggested further reading Material and References IV-6

4
The definition of the problem becomes a major part of the innovation. A lot of solutions fail because they’re
solving the wrong problem.
…Elbert Einstein
4.1 General
Strength evaluation of an existing structure or its portion may be required if it is considered
that there is:
a. Evidence of faulty design/construction
b. Structural deterioration due to ageing or otherwise 4
c. Need for changed use of structure for which it was not originally designed
d. New codal requirement to which the existing structure does not conform
Analysis and design process of a damaged structure has to be based on its actual existing
condition. Before taking it up, the in situ properties of material used and its structural
sizes have to be determined based on field investigations and measurements. Whereas,
in case of new structures, option of alternative standard materials and structural sizes
are open and the design process could be adopted to get the optimum results based on
loads as per its design use.
Basic principles of analysis and design of a distressed structure are same as in case of
new structures. However, these require extra inputs based on sound and experienced
engineering judgment of the structure and its materials.
4.1.1 Reserve Strength

The old structures have reserve strength due to:
a. Increased strength of concrete with ageing, which needs to be established by actual
assessment.
b. Conservative design approaches e.g. non-consideration of live load reduction factor
etc.
c. Steel reinforcement provided is quite often more than the actual requirement.
d. Based on engineering judgment, some higher stresses could be permitted for short
durations while carrying out repairs.
e. While taking the benefit of reserve strength, care shall however be taken, to ensure
that the structure is not subjected to higher stresses so as to impair its stability.
4.1.2 Analysis necessary to Identify Critical Section

There is loss of capacity of structural member due to damaged concrete and/or
reinforcement steel. The first step is the capacity determination of the structure by
Central Design Organisation IV-1

establishing the existing in situ cross-sectional details of damaged structural members and
their material properties. The analysis of the structure can be done in accordance with the in-
situ relative stiffness. If the deflections exceeds the permissible values, the same may be
allowed with caution, provided modified serviceability criteria of appearance and efficiency
is satisfied. The analysis should, however, identify the critical sections in the structure needing
structural strengthening.
4.1.3 Active and Passive Repairs
It is essential to halt its further deterioration and undertake strengthening, if required, for
additional anticipated loads. The repaired structure comprises of parent as well as new repair
material. The repairs can be termed as active or passive depending on the load sharing
mechanism of repair material and parent material. The passive repairs are those, which are
applied on existing loaded structural members and are able to share only a part of subsequent
additional loading. Whereas, in active repairs, the repaired structural member is initially
unloaded to relieve it of loads before the application of repairs. This is done basically to
ensure that the repair material and the parent material share the loads jointly.
4 The structural members can be repaired or strengthened for resisting excess shear and flexure
by providing additional steel reinforcement, carbon fibre wraps/mesh, section enlargement,
external pre-stressing, steel plate bonding etc. The sharing of load between old and new
materials needs to be incorporated in the analysis and design. The type of stresses acting on
the repair system are given in the Fig. 4.1.
4.1.4 Modeling of Repaired Composite Structure
The behaviour of the repaired composite structure is difficult to model due to unpredictable
stress relieving and degree of integration with the existing structure. It will be necessary to
make some rational assumptions based on sound engineering judgment.
The procedure detailed in the following sections can be followed for assessment, evaluation
and design of repaired structures.
4.2. Structural System & Its Validatioin
The documents related to foundation conditions, soil report, analysis, design, execution and
maintenance of work shall be gathered. The illustrative list is given in Chapter–3. As built
architectural/structural drawings are essential for analysis and design.
It is necessary to check and validate the sizes of structural members duly making allowances
for the finishes and damages. The diameter and location of reinforcement can be validated
using available non-destructive bar locator (Cover master/bar locator, etc). The structural
system can be developed based on the validated available structural/architectural drawings.
Wherever such informations are not available, drawings based on actual measurement are to
be developed.
4.3 Mechanical Properties of Materials
The steel reinforcement is relatively consistent in quality. The mechanical properties can be
assessed based on the details available in the drawings or by exposing reinforcement at few
places and taking samples for testing. The losses of cross sectional areas due to effect of
corrosion etc. need to be ascertained.
IV-2 Repairs & Rehabilitation Unit

CHECKLIST OF POSSIBLE FORCES ACTING ON THE REPAIR
Fig. 4.1: Types of Stresses Acting on Reparis

(Source: 1. Peter H. Emmoms, “Concrete Repairs and Maintance Illustrated” Published by Galgotia,
New Delhi, India.
2. Plum, D.R., “Materials–How to Select”, Construction, Maintenance and Repair,
November/December 1991, England).
Central Designs Organisation IV-3

The assessment of mechanical properties of concrete is rather elaborate and requires detailed
investigations. The strength of the concrete can be evaluated by nondestructive methods like
Ultrasonic Pulse Velocity Tests (UPV), Rebound Hammer Test etc. in conjunction with core
test. Using the results of NDE investigations and methods of interpretation given in Chapter-
3, the strength of concrete can be evaluated with certain degree of confidence.
4.4 Evaluation of Damage to Concrete/Reinforcement

The condition survey of the structure will give an idea regarding extent of damage to concrete
due to spalling, original construction defects, loss of strength due to exposure to high temperature
and also damage to reinforcement due to corrosion/fire. This can be done based on the field
measurements. The observation of the structure can be mapped on a suitable format and the
results incorporated in the analysis of structure.
4.5 Service Loads including due to Change of Building Use

Based on building use, its region of location and the related structural/architectural drawings,
the design loads shall be worked out based on the applicable standards for earthquake and
4 wind (refer IS: 875- Part 1 to 5 and IS: 1893). The loading as per original building use and
also due to its changed use in the past and future, shall be ascertained and appropriately
considered in the design process.
4.6 Evaluation of Building Configuration

The existing building may
a. Not comply with the requirements of current codal provisions of design and construction
b. Also require upgrading to satisfy the changed functional requirements.
These may necessitate structural modification. These could be identified based on the period
of construction of the building and the then prevalent codal practices.
The configuration of the building in plan and elevation provide adequate information regarding
structural dynamic response in the event of earthquakes etc. The locations of stress
concentration need to be identified based on analysis of as constructed structure. These
points of stress concentrations are to be examined in detail. The deficiency if any, in the
original construction should be identified. Particular attention must be given to the non-structural/
structural cracks in the structure to identify the cause of distress including improper construction
joints / separation joints, if any.
4.7 Analysis and Design

Analysis and design of the building shall be done taking into consideration of:
a. Structural sizes and material properties established based on the investigations.
b. The reduction in member dimensions, changes in end conditions, the sequence of
construction and subsequent changes in sizes of element, shall also be taken into
account.
c. All the geometric & material characteristics and end conditions of the existing building
while modeling the structure for analysis .
d. The theoretical model may be checked to compare the analytical results with the actual
observations.
e. The structural safety and load transfer shall be ensured at all the stages of repair.
Some of issues to be considered in the analysis/design/repair process without compromising

the stability of structure as a whole, are:
a. The removal of concrete during repair may reduce the effective size of the structural
member and consequently affect its stiffness. Also the stability of the structure
may be endangered due to transfer of load to adjoining members.
b. The removal of a structural member may increase the effective length of a
compression member affecting its stability.
c. In case of indeterminate the beam / slab element, it may be safe to assume the
member as simply supported in the design and proceed accordingly. It would also
give flexibility during execution of repair work.
d. Effectiveness of fully exposed reinforcement in the structural member be assessed.
4.8 Load Tests for Flexural Members:

Load test in accordance to IS: 456-2000 shall be carried out for flexural members, in
case of doubt regarding the capacity of repaired structural element. Before a load test
is carried out,
a. Analysis shall be done taking into account the possible load transfer path. 4
b. The safety of the structural element and the personnel shall be ensured before
allowing the load test.
c. Emergency support system shall be erected below the structure to face the situation
of sudden deflection of a member or the structure.
d. The continuous monitoring of the flexural member, being tested, shall be done
and behaviour compared with the expected results.
✯ ✯ ✯
Central Designs Organisation IV-5


1. IS:456, Indian Standard on Plain and Reinforced concrete-Code of Practice ( Fourth
Revision)
2. IS:875, Indian Standard Code of Practice for Design Loads other than Earthquake
for Buildings and Structures Part 1 to 5
3. IS:1893, Indian Standard on Criterion for Earthquake Resistant Design of
Structures
4. IS:4326, Indian Standard on Earthquake Resistant Design and Construction of
Buildings- Code of Practice
5. IS:13920, Indian Standard on Ductile Detailing of Reinforced Concrete Structures
Subjected to Seismic Forces - Code of Practice
6. IS:1905, Indian Standard Code of Practice for Structural use of Un-reinforced
Masonry(Third Revision)
7. IS:3412, Code of Practice for Installation of Joints in Buildings
4 8. IS:2212 Code of Practice for Brickwork
9. SP:16 Design Aids to IS:456
10. SP:22 Explanatory Hand Book on IS:4326 & IS:1893
11. SP:24 Explanatory Hand Book on IS:456
12. SP:34 Handbook on Concrete Reinforcement Detailing
13. SP: 20 Explanatory Hand Book on IS:1905 & IS2212
14. ACI: 318, Building Code Requirements for Reinforced Concrete
15. Concrete Society Committee Report No.26
16. Concrete Society Committee Report No.33
17. ACI: 437, Strength Evaluation of Existing Concrete Buildings
18. Concrete Repair and Maintenance Illustrated by Peter H. Emmons Published by
Galgotia

CHAPTER 5
SELECTION OF REPAIR MATERIALS

FOR CONCRETE
PAGE NO.
5.1 General V-1
5.2 Essential Parameters for Repair Materials V-1
5.2.1 Low Shrinkage V-2
5.2.2 Requisite setting/hardening Properties V-2
5.2.3 Workability V-2
5.2.4 Bond with the Substrate V-2
5.2.5 Compatible Coefficient of thermal Expansion V-3
5.2.6 Compatible Mechanical Properties & Strength V-3
5.2.7 Relative movement, if expected V-4
5.2.8 Minimal or no curing Requirement V-4
5.2.9 Alkalinity V-4
5.2.10 Low air & water permeability V-4
5.2.11 Aesthetics V-4
5.2.12 Cost V-4
5.2.13 Durability & Bio non-degradability V-4
5.2.14 Non-Hazardous/Non-Polluting V-5
5.3 Materials for Repair V-5
5.3.1 Premixed cement concrete/mortars V-5
5.3.1.1 Cements V-5
5.3.1.2 Mineral Additives V-8
5.3.1.3 Chemical Admixtures V-8
5.3.1.4 Water Cement Ratio V-8
5.3.2 Polymer Modified Mortars and Concrete (PMM/PMC) V-8
5.3.2.1 Materials V-9
5.3.2.2 Process of Polymer Modification in Cement concrete/mortar V-11
5.3.2.3 Composition of Polymers V-12
5.3.2.4 General Requirements of a Polymer Latex V-12
5.3.2.5 Classification of Polymer Latexes V-13
5.3.2.6 Properties of Polymer Latexes V-13
(i)
(ii)
5.3.2.7 Physical and Mechancial Properties of Polymer Modified

Mortars/Concretes V-14
5.3.2.8 Mix Proportioning V-15
5.3.2.9 General Guidelines & Precautions for use of polymer
modified cement mortar/concrete V-16
5.3.2.10 Fields of Application V-17
5.3.3 Epoxies and Epoxy Systems including Epoxy Mortars/Concretes V-18
5.3.3.1 Epoxies V-18
5.3.3.2 Modified Epoxy Systems V-20
5.3.3.3 Precautions to be taken V-22
5.3.3.4 Field of Applications V-22
5.3.4 Polyester Resins V-23
5.3.5 Surface Coatings V-23
5.3.5.1 Essential Parameters for coatings V-23
5.3.5.2 Types of surface coatings V-23
5.4 Conclusions V-25
Appendix 5.1 V-28
Appendix 5.2 V-46
Appendix 5.3 V-49
5
SELECTION OF REPAIR MATERIALS
FOR CONCRETE
The way my Dad always liked to put it was, that an engineers could find a way to do for one dollar,
what everybody else could do for two.
..Jack Kilby
5.1 General
Selection of repair material is one of the most important tasks for ensuring durable and trust
worthy repair. Though, the pre-requisite for a sound repair system is the detailed investigation
and determining the exact cause of distress, yet an understanding of the process of deterioration
of the repair materials (such as concrete and other auxiliary materials i.e. plastics, resins, etc)
under service conditions is vital. Of course, availability of materials of relevance, equipment
and skilled labour have to be explored before deciding upon the repair material. 5
The analogy for selection of repair material is similar to repairing of a torn garment with sound
fibre/fabric but of similar performance characteristics (i.e. preshrunk and similar fibre/fabric)
as that of the original garment. Had the patch repair been done with un-shrunk or dissimilar
fibre/fabric, it would have inflicted a greater damage to the repaired garment due to its pulling
away on a subsequent shrinking after washing. Exactly this is applicable to selection of materials
for repair of concrete/plaster. Also the selection of the repair material has a chemical angle
and the manufacturer’s literature normally highlights the composition of the material rather
than performance characteristics. Since, cementitious products have a tendency to shrink
and hardening with age, it is essential that the repair material for repairing concrete or plaster
should be of non shrink type and compatible with parent material.
5.2 Essential Parameters For Repair Materials

Besides being of compatible properties, repair materials for cement concrete/mortar shall
also be easy to apply and require no attention after the repair has been applied. The essential
parameters for deciding upon a repair material for concrete are :
l Low shrinkage properties
l Requisite setting/hardening properties
l Workability
l Good bond strength with existing sub-strate
l Compatible coefficient of thermal expansion
l Compatible mechanical properties and strength to that of the sub-strate
l Should allow relative movement, if expected, particularly in case of sealing of cracks or
dealing with expansion joints.
l Minimal or no curing requirement
l Alkaline character
l Low air and water permeability
l Aesthetics to match with surroundings
Central Designs Organisation V-1

l Cost
l Durable, non degradable or non-biodegradable due to various forms of energy, life,
UV rays, heat etc
l Non-hazardous/non-polluting
5.2.1 Low Shrinkage

It is well known that the cementitious repair materials shrink with passage of time. Most of
the shrinkage generally takes place in the initial period from the time of casting to 21 days.
Therefore, cementitious repair material in its original form, if used for repair to concrete/
mortar, is likely to get either delaminated due to de-bonding or develop shrinkage cracks on
its surface due to shrinkage strains and stresses. Shrinkage cracks so developed in the repair
patch would allow the easy access of atmospheric air and water, which could be harmful for
concrete and reinforcement.
It is, therefore, essential that the low shrinkage property of repair material shall be looked for
while selecting a material for concrete repair. Cementitious materials need additional non-
shrink compounds so as to be effective in achieving the desired property. Therefore, the
formulation of the patch mortar incorporates, in the cement matrix, several special chemicals
to mitigate the shrinkage. Using low cement content and low water cement ratio will also
5 reduce the drying shrinkage.
5.2.2 Requisite setting/hardening Properties

It is desirable that the repaired structure shall be put to use at the earliest possible to reduce
the down time of plant, machinery, building or road. It is, therefore, essential that repaired
patch shall harden in the minimum possible time. However, in exceptional cases, it could also
be essential to have the slow setting property as a desirable property for repair material.
Such situation could be where more working time is required to work on repair materials or
the repair process is intricate that more working time is required.
5.2.3 Workability
The repair material is to be applied by the field workers and hence its acceptability by them
is very important. The property desired by the field workers is good workability. Hence
optimum workability is to be achieved without sacrificing the other desirable properties by
use of suitabile additives/admixtures.
5.2.4 Bond with the Substrate
The bond strength of repair patch with the substrate is essential to have a successful repair
system. If it is felt that the bond strength of the repair material with the base material is
inadequate or less than the strength of the base material, then some other suitable means
could be explored to improve bond strength between repair material and substrate. These
could be use of:
l Adhesive,
l Surface interlocking system, and/or
l Mechanical bonding
A variety of adhesives, in the range of epoxies, polymer modified cement slurries including
unmodified polymer applications are available. The selection depends upon available open
V-2 Repairs & Rehabilitation Unit
SELECTION OF REPAIR MATERIALS FOR CONCRETE
time for bonding etc, which are being specified for different applications. Surface interlocking
system and methods of mechanical bonding are, however, detailed out in the subsequent
chapter on Repair Methods.
5.2.5 Compatible Coefficient of thermal Expansion:

The difference in volume change because of temperature variation can cause failure either at
the bond line or within the section of lower strength material. Therefore, in the areas exposed
to temperature variations, the patches of repair should have same coefficient of thermal
expansion to ensure that no undue stresses are transferred to bonding interface or the substrate.
Due to similar coefficient of thermal expansion, cementitious materials are preferred over
epoxy materials. Coefficients of thermal expansion of commonly used construction/repair
materials are given in Table 5.1.
Table 5.1: Coefficient of Thermal Expansions of

Commonly Used Building Materials
S. Material Co-eficient of thermal

No. expansion in 10-6/°C
5
1. Stones
(i) Igneous rocks 8 to 10
(ii) Lime stones 2.4 to 9
(iii) Marbles 1.4 to 11
(iv) Sand & sand stones 7 to 16
(v) Slates 6 to 10
2. Metals
(i) Aluminium 25
(ii) Bronze 17.6
(iii) Copper 17.3
(iv) Lead 29
(v) Steel and iron 11 to 13
3. Bricks and brickwork 5 to 7
4. Cement mortar and concrete 10 to 14
5. General purpose non-shrink concentitious micro-concrete 10 to 12
(Renderoc RG)
6. Polymers modified mortar/concrete 10-12
7. Epoxy mortar/concrete 20-25
5.2.6 Compatible Mechanical Properties & Strength

The hardened material shall have compatible mechanical properties or rather slightly better
strength than that of base material. This property is desirable to ensure uniform flow of stresses
and strains in loaded structures. It is well known that the elastic modulus of two concretes
would be different for different crushing strength so if repair concrete is having strength much
different than the base, it could lead to non-uniform flow of stresses and may result in an early
failure of the repair patch. For example, if M-20 grade of concrete has been used in original

construction, the grade of the repair material shall neither be less than M-20 nor higher than
M-25.
5.2.7 Relative movement, if expected

Particularly in case of sealing of such cracks where movement is expected or at expansion
joints, the repair material selected shall be resilient and elastic to be able to absorb the
anticipated relative movements of the structure without any signs of distress or crack.
5.2.8 Minimal or no curing Requirement

It is desirable that the repair material shall not have any curing requirement after the repair has
been applied or even if it is required, it should be minimal to ensure that the repair patch
hardens and attains the desired strength without much post-repair-care. Only epoxies don’t
need any curing. Other material applications need nominal to moderate curing, which need to
be specified. Such materials have several other merits, which are to be kept in view, while
making a selection. Curing compound can be applied over cementitious materials used for
repairs but after examining its compatibility.
5.2.9 Alkalinity
5
In case of RCC, it is important to maintain the alkalinity of concrete around reinforcement
with its pH above 11.5 from corrosion protection point of view. In this context, it is necessary
for the repair material to have chemical characteristics such that it does not adversely affect
the alkalinity of the base concrete at a later date. The chemical characteristics of the repair
material and its after effect on the pH of RCC shall be examined beforehand. In addition, the
pH of reinforcement protection applications, bonding coats and that of the repair material
must also be similarly alkaline. This would ensure inbuilt compatibility.
5.2.10 Low air & water permeability

Permeable material allows easy permeation of environmental chemicals including carbon
dioxide, water, oxygen, industrial gases/vapours etc. It is essential that repair materials should
have a very low air/water permeability to provide protection to the reinforced concrete against
ingress of harmful environmental chemicals.
5.2.11 Aesthetics
It is desirable that colour and texture of the repair material should match with the structure
and give aesthetically pleasant appearance. If need be, this could be achieved through
appropriate finishes.
5.2.12 Cost
Economics is important while considering various options for repair materials but cheaper
repair material should not be selected at the cost of performance characteristics.
5.2.13 Durability & Bio non-degradability:

The repair material selected should be durable under its exposure conditions during the service
life against chemical attack, resistant to any form of energy like ultra violet rays, infra red rays,
heat etc and should be bio non-degradable.

5.2.14 Non-Hazardous / Non –Polluting :

The repair materials should not be hazardous to field workers. However adequate Safety
measures are required to be taken for repair Materials, which are hazardous to workers
involved with their application, etc. These should also be environment friendly.
5.3 Materials For Repair

Wide range of materials for repair of concrete is available differing in cost and their
performance. Their application range covers:
l Materials for Surface Preparation
l Chemical Rust removers for corroded reinforcement
l Passivators for reinforcement protection
l Bonding Agents
l Structural Repair Materials,
l Non-structural Repair Materials,
l Injection grouts,
l Joint sealants,
l Surface coatings for protection of RCC
Products available in the market are generally in pre-proportioned and in pre-weighed packs
together with accompanying instructions regarding mixing procedure, pot life, dosage and 5
application procedure etc. It is desirable that the manufacturer indicates the generic name
and proportion of the components in the products on the packs.
Though, these materials are being marketed under their brand names, yet these could be
classified in the following categories:
l Premixed Cement concrete/mortars (modified with non-polymeric admixtures/additives).
l Polymers/latex modified cement additives for mortars/concrete/cement slurry [styrene
butadiene rubber (SBR) latex, Poly (Vinylidene Chloride-Vinyl Chloride) (PVDC),
acrylics and modified acrylics)]
l Epoxy resins
l Chemicals for corrosion inhibitor, removal of rust
5.3.1 Premixed Cement concrete/mortars

Though, the cement concrete and mortars are most natural repair materials for carrying out
the repairs to RCC. Yet, they are not favoured as a repair material due to its inherent undesirable
properties like drying shrinkage, slow setting, low workability, prolonged curing requirement,
permeability, etc.
5.3.1.1 Cements:
Cement paste, being a binder in concrete or mortar holds fine aggregates, coarse aggregates
and other constituents together in a hardened matrix. Cement forms one of the most basic
material used for not only in new construction but also as repair material. Therefore, selection
of the appropriate type of cement for new construction as well as repair work is important
and determines the final efficacy and durability of the structure. The portland cements generally
consist of Tricalcium silicate (3CaO.SiO2), Dicalcium Silicate (2CaO.SiO2), Tricalcium
aluminate (3CaO. Al2O3.Fe2O3) and tetracalcium aluminoferrite (4Cao.Al2O3). These minerals
are more often denoted as C3S, C2S, C3AF, C4A respectively. In addition to these minerals,

OPC also contains about 60–70% free lime and small quantities of gypsum. The percentage
of these minerals in OPC and their impact on cement properties are given in Table 5.2.
Table 5.2: Mineralogical Composition of OPC and Effect of

Constituents on its Properties
Characteristics C3S C2S C3A C4AF

% by mass in OPC 30-55 20-50 7-12 6-11
Setting Time Rapid Slow Rapid -
% contribution to 30 10 58 2
heat of hydration
Early Strength High upto Low upto Gain upto Nil
7-14 days 14 days 1 day
Long Term strength Less Gain High gain Nil Nil
later later
Various types of portland cements available are:

5
l 33 Grade Ordinary Portland Cement (IS: 269),
l 43 Grade Ordinary Portland Cement (IS: 8112),
l 53 Grade Ordinary Portland Cement (IS: 12269)
l Rapid Hardening Portland Cement (IS: 8041)
l Portland Slag Cement (IS: 455)
l Portland Pozzolana Cement (Fly Ash based) (IS: 1489 Pt-I)
l Portland Pozzolana Cement (Calcinated Clay based) (IS: 1489 Pt-II)
l Hydrophobic cement (IS: 8043)
l Low Heat Portland Cement (IS: 12600)
l Sulphate Resisting Cement (IS: 12330)
Types of cement to be used in a repair work depends on its suitability for the intended use. In
general the following guidelines may be referred:
Ø Ordinary Portland Cements (OPCs) The IS:456 allows use of 33, 43 and 53 grade
of OPC, where figures indicate the 28 days strength in N/mm2. Grade 33 and 43 may
be used for most of the repair purposes, if necessary with modification by suitable
admixtures or additives. Whereas Grade 53 cement or a cement having still higher
fineness could be more suited for injection grouting of cracks or honey combed concrete
preferably with non-shrink admixture in suitable proportion.
The hydrated gel of OPCs on its hardening has high pH, ranging from 12.5 to 13.5. As
the threshold value for formation of g-Fe2O3 passivating layer over steel is reported to
be 11.5, these cements have an additional advantage of being used for passivating coats
over reinforcing bars for their corrosion protection.
Ø Rapid Hardening Portland Cements gains strength more rapidly at early ages but
has its ultimate strength comparable to OPCs. It is used where early strength is required.
Ø Portland Slag Cements and Portland Pozzolana Cements: Generally, such cements
have low heat of hydration, better sulphate and chloride resistance and have low

permeability. These are more suited for use in marine structures and in structures having
contact with soils and water containing high percentages of sulphates and acids. These
consist of OPC clinker and gypsum ground together with blast furnace Slag (Ground
Granulated Blast Furnace Slag) or other pozzolanic material e.g. ground calcinated clay
or fly ash conforming to IS: 3812. Ground slag or pozzolana, which by themselves do
not possess any cementitious properties, but these, when in finely ground state, chemically
react with free lime available in OPC cement paste in presence of moisture at ordinary
temperature to form compounds possessing cementitious properties. This chemical
reaction is initiated due to generation of free lime as a result of hydration of OPC.
Substantial part of the free lime i.e. Ca(OH)2 available in cement paste, which does not
contribute towards strength development, is used up in hydration of ground slag or
pozzolana present in finely divided form in cement. This results into a stable pore sealing
product and contributes to delayed strength development even though the pattern of
gain of strength is similar to that of OPC. Therefore, pozzolanas are being used as
additives as partial substitute of OPC clinker from 20 to 35%. Presence of moisture is
necessary for pozzolanic reaction, which is a delayed process. Therefore, adequate
extended curing is required. Loss of free lime in pozzolanic reaction causes the pH of
hydrated gel of cement paste to be lower than OPC, which is generally not more than
12 in such cements. There is evidenced that the blended cements with substantial contents
of pozzolanic materials or blast furnace slag have reduced permeability to chlorides. On
5
the other hand, the advantage of reduced permeability of such cement paste is not
generally available in micro-cracked tension zones of flexural members, accommodating
active steel reinforcement. So, from corrosion point of view of reinforcing steel, in
flexural members, use of such cements may prove to reduce durability and in compression
members with compression loads less than 0.2fckAg and also for concretes of grades up
to at least M30.
Ø Shrinkage Compensating Expansive Cements: Shrinkage compensating expansive
cements are used to minimize cracking caused by drying shrinkage in repair concrete in
addition to its use in concrete structures. Drying shrinkage is the contraction caused by
moisture loss from concrete. It does not include plastic volume changes that occur due
to temperature change, structural loads, other chemical reactions or those before setting
of concrete/mortar, when surface evaporation exceeds the concrete bleeding rate. These
cements are designed to expand by small extent during the first few days of hydration.
The extent of expansion intended is to approximately offset the amount of drying shrinkage
anticipated in the concrete or mortar. The expansion is brought about by incorporating
some specific compounds such as calcium sulphoaluminate, calcium aluminate and calcium
silicate or other phases that, in presence of water, react to produce larger quantity of
ettringite than is normally produced by Portland cements. The production of ettringite in
the hardened concrete/mortar causes the concrete to expand. The expansive reaction
essentially gets completed in first seven days. The value of expansion between 7 and 28
days is limited to be not more than 15% of the 7 day expansion.
To achieve proper performance of shrinkage compensating expansive cements, inclusion
of appropriate amount of reinforcing steel in concrete is necessary. For maximum
expansion, additional moisture beyond that added as mixing water must be supplied
during curing of the concrete to ensure that the desired amount of ettringite will be
produced.
Ø All other special cements should be used for special purposes intended as per
specialist’s recommendations

5.3.1.2 Mineral Additives

Fly Ash (FA), Silica Fume (SF), Rice Husk Ash (RHA), Ground Granulated Blast Furnace
Slag (GGBS) and metakaoline, which have good pozzolanic properties are being used as
mineral additives in concrete and mortars with certain advantages in regard to their
impermeability, resistance to leaching, resistance to chloride & sulphate attack and better
crushing strength. As already explained, the pozzolanic reaction results in reduction of free
lime and pH of hydrated cement paste. Such additives are to be used with caution,
while repairing flexural structural members requiring protection of reinforcement against
corrosion.
5.3.1.3 Chemical Admixtures

It is a material, other than water, aggregates, hydraulic cement, mineral additives and fibre
reinforcement, used as ingredients of concrete or mortar and added to the batch immediately
before or during its mixing to modify one or more properties of the repair concrete/mortar/
slurry in plastic or hardened state. As per IS: 9103, the admixtures are classified
as under:—
l Retarding admixtures
5 l Water reducing admixtures
l Air entraining admixtures, and
l Super-plasticising admixtures
Dosage & Compatibility of Chemical Admixtures: It is important to note that the dosage
of admixture varies depending upon the type & source of cement, aggregate and environmental
conditions. It is, therefore, desirable to always determine compatibility of the admixture and
its dosage experimentally before using the same in any work, to achieve the desired properties
of repair mortar/concrete.. The manufacturer’s literature, may however render preliminary
guidance and should be treated as starting point for carrying out the test exercise for determining
the optimum dosage of admixture.
5.3.1.4 Water Cement Ratio:

Water cement ratio plays a vital role in controlling shrinkage, water permeability, percentage
of capillary pores and enhancing strength. As it is very difficult to control water cement ratio
while producing concrete or mortars in scattered works, a mechanical control of quantity of
water is essential to ensure consistently uniform quality of concrete/mortar batch after batch
with the use of Mechanical Water Dozer. Details of the one developed by Central
Design Organisation are given in Fig 5.1. The plasticisers and super plasticisers
can be gainfully used to control water/cement ratio without any compromise on the
workability.
5.3.2 Polymer Modified Mortars and Concrete (PMM/PMC)

The process technology of making the latex-modified mortar and concrete is similar to that of
the conventional binding systems. Most polymers, such as latexes, are in the dispersed form.
These are initially mixed in water in required proportion and then added to the cement mortar
or concrete. The latex-modified mortar or concrete, are placed similar to normal concreting
and cured under optimum conditions.
Fig 5.1 Mechanical Water Dozer
5.3.2.1 Materials:
The materials used in polymer modified systems are the same as those employed in normal
mortar and concreting operations but for the latex/polymers, which is used as a modifier.
However these are briefly described as under:
A. Cements: OPC is widely used for polymer modified mortars and concrete including all
other portland cements depending upon their applications. However, air entraining cement
are not used because air entrainment occurs due to latex addition.
B. Aggregates: The aggregates used for normal concreting operations are recommended
for latex mixes. The aggregates should be clean, sound and of proper grading.
C. Other Materials: Alkali- resistant glass, steel polyamide, polypropylene, polyvinyl
alcohol, acramide, and carbon fibers are used as reinforcements. Production of
coloured latex mortars needs inclusion of pigments that are alkali resistant and
weatherproof. They should also not interfere with the stability of latexes and hydration
of cements.
D. Polymers: Polymers are long molecules, built by combination of single units called
monomers. Polymers are essentially hydrocarbons. The process of conversion of
monomers into polymer is called polymerisation. In civil engineering, polymers
obtained from monomer at ambient temperature are important from practical point of
view.
Polymer Latexes: Polymer Latexes consisting of very small diameter particles

(0.05 – 5mm) emulsified in water are shown in Fig.5.2. Most of the commercially available
polymer latexes for cement modification are based on elastomeric and thermoplastic polymers,
which form continuous polymer films when dried. Out of the several types of PMM/PMCs
produced, the latex modified mortars and concretes are by far the most widely used cement
modifiers. It is important to note that the cement hydration is a continuous process. Latex
modification of cement mortar and concrete is governed by both cement hydration and polymer
film formation process in their binder phase. The cement hydration process generally precedes
the polymer formation process. In due course, a co-matrix phase is formed by both cement
and polymer film formation processes. This yields a monolithic interwoven matrix of solidified
polymer and its continuous film with hydrated cement and this binds the aggregates strongly.
Consequently, the properties of hardened cement mortar/concrete are improved.
Fig 5.2 : SBR latexes for cement modifiers
Redispersible Polymer Powders: The principles of modification of cement mortars/

concretes is almost the same as that of the polymer latex modification except that it involves
addition of redispersible polymer powders. Mostly these are used by dry mixing with
cement and aggregate pre-mixtures followed by wet mixing with water.
Water Soluble polymers: These, being water soluble, are mainly used for improving
workability of cement mortars and concretes and prevents “dry out” phenomenon due to
increased viscosity of water phase in the modified cement mortar/concrete and a sealing
effect due to formation of a very thin impervious film in them. In general these do not
contribute to any improvement in strength of modified system. These are normally used at
polymer: cement ratio less than 3% by weight. When added in powder form, , it is advisable
to dry blend the polymer with cement aggregate mixture before adding water.
Liquid Resins: Liquid thermosetting resins are polymerisable low molecular weight
polymers and pre-polymers. These are added to cement mortars/ concrete in a liquid
form. Polymer content in cement mortars/concrete is generally higher than the latex system.
In this modification, polymerisation is initiated in presence of water to form a polymer
phase and simultaneously the cement hydration occurs. As a result a co-matrix phase
similar to latex modified systems is formed and this binds the aggregates strongly.
Consequently, the properties of hardened cement mortar/concrete are improved.

Monomers: Principles of modification of cement composites remain the same as that of the
liquid resins detailed above except that here monomers are added instead of liquid resins. In
such a case of modification, polymerisation and cement hydration takes place simultaneously
at the same time during or after curing to make it a monolithic matrix, which binds aggregates.
Generally, such a system of modification is not successful because of degradation of monomers
by alkalis present in cement paste and interference of cement hydration and difficulty in
uniformly dispersing monomers and other components during mixing..
5.3.2.2 Process of Polymer Modification in Cement concrete/mortar:

Polymer modified mortars and concretes (PMM/PMC) are prepared by mixing polymer in a
dispersed, powdery or liquid form with fresh cement mortar and concrete mixture, subsequently
cured. Polymers and monomers used as cement modifiers are shown in
Table 5.3.
Polymers and Monomers for -Polymer Latexes -Elastomeric Latexes

Cement Modifiers -Thermoplastice Latexes
-Thermosetting Latexes
-Bituminous Latexes
-Mixed Latexes
5
-Redispersible Polymer Powders
-Water-Soluble Polymers
-Liquid Resins
-Monomers
Table 5.3 Polymers and monomers for cement modifiers
Thus both, the particle dispersion of the polymer and the formation of polymer films are
necessary for the composite mechanism of the latex-modified systems. The process of the
polymer film formation on the cement hydrate is represented in Fig 5.3.
Fig 5.3: Simplified model of Process of Polymer film formation on Cement hydrates
(Source: Yoshikiko Ohama, “Handbook of Polymer-Modified concrete and Mortars” published
by Noyes Publications, Park-Ridge, New Jersy, USA)

First Stage
In the first step, when polymer latexes are mixed with fresh cement mortar or concrete, the
polymer particles are uniformly dispersed in the cement-aggregate paste phase.
Second Stage
In the second step, with drainage due to the development of the cement gel structure, the
polymer particles are gradually confined in the capillary pores.
Final Stage
Ultimately, with water withdrawl by cement hydration, the close-packed polymer particles
on the cement hydrates coalesce into continuous films or membranes, and the films or
membranes bind the cement hydrates together to form a monolithic network in which the
polymer phase interpenetrates throughout the cement hydrate phase. Such a structure acts as
a matrix phase for latex-modified mortar and concrete, and the aggregates are bound by the
matrix phase to the hardened mortar and concrete.
5.3.2.3 Composition of Polymers:

Polymer Latexes: The typical recipe of materials used for such emulsion polymerisation
comprises of Monomers (100 pbw), Surfactant (1-2 pbw), Initiator (0.1-2.0 pbw), water
5 (80-150 pbw) and other ingradients (0-10 pbw). These are charged in a reactor under
constant agitation and heated to the required temperature. It is the initiator, which generates
a free radical to cause the chain polymerisation of monomers to form polymer latex. A stripping
process removes the unreacted monomers in the resultant latex. The latex is diluted or
concentrated and a small amount of preservatives, stabilizers, antifoaming agents are added.
However, natural rubber latex and epoxy latex is not produced by such process. The natural
rubber latex is tapped from rubber plants and then concentrated to have appropriate solid
contents.
Redispersible Polymer Powders: Redispersible polymer powders as cement modifiers are
manufactured by a two step process. Firstly polymer latex is manufactured as raw material
by emulsion polymerisation and then these are spray dried to get the polymer powders.
Before spray drying the polymer latexes are further formulated with some ingredients as
bactericides, spray drying aids and antifoaming aids. Anti-blocking aids such as clay, silica
and calcium carbonate are added during or after spray drying to prevent “caking” of powders
during storage.
Water Soluble Polymers: These are polyvinyl alcohol (PVA, poval) and the derivatives of
cellulose including methyl cellulose (MC), carboxy methyl cellulose (CMC) and hydroxyethyl
cellulose (HEC), polyethylene oxide, polyacrylamide, etc.
Liquid resins: In general, these are epoxy resin system used as cement modifier. It consists
of two part system one as resin and the other as hardener or curing agent and essentially
contain ‘anti-foaming agent’ to prevent excessive entrainment of air and ‘surfactants’ to
effectively disperse the epoxy resin throughout the mortars or concrete.
5.3.2.4 General Requirements of a Polymer Latex:
The general requirements for polymer latexes as cement modifiers are as follows:
l Very high chemical stability towards the active cat-ions, such as calcium and aluminium,
liberated during the hydration of cement.
l Very high mechanical stability during mixing, and in transfer pumps.

l Low air entrainment. This is generally achieved by addition of antifoaming agents during
manufacture of polymer latexes. Excess of anti-foaming results into loss of adhesion to
the substrate. The balance has to be judiciously maintained.
l No adverse influence on cement hydration.
l Formation of continuous films in mortar or concrete. High adhesion of the films to
cement hydrates and aggregates.
l Very good water, alkali and weather resistance
l Thermal stability: In special cases dealing with higher temperatures
5.3.2.5 Classification of Polymer Latexes:
The polymer latexes are classified in to three categories as cat-ionic (negatively charged), an-
ionic (positively charged) or non-ionic (not charged), which is governed by the type of
surfactant used in production of latexes.
5.3.2.6 Properties of Polymer Latexes:
In general, polymer latexes are copolymer systems of two or more different monomers and
their total solid content including polymers, emulsifiers, stabilizers, etc. is 40-50% by weight.
Most of the commercially available latexes for cement have solid contents 40+3%. Higher
percentage would adversely affect concrete compressive strength. These form continuous 5
polymer films when dried. Most popular polymers are urethane, acrylics and modified acrylics.
Polyvinyl acetates, styrene butadiene rubber (SBR), chloroprene rubber (CR) also called as
neoprene, Poly Acrylic Ester (PAE), Poly (Ethylene Vinyl Acetate) (EVA or VAE), Poly
(Styrene Acrylic Ester) (SAE) are being used in cementitious repair work. Typical properties
of such polymers commercially available are given in Table 5.4. Polyvinyl acetate latex and
polyvinylidene chloride and poly vinyl chloride latex are generally not recommended as cement
modifiers because of poor resistance and chloride ions liberation.
All latex systems should ensure controlled foaming. Commercially available polymers for
cement modification must contain proper amounts of appropriate anti-foaming agents. One
should be able to use them directly for mixing without addition of anti foaming agent during
such operation at site.
Table 5.4 provides typical properties of polymer latexes. Table 5.5 shows the quality
requirements for the polymer latexes as specified in JIS 6203
Table-5.4: Typical Properties of Commercially available Polymer Latexes
(Source: “Polymer Modified Concretes and Mortars” by Y Ohama)
Type of Stabiliser Appearance Particle Total Specific pH Viscosity Surface

Polymer Type Size Solids Gravity (at 20OC) (at 20OC, Tension
(mm) (%) (at 20OC) cP) (at 20OC),
dyn/cm)
SBR Non-ionic Milky White 200 46.5-49.5 1.010 10.0-11.0 10-12 32
An-ionic Milky White 219 44.0-46.0 1.016 7.06 53 31
PAE Non-ionic Milky White 500 44.5-45.5 1.054 8.6-10.2 29 45
Non-ionic Milky White 500 44.0-46.0 1.054 9.4-10.0 1328 45
CR Cat-ionic Milky White 120 50.0 1.100 9.0 16 35
Cat-ionic Milky White 700 50.0 1.100 6.0 10 30
EVA Non-ionic Milky White 700 52.8 1.050 6.0 1100-1600 75
Non-ionic White 400 55.0 1.060 4.5-6.5 3000-7000 40-45
An-ionic Milky White 300 50.0 1.127 5.0-7.0 5000 40

Table 5.5 : Quality Requirements for Latexes (Polymer Dispersions for

Cement Modifiers)
Kind of test Test item Requirement
Latex Test Appearance Exclusive of coarse particles, foreign
substances and coagulants.
Total solids Not less than 35.0% and within
+/- 1.0% of the value marked by
the manufacturer
Polymer-Modified Flexural strength Not less than

Mortar Test 40 kgf/cm2 (3.9MPa)
Compressive Strength Not less than
100 kgf/cm2 (9.8MPa)
Adhesion Not less than
10kgf/cm2 (0.98Mpa)
Water absorption Not more than 15.0%
Amount of water Not more than 30g.
permeation
5
Length change 0 to 0.15 %
5.3.2.7 Physical and Mechanical Properties of Polymer Modified Mortars/Concretes:

Admixing of polymer latex in cementitious mixtures modifies the following physical and
mechanical properties:
i. Workability: Generally polymer mortars/polymers modified concrete (PMM/PMC)
have better workability compared to conventional mortar/concrete.
ii. Water retention: PMM/PMC have remarkably improved water retention property
over ordinary mortar/concrete. The water-curing requirement is substantially reduced
and needs to be specified accordingly to suit the polymer type, its proportion and
method of curing.
iii. Bleeding and Segregation: A better resistance to bleeding and segregation even though
they have better flowability.
iv. Increased Resistance to Crack Propagation: Micro cracks occur easily in the
ordinary stressed hardened cement paste. This leads to poor tensile strength and fracture
toughness. Whereas, in the latex-modified mortar and concrete, it appears that the
micro cracks are bridged by the polymer films or membranes, which prevent crack
propagation and simultaneously, a strong cement hydrate-aggregate bond is developed.
v. Strength: PMM/PMC with styrene butadiene polymer (SBR) latexes have a noticeable
increase in tensile and flexural strength but there is hardly any improvement in its
compressive strength compared to ordinary mortar/concrete. An increase in the polymer
content or polymer-cement ratio (defined as the weight ratio of the amount of total
solids in polymer latex to the amount of cement in a latex-modified mortar or concrete)
leads to increase in flexural tensile strength and fracture toughness. However, excess air
entrainment and polymer inclusion cause discontinuities of the formed monolithic network
structure, whose strength is reduced.

vi. Chemical resistance of PMM/PMC: This depends on the type of polymer, polymer
cement ratio and type of chemicals. Most PMM & PMC with styrene butadiene polymers
(includes other like modified acrylics etc.) are attacked by strong organic and inorganic
acids and sulphate but these resist alkalis and salts other than sulphates. Their resistance
to chlorides, fats and oils is also rated as good while they have a poor resistance to
organic solvents.
vii. Temperature effect: The strength of PMM/PMC depends on temperature. They
generally show a rapid reduction in strength with increase in temperature. Most
thermoplastic polymers have a glass transition temperature of 80 deg. to 100 deg.
Centigrade.
viii. Shrinkage: The drying shrinkage of PMM/PMC may be larger or smaller than that of
standard mortar or concrete depending on type of polymer and polymer: cement ratio
used. More is the polymer ratio, lesser is drying shrinkage.
ix. Water proofing Quality or permeability: PMM/ PMC have a structure in which the
larger pores are filled by polymer or these are sealed by continuous polymer flow.
The sealing effect and porosity due to the polymer films or membranes formed in the
structure also provides a considerable increase in water proofness or water tightness as
well as resistance to chloride ion penetration, moisture transmission, carbonation and
oxygen diffusion chemical resistance, and freeze-thaw durability. Such an effect 5
is promoted with increasing polymer- cement ratio upto a certain level of polymer
loading.
x. Adhesion or bond strength: A very useful aspect of PMM/PMC is their improved
adhesion or bond strength to various sub-strata compared to conventional mortar/
concrete.
xi. Abrasion Resistance: PMM/PMCs have abrasion resistance better than the
conventional mortar/concrete.
xii. Durability and non-degradability: Generally these materials are bio non-degradable
after total polymerization takes place. However, certain polymers tend to
disintegrate under any form of energy like ultra violet rays, heat etc. Particularly
“styrene” based materials are reported to undergo such rapid
disintegration and degradation and hence advised to be avoided. Whereas
“acrylate” based materials are accepted due to their non-degradable and robust
properties.
5.3.2.8 Mix Proportioning:

Most of the cement mortars’ proportion for polymer modification used is in the range of
1:2 to 1:3 (Cement- fine aggregate ratio). The polymer latex (solid contents) : cement ratio by
weight ranges from 5 to 20 % by weight. Whereas water/cement ratio is of the order of
0.30 to 0.60 depending upon the required workability. The standard mix proportions are
shown in Table 5.6.
The mix proportions for most latex modified concretes can not be easily determined in the
same manner as that of latex modified mortars. Because of many factors in design. Normally
the polymer latex : Cement ratio ranges from 5% to 15% and water cement ratio from
0.30 to 0.50.

Table 5.6: Typical Applications and Standard Mix Design of Latex Modified Mortars
(Source : “Polymer modifed concrete and mortars”………….Y.Ohama)
Appli- Location of work Standard Mix Proportions

cation (By weight) Thickness
of Trowel-
Cement Sand Latex ling or
(Solid coating
contents) (mm)
Paving Floors for general houses, ware house, 1 3 0.2-0.3 5-10
Materials office and shops, toilet floors, etc
Flooring Passengers, stairs, chemical plants, railway 1 3 0.3-0.5 10-15
platforms, roads, garages, etc
Water Concrete roof decks, mortar and concrete 1 2-3 0.3-0.5 5-20
Proofing block walls, water tanks, swimming pools,
Material septic tanks, silos, etc
Adhesive Adhesives, when flooring materials, walling 1 0-3 0.2-0.5 -
materials, heat insulating materials, etc are
bonded to concrete floors and walls
Joining new concrete to old concrete or new 1 0-1 Over 0.2 -
mortar to old mortar
5 Repair Cracks 1 0-3 Over 0.2 -
Anti Effluent drains, chemical factory floors, grouting for 1 2-3 0.4-0.6 10-15
corrosive acid proof tiles, septic tanks, foundation for machinery
lining plants, floor for chemical laboratories, pharmaceutical
warehouses, etc
Deck Internal and external ship decks, bridge decks, train or
covering car floors, foot bridge decks, etc 1 2-3 0.9-1.0 1-2
1 3 0.4-0.6 5-6
1 3 0.5-0.6 3-4
5.3.2.9 General Guidelines & Precautions for use of polymer modified cement Mortar/
concrete
l The speed and time of mixing should be properly selected to avoid unnecessary
entrapment of air.
l The PMM/PMC have excellent adhesion even to metal and hence all equipment should
be washed immediately after use.
l For resurfacing, flooring and patching, all loose and non-durable materials including
laitence must be removed either by sandblasting, wire brushing and blowing with
compressed air. The cleaned surface should be thoroughly wetted well before placement
of PMM/PMC. Before application, surface should be in saturated dry (wet but no
standing water) condition.
l The choice of type of PMM/PMC depends on thickness of coating to be applied.
l It is advisable to finish the surface by trowling 2-3 times. Over trawling is not advisable.
l PMM/PMC should never be placed below 5o C and above 30o C. The surface of
newly placed material should be protected from rainfall or other source of water. The
surface should be immediately covered with burlap or plastic sheet.
l In large area of application, it is advisable to provide joints of 15 mm width at intervals
of 3-4 meter.
l Curing under water immersion or under wet condition is detrimental to PMM/PMC. It
should be moist cured for 1-3 days followed by curing at ambient temperature. Steam
curing is not recommended.
l Polymers and Latexes are non-toxic and safe for handling.

l Polymers should be stored in a cool dry room & should not be kept in exposed areas.
l Polymers should be mixed with cement slurry or mortar in the proportions recommended
by the manufacturers for various uses.
5.3.2.10 Fields of Application:

A. Structural repairs to RCC: PMM/PMC are used to make up the damaged/lost cover
concrete due to their better bond with substrate, including the reinforcement.
B. Ultra Rapid Hardening Polymer Modified Shotcrete:
Ultra Rapid Hardening Polymer Modified Shotcrete system can be classified in to two
categories:
— One, which uses a polymerisable monomer that reacts with Ordinary Portland
cement at ambient temperature. This system is used as repair and protective material
for concrete structures with leaking and flowing water. It uses magnesium acrylate
monomer and its setting time can be controlled within few seconds or less. Fig 5.4
represents a schematic diagram of this shotcrete system.
— Second, which uses ultra rapid hardening cement concrete with SBR latex and is
often used for urgent construction and repair works. 5
Fig 5.4: Schematic Diagram of Ultra-rapid hardening polymer modified shotcrete

(Source : Y. Ohama, “Handbook on Polymer Modified conrete and Mortars”)
C. Polymer Ferrocements:
For the purpose of improving the flexural behaviour and durability of conventional
ferrocement, polymer-ferrocements have been developed using latex modified mortars
instead of ordinary cement-sand mortars. Use of SBR and EVA modified mortars is
found to be very effective in improving their flexural behaviour, impact resistance, drying
shrinkage and durability. Incorporation of short fibres such as steel and carbon fibres in
the latex modified mortars is found to be further effective in improving such characteristics.
D. Anti Washout Underwater Concrete:

The major requirements from anti-washout under water concrete are anti washout or
segregation resistance, flow ability, self-leveling ability and bleeding control. Anti-washout
admixtures are water-soluble polymers and are classified in two types as Cellulose-
type polymers such as MC and HEC and Poly-acryl amide and poly acryl amide-
sodium acryl ate. These are added at polymer-cement ratios of 0.2% to 2.0% during
mixing of the ordinary cement concrete. The water soluble polymer bonds to a part of
mixing water by hydrogen bonds in the concrete and disperses in a molecule form in the
mixing water. As a result, the mixing water is confined in the network structure of the
dispersed polymer and becomes very viscous. The very viscous water envelops cement
and aggregate particles to impart an anti-washout character to concrete.
E. Protective Anti Corrosive and Water Proofing Coatings:
Hydrated type flexible water proofing materials are polymer modified pastes or slurries
with very high polymer: cement ratios of 50% or more and have been widely used as
liquid applied water proofing membrane materials, repair materials, etc. The constituents
normally comprise of Portland cement, silica sand, water and polymer latexes such as
SBR, PAE, EVA, SAE, epoxy and asphalt latexes besides some other additives.
5 Thickness of such water proofing membranes is 2 to 4 mm and is generally available in
pre packaged type products. The performance advantages of such membranes are:
l Safe application due to no organic solvent system.
l Convenience of application as it does not require the surface to be dry.
l Good adhesion with the cementitious, metallic and most other substrates.
l Excellent elongation, flexibility and crack resistance.
l Good water proofness.
l Resistant to carbonation and chloride ion penetration.
PAE modified water proofing materials appear to have excellent elongation and water
resistance. Crack bridging capacity of such flexible membranes is being successfully
tested in Germany.
An interesting water proofing material, which solidifies in water has recently been
developed in Japan for tunnels and dams. It has a potential as a shock absorbing, water
proofing backfill material.
F. Bond Coats (Structural Adhesives) and Grouts: Polymer modified cement mortars
as well as slurries are used as bond coats and grouts due to their very good adhesive
qualities on cementitious as well as metallic surface.
5.3.3 Epoxies and Epoxy Systems including Epoxy Mortars/Concretes:
5.3.3.1 Epoxies
Epoxies also come in the category of polymers but in the case of epoxies, the polymerisation
process takes place when two materials called the epoxy resin and hardener come in contact
by thoroughly mixing in specified proportion. The epoxy resin materials have good mechanical
strength, chemical resistance and ease of working. These are being used in civil engineering
for high performance coatings, adhesives, injection grouting, high performance systems,
industrial flooring or grouting etc.

A. Epoxy resins: These are characterized by a three membered ring known as epoxy/
epoxide / oxirane or ethoxyline group refer Fig.5.5 (a). On an average it contains more than
one epoxide group per molecule. Basic epoxy resin used in the building industry is “DiGlycidyl
Ether of Bisphenol-A” (DGEBA) and can be represented as given in
Fig. 5.5(b). In its simplest and most standard form epoxy resin is the condensation product of
bisphenol-A and epichlorohydrin. Depending upon the amount of excess of epichlorohydrin
to bisphenol-A used in the manufacturing process, epoxy resins ranging from low molecular
weight liquids to high molecular weight solids can be obtained. However, basic resin of this
type is not suitable for many applications because of its higher viscosity. Modification of basic
resin is therefore, necessary to achieve the required wet-ability, curing rate and numerous
other properties in addition to lower viscosity.
B. Epoxy hardener (Curing Agent) : The proper choice of a hardener/curing agent can
be as important as the choice of resin itself, both playing a significant role in determining the
extent and nature of inter molecular cross linking. This curing agent, commonly called as
hardener, combines with the epoxy resin and changes it from a liquid to a solid. The process
of setting, together with the terminology often used is illustrated in Fig-5.6 Out of a vast
number of compounds, most commonly used curing agents are aliphatic and aromatic amines
and polyamides and their adducts, which form room temperature curing compositions relevant

to construction applications. The aromatic polyamine curing agents react faster than the aliphatic
polyamines. The properties of some common nitrogen containing hardeners are given in
Table – 5.7. Aliphatic amines are used as such or in adduct form for ambient temperature
curing. They have critical mix ratios, toxicity, high vapour pressure and brushing tendency.
Aromatic amines are solid at room temperature. Adducts of these along with accelerators
like sali-cyclic acid are used for ambient temperature curing. Polyamides are used as such
or in adduct form with or without accelerator for ambient temperature curing. The chief
advantages are low toxicity, convenient mix ratio and good flexibility. The main disadvantages
are high cost, high viscosity and poor resistance against heat and solvent compared to amine
cured system. Some other resins/ elastomers such as phenol formaldehyde resin, thermosetting
acrylics, isocynates and polysulphides are also used as co-cross linking agents (10–50% by
wt. of total resins) with amines to obtain the desired properties of the finished products. They
are mostly used for corrosion resistant linings, food and beverages containers / tank coatings,
kitchen appliance coatings etc.
Table 5.7 Prperties of nitrogen-containing harnders
(Source: B. Singh, etal “Epoxy Resins in Civil Engineering, ICJ January 1995 Vol 69. No 1. pp 13.21)
Type Polyamide Amine adduct Polyamide Low Aromatic

5 (A) (B) viscosity amine
polyamide adduct
Viscosity 10-20 3,000-5,500 9,000-16,000 3,000-4,500 6,000-20,000
(25°C MPa s)
Amount
recommeded, 16-20 40 110-190 140-200 100-120
(gm. eq/epoxide)
Nature sl. Volatile, less volatile non volatile, not non volatile, non volatile non
irritant strong not strong smelling
smelling smelling-
Haze or blush Marked V. Slight Almost nil almost nil Nil
Flexibilty and
impact resistance Poor Poor Good Good Better than amines
amine adducts
Chemical resistance Better Better Good Good Excellent
Water resistance Moderate Moderate Good Good Excellent
5.3.3.2 Modified Epoxy Systems

A. Diluents: These are used for lowering the viscosity and improving handling
characteristics. Diluents are classified as:
Reactive Diluents, which are mostly low molecular weight glycidyl ethers with low
viscosity, which reduce the cross link density of the system. Because of their low viscosity,
other cyclo aliphatic resins have also been used with the liquid diglycidyl ether resins or
with solid epoxidised novolac resins.
Non reactive Diluents such as toluene, xylene and other aromatic hydrocarbons can
bring about significant reduction in the viscosity of low molecular weight resins. The
casting have inferior chemical resistance and if it is heat cured, the diluent can be volatile
and cause blow holes and bubbles.. A popular non reactive diluent is dibutylpthalate,
used as a concentration of 15 to 17% with a liquid resin.

B. Coal Tar Epoxy System : Coal Tar epoxy resin combinations with polyamine hardener
have been widely used as water resistant protective coatings for ships and other marine
structures. Coal Tar plays an important part in the improvement of corrosion resistance
of epoxy resin system. It is Coal Tar/Epoxy in proportion of 40 : 60., which has been
reported to give optimum results under aggressive environment.
C. Rubber Modified Epoxy System: This system is used to improve the draw back of
brittleness and low elongation of unmodified epoxy resin based on bisphenol-A and
epichlorohydrin with hardeners such as polyamines and anhydrides. The incorporation
of small amount of elastomer particles promote absorption of strain energy by interactions
involving craze and shear formation. Craze formation is promoted by 1- 5 micron
particles and shear formation by 0.5 micron particles. Systems possessing both small
and large particles provide maximum toughness. The most widely used toughner in
epoxy resin is a liquid carboxy terminated butadiene- acrylonitrile.
D. Epoxy Phenolic Interpenetrating Polymer Network Systems: Interpenetrating
Polymer Networks (IPN)s are relatively novel types of polymer alloys consisting
of two or more polymers in network forms, at least one of which is synthesized
and/or cross linked in the immediate presence of the other. Polymer phases are devoid
of chemical linking between them interwoven to each other and help together by
permanent entanglements. An indigenous attempt has been made to modify epoxy resin
with a low cost, locally available phenolic resin to obtain optimum properties with the 5
added advantage of cost performance ratio benefits. Two different resins (1. Medium
viscosity epoxy resin based on epichlorohydrin and bisphenol as base and an aromatic
amine adduct as the cross-linker and 2. Phenolic resin obtained from an indigenous
phenol with its cross-linker) were mixed in different ratios and cross-linked simultaneously
by a separate non interfering mechanism. These are used with advantage in coatings for
protection of concrete structures and steel reinforcement bars against corrosion due to
their good resistance to chlorides and chemicals. The elongation of its film increases to
17.5 percent as against 5 percent in case of neat epoxy resin systems allowing it to be
used over steel reinforcement even at higher fatigue limits. Tables 5.8 compare properties
of neat epoxy and IPN coatings. The IPN polymeric systems thus, obtained were
evaluated for various physico-mechanical properties, using standard methods of testing.
The properties of neat epoxy and IPN coatings
Table 5.8: Properties of Neat Epoxy Coatings vis-à-vis IPN Coatings
(Source: Aggarwal L.K. “IPN protective coating for enhancing the durability of concrete structures”—
ICJ July 1996, Vol. 70, No. 7, pp 367-370)
Sl. Property Test Results

No. Neat Epoxy IPN Coating
Coating
1 Tensile Strength, Kg/cm2 220.000 243.00
2 Elongation, percent 5.00 17.50
3 Hardness, Shore D 85.00 83.00
4 Specific permeability, mg/cm2-mm-24 Hrs 0.2043 0.140
5 Shear Strength, Kg/cm2 53.600 77.000
6 Vicat Softening Point, OC 43.00 64.00
7 Coefficient of thermal expansion, OC 1.714 X 10-5 0.90 X 10-5
8 Adhesion with concrete, Kg/cm2 to surface 30.000 30.000
9 Scratch Hardness, 1500 g load No failure No failure
10 Salt Spray Test, 1000 Hr No corrosion Spots No corrosion Spots
11 Impact Test, falling Weight Method No failure No failure
12 Scrub Resistance, 10,000 cycles No failure No failure

E. Epoxy Mortar and Concrete: Epoxy resins are used with aggregate (silica sand) to
produce epoxy mortar or epoxy concrete, which is used for structural repairs of concrete,
RCC besides its use in new construction in industrial flooring, foundation grouting, roads
etc. They are normally used where volume of materials is not large and where rapid
curing can be obtained. The rate of curing epoxy mortar is directly dependent on the
ambient temperature. In cold weather, small patches of mortar can be easily heated
artificially to provide a rapid cure. Clean, dried, specially graded silica sand is used as
filler with a resin- hardener mixture. Addition of sand helps in reducing shrinkage, improves
abrasion, thermal shock resistance and lower thermal coefficient of expansion making it
nearer to concrete. The optimum resin; sand ratio for maximum strength is reported to
be 1:7
F. Composite Fibre System: The system comprises of a fiber reinforcement layer that is
wrapped to the exterior surface of the structural element to be retrofitted. The fiber
composite reinforcement layer consists of at least one fabric layer that is located
within a resin matrix. The primary fibres are oriented in a desired direction with reference
to the axis of the structural element concerned. The composite reinforcement
layer provides a quick, simple and effective means for increasing the resistance of
the structural element to failure during the application of loads. All the components of
the composite (epoxy, fabric etc.) shall be fully compatible and supplied by a supplier
5 that is competent in the technology, design, installation and materials of the composite
system.
5.3.3.3 Precautions to be taken:

Epoxies are generally toxic in nature and these require lot of care in their handling.
The special care required to be taken during their mixing and applications are as
under:
i. They should not come in contact with the skin. Workers should be provided with rubber
gloves.
ii. The utensils/ equipments used for the mixing resin and hardener should be cleaned
immediately after their use.
iii. The pot life of the mixed epoxy is generally very limited, ½ to 2 hours. It should be
finally applied as adhesive within pot life period. Therefore, material should be prepared
just sufficient to cover the area within the pot life period as recommended by the
manufacturers.
iv. The epoxies are generally used as an adhesive to act as bond coat between the old
concrete and repaired concrete. The epoxies have a glass transition range at temperatures
at 60 to 80o C depending upon the epoxy type. Therefore, they should not be used in
the exposed environment.
v. Epoxies have much higher bond strength than other polymers, but at the same time,
these are costlier.
5.3.3.4 Field of Applications:

A. Anti Corrosive and Water Proofing Protective Coatings:
Fusion Bonded Epoxy Powder Coatings(FBEC) as well as IPN Coatings are being
used for protection to reinforcing bars against corrosion in RCC structures located in
highly aggressive environment. FBEC process provides a tough film, which can withstand

bar bending without cracking, whereas IPN coatings are used for new constructions for
in situ coatings to steel reinforcement.
IPN coatings are also used as surface coatings for RCC structures for arresting further
carbonation of cover concrete or other chemical attack by sealing their surface against
ingress of environmental aggressive chemicals and their consequential attack on
concrete.
Epoxy coatings in conjunction with epoxy grouting have been used to render leaking
roofs, toilets, bath rooms as impervious. However, their use in exposed locations directly
exposed to sunlight is to be avoided.
Polyurethane Coatings: Polyurethane Coatings are used as Surface Coatings on
exposed RCC Structures as they have excellent UV resistance. These coatigns have
good elasticity and abrasion resistance also. These are used as such or as a finishing
coat over other coating systems.
B. Bond Coats (Structural Adhesives) and Grouts: Epoxies are used as bond coats
and grouts due to their excellent adhesive qualities on cementitious as well as metallic
surface.
C. Structural repairs to concrete: Due to excellent Mechanical properties and bond
characterstics with most of the materials epoxy mortars/concrete are used to make up
5
the damaged or lost cover concrete etc.
5.3.4 Polyester Resins
5.3.5 Surface Coatings
5.3.5.1 Essential Parameters for coatings
Protective coatings over structural concrete should necessarily possess following
properties:
1. Posses excellent bond to substrate
2. Be durable with a long useful life normally 5 years.
3. Little or no colour change with time.
4. Little or no chalking.
5. Should have maximum permeability to allow water vapour escape from concrete
substrate.
6. Should have sufficient impermeability against the passage of oxygen and carbon dioxide
from air to concrete.
7. Should be available in a reasonable range of attractive colours.
5.3.5.2 Types of surface coatings

The surface coating could be classified as ;
1. Solvent based coatings
2. Solvent free coatings
3. Water borne coatings
4. Reinforced coatings (preferred for repairing
Badly damaged liquid Retaining structures)

Table 5.9: List of various types coatings and their

pefrormance characterstics
Coating Type Characterstics

Epoxy coatings and modified Excellent adhesion to concrete, abrasion impact resistant, Impermeable to
epoxy coating such as coal tar organic and inorganic chemicals water and chloride ions. Excellent resistant
epoxy, epoxy-phenolic to corrosion & steel reinforcement. Generally used for internal
(IPN etc.) applications
Chlorinated rubber coatings Resistant to heat, sunlight and weather, moderately resistant to acids, alkalis.
Not recommended for immersed conditions. Adhesion to concrete is good.
Acrylic Coatings Higher permeability, a life of three years may be possible
Polyurethane coatings Excellent UV resistances abrasion and cracking resistance, has high elasticity
and resistance to biological department.
Bitumen or Tar Products. Provide excellent protection; however aesthetics is affected
Products based on cement Showed satisfactory performance for more than six years in tropical marine
sand and asphalt atmosphere at exteme exposure condition.
Vinyl copolymer resin paints Showed satisfactory performance
a) Polyvinyl Alcohol Adhesion to concrete is good, Moderately resistant to water and mild
5 aggressive chemicals, Good, flexibility, hardness and abrasion resistance.
b) Polyvinyl Chloride Adhesion to concrete is very poor. Excellent acid resistance Not suitable on
moist surface.
c) Polyinylidene Chloride Bonding to concrete is poor. Impact resistance is also poor.
Polyvinyl acetate Because of its tendency to reemulsify on contact with water, it is suitable only
where the concrete will remain permanently dry.
Polyvinyl butyrol Outstanding abrasion, resistance, toughness, flexibility, water and heat
resistance
Rubber and resins Excellent water resistance and good abrasion resistance, Adhesion to
a) Chlorinated Waxes concrete is good. Fade under sunlight.
b) Polyrene Butadine Excellent resistance to both strong and weak acids as well as strong alkalis, oil
grease and water exterior durability is good fade under sunlight.
c) Chlorosulphonated Good flexibility, excellent weather resistant and good chemical resistant.
polythlene resins
Neoprene Coatings Excellent Weather resistant
Alkyd – isocyanate Often recommended on concrete as a first coat or as a medium coat system
and fails to function under extreme weather conditions.
Polyester-isocynate Generally not recommended as the first coat on concrete because with
polyurethanes residual alkalinity on concrete, such a polymer may undergo saponification
reactions. The coating may break into powder (especially with aroma ) ?
Alkyd and oil based paints Not recommended over concrete surface
Phenolic paints Not recommended due to poor alkali resistance
Oil based and olcoresinous Not recommended due to softening and blistering the alkaline environment.
Paints
Surface water proofers like Not satisfactory
silicones, soaps, wax, oil etc.

Coating Type Characterstics
Coating for steel bridges Best performing low volatile organic compound with zinc rich (organic
and inorganic) Primers. Best performing carrier coating systems- three coat
acrylic coating, an epoxymastic urethane, an epoxymastic/water borne epoxy
enamel and a three coat water borne styreo acrylic.
Maitenance painting jobs Performance not satisfactory
on bridges
a) Long oil alkyd coatings
with red led
b) Aluminium fix epoxy Successful performance
mastic system
c) A moisture cured urethane Successful performance
system
5.4 Conclusions: The material selection for structural reparis and protective coatings is an
intricate process which may put a practising Engineer in a difficult situation hence.for
guidance regarding selection of proper concrete repair material/coating material, the
following tables 5.10 and 5.11 may be referred. Product Guide on Constructions &
Repairs Chemicals given in Appendix 5.1 provides information on commercially available
products and Appendix 5.2 provides addresses of manufacturers of such products. 5
Appendix 5.3 provides list with addresses of reputed laboratories where such products
could be tested. These are given for ready reference and convenience of readers.
Table 5.10: MATERIALS SELECTION FOR CONCRETE REPAIR
(Source: Concrete society report No. 26. “Repair of concrete damaged by reinforcemnt corrosion)
Possible Spalling over Spalling over Crack Structural Bond-

material large areas small areas sealing Crack ing
for repair repair aids
Cover (mm) Cover (mm)
>25 12-25 6-12 12-25 6-12
Concretes *
Sprayed
concrete or
cement-sand
mortors
Polymer- * *
modified
cementitious
mortars
Epoxy resin * *
mortars
Polyester resin *
mortars

Moisture *
tolerant
epoxy resins
SBR, acrylic * *
and copolymer
emulsions
Low-viscosity *
polyester and
acrylic resins
Low- viscosity *
epoxy resins
PVAc bonding Not recommended for external repairs

aids
PVAc-modified Not recommended for external repair

5 mortars

TABLE – 5.11: SELECTION OF MATERIAL FOR INJECTION
(Source: SURLAKAR, SAMIR, Rehabilitation of Structures-Criteria for material selection-ICJ January 2000, Vol 74, No1 pp 31-37))
Type of Cracks Width, Movement Water Type of material Mode of application and/or principle
mm
Shrinkage cracks < 0.2 No No Two-component Surface treatment which works through
in concrete epoxy injection capillary action
Shrinkage cracks < 0.2 No Generally One-component flexible Coat with roller or brush
in plaster not paint or acrylic base

Structural cracks in 0.2-1 No No Two component epoxy Low pressure injection, shorter cracks
concrete, brickwork low viscosity with high pressure injection
Structural cracks in 1-2 No No Two component epoxy Low pressure injection
concrete, brickwork injection and solvent free
Central Designs Organisation
epoxy
Structural cracks in 2-5 No Solvent free epoxy Low pressure injection, with hand pump
concrete brickwork thicotropic
Structural cracks in >5 No Dry/wet Polymer modified cement Grout with injection grout or hand pump
concrete brickwork based grout
Structural cracks in >15 No Dry/wet Non-shrink grot Cut and fill non-shrink mortar
concrete brickwork
Moving cracks in 0.2-1 Due to Dry/wet Two component High pressure injection with (low pressure injection
concrete, brickwork temperature polyurethane injection also possible )then coat with roller/brush
changes injection and flexible paints
when wet joints, primary
injection with polymer
gel forming
Butt joint in pres- 0.2-2 Vibration Dry/wet Two component polyurethane For joints pressure injection, for floors, seal joints with
tressed concrete injection and joint sealant, sealant guns or spatulas
(coupling joints) when wet joint, primary
injection with polyurethane
gel forming
Moving cracks in >2 Vibration Dry/wet Sealant on different basis Sealant gun or spatuals; for horizontal surface flowable
concrete, brickwork including flowable grades grade of joint sealant can be used.
and floors
V-27
5
Appendix 5.1
Product Guide on Construction and Repair Chemicals
Contents
1 Injection Grouts
2 Rust Convertors/Removers for Reinforcements
3 Corrosion Inhibitors as admixture in Concrete/Mortar
4 Passivating/Protective/Bond Coats on Reinforcement
5 Bonding Coats
6 Plasticisers
7 Super Plasticisers
8 Shrinkage Reducing/Compensating Compounds
5
9 Free Flow Self Compacting Micro Concrete
10 Polymer/Epoxies in Repair Mortar/Concrete
11 Quick Setting Compounds
12 Retarders
13 Curing Compounds
14 De-Shuttering Oils
15 Floor Hardners
16 Water Proofing Compounds
17 Air Entraining Agents
18 Anti Carbonation Protective Coating on Concrete
19 Protective Coat on Steel Structures
20 Acid Resistane Enhancer
21 Michanical/Chemical Anchors

Product Guide on Construction and Repair Chemicals

1. This is just a compilation of extract of information supplied by the manufacturers
2. CPWD owns no responsibilty for the correctness of data given in this product guide.
3. The products have been classified with indicative limitations for user guidance.
4. The list is not comprehensive as information about all products manufactured in the coun-
try could not be obtained due to paucity of time.
5. The manufacturers’ name given in abbreviated form shown within bracket as (MANU-
FACTURER) against each product is to be correlated to complete name and address
given at the end of this appendix.
6. Different abbreviations and units have been used by the manufacturers in their product
information. The possible explanations are: ‘bwoc’- ‘by weight of cement’; ‘w/w’- ‘weight
by weght’; ‘pbw’- ‘parts by weight’; ‘gm’-’gram’ etc
Sl. Proprietory Name of Product—(Abreviated Manufacturer’s Specific Remarks and its recommended
No. Name of Manufacturer) Dosage /Coverage wherever made available
5
1 INJECTION GROUTS (Seals Cracks in Concrete & other building materials by Injecting under pressure)
a EPOXY BASED INJECTION GROUT (Low pot life, non-resistant to ulitrea violet exposure and high temperatures, Non-
shrink, flowable, effective in sealing cracks, excellent bonding with almost all building materials, good chemical resistance)
1 EPOIN-AG-(AG) 1.05kg/litre
2 CERAscreed EP(LV)-(CERA) 1 litre / 2 kg
3 MASTER- GROUT EP - 150-(CHOKSEY) Approx. density 1.08 kg/ litre. Low viscosity. It is also used
for filling base plates & bolt pockets.
4 CICO POXY-21-(CICO)
5 Quickmast 231-(DON)
6 Expacrete SNE1-(ESSEN)
7 FLOWGROUT EPLV-(FAIRMATE) Suitable for damp or dry surfaces
8 Conbextra EP10-(FOSROC) Low creep characteristics under sustained loading. Crack width
range 0.25 to 10 mm
9 Groutfast (GREENSBORO) 1950 kg/cum
10 EPCO KP/HP-250 SLV-(KRISHNA)
11 MC DUR 1264-(MC) 2 kg Resin:1 kg hardener. It can penetrate into concrete upto
0.25 mm
12 OMAIPLAS 501-(OM) Base & Catalyst 1:0.5 Proportion.
13 OMAIPLAS 901-(OM) Base & Catalyst 1:1 Proportion. For grouting of concrete or
masonry structures under water.
14 Pidigrout EG-2-(PIDILITE) 1010 kg/cum
15 Pidigrout EG-3-(PIDILITE) 2150 kg/cum
16 Roff Crackfill EP (Two pack Epoxy)-(ROFFE)
17 EUCO INJECTION RESIN-(STP)
18 SUNEPOXY 368-(SUNANDA) SUNEPOXY 368 & Hardner (3:1) - High Gel time
19 SYSTEM - I GY-257: Aradur -840 100:50 pbw Medium Viscosity 2000-3000 mPa at 25o C
(VANTICO)
20 SYSTEM - II GY-257:Aradur -21 100:21 pbw Very Low Viscosity 150-130 mPa at 25o C
(VANTICO)
21 SYSTEM - III GY-257:Aradur -54 100:50 pbw Low Viscosity 400-800 mPa at 25o C
(VANTICO)
22 SYSTEM-IV Py-340-2:Aradur-54:Aradur-2958 Water based low viscosity System-Ideal for sealing of under
100:38:4 pbw -(VANTICO) ground structures. Develops Excellent Bond even in wet
conditions.
Contd...

Appendix 5.1 (...Contd)
23 Araldite GY 257 Aradur - 840 Quartz Sand Mix 400 pbw Quartz Sand gives flowable Mortar and 800 pbw Quartz
no.10- 100:50:400-800 pbw -(VANTICO sand will give tampable Mortar System gives excellent mechani-
cal properties and is tested for dimensional properties.
b ACRYLIC POLYMER BASED INJECTION GROUT( Possess improved flexural and tensile properties, resistance to
cracking, segregation, improved impermeabilitrey, chemical resistance, rapid setting, Shrinkage may reduce/increase ,
resistance to corrosion of Steel, Dynamic load/vibrations resistant)
1 CICO NON SHRINK POLY- MERIC GROUTING Used as admixture in neat cement/ cement-sand grout, Dosage :
COMPOUND (NSPGC)-(CICO) 1 to 2 kg per 50 kg Cement.. To be used within 30 minutes from
the time of production
2 Emcekrete -(MC) Apporx. 2 kg per litre
3 OMAICRYL-(OM) Omaicryl+Water+Cement mixed in 1:1:2.
4 Pidigrout 10M (PIDILITE) 2200 kg/cum Non-shrink grout
5 Roff Hygrout (Powder)-(ROFFE) Expanding in nature.
c LIGNOSULPHATE BASED INJECTION GROUT ADMIXTURE (Lowers viscosity of cement slurry, compensates drying
& plastic shrinkage)
1 INTRAPLAST EP-(SIKA) 0.6-1.0% by weight of cement.

5 2 CICO GROUT E1-(CICO) As per manufacturer’s instruction
3 FAIRADD-(FAIRMATE) 200 gm per 50 kg bag of cement.
d INJECTION GROUTS WITH UNDISCLOSED BASE (Disadvantages/advantages cannot be generalised)
1 ASIAN Super Grout-(ASIAN) 2300kg Grout Powder /CuM-Non-shrink cement grout

2 CERA Grout-(CERA) 26 litre / bag
3 MASTER- GROUT CNS - 50-(CHOKSEY) Approx. 2180kg/m3. Mix 5.4 litre water with 30 kg of powder
W/P=0.18.
4 Flogrout 40-(DON) Yield:25kg +4.25 litre of water yield 13.0 litreres
5 Flogrout 60-(DON) Yield: 25kg + 3.75 litrere yield 12.8 litreres
6 Polygrout-(ENEM) 2 kg/litre of grout
7 Flowcable 50-(MBT) 0.2% - 0.5% w/w of cement Expands up to 4 %. 28 day strength
> 65 Mpa
8 Masterflow IN-(MBT) Premixed. 28 day strength > 65 Mpa
9 SUNPLEX-(SUNANDA) 330 gm SUNPLEX per bag cement Expanding admixture & free
from chlorides
2 Rust Convertors/Removers for Reinforcements

a ACRYLIC POLYMER BASED Rust Convertor for Steel surface
1 RESIKON RSK-(ANUVI) Converts rust to chemically stable chelate compound. Cover-

age: 150 - 200 sqft per kg
b RUST REMOVER WITH MISCELLENOUS/ UNDISCLOSED BASE
1 AMCOR RR-(ANUVI) Removes rust & phosphatises iron metal.. Coverage: 15 sqm
per kg
2 Cleancrete-(ASIAN) Coverage: 6 – 9 sqm/litre.
3 FM RUST REMOVER-(FAIRMATE) To protect deposition of rust by eliminating existing rust. The
coverage rate will depend upon the degree of contamination
4 Feo Vert-(KRISHNA) Rust converting Primer. Coverage: 9 - 10 sqm/litre./ coat.
5 Pidicrete URP and pidiclean RR-(PIDILITE) SBR Based- Clean Rusted Reinforcement with Pidiclean RR and
apply bond coat of 1-part cement and 1-part URP
6 Protekta Recor-(TECH) Lignosulphate based admixture. Coverage: 100gm per bag of
cement
7 Roff Rust Clear (Liquid)-(ROFFE) Easy, economical & eco-friendly removal of rust. Coverage: 30
sqft per litre.
Contd...

Appendix 5.1(...Contd)
8 Roff Rust Clear ZR (Liquid)-(ROFFE) Easy removal of rust. Anti-corrosive as well as primer coating
of zinc to prevent future rusting. Coverage: 40 sqft per litre.
9 RUSTICIDE-(SUNANDA) Direct easy application. Single liquid component free from chlo-
rides & phosphates.
10 Concressive ZR(MBT) 7.5 sqm/lir
3 Corrosion Inhibitors as Admixture in Concrete/Mortar

(Effective in preventing rust of embedded reinforcement.
1 FAIRCRETE C-(FAIRMATE) Integral corrosion inhibitor.
4 Passivating/Protective/Bond Coats on Reinforcement

a EPOXY BASED Passivating/Bond Coat (protect reinforceemnt from Chloride attack and other chemical )
1 FRIAZINC R-(SIKA) Zinc- rich system . Coverage:150g/sqm/coat.
2 ICOSIT K25 I/3-(SIKA) Zinc- rich system . Coverage:175g/sqm/coat.
3 Nitozinc Primer-(FOSROC) Zinc- rich system . Coverage: 4.5 sqm per litrere
4 IPNet RB-(KRISHNA) Coverage: 12 litrere/ton for 16 mm bar diameter
5 Dr.fixit Epoxy Zink primer-(PIDILITE) Zinc- rich system
5
6 CORRO BOND-(STP) Coverage: 200gm/sqm
7 SHALIZINC PRIMER-(STP) Coverage: 100gm/sqm
b ACRYLIC POLYMER BASED Passivating Coat (Protects Steel against corrosion. Provides impervious layer,high
Alkalinity & Good adhesion It is a co-polymer of various acrylic monomers and it is solvent based.)
1 RESIKON COASTAL-(ANUVI) Proportion: 2:1 ratio (OPC:RESIKON COASTAL)

2 Cempatch R-(DON) Coverage: 1 kg pack covers 50 kg of 12mm dia Steel
3 SIKA RUSTOP(two-component, liquid& powder)-(SIKA) Coverage: 110 gm./running metre for 10 mm. Dia
rod.
4 POLYALK FIXOPRIME-(SUNANDA) Proportion: POLYALK FP & Cement in ratio 1:1.25
5 Protekta -M-(TECH) Coverage: 40 -50 sqft
c SBR BASED Passivating Coat, (May degrade over long periods.Protects Steel against corrosion. .Provides impervious
layer, high Alkalinity & Good adhesion.)
1 POLYCRYLE-(GREENSBORO) Coverage: 100 to 300 per sqm.

2 Roff Bond Repair (Liqiud)-(ROFFE) Coverage: 60 sqft per litrere
d LIGNOSULPHATE BASED Passivating coat
1 Protekta GAC -(TECH) Creamy consistency., brush applied over cleaned reinforcement.
Coverage: 20-25 running feet
e WITH UNDISCLOSED BASE Passivating Coat (Excellent weather resistance, anti corrosive coating for Steel and
reinforcements.)
1 NR-900-(ASIAN) Coverage: 10kg/cum of conc.

2 SAFECORE R-(FAIRMATE) Coverage: 2 kg + 1 litre Pack will cover 100 kg Steel of 12mm
dia.
3 POLYDEE -RC-(GREENSBORO) Coverage: 80 to 150 ml/sqm
4 SIKA RUSTOP-(SIKA) Two component Liquid and Powder. Coverage: 110 gm/running
metre for 10 mm dia rods
5 Renderoc Galvashiekd XP-(FOSROC) Ligno-sulphate based. Coverage: One unit for 2 running metre
of reinforcement bar
6 POLYPROOF-21 (Microfine Powder Concentrate)- Coverage: Coverage: 0.2% by weight of cement
(GREENSBORO)
Contd...

5 Bonding Coats (Applied by brush or spray. Bonding Agent for old concrete with newly poured concrete )
a EPOXY BASED Bonding Coat, (Low pot life.Excellent bonding under dry conditions, high mechanical proprerties )
1 EPOBOND-AG-(AG) Excellent bonding under dry & wet Conditions both. Coverage:
0.200 to 0.300 kg per sqm
2 Bond-Aid-(ASIAN) Dilution 1:3. Coverage: 30-35sqm/kg
3 CERAbond-EP-(CERA) Excellent bonding under dry & damp Conditions both.Coverage:
2.5 sqm/kg
4 MASTER - BOND - EP-(CHOKSEY) Excellent bonding under dry & damp
5 CICO BOND EPO-(CICO) Use this mixed material within 30 minutes after mixing.. Simple
air curing for 7-days Coverage : Three pack 2.5 sqm per
kg Two pack 2 to 2.5 of mixed material.
6 Quickmast 108-(DON) Two part, pre packaged can be applied on damp surfaces. Cover-
age: Approx 0.3kg per sqm..
7 Conbond SNE-(ESSEN) Coverage: 2 - 4 sqm per kg
8 FAIRBOND EP-(FAIRMATE) Cures even on damp surfaces. Coverage: 0.3 kg/ sqm.
9 Nitobond EP-(FOSROC) Allows concreting upto 10 hrs at 20o C and upto 6 hrs at 30o C.
Coverage: 2.2 sqm per kg
10 Epibond-(KRISHNA) Coverage: 3 - 5 sqm / litrere on level surface.
11 Concresisve 1414-(MBT) Conforms to ASTM. Coverage: 2-2.7sqm/kg
5
12 MC DUR 1200-(MC) Coverage: Approx. 500-550 gm/sqm
13 Pidipoxy EBA-(PIDILITE) Coverage: 3 – 4 sqm /kg
14 Roff Concrete Bond GP (Liquid)-(ROFFE) Coverage: 30 sqft per litrere
15 SIKA HIBOND -(SIKA) Coverage: 0.2 kg to 0.5 kg per sqm
16 EUCO 352-(STP) Coverage: 4-6sqm/kg
17 SUNEPOXY 358-(SUNANDA) Proportion: Sunepoxy 358 & Hardner in ratio 1:0.5
18 Protekta Bond-(TECH) Coverage: 4-5 sqft
19 SYSTEM - I GY-250 Aradur -830 Aradur -850 Concrete to be poured within tacky period, which is 1 hr at
Aradur -825 Silica Flour-(VANTICO) 25-30o C. Mixing Ratio: 100parts by weight:20parts by
weight(pbw)
20 SYSTEM - I I GY-257 Aradur -840-(VANTICO) Concrete to be poured within tacky period, which is 1 hr at 25-
30o C. Mixing Ratio: 100pbw:50pbw
21 Araldite GY-257 Aradur-450 Aradur-2958 Develops Excellent bond even in wet conditions. Concrete to be
-(VANTICO) poured within tacky period, which is 1 hr at 25-30o C. Mixing
Ratio- 100pbw: 30pbw: 9pbw
b ACRYLIC POLYMER BASED Bonding Coat (Good bonding between old and new concrete. UV resistant, non-re-emuslifiable,
resistant to water penetration, no rebound loss, high flexural strength)
1 RESIKON 400-(ANUVI) 2:1 ratio (OPC : RESIKON 400) .

2 Cempatch Primer-(DON) Coverage: 1kg pack covers 3 to 4 sqm.
3 Conbond SNA-(ESSEN) Coverage: 5 - 6 sqm per litrere
4 EL-Monobond-(KRISHNA) Coverage 3 to 4 sqm. per coat
5 MC BONDAID PLAST-(MC) Coverage: 8-10 sqm/kg
6 High Bond-40-(NEELAM) Coverage: 250gm./sqm.
7 OMAICRYL-(OM) Dilute with water 1:1. Bonds old concrete surface with fresh
mortar. Coverage: 8 to 9 sqm per kg
8 Pidicrete MPB -(PIDILITE) Coverage: 8-10 sqm /kg (by spray)
9 FLEXCON-(STP) Coverage: 10sqm/titre
10 Protekta -400-(TECH) Produces highly flexible membrane. Coverage: 12 -15 sqft (slurry)
a 1.5-2mm thick
c SBR BASED Bonding Coat (May be non-resistant to UV exposure and could degrade over long periods. Improves bonding,
reduces cracking, wear resistant , improves tensile flexural strength, chemical resistant.)
1 BONDCRETE-AG-(AG) Coverage information not supplied by firm

2 CERAlatex SBR-(CERA) Coverage: 8-10 sqm/litrere
Contd...

3 POLYDEE-MC -(GREENSBORO) Coverage: 2 kg per bag cement
4 Rheomix 141-(MBT) Compressive strength upto 40 Mpa. Coverage: 5-7 kg per bag of
cement
5 Roff Bond Repair (Liqiud)-(ROFFE) Coverage: 35 sqft per litrere
6 SIKA LATEX POWER(Liquid product)-(SIKA) Coverage: 3 kg to 6 kg per 50 kg bag of ratio SLP:W = 1:4 to 1:8
by vol.
7 Protekta -500-(TECH) Coverage: a 12-15 sqft (slurry) a 5-2 mm thick
d WITH UNDISCLOSED BASE Bonding Coat, (Excellent interfacial bonding, Easy to use,Hacking totally eliminated)
1 HACK AID PLAST-(TECH) Ready to use by brush

2 Ashford Formula-(JB) 40 sqft. to a litre. on fresh concrete floor.
6 PLASTICISERS ( Reduces water demand upto 15 % for same level of workabilitrey to result in higher strength,
Increased flowabilitrey/workabilitrey for same w/c ratio to allow it to be placed without vibration at poorly
accessible locations, essentially needed for producing higher grades of concrete )
a ACRYLIC POLYMER BASED PLASTICISER(Excellent abrasion resistant, wearing coat of bridge slabs, repair of abraided
surface of concrete roads. Industrial flooring )
1 OMAICRYL-(OM) Dosage: 10% to 20% bwoc 5

b WITH UNDISCLOSED BASE PLASTICISER
1 POLYPROOF-22 (Liquid)-(GREENSBORO) 1 to 5% by weight of cement

2 Stanro SPS-(NEELAM) 0.5 to 1% by wt. of cement.
3 CICO PLAST-A-(CICO) Optimum Dose: 1000 ml per 50 kg Cement.- Range : 700 to
1500 ml per 50 kg Cement.
4 Roff Plasticiser-330 (Liquid)-(ROFFE) 140-280 ml per 50 kg bag of cement
c MELAMINE BASED PLASTICISER
1 CICO PLAST - AF-(CICO) It acts only to prevent harmful effects of frost on green con-
crete. Dosage : 0.5 to 1.5 litre per
50 kg bag of count.
d NEPTHALENE BASED PLASTICISER
1 Cemwet Sp-I-(ASIAN) 0.4-2% by wt.of cement

2 CICO PLAST AEP-(CICO) Normally with the 300 kg of cement/cum, Zone II sand, 20 mm
aggregate, 150ml is sufficient to get 4 to 5% air at 30 Deg C.
Range : 100 ml to 200 ml per 50 kg cement.
3 CICO PLAST MMF-(CICO) Used for pumped concrete. Dosage : 300 ml per 50 kg cement.
Range : 200-1000 ml per 50 kg
4 Pidicrete CF 21-(PIDILITE) Dosage: 100-500 ml per bag of cement
5 SIKA PLASTOCRETE SUper .-(SIKA) Marked with IS:9103 & conforms to IS:2645. No added chlo-
rides and sulphates. Dosage: 0.2% by wt. of cement i.e. 100 gm
per 50 kg bag of cement.
e LIGNOSULPHATE BASED PLASTICISER
1 RESIKON 130-(ANUVI) 100 - 500ml per 50kg cement

2 PLASTAID-(ENEM) Dosage: 0.25 kg per bag of cement
3 BLOCKSAVER-(ENEM) Dosage: 0.25 kg per bag of cement
4 Conflow SNP1-(ESSEN) Gives high density concrete. Dosage: 0.10 to 0.25 litres per 50
kg cement
5 FAIRCRETE N -(FAIRMATE) Dosage: 100 ml to 250 ml per 50 kg bag of cement
6 Pozzolitreh 300 R-(MBT) Dosage: 0.1-0.3%
7 PLASTIMENT BV40-(SIKA) Dosage: 0.2-0.8% by wt of cement
8 EUCON WR-(STP) Dosage: 0.4% bwoc
Contd...


7 Super Plasticisers ( Reduces water demand by 15-30% for same level of workabilitrey to result in higher
strength, Increased flowabilitrey/workabilitrey for same w/c ratio to allow it to be placed without vibration at
poorly accessible locations, essentially needed for producing higher grades of concrete )
a MELAMINE BASED SUperPLASTICISER
1 RESIKON SP120 M-(ANUVI) Dosage: 100 - 500ml per 50kg cement

2 Supercon 100-(KRISHNA) Dosage: 0.5% to 4% by weight of cement
3 Roff Superplast - 820 (Liquid)-(ROFFE) Dosage: 250 — 600 ml per 50 kg bag of cement
4 SIKAMENT 320-(SIKA) Dosage: 0.6-2.0% by wt of cement.
b NEPTHALENE BASED SUperPLATICISER
1 RESIKON SP-110-(ANUVI) Dosage: 100 - 500ml per 50kg cement

2 Cemwet SP-3000-(ASIAN) For pumping concrete. Dosage: 0.4-2% by wt.of cement
3 MASTER- PLAST SPL-2-(CHOKSEY) Conforms to IS:9103, BS-5075-Part-3, ASTM-C-494 Type F.
Non-foaming, non-toxic, Does not contain any chlorides or
nitrates, can be used at high dosage without affecting setting
time of concrete to get higher workabilitrey. Dosage: 0.200 to
1.200 litrere per 50 kg
4 OMAI SPNF-(OM) Dosage: 0.5 to 1% by weight of cement
5 5 Roff Superplast-410 (Liquid) -(ROFFE) Dosage: 300—500 ml per 50 kg bag of cement
6 SIKAMENT 170-(SIKA) Dosage: 0.5-2.0% by wt of cement
7 EUCON 37-(STP) Dosage: 6-2% by weight of cement(bwoc)
8 POLYTANCRETE- NGT-(SUNANDA) Dosage: 150ml to 400ml per bag of Cement
9 Protekta -T -(TECH) Dosage: 500gm per bag of cement
c LIGNOSULPHATE BASED SUPER PLASTICISER
1 CICO - MS-(CICO) Ideal for underground structures, parking, bridge decks. Dosage :
3 to 10% by weight of cement.
2 FAIRFLO-(FAIRMATE) Dosage: 300 ml to 600ml per 50 kg bag of cement
3 Pidicrete CF-(PIDILITE) Dosage: 100-500ml per bag of cement
4 Roff Superplast -320 (Liquid)-(ROFFE) Dosage: 250 - 500 ml per 50 kg bag of cement
d WITH UNDISCLOSED BASE SUPER PLASTICISER
1 POLYPLAST-HW/HL-(GREENSBORO) Dosage: 0.3% to 2%
8 Shrinkage, Reducing/Compensating Compounds

a ACRYLIC POLYMER BASED Shrinkage, Reducing/compensating compound (Crack filling abilitrey, non shrink, reduced
creep and shrinkage,resistant to frost and fire damage.Dimensional stabilitrey,excellent abrasion resistant)
1 MC Sunfilla-(MC) Crack filling abilitrey, non-shrink, resists further crack growth.

Dosage: 1.5 kg/sqm/mm thickness
2 MC Einpresshilfe EH-(MC) permanent expansion, reduced creep & shrinkage. Dosage: 0.5
to 1% of cement weight
3 OMAICRYL-(OM) Dosage: 10% to 20% by weight of cement
4 Roff Grout Mix (Powder)-(ROFFE) Non-shrink cement slurry. Dosage: 500 gm per 50 kg bag of
cement.
b SBR BASED Shrinkage, Reducing/compensating compound
1 POLYDEE-MC -(GREENSBORO) Anti shrink compound/ concrete. Dosage: 2 kg per bag cement
c NEPTHALENE BASED Shrinkage, Reducing/compensating compound
1 Fluid-X-(ASIAN) 0.5 by wt. Cement

2 OMAI SPNF-(OM) 0.5 to 1% by weight of cement
3 INTRAPLAST EP-(SIKA) 0.6-1.0% by wt of cement.
Contd...

d LIGNOSULPHATE BASED Shrinkage, Reducing/compensating
1 RESIKON PLASTERAID -(ANUVI) 100 -300ml per 50kg cement

e WITH UNDISCLOSED BASE Shrinkage, Reducing/compensating compound
1 CERA Expan 250-(CERA) Dosage: 225 gm for 50kg cement

2 Conbex 100-(FOSROC) Dosage: 225 gm per per 50 kg cement
3 OMAIPLAS 801-(OM) Dosage: 5% to 20% weight of cement
4 SHALIGROUT IP-(STP) Dosage: 1% bwoc
5 Protekta AC1-(TECH) Dosage: 1.4 litre per bag of cement
6 Protekta -DX-(TECH) Dosage: 100gm per bag of cement
7 Floadd-(DON) Yield : 36 litreres when 20 litreres of water added
8 GROUTFAST Cementitious-(GREENSBORO) 2250 kg/cum
9 SUNPLEX-(SUNANDA) 330 gm SUNPLEX per bag cement
9 Self Flow Micro Concrete (Highly fluid, non shrink, self compacting concrete with very high early and ultimate
strengths.,excellent adhesion, used for structural repairs like Jacketting, patch repair, retrofitting of RCC, grout-
ing fondations, anchor bolts)
a EPOXY BASED Self Flow Micro Concrete (May not be suitable in exposed location, at high temperatures or where 5
temperature variation range is large. Excellent mechanical properties and bonds with almost all building materials.Suitable
for sealing crack surface defects, concrete repair, thin jackets, thin film bonding, assembly of prestressed concrete segmental
units and segmental bridge construction.)
no.10- 100:50:400-800 pbw -(VANTICO) sand will give tempable Mortar System gives excellent mechani-
2 CICO POXY SBA-(CICO) Coverage : 1.7 kg of mixed material for 1 mm thickness per
sqmr.
3 Repcrete SNE1-(ESSEN) Coverage : 16 kg gives 8 litreres of volume after mixing
b ACRYLIC POLYMER BASED Self Flow Micro Concrete
1 MC Floorpatch-(MC) Ideal for repair of blow holes in Industrial floors. Coverage: 1.5
kg/sqm/mm thickness
2 MC Floor level-(MC) 1.5 kg/sqm/mm thickness
c SBR BASED Self Flow Micro Concrete (May be effective in exposed locations and degrade over long durations, Used for
Micro concrete/ retrofitting, jacketting )
1 POLYDEE-MC -(GREENSBORO) 2 kg per bag cement

d LIGNOSULPHATE BASED Self Flow Micro Concrete (Self compacting concrete,anti washout,non shrink microconcrete
for underwater repairs. High strength and fast setting,non-shrink,improved impermeabilitrey & chemical resistant)
1 Renderoc RG-(FOSROC) Anti washout for under water repairs Coverage : 1950 kg/cum
2 Renderoc UW-(FOSROC) Coverage : 12 litreres yield per 25 kg bag
3 POLYCRETE -(SUNANDA) Coverage : Ready to use .Mix 12.5% to 13% water.
e WITH UNDISCLOSED BASE Self Flow Micro Concrete
1 POLYGROUT-(ENEM) Coverage: 2 kg per litre volume of grout Also used for grouting
Machine Foundations, bolts, anchors.with positive expansion
2 EUCOCRETE-(STP) Coverage : 2000 kg/cum
3 CERA Microconcrete-(CERA) Coverage : 13.5 litrere / kg
4 Cempatch N-(DON) Conforms to BS-6319 Part-2-1983, BS 6319 Part-7-1985. Cov-
erage : 25 kg pack Yields 11.1 litrere
5 Cempatch HM-(DON) Yield: 25 kg + 4.25 litrere water. Yields 13.5 litrere.
6 Repcrete SNC-(ESSEN) Coverage : Gives 12 litrere volume after mixing with water
7 CEMSCREED HM(F)-(FAIRMATE) Information not supplied by firm
Contd...

8 Supercon UW-(KRISHNA) Effectively fills cavities under water. Coverage : Information

not supplied by firm
9 Emacco S 66 CT-(MBT) Coverage : Information not supplied by firm
10 Roff Crete Repair (Powder)-(ROFFE) Can be used in less thickness. Coverage : 24.5 litrere per 50 kg
bag of cement
11 SIKA MICROCON- CRETE - HS-(SIKA) Coverage : 2000 kg/cum
10 Polymer/Epoxies in Repair Mortar/Concrete (May not be suitable at high temperatures. Improved bonding
with substrate and imperviousnes, to be applied in thin layers, Excellent mechanical properties)
a EPOXY BASED Repair mortar/Concrete (May not be suitable in exposed location, at high temperatrures or where
temperature variation range is large. Excellent mechanical properties and bonds with almost all building materials)
no.10- 100:50:400-800 pbw -(VANTICO) sand will give tempable Mortar System gives excellent mechani-
2 Bond-Aid-(ASIAN) Can be applied on wet surfaces. Dilution 1:3. Coverage: 30-
35sqm/kg Dosage: 2-3 cum per kg
3 Emacco S 88 CT-(MBT) Premixed
4 Concressive 2200-(MBT) Coverage: 3kg/sqm
5
b ACRYLIC POLYMER BASED Polymer in Repair Mortar/Concrete (May not be suitable at high temperatures. Used
as an admixture by weight of cement. Improves bonding and flexural tensile strength. Reduces Chloride ingress and water
absorption. Resistant to UV Radiation.Suitable for Exterior use, abrasion and impact resistant, chemical attack, non-toxic,
resists fungus and micro-organism growth, protects Steel reinforcement, Chloride free, can be used in wet areas)
1 RESIKON 400-(ANUVI) Dosage: 5 -15 % of cement depending on application

2 CERA Poly Crackfiller-(CERA) Dosage: 40 rm/kg to fill V groove of 6mm
3 CERA Patchcrete-(CERA) Dosage information not supplied by firm
4 ELASTOCRETE-(CHEMLINE) Dosage: 1.5 sqm per 2 coats 0.6mm thickness per coat
5 ELASTOCRETE-(CERA) Dosage: 1.2 sqm per 2 coat thickness of per coats 2 mm
6 MASTER- CRETE M-81-(CHOKSEY) Coverage: 4-4.5 sqm./ 3 kg mix per coat . Mix M-81:OPC ( 1:2)
7 Setcrete SB-(DON) Coverage: 0.5 kg of SB +1 kg of OPC cement for one sqm. 15 kg
of Setcrete SB for 50kg of cement.
8 FAIRCRETE SB (L)-(FAIRMATE)
9 CEMSCREED R-(FAIRMATE) Coverage: 5 to 7 sqm.
10 Nitobond AR-(FOSROC) Coverage: 10 % by wt of cement
11 Monobond-(KRISHNA) Dosage: Appox. For Mortar 10 to 15 % parts by weight.
12 MC Floorpatch-(MC) Coverage: 1.5 kg/sqm/mm thickness
13 MC Floor level-(MC) Coverage: 1.5 kg/sqm/mm thickness
14 OMAICRYL-(OM) Dosage: 10% to 20% by weight of cement
15 Roff Supercrete (Liquid)-(ROFFE) Dosage: 6-10 % of cement
16 SIKA TOP 77-(SIKA) 6% by wt of cement.
17 POLYALK EP 25-(SUNANDA) Composition: POLYALK EP & cement as 1:0.5
18 Protekta Flexphalt-(TECH) Used as flexible membrane and gives total water protection.
Coverage: a 15-20 sqft
19 Protekta Flexjoint-(TECH) Coverage: a 15-20 sqft can be higher depends on the surface
20 Protekta STG-(TECH) Information not supplied by firm
21 Protekta Crack Filler -(TECH) Information not supplied by firm
c SBR BASED Polymer in Repair Mortar/Concrete (Liable to be affected by UV exposure and at high temperatures,
could degrade over long durations. Good bonding, reduces cracking, abraison resistant, water resistant, resistant to cracking
, resistant to chemical attacks, improves imperviousness and tensile strength )
1 BONDCRETE-AG-(AG) Information not supplied by firm

2 Nitobond SBR-(FOSROC) Information not supplied by firm
3 POLYDEE-MC -(GREENSBORO) Dosage: 2 kg per bag cemt
4 Rheomix 141-(MBT) Dosage: 5-7 kg per bag of cement
Contd...


5 Nafufill SBR-(MC) Dosage: Varies according to field of application

6 Roff Bond Repair (Liquid)-(ROFFE) Dosage: Dosage: 3 - 5 % of cement
7 SIKA LATEX POWER(Liquid product)-(SIKA) Dosage: 3 kg to 6 kg per 50 kg bag of ratio SLP:W = 1:4 to 1:8
by vol.
8 SBR LATEX-(STP) Dosage: AS per litreREATURE
9 POLYALK -SB-(SUNANDA) Dosage: POLYALK SB,Cement & Quartz Sand as 1:5:15 by wt.
d FIBRES BASED Polymer in Repair mortar/Concrete (Provides resistance to crack formation etc.)
1 CERA Fibercrete-(CERA)
2 SMASHTOUGH-(ENEM) Coverage: 2 kg per litrere volume of mortar
e WITH UNDISCLOSED BASE Polymer in Repair Mortar/Concrete
1 REPAID-(ENEM) Coverage: 2 kg per litre volume of mortar

2 OMAIPLAS 801-(OM) 5% to 20% weight of cement
11 Quick Setting Compounds (Rapidly sets concrete/mortar to yield early strength)

a EPOXY BASED Quick Setting Compounds
1 GROUTFAST-(GREENSBORO) Structural Grouting/ RCC Cracks, Renderings, non-shrink. 1950

kg/cu.m. 5
b ACRYLIC POLYMER BASED Quick Setting Compounds
1 MC Fix ST-(MC) Depends on application

c MELAMINE BASED Quick Setting
1 Cemwet-ACC-(ASIAN) Chloride free high early strength. Dosage: 1-1.5kg by wt. Of

cement
d NAPTHALENE BASED Quick Setting Compounds
1 OMAI SPNF-(OM) Good workabilitrey, flowabilitrey, pumpable concrete, reduces

w/c ratio. Dosage: 0.5 to 1% by weight of cement
e LIGNOSULPHATE BASED Quick Setting Compounds
1 Patchroc-(FOSROC) 2000 kg/cum

2 QS-530-(NEELAM) 1:3 with cement
f WITH UNDISCLOSED BASE Quick Setting Compounds
1 CERA Polymortar-PE-(CERA) Resistant to oil, grease and chemicals. Dosage: 2.6 litrere / 4 kg;
13 litrere / 20 kg
2 CERA Anchorset-(CERA) High pullout stength achievement. Dosage: 0.5 litre per kg
3 CICO No.2 & 2A-(CICO) Profusely water leaking locations in concrete. Final setting time
20-40 secs for CICO no 2. Dosage: Approx. 20 litrere per 50kg
cement
4 CICO NO.3 (CB) CICO NO.3A(CF)-(CICO) For masonry, rock tunnels for moderate leakage. Dosage:
Approx. 12 litrere per 50 kg cement or 16 to 17 kg per 50 kg
cement
5 CICO SHOT P (Powder)-(CICO) Mixed with dry cement for shotcreting/gunite and water proof-
ing applications. Dosage : 1.5 kg to 2 kg per 50 kg cement.
6 CICO SHOT LP 100 (Liquid)-(CICO) Mixed in mixing water for shotcreting/gunite and water proof-
ing applications. Normal Dosage : 1.5 to 2 litres. per 50 kg
cement.
7 CICO SHOT L 100-(CICO) Mixed in mixing water for shotcreting/gunite and water proof-
ing applications. Normal Dosage : 1.5 to 2 litres. per 50 kg
Cement.
Contd...

8 SPRAYCRETE-(FAIRMATE) For dry mix shotcrete application. Dosage: 2% to 5% by weight

9 SPRAYCRETE L-(FAIRMATE) For wet mix shotcrete applications. Dosage: 2% to 5% by
weight
10 FAIRCRETE NC-(FAIRMATE) Improves frost resistasnce. Dosage: 1 to 2 litres.per 50 kg bag
of cement
11 Conplast Sprayset Powder-(FOSROC) Allows higher buildup thickness. Dosage: 4% to 6% by wt of
cement
12 OMAIPLAS 801-(OM) Dosage: As per reqd. acceleration.
13 OMAIPLAS 801-(OM) Hardens within 3 to 15 minutes. Dosage: 5% to 20% weight of
cement
14 Roff Hyplug (Liquid)-(ROFFE) Instant setting mortar. Dosage: 15 litrere per 50 kg bag of
cement
15 SIGUNIT POWDER 1 (SIKA) For Dry shotcreting. Dosage: 2-3% by wt of of cement.
16 SIGUNIT L .-(SIKA) For Wet shotcreting. Dosage: 5-6% by wt of cement
17 DAM IT-(STP) Information not supplied by the manufacturer
18 CERA Plug-(CERA) Information not supplied by the manufacturer
19 RAPIDFAST-(GREENSBORO) Dosage: 1-5% by wt. of cement.
12 Retarder (To extend the initial and final setting time)

5 a SBR BASED Retarder ( May not be suitable for locations, which are exposed or subjected to high temperatures. May
degrade over long durations. watertight- ness, good bond, impact & flexural tensile strength, improve chemical resistance.)
1 SIKA LATEX POWER (Liquid product)-(SIKA) Dosage: 3 kg to 6 kg per 50 kg bag of ratio SLP:W = 1:4 to 1:8
by vol.
b MELAMINE BASED Retarder ( Increases workability, reduces water cement ratio.)
1 FAIRFLO RM-(FAIRMATE) Dosage: 200 ml to 800 ml per 50 kg

NAPTHALENE BASED Retarder ( reduces water cement ratio, workability retaintion for longer period)
1 FAIRFLO S -(FAIRMATE) Dosage: 200 ml to 800ml per 50 kg bag of cement

2 EUCON 537-(STP) Dosage: 0.6 - 1.5% bwoc
c LIGNOSULPHATE BASED Retarder ( Increases setting time, cold joints can be avoided, requires less curing, improves
impermeabilitrey )
1 CICO-PLAST-R-(CICO) With OPC for M 25 grade concrete and 3 hours retardation

normal dosage : 200 ml per 50 kg Cement. Range : 150 ml to
300 ml per 50 kg cement.
2 RETAID-(ENEM) Coverage: 0.14 kg per bag of cement
3 Pozzolitreh 300 R-(MBT) Dosage: 0.1-0.3%
4 EUCON 537-(STP) Dosage: 0.6 - 1.5% bwoc
d Retarder WITH UNDISCLOSED BASE
1 Roff Retard - 310 (Liquid)-(ROFFE) Dosage: 140-420 ml per 50 kg bag of cement

2 Protekta -DX-(TECH) Dosage: 100gm per bag of cement
3 CemwetSRA -(ASIAN) Dosage: 0.05-0,2%by wt.ofcement
4 POLYPLAST-R-(GREENSBORO) Dosage: 1 to 2%
13 Curing Compound (It prevents premature water loss.. Stops dusting in floor, curing compound. can be applied
at difficult locations, on vertical surfaces, roads, runways, external floors, dams)
a LIGNOSULPHATE BASED Curing Compound
1 CICO CUREFREE (WP OR C)-(CICO) Coverage : 2.5 to 5 sqm per litre depending on surface texture.
2 CICO RITECURE-(CICO) Coverage : On Steel troweled surface 7-10 sqm/litrere; On wood
troweled surface 5-7 sqm/litrere.
Contd...

b Curing Compound WITH UNDISCLOSED BASE
1 Setcrete 8-(DON) Coverage : 5 to 6 sqm per litre

2 Setcuro WB-(DON) Coverage: 5 to 6m sqm per litre
3 FARICURE RA-(FAIRMATE) Coverage: 4 to 5 sqm. per litre.
4 Roff Cure WB-White (Liquid)-(ROFFE) Coverage: 50 sqft per litre
5 Curewell-WB-(ASIAN) 9 to 10sqm/litre
6 Curaid SN2-(ESSEN) 4 to 6 sqm per litre
7 POLYCURE-(GREENSBORO) NA
8 Ashford Formula-(JB) 40 sqft. to a litrere on fresh concrete floor.
9 Masterkure 106-(MBT)
10 EUCOSIL-(STP) 5-8 sqm/litre
11 MASTER- CURE WB1 &WB2 *WB-1(clear) 4-6 sqm per litre/ coat
*WB-2(white)-(CHOKSEY)
12 MASTER- CURE RB1&RB2 *RB-1-clear resin Depends on requirments within the range of 0.1-0.2 kg per
based *RB-2 -white Aluminized synthetic resin sqm
based-(CHOKSEY)
14 Shuttering Oil
a UNSPECIFIED BASE Shuttering Oil 5
1 SETRELEASE RU-(FAIRMATE) 20 to 60 sqm. per litre.

2 POLYDEE-RL-(GREENSBORO) NA
3 Roff Shutter Release (Liquid)-(ROFFE) 300 sqft per litre
b LIGNOSULPHATE BASED Shuttering Oil (Fair laced concrete)
1 CICO LEASE-(CICO) Coverage : On Steel : 25 to 60 sqm/litre. On Timber : 15 to 30

sqm/litre.
2 ASIAN MRA-(ASIAN) 30-40sqm/litre
3 POLYDEE-RL-(GREENSBORO) NA
4 Rheofinish 202-(MBT) Brush/Spray Applied. Coverage upto 65 sqm per litres
5 EUCOSLIP-(STP) 12-18 sqm/litre
6 MASTROL- MRA-(CHOKSEY) 30- 80 sqm/ litre.
7 MASTROL- WD-(CHOKSEY) *Plywood- 90-110sqm *Steel 130-170sqm
15 Floor Hardners
a EPOXY BASED FLOOR HARDNER (Excellent abrasion resistance and other mechanical properties)
1 Primer : Araldite GY-257 Aradur-840 Mortar: Primer: 100 pbw :50 pbw Mortar: 100pbw:50pbw:800pbw
Araldite GY 257 Aradur - 840 Quartz Sand Mix Seal Coat: 100pbw:50pbw Heavy duty industrial floor
Seal Coats (2) :Araldite GY-257 Aradur-840 topping.
-(VANTICO)
2 Araldite GY-257 Aradur-2963 or Aradur XY-54 Self levelling multilayer system with good aesthetics for Indus
Silica Flour Quartz Sand Flow trial flooring. Composition: 100pbw: 45pbw: 50pbw: 30pbw:
Control Agen Antifoaming Agent 240pbw: 2pbw: 2pbw: 3pbw
Pigment Paste -(VANTICO)
3 Araldite GY-257 Aradur-2963 -(VANTICO) Industrial surface coating with good aesthetics. Composition:
100pbw: 45pbw:
b ACRYLIC POLYMER BASED FLOOR HARDNER
1 Protekta Senfloor -(TECH) Resistant to acid, alkali, organic solvents. Suitable for Industrial
floors. Coverage: 30 sqft.per kg
2 ELASTOCRETE-(CHEMLINE) To produce high strength polymer floor topping and thin sec-
tion screeds.
Contd...

c LIGNOSULPHATE BASED FLOOR HARDNER (It provides the hardest surface to floors and pavements)
1 CICO SURFACE HARDENER-(CICO) For heavy duty industrial floors Coverage: 2 kg per sqm for 13
mm thickness of topping . For light duty floors1.Coverage: 1.5
kg per sqm for 13mm thickness .
2 CICO FLORTOP-E-(CICO) From moderate to heavy duty floors coverage: 2 kg per sqm to
5 kg/sqm
d FLOOR HARDNER WITH UNDISCLOSED BASE
1 SUperSCREED -P-(ENEM) Coverage: 3.3 kg pack per bag of cement

2 POLYDEE-FT-(ENEM) Coverage: 4-7kg/sqm
3 SURFLEX-(STP) Coverage: 3.5kg /sqm
4 Protekta Guard-(TECH) Coverage: 30 sqft per kg
5 Ironate-A-(ASIAN) Coverage: 1.5-5.5kg/sqm
6 FAIRTOP -(FAIRMATE) Coverage: sprinkling rate 5 kg per sqm. on a green concrete.
7 POLYDEE-FT-(GREENSBORO) Coverage: 4-7kg/sqm
8 Ashford Formula-(JB) Coverage: 40 sqft. to a litre. on fresh concrete floor.
9 Hard Top-70-(NEELAM) Coverage: 3.5 to 9 kg/sqm.
10 Super Magnum Floor-(NEELAM)
5 11 Rofflor DURA -999 (Powder)-(ROFFE) Coverage: Lt Duty.3.5 kg/ sqm, Med Duty 5.0 kg/sqm Heavy
Duty 7.0 kg / sqm
12 SHALIHARD-(STP) Coverage: 250gm /sqm
13 TECH FLOOR HT - 200-(CHOKSEY) TRAFFIC *HEAVY 7 kg/sqm *MEDIUM 5 kg/sqm *LOW
3 kg/sqm
16 Water Proofing Compounds (Surface coatings as well as Integral Water Proofing Compound)
a EPOXY BASED Water Proofing Coating (Seals pores & network of fine cracks, good bonding, withstands positive water
pressure, resists chemicals aggression)
1 TECHOXY-(STP) Can be applied on damp surfaces. Coverage: 7-8 sqm./kg per

coat
2 CHOKSEYS COAL TAR -EPOXY-(STP) Resistant to UV exposure. Coverage: 4-4.5 sqm./litre per coat
3 CICO AQUAPOXY-(CICO) Can be applied on damp surfaces. Coverage: 3 to 4 sqm per kg
of mixed material per coat
4 POLYDEE-10 TAR POLYMER -(GREENSBORO) Coverage: 0.3-0.5kg/sqm
5 OMAIPLAS EP-101-(OM) Coverage: 4 to 6 sqm/set in 2 coats.
b ACRYLIC POLYMER BASED Water Proofing (Good bonding with concrete, metallic, CERAmic surfaces.,crack
resistant, flexible, elastomeric, anti-carbonation, UV resistant & breathable)
1 RESIPOLYPROOF-(ANUVI) Proportion: 1 : 1 ratio (OPC : RESIPOLYPROOF). 1kg OPC +

1kg Polyproof covers appx.4 sqm
2 ELASTOCRETE-(CHEMLINE) Coverage: 1 sqm of 1mm thick- coat
3 CICO ACRYL-(CERA) Coverage: 1 kg per 50 kg cement.
4 CICO DURAFEX OR FLEXICOAT-(CERA) Coverage: Minimum 4.5 kg to 3 kg per sqm along with non-
woven polyester fabric and 1 kg to 1.6 kg per sqm in 2 coats
without polyester fabric.
5 TAPECRETE P151-(CICO) Proportion for PMC Slurry for 1 coat : Tapecrete P 151-0.25kg
; Cement 0.5kg PMC Slurry for 2 coat Tapecrete
P151- 0.4kg; Cement 0.8kg PMC
Brush Topping 1.5mm thick /sqm Tapecrete P151-0.67kg; Ce-
ment - 1.3kg; Silica sand 1.3kg For PMC Filler & Mortar the
mix ratio can be approx.as follows : Tapecrete
P151- 1kg; Cement-2 kg; Graded sand -5.6kg
6 Aquacoat SNF-(ESSEN) Coverage: 1 kg to 3 kg per sqm
7 Master Seal 550-(MBT) Flexible up to 5%. Bnd strength upto 1.2 Mpa. Coverage: 1.8 kg
per sqm
Contd...

8 BPG-700-(NEELAM) Coverage: Depending upon the width & depth of the Sealant
9 OMAICRYL-(OM) Coverage: 10% to 20% by weight of cement
10 OMAISEAL-703-(OM) For cracks/joints upto 10 mm width. Coverage: 25 Rmt/kg
11 Roff Hyfex (Liquid)-(ROFFE) Single component, highly flexible. Coverage: 5 sqft per kg
12 Roff Hyguard EX (Powder & Liquid)-(ROFFE) Flexible. Coverage: 6 sqft per kg
13 Roff Supercrete (Liquid)-(ROFFE) Coverage: 25 sqft per litre
14 EUCO ELASTIC PLASTER[-(STP) Coverage: 2kg /sqm
15 POLYALK WP-(SUNANDA) Proportion: POLYALK WP & cement in the ratio 1:1.5
16 Protekta EJR-(TECH) Developed for expansion joints. Can withstand positive and
negative hydrostatic pressure.
17 Protekta Micro Emulsion-(TECH) Neutral, alkali stable. Coverage: 30-40 sqft
c SBR BASED Water Proofing (May not be suitable for locations, which are exposed or subjected to high temperatures. May
degrade over long durations., Good bonding, reduces cracking, abraison resistant, water resistant, resistant to cracking ,
resistant to chemical attacks, improves imperviousness and tensile strength)
1 BONDCRETE-AG-(AG) Information not supplied by firm

2 MASTER- BOND SBR-LATEX-(CHOKSEY) Information not supplied by firm
3 POLYDEE-SG -(GREENSBORO) Coverage: 0.3 to 0.5 kg/sqm
4 Roff Bond Repair (Liquid)-(ROFFE) Coverage: 30 sqft per litre
5 SIKA LATEX POWER(Liquid product)-(SIKA) Coverage: 3 kg to 6 kg per 50 kg bag of ratio SLP:W = 1:4 to 1:8 5
by vol.
d FIBRES BASED Water Proofing(Eliminates cracking of plaster.)
1 Krifib-(KRISHNA) 125 gm / bag of cement.

e MELAMINE BASED Water Proofing (Properties are enhanced due to reduction in water demand)
1 CICO No.1-(CICO) Dosage: Approx. 1.5 kg per 50 kg Cement for 1:6 or leaner
mortar mix; 1 kg per 50 kg Cement for 1:4 or richer mortar
mix. For concretes with cement content upto 350 kg/cum., 1.5
kg/50 kg of Cement, For concretes with cement contents above
350 kg/cum. 1 kg/50 kg cement.
f NEPTHALENE BASED Water Proofing (Properties are enhanced due to reduction in water demand)
1 RESIKON LWP-(ANUVI) Dosage:Coverage: 100- 300ml per 50kg cement.

2 CICO SUper-(CICO) Dosage: 150 ml/50 kg of cement.
3 CICOPLAST-N-(CICO) Normal dosage 500 ml/50 kg Cement. Range : 150 ml to 300
mil per 50 kg Cement.
4 Cemwet-AEA-(SIKA) Dosage: 70-75m/bag
5 SIKA PLASTOCRETE SUper - marked with IS:9103 & conforms to IS:2645.-(SIKA) Dosage: 0.2% by wt. Of
cement i.e. 100 gm per 50 kg bag of cement.
g LIGNOSULPHATE BASED Water Proofing (Properties are enhanced due to reduction in water demand)
1 CICO POLYGROUT-(CICO) As the volume to be sealed is not known the consumption is not
predictable. However, about 25% of the volume to be sealed is
the required consumption of POLYGROUT.
2 Conflow SNW1-(ESSEN) 0.10 to 0.20 litres per 50 kg cement
3 FAIRCRETE RMW-(FAIRMATE) Dosage: 100 ml to 250ml per 50 kg bag of cement. Ideal Dose:
150 ml per 50 kg bag of cement.
4 Thioflex 600-(FOSROC)
h WITH UNDISCLOSED BASE Water Proofing Advantages/disadvantages cannot be generalised in absence of the base
material of the products.
1 SUperSCREED -P-(ENEM) Dosage: 3.3 kg pack per bag of cement

2 FAIRPLAST IP-(FAIRMATE) Dosage: 200 gm. per 50 kg bag of cement
3 SUper-SIL-(NATIONAL) Dosage: One kg covers 35-40 square feet. On primer coat of
white cement
Contd...

4 B.Guard-(NEELAM) Dosage: 2-2.5 sqmt./kg

5 Stanro IW-4-(NEELAM) Dosage: 0.2% of cement wt.
6 OMAIPLAS 801-(OM) Dosage: 5% to 20% weight of cement
7 Pidiproof LW-(PIDILITE) Dosage: 200ml per bag of cement
8 Roff Hyproof (Liquid)-(ROFFE) Dosage: 140 ml per 50 kg bag of cement
9 NOLEEK POWER - marked with IS:2645-(SIKA) Dosage: 1% by wt. of cement, i.e.500 gm per 50 kg bag of
cement.
10 SIKA DAMPROF (Liquid product)-(SIKA) Dosage: 50 ml. to 100 ml (Diluted version, dilution ratio =
SD:Water=1:10 by vol.) per hole.
11 Protekta -SP2-(TECH) Dosage: 200 gm per bag of cement
12 Protekta -G-(TECH) Dosage: 30-40 sqft
13 Cemwet-WPCC-(ASIAN) Dosage: 150gm/bag of cement
14 TECH-REPEL- WB-(CHOKSEY) Dosage: Dilute 1 litre.with 20 litre.water. *1000 sqft./litre. per
21 litre. Diluted per coat.
15 TECH- FORCE-(CHOKSEY) Dosage: 1-1.5 sqm./kg per coat withstandsnegative w.p. upto 1
kg/csqm, use 1-3 coats
16 POLYMOD -AP-(CHOKSEY) Dosage: 1.1-1.5 sq mtr.of memb-rane will cover 1 sqmtr. Area
17 Aquarepel SN1-(ESSEN) Dosage: 8-10 sqm per litrere
18 POLYDEE-10 TAR POLYMER -(GREENSBORO) Dosage: 0.3-0.5kg/sqm
5 19 Sifumex 100 D-(KRISHNA) Dosage: 1% to 2% by weight of cement.
20 Rheomac 707-(MBT) Dosage: 0.32% v/w of cement
21 Aquaep-(NEELAM) —
22 Multiseal-(NEELAM) Dosage: Depending upon the width & depth of the Sealant
23 OMAIPLAS-AB-(OM) Dosage: 1sqm per kg in 2 coats
24 Roff AEA - 310 (Liquid)-(ROFFE) 120- 280 ml per 50 kg bag of cement
25 POLYDEE-AEA-(GREENSBORO) 1 to 2%
17 Air Entraining Agents (Increases frost resistance, resistant to de-icing of salts, improves workabilitrey and
durabilitrey.)
1 Roff AEA-310 (Liquid) (ROFFE) Dosage: 120-280 ml per 50 kg bag of cement
2 Cemwet-AEA-(ASIAN) Nepthalene based. Dosage: 70-75 m/bag
3 POLYDEE-AEA-(GREENSBORO) Dosage: 1 TO 2%
18 Anti Carbonation Protective Coating on Concrete

a EPOXY BASED (Likely to be adversely affected at high temperatures as well as under UV exposure. High adhesive ,
excellent dimensional stabilitrey, abilitrey to cure dry conditions, good chemical resistance, excellent mechanical
properties.)
1 EPOBOND-AG-(AG) Adhesion under dry and wet condition. Coverage : 0.200 to

0.300 kg per sqm
2 CICO POLYCOTE-(CICO) Resilient and flexible membrane. Coverage : 3 to 4 sqm per kg
Of mixed material which should be used within 30 minutes after
mixing. The coverage depends on the surface textgure of the
surface of application.
3 CICO POLYCOTE 1100-(CICO) No priming, single coat application. For all type of exposed,
buried or immersed concrete and Steel surfaces. Coverage : 2 to
6 sqm per kg of mixed material.
4 CICO POXY NS-(CICO) Applied on dry & cleaned surface over a zinc rich primer coat-
ing.. Coverage : 3-5 sqm/kg Depending on the surface texture.
5 Quickmast 405-(DON) Tar extended epoxy coating. Coverage : 1 kg covers 1.6 to 2
sqm for 2 coats
6 Quickmast 173-(DON) Epoxy primer. Coverage: 4 to 6 sqm per Lt for 2 coats
7 SAFECORE EP (F)-(FAIRMATE) High build solvent epoxy coating over Quickmast 173 primer.
Coverage : 12- 14 sqm.per 5 kg Pack per two coats.
Contd...

8 Waterseal-(KRISHNA) Foodgrade non-toxic coating for water tanks/treatment plants.
Coverage: 5-6 sqm./litre
9 Roff Tuff Coat (Liquid)-(ROFFE) Coverage : 40 sqft per kg
10 SHALIPOXY PB-(STP) Coverage : 4 sqm/kg
11 SHALIPOXY CTE-(STP) Coverage : 5sqm /kg
12 System-I: Araldite GY-250 Aradur-830 Proportion: 100pbw:45pbw:15pbw
Aradur-850-(VANTICO)
13 System-I I: Araldite GY-250 Aradur-2969 Proportion: 100pbw: 60pbw
-(VANTICO)
14 System-I I I Araldite GY-257 Aradur-840 Proportion: 100pbw: 50pbw
-(VANTICO)
15 System-IV Araldite GY-255 Aradur-45 Water impermeable coating/ Coaltar epoxy. Proportion: 100pbw:
-(VANTICO) 100pbw
b ACRYLIC POLYMER BASED Anti Carbonation Coating (Likely to be adversely affected at high temperatures. Used
as an admixture by weight of cement. Very good adhesive , excellent dimensional stabilitrey, good chemical resistance,
protects against corrosion, allows surface to breath).
1 RESIKON 400-(ANUVI) Coverage : 1 : 1 ratio (OPC : RESIKON 400)

2 ACRYCRETE-AG-(AG) Coverage : 4.25 sqm./23kg /3mm THICK
3 CERA Infraguard-S-(CERA) Coverage : 4-5 sqm/kg
5
4 FUTURA- 5-(CHOKSEY) Coverage : 8-9 sqm. per litreer/coat
5 CICO SEALOCOTE-(CICO) Coverage: 4 to 5 sqm per kg In two coats depending on surface
texture.
6 TAPECRETE MARINE COATING-(CICO) One cubic meter of Marine Coating required the following :
Marine coating :446 kg —Portland cement: 858 kg— Fine Silica
sand:858 kg For a 2mm thickness of coating the requirement
will be about 4 kg of the three component of Marine Coating/
per sqmr. The generally applicable thickness ranges from 0.8 to
10mm. The corresponding requirement can be worked out from
the 2mm thickness value.
7 Repcoat-(DON) Coverage: 3.5 to 4sqm per kg for 2 coats
8 WATERGUARD -(FAIRMATE) Coverage: 16.5 sqm. to 25 sqm.
9 Monopol 456-(KRISHNA) Coverage: 4.0 sqm - 6.0 sqm./ litre / coat.
10 Master Seal 550-(MBT) Two component. No site mixing. Flexible upto 5%. Coverage:
1.8 kg per sqm
11 Master seal 300H-(MBT) Flexible. Can bridge crack up to 5 mm. Coverage: 1 to 1.6 litrere
per sqm.
12 OMAICRYL-(OM) Coverage: 3sqm/kg/3coats.
13 ICOSIT ELASTIC (I)-(SIKA) Coverage: 250g/sqm/coat.
14 Protekta Flexstone Coat-(TECH) Water clear transparent. Coverage: 10-15 sqft. depents on the
surface
c SBR BASED Anti Carbonation Coating ( May not be suitable for locations, which are exposed or subjected to high
temperatures. May degrade over long durations.Improves bonding with hardened concrete,reduces cracking , abraison
resistant).
1 BONDCRETE-AG-(AG)
2 Rheomix 141-(MBT) 5-7 kg per bag of cement
d LIGNOSULPHATE BASED (Arrests dust / din accumulation, preserve natural colour, hydrophobic,provides excellent
barrier to carbondioxide chlorides, sulphates and water inside.i) Highly resistant to UV rays and long term weathering.).
1 CICO PEL-W OR SIPEL-(CICO) 6 to 10 sqm per litre, depending on porsity of the sub-stratam.
2 Dekguard S & Dekguard Primer-(FOSROC) 3 sqm/litre
3 BPG-600 -(NEELAM) 200-400 gm./sqm.
e Protective coating on concrete WITH UNDISCLOSED BASE (Advantages/disadvantages cannot be generalised in
absence of the base material of the products)
1 POLYDEE-ADG-(GREENSBORO) Coverage: 0.3-0.5kg/sqm

Contd...

2 Bondfit-8000-(NEELAM) Coverage: 1.2 to 2 sqm./kg/coat

3 TECH-REPEL- WB-(CHOKSEY) Coverage: Dilute 1 litre.with 20 litre.water. *1000 sqft./litre.
per 21 litre. Diluted per coat.
4 POLYDEE-ADG-(GREENSBORO) Coverage: 0.3-0.5kg/sqm
5 SIlitreEX (Colourless liquid Repellent)-(GREENSBORO) Coverage: 200 to 300 gm/sqm only one coat can be applied.
6 OMAIPLAS-AB-(OM) Coverage: 1 sqm per kg in 2 coats
7 OMAICRYL + OMSIPLAS AB-(OM)
19 Protective coat on Steel

a EPOXY BASED Protective coat on Steel (Non-resistant to UV radiation, exposed locations and high tempera-
tures. Protects Steel against corrosion. Zinc rich primer to avoid corrosion. Anti-corrosive, chemical resis-
tant, W/P, good bonding)
1 AMCOR PR-(ANUVI) Should be covered with mortar, concrete or paint for durabilitrey.
Coverage: 16-18 sqm per kg
2 EPOBOND-AG-(AG) Good for dry and wet conditions. Coverage: 0.200 to 0.300 kg
per sq m
3 CERA Zinc ZR (CERA) Zinc rich primer. Coverage: 4-5 sqm/kg
4 CICO POXY FC (CICO) Applied in dry condition after surface cleaning. Coverage 6-8
5 sqm/kg Depends on sub-strate
5 Quickmast 405-(DON) High build tar extended coating. Coverage: 1 kg covers 1.6 to 2
sqm for 2 coats
6 Quickmast 471-(DON) High build solvent epoxy coating.needs Quickmast173 primer.
Coverage: 1 kg covers 1.6 to 2 sqm for 2 coats
7 Procoat SNZ-(ESSEN) Good for marine environment. Coverage: 6 - 10 sqm per litre
8 SAFECORE EP (S)-(FAIRMATE) Coverage: 12 - 14 sqm. per 5 kg Pack per two coats DFT: 175
microns.
9 Corroseal ZR - (KRISHNA) Coverage: 3 - 5 sqm / litre on level surface.
10 MC DUR ZKE-(MC) Coverage: Approx. 100-300 gm/sqm
11 MC DUR ZKE-(MC) Approx. 100-300 gm/sqm
12 Roff Pitch Coat (Liquid) (ROFFE) Coverage: 20 sqft per litre
13 SHALIPOXY PB-(STP) Coverage: 4 sqm/kg
14 SHALIPOXY CTE-(STP) Coverage: 5sqm /kg
b ACRYLIC POLYMER BASED Protecting coat on Steel (Likely to be adversely affected at high temperatures. Used as
an admixture by weight of cement. Seals the surface against humidity, carbonation & corrosive atmosphere Excellent
breathabilitrey Fills pores, honeycombs and voids to give uniform surface)
1 ACRYCRETE-AG- (AG) Coverage: 4.25 sqm./23kg /3mm THICK

2 FLEXCRETE-AG -(AG) Coverage: 2.5 TO 3.0kg/ sqm/1.5 TO 2 mm
3 TAPECRETE MARINE COATING- (CICO) One cubic meter of Marine Coating required the following :
Marine coating :446 kg Portland cement: 858 kg Fine Silica
sand:858 kg For a 2mm thickness of coating the requirement
will be about 4 kg of the three component of Marine Coating/
per sqmr. The generally applicable thickness ranges from 0.8 to
10mm. The corresponding requirement can be worked out from
the 2mm thickness value.
c WITH UNDISCLOSED BASE Protective coat on Steel (Advantages/disadvantages cannot be generalised in absence of
the base material of the products)
1 POLYDEE -RC -(GREENSBORO) Coverage: 80 to 150 ml/sqm

2 SUPER-SIL - (NATIONAL) Coverage: One kg covers 35-40 square feet. On primer coat of
white cement
3 NICON-(NATIONAL) Coverage: One kg covers 250 square feet.
4 Cinter Flux-20(NEELAM) Coverage: 0.5 kg/sqm./coat
5 DERUSTER-(OM) Coverage: 10 sqm/kg/coat.
Contd...

6 OMAISOL-(OM) Coverage: 10 sqm/kg/coat.
7 OMAI ANTI-CORR-(OM) Coverage: 8 sqm/kg
8 NR-900-(ASIAN) Coverage: 10kg/cum of conc.
9 POLYDEE-10 TAR POLYMER-(GREENSBORO) Coverage: 0.3-0.5kg/sqm
20 Acid Resistane Enhancer

a EPOXY BASED Acid Resistane Enhancer (Acid resistant coating for concrete and Steel (Non-resistant to UV
radiation)*Excellent bonding and adhesion under dry and wet conditions both. Outstanding chemical resistance such as
sulphuric acid, methyl, ethyl, ketones and methanol etc.)
1 EPOBOND-AG-(AG) 0.200 to 0.300 kg per sq m

2 TECH FLOOR SL - 2-(CHOKSEY) 0.25 -0.30 sqmr./kg mix with 2 mm.thickness
3 Quickmast 401-(DON) 1 kg covers 1.4 to 1.8 sqm. for 2 coats
4 Quickmast 402AR-(DON) 1 kg covers 1.4 to 1.8 sqm. for 2 coats
5 SAFECORE UlitreACOAT-(FAIRMATE) 9 -10 sqm. per 5 kg pack for two coats.DFT:400-500 microns
6 Nitomortar S-(FOSROC) 8 litre yield per 16 kg pack
7 Top Cinter-48 Epoxy-(NEELAM) 200 gm./sqm./coat
8 Roff Tuff Coat-HD (Liquid)-(ROFFE) 20 sqft per litre
9 SHALIPOXY FC-(STP) 250gm /sqm
10 SHALIPOXY ARC-(STP) 4 sqm/kg 5
b WITH UNDISCLOSED BASE Acid Resistane Enhancer (Anti corrosive,100 % Inorganicpaint,non fading,insulating
property,permits breathing,anti fungus and algae. reflects Infrared and Ulitreaviolet rays, water proofing characteristics)
1 POLYDEE-ADG-(GREENSBORO) 0.3-0.5kg/sqm
2 SUPER-SIL-(NATIONAL) One kg covers 35-40 square feet. On primer coat of white ce-
ment
3 EUCON CIA-(STP) 1.6% bwoc
4 Accidet-X-(ASIAN) 16 litre liquid in50kg powder
5 POLYDEE-ADG-(GREENSBORO) 0.3-0.5kg/sqm
21 Anchoring
a EPOXY BASED Anchoring
1 CICO POXY EW-N-(CICO) Density : 1.10 kg/litre. Consumption rate depends on the inter-
nal condition of the structure.
2 CICO POXY EW 1000-(CICO) Depends upon the area to be sealed.
3 CICO RESIFIX-(CICO) The number of capsules to be used is dependent on the pull out
force. The capsules are manufactured in wide range of diameter
between 25 to 40 mm and in 3 different lengths. The borehole
diameter is about 8mm bigger than the anchor bolt diameter. In
general, for 12 t pullout force, 3x30mm dia x 300mm length
capsules are sufficient.
4 GROUTFAST-(GREENSBORO) 1950 kg/cum.
5 E 3 G-(STP) —
6 Lokset L / S / P-(FOSROC) Yield per 5 kg pack is 2.5 litres
7 CICO GROUT GP-(CICO) Yield : 1800-2000 kg of dry powder grout mix per cum. of grout
depending on flowabilitrey requirement and gap.
8 CICO FAST/ NORMAL SETTING HIGH The capsules are manufactured in variable length and diameter
STRENGTH CEMENT CAPSULES-(CICO) depending on customer’s demand. The number of capsules to be
used depends on the length of embeddment of the the anchor
bolts which in turn depends on the design pull out force. The
diameter of the bore hole is about 10-12 mm more than the
diameter of anchor bolitre
9 ANCHORGROUT-(FAIRMATE)
10 Rockset-(ASIAN) 32mmX300mm length
11 Roff Grout -GP (Powder)-(ROFFE) 0.028 m3 per 50 kf bag of cement
Contd...

Appendix 5.2
List of Material Manufacturers / Suppliers & their Addresses
Sl No. Abreviated Name of Manufacturer/ Dealer City PIN Phone Fax

Name No. No.
1 AG A.G. Devlopers Private Limited, B-283, 1st Floor, NEW DELHI 110034 7014140, 7028293
Saraswati Vihar, Delhi-110034, 7022213
Emai: [email protected]
2 ANUVI Anuvi Chemical Private Ltd.G-212, Godavari, Iind Floor, THANE 406606 022- 022-
Laxmi Industrial Premises, Pokharan Road No. 1, 5392219(O) 5392461
Vartak Nagar, Tane-406606, maharastra, India
3 ASIAN Asian Laboratories India, 88, New Okhla Indl. Complex, NEW DELHI 110020 6918093, 6316063
Scheme 1,DSIDC shed, Phase II,New Delhi 6836392
email: [email protected]
4 CERA Cera-Chemical Pvt. Ltd., CHENNAI 600002 6453498, 044-

71-C New Avadi Road, Kilpauk, Chennai-2 6441013 6446104
e-mail:[email protected], web:www.cerachemindia.com
5 CHEMLINE Chemline India Limited. (Construction Chemical Divn.) NEW DELHI 110085 11- 011-
F-1, Sarda chamber-ICentral Market, Prashant 7864419/20, 7566966,
5 Vihar Rohini, DELHI - 110 085 (INDIA ) 7566965, 7862992
e-mail:[email protected] 7871304
6 CHOKSEY Choksey Chemical Pvt.Ltd., 111-Industrial Area, MUMBAI 400022 4090124, 22-
Sion, Mumbai-400022. 4040127, 4072949
[email protected] 4090325
http//www.chockseychem.com.
7 CICO CICO Technologies Limited, A- 9 Chitranjan NEW DELHI 110019 6420544, 6221055,
Park (LGF), Outer Ring Road, New Delhi-110019, 6235335 6489365
Email: [email protected],
Web site: www.cicogroup.com
8 DON Don Construction Chemical India Ltd., No. 4, CHENNAI 600035 4331817, 044-
II Block Chowdhary Complex, 5th Street, 4335345 4338272
Nandanam Extension, Chennai-600035.
Email dccil@ vsnl.com , utechindia @epatra.com
9 ENEM Enem Polymers, 8, Sanket Colony, Vedant Nagari, PUNE 411 052 020- 020-
Karvenagar, Pune 5461501 5431189
email - [email protected]
10 ESSEN Essen SUPPLEMENTS India Ltd, Plot No. 35, SECUND- 500026 040- 7808889
Samrat Colony, West Marredpally, Secunderabad-26. RABAD 7700300,
11 FAIRMATE FAIRMATE Chemical Pvt Limited, 8/1, SAI Sudha, VADODRA 390007 0265- 0265-
Arunoday Society, Alkapuri, Vadodra-390007, 331193, 338733
Email: [email protected], 330803
Web Site: www.faimate.com
12 FOSROC Fosroc Chemicals (India) Limited , Hafeeza Chambers, BANGLORE 560027 (080) (080)
II floor, 111/74,K.H.Road, Banglore-560027 2225495, 2233474
e mail: [email protected] 2240018,
Web site: www.fosrocindia.com 2240120
13 GREENBOROGreensboro Polychem Private Ltd. 199,

Defence Colony Flyover Market, New Delhi-110024, NEW DELHI 110024 4329335, 11-
email:[email protected], [email protected] 4316209, 4319123
Website www.123polydee.com www.buildingclinic.com 4319123
Contd...


Name No. No.
14 JB J. B. Associates, Construction Chemical Company, NEW DELHI 110003 4625997, 4618346

135 Arjun nagr, Kotla Muarakpur, Opp. Defence Colony, 4632541
New Delhi-110003, email: [email protected],
web site:www.ashfordformula.com
15 KRISHNA Krishna Conchem Products Pvt. Ltd. 1 & 2, Bldg No.6, MUMBAI 400 705 022- 022-
Sector No.3, M.B.P Mahape, Navi Mumbai. 772923/24 7782808
email: [email protected], Web site:
www.krishnaconchem.com
16 MBT MBT India, 704, Krishna Govinda Towers, Sector-4, MUMBAI 400703 022- 022-
Sanpada, Navi Mumbai, 400703, 619992/3, 7619242,
email: [email protected], 011- 011-
Web: www.mbt-india.com , 5819390, 5819391
Master Builders technology (MBT) India Pvt. Ltd, 5825540
1403, Vikram tower, 14th Floor, 16 Rajendra Place,
New Delhi-110008 email [email protected]
17 MC MC. Bauchemi (India) Pvt.Ltd., 201, Vardhaman MUMBAI 400703 7893867, 7845265,
Chambers Sectors-17, Vashi, Navi Mumbai-400703, 7895231, 7843870.
Email [email protected], 7842827, 5
www.mc-bauchemieindia.com 7893876.
18 NATIONAL National Industries Company, 432, Naigaun Cross road, I MUMBAI 400031 022- 022-
st Floor, Wadala, Mumbai-email: [email protected] 4121176 4148196
19 OM Om Agro industrial Plastics Pvt.Ltd. MUMBAI 400093 820 28 75 91-22-422

OM AGRO INDUSTRIAL PLASTICS PVT.LTD., 820 85 41, 94 82
6, Sarvodaya Industrial Estate, 823 00 31
Mahakali Caves Road, Andheri (East),
MUMBAI - 400 093.
E-mail : [email protected]
E-mail : [email protected]
20 PIDILITE Pidilite Industries Ltd, Ramakrishna Mandir Road, MUMBAI 400059 8357560,
PB No. 17411, Andheri East, Mumbai-59, 8357534,
Web sitewww.pidilite.com 8357527
E mail [email protected]
21 ROFFE Roffe Construction Chemical Pvt.Ltd., 45/A, MUMBAI 400021 022- 022-
Mittal Tower, Nariman Point, Mumbai-400021 2040264, 2042254,
[email protected] www.roffe-in.com. 6132434, 6116057
22 SIKA Sika Qualcrete Ltd, 620, Diamond Harbour Road, KOLKATA 700034 4466594 033-
Commercial Complex-II, Kolkata-700034, 4466958, 468-8688/
(An ISO 9001 Company) 4472448 2665
Email [email protected]
Web site: www.sikaqualcrete.com
23 STP STP Limited, (speciality Chemicals & Additive Division, MUMBAI 400023 022- 022-
16, NGN Vaidya Marg ( Bank Street), 2664643/ 2663599
Fort mumbai-400023 2313/1407
email: [email protected],
www.stpltd.comSTP Limited, Plot No.M6-M9, Cuncolim
Indl.Estate, Cuncolim, Salcete, Goa-403 703, Ph 403703
24 SUNANDA Sunanda Speciality Coating Pvt Limited, MUMBAI 400016 022- 022-
2, Anik Court Pandurang Naik Marg , Mahim, Mumbai-16 4464870, 4456050
Email: [email protected], 4459251
Web site: www.sunandchemcals.com
Contd...


Name No. No.
25 TECH Tech-Dry (India) Private limited, 769, Ground Floor, BANGLORE 560038 5255406, 5289159
Ist Cross, 1st Stage, Indiranagar, Bangalore-560038, 5255294
Email [email protected]
26 VANTICO Vantico Performance Polymer Pvt. Ltd. MUMBAI 400063 022- 011-
Off Aarey Road, Goregaon (E), 8403221 5734745
Mumbai-400063. Ph: 022-8403221 ,
307 , Padma Tower-II, Rajendra Place, New Delhi-110008.
27 NEELAM Neelam Building Protection System Ltd., SCO 861, Chandigarh 160101 0172- 734301
Chandigarh-Kalka Road, Manimajra (Chandigarh)-, 734469,
Tel Fax: E-mail: [email protected],Contact person :

Appendix 5.3
List of Material Testing Laboratories

1 National Chemical Laboratory, Poona
2 National Test House, Alipore, Kolkata
3 National Test House, Chennai
4 Central Building Research Institute (CBRI), Roorkee, U.P.
5 Nation Council of Cement and Building Materials, 34 Km Mathura Road, Ballabhgarh,
Faridabad, Harayana
6 Central Soil and Material Research Station (CSMRS), Hauzkhas, New Delhi
7 Structural Engineering Research Centre, P.O. Taramani, CSIR Campus, Chennai
8 Indian Institute of Chemical Technology, Hydrabad
9 Indian Istitute of Technology, Guwahati
10 Indian Istitute of Technology, New Delhi
5
11 Indian Istitute of Technology, Roorkee
12 Indian Istitute of Technology, Kharagpur
13 Indian Istitute of Technology, Mumbai
14 Indian Istitute of Technology, Chennai
15 Indian Istitute of Technology, kanpur
16 Indian Istitute of Technology, Varanasi
17 Shri Ram Institute of Industrial Research(Pvt) , 19, University Road, Delhi-110007,E-mail:
delhi. [email protected] Web Site: [email protected]
18 Structural Designers & Consultants Pvt.Ltd. 1008/9, 10th Floor, Raheja centre, Nariman
Point, Mumbai-400021. Tel: 2833506 (5lines) Fax: 91-22-287 59 85 Gram:STRUCTWEL
E-Mail: [email protected] Web:http://www.structwel, com.
19 AIMIL LTD (pvt), Mathura Road, New Delhi. Ph:6950012; 6950001-09, Fax: 6950011

CHAPTER 6
REHABILITATION AND RETROFITTING METHODS

PAGE NO.
6.1 General VI-1

6.2 Repair Options VI-1
6.3 Performance Requirements of Repair Systems VI-2
6.4 Important factors to be considered for selection of repair methods. VI-2
6.5 Repair Stages VI-2
6.5.1 Concrete Removal and Surface preparation VI-2
6.5.2 Form work VI-3
6.5.3 Apply Bonding Coat and Repair Application VI-4
6.6 Repair Methods VI-4
6.6.1 Repairs using Mortars VI-4
6.6.1.1 Portland Cement Mortars VI-4
6.6.1.2 Polymer Modified Cement Mortars VI-5
6.6.1.3 Epoxy Mortars VI-5
6.6.2 Dry Pack and Epoxy Bonded Dry Pack VI-5
6.6.3 Pre-placed Aggretage Concrete (PAC) VI-6
6.6.4 Shotcrete VI-7
6.6.5 Concrete Replacement VI-9
6.6.6 Epoxy Bonded Concrete VI-9
6.6.7 Silica Fume Concrete VI-9
6.6.8 Polymer Concrete System VI-9
6.6.9 Strengthening concrete by Surface impregnation using
Vacuum Methods VI-9
6.6.10 Thin Polymer Overlays VI-11
6.6.11 Thin Epoxy Overlay VI-11
Contd...
(i)
(ii)
PAGE NO.
6.6.12 Resin/Polymer modified Cement Slurry injection VI-11
6.6.13 Protective Seal Coats on the Entire Surface VI-11
6.6.14 Ferro-cement VI-12
6.6.15 Plate bonding VI-12
6.6.16 RCC Jacketing VI-13
6.6.17 Propping and Supporting VI-15
6.6.18 Fibre Wrap Technique VI-15
6.6.19 Foundation Rehabilitation Methods VI-17
6.6.20 Chemcial and Electro-chemical Methods of Repair VI-18
6.7 Repair/Rehabilitation Strategies VI-23
6.7.1 Stress Reduction VI-23
6.7.2 Repair/Strengthening Column,s Beams and slabs VI-23
6.7.3 Compressive Strength of Concrete VI-26
6.7.4 Cracks/Joints VI-26
6.7.5 Masonry VI-26
6.7.6 Protection VI-28
6.7.7 Foundation VI-28
6.7.8 Base Isolation VI-28
Appendix 6.1 VI-30
Appendix 6.2 VI-35
Appendix 6.3 VI-37
6
Concepts are extremely useful... but concepts change and change very fast. What remains are the facts, the
experimental facts.
..Imre Lakatos
6.1 General:
The decision to repair or replace a structure or its component can be taken only after
consideration of likely service life of the structure is established based on the technical
& economic evaluations. Once a decision, based on preliminary investigations, is taken
to carry out the repairs, proper diagnosis, identification & extent of distress in structural
members has to be correctly assessed. A detailed methodology should be developed,
which should include available
l Methods of repair &
6
l Repair materials
Thus, a repair strategy can be adopted, keeping the objective in view. This shall be
based on evaluation and available alternative methods of repair & material. Priority
should be assigned to
l Repair of structural defects to ensure safety of the structure and
l Protection of the structure from further deterioration.
The selected method of repair should achieve one or more of the following objectives:
l Reinstate the structural integrity of the member by restoring or increasing its
strength & stiffness.
l Prevent the ingress of distress promoting agents such as moisture, chlorides and
carbon dioxide to improve durability.
l Maintaining the aesthetics/appearance of concrete surface.
6.2 Repair Options:

Depending upon the specific condition of deteriorated structure, the option of the repair
methods could be one or more of the following:
l Grouting & crack repair
l Patch Repair
l Replacement of structurally weak concrete
l Replacement of spalled, and/or delaminated concrete
l Replacement of carbonated concrete surrounding steel reinforcement
l Cleaning and passivating the corroded steel reinforcement
l Concrete overlays with normal, low or highly fluid concrete, latex modified
concrete & corrosion protection such as jacketing etc.
Central Design Organisation VI-1
l Re-alkalisation of carbonated concrete.

l Electro-chemical removal of chloride from concrete
l Water proofing and/or protective coating.
6.3 Performance Requirements of Repair Systems

l Strength, Serviceability and Durability
l Protection of steel
l Bond with parent surfaxce
l Dimensional stability
l Resistance to environmentally induced damage.
l Ease of application
l Appearance
6.4 Important factors to be considered for selection of repair methods:

l Type and extent of distress
l Location of distress
l Environmental exposure
l Availability of skill
l Availability of time and access for repairs.
l Appearance
6
l Cost
6.5 Repair Stages

l Concrete Removal and Surface Preparation
l Fixing suitable formwork
l Bonding / passivating coat and repair application
6.5.1 Concrete Removal and Surface preparation

The general procedure for marking area to prepare the surface of spalled area for
carrying out repairs is illustrated in Fig 6.1.
BOUNDARY OF LOOSE AND RECOMMENDED LAYOUT

DELAMINATED CONCRETE
Fig 6.1 Recommended Layout of Surface Repairs
VI-2 Repairs & Rehabilitation Unit

Prior to preparation of concrete surfaces, exposed reinforcement should be inspected for

access clearance, cross-sectional area and location. Reinforcing bars must be further exposed
if the remaining concrete is de-bonded from the reinforcing steel. Removal must be continued
to completely expose the bar if more than half of a reinforcing bar perimeter has been exposed.
For completely exposed reinforcing bars, a minimum average clearance of 25 mm or nominal
maximum size of aggregate plus 5mm, whichever is greater, must be provided between the
reinforcing bar and surrounding concrete. A structural engineer should be consulted if the
cross-sectional area of an individual bar has been reduced by 15 percent or more or if two
adjacent bars have been reduced by 10 percent or more. Out-of-plane and loose reinforcement
should be secured in its design location.
The process of Surface preparation is illustrated stepwise (Step 1 to 3) in Fig 6.16. The
general procedure in preparing concrete and reinforcement surfaces for optimum
bonding is to sandblast the surfaces and then remove dust and debris by air blasting,
low-pressure water blasting, or brooming. If the damage is due to corrosion, a suitable
coating may be considered after removal of total rust from its surface to protect the
exposed reinforcing steel. Final inspection of the prepared area including remedying
any deficiencies should be completed just prior to batching the repair material.
6.5.2 Form work

If repairs are required on vertical or overhead surfaces and if the repair material is 6
likely to sag, formwork will be required. Prior to installing forms, the concrete surface
must be inspected for any surface contours that could result in air being trapped during
concrete placement or pumping. If air is likely to get trapped, concrete must be removed
to change the contour, or vent tubes must be installed. Formwork should be secured to
the concrete with expansion anchors of standard makes etc. Installed form anchors
should be pre-tested for slippage. Preformed foam gaskets or cast-in-place foam may
be required to provide a watertight seal between the concrete and form
surfaces (Fig 6.2).
TASLA
VENT TUBE TO REMOVE

TRAPPED AIR CONCRETE IS PLACED
THROUGH LETTER-BOX
ENTRY EXPANSION ANCHORS SURFACE CONTOURS TO
TRAPPED AIR
TIMBER OR STEEL FORM ENSURE NON-ENTRAPMENT
OF AIR
OUTLET FOR
FORM WORK TRAPPED AIR
PACKED DRY AGGREGATE

FRESH CONCRETE
INLET FOR REPAIR
MORTAR
RCC COLUMN FORM WORK SCREWED

WITH EXPANSION
ANCHORS
(a) VENT TUBE FOR TRAPPED AIR PACKING WITH PREFORMED
FOAM JACKETS OR
CAST-IN-PLACE FOAM
(b) REMODELLING OF SURFACE CONTOURS OF CONCRETE

TO ENSURE NON-ENTRAPMENT OF AIR
Fig 6.2 Form Work
Central Designs Organisation VI-3

6.5.3 Apply Bonding Coat and Repair Application:

These shall be carried out as per the repair method/system selected based on engineering
judgment considering various options available as under:
l Filling of cracks with cement and/or resin based grout
l Injecting grout into a mass of dry aggregate.
l Poured concrete
l Pre-packed concrete
l Dry packing
l Sprayed concrete (shotcrete), etc
Repair and Strengthening Methods/Systems be in three groups
l Materials
l Methods
l Systems
The repair materials have been separately dealt in Chapter-5. Repair methods and repair
systems are described herein below:
6.6 Repair Methods:

The various repair methods are available for carrying out the structural repairs to a
6 distressed structure. The basic methods, which could be used singly or in combination
of more than one are briefly described in the following subsections. For detailed
specifications and stepwise sequence of operations, Chapters 8 and 9 and relevant
references given at the end of this chapter could be referred.:
6.6.1 Repairs using Mortars:

Mortar repairs are the most common form of repairs being resorted to in the field
without knowing the limitations of such repairs in structural rehabilitation/strengthening.
A variety of mortars are available for carrying out repairs of a structure, these are
explained with their limitations and areas of application in the following subsections:
6.6.1.1 Portland Cement Mortars: Structural repairs with Portland cement mortar shall be
made only if specifically approved by the Engineer-in-charge. Approval for hand-
applied cement mortar repairs will be given only for very small repair areas, not
associated with critical performance of the structure. When approved, Portland cement
mortar may be used for repairing defects on exposed, new concrete surfaces only.
Such repairs are applied only if the defects are small and are too wide for dry pack and
too shallow for concrete replacement and only if the repairs can be completed within
24 hours of removing the forms. Portland cement mortar shall not be used for repairs
to old or existing concrete or for repairs that extend to or below the first layer of
reinforcing steel.
Portland cement Mortar shall consist of Ordinary Portland Cement Grade 43, clean
water and clean graded sand. The proportion of Portland cement and sand shall
preferably be in the same proportion as used in preparation of parent concrete. All
materials of mortar mixtures and their application techniques shall be in accordance
with relevant specifications.
6.6.1.2 Polymer Modified Cement Mortars are used for repairs on old hardened concrete for
repairing defects on exposed concrete surface only. For larger repair areas with thickness
in excess of 50 mm, concrete, as repair material, is a better option. For thicker
applications, over larger areas, it is desirable to use appropriate reinforcing mesh fixed
with U-nails. These shall use Polymers admixed in specified proportions, based on
selection criterion given in Chapter 5. Other materials shall be same as in Portland
Cement Mortars stated above. However, these shall follow the given relevant
specifications, if specified.
6.6.1.3 Epoxy Mortars: These mortars consist of resin, hardener and silica sand and are applied
over an epoxy bonding coat over old hardened concrete surface.. These mortars attain
strength in few hours. These mortars have very high strength and are abrasion resistant,
water resistant and can be used in few millimeter thickness overlays. These are used
for repairs at locations where
l It is difficult to use epoxy bonded concrete,
l Depth of repair is less than 40 mm or
l Repair areas are small (less than 0.1 sqm) and few in number.
When depth of repair exceeds 15 mm but is less than 40 mm, the build up of patch
repair over large areas shall be in layers using appropriate reinforcing mesh fixed with
U-nails or shear keys. 6
6.6.2 Dry Pack and Epoxy Bonded Dry Pack:

The Dry Pack Repair technique is application of dry cement sand mix . It consists of
cement and clean sand (in proportion 1:2.5) with just enough water to be able to form
a ball by hand. It is immediately packed into place before the bond coat has dried or
cured, with suitably shaped hardwood dowel and hammer in 8 to 10 mm thick layers
(Refer Fig 6.3).
DRY PACK MATERIAL PLACED IN LAYERS
HARD WOOD
RESTRAINING FORMWORK HAMMER USED TO

COMPACT DRYPACK
MATERIAL
DRYPACK MATERIAL SHOULD

BE DRY BUT COHESIVE ENOUGH
TO BE FORMED INTO A BALL.
Fig 6.3 Dry Packing

If the epoxy is used as bonding material between the repair material and the substrate,
the method is termed as Epoxy Bonded Dry Pack. Its application shall be limited to
areas that are small in width and relatively deep but not less than 25 mm in depth..
The application areas include core holes, holes left by removal of form-ties,
cone-bolts, she bolt holes, narrow slits for critical repairs or for repairs expected to be
exposed to severe service conditions. Dry pack shall neither be used for shallow
depressions where lateral restraint cannot be obtained nor for filling behind steel
reinforcement.
6.6.3 Pre-Placed Aggregate Concrete (PAC):

Pre-placed aggregate concrete (PAC) is concrete that is made by forcing grout into the
voids of a mass of clean, graded coarse aggregate densely pre-packed in formwork
(Refer Fig 6.4). PAC is used where placing conventional concrete is extremely difficult,
such as where massive reinforcing steel and embedded items are present, in underwater
repairs, concrete and masonry repair, or where shrinkage of concrete must be kept to a
minimum.
For the purpose of this repair method, grout typically consists of sand, cement,
pozzolana, plasticiser/ super-plasticiser and an air entraining agent (for anticipated
freeze & thaw problem, if required). The pozzolana and the plasticiser/super plasticiser
6 are used to impart flowability to the grout. The coarse aggregate is washed to remove
all fines and screened just prior to placement. Grout is then injected through forms to
provide the cementing matrix. Grouting is begun at the bottom of the pre-placed
aggregate.
Characteristics of the grout are affected by the water content, sand grading, cement,
pozzolana and the types & amount of admixtures. For each design of grout mixture,
CEMENT GROUT IS PUMPED IN

THROUGH THE INJECTION TUBES
INJECTION TUBES
WITHDRAWN AS GROUT
RISES
WALL FORMWORK WITH
RAKING SUPPORTS
COARSE AGGREGATE PLACED DRY
EXISTING RETAINING WALL
FOUNDATION
Fig 6.4(a) Preplaced Aggregate Concrete Repair to Concrete Wall

REINORCEMENT
OVERLOW VENT
GAP GRADED
AGGREGATE INLET FOR GROUTING
STEP-1 STEP-2
GAP GRADED AGGREGATE WASHED,FREE OF FINES FORMS ARE FITTED WITH PIPES AND NIPPLES
AND BOND-INHIBITING MATERIALS ARE PLACED IN AND VALVES FOR PLACEMENT OF GROUT.
CAVITY.
OVERLOW VENT
INLET FOR GROUTING

FLOWABLE GROUT IS MIXED
AND PLACED INTO PUMP.
PUMP
STEP-3
FLOWABLE GROUT IS MIXED AND PUMPED INTO STEP-4
FORAMED CAVITY, FILLING SPACE BETWEEN AGGREGATE. FORMS ARE REMOVED AND SURFACE IS FINISHED
6
Fig 6.4(b) Preplaced Aggregate Concreting
there are optimum amounts of fillers and admixtures to produce the best pumpability or
consistency. Proper proportioning for the structural grout mix components is necessary to get
the required strength and durability of the finished pre-placed aggregate concrete. Trial mix
design is necessary for each job.
In underwater repair, injection of grout at the bottom of the PAC displaces water, leaving a
homogenous mass of concrete with minimum of paste wash out. In such applications, addition
of anti wash admixtures minimizes the paste wash out. For underwater PAC, the quality of
underwater should also be tested to determine its influence on PAC over a period of time for
taking appropriate corrective action.
6.6.4 Shotcrete
Shotcrete is defined as pneumatically applied concrete or mortar placed directly on to a
surface. The shotcrete shall be placed by either the dry mix or wet mix process.
The dry mix process (Fig 6.5) shall consist of
l Thoroughly mixing the dry materials,
l Feeding of these materials into mechanical feeder or gun,
l Carrying the materials by compressed air through a hose to a special nozzle,
l Introducing water at nozzle point and intimately mixing it with other ingredients
at the nozzle;
l Jetting the mixture from the nozzle at high velocity on to the surface to receive
the shotcrete.
COMPRESSED AIR IS USED TO

CONVEY REPAIR MATERIAL THROUGH
HOSE
BLENDED DRY (OR DAMP)

REPAIR MATERIAL IS
DEPOSITED INTO PUMP
INTO SHORTCRETE MACHINE
PUMP
NOZZLE
WATER
Fig 6.5 Dry Mix Shortcrete
The wet-mix process (Fig 6.6) shall consist of

l Thoroughly mixing all the ingredients with the exception of the accelerating
6 admixture, if used;
l Feeding the mixture into the delivery equipment;
l Delivering the mixture by positive displacement or compressed air to the nozzle;
l Jetting the mixture from the nozzle at high velocity on to the surface to receive
the shotcrete.
If specified, fibres of steel, poly propylene or other material, as may be specified,
could also be used together with the admixtures to modify the structural properties of
the concrete/mortar being placed in position.
COMPRESSED AIR IS ADDED TO

PROPELL THE MATERIAL OUT OF
THE NOZZLE
MIXED MATERIAL IS
PLACED INTO PUMP
NOZZLE
Fig 6.6 Wet Mix Shortcrete

6.6.5 Concrete Replacement:

It should be used on areas of damaged or unacceptable concrete greater than 0.1 sqm.
having a depth greater than 150 mm or a depth extending 25 mm below or behind the
back-side of reinforcement. Concrete replacement shall also be used for holes extending
entirely through concrete sections and for longer areas of repair greater than 100 mm
in depth when the concrete to be repaired is less than 7 days old. Epoxy bonding
agents, latex bonding agents, dry neat cement, cement paste or cement and sand mortar
shall not be used to bond, fresh concrete to concrete being repaired by this method.
6.6.6 Epoxy Bonded Concrete:
It is defined as freshly mixed portland cement concrete that is placed over epoxy resin
bond coat on existing hardened concrete. This method should be used when the depth
of repair is 40 mm or greater. It will be necessary to provide suitable reinforcement as
per design requirement. In addition, epoxy bonded shear keys may also be used for
shear transfer through the interface.
6.6.7 Silica Fume Concrete:
Silica fume concrete is a portland cement concrete with silica fumes used as an effective
Pozzolana material in quantities not exceeding 10% by weight of cement. The mix
shall invariably involve use of super-plasticisers. It may be used where a high strength
6
repair concrete of low permeability is the requirement. If the depth of repair is at least
50 mm but less than 150 mm, epoxy-bonding agent to bond fresh silica fume concrete
to parent concrete shall be used.
6.6.8 Polymer Concrete System:
Methyl Methacrylate (MMA) and Vinyl Ester Resin are commonly used polymer
systems. These materials may be used for patches, overlays, grout pads, and embedment
of slits, gates, and similar structures in concrete members. This system generally consist
of
l 100% reactive monomer or resin system (only reactive solvents are permitted),
l Inhibitors to prevent premature polymerization of the resin or monomer system,
which are normally added to the monomer by the acrylic manufacturers and require
no site mixing, whatsoever.
l Promoter in very small quantity to decrease decomposition rate of the initiator
l The initiator to initiate polymerisation process. Its quantity is directly proportional
to the rate of curing of the polymer concrete.
l Aggregates
l A compatible primer to be applied to the surface of concrete to be repaired.
The physical properties (e.g. compressive, tensile, flexural strength and modulus of
elasticity) of cured repair materials so produced are very high.
6.6.9 Strengthening concrete by Surface impregnation using Vacuum Methods :
The surface impregnation is based upon first creating a partial vacuum within the
concrete and then introducing a repair material i.e. the resin of very low viscosity into
the cracks, voids, micro cracks and capillary system. The resin so impregnated fills the

cracks, including micro cracks down to a width of 5 microns. Upon curing, the repair resin
bonds the fractured and fissured matrix into a monolithic structural member of exceedingly
high strength. Partial vacuum creation and introduction of repair resin are achieved by
maintaining vacuum with the porting devices in the fracture or surface being repaired, connected
to the vacuum source. The partial vacuum pressures are, thus, applied to the enclosed system.
The repair resins are introduced, while maintaining the negative pressures, to fill the major
cracks, interconnected cracks & voids and micro cracks. The concrete matrix, including the
voids within fracture, is impregnated with the repair resin materials. This method can also be
made applicable to stone or masonry structures.
The advantage lies in moisture evacuation along with any deleterious gases and/or materials
from the concrete matrix of the fracture wall surfaces. The concrete drying process can be
monitored by using in-line hydrometers installed in the special vacuum tubing.
The vacuum process offers the following advantages over pressure injection methods.
l Repairs can be completed in a relatively shorter period of time with no sacrifice to the
quality of the repair.
l Repairs could be cost effective.
l Efficient and complete filling of existing fractures, interconnected fractures and
voids and the complete filling of micro fractures.
l Total absence of pressure pockets ensures and facilitates deeper fill of repair resin.
6 l Evacuation of moisture from the interior concrete matrix of the fracture.
l No possible extenuation of the damage due to absence of applied pressures.
l Ability to introduce ultra – low viscosity materials into the fracture areas.
l Improved bonding due to lack of air bubbles normally associated with low
viscosity, low specific gravity repair resins.
l Continued corrosion of reinforcement would be significantly diminished because
of the evacuation of, and sealing out of moisture from the treated concrete matrix.
A. Using Methyl Methacrylate (MMA)
In the vacuum system, the requirement is of impregnating concrete with a Methyl
Methacrylate (MMA) based monomer catalyst system followed by in-situ
polymerization of the monomer by heat. MMA is low viscosity high strength
material suitable for vacuum injection processes. Its viscosity is 5-15 cps with
superior physical properties, flexibility and superior bonding and wetting
properties.
B. Using Expanding Vinyl Ester Gel
These are low viscosity gels, which are water-soluble acrylic monomers. The gel
is used for injection and sealing of joints and cracks against water leaks. Due to
its ultra low viscosity, it has a very low flow resistance and is able to permeate
into the smallest hairline cracks and capillaries. Thus, it seals them reliably and
permanently. When it contact with water, it swells to double its volume while
retaining its shape. This process is purely physical and reversible. As a result of
this unique property, the material will retain its self healing property even when
in a dry condition.
These processes involve unique materials and hence need specialist advice and close supervision
in their field applications.
6.6.10 Thin Polymer Overlays:

Thin polymer overlays are used to improve the abrasion resistance and for creating
waterproofing barriers on the surface and act as protective coatings. These are applied
in less than 10 mm thickness. It is quite suitable for improving surface characteristics
and also it acts as protective coating. It generally comprises of
1 One coat of primer and
2 One or more coats of sealant.
The primer coat shall consist of vinyl ester resin, initiator and promoter. Each coat of
sealant shall consist of the same material as in the primer but with the addition of silica
filler, titanium dioxide pigment and carbon black pigment.
6.6.11 Thin Epoxy Overlay:
These are used to improve the abrasion resistance of surface and for creating
waterproofing/protective coating. Thin epoxy overlays are applied in 2 to 3 mm
thickness. It generally comprises of resin and hardener. The strength gain is much
faster than polymer overlays. There are several types for epoxy overlays available to
suite different performance requirement. Epoxy overlays require protective coating in
exposed locations subjected to ultra violet exposure.
6.6.12 Resin/Polymer modified Cement Slurry injection: 6
One of the most prevalent techniques used for repairing cracks is by injection of different
types of materials depending upon the nature of the defect. The selection of material
for injection requires thorough understanding of the property of that repair material
and the functions that such a repair has to perform. In all cases, it is imperative that the
cause of cracking is properly determined, otherwise, the selection of material could be
totally faulty. The selection criteria of injection material is given in Table no. 5.11 in
chapter- 5.
The method of crack repair by injection grouting is indicated in fig 6.14 & 6.15. The
materials and step wise sequence of carrying repair are given in detail in chapter 8 & 9
for various applications.
6.6.13 Protective Seal Coats on the Entire Surface
These are defined as liquids that are applied to the surface of hardened concrete to
prevent or decrease the penetration of liquid or gaseous media, such as water, aggressive
solutions, gases like carbon dioxide, etc during the service exposure conditions. Patch
repairs carried out on patch work basis and wherever polymer modified cementitious
mortars or epoxy mortars are used, the chemical effects are not anticipated. However
to protect the remaining areas from the environmental attacks and to avoid subsequent
repairs in such areas, application of seal coats becomes necessary. Generally, these
protective seal coats are suitably pigmented so that besides protection, aesthetics of
the structure can also be taken care of simultaneously. Various coatings like
polyurethane, epoxy, alkyds, chlorinated rubbers, acrylic emulsions can be used for
the purpose however, the selection should be done considering the following
points:
l Adhesion to surface
l Compatibility with the alkalinity of surface

l Coating should be impermeable enough but simultaneously, it should permit
evaporation of moisture from concrete mass.
l Resistance to various aggressive environmental chemical attacks
l Expected life of the treatment
l Capacity to cover surface irregularities
l Ease of application and aesthetics
After considering all these parameters, appropriate coating material can be selected.
Generally, water based coatings are preferred over solvent based.
There are number of properietory as well as other systems for providing surface
coatings to the hardened concrete surface and have been dealt in detail in
chapter 8 & 9. Also some commercially available products have been listed out in
Appendex 5.1.
6.6.14 Ferro-cement:
Ferro-cement is a thin wall type composite, having a total thickness ranging between
12 to 30 mm. It is composed of hydraulic cement mortar reinforced with a minimum
two layers of continuous and relatively small diameter orthogonally woven wire mesh
separated by 4 to 6 mm dia galvanised spacer wires. The cement mortar is admixed
6 with plasticisers and polymers for sealing pores. The wire mesh is mechanically
connected to the parent surface by U-shaped nails fixed with suitable epoxy bonding
system. The mesh may be made of hot dip galvanised MS wire or some other
metallic or suitable material. Special technique for compacting ferro-cement layer is
used with the help of orbital vibrators to ensure proper encapsulation of wire mesh in
mortar.
It is a durable composite material, in which shrinkage cracks are distributed
uniformly due to the presence of closely spaced, thin woven galvanized wire mesh. It
is coupled with excellent corrosion resistance and impermeability to the ingress of
water.
This repair technique is used for providing protective reinforced membrane for
rehabilitation of distressed RCC structures. This acts as a protective layer against the
vagaries of the environment. It is also used as a water proofing technique over reinforced
concrete shell structures and RCC slabs as it provides impermeable thin membrane,
which prevents seepage and leakage of water.
6.6.15 Plate bonding
Plate bonding is an inexpensive, versatile and advanced technique for rehabilitation,
up gradation of concrete structures by mechanically connecting MS plates by bolting
and gluing to their surfaces with epoxy as shown in Fig 6.7. Plate bonding can
substantially increase strength, stiffness, ductility and stability of the reinforced concrete
elements and can be used effectively for seismic retrofitting.
In this method the bolts, which are first used to hold the plates in position during construction,
act as permanent shear connectors and integral restraints. The bolts are also designed to
resist interface forces assuming the epoxy glue used as non-existent assuming it as destroyed

TENSION FACE PLATE

BOLTS
SIDE PLATES
GLUE LINE
(a) ENHANCE FLEXURAL STRENGTH
REINFORCED CONCRETE BEAM

SIDE PLATE
(b) ENHANCE SHEAR AND FLEXURAL (c) L-PLATES

STRENGTH AND DUCTILITY
Fig 6.7 Tension Face Plates 6
by fire, chemical break down, rusting or simply bad workmanship. Since epoxy is prone to
premature debonding, use of mechanical anchorage along with epoxy bonding is considered
more reliable.
Since the steel plates are unobtrusive, with this technique original sizes of the structural members
are not increased significantly. This method is preferred where enlargement of the members
is going to affect the headroom, existing windows, doors and other fixtures.
6.6.16 RCC Jacketing

Reinforced concrete jacketing increases the member size significantly. This has the advantage
of increasing the member stiffness and is useful where deformations are to be controlled. If
columns in a building are found to be slender, RC jacketing provides a better solution for
avoiding buckling problems. Design for strengthening/repair work is based on composite
action between the old and the new work. Strain compatibility calculations may have to be
carried out carefully giving due account to factors such as creep. As the new jacket is to
behave compositely with the parent member, the new jacket can take additional loads only
with the increase in the stresses & strains in the old one. The problem arises if the;
l Old concrete has reached limiting strain and is not likely to sustain any more significant
strain
l Old concrete is weak and porous and started deteriorating due to weathering action
and corrosion of reinforcement.
The question then arises as to whether the composite action should be abandoned and
the new jacket (plate or RC) designed to carry the entire load. It is perhaps best to

design the strengthening in this manner, but detailing must be right to ensure transfer of load to
the new jacket, if the old concrete fails. It is however, necessary to ensure perfect bond also
between the old and new concrete by providing shear keys and effective bond coat with the
use of epoxy or polymer modified cement slurry giving strength not less than that of new
concrete.
Plate bonding and RC jacketing are the common methods of strengthening RCC structures
(detail procedure and stages given in Fig 6.8). The cost difference between the two methods
is not significant. A choice has to be made between the two methods based on actual needs
and the suitability of each method with respect to the structural /architectural and other details
of buildings.
6.6.17 Propping and Supporting:

Problem arises in deciding on propping and supporting the structure to give relief in stresses
and strains in some of the existing weak members being strengthened. Mere vertical props
ADDED LONGITUDINAL
REINFORCEMENT
RESIN ADDED WELDED STRRUPS
CONCRETE
SEALING WITH
6 RESIN MIX
Fig 6.8(a) Column Strengthening Concrete Jacket
C.C. JACKETTING
1/2 THE THICKNESS OF PROPOSED

JACKETTING OR 40 MM WHICHEVER
IS MORE PROJECTING BEYOND THE
ORIGINAL COLUMN FACE
SHEAR KEY @ 300 MM C/C

PLACED STAGGERED
INSERTED LENGTH OF SHEAR KEY DIPPED

IN EPOXY EQUAL TO 4 TIMES THE DIA.
OF BARS OR 50 MM WHICHEVER IS MORE
EXISTING COLUMN EXISTING FACE OF DISTRESSED COLUMN
NOTE :- SHEAR KEY SHALL BE PROVIDED IN

LOCATIONS WHERE IT IS TO FUNCTION
AS SUCH i.e. SIDES OF COLS AND BEAMS
ETC.THEY SHALL NOT BE PROVIDED IN
THE SOFFIT OF THE BEAMS OR CEILING OF
SLAB
Fig 6.8(b) Details of Shear Key Bars

sitting on some beams & slabs may not be enough.

Diagonal bracing to transmit the loads to the adjacent columns should also be considered.
The first item of schedule in Chapter 8 has been prepared which may be read in conjunction
with its related specifications in Chapter 9 and Fig 6.9
TOPMOST STOREY
4 C4
IMPORTANT
1 FOR PROPPING/SUPPORTING ANY COLUMN AT TOP,LOWEST
OR INTERMEDIATE STOREYS, PROPS SHALL BE PROVIDED AT
ALL STOREYS BELOW ALL BEAMS MEETING AT COLUMN.
PROP/SUPPORT 2 ALL PROPS SHALL BE CONCENTRIC i. e. AT THE SAME

3 C3 LOCATION IN ALL STOREYS.
3 PROPS/SUPPORTS SHALL BE MADE OF BUILT UP STRUCTURAL

SECTIONS OR TUBULAR STEEL OF ADEQUATE CAPACITY TO
BE ABLE TO RESIST TOTAL OF BEAM REACTIONS
FROM ALL UPPER STOREYS. USE OF BALLIES BAMBOOS
ARE TOTALLY PROHIBITED.
COLUMN TO BE REPAIRED
2 C2 4 SEQUENCE OF PROPS/SUPPORTS FIXING WOULD BE 1-2-3-4
WORKINGCLEARANCE i.e. FROM LOWEST TO UPPERMOST STOREY.
(TO BE KEPT MINIMUM) 5. SEQUENCE OF DISMANTLING COLUMNS IF REQUIRED WOULD
BE C4-C3-C2-C1 i.e. FROM TOP TO LOWER STOREY. 6
6. SEQUENCE OF REPAIRING COLUMN WOULD BE C1-C2-C3-C4
7 AEQUENCE OF PROP/SUPPORT REMOVAL WOULD BE 4-3-2-1
i.e. FROM TOP TO LOWER STOREYS.
1 C1
LOWEST STOREY A
ELEVATION
TUBULAR PIPE/BUILT UP PROP
FOOTING DESIGNED TO CARRY THE

TOTAL LOAD COMING ON PROP
PLAN DETAIL AT-A
Fig 6.9 Typical Arrangement For Propping & Supporting a Column to Releive at Form Load
6.6.18 Fibre Wrap Technique:

The fibre wrap technique, also known as Composite Fiber System is a non-intrusive structural
strengthening technique that increases the load carrying capacity (shear, flexural, compressive)
and ductility of reinforced concrete members without causing any destruction or distress to
the existing concrete. (Refer Fig 6.10)
There are two systems followed in adopting this technique:
a. Bi-directional Woven Fabric: This system comprises of woven fabric presoaked in
specially formulated epoxy and applied over prepared surface after application of epoxy
primer. Woven fibre fabric is composed of bi-directional high strength fibers that are
FIBRE WRAP
CONCRETE SECTION
TENSION CRACK
Fig 6.10 Fibre wrap technique for improving load carrying capacity of a column.
combined with specially formulated epoxy in a pre-determined proportion to form a

6
composite-Material. This composite material is wrap applied onto the reinforced concrete
or steel member requiring strengthening or protection and left to cure at ambient
temperature. The subsequent layer/s of unidirectional fibre fabric could be applied after
giving the required overlap along the direction of fibres as per design requirements
b. Uni-directional E-glass Fibres: This system comprises of precut unidirectional E-glass
fibre wrapped over epoxy primer applied prepared surface of member requiring structural
strengthening and/or surface protection. Subsequent to its wrapping, it is saturated with
epoxy using rollers and stamping brushes manually to remove air bubbles, if any and left
to cure at ambient temperature. The subsequent layer/s of unidirectional fibre fabric
could be applied after giving the required overlap along the direction of fibres as per
design requirements.
Though the underlying principle of the above two methods is more or less identical, but the
application techniques and basic materials adopted are at slight variance. Each of the above
systems has their own merits.
Enhancement in lateral drift ductility and horizontal shear carrying capacities of a concrete
member can also be obtained by confinement of the member by this method. The flexural,
shear and axial load carrying capacities of the structural members can be enhanced by
appropriate orientation of primary fibres of the composites. The resulting cured membrane
not only strengthens the reinforced concrete member but also acts as an excellent barrier to
corrosive agents, which are detrimental to concrete and the reinforcement. Ingress of water,
oxygen and carbon dioxide through the external surface of concrete member is prevented by
the application of composite jacket.
The system is useful for its structural enhancement and protection capabilities under severe
environmental conditions. It can be used for retrofitting of a wide variety of structures that

include bridges, flyovers, chimneys, water tanks, buildings, large diameter pipes, industrial
plants, jetties, sea-front and underwater structures
6.6.19 Foundation Rehabilitation Methods:

The methods to repair and rehabilitate a structure having foundation distress generally involve
shoring & underpinning work for structures that are out of plumb, or are sensitive to effects of
small settlement etc.
A. Shoring: Before any shoring work is commenced, the building should be carefully
surveyed & record of levels, cracks & tilts kept. The observations should
be continued throughout the period of shoring & under pinning and till
the time when detectable measurements have ceased. The terminology
used is:
1. Raking shores with the angle of shores generally 60o to 75o are usually used
where external support is necessary. In case, the feet of raking shores are to
be kept free, then flying shores can be provided which strut against another
structure or wall.
2. Flying shores merely provide a restraint against building or tilting.
3. Dead shores are verified struts bearing on the ground at the required distance
& supporting the vertical load of a wall wherever required in conjunction 6
with flying shores or horizontal ties.
The level of raking shores & flying shores are so arranged as to bear on the wall at
floor or ground with a firm bearing. Folding wedges should be inserted at the foot of
shores to take up yielding if any, of the ground & elastic shortening of the struts.
Columns can be shored up individually by needle beams. The needle system has to be
properly designed to suite the particular requirements. Suitable placing of jacks for
exerting upward pressure can also be planned & designed.
B. Underpinning: If underpinning is necessary to arrest settlement, it is essential
that the underpinned foundation should meet the requirements of correct allowable
bearing pressures. Depending on the cause of settlement, shallow underpinning
may be satisfactory in some cases, whereas in some cases the underpinning has to
be taken down to a deeper & relatively incompressible stratum. Underpinning
material are metals in case of comparatively shallow underpinning. Underpinning
by piles or piers is suitable, only if the new bearing stratum is deep.
l Underpinning piles are normally provided in pairs, one on each side of the
load bearing walls or in groups around the sides of columns.
l Micro-piles are a useful means of underpinning. They can be installed from
the ground surface without deep excavation and the equipment in installing
the piles is suitable for working in confined spaces. The rotary drilling
results in less damage & loss of ground, as compared to the percussion method.
l Proprietary jacked piles with pre-cast segments are another means of
underpinning. In the proprietary ‘pretest’ methods of underpinning the
underlying ground is preloaded before the load of the structure is finally
transferred by means of jacking between the tilted existing structure & the

new underpinning. There are various patented systems of jacking, involving

interconnection of jacks with centralised pumping plant etc.
l Underpinning by injection of the ground with cement or chemicals to
fill voids or to permeate and strengthen the ground is sometimes used. Various
forms of grout can be introduced into granular soils or cavernous rock
formations to increase their strength to reduce their compressibility grouts,
however, cannot be induced to permeate clays or clayey silts, though by
means of high injection pressure and using closely spaced points the “hydro-
fracture” technique can be used to uplift the mass of clay or self & thereby
provide a means of raising a structure. However, it may be worthwhile in
many cases to take the foundation down to a deeper & more incompressible
stratum say by piles rather than try to compensate & stop the settlement by
grouting.
At the end, it is worthwhile bearing in mind that a foundation is not an entirely nor an
end in itself. The ability to discern differences in type of framing etc. , is also an
essential attribute of an expert investigator. In certain, cases, the results of fresh site
investigates would indicate that the settlement may continue but at a deceasing rate. In
that case, a possible solution could be to keep on monitoring and when the rate of
settlement has decreased sufficiently, the building could simply be “patched up”.
6 It is worth noting that damage investigations include both the design & operation (or
lifetime usage) assessment, which involve “looking backwards in time” as are time
dependent. As stated earlier the concept of time scale is important. In any case, for a
good & effective damage investigation, proper causation statement are essential. They
need to cover information about the damages, technical details, facts about what &
when precise explanation of the causes of damages etc. causation is about opinion &
fact meshed together so that they explain what happened. There must be clarity and it
must be based on evidence. This will then load to the appropriate repair & rehabilitation
strategy, always bearing in mind that foundation is not an isolated entity but a part of
the structure as a whole.
6.6.20 Chemical and Electro-Chemical Methods of Repair

Chlorides are the most difficult to deal with by any other methods of repair except the
electro-chemical methods. The chlorides could be introduced in the concrete either
through ingredients of concrete during its making or during its service life from the
environment to which the structure is exposed. These methods have also been used for
realkalisation of concrete in contact with steel reinforcement with some success and
have enhanced life of structures by few years. Though the electro-chemical methods
are not very commonly used methods for buildings, yet these have been tried on limited
scale and with success. Whereas these methods have been very successfully used for
underground structures, where sufficient moisture and grounding medium is
available.
A. Cathodic Protection:
As the steel reinforcements embedded in concrete undergoes corrosion due to an
electrochemical process taking place within the concrete, micro and /or macro
galvanic cells are formed due to various factors related to both concrete as well as
steel. Thus, corrosion current flows form one region of the steel reinforcement called
anode to another region of the steel reinforcement called cathode. Concrete due to
pore-water present in it, acts as the conducting medium for this corrosion process.
Normally the region where there is relatively high concentration of chloride salts (coupled
with a lowering of alkalinity due to carbonation) acts as anode where corrosion occurs.
The region where there is relatively lower level of chloride contamination (alkalinity is
also maintained relatively at a higher level) acts as cathode of the galvanic cell where
oxygen reduction reaction occurs. At the anode, iron goes into solution as ferrous ions
as follows:
Fe = Fe++ + 2 e–
At the cathode, hydroxyl ions are produced as follows:
O2 + 2H2O + 4e = 4 OH-
Under micro galvanic process, tiny anodes and cathodes are formed and they also shift
positions leading to general corrosion. Under macro-galvanic process, anodes and
cathodes operate at a macro level.
Principle of Cathodic Protection:
The principle of cathodic protection is nothing but applying a direct current (DC source)
in opposition to corrosion current. While applying cathodic protection, the entire steel
reinforcement network is made as cathode while a more active engineering metal (Zinc, 6
aluminum or magnesium) system (sacrificial anode) or an inert metal system (impressed
current anode) is made as anode. However, zinc, aluminum or magnesium have been
employed either as sacrificial or impressed current anode. A wire mesh of titanium
substrate insoluble anode in conjunction with a suitable rectifier system has been widely
used.
After extensive research and testing it has bee established that the only rehabilitation
technique that has proven to stop corrosion in salt contaminated bridge decks regardless
of the chloride content of the concrete is the cathodic protection. Once chloride entered
into concrete, other rehabilitation techniques such as overlays, sealers and water proofing
membranes were found no longer effective.
Cathodic protection as applied to buildings:

a. Impressed Current Technique:
Even though cathodic protection technique has been adopted in bridges and parking
garages, it has been tried in buildings only to a very limited extent. This is mainly
due to the following reasons.
a. Buildings are normally exposed to open dry atmosphere and as such are not
conducive to adoption of this technique.
b. Dry atmosphere coupled with high electrical resistivity of concrete make it
difficult to effectively apply and maintain cathodic protection.
c. Buildings may not need such sophisticated approach
d. Initial investment cost being comparatively higher, cost benefit ratio might
not be favourable.
b. Sacrificial Anode System:
However, when one considers cathodic protection as a fool-proof technique particularly

for chloride contaminated concrete, it is quite feasible to install a sacrificial anode system,
which will work out to be quite economical. It has recently been shown that reinforced
concrete exposed to ambient condition under high humid condition can be cathodically
protected. The prerequisite is an ion conductive backfill to be inserted between the
anode and the concrete.
Sacrificial anodic protection for RCC buildings will therefore consist of the following:
a. Strip or mesh type sacrificial anode (based on zinc or aluminum or magnesium
alloys)
b. Ion conductive backfill (hydro-gel or polymer system)
c. Embeddable reference electrodes (maintenance free electrodes)
d. Shielded electrical leads to be taken from anodes embedded steel
reinforcements and embedded reference electrodes.
The ion conductive backfill should be capable of maintaining conductivity even
under ambient exposure conditions.
The criterion of cathodic protection is based on four hour potential decay. A
decay of 150 to 250 mV might be needed depending on the field conditions. This
can be periodically monitored using a hand held high impedance multimeter.
6 Otherwise, this sacrificial system does not require any major maintenance work
till the expiry of design life.
Advantages of Cathodic Protection:
The major advantages of cathodic protection system as applied to reinforced
concrete;
(i) chloride ions move away from the steel reinforcement as they are drawn
towards the externally placed anode.
(iii) Passivation of steel reinforcement gets strengthened due to build up of
alkalinity at the cathode (production of OH- ions)
B. Chloride Removal
The chloride ion attacks the passive layer, even though there is no drop in pH.
Chlorides act as an electron carrier to become a catalyst to corrosion. Chloride
ions are not consumed in the process, but help to break down the passive layer of
iron oxide on the steel. These allow the corrosion process to proceed quickly.

“Chloride threshold” for corrosion, is given in terms of the chloride/hydroxyl ion

ratio. When the chloride ion concentration exceeds 0.6 of the hydroxyl ion
concentration, then the protective passive layer over the steel reinforcement breaks
down. This approximates to a concentration of 0.4% chloride by weight of cement.
The approximation is because:
(a) Concrete pH varies with the cement powder and the concrete mix. A little
pH change causes an appreciable change in OH- concentration and therefore,
the threshold moves radically.
(b) Chlorides can be bound chemically by aluminates available in hydrated
cement paste and physically by absorption on the pore walls. This removes
them (temporarily or permanently) from the corrosion reaction.
(c) In very dry concrete corrosion may not occur even at very high chloride
concentration as the water, presence of which is essential for ionic movement,
is missing.
(d) in saturated concrete corrosion may not occur even at a very high chloride
concentration as the oxygen, an essential ingredient for corrosion activity, is
missing.
Process
In the process of chloride removal, an external anode is temporary attached to the
6
concrete surface and the reactions are driven by a DC power supply. Chloride
ions are negatively charged and the electrochemical process can be used to repel
the chloride ion from the steel surface and move it towards an external anode.
One essential requirement for the success of electrochemical treatment is good
electrical continuity to ensure that current flows from the anode to all areas of
steel. Electrical continuity must be checked and, if necessary, established in all
applications of these techniques. If there is any discontinuity, current will short
circuit the concrete pore structure and the ions will not flow.
Anode types
The most popular anode is the coated titanium mesh used for chloride removal.
This is placed inside a cassette shutter. Where the shape of the member is especially
difficult, a sprayed papier-mache system can be applied over the anode, soaked
with the electrolyte.
When to Stop Process
End point determination can be by several means:
(a) Point of diminishing returns- When resistance goes up, amount of chloride
removed goes down. Similarly when the current is small then also the amount
of chloride removed is small. Under such situations, it is switched off.
Switching off for about a week will bring the system resistance down. But
how much more chloride is removed by allowing “rest” periods is not known.
(b) Direct measurement- Take samples from the concrete and when an agreed
level is reached, stop. This assumes that good sampling is possible and the
samples are representative.

(c) Indirect measurement- Sample the anode system and or electrolyte. When
chloride level is either at a plateau or an agreed level stop. This assumes
good sampling.
(d) Experience of charge density needed – Measure charges passed (ampere-
hours per square metre), and when an agreed limit is reached, switch off.
It is of course impossible to remove all the chlorides from the concrete. The area
immediately around the steel reinforcement is almost chloride free, but farther
away there is less effect. This is particularly true behind the steel. Chloride removal
will deplete the amount of chloride immediately in contact with the steel
reinforcement, and will replenish the passive layer. Field data shows that this is
effective for at least six years, but for how much longer is uncertain. The results
suggest about 10 years, but only real experience will show that.
One implication of the amount of chloride which can be removed is that if large
amounts of chloride have penetrated beyond the steel reinforcement or were cast
uniformly into the concrete, then chloride removal will only effect the chloride
level in the “cover concrete”. The chlorides in the bulk of the concrete will then
diffuse back around the steel and the corrosion may eventually be re-established.
When the process is carried out, the steel is polarized for some time, perhaps a
year, making half cell potential testing difficult to interpret. The charge on the
6 steel means, however, that chloride ions will be repelled by the charge during this
time.
Side Effects
Passing large amount of electricity through concrete can have effects upon its
chemistry and therefore, its physical condition. There are two known side effects
of chloride removal as follows.
l The first is the acceleration of alkali silica reactivity (ASR)
l Reduction in bond at the steel concrete interface.
C. Realkalisation:
Realkalisation is non Destructive Electrochemical Treatment to restore the
alkalinity of carbonated concrete to prevent further corrosion of reinforcement.
In this process, instead of breaking and mechanically replacing a sound but
carbonated concrete, pH of such concrete is increased to more than 12 initially,
which favours the passivation of steel reinforcement with a final value
greater than 10.5, which is considered sufficient to maintain the passivity of
reinforcement.
It is indeed an electrochemical process as is the reinforcement corrosion. The
corrosion reaction consists of an anode and a cathode reaction. The anode reaction
causes the steel reinforcement to be dissolved and occurs at sites where concrete
has lost its corrosion protective nature. Simultaneously, the cathode reaction
produces hydroxyl ions at other sites along the steel reinforcement. While the
anode reaction has harmful nature, cathode reaction improves the corrosion
protection of steel.

Process:
Realisalisation is performed by applying an electric field between the reinforcement in
the concrete and an anode system consisting an anode mesh embedded in an electrolytic
reservoir and temporarily placed on the concrete surface. The system is schematically
presented in fig….. During the treatment, electrolyte, which is sodium carbonate
solution, is transported in to carbonated concrete as symbolized by the penetrating
front. The dominant transport mechanism may vary, but electro-osmosis and migration
of ions are the two main contributors. Simultaneously, electrolysis at reinforcement
surface produces alkaline environment, symbolized by a passive barrier around the
reinforcement.
6.7 Repair/Rehabilitation Strategies:

A number of options are available for giving a relief to a distressed structure, which could
cover any of the following:
l Reduction of dead/live loads
l Repair/strengthening of Columns, beams and slabs
l Improving the compressive strength of concrete.
l Attending to Cracks and joints
l Improving the masonry structure to be able to resist earthquake forces
l Providing protective cover against the aggressive deteriorating chemicals 6
6.7.1 Stress Reduction: The reduction is another method of providing relief to the distressed
structure. This can be achieved by-
l Reducing dead load and live loads;
l Replacing heavy solid partitions with lightweight partitions;
l Enlarging openings by removing filler walls;
l Reducing numbers of stories;
l Changing the building use to a lower classification of loading;
l Span reduction of beams by providing struts etc;
Installation of shear movement joints in a continuous spans at points of zero moment.
6.7.2 Repair/Strengthening Columns, Beams and slabs:

These form the basic structural elements in most of the building structural systems,
which are deteriorated and require attention to improve the load carrying capacity.
Their structural modification or strengthening would give the required relief to the
structure and enhance its performance as under:
l Columns: The strengthening of columns may be required for the following
a. Capacity: The load carrying capacity of the column can be enhanced by
section enlargement. Different types of arrangement for section enlargement
are shown in Fig. 6.11
b. Ductility/confinement: The ductility of the column can be enhanced by
providing additional tiles, steel plate bonding, and fibre wrap.

EXISTING NEW SPECIFIED BOND COAT
SPECIFIED GRADE CONCRETE
METHOD A
BOND COAT OF
SUNEPOXY 368
EXISTING NEW
M20 GRADE CONCRETE
METHOD A
BOND COAT OF
SUNEPOXY 368
EXISTING
6
M20 GRADE CONCRETE
NEW
METHOD A
Fig. 6.11 Column Compressive Strengthening by Section Enlargement
c. Joints: The joints play crucial for resisting earthquake forces. The joints can be
strengthening by enlargement, jacketing by steel collar and fibre wrap.
l Beams: These can be strengthened for:
a. Flexural Strength: The flexural strength of the beam can be enhanced by
i. Section enlargement in compression,
ii. Additional reinforcement in the tension. Caution shall be exercised to
ensure that section is not over reinforced while providing additional
reinforcement to compensate loss of reinforcement due to corrosion
etc.
iii. The provisioning for enhanced tensile strength if being undertaken,
this should be accompanied with corresponding increase in compression
as well .Due to such increased flexural capacities extra shear capacities
required to ensure ductile behaviour during earthquake shall also
considered for provision.
iv. MS plate bonding
v. High Strength Fibre Fabric Wrap Technique (without section
enlargement)

ORIGINAL SECTION
INCREASED SECTION WITH MICRO CONCRETE/
SHORTCRETE SELF COMPACTION CONCRETE
FIXING OF STRRUP WITH
EPOXY AND QUARTZ SAND
MORTAR AS SPECIFIED
TENSION REINFORCEMENT
BEAM SECTION ENLARGEMENT
INCREASED SECTION WITH MICRO CONCRETE/

SHORTCRETE SELF COMPACTION CONCRETE
ORIGINAL SECTION
SPECIFIED BOND COAT
6
TENSION REINFORCEMENT
COMBINATION SLAB AND BEAM OVERLAY WITH BEAM ENLARGEMENT
Fig. 6.12 Beam Strengthening : Concrete Overlay And Section Enlargement
b. Shear Strength: The shear strength of the beam can be enhanced by any of the
following:
i.Section enlargement
ii.Shear ties anchored in compression zone of beam.
iii.Post tension strap around the section
iv. Diagonally anchored bolts (the holes are drilled perpendicular to the
possible shear cracks)
v. MS Steel plate bonding
vi. Fibre wraps
l Slabs: The performance of the slab can be improved by providing overlays
(in case of negative moment deficiency) or underlay (in case of positive moment
deficiency). The addition of overlay/underlay will also increase the stiffness of
the slabs and control the excessive deflections problems. The slabs are generally
safe in shear and as such no need is likely to occur for shear strengthening except
flat slabs near column capital.

NEW REINFORCEMENT OVERLAY WITH MICRO-CONCRETE
SPECIFIED BOND COAT

EXISTING SLAB
OVERLAY ON TOP OF SLAB
SPECIFIED BOND COAT EXISTING SLAB
NEW REINFORCEMENT OVERLAY WITH SHORTCRETE
Fig. 6.13 Slab Strengthening : Concrete Overlay
Structural repairs to Columns/beams/slabs due to corrosion of reinforcement are most

frequented in the normal practice. The step by step sequence of repair stages have been
given in Annexure 6.1 for structural repairs to RCC columns, beams and slabs under
different conditions of deterioration
6.7.3 Compressive Strength of Concrete: The concrete strength can be enhanced substantially
by impregnation with specific polymers. The process has already been explained under section
6.5.9
6.7.4 Cracks/Joints: The concrete and masonry are weak in tension. The cracks indicate the
tensile failure of the material. The cause of cracking should be examined in detail and remedial
measures taken accordingly. Inactive (i.e. non-moving) cracks in masonry can be repaired
by stitching. Grouting with non-shrink grouts also repairs these types of cracks. The active
cracks required for accommodating thermal movements shall be repaired by suitably locating
the expansion joints and filling them with flexible materials like poly-sulphides, bituminous
fillers etc.
6.7.5 Masonry: The masonry may be required to be strengthened for resisting earthquake forces
by external pre-stressing, splint and bandage methods. The techniques are explained in IS:
13935-1993

REPAIR STEPS :
MARK AND DRILL HOLES ON BOTH

SIDES OF THE CRACK
CHASE A GROOVE BETWEEN

THE DRILLED HOLES
INSERT U-SHAPED M.S. BARS

IN THE HOLES AND SPAN
ACROSS THE CRACK
GROUTING THE HOLES WITH EITHER

EPOXY OR NON-SHRINK GROUT
Fig. 6.14(a) Stitching Method of Rapairing Wall/Slab Cracks
REINFORCED CEMENT
CONCRETE 1:2:4
REINFORCEMENT BARS
CRACK
Fig. 6.14(b) Elevation of Brick Masonry Wall Showing Typical Cracks (Vertical or Diagonal)

6.7.6 Protection: Protective measures for preservation and extending the service life of the structure.
They are given below.
l Water Proofing
l Depressed Floor Treatment (The step by step sequence of stages for one of the
alternatives of treatments have been given in Annexure-6.2)
l Terrace Treatment(The step by step sequence of stages for treatment of Khurrahs
at terrace have been given in Annexure-6.3)
l Sun Shade
l Surface Treatment
l Creation of Barrier
6.7.7 Foundation: The methods are explained in section 6.5.19
6.7.8 Base Isolation: Seismic forces are transmitted to the structure due to ground motion
caused by the seismic activity. In this method, structure is isolated from ground motion
by inserting elastomeric isolators. Most of the energy input from the earth due to seismic
activity is absorbed due to isolators movement and thus the building is protected from
damage. This method is of significance where it is not possible to make structural/
architectural alterations in the superstructure heritage value. The essential requirement
6
of this method is availability of sufficient space all-round the building for movement
of the superstructure and high cost.
✯ ✯ ✯


1. REMR Technical Note CS-MR-4.5 Suppl 6 (1994) of Repair-Evaluation-
Maintenance-Rehabilitation
2. Jerry L Boyd, Gajanan M Sabnis and Josua A Boyd ‘Application of Vacuum
Technology to Restore Concrete Structures’ Indian Concrete Journal, Jan, 2001;
Vol 75, No 1 pp 35-40
3. Manjrekar, S K, ‘Polymer Modified Concrete/Mortars for Repair and
Rehabilitation Works’ Indian Concrete Journal, Jan, 1995, Vol 69, No 1 pp 41-44
4. Internet site of ‘Civil Engineering Projects, School of Engineering, University of
Adelaide, Australia’
5. Assessment & Repair of concrete Structural methods, problems choice & new
development by C.Keshva Murthy, CKM Consultants Pvt. Ltd., 47, Beach Road,
03-03 Khanchin Building, Singapore 0718
6. REMR (Repair, Evaluation, maintenance Rehabilitation Programme ) Technical
note NCS – MR – 9.4 prepared - Aggregate concrete
7. REMR Technical note CSMR- 4 spall repair.
8. Technical information service on “Repair Rehabilitation of RCC structures”
6
Circular no. 1 issued vide CDO/SE(D)-II/Information series/253 dt. 20/12/1996.
9. Fig. 4- Recent advances in Repair and Rehabilitation of RCC Structures with non
metallic fibres.
10. Shotcrete Guides and Specifications by D.K. Morgan. Shotcrete magazine fall
2000. (fibre reinforced shotcreted)
11. Recommendations for maintenance of concrete structures (Draft Japan Society of
Civil Engineers (JSCE) copy from the Concrete Library International no. 29
published by JSCE June 1999.

Appendix 6.1
Structural Repairs to RCC Columns, Beams and Slabs
CASE-I: Crack Repair and Protective Coating for less damaged structural members
like minor/hair cracks or spalling from beams and columns, where
carbonation depth in cover concrete has not reached reinforcement level.
Caution: It may be stated that recommended measures are cosmetic measures.
The distress may continue to take place even after repairs, if the protective coating,
provided as per step no. 7 below, is damaged or ineffective.
Step-1: Measures shall be taken to ensure that no seepage/leakage etc. affects
the RCC columns/beams.
Step-2: The plaster/finishes over the RCC columns/beams shall be removed as
per relevant item in sub head 2 of Chapter 8 and relevant specifications
in Chapter 9. The concrete surface exposed, spalled and loose cover
concrete removed, cracks marked after close examination on the surface
of concrete. Whereas the good surface of concrete shall be hacked and
roughened for receiving the repair as per relevant item in sub heads 4 &
5 of Chapter 8 and relevant specifications in Chapter 9.
Step-3: Wherever loose/spalled cover concrete is removed, it shall be repaired
6
with polymer modified cement mortar, done up in layers as per
nomenclature of items in sub-heads 4 & 5 of Chapter 8 and relevant
specifications in Chapter 9.
Step-4: All cracks in RCC columns/beams wherever noticed shall be sealed by
injection grouting through nipples fixed along the crack line as per
nomenclature of items in sub head 3 of Chapter 8 and relevant
Step-5: Over the prepared surface of RCC columns/beams, 6 mm thick 1:3
cement sand plaster shall be applied with polymer modified cement
NARROW AND DEEP CRACK
FAST-SETTING POLYESTER RESIN PUTTY

PRE-DRILLED INJECTION POINT
ENTRY PORT WITH ONE-WAY NIPPLE CHASE A V-GROOVE ALONG THE CRACKS
FOLLOWED BY WATER-JETTED CLEANING
CL
5 4 3 2 1 6 7 8 9
ALTERNATIVE A
CL
8 6 4 2 1 3 5 7 9
ALTERNATIVE B
SEQUENCE OF INJECTION OPERATION
Fig. 6.15 Crack Sealing with Resin Injection Technique

slurry bond coat (item no. 3.2) within 24 hours of injection grouting as per
preceding para.
Step-6: Cement plaster shall be cured strictly as per the nomenclature and of items
in subhead 6 of Chapter 8 and relevant specifications in Chapter 9.
Step-7: After RCC columns/beams are cured and completely dried, a protective
coating shall be applied over it for protecting the reinforcement and concrete
against environmental aggressive chemicals in accordance with items of
sub-head 8 in Chapter 8 and relevant specifications in Chapter 9
CASE-II: Repair to Damaged Columns/Beams/Slabs where carbonation depth of

concrete has reached reinforcement level:
(i) Shotcreting
Stepwise sequence of methodology to be adopted is given hereunder
Step-1: Prop and support the structure in order to relieve the RCC column of
stresses due to load coming over it as per the nomenclature of items in
subhead 1 of Chapter 8 and relevant specifications in Chapter 9.
Step-2: Remove plaster and finishes all around the distressed RCC columns.
Thereafter remove loose, cracked and spalled concrete to expose the
rusted reinforcement as per the nomenclature and of items in subhead 2 6
of Chapter 8 and relevant specifications in Chapter 9.
Step-3 Remove concrete all around the reinforcement in order to get average
25 mm air gap all around i/c behind the reinforcement & clean the
reinforcement of concrete and rust by appropriate methods as per
nomenclature of items in subhead 2 of Chapter 8 and relevant
Step-4 Put additional reinforcement wherever the reinforcement diameter has
been reduced by more than 15% with the necessary overlap or
welding with the existing reinforcement as per the nomenclature and of
items in subhead 5 of Chapter 8 and relevant specifications in
Chapter 9.
Step-5: Fix shear key bars of appropriate diameter at specified spacings in both
directions over the surface to be covered with repair materials as per
the nomenclature of items in subhead 2 of Chapter 8 and relevant
Step-6 Apply appropriate passivating and bond coat over the reinforcement
and prepared RCC surface as per the nomenclature of items in subhead
4 of Chapter 8 and relevant specifications in Chapter 9. Shotcrete the
RCC column within the time limit specified as pot life of the epoxy or
tacking period of slurry as per the nomenclature and of items in subhead
4 of Chapter 8 and relevant specifications in Chapter 9. The necessary
shuttering as specified in specifications of shotcreting shall be used for
ensuing the desired thickness and shape of the columns.

Step-7: 6 mm thick finishing coat with cement sand plaster 1:3(1cement:3fine sand)
(of least possible thickness) if felt necessary, shall be applied within 48 hours
of application of shotcreted repair.
Step-8 Wet curing shall be done over the finished surface of the shotcrete for a
minimum period of 7 days as per the nomenclature and of items in
Step-9: After RCC columns/beams are cured and completely dried, a protective
coating shall be applied over it for protecting the reinforcement and
concrete as per the nomenclature and of items in subhead 8 of Chapter
8 and relevant specifications in Chapter 9.
(ii) RCC Jacketting
Step no.1 to 5, same as in (i) above
Step-6: Appropriate passivating and bond coat shall be applied over the prepared
surface as per the nomenclature and of items in subhead 4 of Chapter 8
and relevant specifications in Chapter 9.
Step-7: Within the tacky period of bond coat, shuttering and concreting shall
be done with specified grade of concrete with minimum cement content
as specified and water cement ratio not more than 0.45. The consistency
6
of this concrete shall be flowing and self-compacting which shall be
achieved by using super plasticiser. The thickness of RCC jacket shall
be as specified.
Step-8: Follow steps no. 6 to 8 as in (i) above.
Case-III: Stages for repairs to RCC Slabs, where carbonation depth has reached
reinforcement level.
(i) Repair with polymer modified cement mortar (For patch repairs or repairs
over smaller magnitude)
Step-1: Propping and supporting of RCC slab under distress shall be as per the
nomenclature of items in subhead 1 of Chapter 8 and relevant
Step-2: All loose and spalled cover concrete shall be removed including finishing
plaster wherever found loose by tapping as per the nomenclature and
of items in subhead 2 of Chapter 8 and relevant specifications in
Chapter 9.
Step-3: The rusted reinforcement shall be cleaned of concrete preferably by
using sand blasting to give a minimum 15 mm clear air gap all around
including behind the reinforcement as per the nomenclature of items in
Step-4: Additional reinforcement wherever necessary shall be added and tied
to the RCC slab with necessary binding wires and nails.

Step-5: Fix shear key bars of appropriate diameter at specified spacings in both
directions over the surface to be covered with repair materials as per
the nomenclature of items in subhead 2 of Chapter 8 and relevant
Step-6: The rusted reinforcement shall be cleaned of rust and passivated and
applied bond coating as per the nomenclature and of items in subhead 4
of Chapter 8 and relevant specifications in Chapter 9.
Step-7: The prepared concrete surface shall be covered with appropriate mix of
polymer modified cement sand mortar in layers including behind
reinforcement over a bond coat with polymer modified cement slurry
as per the nomenclature of items in subhead 4 & 5 of Chapter 8 and
relevant specifications in Chapter 9. The mortar cover thickness shall
be not less than 15 mm over the reinforcement. The maximum thickness
shall be not more than 30 mm with each layer not exceeding 10 mm.
CUT AT RIGHT-ANGLE WITH THE

HELP OF DISC TYPE MECHANICAL
CUTTER
REQUIRED OVER-CUT BEYOND REINFORCEMENT

BAR FOR CONCRETE COVER TO REINFORCEMENT 6
STEP-1 REMOVE ALL DEFECTIVE CONCRETE AND PARENT CONCRETE

EXPOSE CORRODED REINFORCING BARS
TO THEIR FULL CIRCUMFERENCE
STEP-4 PATCH WITH REPAIR MORTAR

OR CONCRETE AND RESURFACE
TO REQUIRED THICKNESS
STEP-2 REMOVE THE CORROSION PRODUCT FROM
REINFORCING BARS UNTIL THEY SHINE
STEP-3 APPLY ANTI-CORROSIVE PROTECTIVE PROTECTIVE SURFACE

FINISH FOLLOWED WITH
PASSIVATING COAT TO PROTECT
DECORATIVE FINISH
REINFORCING BARS
STEP-5 APPLY PROTECTIVE COATING
AND FOLLOW UP WITH
DECORATIVE PAINTING
Fig. 6.16 Typical repair procedure for patch repair and corrosion damaged concrete
Step-8: Water curing shall be carried out for a minimum period of 7 days as per the
nomenclature and of items in subhead 6 of Chapter 8 and relevant
Step-9: Necessary white washing /painting of the surface may be carried out
after the curing period is over and the surface gets dried up.

(ii) Shotcreting: (For repair jobs covering large areas and/ or large magnitude)
Step-1: Step no. 1 to 6 shall be same as in case of no. (i) above.
Step-7: Shotcreting with average thickness of 50 mm shall be done within the
tacking period of epoxy bond coat to be applied over the prepared surface
of concrete.
Step-8: Finishing plaster if necessary, may be provided within 48 hours of
shotcreting without allowing the RCC slab to become dry during the
intervening period.
Step-9: Water curing shall be carried out for a minimum period of 7 days as per
the nomenclature and of items in subhead 6 of Chapter 8 and relevant
STAGE 1 STAGE 2 STAGE 3
FIRST STAGE FIRST STAGE PREVIOUSLY GUNITE/

GUNITE / SHORTCRETE GUNITE / SHORTCRETE SHORTCRETE SURFACE
6
TIMBER FORM WORK AND
CROSS FRAMING SECOND STAGE
GUNITE / SHORTCRETE
SHUTTER FINISHED SURFACE
(A) BEAM REPAIR (TIMBER FORM WORK REMOVED)
TIMBER FORM WORK AND SHUTTER FINISHED SURFACE

CROSS FRAMING (TIMBER FORM WORK REMOVED)
FINISHED GUNITE/
FIRST STAGE SHORTCRETE
GUNITE / SHORTCRETE
SECOND STAGE
GUNITE / SHORTCRETE
a. REMOVE COVER CONCRETE b. FIXED SCREEDS AND SPRAY TWO SIDES c. SPRAY REMAINING SIDES AND
APPLY FLASH COAT TO FULL AREA
(B) COLUMN REPAIR
Fig. 6.17 Typical Column repair by Guniting

Appendix 6.2
TREATMENT OF DEPRESSED FLOOR IN TOILETS/KITCHEN
Step-1 Remove all materials /flooring from the sunken floors and expose the drainage
pipes/G.I. water supply lines.
Step-2 Test the G.I. water supply lines less than 6 kg per sq.cm. Water pressure
using the pressure-testing machine with pressure guage, which is readily
available in the market.
Step-3 Test the drainage pipes and other joints for leakages if any, by plugging of
horizontal pipe at tee junction with vertical stack and filling with water upto
the finished floor level for 48 hours. Leakages noticed, if any, shall be attended
to.
Step-4 Provide 40 mm dia G.I.pipe spout and CC flooring with water proofing
compound laid in slope(1:48 minimum) for draining out leaking water, if
any, from the sunken portion in the shaft.
Step-5 Provide 12mm thick cement plaster 1:3(1cement:3 fine sand) mixed with
water proofing compound on the vertical walls of the sunken portion including
providing necessary repair around the drainage spout provided.
6
CEMENT PLASTER
WATER TIGHT JOINT
BRICK WALL
BITUMEN COATING
KHURRA 150 X 150 (MIN.)
"A"
DRAINAGE SPOUT
R.C.C. SLAB R.C.C. BEAM
GRADING CONC. 1:1.5:3
(WITH NEAT CEMENT PUNNING)
STONE AGGREGATE
CEMENT CONC. 1:5:10
FLOORING
DETAIL AT "A"
STEP 1 - PROVIDE DRAINAGE SPOUT
STEP 2 - GRADING CONCRETE 1:1.5:3 LAID TO SLOPE TOWARDS DRAINING SPOUT WITH FLOATING COAT OF NEAT CEMENT
STEP 3 - PROVIDE AND LAY WATER SUPPLY & DRAINING PIPES & TEST FOR LEAKAGE THE DRAINAGE /SANITARY PIPES
SHALL BE LAID TO SLOPE AND A CLEAR GAP UNDERNEATH THE PIPES SHALL BE MADE AVAILABLE BY PROVIDING SUITABLE
C.C. BLOCKS AT APPROPRIATE LOCATION FOR FREE FLOW (OF LEAKED WATER ,IF ANY ) TOWARDS DRAINAGE SPOUT.
STEP 4 - 18 MM TH. CEMENT PLASTER 1:3 ON VERTICAL FACES MIXED WITH POLYMER MODIFIED WITH WATER PROOFING
COMPOUND AND FLOATING COAT OF POLYMER MODIFIED NEAT CEMENT SLURRY & COATED WITH BITUMEN (2 COATS)
STEP 5 - 150 MM TH. 20 MM SINGLE SIZED STONE AGGRAGATE TO PROVIDE A FILTER MEDIA FOR ANY LEAKING WATER TO
TRAVEL TO DRAIN SPOUT BELOW C.C. 1:5:10 ( 1-CEMENT : 5-COARSE SAND : 10-40 MM & DOWN GRADED STONE AGGREGATE )
NOTE :- 1. WATER PROOFING TREATMENT SHALL BE UNDERTAKEN ONLY WHEN ALL DRAINAGE PIPES / SANITARY PIPES /
DRAINAGE SPOUT ETC. HAVE ALL BEEN LAID AND TESTED.
Fig. 6.18 Typical arrangement for treatment of Depressed Floor of Toilets etc.

Step-6 Provide two coats of bitumen (85/25 grade) coating in the sunken portion to
ensure that the entire surface is properly covered and drainage pipes are also
painted with bitumen.
Step-7 Provide a 100 mm thick dry stone aggregate in the sunken portion. The mouth
of the drainage spout provided earlier shall have graded filter so as not to get
choked.
Step-8 Rest of the depth of sunken portion shall be filled with lean concrete
1:5:10(1cement:5coarse sand:10aggregate) with stone aggregate and flooring
laid to slope.
Step-9 The rusted/leaking G.I. pipes wherever noticed during carrying out the repairs
shall be replaced or otherwise be cleaned of rust and coated with polymer
modified cement slurry and two coats of bitumen painting.

Appendix 6.3
LEAKAGES FROM TERRACES
The source of leakage from terraces is invariably from

1. Khurrah locations
2. Through tile joints
3. Improper slope of tile terracing
4. Improperly done Gola
5. Depressions to cause stagnation of water
Stepwise sequence of methodology to be adopted is given hereunder, which has
also been explained in Refer Fig
Stepwise Sequence of operations:
Step-1: Dismantle the terrace tiling, mud phuska, gola, khurrahs etc and remove the
earth and tiles from the roof slabs .
Step-2: Remove the brickwork of parapet so as to expose RCC slab in a width of 1.5
metre at the location of khurrahs.
Step-3: Clean the RCC surface of roof slab of all dust etc by suitable method including
washing with clean water etc.
Step-3: Apply a coat of kerosene oil primer on the whole surface including the portion
6
of RCC slab below the removed parapet at the location of khurrahs.
Step-4: Before the kerosene primer evaporates, apply the bitumen painting over whole
terrace including the portion of RCC slab below the removed parapet at the
location of khurrah.
Step-5: Provide 400 micron thick poly-ethylene sheet of appropriate size with hot
bitumen under-laid at the location of khurrahs with one side of sheet taken
up to the outer edge of parapet wall/RCC slab.
Step-6: Provide 50 mm thick cement concrete khurrah over the aforesaid poly-
ethylene sheet as per CPWD specifications with one of the four sides (two
adjacent sides in case of corner location) of the khurrah concrete taken out
up to outer edge of the parapet wall.
Step-7: Re-fix the rain water pipe spout
Step-8: Redo the masonry of parapet at Khurrah location.
Step-9: Provide mud-phuska or the specified terrace treatment strictly as per CPWD
specifications taking extra care while redoing mud-phuska in regard to
following:
l Terrace tiling shall be laid to a minimum slope of 1: 48 with valleys
pointing towards the khurrahs
l Terrace tiles shall be supported over the cement concrete of Khurrah
overlapped by a minimum of 50 mm.
Step-10: The terrace tiles shall be saturated with water.
Step-11: The joints of terrace tiles shall be grouted with dry cement sand mortar 1:3
mixed with water proofing compound. Grouting shall be done using coconut
broom and appropriate tools to ensure dry compaction of the mortar in the

joints. This sand mortar should be allowed to set by absorbing moisture from
saturated brick tiles.
Step-12: Wet curing shall be taken up after a minimum of 8 hours of mortar grouting for at
least 7-days duration.
Step-13: Cement concrete gola shall be provided with grooved joints at a spacing of 3
metre centre to centre ensuring the concrete of Gola is provided after .

CHAPTER 7
GUIDELINES FOR FRAMING TERMS AND

CONDITIONS FOR REPAIR &
REHABILITATION WORKS CONTRACTS
PAGE NO.
7.1 General VII-1

7.2 Identification of problem and estimated quantum of job VII-2
7.3 Engagement of Consultatns VII-2
7.3.1 Short listing of Consultancy Firms VII-3
7.3.2 Entering into contract with consultancy Firm VII-4
7.4 Engagement of Contractors VII-9
7.4.1 Conditions of Contract VII-9
7.4.2 Pre-bid conference VII-11
7.5 Execution of Work VII-11
7.5.1 Materials VII-11
7.5.2 Testing of Completed items of Work VII-12
7.5.3 Tools & Plants VII-12
7.5.4 Supervision and Inspection of works VII-12
7.5.5. Record of Testing, Supervision and Inspection VII-13
7.6 Post Repair Inspection VII-13
7.7 Performance Guarantee VII-13
Appendix 7.1 VII-15
Appendix 7.1.1 VII-17
Appendix 7.1.4.1 VII-27
(i)
(ii)
PAGE NO.
Appendix 7.2 VII-47
Appendix 7.3 VII-65
Appendix 7.4 VII-88
°
7
GUIDELINES FOR FRAMING TERMS AND
CONDITIONS FOR REPAIR & REHABILITATION
WORKS CONTRACTS
Writen words are better than the best memory.
..A Chinese Proverb.
7.1 General:
The structural repairs to RCC are specialised works. These can be satisfactorily carried
out only as per the expert advice of an experienced engineering consultant under strict
engineering supervision through a well-equipped experienced contractor.
The provision relating to safety features, quality assurance and environmental protection
are important aspects concerning structural repairs of RCC works. These are required
to be included as separate individual items of work of measurable performance
specifications to form part of the contract. The omnibus mention like ‘work shall be
carried as per the relevant IS: codes’ etc. are avoided as far as possible. 7
Another aspect is assessment of bill of quantities, as it is very difficult to prejudge the
quantities accurately. It should be ensured that all possible items are included in the
bill of quantities with reasonably assessed quantity. It is desirable to have item rate
contract for structural repairs.
There are three stages in the process of carrying out sound structural repair, which can
be classified as under:
l Field investigation and determination of causes & their extent.
l Identification of repair system, framing of specifications and acceptance criteria.
l Execution of repairs.
The first two stages require higher level of intellectual inputs from experienced technical
personnel (consultants) equipped with instruments for field inspections, sampling and
testing. The third stage requires implementation through competent and experienced
contractor equipped with adequate construction equipments and manpower.
At present in India, there are number of consultancy firms and contractors dealing with
structural rehabilitation works. As such there is no necessity to approach a single firm
of one’s choice for the assignment of such jobs. Simultaneously, in view of the
specialised nature of work, open competitive bidding without screening (based on
credentials of such bidding firms) and awarding the job to the lowest open bid is not
likely to yield the desired results.
In this chapter, broad guidelines have been given for short-listing consultants and
contractors, for taking up major structural rehabilitation jobs. These will help in suitably
formulating and incorporating specific contract conditions related to structural repair
Central Design Organisation VII-1

works in agreements of consultants and the contractor. However, before communicating

with the consultants/contractor, it is necessary for the Employer to identify the job, its
scope and work out its size.
7.2 Identification of problem and estimated quantum of job:
7.2.1 It is necessary for the Employer to be able to communicate with the prospective
consultants/contractors and convey the nature of job and its size in very clear terms for
enabling them to make up their intentions and submit applications for short-listing in
the first instance. Therefore preparation of Terms of Reference and projecting the size
of the project are the first task on the part of the Employer:
l Terms of Reference (TOR): The TOR is the initial statement in regard to the
specific rehabilitation project as a means of communication of the Employer to
the consultant/ contractor. With eventual modifications, this forms an integral
part of the contract, which governs the project that the consultancy/contractor
firm is to perform. Therefore the TOR should be as clear and precise as the nature
of assignment. Normally the TOR should contain the following in regard to the
consultant’s/contractor’s job of a particular rehabilitation project:
i. Objective(s)
ii. Scope and time
iii. Inputs, if any, to be provided by the Employer
iv. Details of the services required from the consultant/contractor
l Size of Project/Cost Estimate: Size of the structural rehabilitation project gives
7
a reasonable idea to the applicant firms beforehand. For this, one should specify
the nature of building & its distress, type of remodeling and its plinth area to be
investigated/ rehabilitated/ remodeled. In addition, it is also desirable to give the
reasonably assessed cost of execution of the structural rehabilitation/remodeling
project.
These could be worked out through engineering establishment of the Employer or an
engineering consultant. This estimated cost could be based on plinth area rates worked
out on actual completion cost of the identically executed projects.
7.3 Engagement of Consultants:
The objective of engaging a consultant is to define the problem, determine its solution
and scope of repair & rehabilitation work. This shall be based on the preliminary
inspection of the work and discussions with Employer. The scope of work shall be
clearly defined.
The competence, experience and dependability of the firm and its personnel, are far
more important parameters for assessing the capability of a consultancy firm for
structural rehabilitation/strengthening jobs.
Thus the engagement of a consultancy firm for a particular structural rehabilitation job
shall be mainly in two principal stages. In the first stage we have to prepare a short-list
of competent, experienced and dependable firms having generally two competent Key
Personnel experienced in structural rehabilitation jobs in addition to other technical
staff and other attributes. Such list of firms shall be prepared from amongst applications
received based on an advertisement published in the press. The second stage of
engagement involves receiving the price bids from short-listed consultancy firms after
VII-2 Repairs & Rehabilitation Unit
GUIDELINES FOR FRAMING TERMS & CONDITIONS FOR R. & R. WORKS CONTRACTS
formulating general and specific contract conditions related to the particular

rehabilitation project. The components of these two stages are as follows:
I Preparing a short-list of firms
a. Determining the selection Procedure
b. Preparing a short-list
II Entering into contract with consultancy Firm
a. Invitation of price-bid from short-listed consultancy firms
b. Evaluation of the price-bids
c. Negotiating a contract with the selected consultancy firm
7.3.1 Short-listing of Consultancy Firms:
l Associate Consultant(s):
It is quite possible that one consultancy firm may not have full capability of
undertaking a consultancy assignment on its own capability. Therefore, it is
generally an accepted practice to allow the main consultant to submit their
applications along with their associate consultant(s) duly supported with explicit
irrevocable consent. Identically, it should also be made a condition that the main
consultant shall not be allowed to change the associate consultant(s) at a later
date. Thus, the combined resources of such main and associate(s) consultants
should be considered in evaluating experience and competence.
l Determining the Procedure for Short-listing: It is essential to prepare and freeze
in advance the procedure before receiving the applications from the intending 7
consultants for short-listing. For arriving at a rational procedure, all possible
attributes of a good consultancy firm are required to be identified, listed out and
assigned appropriate weightage.
Ø Key Personnel: The qualification and experience of the ‘Key Personnel’
made responsible for the project, is of prime importance besides strength of
other technical personnel in the employment. It is necessary that the
consultancy firms in their applications submitted for short-list identify the
Key Personnel for the rehabilitation project. It is desirable to have an alternate
of Key Personnel of equivalent or slightly relaxed capability in consultancy
assignments for ensuring that the alternate Key Personnel is exclusively
available on full time basis for the consultancy project. However, the Key
Personnel shall sign all the proposals/reports on behalf of the consultancy
firm. The qualification, experience, age and length of employment of Key
Personnel should be considered as important pre-requisites in determining
suitability of the consultancy firm. If necessary, it would be desirable to
supplement this by interviews. It shall be an essential condition for a
consultancy firm to have the services of the identified Key Personnel for the
work duration of the consultancy job.
Ø Other Attributes of the Consultancy Firm: The structure and organisation,
experience and adequacy for undertaking a consultancy job are considered
other important attributes for a short-listed consultancy firm. These could be
on the basis of the financial turnover, technical manpower, geographical
location, period of existence of the firm, testing & analytical capabilities,
Central Designs Organisation VII-3

related experience in rehabilitation, analysis & design, field execution of

projects etc.
Appendix-7.1 gives an illustrative procedure of short-listing the Consultancy Firms.
l Preparing a Short-List: It is quite reasonable to have a list of three to six qualified
and experienced short-listed firms through the above stated selection procedure.
In cases, where the short-list is either too short or too long, it may be desirable to
suitably modify the weightage of various attributes so as to bring the list well
within this range. In such a case, it would be essential to go in for fresh invitation
of applications from the intending consultants. The Price bids should be received
only from such short-listed consultancy firms.
7.3.2 Entering into contract with consultancy Firm:

l Invitation of price-bid from short-listed consultancy firms:
A letter for invitation of Price-Bid involves preparation of a document containing
all conditions agreement envisaged pertaining to the consultancy job. It will
necessitate defining clearly the objective & scope of consultancy work (TOR),
various phases of providing consultancy job, time frame for each phase,
responsibilities of the Employer and the consultant, responsibility for accuracy of
project proposals, indemnity for loss due to acts/omissions of consultant, copyrights
and any other special conditions considered necessary to be incorporated in the
agreement with the consultant, etc. These are briefly described as under:
7 Ø OBJECTIVE:
The objective of engaging a consultant is to define the problem, determine
its solution and scope of repair & rehabilitation work. This shall be based on
the preliminary inspection of the work and discussions with Employer. The
scope of work shall be clearly defined.
Ø SCOPE OF WORK:
The consultant shall inspect work and conduct in-situ & laboratory tests
necessary to establish the cause - effect relation. He shall design repair,
rehabilitation and retrofitting scheme for the designated design life and
performance standards. The consultant shall be responsible for preparation
of detailed estimate within specified degree of accuracy, quality assurance
procedure, contract document for call of tender, inspection of work during
the execution of work and periodic inspection of work after completion. The
specifications, nomenclature of items of works, analysis of rates and standards
applicable shall be detailed out. He shall make presentation of his report to
the group of specified number of engineers identified by the Engineer in
Charge. The salient features shall be brought out in the presentation and
supporting literature shall be made available. He shall also be present at the
pre-bid conference to offer clarifications to the prospective tenderers. If
necessary, consultant shall modify the proposal, if necessary, after the pre-
bid conference
Ø PHASES OF THE WORK:
The consultancy job can be distinctly divided in to three phases of job.

A) Phase-I: The details should be given therein and should cover:

1. Collecting of information from the site.
2. Studying the structure in detail to determine the cause & extent of
deterioration of structure, its source, leakage, cracking pattern etc.
3. Recording distortions/deflections of structural members if any.
4. Visual inspection for surface damages, cracks, flaking, colouration,
local weaknesses etc and their damage classification.
5. Testing by tapping elements to test the surface hardness of concrete,
breaking small portions of concrete to assess the homogeneity of
concrete and condition of reinforcing steel with particular reference
to steel corrosion.
6. Conducting further N.D.E. techniques like Schmidt, U.P.V., core
tests etc. or combination of tests as required.
7. Collection & documentation of data in the form of grid drawings,
worksheets etc.
8. Arranging all necessary scaffolding, platforms, necessary T & P,
stationary, etc required for carrying out the field/ laboratory/ other
investigations and preparation of report.
9. Assessment of residual strength.
10. Analysis of structural repairs 7
11. Submission of preliminary report covering the above aspects

including the preliminary estimated cost of repairs/rehabilitation.
12. Identified key personnel shall make required number of visits as
per contract conditions.
13. The report shall be examined by the Employer and in case found
to be deficient or changes are required, modified report shall be
submitted by consultant after additional investigations, if necessary
& discussions with the Employer.
B) Phase-II: On acceptance of the phase-I report by the Employer,
consultant shall prepare & submit a detailed rehabilitation plan, which
shall include the following:
1. Details regarding selection of materials, equipment and methods
of rehabilitation. If any new materials/techniques are proposed,
they shall be supported with necessary technical/documentation/
data.
2. Detailed nomenclature of items to be executed.
3. Detailed specifications including acceptance criteria /standards for
work to be executed & materials used.
4. Identification of critical items of work requiring execution of
sample items of work under specialist supervision of consultant.

5. Step by step procedure for execution of work at different locations/

for different elements including surface preparation, method of
construction & techniques to be adopted.
6. Design of suitable concrete mixes, identification of critical items
of repairs requiring consultants supervision.
7. Detailed cost analysis along with bill of quantities for call of tenders.
8. Time Schedule for execution of work.
9. All drawings for execution shall be submitted in minimum of two
sets along with a set in a reproducible format.
10. Safety plan before and during repair/rehabilitation including details
of shuttering, centering & scaffolding required for repairs at
different locations, keeping in view intricacies involved like large
spans, extra heights, etc. Details for planned demolition of
structurally sensitive portions shall also be prepared.
11. All design calculations regarding residual strength, redesigning of
structure including appropriate strengthening with structural
drawings for approval by the Employer.
12. Methods of fixing fixtures/fittings etc for the reinstallation/
installation of services, false ceiling, interior decoration, etc shall
also be detailed out.
7 13. Detailed Quality Assurance System during execution.
14. Acceptance criteria of materials and the items of work to be
executed
15. Arranging all necessary T & P, stationary, etc required for carrying
out the field/ laboratory/ other investigations and preparation of
report
The proposal will be examined and approved by the Employer. If modification of
same the proposal is required, the consultant shall carry out the same.
a) Phase -III: The consultant shall participate in the pre bid conference to clarify
doubts raised by the prospective bidders. He shall render advice to department in
tender evaluation, if required. He shall also assist in supervision and quality
assurance of work during execution, conducting corrective supervision, acceptance
of work executed and issuing stability and rehabilitation certificate. The consultant
shall prepare guidelines for further maintenance and post repair periodic inspection.
The details of phase-III should provide for:
1) The consultant will be closely associated in the supervision of execution of
samples of critical items as may be identified by the consultant or the
Employer at the time of execution in order to ensure that the same is being
carried out as per their concept and approval. While routine supervision will
be carried out by the Engineer-in-charge, the consultant will render advice at
different stages of execution. The consultant shall send a team of identified
engineers having relevant experience for supervision as and when required
by the Employer.

2) It will also include revision of designs and drawings, due to shortcomings, if

any, which might surface at the time of execution. Consultant shall claim
nothing extra in this regard.
3) Carrying out quality assurance tests during progress of work. During the
actual testing the consultant shall be actively involved with the testing.
4) A detailed plan for maintenance manual.
5) Issue completion certificate based on acceptance tests carried out on
rehabilitated structure.
6) Recasting of as built drawings.
7) Arranging all necessary T & P, stationary, etc required for carrying out the
field/ laboratory/ other investigations.
8) Preparation of documentation using photographs, slides, videos, floppies,
written text etc.
Ø Time Frame
The time frame for each phase of work is shall be clearly defined in the letter of
Invitation of Price-bids as follows:
1. Phase-I PHASE-I (a) ________ weeks from the date of start of
work.
2. phasePhase-II (a) _______ weeks from the date of approval of preliminary 7
project report by the Engineer-in-charge.

3. Phase-III (a) _______ weeks from start of work.
i. The work shall commence from 10th day after the date of written orders
to commence the work.
ii. The progress of the work shall be reviewed in weekly meetings between
representative of consultantand Engineer, Employer and the contractor,
if any. The record of such meetings shall be maintained.
iii In case consultant is unavoidably hindered in carrying out the
investigation, design/drawings on account of delayed decisions or
approval by the Employer, which are necessary to carry out further work,
he shall apply for be allowed suitable extension of time to the on
occurrence of such hindrance. The decision of the Employer shall be
final and bindings on the consultant.
iv. In case of delays attributable to the Employer after the start of work, the
Employer shall be made liable to pay compensation to the consultant at
a rate as may be specified in the agreement towards the fixed charges of
establishment including the remuneration of the key personnel, only if
exclusively employed for the work in question.
v. For the delays attributable to the consultant, the consultant shall be made
liable to pay compensation to the Employer at a rate as may be specified
in the agreement

Ø Responsibility for Accuracy of Project Proposal

The consultant shall be responsible for-
i. Accuracy of the data collected at all stages of work,
ii. Procedure followed ,
iii. Safety & soundness of designs as per the design standards followed,
iv. Drawings prepared and their validation,
v. Quantity and rates taken in the estimates,
vi. Quality assurance procedure followed
Ø Indemnity for Loss
The consultant shall indemnify the Employer against any direct or indirect loss
due to inaccuracies in his proposal, which might surface at the time of
implementation of the project or after the stipulated period after the completion
of the work due to error in the analysis & design
Ø Copyright
All plans, design and data collected by the consultant for this project shall remain
the property of the Employer. The consultant shall have no right to deal with it in
any way, other than the purpose for which these were supplied, without the explicit
written consent of the Employer. All such plans, design and data or the process of
inspection shall be kept strictly confidential & not passed on to any unauthorised
person.
7
The proposals submitted by the consultant shall remain his property and shall not be
utilised by the Employer, without the explicit permission, for any other purpose other
than the purpose for which these are meant.
Ø Special Conditions:
i. The curriculum vitae and composition of the key personnel engaged in the
study & the job assigned to each one of them shall be submitted before hand
& got approved from the Employer.
ii. The key personnel once approved, shall not be changed without the prior
permission.
iii. Members of team should have requisite experience in the filed assigned to
them.
iv. In case of any specialised investigation agency is to be engaged, the details
of such agency shall be submitted & got approved from the Employer prior
to their engagement.
vi) The cost of engaging such an agency shall be borne by the consultants
themselves including cost of any unfrastructural infrastructure support
necessary to carry out the investigation.
l Reports:
The format for the report shall generally be in line with the outline as per the
details given in the Appendix-7.1.4.7. The consultant shall furnish two hard copies
of the final report and one in reproducible format.

l Evaluation of the price-bids:

The financial implications of any condition(s) given in the price bids by the bidders
have to be carefully evaluated and loaded on the prices quoted to bring them at
the equitable level of comparison for determining the lowest price-bid. As the
price-bids have been received out of short-listed consultancy firms of requisite
experience and competence, it would be desirable to select the evaluated lowest
price-bid for negotiating a contract
l Negotiating a contract with the selected consultancy firm:
Following the decision of the winning consultancy firm, the selected firm is invited
to negotiate the contract with the Employer. The work plan, staffing, Employer’s
inputs, and the final form of the agreement are completed before the financial
negotiations. The staff substitution by a consultancy firm is undesirable at any
time and particularly between the receipt of the proposal and the start of fieldwork.
However, if the validity of the price-bid has lapsed, staff substitution may be
discussed during the negotiations. During an assignment, if the staff substitution
is necessary due to ill health or otherwise, the consultant should propose some
other appropriate staff for approval of the Employer during such negotiations.
Conduct of negotiations on price is customary because the selection process has already
been made on technical basis before the receipt of price-bid. In cases where the best
consultancy firm is not the lowest priced, asking them to do the work at the lowest
price, is not appropriate. Another practice, which does not encourage deliverance of
the quality is to negotiate with more than one firm at the same time.
7
Promptly after the completion of negotiations with the selected firm, the Employer
should notify all other firms on the short-list that they were unsuccessful.
A sample form of Agreement with the consultancy firm is available at Appendix 7.2.
7.4 Engagement of Contractors:
The execution of structural repair and rehabilitation works require special skills,
knowledge of new materials and processes. The quality assurance has to be of high
standard. The civil contractors registered for new construction or for routine periodical
repairs cannot be considered competent for repairs and rehabilitation works. Only such
short-listed contractors, who qualify a minimum laid down standard, shall be made
eligible for issue of tender documents. The detailed departmental instructions of CPWD
for pre-qualification of contractors are available at Appendix-7.3.
It has generally been observed that the repairs and rehabilitation works are always
accompanied with the renovation, up-gradation and addition & alterations, which are
new construction works. Hence, it is desirable that single contractor is fixed for both
repairs and rehabilitation works as well as such works involving new constructions,
provided the quantum of such new works is not substantial.
7.4.1 Conditions of Contract
The repairs and rehabilitation contract be drawn up using standard CPWD contract
form PWD-8. However, the issues relating to specific requirement shall have to be
included as special conditions. The main issues to be addressed in such conditions of
contract are as follows:

l General Information:
The general information like content of the tender document, name of the project,
location, engineer-in-charge, the estimated cost, stipulated time, name/s of the
external agencies designated for quality assurance, general specifications, particular
specification, referred standards, minimum tools and plants requirement, technical
manpower requirement, list of mandatory tests & recommended tests, performance
standard, documentation requirement, tender drawings etc. are to be provided
stated in the contract.
l Facilities
a. Electricity
The electricity connection shall generally be made available by the department
at one point marked in the drawing. The sub meter shall be arranged and
sealed by the department. The distribution lines shall be laid by the contractor
at its own cost. The electricity charges at fixed rates shall be deducted from
the running bills from time to time according to actual consumption.
When the department cannot provide electricity, the contractor shall be
required to make his own arrangements.
b. Water
The water connection shall generally be made available by the department at
one point marked in the drawing. The distribution lines shall be laid by the
7
contractor at its own cost. The water charges at fixed rates shall be deducted
from the running bills from time to time according to the actual consumption.
When the department cannot arrange the connection, the contractor shall be
asked to make his own arrangements.
c. Tools & Plant
Tools or plants available with the department, which can be issued to the
contractor are required to be specified in the tender with hiring charges,
conditions etc.
l Constraints
l Sequence and Programme of Work
The contractor shall be required to submit detailed programme in identified
computer software for project monitoring giving details of activities, their sequence,
resources to be employed and time schedule etc for approval by the Employer. In
case the contractor feels that the time schedule mentioned in the contract is required
to be modified, he shall put forward detailed reasons for such a proposal. Such
modifications and other issues should be sorted out during the Pre-bid conference.
l Co-Ordination with other agencies:
Condition has to be inserted to ensure that the contractor extends all necessary
co-operation to the other agencies involved in the work by way of making necessary
adjustment in his work schedule including making site available to the other
agencies.
l Protective Measures:

The contractor shall take all suitable measures to protect the structures, environment
and workforce employed including passersby with necessary barricading,
protective screens, helmets, goggles, gloves etc.
l Temporary Works and Safety Arrangements
The contractor shall carry out temporary works to ensure that required dead loads,
imposed loads shared by the structural members under repair are safely transferred
to the foundation. The rates quoted for all items of work, unless otherwise
specifically provided, shall include the cost of providing all temporary works.
l Signage:
The entry to work area may be restricted to workmen and inspecting staff only.
Notice boards of specified sizes shall be provided at appropriate locations for
wide information.
l Required Skill of workmen:
Certain items of repairs and rehabilitation e.g. jacketing, shotcreting, epoxy/
polymer based items, micro-concreting, pre-placed aggregate concrete, etc require
qualified/experienced & skilled workmen for execution. Wherever feasible,
suitable provision can be incorporated accordingly.
7.4.2 Pre-bid conference:

As the type of job to be contracted is of specialised nature, it could involve certain
innovation with scope of further improvement by way of modification and/or
rectification in the specifications contained in the tender documents. Also, some 7
conditions in the tenders might be difficult to achieve in field. These are required to be
discussed openly and mutually agreed in a Pre-bid conference with all tenderers,
Employer and the consultant. This shall be done at least one week after the date of
issue of tender documents and one week before the date of receipt of tenders. The
proceedings of the Pre-bid Conference and decisions taken shall be made available to
all the tenderers at least 2 days before the date of receipt of the tenders and shall form
part of the tender documents. Provision shall be made in the tender documents
accordingly.
7.5 Execution of Work

The aspects such as material storage, deployment of T & P, quality assurance, execution
of sample of critical items, Tools & plant, etc given in para 9.0 shall also be considered
and included in the tender documents.
7.5.1 Materials: Materials proposed to be deployed at work site, their storage arrangements,
etc shall be submitted by the contractor before the commencement of the work. Suitable
provisions are required to be incorporated for the materials brought to site, which shall
be reported in the prescribed proforma in triplicate (Appendix-7.4) giving clearly the
name of manufacturer, local source (i.e. dealer), batch no, manufacturer’s test certificate
etc. Materials shall be kept under recommended conditions storage to avoid damage to
the materials. The materials shall be kept in the joint custody under double lock and
key system and their receipt & issue recorded in a register by the representative of the
Employer.
l Single Source: It is always recommended to procure all materials for repairs and

protection systems (e.g reinforcement protective system, bonding aid or primer,

repair mortar, surface filler, finishing coat and protection systems) from single
manufacturer. Otherwise there could be divided responsibility in owning up the
non-performance of a material, if such problem arises. If use of product from
multiple manufacturers is unavoidable then the combination should be checked
for compatibility. The evidence of previous successful use of materials in
combination would also be useful.
l Supply: It is desirable to enforce the receipt of total assessed quantity of repair
materials (e.g. reinforcement protective system, bonding aid or primer, repair
mortar, surface filler, finishing coat, protection systems, etc) at site required in
one lot at the appropriate stage. In case total requirement of materials cannot be
brought at a time due to project period being too long or shelf life of the materials
being short, the quantity of material to be brought shall accordingly be received
in minimum number of lots.
l Storage: The storage facilities are required to be stated by the contractor in his
tender. It shall be commensurate with the quantity likely to be stored at the start
and during the execution of work.
l Testing of Materials: The contractor shall supply manufacturer’s test certificate
of each material brought to site of its batch of manufacture. The claims of
manufacturers in regard to performance of materials may vary substantially for
specific climatic conditions. Therefore it is essential that the ambient conditions
for carrying out performance tests be specified in tender documents.
In addition, each lot of supply shall be tested for ensuring the desired quality standards.
7
The sampling of materials shall be done in the presence of representatives of contractor
and the Employer. The sampling and testing shall be done at specified frequency. The
record of test results shall be maintained in the prescribed format for future reference.
7.5.2 Testing of Completed items of Work:
The specific post repair evaluation tests must be specified. The frequency of tests shall
also be incorporated as specified by the consultant.
l Costs of Field/Laboratory tests:
The cost of sample and test charges may be borne by the Employer. However, if
the sample fails in the performance test, the cost of samples and the testing charges
shall be borne by the contractor.
7.5.3 Tools & Plants: The minimum identified Tools & Plant for the all the processes and
testing shall be clearly specified in the tender documents. Also the contractor, while
tendering, should be required to inform the details of Tools & plants proposed to be
deployed by him on the work. The tools and plants shall be kept in good working
condition. Periodic preventive maintenance shall be carried out in order to avoid sudden
break down and loss of working time.
7.5.4 Supervision and Inspection of works
l Critical Repair Items :
Execution of sample of all critical repair items, identified by the consultant, shall
be done in the presence of consultant and the Employer. It shall be pre requisite
for taking up execution of subsequent stage of work. The record of observations
made by the consultant during supervising execution of all such samples of critical
items, shall be maintained in a proforma prescribed by the consultant for each of
the critical repair items.

l Record of Supervision and inspection of Surface preparation:

A record of day-today supervision and inspection of surface preparation shall be
maintained by the contractor in a proforma prescribed by the consultant under the
close supervision of the Employer or their authorised representative.
l Supervision by the Consultant: The consultant shall carry out inspection and
testing at the specified interval for testing integrity of repairs with the substrate
and its soundness, including impermeability and corrosion resistance tests for
repairs. The consultant shall inspect to ensure that the work is carried out as per
his recommendations. The frequency and stages of inspection shall be specified
in the contract. The consultant shall give his written report with his observations
and also make recommendations for any deviation/remedial measures. These shall
be binding on the contractor.
7.5.5 Record of Testing, Supervision and Inspection:
The record of Inspection, supervision and testing of all materials, surface preparation
etc shall all be taken over and preserved by the Employer for a specified period
(preferably 5 years)
7.6 Post Repair Inspection
The consultant along with the Employer and the contractor shall carry out periodical
inspection after completion of works at specified frequency (preferably every year) for
a post repair period of five years. This is to ensure that the post repair defects are
identified and effective remedial measures are taken. Also, the post repair maintenance 7
is ensured to be carried out as per recommendation. This is necessary to ensure that
completed work meets the intended durability and other performance requirements.
Suitable provisions in the contract documents of the contractor and the consultant shall
be made accordingly.
7.7 Performance Guarantee
The consultant shall guarantee the performance of the works as per designs and
specifications prepared by him. In the event of failure to achieve the guaranteed
performance laid down in the agreement due to reasons directly attributed to the
consultant, he shall be liable for such failure and liability shall be limited to a maximum
amount specified in the agreement.
✯ ✯ ✯

1. The Concrete Society Technical Report no. 26, Repair of concrete Damaged by
Reinforcement Corrosion
2. German Committee on Reinforced Concrete, Guidelines for Protection and Repair
of Concrete Components, part 3 Quality Assurance in the Execution of Works
3. Guidelines-Use of Consultants by World Bank Borrowers and by the World Bank
as Executing Agency, August 1981 (ISBN 0-8213-9000-7)
4. National Highways Authority of India methodology including Criteria for Selection
of Consultants
5. Employer-Consultant Model Services Agreement-1999 by Consulting Engineers
Association of India and Consultancy Development Centre
6. Pre-Qualification Document for CPWD Works as amended by Office
Memorandum No. DGW/MAN/65 dated 4 April, 2001 and No. DGW/MAN/81
dated 28-12-2001.

Appendix 7.1
AN ILLUSTRATIVE
PRE-QUALIFICATION DOCUMENT
For
SHORT-LISTING OF CONSULTANTS
7
For Undertaking
FIELD INVESTIGATIONS & SUBMITTING PROPOSALS
For
REPAIRS, REHABILITATION AND

RETROFITTING OF RCC BUILDINGS

Appendix 7.1(Contd..)
INDEX
S. Description Page
No.
1. Press Notice - Invitation to Pre-Qualify Appendix 7.1.1
2. Section I - Brief Description of the work Appendix 7.1.2
3. Section II - Information & instruction to Appendix 7.1.3
applicants
4. Section III - Pre-qualification information Appendix 7.1.4
i) Letter of Transmittal Appendix 7.1.4.1
i) Part-I-Curriculum Vitae Appendix 7.1.4.2
of Key Personal and
Alternate Key Personal.
iii) Part-II Proforma ‘X’ Appendix 7.1.4.3
iv) Part-II Proforma ‘Y’ Appendix 7.1.4.4
7 v) Part-II Proforma ‘Z’ Appendix 7.1.4.5
vi) Evaluation Abstract Appendix 7.1.4.6
vii) Suggested Format of Report Appendix 7.1.4.7

Appendix 7.1.1
PRESS NOTICE
CENTRAL PUBLIC WORKS DEPARTMENT
INVITATION TO PRE-QUALITY
1. The Executive Engineer <Specific particulars of the Employer to be filled> , on behalf
of the President of India invites pre-qualification applications from Consultants/
Consultancy Firms of repute for the following work(s): -
Sl.No. Name of work Nature of Approx. Cost / Plinth Period of
Area of Building Completion
<Write Name of <Size of the project/ <Duration for

Work as per TOR Cost Estimate (Refer completion of
(Refer para 7.2.1 of para 7.2.1 of the Consultancy job up
the Handbook)> Handbook)> to Phase-II as per
para 7.3.2 of the
Handbook>
2. Applicant Consultants/ Consultancy Firms, who fulfill the following requirements shall
be eligible to apply (The applicants are allowed to pool the resources of maximum one
associate consultant/associate consultancy firm). 7
a. Applicants should have satisfactorily completed consultancy jobs of investigating

more than 90% of the plinth area of work in question for of the identically distressed
building projects during the last five years ending the last day of the month with
each job having plinth area not less than 30% of that of the work in question (at
least one project out of them shall be of Central Government/Central Autonomous
Body/Central PSU).
b. Should not have incurred any loss in more than two years during the last five
years ending <Write the last date & month of preceding Financial Year>.
c. Should have been in business of providing consultancy in civil Engineering for a
minimum period of five years as on <Write the last day of preceding calendar
month of the date of receipt of letter of transmittal>.
d. Should have had average annual financial turnover not be less than Rs. <As a
guide, 1.5 times the average equivalent technical personnel (ETP) establishment
cost envisaged in Proforma X> lakhs during the last three years in consultancy
jobs of Investigation of distressed RCC structures, submitting proposals for
rehabilitation, preparation of structural designs and drawings of new buildings.
Year in which no turnover is shown would also be considered for working out the
average.
3. Desirous Consultants or Consultancy Firms may obtain prescribed blank ‘Pre-
Qualification Document’ from the Executive Engineer <Specific particulars of the
Employer to be filled> on payment of Rs. < to be filled in> in cash, upto 3.30 PM on
<Date, month and Year to be filled in> on making a written request.

4. ‘Pre-Qualification Document’ duly completed and supported with prescribed Appendixs

and supporting documents shall be received up to 03.00 P.M. on <Date, month and
Year to be filled in> in sealed envelope with name of work and due date of opening
super scribed legibly in bold letters on envelope. These will be opened by the Executive
Engineer or his authorised representative in his office on the same day at 03.30 P.M in
presence of the applicant consultants/authorised representatives of the applicant firms.
5. If any information furnished by the applicant is found to be incorrect at a later stage,
the applicant shall be liable to be debarred from the tendering/taking up works in CPWD.
The department reserves the right to verify the particulars furnished by the applicants
independently.
6. The department reserves the right to reject any application without assigning any reason
and to restrict the list of prequalified consultants to any number deemed suitable by it,
if too many applications are received satisfying the basic pre-qualification criteria.
EXECUTIVE ENGINEER

Appendix 7.1.2
SECTION – 1
BRIEF PARTICULARS OF THE WORK
1. Salient details of the work for which pre-qualification applications are invited are as
under :
Sl.No. Name of work Nature of Approx. Cost / Plinth Period of
Area of Building Completion
<Write Name of <Size of the project/ <Duration for
Work as per TOR Cost Estimate (Refer completion of
(Refer para 7.2.1 of para 7.2.1 of the Consultancy job up
the Handbook)> Handbook)> to Phase-II as per
para 7.3.2 of the
Handbook>
2. The work is located at < Address of the work> .

3. General features and major components of the work are as under:
7
<Briefly Describe
Ø the Nature of distress,
Ø structural rehabilitation/strengthening, remodeling details,
Ø renovation and other addition/alteration, etc. as may be envisaged>
4. Consultancy services shall be rendered in <Fill number of phases-Refer para 7.3.2 >
phases as under:
a.Stage-I: (Refer para 7.3.2)
b.Stage-II: (Refer para 7.3.2)
c.Stage-III: (Refer para 7.3.2)

Appendix 7.1.3
SECTION II
INFORMATION AND INSTRUCTIONS TO APPLICANTS
1.0 GENERAL:
1.1 Letter of transmittal & Proformas for pre-qualification are given in Section III
1.2 All information called for in the enclosed Proformas should be furnished against the
respective columns in the forms. If information is furnished in a separate document,
reference to the same should be given against respective columns in the forms. If
information is ‘nil’ it should also be mentioned as ‘nil’ or ‘no such case’. If any
particulars/query is not applicable in case of the applicant, it should be stated as ‘not
applicable’. However, the applicants are cautioned that not giving complete information
called for in the application forms required, not giving it in clear terms or making any
change in the prescribed forms or deliberately suppressing the information may result
in the applicant being summarily disqualified. Applications made by telegram or telex
and those received late will not be entertained.
1.3 The application should be typewritten. The applicant’s name should appear on each
page of the application.
1.4 Overwriting should be avoided. Correction, if any, shall be made by neatly crossing
out, initialing, dating and rewriting.
1.5 All pages of the pre-qualification document shall be numbered and submitted as a
7
package with signed letter of transmittal.
1.6 References, information and certificates from the respective past/ present employers
certifying the applicant’s experience, suitability, technical know-how or capability
should be signed by an officer not below the rank of Executive Engineer/Project Manager
or equivalent.
1.7 The applicant may furnish any additional information, which he thinks is necessary to
establish his capabilities to successfully complete the envisaged work. He is, however,
advised not to attach superfluous information.
1.8 No further information shall be entertained after submission of Pre-Qualification
Document, unless it is called for by the Employer.
1.9 The Pre-Qualification Document in prescribed form duly completed and signed shall
be submitted in a sealed cover. The sealed cover superscribed “Pre-Qualification
Document for <Name of Work>”shall be received by the Executive Engineer, or his
authorised representative upto 3.00 P.M. on <Date, month and Year to be filled in>.
Documents submitted in connection with pre-qualification will be treated confidential
and will not be returned.
1.10 The employer reserves the right to verify the particulars furnished by the
applicants independently.
1.11 Any information furnished by the applicant found to be incorrect either immediately
or at a later date, would render him liable to be debarred from taking up work in CPWD.
1.12 Prospective applicants may request clarification of the project requirement and pre-
qualification document. Any clarification given by the Employer will be forwarded to
all those who have purchased the pre-qualification document. No request for clarification
will be considered after <Date, month and Year to be filled in>.
1.13 The department reserves the right to reject any application without assigning any reason
and to restrict the list of pre-qualified consultants to any number deemed suitable by it,
if too many applications are received satisfying the basic pre-qualification criteria.
The department reserves the right to reject
2 DEFINITIONS:
2.1 In this document the following words and expressions have the meaning hereby assigned
to them.
l “APPLICANT” means the individual, proprietary firm, firm in partnership, limited
company private or public corporation engaged in the business of rendering
consultancy services for civil engineering projects and had applied for pre-
qualification as consultant for the project.
l “ASSOCIATE” means an associate consultant/associate consultancy firm of the
Consultant to complement or supplement its resources for performing the
consultancy services for the Project.
l “EMPLOYER” Means the President of India, acting through the Executive
Engineer <Specific particulars of the Employer to be filled>.
l “KEY PERSONAL” and “ALTERNATE KEY PERSONAL” means agreed
technical personnel representing the Consultant, who are overall responsible for
supervising/overseeing all field & laboratory investigations & testing of collected
samples, recommendations and signing all reports, drawings, technical
specifications, contract conditions, quality assurance procedure, execution of
identified critical repair items, etc and their accuracy.
l “PROJECT” means the works for which the consultancy services are to be
7
provided.
l “SERVICES” means the services to be performed by the Consultant in accordance
with the Agreement and comprise Normal Services, Additional Services and
Exceptional Services.
l “WORKS” means the permanent works to be executed (including the goods and
equipment to be supplied to the Employer) for the execution of the Project.
3 METHOD OF APPLICATION:
3.1 If an individual makes the application, the individual above his full typewritten name
and current address shall sign it.
3.2 If a proprietary firm makes the application, it shall be signed by the proprietor above
his full typewritten name and the full name of his firm with its current address.
3.3 If the application is made by a firm in partnership, it shall be signed by all the partners
of the firm above their full typewritten names and current address or alternatively by a
partner holding power of attorney for the firm, in which case a certified copy of the
power of attorney shall accompany the application. A certified copy of the partnership
deed and current address of all the partners of the firm shall also accompany the
application.
3.4 If a limited company or a corporation makes the application, it shall be signed by a
duly authorised person holding power of attorney for signing the application
accompanied by a copy of the power of attorney. The applicant should also furnish a
copy of Memorandum of Articles of Association duly attested by a Public Notary.
3.5 If the applicant has an associate, the applicant shall obtain and submit with the

application an explicit irrevocable written consent from such associate to provide

consultancy service clearly defining scope of services to be provided by the Associate.
3.6 The applicant and the associate consultant(s) shall also give joint undertaking that the
applicant shall not be allowed to change the associate consultant(s) at a later date.
3.6 In case of associates associated with the applicant, the Part I and Part II of the application
form shall be separately filled up & signed by the applicant and the Associate. The
applicant shall necessarily sign the proforma pertaining to the associate.
3.7 The Applicant shall sign each page of the application form and all the Appendixs
submitted therewith.
4.0 FINAL DECISION MAKING AUTHORITY
The employer reserves the right to accept or reject any application and to annul the
pre-qualification process and reject all applications at any time, without thereby incurring
any liability to the affected applicants or specifying the grounds for the Employer’s
action.
4.0 PARTICULARS PROVISIONAL
The particulars of the work given in Section-I are provisional and must be considered
only as relevant information to assist the applicant.
6.0 SITE VISIT
The applicant is advised to visit and examine the site of work and its surroundings and
obtain for himself on his own responsibility, all information that may be necessary for
7
preparing the pre-qualification application. The cost of visiting the site and/or obtaining
any additional information shall be at applicant’s own expense.
7.0 INITIAL CRITERIA FOR ELIBILIGY FOR PRE-QUALIFICATION
7.1 The applicant should be in business of providing consultancy in Civil Engineering for
a minimum period of five years as on <Write the last day of preceding calendar month
of the date of receipt of letter of transmittal>.
7.2 The applicant should have satisfactorily completed works of similar class of magnitude
as specified below during the last five years. For this purpose total plinth area of the
work investigated by the consultant shall be considered, which an officer not below
the rank of Executive Engineer/ Project Manager or equivalent should certify.
“Applicant should have satisfactorily completed consultancy jobs of investigating more
than 90% of the plinth area of work in question of the identically distressed building
projects during the last five years ending the last day of the month with each job having
plinth area not less than 30% of that of the work in question (at least one project out of
them shall be of Central Government/Central Autonomous Body/Central PSU).”
7.3 The applicant’s average annual financial turn-over (gross) should not be less than Rs.
<As a guide, 1.5 times the average equivalent technical personnel (ETP) establishment
cost envisaged in Proforma X> lakhs during the last three years duly audited by
Chartered Accountant in consultancy jobs of Investigation of distressed RCC structures,
submitting proposals for rehabilitation, preparation of structural designs and drawings
of new buildings. Year in which no turnover is shown would also be considered for
working out the average.
7.4 The applicant or his associate should own adequate Investigative Non Destructive
Evaluation equipment and laboratory facilities required for the proper and timely

investigation. The applicant should furnish a list of these equipment.

7.5 The applicant should have sufficient number of Technical and Administrative employees
for the proper execution of the consultancy job. The applicant should submit a list of
these employees stating clearly how these would be involved in this Consultancy job.
7.6 The applicant’s performance for each work completed in the last 5 years and in hand
should be certified by an officer not below the rank of Executive Engineer/Project
Manager or equivalent.
8.0 EVALUATION CRITERIA FOR PRE-QUALIFICATION
8.1 For the purpose of pre-qualification, applicants will be evaluated in the following
manner:-
8.2 The initial criteria prescribed in para 7.2 & 7.3 above in respect of experience of similar
class of works completed and financial turn over will first be scrutinised and the
applicant’s eligibility for pre-qualification for the work be determined.
8.3 Those firms qualifying the initial criteria as set out in para 7.2 & 7.3 above will then be
evaluated for following criteria.
(a) Key Personal and the Alternate Key Personal
(b) Technical Personnel Establishment
(c) Experience in similar class of work.
(d) Performance on these works.
(e) Non-Destructive Evaluation instruments, analytical & design tools, Technical
Library.
7
The details given by the applicants in the pre-qualification document will be evaluated
by scoring method. To pre-qualify, the applicant must secure at least fifty percent in
each of the above criteria and fifty percent in total as under:
S.No Description Weightage Minimum

Marks Obtained Marks for
Eligibility
Part-I KEY PERSONAL /
Alternate KEY PERSONAL
I.Key Personal 100 60
II. Alternate Key Personal 100 50
Part-II GENERAL
X Structure & Organisation (XX) 30 15
i. Existence of the Firm 5 (Refer
Proforma (X)
ii. Financial Turnover 5
iii Equivalent Technical Personnel (ETP) 15
iv. Geographical Location 5
Y Particular Experience (YY) 50 25
i. Experience in Investigation of 20(Refer
Deteriorated Structures and recommending Proforma (Y)
Remedial Measures
ii. Field Supervision of Repairs & Rehabilitation
Jobs 10

S.No Description Weightage Minimum

Marks Obtained Marks for
Eligibility
iii. Structural Analysis and Design 20

Z Adequecy for Assignment (ZZ) 20 10
I. Field/Laboratory Testing Facility 10 (Refer
Proforma Z)
ii. Computer Hardware & Software 5
iii. Technical Library 5
Total (XX+YY+ZZ) 100 50
8.4 Even though applicants may satisfy the above requirements, they could be disqualified
if they have:
(a) Made misleading or false representation or deliberately suppressed the information
in the forms, statements and enclosures required in the pre-qualification document.
(b) Records of poor performance such as abandoning work, not properly completing
the Consultancy job or financial failures/ weaknesses.
9.0 FINANCIAL INFORMATION
Annual financial statement for the last five years to be given in Part-II-Proforma ‘X’.
These should be supported by audited balance sheets and profit and loss accounts duly
7
certified by a Chartered Accountant, as submitted by the applicant to the Income Tax
Department.
10.0 EXPERIENCE, IN CIVIL CONSULTANCY WORKS HIGHLIGHTING
EXPERIENCE IN SIMILAR WORKS
10.1 Applicant should furnish the following :-
(a) List of all works of Nondestructive Evaluation (NDE), Preparation of Reports,
Implementation of Structural Repairs awarded during the last five years: [In
Proforma Y(A) of Part-II ].
(b) List of the projects of work supervision of Structural Repairs awarded in last five
years [In Proforma Y(B) of Part-II ]
(c) Structural Analysis & Design of New Projects of all Consultancy Jobs awarded
in last five years [In Proforma Y (C) of Part-II]
10.2 The performance on completed works, that determine eligibility of applicant shall be
authenticated/ certified by an officer not below the rank of Executive Engineer/ Project
Manager or equivalent and separately for each work.
11.0 ORGANISATION INFORMATION
APPLICANT IS REQUIRED TO SUBMIT THE FOLLOWING IN RESPECT OF
HIS ORGANISATION (In Part-II-Proforma X)
(a) Name and postal address, website, email address i/c telephone & telex number
etc.
(b) Copies of original documents defining the legal status, place of Registration and
principal places of business.

(c) Names and title of Directors and officers to be concerned with the work, with
designation of individuals authorised to act for the organisation.
(d) Authorisation for employer to seek detailed references.
(e) Number of Technical employees with consultant/consultancy firm, associate
consultant/consultancy firm and how these would be involved in this work (In
Part-II-Proforma X).
12.0 Non-Destructive Evaluation Instruments and other Investigative, Analytical &
Design Tools, Technical Library
Applicant should furnish the list of Non-Destructive Evaluation Instruments and other
Investigative, Analytical & Design Tools e. computers, structural analysis and design
software to be used in carrying out the work together with the Technical books and
Joutrnals (In Part-II Proforma Z). Details of any other important investigative instrument
required for the work (not included in Proforma Z) and available with the consultant
may also be indicated.
13.0 LETTER OF TRANSMITTAL
The applicant should submit the letter of transmittal attached with pre-qualification
document.
14.0 Price-Bid Submission
After evaluation of pre-qualification applications, a list of qualified consultants/
consultancy firms will be prepared. Thereafter, only those agencies pre-qualified for
7
the work will be invited to submit price bids for the work.
15.0 SELECTION CRITERIA
15.1 The employer reserves the right to :-
(a) Amend the scope and plinth area of the building for submission of Price-bids.
(b) Reject any or all the Price-Bids without assigning any reason.
15.2 For any of the above actions, the Employer shall neither be liable for any damages, nor
be under any obligation to inform the Applicants of the grounds for the same.
15.3 Effort on the part of the bidder or his agent to exercise influence or to pressurise the
employer for his price bid shall result in rejection of such bid. Canvassing of any kind
is prohibited.

Appendix 7.1.4
SECTION III
PRE-QUALIFICATION INFORMATION
i) Letter of Transmittal Appendix 7.1.4.1

i) Part-I-Curriculum Vitae of Appendix 7.1.4.2
Key Personal and Alternate
Key Personal.
iii) Part-II Proforma ‘X’ Appendix 7.1.4.3
iv) Part-II Proforma ‘Y’ Appendix 7.1.4.4
v) Part-II Proforma ‘Z’ Appendix 7.1.4.5

Appendix 7.1.4.1
LETTER OF TRANSMITTAL
From :-
_____________________
_____________________
_____________________
To
The Executive Engineer,
______________________
______________________
Sub.: Submission of pre-qualification application for the work of <Name of work>.
Sir,
Having examined the details given in pre-qualification Press Notice and Pre- 7
Qualification Document for the above work, we hereby submit the pre-qualification
and relevant documents.
1. We hereby certify that all the statements made and information supplied in
the enclosed form Part-I and Part-II (Proforma X, Y and Z) including that of
the associate consultant/associate consultancy firm and accompanying
documents/statements are true and correct.
2. We have furnished all information and details necessary for pre-qualification
and have no further pertinent information to supply.
3. We submit the following certificates in support of our eligibility to be
determined in accordance with the Press Notice for having successfully
completed the following works:-
Particulars of the Works :
Sl.No. Name of work Plinth Area Completion Month & year

Cost, if of completion
known
1
2
3

4. Following are the details of our Associate for the specific scope of work mentioned
as under:-
Sl Name of the associate Full Address of the associate Specific scope of work of the
No. consultant/associate consultant/associate associate consultant/associate
consultancy firm for consultancy firm consultancy firm
the <Name of Work>
The explicit irrevocable written consent obtained from the above said Associate to
provide consultancy service, with his scope of work as above, is enclosed. Also, a joint
undertaking that we shall not be allowed to change the associate at a later date signed
by us and the associate is enclosed.
5. The Part-I and II of the Application form with the proformas duly complete &
signed by the Associate and by us are also enclosed:-
Enclosures :
Seal of applicant
Date of submission SIGNATURE OF APPLICANT

Appendix 7.1.4.2
PART-I: CURRICULUM VITAE OF ‘KEY PERSONAL’ AND

‘ALTERNATE KEY PERSONAL’
Important: 1. The applicants must fill information in each column without fail.
2. In case of nil information, NIL should be filled in.
3. Additional sheets could be attached; wherever space provided is
not enough.
4. Separate Proforma shall be used in respect of Main Applicant
Consultancy Firm and each of its Associate Consultancy Firm
PART-I Key Personal Alternate Key Personal
1. Name
2. Date of birth
3. Qualifications Subject, year of acquisition

B. Tech/M.Tech./ Other
4. Specialisation 7
5. Length of General Details of companies served, Names of Projects designed/
Professional Experience executed/investigated, duration and nature of experience to
be given in Chronological Sequence starting from latest to
the oldest assignment
6. Length of specialised Details of companies served, Names of Projects investigated,
Experience in duration and nature of experience to be given in
Investigation of Chronological Sequence starting from latest to the oldest
Deteriorated Structures assignment
and recommending
Remedial Measures
7. Experience in Civil Details of companies served, Names of Projects designed/

Engineering Projects in executed/investigated, duration and nature of experience to
Developed countries be given in Chronological Sequence starting from latest to
Developing countries the oldest assignment
8. Experience in Civil Details of companies served, Names of Projects designed/

Engineering Projects in executed/investigated, duration and nature of experience to
other Developing be given in Chronological Sequence starting from latest to
countries Developing the oldest assignment
countries
9. Period of continuous
Employment with
Applicant Consultancy
Firm

Certificate:
The Information furnished above is true to my knowledge and belief. I am aware that
any mis-information or its concealment, which forms the basis of pre-qualification, is
liable for any action against the firm, which could include termination of the agreement
and/or blacklisting.
(Name & Signature

(Name and Signature of the Key Personal or of authorised Signatory of
Alternate Key Personal) the Consultancy Firm with seal)

Appendix 7.1.4.3
PART-II Proforma X: GENERAL INFORMATION:

3. Additional sheets could be attached; wherever space provided is not enough.
4. Separate Proforma shall be used in respect of Main Applicant Consultancy
Firm and each of its Associate Consultancy Firm
1. Name of Consultant Firm :
2. Legal Status of the Firm
(Individual/Proprietary Firm/
Firm in Partnership/Limited
Company/Corporation) Attach
signed copies original documents
defining the status :
3. Particulars of Registration with
various Govt Bodies (Attach
attested Photocopies) : 7
Sl No Name of the Govt Department Registration No Validity Period
4. Postal Addresses of headquarter

& Branches, if any :
5. E-mail Address :
6. Website :
7. Audited Financial Turnover for
Last Five Years :
S.No. Year Turnover ( Rs in lakhs) Profit /loss
1.
2.
3.
4.
5.
(Enclose Copy of audited Reports and Income Tax Clearance Certificates)

8. Technical Staff employed with the firm :
Sl Name of Designa Date of Technical General Proposed

No. the tion Birth Qualification Professional utilisation
Employee and year of experience of the
acquisition in Civil person for
(Diploma/ Engineering the job
Degree/Ph.D in practice
Engineering/
MBA be clearly
mentioned)
Certificate:
7
(Name &Signature of authorised Signatory with seal)

Witness with address:

Appendix 7.1.4.4
PART-II Proforma Y: PARTICULAR EXPERIENCE
A. Nondestructive Evaluation (NDE), Preparation of Reports, Implementation of
Structural Repairs (Chronological list of all Consultancy Jobs awarded in last
five years) (Attach attested photocopies of documentary proof)
S.No Project Employer Estimated Plinth Date of Whether If not
Cost Area award of comple- comple-
involved consulted ? ted,
tancy (Yes/No) state
job reasons
2
7
B. Works supervision of Structural Repairs (Chronological list of all Consultancy

Jobs awarded in last five years) (Attach attested photocopies of documentary proof)
job reasons
C. Structural Analysis & Design of New Projects (Chronological list of all Consultancy
Jobs awarded in last five years) (Attach attested photocopies of documentary proof)
job reasons

D. Whether applicant firm or any of its partners ever debarred or blacklisted by

any organisation at any time? If so, details
Name of the debarring/ Name of the Applicant Firm or Brief Particulars of
blacklisting Department/ any of its partner in individual blacklisting/debarring
Organisation capacity, debarred/blacklisted from tendering
E.
F. Any Other Information related to Experience
Certificate:
(Name &Signature of Authorized Signatory with seal)

Witness with Address
1.
7
2.

Appendix 7.1.4.5
PART-II Proforma Z: ADEQUACY FOR THE ASSIGNMENT
A. Non Destructive Evaluation (NDE) Instruments available with the Consultancy
Firm:
S.No Instrument Make & Year of Field of Whether in

Model acquisition utilization in working
testing of Condition?
structure (Yes/No)
1. 7
2.
B.1 Analytical Computer Hardware:
S.No Machine No Brand & Year of Specifications Whether in

Model acquisi- working
tion Condition?
(Yes/No)
1.
2.
B.2 Structural Analysis and other Softwares
S.No Software Developed by year Purpose

(Commercial Name, if
procured)
1.

C. Technical Library :
S.No. Standard / Books Numbers
1 Technical Books
2 Technical Journals
3 Indian Standards/Codes of Practice
4 Foreign Standards/Codes of Practice
Total
Certificate:
(Name & Signature of authorised Signatory with seal)
7

Appendix 7.1.4.6
EVALUATION ABSTRACT FOR SHORT-LISTING OF CONSULTANTS
(for use in Employer’s Office)
Summery
S.No Description Weightage Marks Minimum

Obtained Marks for
Eligibility
Part-I KEY PERSONAL / Dy

KEY PERSONAL
A Key Personal 100 60
B Dy Key Personal 100 50
Part-II GENERAL
A Structure & Organisation 30 XX 15
i. Existence of the Firm 5 (Refer

ii. Financial Turnover 5 Sheet X)
iii Equivalent Technical
Personnel (ETP) 15
iv. Geographical Location 5 7
B Particular Experience 50 YY 25
i. Experience in Investigation
of Deteriorated Structures and
recommending Remedial Measures 20 (Refer
ii. Field Supervision of Repairs & Sheet Y)
Rehabilitation Jobs 10
iii. Structural Analysis and Design 20
C Adequecy for Assignment 20 ZZ 10
i. Field/Laboratory Testing Facility 15 (Refer

ii. Computrer Hardware & Software 5 Sheet Z)
Total 100 XX+YY+ZZ 50

Appendix 7.1.4.6 (..Contd)

EVALUATION ABSTRACT OF PART-I FOR SHORT-LISTING OF CONSULTANTS
(For use in Employer’s Office)
Part I Proforma for Key and Alt. Key Personal
S. Item Marks Scored

No.
A Educational Qualification Y/N Marks (A)

(Maxi Marks 20)
(I) Graduate in Civil Engineering
(Weightage=75%)
(II) Post Graduate in Civil Engineering
(Weightage=90%)
(II) Ph.D in Civil Engineering
(Weightage=100%)
Total(A) AA
B Age : Max Marks 5 (Y/N Marks (B)

7
(I) 40 to less than 50 yrs
(Weightage=50%)
(II) 50 to less than 60 yrs
(Weightage=100%)
(III) 60 to 65 yrs
(Weightage=50 %)
Total Marks(B) BB
C General Professional Experience (Y/N) Marks (C)

(Max Marks=15)
(I) 25 yrs and above

(Weightage=100%)
(II) 20 yrs and above

(Weightage=80%)
(III) Less than 20 yrs

(Weightage=50%)
Total Marks(C) CC
D Experience in (Y/N) Marks (D)

Investigation of Deteriorated
Structures and recommending
Remedial Measures
(Max Marks=40)

(I) More than seven Projects Completed

(Weightage=100 %)
(II) Four to Six Projects Completed
(Weightage=80%)
(III) One to three Projects Completed
(Weightage=50%)
Total Marks(D) DD
E Experience in Civil Engineering (Y/N Marks (E)

Projects executed in Developed
Countries (Max Marks=10)
(I) Three Projects and above

(Weightage=100%)
(II) Two Projects
(Weightage=80%)
(III) One Project
(Weightage=50%)
Total Marks(E) EE
F Experience in Other Developing (Y/N) Marks (F)

Countries (Max Marks=5)
(I) 5 Yrs and above

(Weightage=100%) 7
(II) 3-5 yrs (Weightage=80%)
(III) 1 to 3 yrs (Weightage=50%)
Total Marks(F) FF
G Employment with the Firm (Max Marks=5) (Y/N Marks (G)
(I) One to three years

(Weightage=20%)
(II) Three to Five yrs
(Weightage=60%)
(III) More than five yrs
(Weightage=100%)
Total Marks(A) GG
Grand
Total: (AA+BB+CC+DD+
EE+FF+GG)


Part-II Proforma X Evaluation Abstract Part-I Proforma-X Structure & organisation of
firm
Maximum Marks( 30 )

No.
A Existence of Firm (Max Marks=5) Y/N Marks (A)
(I) Less than five years

(Weightage=50%)
(II) Five years & less than ten years
(Weightage=75%)
(II) Ten years & above
(Weightage=100%)
Total(A) AA
B Financial Turnover (Max Marks=5) (Y/N) Marks(B)
(I) Up to 50 Lacs
7 (Weightage=50%)
(II) More than 50 Lacs & upto 100 Lacs
(Weightage=75%)
(II) More than 100 Lacs
(Weightage=100%)
Total(B) BB
C Equivalent Technical Personnel (ETP) Strength
Method of Calculation of ETP
Education (Ed) Experience (Ex) No of Personnel ETP (Ed*Ex*No)

in Position (No)
Diploma in Civil Upto five years A

Engineering (Weightage=1)
(Weightage=0.5)
More than five & B
upto ten years
(Weightage=1.5)
More than ten & upto C
fifteen years
(Weightage=2.0)
More than fifteen D
years
(Weightage=2.5)

Education (Ed) Experience (Ex) No of Personnel ETP (Ed*Ex*No)

in Position (No)
Graduate in Civil Upto five years E

Engineering (Weightage=1)
(Weightage=1.0)
More than five & upto F
ten years
(Weightage=1.5)
More than ten & G
upto fifteen years
(Weightage=2.0)
More than fifteen H
years (Weightage=2.5)
Post Graduate in Civil Upto five years I
Engineering Subjects (Weightage=1)
(Weightage=1.5)
More than five & J
upto ten years
(Weightage=1.5)
More than ten & K
upto fifteen years
(Weightage=2.0)
More than fifteen L 7
years
(Weightage=2.5)
Ph.D in Civil Engineering Upto five years M
(Weightage=2.0) (Weightage=1)
More than five & N
upto ten years
(Weightage=1.5)
More than ten & O
upto fifteen years
(Weightage=2.0)
More than fifteen P
years
(Weightage=2.5)
Total number of ETP (A+B+C+D+E+F+G+H+I+J+K+L+M+N+O+P)
(I) Less than five

(Weightage=25%)
(II) Five & upto twenty

(Weightage=50%)
(II) More than twenty

(Weightage=100%)
Total (C) CC

ETP Strength (Y/N) Marks(C)

(Max Marks=15)
D Geographiocal Location (Y/N) Marks(D)
(Max Marks=5)
(I) 201 Km to 500 Km

(Weightage=50%)
(II) 101 to 200 Km

(Weightage=75%)
(III) Less than 100 Km

(Weightage=100%)
Total (D) DD
Grand Total (AA+BB+CC+DD)


Part-II: Proforma Y Evaluation Abstract Part-II: Proforma Y Particular Experience
Particular Experience of Consultant Firm (Max. Marks 50)

No
A Experience in Investigation of (Marks (A)

Deteriorated Structures and
recommending Remedial Measures
undertaken in the last five
years (Max Marks=20)
(I) One Project Completed

(Weightage=50%)
(II) Two Projects Completed
(Weightage=75%)
(III) More than Two Projects Completed
(Weightage=100%)
Total Marks(A) AA
B Works supervision of structural Marks (B) 7

repairs undertaken in the
last five years
(Max Marks=10)
One Project completed
(Weightage=50%)
Two Projects completed
(Weightage=75%)
More than two Projects completed
(Weightage=100%)
Total Marks(B) BB
C Structural Analysis and Design
undertaken in the last
five years
(Max Marks=20) Marks (B)
Two Projects completed
(Weightage=50%)
Three Projects & upto five
Projects completed
(Weightage=75%)
More than five Projects completed
(Weightage=100%)
Total Marks(C) CC
Grand Total (AA+BB+CC) YY


Part-II: Proforma Z: Evaluation Abstract Part-II: Proforma Z Adequacy for Assignment
Adequacy for the Assignment, Max Marks(20)

No
A Field/Laboratory Testing Facility Marks(A)

(Max Marks=10)
(I) Bar locator & cover meter

(Weightage=20%)
(II) Core cutting Machine with
Core Cutting bits
(Weightage=20%)
(III) Ultrasonic Pulse Velocity (UPV),
(Weightage=20%)
(IV) Half Cell Potential Measuring
Instrument or Resistivity Meter
(Weightage=10%)
(V) Rebound hammer
(Weightage=10%)
7 (VI) Laboratory for Geo
Technical Examination
(Weightage=20%)
Total Marks(A) AA
B Computer Hardware & Software: Marks(A)

Max. Marks (5)
(I) Two computer with an acceptable

Structural Analysis Package
(Weightage=40%)
(II) More than two & upto
five computers with an
acceptable Structural
Analysis Package
(Weightage=60%)
(III) More than five computers
with an acceptable
Structural Analysis Package
(Weightage=100%)
Total Marks(B) BB
C Technical Library: Marks(A)

Max Marks (5)
(I) 100 to less than 500 Books/
Journals
(Weightage=50%)

(II) 500 to less than 1000 Books/

Journals (Weightage=75%)
(III) 1000 Books/Journals and
above (Weightage=100%)
Total Marks(C) CC
Grand Total ZZ
(AA+BB+CC)

Appendix 7.1.4.7
Suggested Format of Report

Phase-I: Preliminary Report
1. Introduction and Background History
2. Scope and methodology
3. Results
4. Immediate remedial measures for safety of structure and its users.
5. Information required for further investigations
Note: The report shall indicate the name of technical team members involved with the
inspection and testing separately.
Phase-II: Detailed Investigation Report
1. Introduction
2. Description of the building and brief background history (including information
and data gathered from site during preliminary and detailed inspection)
3. Data furnished by the client
4. Scope of the Report
7 5. Investigations carried out
a. Visual Inspection
b. Analysis and Design
c. Field Testing
d. Laboratory Testing
6. Main observations forming the basis for conclusions
7. Conclusions (specifically covering the causes of deterioration, their source(s),
rehabilitability of the structure)
8. Recommendations (remedial measures given in easy to understand step by step
procedure to be followed with alternatives, cost estimate including nomenclature
of items and related specifications, suggested special conditions of contract, list
of critical repair items, Quality Assurance Procedure and its certification formats,
time required for execution, post repair maintenance procedure and expected life
gain)
Note:
1 Photographs, Worksheets, Record of Field/Laboratory/ visual observations in
statistical format, which form the basis of conclusions, shall also form part of the
report.
2. The report shall indicate the name of technical team members involved with the
inspection and testing separately.

Appendix 7.2
SAMPLE FORM
of
AGSEEMENT
7
with
CONSULTANCY FIRM

Appendix 7.2 (..Contd.)

INDEX
S. No. Description Page Reflected as
1. Agreement Appendix 7.2.1

2. General Conditions Appendix 7.2.2
3. Appendix-A Objectives and Description of the Appendix 7.2.3
4. Appendix-B Commencement and completion of Appendix 7.2.4
services
5. Appendix-C Remunerations and payments Appendix 7.2.5
6. Appendix-D Scope of Services Appendix 7.2.6
7. Appendix-E Prints, Drawings and Specifications Appendix 7.2.7
8. Appendix-F Assigned specialist, personnel, Appendix 7.2.8
equipment, facilities and services of
others to be provided by the employer
i) Letter of Transmittal
ii)
Part-I-Curriculum Vitae of Key Personal and
7 Alternate Key Personal.
iii) Part-II Proforma ‘X’
iv) Part-II Proforma ‘Y’
v) Part-II Proforma ‘Z’

Appendix 7.2.1
AGREEMENT
This Agreement made on today, the < Date> day of <Month and Year> between the
Executive Engineer, < Specific particulars of the Employer to be filled >, on behalf of
the President of India (hereinafter called “the Employer”) of the one part and <Full
Name of the Consultant/ Consultancy Firm with its address>(hereinafter called “the
Consultant”) of the other part.
Whereas the Employer desires that the Consultant should perform certain consultancy
services namely <_______________________________Name of
Work______________________________>
and has accepted a proposal of the Consultant for performance of such Services.
Now this Agreement witnesseths as follows:
1. In this Agreement, words and expressions shall have the same meaning as are
respectively assigned to them in the Conditions of the Employer/Consultant
Agreement hereinafter referred to.
2. The following documents attached hereto shall be deemed to form (and be read
and construed as) part of this Agreement, namely :
7
a. The Letter of Acceptance;
b. The Conditions of the Employer/Consultant Services Agreement (General
Conditions);
c. The Appendices, namely:
Appendix A - Objectives & Description of the Project
Appendix B - Commencement & Completion of Services
Appendix C - Remuneration and Payment
Appendix D - Scope of Services
Appendix E - Prints, Drawings & Specifications
Appendix F - Assigned Specialists, Personnel, Equipment, Facilities and
Services of others to be provided by the Employer.
3. In consideration of the payment to be made by the Employer to the Consultant as

hereinafter mentioned, the Consultant hereby agrees with the Employer to perform
the Services in conformity with the provisions of the Agreement.
4. The Employer hereby agrees to pay the Consultant in consideration of the
performance of the Services such amounts as may become payable under the
provisions of the Agreement at the time and in the manner prescribed by the
Agreement.
In Witness whereof the Parties hereto have caused this Agreement to be executed the
day and year first above written.

B. Binding Signature(s) of Employer Binding Signature(s) of Consultant

(Seal, if any ) (Seal, if any )
In the presence of In the presence of
(1) Witness (2) Witness
Name _____________________ Name __________________
Signature __________________ Signature ________________
Address ____________________ Address _________________
____________________ _____________________
___________________ _____________________

Appendix 7.2.2
CONDITIONS OF
EMPLOYER/CONSULTANT SERVICES AGREEMENT
GENERAL CONDITIONS
1.0 DEFINITIONS AND INTERPRETATIONS
1.1 Definitions
The following words and expressions shall have the meanings assigned to them except
where the context otherwise requires:
l “AGREEMENT” means the Employer/Consultant Services Agreement.
l “ASSOCIATE” means a consultant/consultancy firm associated by the Consultant
to complement or supplement its resources for performing the consultancy services
for the Project.
l “CONSULTANT” means the party named in the Agreement, who is employed as
an independent firm by the Employer to perform the Services, and legal successors
to the Consultant and permitted assignees.
l “CRITICAL REPAIR ITEM” means the item of repair work, which is critical
and important for the durability and successful execution of the rehabilitation
project.
l “DAY” means the period of twenty-four hours commencing with the midnight 7
of any day.
l “EMPLOYER” means the party named in the Agreement, who employs the
Consultant, and legal successors to the Employer and permitted assignees.
l “FEES” means the amount of money to be paid to the Consultant by the Employer
for services rendered by the Consultant to the Employer.
l “KEY PERSONAL” and “ALTERNATE KEY PERSONAL” means agreed
technical personnel representing the Consultant, who are overall responsible for
supervising/overseeing all field & laboratory investigations & testing of collected
samples, recommendations and signing all reports, drawings, technical
specifications, contract conditions, quality assurance procedure, execution of
identified critical repair items, etc and their accuracy.
l “MONTH” means the period of one month according to the Gregorian calendar
commencing with any day of the month.
l “PARTY” and “PARTIES” means the Employer and the Consultant and “Third
Party” means any other person or entity, as the context requires.
l “PROJECT” means the works for which the consultancy services are to be
provided.
l “SERVICES” means the services to be performed by the Consultant in accordance
with the Agreement and comprise Normal Services, Additional Services and
Exceptional Services.
l “WORKS” means the permanent works to be executed (including the goods and
equipment to be supplied to the Employer) for the execution of the Project.

1.2 Interpretations
1.2.1 The headings in the Agreement shall not be used in its interpretation.
1.2.2 The singular includes the plural, the masculine includes the feminine, and vice-versa,
where the context so requires.
1.2.3 If there is conflict between provisions of the Agreement, the written last chronologically
shall prevail.
2.0 PERSONNEL
2.1 Authorised Representative of the Consultant
For administration of the Agreement, the Consultant shall authorise a mutually agreed
Key Personal (and Alternate Key Personal, if the situation so arises), to represent the
Consultant, who shall be available for liasoning with the Employer or its nominee for
communication during the normal working hours. Key Personnel once approved shall
not be changed without the written approval of the Employer.
2.2 Other Technical Personnel
Other members of the team employed by the consultant shall have the requisite
experience in the fields assigned to them.
2.3 Changes in Personnel
If it is necessary to replace any person employed by the consultant on the project, for
7 which the Employer shall make request in writing stating the reasons for the replacement,
the consultant shall immediately arrange for replacement by another person of
comparable competence. The cost of such replacement shall be borne by the consultant.
3.0 COMMENCEMENT, COMPLETION, ALTERATION AND TERMINATION

OF THE AGREEMENT
3.1 Agreement Effective
The Agreement is effective from the 10th day of signing by the Employer of Letter of
Acceptance of the Consultant’s proposal for providing consultancy for the Project.
The appending of signature by the parties is necessary to complete the formal Agreement.
3.2 Commencement and Completion
The Services shall be commenced and completed by or within the times or periods
stated in Appendix B subject to extensions in accordance with the Agreement.
3.3 Modification to Agreement
Should circumstances arise which call for modification of the Agreement, these may
be made by mutual consent in writing. (Proposal in this respect from one party shall be
given due consideration by the other party)
3.4 Delays
If the Services are impended or delayed by, or because of, the Employer or his contractors
so as to increase the duration of the Consultancy services, the Consultant shall inform
the Employer of the circumstances and the adverse impact, if any, in writing.
Accordingly, the time for completion of the Services shall be suitably increased by the
Employer.
3.5 Changed Circumstances

a) If circumstances arise for which the Consultant is not responsible and which make
it impossible for him to perform in whole or in part the Services in accordance
with the Agreement he shall promptly notify the Employer in writing.
b) In these circumstances, if certain Services have been suspended or have to be
suspended, the time for their completion shall be extended until the circumstances
no longer apply plus a reasonable period not exceeding 10 days for resumption of
these services.
c) If the speed of performing certain Services has to be reduced, the time for their
completion shall be extended as may be made necessary by the circumstances.
3.6 Abandonment, Suspension or Termination

a) By Notice of the Employer
i) The Employer may suspend all or part of the Services or terminate the
Agreement by giving notice, in writing, of at least 15 days to the Consultant
who shall immediately make arrangements to stop the Services and minimize
expenditure.
ii) If the Employer considers that the Consultant is, without good reason, not
discharging his obligations, he shall notify in writing to the Consultant stating
the grounds for the notice, terminate the Agreement provided that such further
termination notice is given without 45 days of the Employer’s earlier notice.
7
b) Force- Majeure
Neither the Employer nor the Consultant shall be considered in default in
performance of the obligations under this Agreement if such performance is
prevented or delayed by events such as, but not limited to, war, hostilities,
revolutions, riots, civil commotion, strikes, lock-outs, conflagrations, epidemics,
accident, fire, wind, flood, drought, earthquake, or ordinance of any Government
or of any sub-division thereof, or because of any act of God, or for any other
cause beyond the reasonable control of the party affected, provided notice in writing
of any such cause with necessary evidence that the obligation under the Agreement
is thereby affected or prevented or delayed is given within 10 (Ten ) days from
the happening of the event and in case it is not possible to serve the notice within
the said ten days period, then within the reasonable shortest possible period without
delay. As soon as the cause of force Majeure has been removed, the party whose
ability to perform its obligation has been affected shall notify the other of such
cessation and of the actual delay incurred in such affected activity adducing
necessary evidence in support thereof. From the date of the occurrence of a case
of force Majeure, the obligations of the party affected shall be suspended during
the continuance of any inability so caused until the case itself and the inability
resulting therefrom have been removed and the agreed time of completion of the
respective obligations under the Agreement shall stand extended by a period equal
to the period of delay occasioned by such events.
c) Default by the Employer

The Consultant may, by written notice to the Employer, terminate this Agreement

i) If he has not received payment of that part of any invoice which is not
contested within sixty (60) days of submission thereof;
ii) If the Services have been postponed as provided for in Clause 3.6 and the
period of postponement has exceeded six (6) months.
d) Entitlement of Consultant upon Postponement or Termination
Upon postponement of the Services or termination of this Agreement under Clause
3.6 (a), (b) or (c) and subject to the obligation of the Consultant to reduce
expenditure to a minimum as stated in Clause 3.6(a) the Consultant shall be entitled
to receive the remuneration due up to the effective date of postponement or
termination and reimbursement in full for such of the costs specified in Appendix
–C as shall have been incurred prior to the effective date of such postponement or
termination and for all costs incidental to the orderly termination of the Services,
including return travel of the Consultant’s personnel.
(e) Claims for Default
Any claim for damages arising out of default and termination shall be agreed
between the Employer and the Consultant or, failing agreement, shall be referred
to arbitration in accordance with Clause 3.6(f) of this Agreement.
f) Arbitration
Any dispute or difference arising out of this Agreement including those considered
as such by any one of the parties, shall be finally settled under the provisions of
The Arbitration and Conciliation Act, 1996 as amended from time to time. The
7 Chief Engineer, CPWD shall upon receipt of a request from the party(s) shall
appoint an Arbitrator for adjudication of the disputes. The appointment of
Arbitrator, so made, shall be binding on the parties.
3.7 Exceptional Services
a) Upon the occurrence of circumstances described in Clause 3.6 or abandonment or
suspension or resumption of Services or upon termination of the Agreement
otherwise than under the provisions of Clause 3.6 (a) any necessary work or any
other essential activity involving expense by the Consultant extra to the Normal
and Additional Services shall be regarded as Exceptional Services.
b) The performance of Exceptional Services shall entitle the Consultant to extra
time necessary for their performance and to payment for performing them.
3.8 Rights and Liabilities of Parties
Termination of the Agreement shall not prejudice or affect the rights or claims of the
parties, accruing otherwise.
3.9 Assignment
a) The Consultant shall not, without the written consent of the Employer, assign the
benefits, other than the assignment of any monies due, or to become due, under
this Agreement.
b) The Consultant shall not, without the written consent of the Employer, in any
way assign or transfer his obligations under this Agreement or any part thereof, to
anyone, except its associate(s), which formed the basis for selection of the
Consultant, only for such work, which falls within the scope of work originally
envisaged during the process of pre-qualification.

4.0 FEE & TERMS OF PAYMENT

4.1 The Employer shall pay the Consultant for Normal Services in accordance with the
conditions and details stated in Appendix-C and in accordance with Clause 4.3.
4.3 Terms of Payment
a) Employer shall pay amounts due within 15 days of the submission of bill/claim
by the Consultant.
b) The Employer shall pay the Consultant Service Tax and/or any other levies by
Central/State Governments or any other statutory authority, over and above the
fee specified.
5.0 GENERAL PROVISIONS

5.1 Copyright
All plans, design and data collected by the consultant for this project shall remain the
property of the Employer. The consultant shall have no right to deal with it in any way,
other than the purpose for which these were supplied, without the explicit written consent
of the Employer. All such plans, design and data or the process of inspection shall be
kept strictly confidential & not passed on to any unauthorised person.
The proposals submitted by the consultant shall remain his property and shall not be
utilised by the Employer, without the explicit permission, for any other purpose other
than the purpose for which these are meant.
5.2 Conflict of Interest 7
a) Unless otherwise agreed in writing by the Employer, the Consultant and his
personnel shall have no interest in nor receive remuneration in connection with
the Project except as provided for in the Agreement.
b) The Consultant shall not engage in any activity, which might conflict with the
interests of the Employer under the Agreement.
5.3 Notices:
Notices under the Agreement shall be in writing and will take effect from the date of
receipt at the address of the party. Delivery can be by hand or facsimile message,
against written confirmation of receipt or by registered letter or by telex subsequently
confirmed by letter.
5.4 Publication:
Unless otherwise permitted by the Employer in writing, the Consultant, either alone or
jointly with other, cannot publish material relating to the Works and Services.
5.5 Patent:
If the terms of purchase of patented or patent pending articles, methods or devices
involve or require the payment of any license fee or royalty in addition to the purchase
price, and do not contain patent indemnification in a form satisfactory to the Employer,
no such article, method or device shall be used or supplied in connection with the work
or incorporated in the Work without the prior written approval of the Employer.
5.6 Secrecy
The Consultant shall use all the document, drawings and other date and information of
a proprietary nature received from the Employer, solely for the purpose of performing

and carrying out the obligations on his part under the Agreement and shall not disclose
the same to any other person except to the extent required, in the performance of the
Works for the Project and shall maintain the utmost secrecy. The Consultant shall
bind his employees, who are involved in engineering of the Project, by a suitable secrecy
agreement. The Consultant shall not use the documents, drawings and other data and
information received from the Employer for any other purpose.
5.7 Controlling Laws
The laws of the land will govern the rights and obligations of the Employer and the
Consultant under this Agreement.
6.0 OBLIGATIONS OF THE CONSULTANT

6.1 Scope of Services
6.1.1 The Consultant shall exercise reasonable skill, care and diligence in the performance
of his obligations under the Agreement and shall be responsible for:
vii. Accuracy of the data collected at all stages of work,
viii. Procedure followed for investigations and framing recommendations
ix. Accuracy in arriving at conclusions
x. Safety & soundness of designs as per the design standards followed,
xi. Drawings prepared and their validation,
xii. Quantity and rates taken in the estimates,
xiii. Correctness of technical Specifications, contract conditions and Quality
7 assurance procedure recommended for execution of the project
The Consultant shall perform Services relating to the Project. The scope of the
Services is stated in Appendix – D.
6.2 Report
6.2.1 The format for the report shall generally be in line with the outline as per the details
given in the Annexure-7.1.2. The consultant shall furnish two hard copies of the final
report and one in reproducible format.
6.3 Normal, Additional & Exceptional Services
6.3.1 Normal Services are those described as such in Appendix- D.
6.3.2 Additional Services are those described as such in Appendix –D or which by written
agreement of the parties are otherwise additional to Normal Services.
6.3.3 Exceptional Services are those which are not Normal or Additional Services but which
are necessarily performed by the Consultant consequent to such changed circumstances
for which Consultant is not responsible and in accordance with the Agreement or arising
out of abandonment or suspension or resumption of Services.
6.4 Care and Exercise of Authority
6.4.1 The Consultant shall exercise reasonable skill, care and diligence in the performance
of his obligations under the Agreement
6.4.2 Where the Services include the exercise of powers or performance of duties authorized
or required by the terms of the contract between the Employer and any third party, the
Consultant shall:
a) act in accordance with the contract provided that the details of such powers and
duties are acceptable to him where they are not described in Appendix- D.

b) if so authorized, certify, decide or exercise his discretion fairly between the

Employer and third party not as an arbitrator but as an independent professional
by his skill and judgment.
c) If so authorized, vary the obligations of any third party, subject to obtaining the
prior approval of the Employer to any variation which can have an important
effect on costs or quality or time (except in any emergency when the Consultant
shall inform the Employer of the action taken by him as soon as practicable)
6.5 Performance Guarantee

6.5.1 The Consultant shall carry out the Services in conformity with generally accepted
norms and sound standards of engineering and be responsible for the technical
soundness of the Services rendered. In the event of any deficiency in these Services,
the Consultant shall promptly redo such design and engineering at no additional fees
to the Employer.
6.5.2 The Consultant shall guarantee the performance of the Works as per designs and
specifications prepared by him. In the event of the failure to achieve the guaranteed
performance as laid down in the Agreement due to inaccuracy in its investigations/
testing, recommendations, identification of Critical Repair Items, inappropriate
execution of project, etc for which the responsibility directly attributed to the Consultant,
he shall be liable for such failure and the liability shall be limited to a maximum on all
accounts, upto 10% of the fees received/receivable by the Consultant. However, such
liability shall be limited for a period of five years from the date of actual completion of
executed project. 7
6.5.3 The Consultant shall not be liable for any hardware cost of rectification, consequential
loss, direct or remote or loss of profit suffered by the Employer in connection with or
arising from the Agreement.
6.6 Alterations and Variations
The Consultant shall have authority to make minor alternations to design but he shall
obtain prior approval of the Employer to any substantial modification of the design
and costs of the said Works and to any instruction to a Contractor which constitutes a
major variation, omission or addition to the latter’s contract.
In any emergency requiring immediate action in the Employer’s interest, the Consultant
shall have authority to issue orders as required on behalf of and at the expense of the
Employer.
The Consultant must inform the Employer immediately of any orders issued without
the latter’s prior consent which will result in additional cost to the Employer and follow
up such advice as soon as possible with an estimate of the probable cost.
6.7 Certificate of Completion of Works
6.7.1 When the Works have been completed except for minor items which do not affect its
use or safety in use or operations, the Consultant may submit to the Employer a
Certificate of Completion of Works, which the Employer shall within thirty days of
the receipt thereof, sign and return to the Consultant. The Certificate of Completion of
works shall list such minor items as remain to be completed and such minor items shall
be completed within specified period thereafter.

6.7.2 If the Employer has reasonable grounds for withholding the Certificate of Completion
of Works it shall, not later than thirty days after receipt of the Certificate of Completion
of Works, issue to the Consultant a list of items of Works which remain to be done for
the want of which the plant cannot be used or cannot be operated safely. After the said
items of works have been completed, the Consultant may re-submit the Certificate of
Completion of Works, which the Employer shall then immediately sign and return to
the Consultant.
6.8 Prints, Drawings & Specifications
The Consultant will furnish to the Employer three copies and a suitable reproducible
format of prints of all drawings, specifications, schedules etc. as specified in
Appendix–E.
7.0 OBLIGATIONS OF THE EMPLOYER

7.1 Information
The Employer shall, so as not to delay the Services and within a reasonable time, give
to the Consultant free of cost all information which is in his power to obtain and which
may pertain to the Services.
7.2 Decisions
On all matters properly referred to him in writing by the Consultant, the Employer
shall give his decision in writing within a reasonable time so as not to delay the
7
Consultant’s Services.
7.3 Equipment and Facilities
7.3.1 The Employer shall make available, free of cost, to the Consultant for the purpose of
the Services, the equipment and facilities described in Appendix- F
7.3.2 Delays in receiving the equipment and/or facilities set forth in Appendix –C shall
entitle the Consultant to appropriate time extension for completion of the Services.
7.3.3 If the anticipated equipment and/or facilities are not forthcoming, the Employer and
the Consultant shall agree on how the affected part of the Services shall be carried out
and fix the revised remuneration therefor.
7.4 Services of Others
The Employer shall at his cost arrange for the provision of services from others as
described in Appendix – F, and the Consultant shall co-operate with the suppliers of
such services but shall not be responsible for them or their performance.

Appendix 7.2.3
z
APPENDIX-A OF AGREEMENT
OBJECTIVES AND DESCRIPTION OF PROJECT

Appendix 7.2.4
APPENDIX-B OF AGREEMENT3
OBJECTIVES AND DESCRIPTION OF PROJECT

Appendix 7.2.5
APPENDIX-C OF AGREEMENT
COMMENCEMENT AND COMPLETION OF SERVICES

Appendix 7.2.6
APPENDIX-D OF AGREEMENT
SCOPE OF SERVICES

Appendix 7.2.7
APPENDIX-E OF AGREEMENT
PRINTS, DRAWINGS AND SPECIFICATINS

Appendix 7.2.8
APPENDIX-F OF AGREEMENT
ASSIGNED SPECIALIST, PERSONNEL, EQUIPMENT, FACILITIES AND SERVICES

OF OTHERS TO BE PROVIDED BY THE EMPLOYER

Appendix 7.3

STANDARD PRE-QUALIFICATION DOCUMENT
FOR
7
RESTRICTED CALL OF TENDERS
Standard & Specifications Unit

Central Public Works Department,
Nirman Bhawan, New Delhi – 110 011.

CRITERIA FOR EVALUATION OF THE PERFORMANCE OF

CONTRACTORS FOR PRE-QUALIFICATION
ATTRIBUTES EVALUATION
(A) Financial Strength (i) 60% marks for minimum eligibility
(25 Marks) criteria.
(ii) 100% marks for twice the min.
eligibility criteria or more.
In between (i) & (ii)
- on pro-rata basis.
(B) Experience in Similar (i) 60% marks for minimum eligibility
Class of works criteria.
(30 Marks)
(iii) 100% marks for twice the min.
eligibility criteria.
In between (i) & (ii)
- on pro-rata basis.
7 (C) Performance on works (25 Marks)
Parameter Calculation for points Score Max.

1. Time Over (a) TOR = AT/ST 18
Run- ‘TOR’ Where 15 if TOR = 1.00
ST = Stipulated Time 12 if TOR = 2.00
AT = Actual Time 6 if TOR = 3.00
0 if TOR > 3.50
(b) Compensation levied Bonus/Penalty

for delay in completion Points awarded
= C Estimated cost put (+) 3 if B = 0
to tender = E (+) 0 if B = 1
(Cx100/E)=B(No points (-) 2 if b = 5
awarded if (-) 3 if B = 10
compensation
is not decided).
Note : Marks for values in between the stages indicated in a & b above is to be determined by
straight line variation basis.
2. Quality (i) Very Good 7 7
(ii) Good 5
(iii) Fair 2
(iv) Poor 0

Parameter Calculation for points Score Max.
(D) Personnel and (i) Graduate Engineer

Establishment 3 marks for each.
(10 Marks)
(ii) Diploma holder Engineer
2 marks for each upto
Max. 4 marks.
(iii) Supervisor/Foreman
1 mark for each upto
Max. 5 marks.
(Total Max. marks limited to 10)
(E) Plant & equipment (i) Mixer – 1 mark for each upto
(10 marks) Max. 2 marks.
(ii) Vibrator 1 mark for each upto
Max. 2 marks.
(iii) Trucks/Tippers 2 marks for each upto
Max. 4 marks.
(iv) Steel Shuttering 2 marks for each 800 sqm
upto Max. 4 marks.
(v) Pumps Maximum 1 mark. 7
(vi) Special Equipment (Marks to be fixed as
per requirement)
(Total Max. marks limited to 10)
2.1 Criterion for pre qualification

B. Technical personnel
The contractor shall be required to submit the details of skill, technical qualification,
work experience and number of the personnel available, which are to be deployed on
the works.
C. Financial Capability
The financial soundness is essential for the timely execution of the work. The financial
statements for the past three years as submitted to the income tax authorities shall be
examined viz. a viz. the works in hand. The works in hand with progress of works shall
be ascertained to check the balance capacity available to take up the work under
consideration.
D. Tools and Plants
After the structural repairs have been carried out, these have to be evaluated for their
adequacy in regard to performance requirement and subsequent monitoring. The
availability of such equipments is essential for proper execution of work. The list of
such equipments required should necessarily form part of such pre-qualification
document. The contractors shall be required to submit the list of equipment for actual
execution.

E. Experience of similar works

Experience shall be based on the nature of work, the materials and techniques used in
the execution of works. The contractor shall be asked to furnish the details of such
works carried out.

(i)
Prequalification Document
for
Name of Work: -
This Document consists of pages i & ii and pages 1 to __________ total ________ pages.
Prepared by : -
Checked by :-
A.S.W. S.W. S.S.W.
APPROVED
Chief Engineer

(ii)
INDEX
S. DESCRIPTION PAGE
NO.
1. Press Notice - Invitation to prequalify 1
2. Section I - Brief Description of the work 2
3. Section II - Information & instruction to applicants 3
4. Section III - Pre-qualification information 9
i) Letter of Transmittal 10
ii) Form ‘A’ 11
iii) Form ‘B’ 12
iv) Form ‘C’ 13
v) Form ‘D’ 14
vi) Form ‘E’ 15
vii) Form ‘E-1’ 16
viii) Form ‘F’ 17

PRESS NOTICE
INVITATION TO PRE-QUALITY
1. The Executive Engineer ______________________________________ on behalf
of the President of India invites pre-qualification applications from firms/
contractors of repute for the following works: -
Sl.No. Name of work Approx. Cost Period of Completion
2. Contractors who fulfill the following requirements shall be eligible to apply. Joint
ventures are not accepted.
a. Experience of having successfully completed works of similar class during
the last five years.
b. Average annual financial turn over on civil construction works of Rs.

____________ Cross during the last three years.
3. Eligible applicants may obtain pre-qualification document on request in writing
from the Executive Engineer _______________________________________ on
payment of Rs. 250/- in cash, upto 3.30 PM on _________________.
4. Application for pre-qualification duly supported by prescribed annexure, which
should be placed in sealed envelope, with the name of work and due date written
on envelope, will be received upto 03.00 P.M. on _____________ and will be
opened by the Executive Engineer or his authorised representative in his office on
the same day at 03.30 P.M.
EXECUTIVE ENGINEER

SECTION – 1
BRIEF PARTICULARS OF THE WORK
1.0 Salient details of the work for which pre-qualification applications are invited are as
under :
Sl.No. Name of work Approx. Cost Period ofCompletion
2.0 All drawings (Architectural/Structural/Services) for the work shall be made available
by the employer.
3.0 The work is situated at _______________________.
4.0 General features and major components of the work are as under.
(i)
(ii)
(iii)
7
(iv)
5.0 Work shall be executed as per General Conditions of contract for Central P.W.D. works.

SECTION II
INFORMATION AND INSTRUCTIONS TO APPLICANTS
1.0 GENERAL:
i Letter of transmittal & forms for pre-qualification are attached. (Section III)
ii All information called for in the enclosed forms should be furnished against the
respective columns in the forms, if information is furnished in a separate document,
reference to the same should be given against respective columns. If information
is ‘nil’ it should also be mentioned as ‘nil’ or ‘no such case’. If any particulars/
query is not applicable in case of the applicant, it should be stated as ‘not
applicable’. However, the applicants are cautioned that not giving complete
information called for in the application forms required, not giving it in clear
terms or making any change in the prescribed forms or deliberately suppressing
the information may result in the applicant being summarily disqualified.
Applications made by telegram or telex and those received late will not be
entertained.
iii The application should be typewritten. The applicant’s name should appear on
each page of the application.
iv Overwriting should be avoided. Correction, if any, shall be made by neatly crossing
out, initialing, dating and rewriting. All pages of the pre-qualification document
shall be numbered and submitted as a package with signed letter of transmittal.
v References, information and certificates from the respective Employers certifying
7
suitability, technical know-how or capability of the applicant should be signed by
an officer not below the rank of Superintending Engineer/Chief Project Manager
or equivalent.
vi The applicant is advised to attach any additional information, which he thinks is
necessary in regard to his capabilities to establish that the applicant is capable in
all respects to successfully complete the envisaged work. He is, however, advised
not to attach superfluous information. No further information will be entertained
after pre-qualification document is submitted, unless it is called for the Employer.
vii The pre-qualification document in prescribed form duly completed and signed
shall be submitted in a sealed cover. The sealed cover super scribed “pre-
qualification document for _____________________ ______________- shall be
received by the Executive Engineer, or his authorised representative upto 3.00
P.M. on ____________. Documents submitted in connection with pre-qualification
will be treated confidential and will not be returned.
viii Prospective applicants may request clarification of the project requirement and
pre-qualification document. Any clarification given by the Employer will be
forwarded to all those who have purchased the pre-qualification document. No
request for clarification will be considered after ______________.
2.0 DEFINITIONS:
i In this document the following words and expressions have the meaning hereby
assigned to them.
ii EMPLOYER : Means the President of India, acting through the Executive
Engineer _____________________________.

iii APPLICANT : Means the individual, proprietary firm, firm in partnership, limited
company private or public corporation.
iv ‘Year’ mean ‘Financial Year’.
3.0 METHOD OF APPLICATION:
i If the application is made by an individual, it shall be signed by the individual
above his full typewritten name and current address.
ii If the application is made by a proprietary firm, it shall be signed by the proprietor
above his full typewritten name and the full name of his firm with its current
address.
iii If the application is made by a firm in partnership, it shall be signed by all the
partners of the firm above their full typewritten names and current address or
alternatively by a partner holding power of attorney for the firm, in which case a
certified copy of the power of attorney shall accompany the application. A certified
copy of the partnership deed and current address of all the partners of the firm
shall also accompany the application.
iv If the application is made by a limited company or a corporation, it shall be signed
by a duly authorised person holding power of attorney for signing the application,
ink which case a certified
4.0 FINAL DECISION MAKING AUTHORITY
The employer reserves the right to accept or reject any application and to annual the
7 pre-qualification process and reject all applications at any time, without thereby incurring
any liability to the affected applicants or specifying the grounds for the Employer’s
action.
i PARTICULARS PROVISIONAL
The particulars of the work given in Section I are provisional and must be considered
only as advance information to assist the applicant.
15.0 SITE VISIT
The applicant is advised to visit and examine the site of work and its surroundings and
obtain for himself on his own responsibility, all information that may be necessary for
preparing the pre-qualification application. The cost of visiting the site shall be at
applicant’s own expense.
16.0 INITIAL CRITERIA FOR ELIBILIGY FOR PRE-QUALIFICATION
16.1 The applicant should be in Civil Engineering business for a minimum period of five
years as on ______________.
16.2 The applicant should have satisfactorily completed works of similar class of magnitude
as specified below during the last five years. For this purpose gross value of the
completed work including the cost of materials supplied by the Govt./Employer shall
be considered, which should be certified by an officer not below the rank of
Superintending Engineer/ Chief Project Manager or equivalent.
__________________________________________________________
__________________________________________________________
__________________________________________________________

16.3 The applicant’s average annual financial turn-over (gross) in Civil construction works
during the last three years duly audited by Chartered Accountant should not be less
than Rs. ______________ Crores. Year in which no turnover is shown would also be
considered for working out the average.
16.4 The applicant should own adequate construction equipment required for the proper
and timely execution of the work. The applicant should furnish a list of these equipment.
16.5 The applicant should have sufficient number of Technical and Administrative employees
for the proper execution of the contract. The applicant should submit a list of these
employees stating clearly how these would be involved in this work.
16.6 The applicant’s performance for each work completed in the last 5 years and in
hand should be certified by an officer not below the rank of Superintending Engineer/
Chief Project Manager or equivalent.
17.0 EVALUATION CRITERIA FOR PRE-QUALIFICATION
17.1 For the purpose of pre-qualification, applicants will be evaluated in the following
manner:-
17.2 The initial criteria prescribed in para – 7.2 & 7.3 above in respect of experience of
similar class of works completed and financial turn over will first be scrutinised and
the applicant’s eligibility for pre-qualification for the work be determined.
17.3 Those firms qualifying the initial criteria as set out in para 7.2 & 7.3 above will then be
evaluated for following criteria.
(f) Financial Strength 7
(g) Experience in similar class of work.
(h) Performance on these works.
(i) Personnel/Establishment
(j) Plant and Equipment
The details given by the applicants in the pre-qualification document will be evaluated
by scoring method. To pre-qualify, the applicant must secure at least fifty percent in
each of the above criteria and seventy percent in total.
(a) Financial strength (Form ‘A’) : Maximum 25 marks.
(b) Experience in similar class of
(work during last five years
(Form ‘B’) : Maximum 30 marks.
(c) Performance on works(Form ‘D’) : Maximum 25 marks.
(d) Personnel and establishment
(Form ‘E’ & E-1) : Maximum 10 marks.
(k) Plant & equipment
(Form ‘F’) : Maximum 10 marks.
Total : 100 marks.

17.4 Even though applicants may satisfy the above requirements, they are subject to be
disqualified if they have:
(c) Made misleading or false representation or deliberately suppressed the information
in the forms, statements and enclosures required in the pre-qualification document.
(d) Records of poor performance such as abandoning work, not properly completing
the contract, or financial failures/ weaknesses.
18.0 FINANCIAL INFORMATION
(a) Annual financial statement for the last three years (In Form ‘A’). These should be
supported by audited balance sheets and profit and loss accounts duly certified by
a Chartered Accountant, as submitted by the applicant to the Income Tax
Department.
(b) Name and address of the banker’s, identification of individuals familiar with the
applicant’s financial standing and a banker’s statement on availability of credit.
19.0 EXPERIENCE, IN CIVIL WORKS HIGHLIGHTING EXPERIENCE IN
SIMILAR WORKS
19.1 Applicant should furnish the following :-
(d) List of all works of similar class successfully completed during the last five years:
(In Form ‘B’).
(e) List of the projects under execution or awarded (In Form ‘C’).
19.2 Particulars of completed works and performance of the applicant duly authenticated/
7 certified by an officer not below the rank of Superintending Engineer/ Chief Project
Manager or equivalent should be furnished separately for each work completed or in
progress. (In Form ‘D’).
20.0 ORGANISATION INFORMATION
APPLICANT IS REQUIRED TO SUBMIT THE FOLLOWING IN RESPECT OF
HIS ORGANISATION (In Form ‘E’ and ‘E-1’)
(f) Name and postal address, website, email address i/c telephone & telex number
etc.
(g) Copies of original documents defining the legal status, place of Registration and
principal places of business.
(h) Names and title of Directors and officers to be concerned with the work, with
designation of individuals authorised to act for the organisation.
(i) Information on any litigation / arbitration in which the applicant was involved
during the last five years, including any current litigation.
(j) Authorisation for employer to seek detailed references.
(k) Number of Technical and Administrative employees in parent company, subsidiary
company and how these would be involved in this work (In Form ‘E-1’).
21.0 CONSTRUCTION PLANT AND EQUIPMENT
Applicant should furnish the list of construction plant and equipment including steel
shuttering, centering and scaffolding likely to be used in carrying out the work. (In
Form ‘F’). Details of any other plant and equipment required for the work (not included
in Form ‘F’) and available with the contractor may also be indicated.

22.0 LETTER OF TRANSMITTAL

The applicant should submit the letter of transmittal attached with pre-qualification
document.
23.0 TENDER SUBMISSION
After evaluation of pre-qualification applications, a list of qualified agencies will be
prepared. Thereafter, only those agencies prequalified for the work will be invited to
submit tenders for the work.
16. AWARD CRITERIA
16.1 The employer reserves the right to :-
(c) Amend the scope and value of contract to the bidder.
(d) Reject any or all the bids without assigning any reason.
16.2 For any of the above actions, the Employer shall neither be liable for any damages, nor
be under any obligation to inform the Applicants of the grounds for the same.
16.3 Effort on the part of the bidder or his agent to exercise influence or to pressurise the
employer for his bid shall result in rejection of such bid. Canvassing of any kind is
prohibited.

SECTION III
PRE-QUALIFICATION INFORMATION
LETTER OF TRANSMITTAL
From :-
To
The Executive Engineer,
______________________
______________________
Sub.: Submission of pre-qualification application for the work of

________________________________________________________.
Sir,
Having examined the details given in pre-qualification press. Notice and pre-
qualification document for the above work, we hereby submit the pre-qualification
and relevant documents.
7 6. We hereby certify that all the statements made and information supplied in the
enclosed form A to F and accompanying statement are true and correct.
7. We have furnished all information and details necessary for pre-qualification and
have no further pertinent information to supply.
8. We submit the requisite certified solvency certificate and authorise the Executive
Engineer _________________ to approach the Bank issuing the solvency
certificate to confirm the correctness thereof. We also authorise Executive Engineer
_______________________________________________ to approach
individuals, employers, firms and corporation to verify our competence and general
reputation.
9. We submit the following certificates in support of our suitability, technical know-
how and capability for having successfully completed the following works:-
Name of Work : Certificate form
1. 1.
2. 2.
3. 3.
Enclosures :
Seal of applicant
Date of submission SIGNATURE OF APPLICANT

FORM ‘A’
FINANCIAL INFORMATION
1. Financial Analysis – Details to be furnished duly supported by figures in Balance
Sheet / Profit and Loss Account for the last three years duly certified by the
Chartered Accountant, as submitted by the applicant to the Income -–Tax
Department (Copies to be attached).
YEARS
(i) Gross Annual turn-over
In construction works.
(ii) Profit/Loss
(iii) Financial Position :
(a) Cash
(b) Current assets
(c) Current liabilities.
(d) Working capital. (b-c)
(e) Current Ratio:
Current Assets/Current
Liabilities. (b/c)
7
(f) Acid Test Ratio
Quick Assets / Current
Liabilities (a/c)
II. Income Tax clearance Certificate.

III. Certificate of Financial Soundness from Bankers of Applicant.
IV. Financial arrangements for carrying out the proposed work.
(SIGNATURE OF APPLICANT)

7
FORM ‘B’
VII-80
DETAILS OF ALL WORKS OF SIMILAR – CLASS COMPLETED

DURING THE LAST FIVE YEARS
S.No. Name of work/ Owner of Cost of Date of S!tipulated Actual Litigation / Name and Remarks

Proj. & sponsoring work in commen- date of date of Arbitration address/
location organisation crores cement completion completion pending/ in telephone
as per progress of officer
contract with details to whom
reference
may be made.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Repairs & Rehabilitation Unit
FORM ‘C’
DETAILS OF ALL WORKS OF SIMILAR – CLASS COMPLETED
DURING THE LAST FIVE YEARS
S.No. Name of work/ Owner of Cost of Date of Stipulated Up-date Slow Progress Name and Remarks (indicate
Proj. & sponsoring work in commen- date of percentage if any, and address/ whether any show
location organisation crores cement completion progress reasons telephone cause notice issue
as per of work thereof of officer or arbitration
contract to whom initiated during
reference the progress of
may be made work)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
VII-81
7
FORM ‘D’
PERFORMANCE REPORT OF WORKS REFERRED IN FORM ‘B’ & ‘C’
1. Name of work/
Project & Location
2. Agreement No.
3. Estimated Cost
4. Tendered Cost
5. Date of start
6. Date of Completion
(a) Stipulated date of completion
(b) Actual date of completion
7. Amount of compensation levied for delayed completion if any.
8. Performance report
i) Quality of work Very Good / Good / Fair / Poor
ii) Resourcefulness Very Good / Good / Fair / Poor
7
Date : SUPERINTENDING ENGINEER/

CHIEF PROJECT MANAGER
OR EQUIVALENT

FORM ‘E’
STRUCTURE AND ORGANISATION
1. Name and address of the applicant.
Website and email Address:
2. Telephone No./Telex No./ Fax No.
3. Legal status [Attached copies of original document defining the legal status]
The applicant is :
(a) An Individual
(b) A proprietary Firm
(c) A Firm in Partnership
(d) A limited Company or Corporation
4. Particulars of registration with various Government bodies
(Attached attested photocopy)
(a) Registration Number.
(b) Organisation/Place of registration.
5. Names and Title of Directors and Officers with designation to be concerned with
this work with designation of individuals authorised to act for the organisation.
7
6. Were you ever required to suspend construction for a period of more than six
months continuously after you commenced the construction? If so, give the name
of the project and give reasons there of.
7. Have you or your constituent partner ever left the work awarded to you incomplete?
(If so, give name of the project and reasons for not completing the work).
8. Have you or your constituent partner been debarred/black listed for tendering in
any organisation at any time? If so, give details.
9. In which field of Civil Engineering construction, you claim specialisation and
interest?
10. Any other information considered necessary but not included above.

7
VII-84
FORM ‘E-1’
DETAILS OF TECHNICAL AND ADMINISTRATIVE PERSONNEL TO BE EMPLOYED FOR THE WORK

S.No. Designation Total Number Number Name Qualifications Professional How these would Remark
available for experience and be involved in
this work details of work this work
carried out
1. 2. 3. 4. 5. 6. 7. 8. 9.
FORM ‘F’
DETAILS OF CONSTRUCTION PLANT & EQUIPMENT
LIKELY TO BE USED IN CARRYING OUT THE WORK
S. Name of equipment Nos. Capacity Age Condi- OWNERSHIP STATUS How these would Remarks
No. or Type tion Pre Leased To be be involved in this
sently Pur- work
owned chased
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
EARTH MOVING EQUIPMENT
1. EXCAVATORS (VARIOUS SIZES)

EQUIPMENT FOR HOISTINKG &

LIFTING
1. TOWER CRANE
2. BUILDING
EQUIPMENT FOR CONCRETE WORK
1. CONCRETE BATCHING PLANT
2. CONCRETE PUMP
3. CONCRETE TRANSIT MIXER
4. CONCRETE MIXER (DIESEL)
5. CONCRETE MIXER (ELECTRICAL)
6. NEEDLE VIBRATOR (ELECTRICAL)
7. NEEDLE VIBRATOR (PETROL)

VII-85
8. TABLE VIBRATOR (ELECT./PETROL)

Contd...
7
7
VII-86
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
EQUIPMENT FOR BUILDING WORK
1. BLOCK MAKING MACHINE
2. BAR BENDING MACHINE

3. BAR CUTTING MACHINE
4. WOOD THICKNESS PLANER
5. DRILLING MACHINE
6. CIRCULAR SAW MACHINE
7. WELDING GENERATORS
8. WELDING TRANSFORMERS
9. CUBE TESTING MACHINES
10. M.S. PIPES
11. STEEL SHUTTERING
12. STEEL SCAFFOLDING
13. GRINDING/POLISHING MACHINES
EQUIPMENT FOR ROAD WORK
1. ROAD ROLLERS
2. BITUMEN PAVER FINISHERS
3. HOT MIX PLANT
4. SPREADERS
5. EARTH RAMMERS
6. VIBRATORY ROAD ROLELRS Contd...

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
EQUIPMENT FOR TRANSPORTATION
1. TIPPERS
2. TRUCKS
PNEUMATIC EQUIPMENTS
1. AIR COMPRESSOR DIESEL
DEWATERING EQUIPMENT
1. PUMP DEWATERING (DIESEL)
2. PUMP DEWATERING (ELECTRIC)
POWER EQUIPMENT
1. DIESEL GENERATORS
ANY OTHER PLANT/EQUIPMENT
VII-87
7
APPENDIX 7.4
REPAIR MATERIAL
1. Name of the work :

2. Agreement no. :
3. Contractor :
4. Name of Material :
5. Manufacturer :
6. Dealer/Soruce :
7. Bill No. & date :
8. Batch No. & date :
9. Expiry date :
10. Pot life :
11. Systems for erpair :
12. Storage Recommendation :
13. Manufacturers test Certificate :
7
(Name of Contractors Representative)

Enclosure:
For Office use:

1. Manufactures test certificate: attached/not attached
2. Samples taken/not taken for testing:
3. Samples sent to:Laboratory name and address
4. Entry made in the register: Page———date——
Date:
Place:
(Name of Representative of Engineer in Charge)

CHAPTER 8
SCHEDULE OF SPECIAL ITEMS FOR

STRUCTURAL REPAIR WORK
SUB-HEAD DESCRIPTION PAGE NO.

I General VIII-1
II Surface Preparation VIII-3
III Crack/Honey Comb Area Repair VIII-6
IV Bonding Coats VIII-8
V Structural Repair Items VIII-9
VI Curing VIII-15
VII Chhajja/Sunshades VIII-16
VIII Water Proofing & Protective Coatings VIII-18
IX Masonry Repairs VIII-20
X Testing of Materials and Pre/Post Repair VIII-21

Testing of Structure
8
SCHEDULE OF SPECIAL ITEMS FOR
STRUCTURAL REPAIR WORK
What we have to learn to do, we learn by doing.
..Aristotle
Item Description of item Unit of

No. Measurement
SUB-HEAD I GENERAL
8.1.1 Propping and supporting the structural members and its
adjoining areas with steel props (adjustable or as required),
bracings, steel/timber runners etc to relieve the structural member
of the required load coming over it as per the pattern given by the
contractor & approved by Engineer-in-charge complete.
A (a) Steel Prop of up to 5 MT Capacity and up to 3.2 m height Each
(b) Extra for every additional height of 0.3 M or part thereof Each per 0.3 M 8
extra height
B (a) Extra for steel prop (adjustable or as required ) for having
additional capacity of 2 MT or part thereof beyond 5
MT and up to 3.2 M height Each
(b) Extra for every additional height of 0.3 M or part thereof Each per 0.3 M
extra height
8.1.2 Providing and fixing special water tight centering and
shuttering including bolting, strutting, propping etc so as to
withstand a pressure of 0.1 Mpa including removal of forms for
all locations including beams, columns, slabs, walls, foundations,
footings, landings, stairs, balconies etc. sqm
8.1.3 Providing and fixing temporary engineered steel tubular

standard double scaffolding system on the exterior side,
maintaining it in a serviceable condition for the required duration
as approved and removing it thereafter. The scaffolding system
shall be stiffened with bracings, runners, connection with the
building etc with suitable working platforms at required locations
with essential safety features for the workmen etc complete as per
directions and approval of Engineer-in-charge. The elevational
area of the scaffolding shall be measured for payment purpose. sqm
Central Designs Organisation VIII-1


No. Measurement
8.1.4 Providing and fixing plywood covering panels as per the directions
of Engineer-in-charge with necessary backing framework to shield
windows etc. from falling debris and removing and taking away the
material after completion of work including making good any incidental
damage(s) to the existing building or its finishes etc complete. (The
measurements for payment shall be made in terms of the area protected
by such covering). sqm
8.1.5 Providing, erecting, maintaining and removing temporary
protective barricading/screens of 1.8 m in height made in panels
with each panel having minimum 40x40x6 mm size MS angle frame
with minimum 24 g thick G.I corrugated sheet or suitably stiffened
plane G I sheet fixed on one side of the frame. Such panels shall be
interconnected to each other with nuts and bolts, fixed to ground
firmly, at about 2 m spacing for the work duration as required by
the Engineer in charge. (The rate shall cover applying at least one
coat of paint over existing paint or red-oxide zinc chromate primer). sqm
protective barricading/screens of 1.8 m. in height, made out of
minimum 100 mm dia ballis or wooden verticals of minimum size
8 50 mm x 100 mm, fixed to ground firmly at a spacing of about 2 m
and with at least two horizontals of 50 mm x 100 mm with minimum
24 g. thick G.I corrugated sheet fixed on one side for work duration
as required by Engineer in charge. (The rate shall cover applying
at least one coat of paint over existing paint or primer). metre
protective barricading/screens of 1.8 m height, made out of
bamboo or other locally available panels with verticals and atleast
two horizontals of required sizes, made out of acceptable local
wood, fixed on one side of the panels and secured to the ground at
required spacing for the work duration as per directions and
approval of Engineer-in-charge. metre
protective screens made out of specified fabric with all necessary
fixing arrangement to ensure that it remains in position for the
work duration as required by Engineer in charge.
A Jute Cloth sqm
B Woven PVC Cloth sqm
C Geotextile sqm
D Wire Mesh sqm
VIII-2 Repairs & Rehabilitation Unit

SCHEDULE OF SPECIAL ITEMS FOR STRUCTURAL REPAIR WORK

No. Measurement
8.1.9 Providing and fixing the G.I. corrugated sheet door shutter,
maintaining in serviceable condition for the work duration and
removing it thereafter. The door shutter shall be made of G.I.
corrugated sheet (24 gauge) fixed on accepta ble local wooden
frame with verticals, horizontals of required size and middle
horizontal member at centre including at least one aldrop with
locking arrangement, required number of hinges etc complete as
per the Engineer in charge. (The rate shall cover applying at least
one coat of paint over existing paint or primer ). sqm
8.1.10 Providing & erecting covered shelters complete with side
coverings, door/window frame and its openings, raised pacca
platform for storage of materials, maintaining them in serviceable
condition for the work duration and removing thereafter. The
covered shelters shall be made of steel/ timber/bamboo verticals
and steel/timber/ bamboo horizontals covered with AC/GIsheets,
tarpaulin etc. to remain in serviceable condition during work
duration as directed by Engineer- in –charge (Plan area shall be
measured for payment) sqm
SUB-HEAD II : SURFACE PREPARATION

8.2.1 Chipping of existing plaster manually from masonry or concrete 8
surface using chisel and hammer and disposal of debris within a
lead of 50 m complete as per directions of Engineer-in-Charge
8.2.2 Chipping of unsound/weak concrete material from slabs, beams,
columns etc. with standard power driven percussion type or
pneumatic chisel of standard make as directed by Engineer-in-
charge including tapering all edges, making square shoulders of
cavities etc complete and disposal of debris up to 50 metres and
all lifts.
A 25 mm average thickness for slabs sqm
B 50 mm average thickness for Beams sqm
C 75 mm average thickness for Columns sqm
D Deduct/Add for every less/extra 10 mm thickness. sqm
E Extra for disposal of debris beyond 50 meters and up to 1
kilometer
[Area for payment under this item shall be sum total of area
measured and debris disposed under A,B,C and D as
(A+2B+3C±0.4D)] sqm
F Extra for disposal of debris beyond 1 kilometer and up to 5
kilometers
[Area for payment under this item shall be sum total of area
measured and debris disposed under A,B,C and D as
(A+2B+3C±0.4D)] sqm


No. Measurement
8.2.3 Dismantling & removing existing treatment over RCC slabs at

all heights including stacking of serviceable material for reuse as
per direction of Engineer-in-Charge & disposal of balance
unserviceable material within a lead of 50 metre cum
A. Extra for disposal of unserviceable material beyond 50 metres
and up to 1 kilometer cum
B. Extra for disposal of unserviceable material beyond 1
kilometer and up to 5 Kilometers cum
8.2.4 Dismantling existing RCC work but excluding cutting of
reinforcement bars at all heights including disposal of
unserviceable material within a lead of 50 metre.
A. Manually using chisel and hammer cum
B. Mechanically using power driver/pneumatic percussion
chisels/hammers cum
C. Extra for disposal of unserviceable material beyond 50 metres
and up to 1 kilometer cum
D. Extra for disposal of unserviceable material beyond 1
kilometer and up to 5 Kilometers cum
8
8.2.5 Cutting reinforcement bars in RCC or reinforced brickwork.
carefully without damaging the existing structure and its finishes
A Bars of dia 12mm or less Each
B Bars of dia more than 12 mm but not exceeding 20 mm Each
C All bars of dia more than 20 mm Each
8.2.6 Removing concrete all around reinforcement including from
behind the reinforcing bars to give an average 25mm (but not less
than 15mm clear air gap). Length of reinforcement bars cleared of
concrete all around shall be measured for payment
A By manual methods (hammering the rebar, using wire brushes,
chiseling etc.)
(a) Bars up to and including 12mm diameter metre
(b) Bars above 12mm diameter metre
B Extra for using standard power driven or pneumatic abrading
tools/chisel of standard make.
(b) Bars above 12 mm diameter metre
8.2.7 Cleaning reinforcement of total rust including from behind
the reinforcing bars to give it a totally rust free finished steel surface.
Length of reinforcement bars cleaned of rust all around shall be
measured for payment


No. Measurement
A By manual methods (hammering the rebar, using wirebrushes,
chiseling etc.)
(b) Bars above 12mm diameter metre
B Extra for using sand blasting
C Extra for using alkaline chemical rust remover with paint
brush and removing loose particles after 24 hours of its
application with wire brush and thoroughly washing with
water and allowing it to dry. metre
(a) Bars upto 12 mm diameter metre
(b) Bars above 12 mm diameter metre
8.2.8 Introducing new reinforcement bars for structural connections
in RCC beams, lintels, columns and slabs including power drilling
holes of appropriate diameters in reinforced or plain cement
concrete to a minimum depth of 150mm and upto 200 mm, fixing
the reinforcement in position using epoxy. (Rate shall include cost
of labour, T&P for power drilling in concrete, epoxy cartridges,
plastic nozzle etc complete including cleaning the drilled holes of
loose dust by blowing air. The cost of reinforcement shall be
payable separately
8
A Upto and including for 12 mm dia reinforcing bar each
B Bars of dia more than 12 mm but not exceeding 20 mm each
C All bars of dia more than 20 mm each
8.2.9 Providing and inserting mild steel shear key bars/ leveling
gauges (for shotcreting) of required length and diameter in
reinforced/plain concrete as per drawing and directions of
Engineer-in-charge including power drilling holes of appropriate
diameters to a minimum depth of equal to 12 times the diameter
of shear key bar/levelling gauge, cleaning the drilled holes of loose
dust by blowing, insertion of epoxy from cartridge, placing the
shear key bar in position and allowing it to stay undisturbed for 24
hours. (Rate shall include cost of labour, all materials, T&P for
power drilling in concrete, epoxy cartridges, plastic nozzle etc
complete including cleaning the drilled holes of loose dust by
blowing air.
A 12mm dia. 300 mm long@ M.S. shear key each
@
B 16mm dia. 400 mm long M.S. shear key each
8.2.10 Cleaning exposed concrete surface of lightly sticking materials
including foreign materials, loose concrete/aggregates, etc. The
rates shall include cost of movable scaffolding & working platform
@ The projected length of shear key shall be more than 10 times its diameter plus half the
thickness of cover concrete plus bend length.


No. Measurement
(cost of working platform shall not be paid under other item) disposing
of all debris up to a lead of 50 metres and complete in all respects.
A With wire brush, chisel etc for all heights sqm

B By sand blasting with coarse sand followed by and including
cleaning with oil free air blast
i) Up to a height of 15metre above plinth level sqm
ii) Extra for every additional height of 3 metre or part
thereof beyond 15 metre height above plinth level. sqm
8.2.11 Providing and fixing anchor fastener system, mechanical/epoxy
based of standard make for connections in concrete as per design
and drawings and/or as directed by Engineer-in-charge. ( Rate shall
include cost of bolts, labour, all materials including epoxy
cartridges ( wherever required), T&P for power drilling, cleaning
the drilled holes of loose dust by blowing air, insertion of epoxy
from cartridge with plastic nozzles as may be required, placing
internally threaded sleeve, driving of bolts, 2 nos-4mm thick (hot
dip galvanized/epoxy coated ) washers, fastening screw and
tightening with nuts and check nuts etc. as may be required
8 A. Mechanical Anchor fastener:
a) 8mm dia anchor fasteners each
a) 10 mm dia anchor fasteners each
b) 12 mm dia anchor fasteners each
c) 16 mm dia anchor fasteners each
B Extra for epoxy in mechanical anchor fasteners, if used
a) 8 mm dia anchor fasteners each
b) 10 mm dia anchor fasteners each
c) 12 mm dia anchor fasteners each
d) 16 mm dia anchor fasteners each
SUB HEAD III: CRACK/HONEYCOMB AREA REPAIR

8.3.1 Providing and inserting 12mm dia Aluminium/ galvanized iron
injection nipples along crack lines or honey-comb area, including
i) drilling holes of required diameter up to depths from 40mm
to 80mm or half the thickness of member (whichever is less),
at required spacing but not exceeding the thickness of member
or 300 mm
ii) Making grooves of size 12mm x 12mm along the crack line.
iii) Making the crack dust free by blowing compressed air and
then washing with water.


No. Measurement
iv) Sealing the distance between the injection nipples with approved
putty (Polymer modified cement mortar /polyester putty/epoxy
putty) etc and allow it to cure.
v) If cementitious grout material proposed to be used, washing and
saturating the cracked surface with water by pumping from top
most nipple and down wards
complete as per the direction of Engineer-in-charge.( The rate shall
include all material, labour and all operations above. The cost of
grout material shall be paid separately on the basis of actual quantity
consumed.
A In concrete work each
B In masonry work. each
8.3.1a Supply of approved crack/honeycombed area sealing material/
Admixture.
A Approved Emulsified acrylic Polymer (Rates shall be in terms
of solid contents of polymer) kg
B Approved Emulsified SBR Polymer (Rates shall be in terms
of solid contents of polymer) kg
C Approved epoxy (Total weight of Resin & hardener in
proportion specified by manufacturer) kg 8
D Shrinkage compensating cement kg

8.3.2 Injecting approved grout in appropriate proportion excluding cost
of such grout material covered under item No. 8.3.2a into cracks/
honey-comb area of concrete/masary by suitable gun/pump at
required pressure including cutting of nipples after curing etc.
complete as per directions of Engineer-in-charge. (The payment
shall be made on the basis of actual weight of approved grout
injected).
A Epoxy grout in
a) Concrete/ RCC work Kg
b) Masonry Work Kg
B Stirrer mixed acrylic Polymer modified cement slurry made
with shrinkage compensating cement in
a) Concrete/RCC work Kg
b) Masonry Work Kg
C Stirrer mixed SBR Polymer modified cement slurry made
with shrinkage compensating cement in
b) Masonry Work Kg


No. Measurement
D Stirrer mixed shrinkage compensating plain cement slurry in
b) Masonry work Kg
E Stirrer mixed shrinkage compensating cement sand slurry in
RCC/PCC/Masonry in proportion
a) 1:0.5 (1- cement and : 0.5-specified grade of sand by
weight) Kg
b) 1:1 (1- cement and : 1-specified grade of sand by weight) Kg
c) 1:1.5 (1- cement and : 1.5-specified grade of sand by
weight) Kg
d) 1:2 (1- cement and : 2-specified grade of sand by weight) Kg
8.3.2a Supply of approved grout material/admixture
of solid contents of polymer) Kg
proportion specified by manufacturer) Kg
8 D Approved shrinkage compensating cement Kg
E Approved Ordinary Portland Cement of Grade 43 Kg
F Approved Ordinary Portland Cement of Grade 53 Kg
SUB-HEAD IV BONDING COATS

8.4.1. Mixing and applying bonding coat, excluding cost of material,
on prepared non-metallic surface of parent material as per
specifications and direction of Engineer-in-Charge complete.
A. Acrylic polymer modified cementitious bond coat @ 2.2 Kg
cement per sqm. of surface area with specified proportion of
polymer admixed (Rate shall include cost of cement) sqm
B. SBR polymer modified cementitious bond coat @ 2.2 kg
cement per sqm of surface area with its proportion as specified sqm
C. Approved epoxy adhesive. sqm
8.4.1a Supply of approved bonding material for prepared non-metallic
surface
proportion specified by manufacturer) Kg
D Ordinary Portland Cement 43 Grade Kg

No. Measurement
8.4.2 Applying alkaline passivating & bonding coat of approved adhesive
excluding the cost of material over reinforcement duly approved by
Engineer-in-Charge with.
A Approved CPCC material, a two coat patented system of CECRI
on
a) Steel reinforcement bars up to 12 mm diameter metre metre
b) Steel reinforcement bars above 12 mm diameter metre
B Two coats of approved acrylic polymer and cement in the ratio of
1:5 (1-solid contents of acrylic polymer and 5-cement) by weight
at an interval not less than 4 hours
a) Steel reinforcement bars up to 12 mm diameter metre
b) Steel reinforcement bars above 12 mm diameter metre
C Epoxy phenolic IPN-RB, an epoxy based, CBRI patented coating
system, including sprinkling silica sand (no 10) for:
a) Bars upto 12 mm diameter metre
b) Bars above 12 mm diameter metre
D Approved epoxy bonding coat as per manufacturer’s specifications
including sprinkling silica sand (no 10) for;
a) Bars upto 12 mm diameter 8
metre
b) Bars above 12 mm diameter metre
8.4.2a Supply of approved bonding / passivating adhesive for reinforcement
A Emulsified acrylic Polymer (payment shall be made for the weight litre
of solid contents of polymer)
B CPCC coating material (excluding the weight of cement) Kg
i) Primer coat
ii) Sealer Coat litre
C Epoxy phenolic IPN-RB, a CBRI licensed product (Payment shall Litre
be for quantity of Resin plus hardener in manufacturer specified
proportion)
D Approved epoxy (payment shall be for total weight of Resin plus Kg
hardener in manufacturer specified proportion)
E Ordinary Portland Cement 43 Grade Kg
Kg
SUB-HEAD V STRUCTURAL REPAIR ITEMS
8.5.1 Providing and placing in position Micro-concrete, which shall be
cement based prepacked single component, chloride free, non-shrink,
free flow, self compacting, ready to use after mixing water in specified
proportion obtained from approved manufacturer as per specification
and directions of Engineer in charge (Payment under this item shall be


No. Measurement
made only after proper wet curing has been done and surface has been
satisfactorily evaluated by sounding/tapping with a blunt metal instrument)
A Grade M25
B Grade M30 cum
C Grade M40 cum
D Grade M50 cum
E Grade M60 cum
cum
8.5.2 Shotcreting R.C.C. columns, beams and slabs etc. in layers with
approved design mix concrete having the specified minimum
characteristic compressive strength [with ordinary portland cement,
coarse sand and graded stone aggregate of 10 mm maximum size
in proportion as per design criteria] including the cost of centering
and shuttering at edges and corners etc. as directed by Engineer-
in-Charge The rates shall include the providing necessary ground
wires etc. The levelling gauges, if used, shall be paid separately.
(Payment under this item shall be made only after proper wet curing
has been done and surface has been satisfactorily evaluated by
sounding/tapping with a blunt metal instrument)
8
A Upto a height of 15m above plinth level.
a) 25 mm thick in Grade M 20 with cement content not
less than 320 Kg per Cu M
sqm
b) 50 mm thick in Grade M 20 with cement content not
sqm
c) 75 mm thick in Grade M 20 with cement content not
d) 25 mm thick in Grade M 25 with cement content not sqm
e) 50 mm thick in Grade M 25 with cement content not sqm
f) 75 mm thick in Grade M 25 with cement content not sqm
sqm
g) 25 mm thick in Grade M 30 with cement content not
h) 50 mm thick in Grade M 30 with cement content not sqm
sqm
i) 75 mm thick in Grade M 30 with cement content not
sqm
B Deduct for every 10 mm thickness provided less than the specified


No. Measurement
thickness of shotcrete.
a) in Grade M 20 with cement content not less than 320 Kg
per Cu M
sqm
b) in Grade M 25 with cement content not less than 350 Kg
per Cu M
sqm
c) in Grade M 30 with cement content not less than 400 Kg
per Cu M
C Extra for every additional height of 3 metre or part thereof sqm
beyond 15 metre height for every 25 mm thick layer or part
thereof
8.5.3 Providing and laying plain/reinforced concrete jacket for the sqm
structural members e.g. columns, pillars, piers, beams etc with
concrete having the specified minimum characteristic compressive
strength [with ordinary portland cement, coarse sand and graded
stone aggregate of 10 mm maximum size in proportion as per design
criteria] with specified average thickness all-round existing core
of RCC member. Rates shall be for finished surface area of concrete
and shall include the cost of making holes in existing RCC slab, if
required, for pouring concrete in shuttering mould of jacket and
appropriate approved super-plasticiser for rendering concrete as
8
flowable, self compacting but shall exclude cost of reinforcement,
bond coat, shear keys, centering and shuttering, strutting, propping
etc (Payment under this item shall be made only after proper wet
curing has been done and surface has been satisfactorily evaluated
by sounding/tapping with a blunt metal instrument)
A a) 150 mm thick in Grade M 20 with cement content not

b) 100 mm thick in Grade M 20 with cement content not sqm
c) 75 mm thick in Grade M 20 with cement content not sqm
d) 50 mm thick in Grade M 20 with cement content not sqm
sqm
e) 150 mm thick in Grade M 25 with cement content not
f) 100 mm thick in Grade M 25 with cement content not sqm
g) 75 mm thick in Grade M 25 with cement content not sqm
h) 50 mm thick in Grade M 25 with cement content not less sqm


No. Measurement
than 350 Kg per Cu M
i) 150 mm thick in Grade M 30 with cement content not less sqm
j) 100 mm thick in Grade M 30 with cement content not less sqm
k) 75 mm thick in Grade M 30 with cement content not less sqm
l) 50 mm thick in Grade M 30 with cement content not less sqm
B Extra for every 10 mm thickness of jacket over the specified sqm
thickness
a) Grade M 20 with cement content not less than 320 Kg
per Cu M
sqm
b) Grade M 25 with cement content not less than 350 Kg
per Cu M
c) Grade M 30 with cement content not less than 400 Kg sqm
per Cu M
8.5.4 Providing and laying an overlay of plain/reinforced concrete sqm
over prepared surface of existing concrete slab with concrete [as
8 per design mix criteria] of [specified] average thickness as per the
direction of Engineer-in-Charge. Rates shall be for finished surface
area of concrete and shall include the providing necessary ground
wires etc. the cost of appropriate approved super-plasticiser for
rendering concrete as flowable self compacting but shall exclude
cost of reinforcement, bond coat, shear keys, centering and
shuttering, strutting, propping, levelling gauges (if used),.etc
(Payment under this item shall be made only after proper wet curing
has been done and surface has been satisfactorily evaluated by
sounding/tapping with a blunt metal instrument)
8.5.5 Reinforcement for R.C.C. work including Cutting bending, sqm
binding, straightening and placing in position &/or welding with
the existing bars wherever necessary complete.
A MS bars
B Cold twisted CTD bars kg
C TMT bars kg
D Hard drawn hot dipped galvanized steel wire fabric kg
E Hot dipped galvanized Wire kg
8.5.6 Providing structural connections including necessary formwork kg
for concreting, wherever required, as directed by Engineer-in-
charge by :
i) Chipping of concrete and exposing the reinforcement to the
required extent.
ii) Welding necessary dowels to the existing exposed main

No. Measurement
reinforcement.
iii) Providing shear keys/ mechanical anchors
iv) Applying a bonding coat of approved epoxy resin on the substrate
as per manufacturer’s specifications
v) Concreting the joint along with new structural member within the
pot life of epoxy bonding coat.
Costs of concrete, reinforcement, welding, shear key/mechanical anchors
and formwork shall be paid under the relevant items separately. Under
this item, finished surface area at interface of the connection shall be
measured for payment. Rates shall include cost of all the operations
mentioned above. (Payment under this item shall be made only after
proper wet curing has been done and surface has been satisfactorily
evaluated by sounding/tapping with a blunt metal instrument)
8.5.7 Providing, mixing and applying polymer modified cement mortar
in layers, each layer not exceeding 10mm thick, including trowelling sqm
with wooden tools etc. complete as per specifications and directions of
Engineer-in-charge (cost of polymer shall be paid separately) For
payment purposes, pre-measurement of thickness shall be done just
after the surface preparation is completed. (Payment under this item
shall be made only after proper wet curing has been done and surface
has been satisfactorily evaluated by sounding/tapping with a blunt metal 8
instrument)
A Cement Sand mortar in proportion of 1:2 (1-cement: 2-graded
coarse sand) with polymer admixed in proportions approved
by Engineer-in-charge. (75mm size cube crushing strength
at the end of 28-day to be not less than 30 N/sqmm)
a) 25 mm average thickness for slabs
b) 50 mm average thickness for Beams
sqm
c) Deduct/Add for every less/extra 10 mm thickness
sqm
B. Cement Sand mortar in proportion of 1:2.5 (1-cement: 2.5
graded coarse sand) with polymer admixed in proportions sqm
approved by Engineer-in-charge. (75mm size cube crushing
strength at the end of 28-day to be not less than 25 N/sqmm)
b) 50 mm average thickness for Beams
sqm
c) Deduct/Add for every less/extra 10 mm thickness
sqm
C. Cement Sand mortar in proportion of 1:3(1-cement: 3- graded
coarse sand) with polymer admixed in proportions approved sqm
by Engineer-in-charge. (75mm size cube crushing strength
at the end of 28-day to be not less than 20 N/sqmm)


No. Measurement
b) 50 mm average thickness for Beams sqm
c) Deduct/Add for every less/extra 10 mm thickness sqm
8.5.7a Supply of Polymer for polymer modified mortar sqm
A Emulsified Acrylic Polymer (Rates shall be in terms of solid contents
of polymer)
B Emulsified SBR Polymer (Rates shall be in terms of solid contents kg
of polymer)
8.5.8 Mixing and applying epoxy mortar using approved epoxy resin, kg
hardener and silica sand in proportions as per manufacturer’s
recommendation complete. (The rate shall include the cost of silica
sand. The epoxy shall be paid separately on the basis of actual
consumption of the resin and hardener by weight and nothing extra
shall be paid for silica sand.
(priming/ bonding coat of epoxy to be paid separately as per the sqm
relevant item in the schedule)
A 25 mm average thickness for slabs
B 50 mm average thickness for Beams sqm
C Deduct/Add for every less/extra 10 mm thickness sqm
8.5.8a Supplying approved epoxy for epoxy mortar(payment shall be for sqm
8
total weight of Resin plus hardener in manufacturer specified
proportion)
8.5.9 Providing, mixing and applying dry pack mortar 1:2.5 Kg
(1-cement: 2.5- graded sand passing 1.18 mm size sieve) by weight.
Priming/ bonding coat required to be applied shall be paid
separately as per the relevant item in the schedule. For payment
purposes, pre-measurement of volume shall be done just after the
surface preparation is completed. (Payment under this item shall
be made only after proper wet curing has been done and surface
has been satisfactorily evaluated by sounding/tapping with a blunt
metal instrument)
8.5.10 Providing Pre-placed Aggregate Concrete (PAC) with well cum
compacted or hand packed aggregates of size not less than 20 mm
with self flowing grout of cement sand mortar, to be injected as
per specified proportions [neither leaner than 1:2 (1-cement: 2
clean sand passing 1.18 mm size sieve) nor richer than 1:1(1-
cement : 1 clean sand passing 1.18 mm size sieve)]. The water
cement ratio shall be not more than [to be specified but not
exceeding 0.5) but with approved super plasticisers admixed to
achieve required flowability etc complete. For payment purposes,
pre-measurement of volume shall be done just after the surface
preparation is completed. The rates shall include all necessary
labour, materials, T&P including grout pumps etc for executing the job


No. Measurement
as per specifications. Shuttering and priming/ bonding coat, if applied,
shall be paid separately as per the relevant item in the schedule. (Payment
under this item shall be made only after proper wet curing has been
done and surface has been satisfactorily evaluated by sounding/tapping
with a blunt metal instrument)
8.5.11 Strengthening RCC structural member (Beam/Column/Slab/etc) sqm per layer
with hybrid fabric system of a reputed firm comprising of E-glass
and Kevlar fibres woven in the two orthogonal directions soaked in
epoxy complete. Rate shall include cleaning surface, patching up surface
irregularities, rounding of the corners to min. radius of 20 mm, pre-
cutting the fabric according to dimensions required, mixing the epoxy
with high speed mixer for 5 minutes, saturating the fabric with epoxy
manually or using the mechanical saturator, wrapping the member with
the saturated the fabric material after priming the surface with epoxy
and curing for 24 hours at ambient temperatures including applying
cement plaster finish over the outermost layer etc complete. Removing
plaster from the parent surface, if involved, shall be paid for separately
under the relevant item. (The rates shall be for finished surface area and
shall cover the cost of a minimum of 100 mm over laps).
8.5.12 Strengthening RCC structural member (Beam/Column/Slab/etc)
sqm per layer
with unidirectional high strength fibres comprising of E-glass fibres 8
wrapped over prime coated surface with special epoxy, saturated after
wrapping with saturant epoxy complete. Rate shall include cost of
cleaning surface, patching up surface irregularities, rounding of the
corners to min. radius of 20 mm, pre-cutting the fibres according to
dimensions required, mixing the epoxy with high speed mixer for 5
minutes, saturating the fibres with epoxy manually or using the mechanical
saturator, wrapping the member with the high strength fibres after priming
the surface with epoxy and curing for 24 hours at ambient temperatures
including applying cement plaster finish over the outermost layer etc
complete. Removing plaster from the parent surface, if involved, shall
be paid for separately under the relevant item. (The rates shall be for
finished surface area and shall cover the cost of over laps, if any).
SUB HEAD VI: CURING

8.6.1 Wet curing of shotcreted or plastered surface or RCC work as per sqm per layer
specifications by keeping it continuously wet for a minimum period
of seven days
A With regular sprinkling of water by keeping the surface
continuously wet.
B Using pre-tested and approved water based concrete curing
compound
sqm
a) Using non-pigmented wet curing compound

No. Measurement
b) Using pigmented wet curing compound
8.6.1a Supplying pretested and approved water based concrete curing
compound sqm
A Non-pigmented wet curing compound sqm
B Pigmented wet curing compound
SUB-HEAD VII CHHAJJA/SUN SHADES

Litres
8.7.1 Providing and fixing [40 mm or to be specified] thick [red Litres
sandstone or to be specified] chajja over door/window/ventilator
in MS angle iron [40x40x6mm or to be specified] frame pre-painted
with a coat of zinc rich epoxy primer and two coats of tar-epoxy
paint. The stone slab shall be supported on three sides of the frame,
the fourth side of the stone slab to be supported on brick wall as
shown in the drawing (Fig 8.1, which could be modified as per
site specific requirements). The angle iron are to be embedded in
brick wall as shown in drawing in cement concrete block of
specified size including providing gola as per CPWD specification
along the wall face. Measurements shall be done for the funished
projected chhajja in sqm correct to second place of decimal. Rates
shall include cost of all labour and materials. (The size of angle
8 iron frame could be modified as per structural requirement
depending upon the size of chhajja)
8.7.2 Providing and constructing average 25mm thick Ferro-cement
Chhajja/ weather shade, reinforced with 2 layers of 21 gauge
galvanised Iron orthogonally woven wire mesh of 12x12mm size,
sqm
sandwiching a layer of 3.15 mm dia M.S. weld mesh of
100x100mm size, grouted to full depth with cement mortar 1:2.5
(1-cement: 2.5 graded sand, conforming to zome-II of IS:383,
admixed with polymer admixture @ 2 Kg per 50 Kg of cement)
and a cover of 4 mm of same mortar at top and bottom and with
necessary fixing on beam/drop pardi etc. complete with water drip
course (cost of polymer admixture, shuttering, and structural steel
supports to be paid separately). Ferro-cement units must be vibrated
during casting using modified vibrator or orbital vibrators.
8.7.2a Supply of Polymer admixture for Ferro-cement Chhajja/weather
shade
A Emulsified Acrylic Polymer (Rates shall be in terms of solid sqm
contents of polymer)
B Emulsified SBR Polymer (Rates shall be in terms of solid
Kg
SUB HEAD VIII WATER PROOFING & PROTECTIVE
COATINGS
Kg

Fig 8.1: Details of Sand stone Chhajja in MS Angle Iron frame


No. Measurement
Note: Also Refer Section on Water Proofing of ‘CPWD-Delhi
Schedule of Rates’. All items covered under this subhead ‘Water
Proofing & protective coatingsd’ shall carry 10 year guarantee
for water tightness and dry surface on opposite side of treatments
on non-judicial stamp paper. The work shall be carried out by
specialised agency having excellent track record.
8.8.1 Providing, mixing and applying two coats of polymer based
protective, waterproofing and anticarbonation coating with
manufacturer’s recommended admixed dose in cement mixed with
minimum quantity of additional water to make mix workable over
exposed surface at all heights as per specifications. Mixing to be
done by a vertical stirrer type grout mixer. (The cost of polymer
shall be paid separately as per the actual consumption)
8.8.1a Supply of Polymer admixture for waterproofing and anti
carbonation coating sqm
A Emulsified Acrylic Polymer (Rates shall be in terms of solid
kg
8
8.8.2 A Applying an appropriate priming coat of standard primer
compatible to the substrate (bituminous or cementitious) kg
surface including injection grouting the cracks, filling the
voids, undulations etc. complete using quantity not less than
theoretical consumption as per manufacturer’s specifications
and directions of Engineer-in-Charge. The rates shall include
the cost of carrying out repairs to concrete surface, if required
but shall not cover the injection grouting, which shall be
payable separately under the relevant item.
B Applying two or more coats of ready mixed UV resistant
acrylic polymer based water proof coatings with broad sqm
brush or roller over prepared and primer applied surface using
not less than theoretical consumption as per the manufacturer’s
specifications and directions of Engineer-in-Charge (time gap
between two coats of coatings shall be not less than 8 hours).
8.8.2a Supplying appropriate primer for bituminous/cementitious
substrate for water proof coating with UV resistant acrylic polymer sqm
manufactured by reputed manufacturer as approved by the Engineer
in charge in sealed containers.
8.8.2b Supplying ready mixed UV resistant acrylic polymer based water
proof coating manufactured by reputed manufacturer as approved kg
by the Engineer in charge in sealed containers.
8.8.3 Providing and laying ferrocement water proofing treatment
comprising of layers of hot dip galvanised 22 gauge orthogonal kg

No. Measurement
woven wire mesh with 12 mm size mesh openings stretched and fixed
to substrate with 100 mm overlaps in both directions at a clear spacing
of 4 mm and also maintaining a clear bottom cover of 4 mm complete
with plasticiser and polymeric pore sealant admixed in appropriate
approved proportions to 1:2 cement mortar (1-Cement : 2-graded
coarse sand) applied over a bond coat of polymer modified cement
sand slurry, finished with mechanical vibratory orbital trowel. The bottom
cover and the gap between the layers shall be maintained with 4mm dia
GI wire with one layer of wire mesh stretched in the one direction &
fixed with GI wire nails/clamps at 450 mm c/c and another set of 4 mm
GI wires stretched in the other direction and second layer of mesh
stretched over and fixed with GI wire nails/clamps at a spacing of 450
mm c/c. The fixing with G.I. wire nail/clamps shall be done with epoxy
in drilled holes complete as per standard specifications and directions
of Engineer-in-Charge. The rates shall include cost of all materials,
labour, T&P involved, but shall not cover the cost of woven wire mesh,
polymer admixed as pore sealant and bond coat which shall be paid for
separately.
A 15 mm thick with two layers of woven wire mesh
B 20 mm thick with three layers of woven wire mesh
C 25 mm thick with three layers of woven wire mesh
8.8.3a Supplying hot dip galvanised 22 g orthogonal woven wire mesh sqm 8
sqm
with 12 mm size mesh openings in rolls with widths 750 mm to
sqm
1200 mm as may be approved by Engineer-in charge
8.8.3b Supply of Polymeric pore-sealant for ferrocement water proofing
traetment
A Emulsified Acrylic Polymer (Rates shall be in terms of solid sqm
8.8.4 Providing and laying polymeric water proofing compound kg
admixed cement plaster 1:4 (1-cement : 4-graded coarse sand
conforming to zone-II of IS : 383) (specify thickness 12 mm to 18 mm kg
thick) mm thick in layers with the water proofing compound mixed in
proportions as per manufacturer’s recommendations including
preparation of surface and application of bond coat etc. complete over
all vertical and inclined surfaces of RCC work/ Brick Masonry/ block
masonry including necessary scaffolding, clearing the site complete
as per. directions of Engineer-in-Charge. The rates shall include cost
all materials, labour and operations but shall exclude the cost of bond sqm
coat, which shall be paid separately. sqm
8.8.5 Providing injection type post construction water proofing to sqm
concrete structures such as under ground tanks, swimming pools
etc by installing minimum 12/15 mm dia aluminium or GI nozzles Sqm


No. Measurement
at specified intervals and mechanically injecting machine mixed water
proofing polymer modified cement slurry at the minimum pressure of 3
kg/sqcm. Water proofing polymeric compound and shrinkage
compensating admixtures shall be added in proportion as per
manufacturer’s recommendations. The rate shall include all materials,
labour and operations and finishing etc complete but shall exclude the
cost of providing, fixing and cutting off nozzle projections grouting holes,
which shall be paid separately. (Only treated surface area measurement
to be measured).
SECTION IX: MASONRY REPAIR
8.9.1 Cutting, removing, and rebuilding the decayed/damaged masonry Sqm
with
A Brickwork of class designation 75 in
a) Cement Sand Mortar 1 : 4 (1-Cement : 4-Coarse Sand
b) Cement Sand Mortar 1 : 5 (1-Cement : 5 Coarse Sand)
c) Cement Sand Mortar 1 : 6 (1-Cement : 6 Coarse Sand)
B In situ concrete 1:2: 4 (1-cement: 2-coarse sand : 4-12 mm cum
and downsized graded stone aggregate) in part section of a cum
brick or part there of. cum
8 C Build up by guniting in thickness Per brick or part
thereof
a) up to 25 mm
b) Above 25 mm but not exceeding 50 mm
D Applying bonding coat, providing & fixing GI wire mesh
and building up the masonry section to required thickness by sqm
providing polymer mortar 1:3 (1-Cement : 3-Sand sqm
Conforming to zone-III as per IS : 383) in layers not more
than 12mm in thickness or part there of. Polymer shall be
paid separately.
8.9.1a Supply of polymer for polymeric bond coat and/or polymer mortar
A Emmulsified Acrylic Polymer (rates shall be in terms of solid sqm layer
B Emulsified SBR polymer (Rates shall be in terms of solid
contents of polymer
kg
8.9.2 Repair of cracks in 115 mm/230 mm thick masonry wall by
cutting the masonry, and providing and fixing precast RCC runners kg
in M20 concrete and packing with stiff cement mortar 1:4
A 600mm x 115mm x 75mm with 2 nos.6mm MS bar
B 600mm x 230mm x 75mm with 2 nos. 6mm MS bar
8.9.3 Repair of cracks in 115/230 mm thick masonry wall by cutting the each
masonry, and providing cast in-situ RCC runners in M20 concerte each


No. Measurement
A 600mmx115mmx70mm with 2 nos. 6mm MS bar
B 600mmx230mmx70mm with 2 nos. 6mm MS bar
C 1200mmx230mmx70mm with 2 nos. 10mm CTD/TMT
8.9.4 Dismantling removing and cleaning damaged masonry and each
Providing cast in-situ RCC Bed Blocks in M20 concrete each
including shuttering complete excluding reinforcement, if any each
8.9.5 Raking of joints , washing and applying salt peter antidote
and replastering with cement plaster 1:4 (1 cement :4 coarse sand).
8.9.6 Chipping off the area and removing the plaster ,cleaning wetting cum
and applying a layer of polymer mixed bonding coat covering the
joint with one layer of 20 gauge hot dipped galvanised wire mesh sqm
strip in plaster area extending it 75 mm on both sides of the joint
and replastering in cement mortar 1:4. Polymer shall be paid
separately.
8.9.6a Supply of polymer for polymeric bond coat and/or polymer mortar
A Emmulsified Acrylic Polymer (rates shall be in terms of solid sqm
B Emulsified SBR polymer (Rates shall be in terms of solid
contents of polymer
kg 8
SECTION X: TESTING OF MATERIALS AND PRE /
POST REPAIR TESTING OF STRUCTURE kg
8.10.1 Ultrasonic Pulse Velocity (UPV) measurement in accordance
with IS: 13311 Part-1-1992 by measuring the time taken for travel
of a known distance through concrete medium being tested. The
rate shall include the necessary surface preparation including its
smoothening and making it flat, application of petroleum jelly,
etc necessary for intimate contact of the transmitter & receiver
with the concrete surface, recording the minimum & stable reading,
necessary scaffolding and platform, presentation of results in an
acceptable format etc all complete.
8.10.2 Measurement of Rebound Index in accordance with IS: 13311
Part-2-1992 for a location on concrete surface with calibrated
rebound hammer placed perpendicular to the surface and taking Each
required number of rebound readings. The rate shall include surface
preparation, which shall cover removal of surface plaster, if any,
with chisel etc, removal of cement slurry layer from concrete
surface with grinding stone, making surface even & smooth,
necessary scaffolding and platform, presentation of results in an
acceptable format etc all complete.
8.10.3 Measuring the Half Cell Potential readings at the nodes of pre-
marked grid on concrete surface for determining the probability
Each location


No. Measurement
of corrosion activity of embedded steel reinforcement in concrete with

specified half cell electrode in accordance with ASTM C876-1980
after moistening the concrete surface with water. The rate shall include
surface preparation, moistening concrete surface, all the operations and
materials enumerated above, necessary scaffolding and platform,
presentation of each location results in an acceptable format etc all
complete.
A i) With Copper-Copper Sulphate Half Cell Electrode
ii) With Silver-silver chloride Half Cell Electrode Each set of 10

readings
iii) With Calomel Electrode Each set of 10
readings
B Plotting the half cell potential readings in graphical Each set of 10
presentation with potential contours plotted in acceptable readings
format Each set of 10
readings
8.10.4 Measuring the Half Cell Potential readings with wheel electrode
at the nodes of pre-marked grid points on concrete surface in a
suitable grid for determining the probability of corrosion activity
of embedded steel reinforcement in concrete with specified half
8 cell electrode in accordance with ASTM C876-1980 after
moistening the concrete surface with water. The rate shall include
surface preparation, moistening concrete surface, all the operations
and materials enumerated above, necessary scaffolding and
platform, presentation of results in an acceptable format etc all
complete.
A. i) With Copper-Copper Sulphate Half Cell Electrode
ii) With Silver-silver chloride Half Cell Electrode Each set of 10

readings
iii) With Calomel Electrode Each set of 10
readings
B. Plotting the half cell potential readings in graphical Each set of 10
presentation with potential contours plotted in acceptable readings
format Each set of 10
readings
8.10.5 Cutting and extracting undisturbed concrete core of specified
diameters preferably with its length finished after end preparation
equal to twice the diameter but in any case not less than the diameter
of the core, without encountering any steel reinforcement from
the RCC members at specified locations with portable power driven
core cutting equipment. After the core has been extracted, the hole
shall be made good by plugging with dry pack concrete and finished as
per the existing finish. The rate shall include necessary scaffolding and

No. Measurement
platform and cost of all the operations, scanning T& P and materials
etc complete.
A (i) 50 mm diameter
(ii) 75mm diameter
(iii) 100 mm diameter Each
Each
B Testing the extracted concrete cores of any diameter for Each
i) Evaluating compressive strength
ii) Determining density of concrete
Each
iii) Determining depth of carbonation with phenolphthalein
indicator Each
iv) Determining the total acid soluble chloride contents in
Each
concrete as per BS 1881:Part 124
v) Determining the total sulphate contents in concrete
Each
expressed as sulphate buy mass of concrete as per BS
1881:Part 124
8.10.6 Determining depth of carbonated cover concrete by spraying Each
phenolphthalein pH indicator with physician’s injection syringe
(or other fine spraying equipment) over freshly broken/drilled 8
concrete surface (after blowing away dust, if any, due to drilling
operation). The rate shall include cost of all the operations, T&P
and materials including making good the surface damaged with
dry pack concrete, etc as approved by Engineer-in-charge.
8.10.7 Scanning the concrete surface with standard non-destructive Each
embedded metal detecting instrument and plotting the
reinforcement scan, determining its diameter and concrete cover
thickness
A Plot of reinforcement
B Cover Thickness
C Bar diameter sqm
Each
8.10.8 Determination of relative density of samples of fluid, Pyknometer Each
or relative density bottle for polyester resins, etc according to
Annex-F of IS:6746:1994
8.10.9 Determination of relative density samples of liquid admixtures Each
using hydrometer and according to Annex-E of IS:9103:1999
8.10.10 Determination of solid content of samples of polymer according Each
to IS 13435 (Part 1) 1992
8.10.11 Determination of pH value of sample using pH meter electrode
conforming to IS:2711:1979 and testing done according to IS13435 Each


No. Measurement
(Part 4) 1992.
8.10.12 Determination of viscosity of samples of polyester resin by
Brookfield viscometer, expressed in centipoises according to Each
Annex-A of IS 6746:1994
8.10.13 Determination of percentage of air entrained in hardened
concrete/mortar due to an admixture with reference to standard Each
concrete/mortar without admixture considered as reference by
casting standard 75 mm size concrete cubes, three nos. each of
admixed and standard mortar samples respectively prepared and
weighing them after 28 days of standard curing procedure.
8.10.14 Determination of water soluble chloride content in samples of
admixtures according to IS:6925-1973 Each
8.10.15 Determination of total acid soluble chloride content of concrete
/mortar, expressed as percent of mass, according to BS 1881: Each
Part 124
8.10.16 Determination of total acid soluble sulphate content of concrete
/mortar, expressed as percent of mass, according to BS 1881:Part Each
124
8.10.17 Determination of gel time expressed in minutes, of polyester
resins, according to Annex-D of IS 6746:1994 Each
8 8.10.18 Determination of air content of freshly prepared concrete /
mortar, expressed as percent of mass, according to IS:1199-1959 Each
8.10.19 Conducting tests for uniformity tests (dry material content, ash
content, relative density, chloride ion content &pH) on admixtures Each
according to Annex E of IS:9103-1999.
8.10.20 Determination of resistance of concrete against freezing and
thawing according to Annex B of IS:9103-1999. Each
8.10.21 Determination of flow of concrete of high workability concrete
according to Annex C of IS:9103-1999. No.
8.10.22 Determination of bleeding of concrete according to Annex D of
IS:9103-1999. No.
@ the projected length of shear key shall be more than 10 times its
diameter plus half the thickness of cover concrete plus bend length No.
✯ ✯ ✯

CHAPTER 9
SPECIFICATIONS FOR STRUCTURAL REPAIR WORK
PAGE NO.
9.0 General IX-1

9.0.1 Quality Assurance IX-1
9.0.1.1 Submittals IX-1
9.0.1.2 Labelling IX-1
9.0.1.3 Manufacturer’s Test Certificate IX-1
9.0.1.4 Application control IX-1
9.0.1.5 Measurements Control IX-1
9.0.2 Product Delivery, Storage and Handling IX-1
9.0.3 Environmental Requirements IX-2
9.0.4 Personnel IX-2
9.0.4.1 General Requirements IX-2
9.0.4.2 Engineer-in-Charge IX-2
9.0.4.3 Site Contract Manager IX-2
9.0.4.4 Skilled Site Personnel IX-3
9.0.5 Safety IX-4
9.0.6 Tools & Plants (T&P) IX-4
9.0.7 Materials Field Testing Laboratory IX-4
9.0.8 Supervision of Work IX-5
9.0.8.1 General IX-5
9.0.8.2 Internal Supervision IX-6
9.0.8.3 External Supervision IX-23
9.0.9 Records IX-25
9.1 Site Requirement IX-25
9.1.1 Propping & Supporting Structural IX-25
Members Schedule Item No. 8.1.1
9.1.1.2 Design Brief IX-26
9.1.1.3 Requirements of good false work IX-26
9.1.1.4 Inspection of False Work IX-27
9.1.1.5 Execution Procedure IX-27
9.1.1.6 Measurements IX-28
9.1.1.7 Rates IX-28
(i)
(ii)
PAGE NO.
9.1.2 Special Watertight Shuttering/Formwork IX-29
(Schedule Item No. 8.1.2)
9.1.2.2 Materials IX-29
9.1.2.3 Design IX-29
9.1.2.4 Testing IX-29
9.1.2.5 Fabrication and Erection IX-29
9.1.2.6 Measurement IX-29
9.1.2.7 Rates IX-30
9.1.3 Engineered Steel Tubular Double Scaffolding System IX-30
9.1.3.2 Design IX-30
9.1.3.3 Fabrication and Erection IX-30
9.1.3.5 Rates IX-30
9.1.4 Plywood Covering Panels To Cover Windows IX-30
Etc. During Repairs (Schedule Item No. 8.1.4)
9.1.4.2 Fabrication IX-31
9.1.4.3 Fixing IX-31
9.1.4.4 Removal IX-31
9.1.4.6 Rates IX-31
9.1.5 Temporary Barricading Using Angle Iron Verticals IX-31
And Cgi Sheets Panels (Schedule Item No. 8.1.5)
9.1.5.2 Fabrication & Erection IX-32
9.1.5.4 Rates IX-32
9.1.6 Protective Barricading Using Ballis Or Wooden Verticals IX-33
And Cgi Sheet Panels (Schedule Item No. 8.1.6)
9.1.6.2 Fabrication& Erection IX-33
9.1.6.4 Rates IX-33
9.1.7 Protective Barricading Using Bamboo IX-33
And Locally Available Panels (Schedule Item No. 8.1.7)
9.1.7.2 Fabrication& Erection IX-33
9.1.7.4 Rates IX-33
(iii)
PAGE NO.
9.1.8 Temporary Protective Fabric Screens IX-33
9.1.8.2 Procedure IX-34
9.1.8.4 Rate IX-34
9.1.9 Providing And Fixing Door Of Corrugated Or Stiffened Plain IX-34
Gi Sheet Over Frame Of Local Wood Etc.
9.1.9.1 Material IX-34
9.1.9.2 Fabrication IX-35
9.1.9.3 Fixing IX-35
9.1.9.5 Rate IX-35
9.1.10 Providing And Erecting Covered Shelters IX-35
9.1.10.4 Rates IX-36
9.2.1 Removal Of Plaster Manually From Masonry Or IX-36
Concrete Surface Using Chisel And Hammer
And Disposal Of Debris Etc.
9.2.1.3 Rate IX-37
9.2.2 Chipping Of Unsound/ IX-37
Weak Concrete Material
9.2.2.1 Materials And T&P IX-37
9.2.2.2 Safety Safety Shall Be Ensured In Accordance IX-37
9.2.2.5 Rates IX-38
9.2.3 Dismantling & Removing Existing Treatment Over IX-39
Rcc Slabs At All Heights
9.2.3.1 Materials and T&P IX-39
9.2.3.5 Rates IX-39
(iv)
PAGE NO.
9.2.4 Dismantling Existing Rcc Work Manually IX-39
But Excluding Cutting Reinforcement Bars
(Schedule Item No 8.2.4)
9.2.4.2 Safety IX-39
9.2.4.5 Rates IX-40
9.2.5 Cutting Reinforcing Bars In Rcc Or Reinforced Brickwork IX-40
9.2.5.5 Rates IX-41
9.2.6 Removing Concrete All Around Reinforcement Including IX-41
From Its Behind (Schedule Item No. 2.6)
9.2.6.5 Rates IX-42
9.2.7 Cleaning Reinforcement Of Total Rust Including IX-42
From Behind Reinforcement (Schedule Item No. 8.2.7)
9.2.7.6 Rates IX-43
9.2.8 Introducing New Reinforcement Bars For Structural IX-43
Connection In Rcc Structural Member (Schedule Item No. 8.2.8)
9.2.8.1 Material And T&P IX-43
9.2.8.5 Rates IX-49
9.2.9 Specification for Providing and Inserting Shear Key Bars IX-49
9.2.9.4 Rates IX-49
(v)
PAGE NO.
9.2.10 Specification for Cleaning Exposed Concrete Surface IX-50

of Loose and Foreign Materials by Means of sand
Blasting (Schedule Item No. 8.2.10)
9.2.10.2 Testing of Materials and T&P IX-50
9.2.10.3 Safety IX-50
9.2.10.6 Rates IX-50
9.2.11 Pdg. and fixing anchor fastner system IX-50
Mechanical/ Epoxy based (Schedule item No. 2.11)
9.2.11.5 Rates IX-51
9.3 Crack/Honeycomb srea Repair IX-51
9.3.1 Specification for providing drilling and inserting IX-51
Nipples along crack lines (Schedule Item No. 8.3.1)
9.3.1.5 Rates IX-52
9.3.2 Sealing of cracks by Injection of approved grout IX-52
(Schedule Item No. 3.2)
9.3.2.2 Execution IX-53
9.3.2.4 Rates IX-56
9.4 Bonding Coats IX-56
9.4.1 Bonding Coat for Hardened Concrete with IX-56
Repair Concrete/ Shotcrete/ Cement Mortar IX-56
(Schedule Item No. 8.4.1) IX-56
9.4.1.3 Field Quality Performance Requirement IX-58
9.4.1.5 Rates IX-59
9.4.2 Alkaline Passivating Bond Coat Over Reinforcement IX-59
(vi)
PAGE NO.
9.4.2.4 Rates IX-61
9.5 Repair Items IX-61
9.5.1 Specification For Micro-concrete (Schedule Item No. 8.5.1) IX-61
9.5.1.4 Rates IX-63
9.5.2 Specification For Shotcrete (Schedule Item No.. 9.5.2) IX-63
9.5.2.1.1 Materials IX-63
9.5.2.1.2 Equipment IX-65
9.5.2.4 Rates IX-70
9.5.3 Plain/Reinforced Concrete Jacket for the Structural IX-70
Members e.g. Columns, Pillars, Piers, Beams etc.
9.5.3.1 Materials and T&P- IX-70
9.5.3.4 Rates IX-72
9.5.4 Providing and Laying an overlay of reinforced Concrete over IX-72
prepared surface of existing RRCC Slab/Beam etc.
9.5.4.4 Rates IX-74
9.5.5 Reinforcement for RCC work etc. (Schedule Item No. 8.5.5) IX-74
9.5.5.1 Material & T&P IX-74
9.5.5.4 Rates IX-76
9.5.6 Providing Structural Connection (Schedule Item No. 8.5.6) IX-76
9.5.6.1 Specifications IX-76
9.5.6.3 Rates IX-76
9.5.7 Cement Based Polymer Modified Mortar IX-76
(vii)
PAGE NO.
9.5.7.3 Inspection & Quality control IX-79
9.5.7.5 Rates IX-79
9.5.8 Epoxy Mortar ((Schedule Item No. 8.5.8)) IX-79
9.5.8.3 Inspection & Quality control IX-82
10.5.8.5 Rates IX-82
9.5.9 Dry Pack And Epoxy Bonded Dry Pack IX-82
(Schedule Item No. 8.5.9) IX-82
9.5.9.3 Rates IX-82
9.5.10 Preplaced Aggregate Concrete IX-83
(Schedule Item No 8.5.10)
9.5.10.2 Rate IX-83
9.5.11 Strengthening with Hybrid Orthogonal Woven Fabric IX-83
System Soaked in Epoxy
(Schedule Item No. No 8.5.11)
9.5.11.3 Rate IX-83
9.5.12 Strengthening with Unidirectional High Strength Fibres IX-83
over Epoxy Coated Surface
(Schedule Item No. No 8.5.12)
9.6 Curing IX-83
9.6.1 Curing of Shotcreted, Plastered and/or RCC Surfaces IX-83
etc. (Schedule Item No 8.6.1)
9.6.1.4 Rate IX-85
9.7 Chhajja/Sun Shades
9.7.1. Specified Sand Stone Chhajja IX-86
9.7.1.4 Rates IX-86
(viii)
PAGE NO.
9.7.2 Average 25 mm thick Ferro-cement Chajja/Weather IX-86

Shade etc.
9.8 Water Proofing & Protective Coatings
9.8.1 Polymer Modified Cement Slurry Waterproofing IX-87
and Anticarbonation Coating
9.8.2 Uv Resistant Acrylic Polymer Based Water IX-87
Proof Coatings
9.8.3 Ferro-cement Water Proofing Treatment IX-87
9.8.3.5 Rates IX-89
9.8.4 Cement Plaster With Polymeric Water Proofing IX-90
Compound
9.8.1.1 Materials, Procedure, Measurements and Rates IX-90
9.8.5 Injection Type Post Construction Water Proofing IX-90
to Concrete Structures
9.8.5.1 Materials, Procedure, Measurements and Rates IX-90
9.9 Masonry Repair
9.9.1 General IX-90
10.0 Testing of Materials and Pre/Post Repair Structure
Appendix 9.1 IX-91
9
SPECIFICATIONS FOR STRUCTURAL REPAIR WORK
Science is a self-correcting system. No fraus (or honest mistake) is going to stay undetected for long.
..C.P. Snow
9.0 GENERAL
9.0.1 Quality Assurance
9.0.1.1 Submittals:
The contractor shall submit manufacturer’s certification that the firm has manufactured the
supplied materials.
9.0.1.2 Labelling:
All containers shall be clearly marked with following information.
(a) Name of Manufacturer
(b) Manufacturer’s product identification
(c) Manufacturer’s instruction for mixing.
(d) Warning for handling and toxicity.
(e) Date of manufacturing & its shelf life.
9
9.0.1.3 Manufacturer’s Test Certificate:
°
The contractor shall submit manufacturer’s certification verifying conformance to
material specification as specified.
9.0.1.4 Application control:
The contractor shall submit mixing application procedure for each of the manufactured
repair material for the approval of Engineer-in-Charge prior to their use.
9.0.1.5 Measurements Control: Measurements for payment of the item of repair shall be
done only after completion of all steps of execution listed in the particular specification.
9.0.2 Product Delivery, Storage and Handling:
Storage: The contractor shall get approved from the Engineer-in-Charge the storage
space for epoxy/polymer/patented/other manufacture of materials to ensure that the
storage temperature is maintained between 50 C and 380 C unless recommended
otherwise by the manufacturer.
Delivery: Contractor shall deliver all materials in sealed containers in packing as
approved by Engineer-in-Charge with labels legible and intact.
Handling: All materials shall be handled in a safe manner and in a way to avoid
breaking container seals.
Central Designs Organisation IX-1

9.0.3 Environmental Requirements:

Contractor shall comply with manufacturer recommendations so as to comply with
environmental conditions under which the repair materials may be applied.
9.0.4 Personnel:
9.0.4.1 General Requirements
(1) Production, processing, testing and supervision require the employment of an
Engineer-in-Charge by the Employer and Site Contract Manager & skilled site
workers by the contractors who shall have adequate qualifications and experience
for the proper execution of such works and already performed works of this kind
with success.
9.0.4.2 Engineer-in-Charge:
(1) The Engineer-in-Charge shall represent the Employer and should have adequate
knowledge and experience in protection and repair measures for the work.
(2) The Engineer-in-Charge is in charge of and responsible for work on the
construction site and where relevant, for the management of the Materials Field
Testing Laboratory. He may perform the tasks of the competent planning engineer
(3) So far as they have not been dealt with at the planning stage, the tasks of the
Engineer-in-Charge include:
- Recording and evaluating the states of structures, for example in terms of
statics, design, concrete technology, materials technology, fire protection
technology and physics relating to construction (determination of the actual
state and of the causes of damage).
- Deciding whether additional experts should be consulted in respect to
9
safety, relevant work and other specialized tasks.
- Assessing protection and repair plans especially in respect of the choice of
the repair systems to be employed.
- Planning and assessing application oriented suitability tests.
- Setting out and, where relevant, assessing performance specifications and
assessing the feasibility, effectiveness and durability of the protection and
repair measures, taking structural stability aspects into account.
- Devising working plans.
- Assessing the specialist qualifications of the skilled site personnel and test
laboratory personnel
- Evaluating internal supervision measures.
9.0.4.3 Site Contract Manager
(1) The site contract manager or a qualified deputy of the site contract manager is the
engineer representing the contractor, whose credentials were submitted and
approved by the employer before issue of tender forms. He must be present on
the construction site at all times during construction works.
(2) The site contract manager ensures safe execution of the works according to the
plans and, in particular, discharges the following tasks over and above his tasks.
IX-2 Repairs & Rehabilitation Unit

SPECIFICATION FOR SPECIAL ITEM FOR STRUCTURAL REPAIR WORK
a) Notifying the works to the employer and the consultant

b) Arranging for and carrying out supervision
c) Using the envisaged, (quality) assured construction materials.
d) Where relevant, ensuring adequate treatment of the concrete substrate and
intermediate layers.
e) Ensuring compliance with the technical conditions for the works and with
proper production, processing, after-treatment, and formwork removal as
stipulated by the Engineer-in-Charge or the consultant.
f) Communicating the most important results of internal supervision measures
to the external supervising authority.
g) Supervision measures in respect to preventive safety engineering and
occupational medicine.
9.0.4.4 Skilled Site Personnel
(1) Skilled workers shall be employed by the Contractor. They shall be equipped
with special training in manual crafts and possessing knowledge, skills and practical
experience in respect of concrete technology and other materials appropriate to
the scope, type and difficulty of the repair measures. They must be present on
each construction site at all times. His qualification for works according to these
guidelines must be demonstrated to the external supervision agency by means of
an appropriate certificate.
(2) The Contractor must ensure that the skilled workers employed at site, are informed
of and instructed in protection and repair measures at maximum intervals of 3
years so as to enable them to take all measures for the proper execution of the
construction measure, including tests and internal supervision as per the latest
prevalent technology. 9
(3) The tasks of the skilled site personnel include
- practical execution of the protection and repair measures according to the
prescribed planning / execution documents (directions for execution).
- specifying and supervision any work delegated to other skilled site personnel,
insofar as it affects the success of the measure.
- directing the other skilled site workers to whom execution of the construction
measures has been entrusted and checking their manual craft skills.
- carrying out the tests required as part of internal supervision and recording
and interpreting the results.
(4) If the Contractor has a Materials Field Testing Laboratory (see Section 9.0.7)
with appropriately qualified personnel the requirements contained in Paragraphs
(1) and (2) in respect to the skilled site personnel are deemed to be satisfied if
- responsibility for the tasks is assumed by the Materials Field Testing
Laboratory and
- a person delegated by the Materials Field Testing Laboratory is present on
the construction site at all times and
- This delegated persons has been instructed and trained in the relevant
protection and repair measure and the results of the training have been
documented to the external supervising authority.

9.0.5 Safety:
Workers: Contractor shall advise all workers working with epoxies to avoid contact with
eyes and skin, inhalation of vapours, and ingestion. Necessary protective and safety equipments
in the form of hand gloves, welders’ goggles, shall be provided by the contractor and used on
site.
Structural Safety: Care shall be taken to ensure that vibrations are well within acceptable
limits for structural safety and users of the building.
9.0.6 Tools & Plants (T&P):
(1) For the execution of protection and repair works, properly maintained plant and
equipment permitting adequate treatment of the concrete substrate, proper
execution of the work and determination of the required properties of the
construction materials and construction measures must be present on the
construction site.
In particular, these are plant and equipment for
a) Treatment of the concrete substrate
b) Dosing of the base materials.
c) Mixing of the base materials
d) Processing and after-treatment
e) Measurement and testing.
(2) To ensure efficient and effective functioning, all plant and equipment must be
checked on-site and at field material testing laboratory prior to first use and at
appropriate intervals thereafter.
9 9.0.7 Materials Field Testing Laboratory:
(1) The Materials Field Testing Laboratory must be equipped and staffed to carry out
all pre and post repair tests (Refer Appendix 9.1-Test Methods for Execution of
Works) to ensure required quality of repair jobs and also to monitor the satisfactory
performance of plant and equipment during execution. The testing laboratory
and the site must cooperate closely with one another.
(2) The materials testing laboratory carries out the following specific tasks:
a) Suitability testing for concrete and shotcrete; assessment and choice of
premixed construction materials.
b) Assessing and, where necessary, testing the concrete substrate and
intermediate layers.
c) Checking and supervision of the required technical conditions.
d) Testing quality and setting, in so far as such tests are not performed by the
skilled site personnel.
e) Checking the equipment of the construction sites according to Section 9.0.6
above prior to commencement of the works.
f) Continuous checking and advice in respect to the production, processing
and after-treatment of the construction materials. The results of checks
according to e) and f) are to be recorded.

g) Interpreting and assessing the results of site tests on all work sites advised by the
materials testing laboratory and communicating the results to the Contractor and
its site contract manager.
h) Training / refreshing the know-how of the skilled site personnel.
(3) The Contractor may not entrust internal supervision to a field materials testing
laboratory also responsible for supervising one of its suppliers.
(4) The Materials Field Testing Laboratory may also cause the sites to be equipped
with test devices.
This applies particularly to
i) testing of base materials
ii) testing of the concrete substrate
iii) testing processing conditions
iv) testing the construction materials in the green state and after setting.
v) Where necessary, checking layer adhesion.
vi) Making up and storing test specimens and retained specimens.
(5) Where necessary, the Materials Field Testing Laboratory must ensure that the
site is equipped with the necessary plant and equipment for supervision measures
and tests during the required period. Functioning of all plant and equipment at the
Materials Field Testing Laboratory and on the construction site must be checked
prior to first use and at appropriate intervals thereafter.
9.0.8 SUPERVISION OF WORKS

9.0.8.1 General
(1) Supervision consisting of internal and external supervision must be conducted 9
for construction measures according to these guidelines.
(2) Internal supervision must be carried out by the site contract manager in conjunction
with the specialized staff of the Contractor and possibly in conjunction with the
field materials testing laboratory.
(3) External supervision must be carried out by a supervisory association or on the
basis of a specified contract with an official testing institute.
(4) For construction measures according to these guidelines, the Contractor or the
site contract manager must notify the following information to the external
supervising authority at latest 48 hours before commencement of the relevant
works.
a) designation of the construction site, qualified executive manager, site contract
manager, skilled site personnel.
b) The existence of written directions for the site in respect to the production,
processing, after-treatment and supervision of all tasks required.
c) The intended time of commencement and probable time of completion of
the works.
d) The internal supervision laboratory.
e) If work is interrupted for a lengthy period – especially following lengthy
periods of frost or, where relevant, rain – recommencement of the works
must be notified.

m
9.0.8.2 Internal Supervision

Documentation during Execution of the Works
(1) Depending on the type and scope of the works, continuous verifiable records of
all data significant for the quality and durability of the structure and its parts are
to be made in a certifiable form, e.g. on forms (site log)., by the site contract
manager, his deputy or the skilled site personnel for construction measures
according to these guidelines. They must contain at least the following information
a) commencement and completion of the individual works.
b) Whether conditions, air temperature, atmospheric humidity (where relevant),
temperature of the materials at the time of execution of the individual
construction phases or components up to adequate hardening. A special
note must be made of days on which the processing conditions were not
fulfilled (e.g. due to frost, rain).
c) The materials processed
d) Supplier and delivery note, batch number where relevant
e) Records of the work procedures and checks according to the directions for
work and execution.
f) Proper functioning of the equipment employed
g) Specimens made up, with their designations, date of making up and details
of the individual components or phases of construction for which the
associated construction material was used, test date and results and required
properties.
9 h) Testing of the concrete substrate and, where relevant, of intermediate layers,
with results specified for each component
i) Where necessary, temperatures and moisture of the components.
j) Measures taken when requirements were not met
k) Names of the skilled site personnel executing and supervision the work.
(2) The records must be available on the site during the construction period and must
be shown on demand to the person responsible for supervision.
(3) Following completion of the construction works, the results of important tests
stipulated by the external supervision agency must be handed over to that agency.
Type, Scope and Frequency of Supervisory Measures
(1) The type, scope and frequency of the supervision measures are specified in Tables
9.1 to 9.7; if the construction measure is interrupted, the test time spans are
prolonged accordingly.
(2) In case of doubt, tests which are not normally required, for example on properties
of the base materials, their composition, suitability of methods of execution and
testing, must also be performed. The qualified executive manager is responsible
for ordering such tests.
(3) If test results are inadequate, the Contractor must eliminate the causes and any
defects – where necessary including defects on the structure – without delay.

Table 9.1: Concrete according to IS: 456 (continued)
Sl. Object of test Type of test, Requirements Frequency,

No. test on, time
test variable
Base materials
1. Cement Delivery note and packaging Labelling (type, strength Each delivery
stamp or silo certificate class and proof of moni-
(possibly lead-sealing) toring) according to IS269
IS:3466
2. Aggregate Delivery note Designation, proof of Each delivery

monitoring according to
IS 383
3. Visual inspection for aggregate Compliance with specifi- Each delivery

type, granulometric composition cations according to
absence of rock defects, harmful IS 383: 1952
constituents (e.g. clay, chalk,
coal) and particle shape
4. Granulometric composition Compliance with At first delivery, at

Through sieve analysis granulometric composi- appropriate intervals, on
according to IS 383 tion and reproducibility change of a manufact-
uring works
5. Concrete agents, Delivery note and possibly Designation, mark of Each delivery
fibres, colorants sack labeling or silo lettering conformity or approval
and proof of monitoring
6. Concrete agents Delivery note and packaging Designation, mark of Each delivery
or drum labels or silo lettering conformity and proof of 9
labeling monitoring
7. Admixed water Constituents interfering with No constituents inter- Only if potable water is
initial setting and hardening fering with initial setting not used and if interfering
and hardening constituents are
suspected
Prefabricated materials
8. Handover of Delivery note Complete specification Each delivery
ready mixed data according to
concrete and IS 4926
fresh mortar
9. Handover of Delivery note and packaging Designation, proof of Each delivery

plant-mixed stamp, labeling monitoring
dry products
10. Visual inspection No obvious changes Continuously
11. Storage Storage conditions According to manufact- On storage, in case of

urer’s directions for use doubt
12. Working plan Directions for treatment of the Mean Tensile Strength Prior to commencement
substrate > 1.5 N/sq mm; Min. of works
& Max Temp as per
Step-9 in 9.4.1.2


No. test on, time
test variable
13. Concrete Visual inspection Suitability of concrete Prior to commencement

substrate substrate for the planned of works
measure
14. Surface tensile strength Suitability of the concrete > 20m² 3 single tests
substrate in terms of > 200m² 3 single tests
surface tensile strength per started 200m2
according 3.2.1.4
Concrete
15. Composition of Suitability tests based on IS: The properties required Prior to commencement
materials 456 in each case must be works and if the base
attained reliably materials or site onditions
change significantly.
16. Mixed materials Composition of the mixture Compliance with mixing First use of each type; at
directions appropriate intervals;
during production of test
specimens for strength
tests
17. Green concrete Consistency (appearance) Compliance with speci- Each mix or delivery
fied consistency range vehicle
18. Consistency factor according Compliance with the First use of each type;
IS 1199: or as consistency factor appropriate intervals;
determined specified in the production of test
suitability test for specimens for strength
tests
9
19. Water content Compliance with the According to IS:456:2000
specification
20. Air content according to Proof of air content for First use of each type; at
IS 1199 concrete or mortar with appropriate intervals (each
high frost/salt resistance mix)
according to IS 456
21. Hardened Compressive strength according Proof of compressive Every 7 days during use of
concrete to IS 516 strength of concrete concrete/mortar, a series of
according to IS 456 six test specimens
22. Impermeability to water Compliance with By agreement, but at least

according to IS 3085 specification three test specimens
23. Working plan Directions for making up (mixing Compliance with Prior to commencement of
directions), transportation, specifications works
working and after treatment
24. Weather Air temperature, maximum and Compliance with Every working day, prior to
minimum values specifications commencement of works, in
case of doubt
25. Relative atmospheric humidity Compliance with Every working day, prior to
specifications commencement of works, in
case of doubt


No. test on, time
test variable
26. Concrete Moisture Compliance with Prior to commencement of

substratespecifications subsequent works, in case
of doubt
27. Temperature Compliance withIn In case of doubt

Specifications
28. Construction Temperature Compliance with Every working day, in

Material Specifications case of doubt
29. Finished Adhesive strength Compliance with By agreement with the client
Component Specifications if not agreed, then at least
half the tests for surface
tensile strength
30. Concrete cover Compliance with As specified

specifications according
to IS 456
Technical equipment
31. Dosing equipment Visual inspection Unexceptionable Weekly
for cement functioning
32. Aggregate, colouring Function check Compliance with At commencement of

agents, fibres, admixed projected quantity to works, thereafter monthly
water, plant-mixed an accuracy of 3%
materials.
9
33. Dosing equipment Function check Compliance with At least once per working
for concrete projected quantity to day
additives an accuracy of 3%
34. Mixing machines Function check Unexceptionable functi- At commencement of works,

transportation, oning, in the case of thereafter at least monthly
charging and mixing in ready-mixed
compacting concrete transporters
machines adequate screw height
35 Measuring Function check Adequate measuring On first use, at appropriate

testing and accuracy intervals
laboratory
equipment
36. Own or hired Adequate instruction of Compliance with On first use, then at
vehicles with driver by Test Station E specification per appropriate intervals
IS 456
agitating equip
-ment or mixer
vehicles for
transporting
concrete and
mortar

Table 9.2: Shotcrete

No. test on, time
test variable
Base materials
1. Cement Delivery note and packaging Labelling (type, strength Each delivery
label or silo certificate (possibly class and proof of monit-
lead-sealing) oring) according to IS 269
2. Concrete Delivery note Designation, proof of Each delivery

aggregate monitoring according to
IS 383
3. Concrete Visual check of type of aggregate Compliance with speci- Each delivery
additives granulometric composition stone fications in IS 383
quality and harmful constituents
(e.g. clay, chalk, lime, coal)
4. Granulometric composition by Compliance with granulo- At first delivery, once each

sieve analysis according to metric composition and week of concreting
IS 383 reproducibility
5. Concrete Delivery note and possibly Designation mark of Each delivery

agents packaging or drum label or conformity to IS:9103
silo lettering or approval & proof of
monitoring
6. Delivery note and packaging or Designation, mark of Each delivery

drum label or silo lettering conformity to IS:9103
9 and proof of monitoring
8. Storage of Storage conditions According to manufact- At storage, in case of doubt

base materials urer’s directions
9. Admixed water Constituents interfering with No constituents interfe- Only if potable water is not
setting and hardening ring with setting and used and interfering conta-
hardening mination is suspected
Pre-mixed materials
11. Ready-mixed Delivery note Completeness of Each delivery
concrete or specified data
fresh mortar
Plant-mixed dry Delivery note and packaging Designation, proof of Each delivery
Products stamp, labelling monitoring
12. Plant-mixed dry Visual inspection No obvious changes Continuously

products
13 Shortage conditions According to manufact- At storage, in case of doubt
urer’s instructions
(directions for use)
Ready-mixed material,
Test level 1
14. Concrete Suitability tests The properties required Prior to commencement of
in each case must be works and if the base
attained materials or site conditions
change significantly.


No. test on, time
test variable
15. Job-mixed Composition of the mix Compliance with mixing At the beginning of each day
concrete instructions of concreting, during produ-
ction of test specimens for
Strength tests
16. Ready-mixed Inherent moisture Compliance with agreed <100m³ or 500m² = 1 series,
material, dry inherent moisture 100m³/500m² to 300m³/
spray method 1500m² = 1 series per 100m³/
500m², >300m³/1500m² = 1
series per 250m³/1250m²+
1 series at commencement of
concreting
17. Ready-mixed Consistency Compliance with con-

material, wet method sistency factor specified
dry method with on the basis of the
admixed water suitability test
18. Green concrete apparent Compliance with the green

specific density concrete apparent specific
density specified on the basis
of the suitability test
19. Compressive strength Compliance with the com-

pressive strength specified on
the basis of the suitability test.
Shotcrete, test level 2
20. Green concrete Green concrete apparent Compliance with the green <100m³ or 500m² = 1 seri- 9
specific density concrete apparent specific es,100m³/500m² to 300m³/
density specified on the 1500m=1series per 100m³/
bases of the suitability 500m2 >300m3 /1500m2
test. = 1 series /1250m2 + 1 series
at commencement of
concreting
21. Green concrete Water content Compliance with the water
content specified on the
basis of the suitability test.
22 Granulometric composition < Compliance with the In case of doubt

0.25 mm granulometric composi-
tion specified on the basis
of the suitability test.
23. Hardened Apparent specific density (air Compliance with the <100m³ or 500m² =1 series,
concrete dry at storage 20°C, 65% relative apparent specific density 100m³/500m² to 300m³/
atmospheric humidity) specified on the basis of 1500m²= 1 series per 100m³/
the suitability test. 500m2,>300m³/
1500m² = 1 series per 250m3
/1250m2 at commencement
of concrete.
24. Compressive strength Compliance with the

strength class specified on
the basis of the suitability
test


No. test on, time
test variable
25. Impermeability to water Compliance with the imper- Half the tests for compressive
meability to water specified strength, at least three specimens
on the basis of the suitability
test
Concrete substrate
26 Surface for Directions for the treatment of Compliance with Prior to commencement
coating the concrete substrate and, specifications of works
where relevant, placing of re-
inforcement
27 Visual inspection Suitability for the planned Prior to commencement
measure of subsequent works
28. Moisture Suitability in terms of Prior to commencement
moisture for the planned of subsequent of works,
measure in case of doubt.
29. Temperature Compliance with In case of doubt
specifications
30. Surface tensile strength Suitability By agreement with the
for the planned measure client; in the absence of an
agreement: >20m² 3 single
tests> 200 m² 3 single tests
per started 200m². The
single tests must be distributed
uniformly throughout the area.
Processing
9
31 Working instructions Directions for making up Compliance with Prior to commencement
(mixing instructions) specifications of works
transportations,
working and after
treatment
32. Weather Air temperature, maximum Compliance with Every working day
and minimum value; specificatons
weather condition
33. Construction Temperature Compliance with Every working day in
specificatons case of doubt
34. Surface of shotcrete After-treatment Compliance with Each stage of work

specificatons
35. Finished component Layer thickness Compliance with agreed Each stage of work
layer cover
36. Percussion No cavities Each layer
37. Adhesive strength Compliance with By agreement with client;
specifications or according in the absence of an
to repair concept agreement 5 values per started
250m²; at least 5 values per
structure
38 Concrete cover Compliance with In case of doubt
specifications


No. test on, time
test variable
Technical equipment
for base materials functioning
40 Prefabricated Function check Compliance with projected At commencement of

materials quantities works, thereafter monthly.
41. Mixer, shotcreting Function check

equipment
42. Unexceptionable At commencement of

functioning works, thereafter at least
monthly
43. Measuring and Function Check Adequate measuring On first use, at appropriate
testing devices accuracy intervals
Where relevant, Adequate instruction of Compliance with requirements On first use, then at
own or hired drivers by Test Station appropriate intervals
transport
vehicles with
agitation
equipment or
readymixed
concrete and
mortar
transporters
9

Table 9.3: Polymer-modified cement mortar and concrete, cement mortar

No. test on, time
test variable
Pre-fabricated materials
1. Handover of Delivery note and Designation, proof of Each delivery
plant-mixed packaging stamp monitoring
products
3. Storage Storage conditions According to directions On storage, in case of doubt

for use
Concrete substrate
4. Working plan Directions for treatment of the Compliance with Prior to commencement
concrete substrate specifications of works
5. Concrete substrate Visual inspection Suitability of the concrete Prior to commencement of

substrate for planned subsequent works
measure
6. Surface tensile strength Suitability of the concrete > 20m² single tests; >200 m² 3
substrate in terms of surface single tests per started 200m²
tensile strength
Mortar/concrete
7. Composition of Basic test The properties required in Prior to commencement
construction each case must be attained of works
materials reliably
9 8. Mixed materials Compositions of the mix Compliance with mixing At first use of each type;
instructions at appropriate intervals; when
specimens are made up for
strength tests
9. Green mortar/ Consistency (appearance) Compliance with specified Each mix

concrete consistency range
10. Air content Proof of required air content At first use of each type,
at appropriate intervals
11. Hardened mortar / Flexural tensile and Proof of strength Every 6 days during
concrete compressive strength working of concrete / mortar, a
series of 3 specimens; at least
one series of 3 specimens.
12. Processing Directions for making up Compliance with directions Prior to commencement
(mixing instructions), for use of works
transportation, working and
after-treatment
13. Weather Air temperature, maximum Compliance with Every working day, prior to
and minimum values specifications commencement of works in
case of doubt.
14. Relative atmospheric Compliance with Every working day , prior to

humidity/weather conditions specifications commencement of work,
incase of doubt.


No. test on, time
test variable
15. Concrete Moisture Compliance with Prior to substrate commence

specifications ment of subsequent works,
in case of doubt.
16. Temperature Compliance with In case of doubt.

specifications
17. Construction Temperature Compliance with In case of doubt.

material specifications
18. Finished Adhesive strength Compliance with By agreement with the

component specifications client, in the absence of
an agreement, at least half
the tests for surface tensile
strength
19. Concrete cover Compliance with By aggrement

specifications
Technical equipment
20. Dosing equipment Visual inspections Unexceptionable Weekly
for additives and functioning
water.
21. Function Check Compliance with At commencement of works,

projectedquantity to thereafter monthly 9
an accuracy of 3%
22. Mixing Function check Unexceptionable At commencement of works,

equipment, functioning thereafter at least monthly.
transportation,
charging and
compacting
equipment

Table 9.4: Epoxy mortar and concrete

No. test on, time
test variable
Prefabricated materials
1. Handover of plant Delivery note and packaging Designation, proof of Each delivery
mixed products stamp monitoring
3. Storage Storage conditions According to directions On storage, in case of doubt

for use
Concrete substrate
4. Working plan Directions for treatment of the Compliance with Prior to commencement of
concrete substrate specifications works
5. Concrete substrate Visual inspection Suitability of the concrete Prior to commencement

substrate for the planned of subsequent works
measure
6. Surface tensile strength Suitability of the concrete >20 m2 tests;>200 m2 3

substrate in terms of surface single tests per s.
tensile strength
Epoxy mortar/concrete
7. Composition Basic test of construction The properties specified in Prior to commencement of
materials each case must be attained works.
reliably
9
8. Mixed construction Composition of mix Compliance with mixing On first use of each type;
materials Instructions at appropriate intervals;
when specimens are made
up for strength tests.
9. Green mortar/ Consistency (appearance) Compliance with specified Each mix

concrete consistency range
10. Hardened mortar/ Flexural tensile and compressive Proof of strengths according Every 6 days during working
concrete strength according to Table 5.8 to specifications of concrete / mortar, a series
of 3 specimens; at least one
series of 3 specimens.
Processing
11. Working plan Directions for making up Compliance with directions Prior to commencement
(mixing instructions) for use. of works.
transportation, working
and after treatment.
12. Weather Air temperature, maximum Compliance with Each working day, before
and minimum value. specifications. beginning work, in case
of doubt.
13. Weather Relative atmospheric humidity, Compliance with Every working day, prior to
weather conditions specifications commencement of works, in
case of doubt.


No. test on, time
test variable
14. Concrete Moisture Compliance with limits Prior to commencement of

substrate specified by material subsequent works,
manufacturer in case of doubt.
15. Temperature Temperature 3O C higher Prior to commencement of

than dew-point temperature execution of the works and
following changes in the
weather.
16. Construction Temperature Compliance with Prior to commencement of

material specifications execution of the works and
following changes in the
weather.
17. Finished component Adhesive Strength Compliance with By agreement with the client;
specifications in the absence of an agreement,
at least half the test for surface
tensile strength.
Technical Equipment
18. Dosing equipment Visual inspection Unexceptionable functioning Weekly
19. Function check Compliance with projected At commencement of works,

quantity to an accuracy thereafter at least monthly.
of 3%
20. Mixing equipment, Function check Unexceptionable functioning At commencement of works,

transportation, thereafter at least monthly. 9
charging and
compacting
equipment
21. Measuring, testing Function check Adequate measuring On first use, at appropriate
and laboratory equipment accuracy intervals.

Table 9.5: Surface protection systems

No. test on, time
test variable
Base materials/
system
1. Surface protection Delivery note, packaging Designation proof of Each delivery.
System stamp monitoring.
2. Visual inspection No obvious changes Continuously.
3. Storage Storage conditions According to manufacturer’s On storage, in case of doubt.

regulations
4. Composition of Basic test Compliance with directions Prior to commencement of

materials, system for use works, at each change in
materials, systems.
Concrete Substrate
5. Working plan Directions for treatment of the Compliance with directions Prior to commencement of
concrete substrate for use works.
6. Concrete substrate Visual inspection Suitability of concrete Prior to commencement of

substrate for the planned subsequent works.,
measure
7. Surface tensile Suitability of concrete >20 m2 3 single tests; > 200 m2

strength substrate 3 single tests per started 200 m2
Processing
8. Working plan Directions for making up Compliance with directions Prior to commencement of
9 and working for use works
9. Weather Air temperature Compliance with directions 3 x per working day.

for use
10. Relative atmospheric humidity Compliance with directions 3x per working day.
for use.
11. Concrete substrate Temperature Compliance with directions Prior to commencement of

for use execution of works and
following changes in weather.
12 . Moisture Compliance with directions Prior to commencement of

for use execution of works and
following changes in weather.
13. .Dew-point temperature Temperature 3O C higher Prior to commencement of

than dew-point temperature. execution of works and
following changes in weather
Surface protection system
14. Protective measure Quantities of materials Comparison of quantities As specified
15 .Layer thickness Compliance with directions As specified.

for use


No. test on, time
test variable
16. Protective Visual inspection, pores, Compliance with require As specified.

measurements blisters
17 Adhesive strength Compliance with By agreement with the lient;

Specifications. in the absence of an agree
ment at least half the tests
for surface tensile strength.
18. Water absorption, test Compliance with As specified.

method not yet specified directions for use.
19. Grid test Compliance with As specified.

directions for use
20. Roughness (peak – to – Compliance with As specified

valley height) directions for use.
21. Electrical leakage resistance Compliance with As specified

directions for use
22. Voids content, test method Compliance with As specified
currently being validated directions for use
Technical equipment
functioning
9
24. Function check Compliance with On first use, thereafter
projected quantity at least monthly
to an accuracy of 3%
25. Mixing Function check Unexceptionable On first use, thereafter at

equipment functioning least monthly.
26. Processing Function check Unexceptionable On first use, thereafter at

equipment functioning least monthly
27. Measuring and Function check Adequate measuring On first use, at

test equipment accuracy appropriate intervals.

Table 9.6: Crack-Sealing

No. test on, time
test variable
Base material
1. Filler, cement, Delivery note and packaging Designation, proof of Each delivery
damming material, stamp monitoring.
fitting nozzles
3. Storage Storage conditions According to directions On storage, in case of doubt.

for use
4. Composition Basic test Compliance with required Prior to commencement of

properties works
Concrete substrate
5. Working plan Directions for treatment of the Compliance with Prior to commencement of
concrete substrate and the specifications according works.
cracks to directions for use.
6. Concrete substrate Visual inspection Suitability for the planned Prior to commencement of
measure. works.
7. (Component) temperature Compliance with directions Prior to commencement of

for use works.
8. Crack-width / change in As specified Prior to commencement of

crack width works.
9
9. Moisture state of the cracks As per specifications Prior to commencement of
works.
Processing (damming materials, filler)

10. Working plan Directions for making up and Compliance with directions Prior to commencement of
working for use works.
11. Weather conditions Air temperature Compliance with directions Prior to commencement of
for use works.
12. Filling nozzles Function check Through-feed Each crack
13. Damming Function check Sealing Each Crack
14. Cement paste, Marsh funnel Discharge time As in basic test and Each mix.
constant viscosity directions for use
15. Cement paste and Sand column filling No plunger, < 10 min to Daily before beginning work
injection equipment. emergence of cement paste and in case of doubt.
16. Crack-filling Visual inspection Emergence of cement paste Each crack

from next filling nozzle
17. Filling Degree of filling Completeness of filling By agreement with the

employer, in case of doubt.


No. test on, time
test variable
Technical equipment
functioning
19. Function check Projected quantities to On first use, at appropriate

an accuracy of 3% intervals.
20. Mixing equipment Function check

for damming appropriate intervals. Unexceptionable On first use, at
material for filling functioning
compound
21. Filling device Function check Unexceptionable On first use at appropriate

functioning intervals.

Table : 9.7 Corrosion protection materials for reinforcement

No. test on, time
test variable
Base materials
1. Corrosion protective Delivery note and packaging Designation, proof of Each delivery
material stamp. monitoring
3. Storage Storage conditions According to directions On storage, in case of

doubt for use
4. Composition of the Basic test Compliance with required Prior to commencement of

system properties works.
Reinforcement
5. Concrete substrate, Visual inspection Suitability of the substrate Prior to commencement of
reinforcement works.
6. Temperature Compliance with directions 3 x per working day

for use
7. Moisture Compliance with directions Prior to commencement of

for use works.
8. Dew-point temperature Compliance with directions In case of doubt.

for use
9 Processing
9. Working plan Directions for making up and Compliance with directions Prior to commencement of
working. for use. works.
10. Weather Air Temperature Compliance with the Each working day.
specifications
11. Relative atmospheric humidity Compliance with Each working day.

specifications (e.g. < 70%)
12. Finished corrosion Layer density Compliance with directions As specified.

protection for use.,
Technical equipment
13. Dosing equipment Visual inspection Accuracy 3% Weekly
14. Mixing equipment Function check Unexceptionable At commencement of works,

functioning thereafter at least monthly.

(4) After the defect has been remedied, the relevant tests are to be repeated insofar as
they are technically possible and are necessary in order to verify elimination of
the defect.
(5) Materials which fail to comply with the requirements must be separated and marked
as unsuitable.
(6) Working equipment which fails to comply with the requirements must not be
used and must be marked as unsuitable.
9.0.8.3 External Supervision

External Supervision by Consultant/Employer
a. Commencement of External Supervision
(1) Prior to commencement of external supervision of works, being carried out
by Contractor, the external supervising authority must establish whether the
personnel and equipment are such that proper execution of the works may
be anticipated (initial test).
(2) The Contractor must communicate to the external supervision agency in
writing.
a) the name of the Engineer-in-Charge and any change in this post.
b) Where relevant, the internal Materials Field Testing Laboratory the
name of the Engineer responsible and any change in this post.
c) Commencement of work on each construction site at which works
according to these guidelines are carried out.
d) The name of the site contract manager and any change in this post.
9
e) The names of the skilled site personnel according to Section 9.0.4.4
and any changes in these posts.
f) The nature of the work to be carried out.
g) The construction materials intended for use in each construction
measure.
b. Execution of External Supervision
(1) Each notified construction measure must normally be inspected at least once
without advance notice. Construction measures of longer duration must be
re-inspected at appropriate intervals. The frequency of the inspections is to
be decided by the external supervising authority, with due regard to its
responsibilities, and is to be in line with its conclusions and with the results
of internal and external supervision. The reliability of internal supervision
measures, the conclusions arrived at in the course of external supervision
and the special requirements imposed on execution of the works and on the
materials / material – systems are to be taken into account.
(2) No objection is to be made in the case of defects, including any defects on
the structure, which are detected in the course of internal supervision measures
but which are eliminated without delay.
(3) In the case of significant objections, a repeat inspection is to be made.

(4) The person responsible for carrying out the tests must examine the records
of internal supervision measures according to Section 9.0.8.2. including.
a) the site log
b) the test records (test frequency and results) and the internal supervision
documentation
c) the documentation relating to execution of the works and where relevant
the performance specifications and the directions for work.
d) The proofs of suitability and supervision and the directions for use issued
by the manufacturer of the material
e) The delivery notes
f) The mixing instructions in cases where materials are produced on site.
g) The records of function checks carried out on the plant and machinery
employed
(5) The person responsible for carrying out the tests must as far as possible
inspect the execution of the construction measures; during such inspections
he may carry out the tests specified in these guidelines or cause them to be
carried out.
The following items must normally be inspected:
a) the nature and storage of the construction materials
b) the nature of the machines and equipment employed and their
functionality.
c) The execution of the works according to the specified working plans
and directions for execution.
9 d) The suitability and level of instruction of the skilled site personnel.
(6)
In case of doubt, the person responsible for carrying out the tests must perform
additional checks; he is also entitled to take specimens and to cause them to
be tested or to test existing retained specimens or to cause them to be checked.
Sampling
(1) The specimen is normally to be taken on the construction site by the person
responsible for carrying out the tests, in accordance with statistical principles.
(2) A construction material identified as defective or a material identified as unsuitable
by internal supervision measures is to be excluded from sampling only if such
material has been separated and has been clearly marked as defective or unsuitable.
(3) The specimen is to be marked uniquely. The person responsible for making the
tests must prepare a report on the taking of the specimen, must sign the report and
must have it countersigned by the person supervising the construction site. The
report must contain at least the following items:
a) Contractor and site
b) description of the material
c) number or amount of the specimens and their markings.
d) Time and date
e) signatures
Supervision Report
(1) The conclusions arrived at by the external supervising authority and its evaluation
must be recorded in a supervision report. The report must contain at least the
following items:
a)Contractor, site and internal supervision laboratory.
b) Brief description of the construction measure
c) Engineer-in-Charge, site contact manager and skilled site personnel.
d) Details of the materials and requirements.
e)Conclusions on the equipment employed
f) Conclusions on the type and execution of the construction measures
performed.
g) Conclusions on internal supervision.
h) Appraisal of internal supervision
i) Where relevant, details of specimens taken
j) Results of tests carried out in the course of external supervision
k) Date of the inspection, signature and stamp of the person responsible for
carrying out the tests.
(2) The supervision reports must be kept by the Contractor and by the external
supervising authority for at least 5 years.
Site Markings
Construction sites supervised are to be marked at a clearly visible point, citing the
designation and the external supervising authority according to Section 9.0.4.
9.0.9 Records 9
The results of the tests must be recorded and must be subjected to an appropriate degree
of statistical analysis. The records must be kept for at least five years after completion
of the tests or of the construction project.
9.1 SITE REQUIREMENTS

9.1.1 PROPPING & SUPPORTING STRUCTURAL MEMBERS SCHEDULE ITEM
No. 8.1.1
PURPOSE: To provide relief in stress and strains of structural members, which are
deteriorated, overstressed, required to be repaired or strengthened, by transfer of dead
and live loads safely through an alternate system to the founding medium.
9.1.1.1 General
a) In repairs and rehabilitation works, design of false work is essential for avoiding
damage to the distressed structure.
b) This is one of the most important operations in carrying out rehabilitation of a
distressed structure. The success of structural repair depends mostly on ensuring
that the parent material and the repair material of the structure participate jointly
in resisting the applied loads due to self-weight and superimposed loads. Therefore,
the quantum of relief given to distressed structural member determines success of
the repair in the structural member.

c) It is necessary that the self-load and imposed loads over the structural members being
repaired are transferred to the false work and the adjoining existing structural members
safely, taking in to account the capacity of such adjoining members and the false work.
And thus, the structural member is relieved of strains and stresses before it actually
receives the structural repairs.
d) Particular attention is to be given to the shear capacity of the existing beams receiving
load through false work, as it may lead to sudden and permanent damage to the structure
being repaired.
e) Standardised false work systems are preferred option. The design of false work is to
follow the general principles for the design of a permanent structure and relevant codal
provisions.
f) Design brief covering all important operating instructions to the field engineers has to be
prepared meticulously describing all issues crucial for the successful repair process.
g) The specifications of formwork (Centering and shuttering) contained in Para 5.2 of
CPWD specifications 1996 (Vol-II) shall otherwise generally apply except otherwise
mentioned herein these specifications.
9.1.1.2 Design Brief

Following are the important points to be included in the design brief of false work.
a) The plan of the structure.
b) Design considerations clearly giving material properties of the false work.
c) Dead and Imposed loads (including horizontal loads) on the false work.
d) Type of foundation for false work and its capacity, including flooding possibility,
if any.
9
e) Reserve strength of supporting parent members.
f) Drawing & Specifications of falsework complete with required instructions.
g) Adjustment arrangement at the time of repairs.
h) Sequence of fixing and removal of false work including safe load transfer
i) Sequence of repair and strengthening
9.1.1.3 Requirements of good false work
a) It shall be strong enough to withstand all the dead and live loads and forces caused
by dismantling, chipping, ramming, vibration of concrete and other incidental
loads imposed over it including that of working platform and personnel during
and after repair work.
b) It shall be made sufficiently rigid by using adequate number of ties and braces,
screw jacks or hard wood wedges wherever required to ensure actual relieving of
the load from member and its transfer through props, supports and structurally
sound structural members of the existing structure.
c) Sole plates are secured and fixed against movement, forming level, camber as
specified, if any.
d) Necessary plates, screw jacks, hard wood wedges shall be provided wherever
required to make up any settlement in the props/supports.
e) Ladders, platforms, guardrails for providing access to the workmen are secured
with the other members.
f) De-shuttering shall be done after the elapse of specified time and re-propping done if

specified. The manner of de-shuttering shall avoid instability during removal of false
work.
9.1.1.4 Inspection of False Work
Following are the checkpoints before allowing the next stage of false work to proceed:
a) The compliance of notes given in the false work drawing and the specification of materials
to be used in the work.
b) Setting out of the work, founding medium for support and sole plates of the
props.
c) Sequence of erection keeping the stability of the false work in mind at every
stage by ensuring proper connection of joints. It must be ensured that ties and /or
bracing (longitudinal, lateral and inclined) have been joined near the nodes
simultaneously to ensure stability of the false work.
d) The plumb of vertical members to be ensured within specified limit.
e) The false work executed shall conform to the approved design.
f) Centering and shuttering is properly serviced after removal and before its next
use.
9.1.1.5 Execution Procedure:
Step-1 Design the prop and support system using steel tubular sections with
extension pieces or with built-up sections to ensure required relief to structural
members from stresses due to loads coming over it, including the self-load
of the member itself. No timber ballies etc. shall be used as props. However,
timber runners/beams/planks of adequate section could be used for supporting
structural beams, slabs as load distribution mechanism.
Step-2 Prepare the design brief covering all-important operating instructions and
9
shall be got approved from the Engineer-in-charge beforehand.
Step-3 Arrange all propping and supporting elements as per approved design.
Steps- Refer these steps separately for columns, beams and slabs as given
4&5 subsequently.
Step-6 Work shall be inspected before taking up structural repairs for safe
load transfer to the founding medium by implementation of approved
drawings/design of prop & support system.
a) Steps 4 & 5 for Columns:
Step-4 Identify and mark the RCC columns under structural distress, which are
unable to sustain service load conditions and/or which are required to be
ripped open for undertaking structural repairs or retrofitting.
Step-5 Prop and support the column for the full height of building, to relieve its
axial loads through its adjoining intersecting beams and/or slabs at all floor
levels of the building using designed steel props adjustable with extension
pieces, screw jacks etc with sole plates. This shall be done, even if only one
storey length (intermediate, lowest or the uppermost storey) out of many
storey lengths of the same column, had been identified for structural repairs.

The loads relieved are required to be transferred directly through props and
supports on to the building foundation system or to soil as per approved design of
foundations.
Under no circumstances, the column loads above the storey should be transferred
by transfer through adjoining upper or lower intersecting beams alone.
b) Steps 4 & 5 for Beams:
Step-4 Identify and mark the RCC beams under structural distress, which are unable
to sustain the service load conditions and/or are required to be ripped open for
undertaking structural repairs or retrofitting.
Step-5 Prop and support the identified beams to provide relief in stresses & strains to
the distressed beam by suitably supporting such RCC slabs, which are contributing
load to the beam itself. The load relieving shall be done using designed steel props
adjustable with extension pieces, screw jacks, hard wood wedges etc with sole
plates at suitable intervals but shall generally not exceed 1.5 metre centre to centre
as per design approved by Engineer-in-Charge.
To avoid any overstressing of any existing flexural members receiving the
transferred load of the distressed beam, the steel prop and supports shall be taken
and continued to the firm ground. For upper storeys, the steel props shall be taken
at least two storeys below or as per the design approved by Engineer-in-Charge.
c) Steps 4 & 5 for Slabs:
Step-4 Identify and mark the points for propping and supporting on soffit of RCC
slab requiring structural repairs, for transfer of loads to relieve it from stresses and
9 simultaneously avoiding its collapse during the repair process. However, such points
shall preferably be not be farther than 1.2m x 1.2m.
Step-5 Prop and support slabs at identified locations with steel props to provide relief in
stresses & strains suitably as per approved design with bearing plates adjustable
with extension pieces, screw jacks etc.
To avoid any overstressing of existing flexural members receiving the load
of the distressed RCC slab, the steel props and supports shall be provided just
below the aforesaid identified points and shall be taken and continued to the firm
ground or at least two slabs below as per the design approved by Engineer-in-
Charge.
9.1.1.6 Measurements:
Number of props of specified capacity shall be measured for the purpose of payment.
9.1.1.7 Rates:
The rates shall cover cost of all materials, labour and T&P involved in all the operations
described above including its removal after the work duration. The removed material
shall remain the property of the contractor.
9.1.2 SPECIAL WATERTIGHT SHUTTERING/FORMWORK (Schedule Item
No. 8.1.2):
PURPOSE: To provide shuttering or formwork and its joints to be able to resist a

hydraulic pressure at least equivalent to a 10 metres water head without causing any
leakage.
9.1.2.1 General
Special watertight shuttering/formwork shall be provided for special applications
involving concrete or mortar, which are more fluid than normal concrete. e.g. Preplaced
Aggregate Concrete, Self compacting & self levelling concrete (pumpable concrete,
Micro concrete, etc making use of plasticisers/ super plasticisers), etc. This shall
necessarily require structural stability, retention of form shape and resistance to leakage
under hydraulic pressures of water/cement slurry/ concrete/mortar not less than 10
metre water head. The hydraulic pressures could either be externally applied or due to
static pressure of poured concrete or mortar.
9.1.2.2 Materials:
The basic material for shuttering /formwork shall be MS sheet and MS structural
sections, fasteners and the joint sealants
9.1.2.3 Design:
The shuttering/formwork shall be suitably designed to be able to resist the assessed
hydraulic pressures likely to be exerted.
Minimum Configuration of the shuttering plates shall however be as under:
a. Steel plate shuttering materials using a minimum 3 mm thick MS sheets welded
over a frame of MS Angle iron or T-iron of minimum size 40 X 40 X 5 mm thick
with shorter span not exceeding 600 mm. 9
b. 10 mm dia MS nuts, bolts and washers at a spacing of 300 mm c/c for connecting
and tightening joints with suitable resilient packing material to ensure retention
of required shape and water tightness for the required pressure.
9.1.2.4 Testing:
The sample of shuttering shall be tested for retention of its shape and water tightness
before proceeding with the work
9.1.2.5 Fabrication and Erection:

The CPWD specifications for formwork, propping, centering and shuttering shall
generally apply to fabrication and erection.
9.1.2.6 Measurement:
Wherever, water tight shuttering specified and stipulated to be paid for separately,
measurement shall be taken of the area of shuttering in contact with the finished concrete/
mortar surface. Dimensions of the formwork shall be measured correct to a centimeter
and area worked out in square metres correct to second place of decimal.
9.1.2.7 Rates:

described above including its removal after the work duration. The removed material shall
remain the property of the contractor.
9.1.3 ENGINEERED STEEL TUBULAR DOUBLE SCAFFOLDING SYSTEM (Schedule

Item No. 8.1.3)
PURPOSE: To prov ide a scaffolding system with adjustable working platforms on
the exterior of the building for the workmen to work upon any part of the area to be
accessed safely and with ease for surface preparation, application of repairs and
construction activity.
9.1.3.1 Materials:
The standard proprietary tubular double scaffolding system of repute with all accessories,
working platforms etc
9.1.3.2 Design:
It shall be designed for all the incidental dead, live and wind loads as per IS: 875
in steel tubular sections as per general design considerations governed by IS:800.
The design of the scaffolding system shall cater to the safety features for the
workmen.
9.1.3.3 Fabrication and Erection:

Fabrication and erection shall be done as per the design brief and installation instructions
of the proprietary firm. It shall be maintained in functional condition for the work
duration.
9
For the purpose of payments, length and height of double scaffolding on the exterior of
building shall be measured correct to a centimeter and area worked out in square metres
correct up to second place of decimal. For internal work, suitable fixed or mobile
platform, self supporting scaffolding with working platforms shall be erected for which
no payment shall be made.
9.1.3.5 Rates:
9.1.4 PLYWOOD COVERING PANELS TO COVER WINDOWS ETC. DURING

REPAIRS (Schedule Item No. 8.1.4):
PURPOSE: To protect the finished items against their spoiling/damage to finishes
during the process of carrying out repairs in a building. The items could include
finished windows, doors, glass curtain wall or other such items.
9.1.4.1 Materials:
a) Wooden Battens of size 50mm X 50mm (approximately) or as approved by Engineer-

in-charge, free from warping, cracks etc. made from locally available timber.
b) Plywood of suitable thickness, preferably 6 mm thick, as approved by Engineer-in-
Charge.
c) Nails, screws etc. as per requirement.
9.1.4.2 Fabrication
a) Size of covering panels shall be more than the size of windows etc. to be shielded/
protected, enough to be fixed to the walls without damaging the windows etc.
b) Wooden battens shall be cut approximately to the size of panels of windows etc.
to be protected. The joints of the wooden framework shall be lap joint or as
approved by Engineer-in-Charge.
c) Where the panel size is more than 2 square metres or as specified by the Engineer-
in-Charge, the stiffening shall be done with batten backing to impart stiffness
enough to provide rigidity against undue deflection due to impact of falling debris,
self load, etc.
d) Plywood shall be fixed with nails/screws over the batten frames. The spacing of
nails/screws shall be about 300mm c/c or as may be required at site.
9.1.4.3 Fixing
The plywood covering panel shall be suitably fixed without damaging the windows
etc. being protected by such panels with nails/screws fixed in walls strong enough to
resist the forces likely to be imparted during repair work. It shall be done in such a
manner that it can be removed with ease without damaging the covered windows etc.
after completion of repairs.
9.1.4.4 Removal
9
After completion of work, the covering panels shall be removed carefully, so as not to
cause any damage to windows etc. covered. The damages, if any, shall be made good.
9.1.4.5 Measurements
The measurements shall be done correct to a centimeter for the dimensions of window
etc. shielded /protected and area shall be worked out in square metre correct to second
place of decimal.
9.1.4.6 Rates
described above including its removal after the work duration and making good the
damage, if any, caused to windows etc. so protected. The removed material shall remain
the property of the contractor.
9.1.5 TEMPORARY BARRICADING USING ANGLE IRON VERTICALS AND CGI
SHEETS PANELS (Schedule Item No. 8.1.5):
PURPOSE: To provide a barricading on ground to physically define the boundaries
of the site of construction/repair activity for restricted entry of only those involved
with the construction work.
9.1.5.1 Materials:
Available Corrugated G.I. Sheet minimum 24 G thick, Framing structural material
(at least MS Angle iron of size 40x40x5mm or equivalent)
9.1.5.2 Fabrication & Erection:

a) Size of framing panel shall be decided depending upon site conditions and these could
be approximately 2.0 metres long with height as 1.8 metre.
b) It shall be made up at least of two verticals, each with additional length of about 600
mm for fixing in to ground firmly and two horizontals equal to the length of panel.
c) It shall be made up by cutting the structural sections to size, shear punching holes in
verticals and horizontals for nuts and bolts or making other suitable provision for receiving
CGI sheet or other specified panelling material and connection of panel with adjoining
panels.
d) Fabrication of frame of an individual panel shall be by welding at corners, welding MS
plate at base of verticals or any other acceptable practice approved by Engineer-in-
charge.
e) G. I sheet or other specified panelling material shall be suitably fixed. It shall preferably
be done by means of nuts and bolts at its ends spaced at about 300 mm c/c transversely
and at about 600 c/c longitudinally along corrugations. The corrugations of CGI sheet
shall run along the shorter span of the panel.
f) In case of newly fabricated panels, these shall be painted with red oxide zinc chromate
primer on steel work and approved primer on other material and at least one coat of
paint of approved shade. In case of used panels, one coat of paint of approved shade
shall be applied over the existing paint. The portion of verticals to be embedded in
ground shall be suitably protected against rusting by painting it with bitumen or other
suitable paint.
9
g) The fabricated panels shall be suitably fixed vertically and firmly in to the ground to the
satisfaction of Engineer-in charge by maintaining a uniform height of about 1.8 metres
above GL and connecting each panel with the adjoining panels with nut and bolts or
other suitable means.
h) Suitable provision of frame/posts in the openings provided in barricading shall be made
for receiving door shutter (payable separately) at locations as approved by Engineer-
in-Charge.
Length of barricading shall be measured in running metres correct to a centimeter. No deduction
shall be done for such openings made in the barricading, where door frame or posts have
been separately provided to receive door shutter.
9.1.5.4 Rates:
9.1.6 PROTECTIVE BARRICADING USING BALLIS OR WOODEN VERTICALS
AND CGI SHEET PANELS (Schedule Item No. 8.1.6):

with the construction work
9.1.6.1 Materials:
Available Corrugated G.I. Sheet minimum 24 G thick, Framing structural material
comprising of minimum 100 mm dia ballis, nails, Galvanised J-hooks and other related
accessories
9.1.6.2 Fabrication& Erection:
Work shall be carried out according to Para 9.1.5.2
As per Para 9.1.5.3
9.1.6.4 Rates:
9.1.7 PROTECTIVE BARRICADING USING BAMBOO AND LOCALLY
AVAILABLE PANELS (Schedule Item No. 8.1.7):
with the construction work
9.1.7.1 Materials:
9
Locally available bamboo panelling material or equivalent,
Framing structural material comprising of minimum 100 mm and 75 mm dia ballis/
bamboos, nails, Galvanised J-hooks and other related accessories and fixtures
9.1.7.2 Fabrication& Erection:
Work shall be carried out according to Para 9.1.5.2
As per Para 9.1.5.3
9.1.7.4 Rates:
9.1.8 TEMPORARY PROTECTIVE FABRIC SCREENS (Schedule Item No. 8.1.8):
PURPOSE : To protect passersby from falling debris and also to protect the workmen
and structure being repaired against direct exposure to sun.
9.1.8.1 Materials
For screening purpose jute cloth, woven PVC cloth, geo-textile or wire-mesh as specified
and approved by Engineer-in-Charge shall be used, which shall conform to their relevant
BIS Code. Screen materials shall be fixed by suitable means comprising of M.S.Flats/ J-
bolts /nails/clamps, etc with washer or any other suitable means on frames of existing scaffolding
etc.
9.1.8.2 Procedure
l Scaffolding, if required, comprising of verticals, horizontals and diagonal bracings of
steel tubes shall be fixed over ground as per Para 9.1.3 which is payable separately.
l One end of the screening material, brought to site in looms/rolls, shall be properly fixed
over top horizontal member with suitable means and suspended so as to cover the
required area.
l The vertical fall of screen shall be suitably fixed/firmed up at intermediate levels so as to
keep it in position during the work duration.
l Next strip of the screening material shall be fixed with its sides stitched or suitably
jointed or lapped with the previous ones as approved by Engineer-in-charge.
l Spacing of frame member of scaffolding shall be so selected that the sagging of
screen shall not hinder the repair process.
l The contractor shall maintain the protective screens in acceptable conditions for
the entire work duration as required by the Engineer-in-Charge.
9.1.8.3 Measurement
Length and height of screen shall be measured correct to a centimeter and area shall be
worked out in square metres, correct up to second place of decimal.
9.1.8.4 Rate
9
9.1.9 PROVIDING AND FIXING DOOR OF CORRUGATED OR STIFFENED
PLAIN GI SHEET OVER FRAME OF LOCAL WOOD ETC. (Schedule Item
No. 8.1.9):
PURPOSE: To provide door shutter to temporary covered shelters, stores, yard,
openings of temporary barricading etc.
9.1.9.1 Material
a) Door frame shall be local acceptable wood or structural steel of section & size as
approved by Engineer-in-charge and shall be free from warp, bend and shall have
smooth surface.
b) Corrugated GI sheet conforming to IS-277 with thickness not less than 24 gauge
or plain GI sheet stiffened by cold pressing
c) Hinges, aldrops, nails/screws etc.
9.1.9.2 Fabrication:
a) Wooden/structural steel frame shall be made of at least three horizontal members
as bottom, middle and top rail and two vertical members as styles suitably jointed
with diagonal members, if necessary.

b) Corrugated GI sheet or plain GI sheet shall be aligned such that its corrugation
are vertical and fixed suitably with the help of nails /screws, nuts, bolts, washers,
etc and fixed to door opening.
c) One coat of red oxide zinc chromate primer and one coat of paint shall be applied
over GI sheet/steelwork and approved wooden primer and paint shall be applied
over woodwork.
9.1.9.3 Fixing:
a) Door shutter shall be fixed to the existing frame with the help of approved
hinges and screws of size, numbers and shape suitable for the size of door.
b) Approved aldrop shall be fixed to door shutters to make safe locking arrangements
c) If required by Engineer-in-Charge additional aldrops/tower bolts /other suitable
device shall be fixed to the door shutters for ensuring safety.
d) If the GI sheet and /or horizontal rails are already painted, these shall be provided
at least one finishing coat of paint to give it a uniform shade. On new work, one
coat of primer and paint shall be applied.
Finished dimensions of door shutter shall be measured correct to a centimeter and area
worked out in square metres correct to second place of decimal.
9.1.9.5 Rate
9
9.1.10 PROVIDING AND ERECTING COVERED SHELTERS (Schedule Item
No. 8.1.10):
PURPOSE: Erection of temporary shelters for storage of materials, T&P, etc incidental
to carrying out the structural repairs, which require their protection during storage
against extreme weather conditions.
9.1.10.1 Materials
l Corrugated GI Sheets or wooden panels/boards
l Steel /timber/bamboo frame work as may be specified and approved by
l Engineer-in-Charge.
l Bricks
l Ordinary Portland Cement, Sand, any other construction material as may be
required for construction of temporary shelters as per approved design.
l Necessary electrical connection, wiring & fittings essential for lighting, ventilation.
Arrangements for cooling, heating etc to maintain humidity and temperature as
per special material storage requirements.
9.1.10.2 Procedure:-
l The location, size and specifications of temporary covered shelters shall be got approved
from the Engineer-in-Charge with justification of their use for storage of manufactured
repair chemicals during carrying out of repairs. These shall be constructed to serve the

purpose intended and in accordance with Para 9.0.2.

l The shelters shall be made according to the approved plan, size, plinth level and a
desirable average ceiling height of 3.3 metres or as may be approved by Engineer-
in charge and with approved materials.
l Floor shall be pucca and kept sufficiently high to protect materials against weather,
inundation etc.
l Necessary door, window and ventilator openings with frames to receive door
shutters shall be kept in the side walls.
l If necessary, the required grills, window and ventilator shutters, with necessary
fittings shall also be provided for ensuring the safety of stored materials.
l The electrical connection, wiring, fittings, etc as may be required and approved
by the Engineer-in-charge for lighting, ventilation, temperature and humidity
control shall be provided and fixed therein.
l At least one coat of approved primer and paint shall be applied on the inside and
outside to give it a finishing touch and redoing it periodically, if necessary, to
keep it in neat and tidy condition for the work duration
The overall plan dimensions of the covered shelters shall be measured correct to a
centimeter and the area of the covered shelters shall be worked out in square metres
correct to second place of decimal.
9.1.10.4 Rates:
9
9.2 SURFACE PREPARATION
9.2.1 REMOVAL OF PLASTER MANUALLY FROM MASONRY OR CONCRETE
SURFACE USING CHISEL AND HAMMER AND DISPOSAL OF DEBRIS
ETC. (Schedule Item No. 8.2.1):
PURPOSE: For removal of all type of loose /delaminated /damaged/weak cement
plaster from surface of masonry or concrete.
9.2.1.1 Procedure
Step-1 Safety shall be ensured in accordance with Para 9.0.5
Step-2 Provide double scaffolding, if necessary for heights above 3.0 metres Refer
Para 9.1.3) .
Step-3 Provide protective screens, if necessary (Refer Para No 9.1.8).
Step-4 Existing plaster to be to be identified for removal by tapping all areas and
its boundary shall be marked with a colour marking (Refer Fig 6.1a), which
shall be approved by Engineer-in-Charge.
Step-5 Make a cut normal to the surface all along the boundaries with power driven
cutters. The depth of cut shall not exceed the thickness of plaster.
Step-6 Remove the plaster manually with the help of chisel and hammers to completely
expose the parent masonry or concrete surface, so as not to have any traces of
such plaster left behind.

9.2.1.2 Measurement
The dimensions of removed plaster patch shall be measured correct to a centimeter and area
shall be worked out in square metres correct to second place of decimal. The lead of disposal
shall be measured in metres and rounded off to nearest multiple of 50 metres.
9.2.1.3 Rate
described above except those involved in steps 2 and 3.
9.2.2 CHIPPING OF UNSOUND/WEAK CONCRETE MATERIAL (Schedule Item
No. 8.2.2):
PURPOSE: To remove weak, loose or carbonated concrete over an area from its
surface with pneumatically operated or power driven tools by chiselling, chipping etc.
9.2.2.1 Materials and T&P:
Power or pneumatically driven chisel, chipping tools complete with accessories, hand-
tools like chisels, hammer, pH indicator (0.2% phenolphthalein solution) with pH
range at least up to 10.5, clinical injection syringe.
9.2.2.2 Safety: Safety shall be ensured in accordance with Para 9.0.5
9.2.2.3 Procedure:
Step-1 Prop and support (Refer Para 9.1.1) to relieve the structural member of
stress and strains.
Step-2 Scaffolding (Refer Para no 9.1.3), if necessary for the exterior members, shall
be done for working upon the area.
Step-3 Working Platforms for interior members, if necessary, shall be erected
suitably or provided as mobile. 9
Step-4 Provide Protective Screen, if necessary (Refer Para 9.1.8).
Step-5 Mark off the area to be repaired using straight lines between corners. The
marked area shall have 90o corners with the sides parallel or normal to the
direction of the reinforcement. The marked boundaries for the repair area
should be a minimum of 50 mm outside the perimeter of the spall. For a single
spall, the repair area should have a minimum width of 100mm in any direction.
If a number of spalls are closely located to each other, these spalls should be
included in a single area marked for repair (Refer Fig 6.1a).
Step-6 Cut shall be made along the marked boundary, normal-to-the surface. It
should be made with a diamond cutter blade. However, when diamond cutting
is not practical, the normal cut can be made with a power driven chisel.
Minimum depth of cut shall be 10 mm. In situations where the diamond saw
could cut into the reinforcing steel due to inadequate concrete cover, the
boundary edge should be formed manually by means of chisel and impact
hammers. A cover meter could be used to estimate the depth of cover.
Step-7 Chipping to remove all the unsound and weak concrete material shall be done
carefully from the damaged portions of structural members by adopting mechanical
or manual means up to the required depth to produce sound concrete surface to a
near uniform depth for the repair area.
Tolerance: The chipping tolerances shall be ± 5mm
Chiselling Hand Tools are typically applicable for concrete removal for smaller,
moderate and areas of limited access. Removal should begin at the interior of
the repair area and progress toward the boundaries, using suitable hammer.
Power Driven Chisels/Hammers are normally applicable for chiselling
smaller thicknesses up to about 50 mm.
Pneumatic Hammers are normally applicable for chiselling larger thicknesses
in excess of 50 mm
Mechanical Milling (single drum, rotary cutter head with Tungsten–carbide
bits ) is applicable for large areas where the concrete cover is to be removed.
Care must be taken to avoid contact with the reinforcing steel as both the
reinforcement and the cutter drum could be damaged.
Rounded And Feathered Edges should be hand cut to form normal-to-the-
surface boundaries. All the edges and cavities shall be square shouldered.
Step-8 Test for carbonation shall be carried out at embedded or exposed
reinforcement locations, by spraying phenolphthalein indicator on concrete
in contact and in the immediate vicinity of reinforcement soon after its
chipping. As otherwise, chipped concrete surface in contact with air is likely
to get carbonated soon after its coming in contact with atmospheric carbon
dioxide.
Step-9 A full-depth chiselling and removal of concrete all round reinforcement
shall be carried out, in case the concrete in contact and in immediate vicinity
of the reinforcement is carbonated (Refer Para no 9.2.6).
Step-10 Inspection and soundness testing, after concrete removal & cleaning, for
weaknesses and delamination of exposed surfaces shall be visually carried
9 out. If required, additional removal will be done.
Step-11 Cleaning of debris and dust shall be carried out from within the chiselled/
chipped area and its disposal as per direction of the Engineer-in-Charge.
The dimensions of the area chipped off for RCC slabs, beams and columns shall be
measured separately. The average thickness shall be determined by taking an average
of five thickness readings recorded with one reading each at corner and at the point of
intersection of wires stretched diagonally from corner points of the rectangular area
chipped. The extra/less thickness than specified for slabs, beams and columns shall be
recorded in millimeters. Corresponding areas of slab, beam and columns shall be
separately worked out in square meters correct to second place of decimal. The lead of
disposal shall be measured in metres and rounded off to nearest 50 metres.
9.2.2.5 Rates:
described above except those involved in steps 1, 2, 4, 8 and 9.
9.2.3 DISMANTLING & REMOVING EXISTING TREATMENT OVER RCC SLABS
AT ALL HEIGHTS (Schedule Item No. 8.2.3):
PURPOSE: Removal of any type of existing surface treatment e.g roofing, water
proofing treatment, flooring, etc over RCC slabs at all heights


Power or pneumatically driven chiselling, chipping tools complete with accessories, hand-
tools like chisels, hammer.
9.2.3.2 Procedure:
Step-1 Carefully remove the identified portion of the existing surface treatment over the
RCC slab with required chipping, chiselling tools without causing excessive vibrations
or damaging the structure. Para 9.2.2.3 generally applies.
Step-2 Stack the serviceable material for reuse as directed by the Engineer-in-charge.
Step-3 Dispose off the balance material as per the direction of Engineer-in-charge.
The surface area of RCC slab exposed shall be measured correct to a centimeter and
area worked out in square metres correct to second place of decimal. The lead of
disposal shall be measured in metres and rounded off to nearest multiple of 50 metres.
9.2.3.5 Rates:
Rates cover all labour, materials and T&P involved in the operations involved as above.
9.2.4 DISMANTLING EXISTING RCC WORK BUT EXCLUDING CUTTING

REINFORCEMENT BARS (Schedule Item No 8.2.4):
PURPOSE: Dismantling of RCC structural members using hand tools as may be
required for rehabilitation/repair.
Concrete breaking hand tools like Chisels, Hammers and related tools complete with
incidental accessories. 9
9.2.4.3 Procedure:
Step-1 Identify the RCC portion to be dismantled as approved by Engineer-in-
charge.
Step-2 Prop and support (Refer Para 9.1.1), if not done already, to relieve the
structural member of stress and strains.
Step-3 Scaffolding & working platforms for the exterior members (Refer
Para 9.1.3), if not already done and if necessary, shall be erected for working
upon the area.
Step-4 Working Platforms for interior members, if not already done and if necessary,
shall be erected suitably or provided as mobile.
Step-5 Provide Protective Screens (Refer Para 9.1.8), if not already done and if
necessary.
Step-6 Carefully remove only the RCC i.e. concrete portion with the hand tools/
mechanically without causing excessive vibrations or damaging the structure.
Do not cut the embedded reinforcement, if any, but shall be cleaned of concrete.
However, the loose reinforcement shall be recovered for use.
Step-7 Dismantling to remove all the unsound and weak concrete material shall
be done carefully from the damaged portions of structural members by adopting

mechanical or manual means up to the required depth to produce sound concrete

surface to a near uniform depth for the repair area.
Chiselling Hand Tools are typically applicable for concrete removal for
smaller, moderate and areas of limited access. Removal should begin at the
interior of the repair area and progress toward the boundaries, using suitable
hammer.
Power Driven Chisels/Hammers are normally applicable for chiselling
smaller thicknesses up to about 50 mm.
Pneumatic Hammers are normally applicable for chiselling larger thicknesses
in excess of 50 mm
Step-8 Stack the reinforcement, if recovered for reuse in step-6 and balance material
disposed off as per the direction of Engineer-in-charge.
Pre-measurements of the dimensions of RCC to be dismantled shall be recorded before
taking up the dismantling operations and shall be measured correct to a centimeter and
volume worked out in cubic metres correct to second place of decimal. The lead of
disposal shall be measured in metres and rounded off to nearest multiple of 50 metres.
9.2.4.5 Rates:
Rates cover all labour, materials, T&P involved in the operations involved as above
except those involved in steps 2, 3 and 5.
9.2.5 CUTTING REINFORCING BARS IN RCC OR REINFORCED BRICKWORK

9 (Schedule Item No. 8.2.5):
PURPOSE: To cut visible portion of embedded reinforcing bars in RCC or Reinforced
Brickwork using hand tools.

Reinforcing cutting/shearing hand tools like hacksaw, chisels, hammer and related
tools complete with incidental accessories.
9.2.5.3 Procedure:
Step-1 Identify the visible reinforcing bars required to be cut, which shall be
approved by Engineer-in-charge.
Step-2 Carefully cut/shear the reinforcing bars with the hand tools without causing
excessive vibrations or damaging the structure.
Step-3 Stack the reinforcement recovered for reuse as per the direction of Engineer-
in-charge
Pre-measurements of the number of reinforcing bars to be cut shall be recorded in three
categories of diameters e.g. upto 12 mm, above 12 mm and not exceeding 20 mm and those
exceeding 20 mm.

9.2.5.5 Rates:
Rates cover all labour, materials, T&P involved in the operations involved as above and
stacking the reusable material within a lead of 50 metres.
9.2.6 REMOVING CONCRETE ALL AROUND REINFORCEMENT INCLUDING

FROM ITS BEHIND (Schedule Item No. 2.6):
PURPOSE: To create an average clear air gap equal to nominal size of coarse
aggregate plus 5 mm all around embedded reinforcement, in contact with carbonated
concrete for rust removal & passivating its surface with fresh alkaline passivating
coat and concrete/ mortar.
Power or pneumatically driven chiselling, abrading, chipping tools complete with
accessories, hand-tools like chisels, hammer, pH indicator i.e. 0.2% solution of
phenolphthalein indicator for pH range preferably up to 11.5 or at least up to 10.5,
clinical injection syringe.
9.2.6.2 Safety:
Safety shall be ensured in accordance with Para 9.0.5.
9.2.6.3 Procedure:
Step-1 Prop and support (Refer Para 9.1.1), if not done already, to relieve the
structural member of stress and strains.
Step-2 Scaffolding & working platforms for the exterior members (Refer Para
9.1.3), if not already done and if necessary, shall be erected for working upon
9
the area.
Step-3 Working Platforms for interior members, if not already done and if necessary,
shall be erected suitably or provided as mobile.
Step-4 Provide Protective Screen (Refer Para 9.1.8), if not already done and if
necessary.
Step-5 Test for carbonation shall be carried out at embedded or exposed
reinforcement locations, by spraying phenolphthalein indicator on freshly
chipped concrete in contact and in the immediate vicinity of reinforcement.
Step-6 A full-depth chiselling and removal of concrete all round reinforcement
shall be carried out, if the concrete in contact and in immediate vicinity of the
reinforcement is carbonated.
The concrete around reinforcement shall be removed so as to have a near
uniform air gap of about 5 mm plus the nominal size of coarse aggregate to be
used in repair concrete/mortar. However, the air gap shall not be less than 15
mm in any case.
Power/pneumatic driven tools/chisels shall be used for such portions of
carbonated concrete around reinforcement, which could not be removed
manually, to achieve a near uniform required air gap all around including
behind the reinforcement.

Power Driven Chisels/Hammers are normally applicable for chiselling smaller

depths up to about 50 mm.
Pneumatic Hammers are normally applicable for chiselling larger depth in excess
of 50 mm
Step-7 Cleaning of debris and dust shall be carried out from within the chiselled /chipped
area and its disposal as per direction of the Engineer-in-Charge.
The reinforcing bars cleaned of concrete shall be grouped in two diawise categories, i.e. upto
and including 12 mm and the other in excess of 12 mm. For each of such categories of bars,
length cleaned of concrete all around, shall be separately measured for cleaning manually and
using standard power/pneumatically driven abrading/chiselling tools. The length shall be
measured in metres correct up to second place of decimal.
9.2.6.5 Rates:
described above except those involved in steps 1, 2 and 4.
9.2.7 CLEANING REINFORCEMENT OF TOTAL RUST INCLUDING FROM

BEHIND REINFORCEMENT (Schedule Item No. 8.2.7):

Chiselling, abrading, chipping, hammering, wire brushes, paint brush, abrading cloth,
etc hand tools complete with accessories, tested and approved alkaline chemical rust
9 remover.
9.2.7.2 Testing:
Chemical rust remover shall be tested to ensure that it is an alkaline material with its
pH more than 11.5 and for its efficacy by a sample of rust removal.
Sand to be used for sand blasting shall conform to Zone-I or II of IS:383
9.2.7.3 Safety:
Safety shall be ensured in accordance with Para 9.0.5
9.2.7.4 Procedure:
Step-1 Remove the rust manually from all round the surface along the length of
reinforcement, using hand tools like chisels, hammers, wire brushes, abrading
cloth/paper, etc. This shall be continued manually along the length of the
rusted reinforcement till such time that the steel surface is cleared of all rust
that could be removed manually.
Step-2 Remove the Rust by sand blasting and/or using tested chemicals, if directed
by Engineer-in-Charge, due to unsatisfactory results of manual rust
removal.
A. By sand blasting:
Coarse sand shall be sprayed under pressure over the exposed
reinforcement so as to cause an intense abrading of the reinforcement surface

and removal of rust from its entire surface to achieve shining bright metal.
B. Using tested chemicals:
Chemical rust remover shall be brush applied over the reinforcement
surface thoroughly all around the circumference and along the full length
of rusted reinforcement. After 24 hours of its application, the surface
shall be cleaned with wire brush and all loose particles removed. It shall
be washed with water thoroughly and allowed to dry.
The reinforcing bars cleaned of concrete shall be grouped in two diawise categories,
i.e. upto and including 12 mm and above of 12 mm. For each of such categories of
bars, length cleaned of rust all around, shall be separately measured for cleaning
manually, using sand blasting and using alkaline chemical rust remover. The length
shall be measured in metres correct up to second place of decimal
9.2.7.6 Rates:
described above.
9.2.8 INTRODUCING NEW REINFORCEMENT BARS FOR STRUCTURAL

CONNECTION IN RCC STRUCTURAL MEMBER (Schedule Item
No. 8.2.8):
PURPOSE: For introducing additional reinforcing bars for new structural connection
9
or supplementing additional steel area to existing RCC beams, lintels, columns for
cantilevers, chajjas, etc or alike.
9.2.8.1 Material and T&P:

1. Epoxy cartridges and specified steel reinforcement.
2. Standard Power driven drilling/hammering equipment
3. Hand operated blow out pump, brushes, epoxy dispenser, epoxy cartridge holder,
disposable PVC mixing nozzle for epoxy, and any other incidental accessories
and T&P items.
9.2.8.2 Testing:
The epoxy in the cartridges shall be subjected to testing for its conformity to the
manufacturer’s specifications.
The power drilling/hammering equipment, drill bits, etc shall be tested for their effective
functioning.
9.2.8.3 Procedure
Step 1 Design additional cross-sectional area required and get them approved from the
Engineer-in-Charge.
Step-2 Cross sectional area of steel reinforcement provided for new structural
connection or for supplementing the existing cross-sectional area shall be as
per approved design/drawings.
Step 3 Provide the depth of embedment of the reinforcing bar in concrete as specified
in the approved design/drawings. Based on assessed strength of concrete, Tables
9.8 to 9.10 could be used as a guide for assessment of the depth of embedment of
steel reinforcing bar. The strength of concrete shall be determined quantitatively by
core test or capo test for ensuring reliability, which shall be paid for separately.
Step 4 Prepare the surface of the existing RCC member to receive the structural
connection as per Para 9.2 and its sub paras.
Step 5 Mark the new reinforcing bar locations on prepared surface for fixing.
Step 6 Drill holes of specified diameter and depth in concrete at locations marked
as per approved design calculations. Tables 9.8 to 9.10 are rough guide
corresponding to the grade of existing concrete and diameter of the steel
reinforcement.
Step 7 Clean the drilled hole in dry state with round brushes and by blowing air
through a tube inserted in the hole and connected to hand operated blow out
pump (Fig. 9.1).
Step 8 Inject epoxy from the foil pack with the help of epoxy dispenser, epoxy
cartridge holder and disposable PVC mixing nozzle inserted inside the drilled
hole to fill it from bottom of the hole and upwards. The approximate
consumption of the epoxy in cubic cm. is given in Table 9.11 as a general
guide.
Step 9 Insert the reinforcing bar and allow the epoxy adhesive to cure.
Number of reinforcing bars introduced/inserted shall be measured in three separate groups
9
for bars upto and including 12 mm dia, more than 12 mm but not exceeding
20 mm dia and all bars with dia more than 20 mm.
9.2.8.5 Rates:
Fig 9.1: Hand Operated Blowout Pump

Table 9.8
Concrete Grade M 20; Yield Strength of Steel 415 N/mm2
(Source: Literature of Hilti India Ltd.)

Rebar Hole Depth Recommended Tensile Load of Rebar Frec (Kn)
Dia Dia of
Hole
(in (in 100 120 140 160 180 200 220 240 270 300 330 370 400 450 500 600 850
mm) mm)
8 12 9.73 11.6 12.09 12.09 12.09 12.09 12.09 12.09 12.09 12.09 12.09 12.09 12.09 12.09 12.09 12.09 12.09
10 14 10.51 12.62 14.72 16.82 18.90 18.90 18.90 18.90 18.90 18.90 18.90 18.90 18.90 18.90 18.90 18.90 18.90
12 16 13.49 15.74 17.98 20.23 22.48 24.73 26.98 27.21 27.21 27.21 27.21 27.21 27.21 27.21 27.21 27.21
14 18 16.69 19.07 21.46 23.84 26.23 28.61 32.19 35.76 37.09 37.03 37.03 37.03 37.03 37.03 37.03
16 22 21.09 23.72 26.36 29.00 31.63 35.59 39.54 43.49 48.37 48.37 48.37 48.37 48.37 48.37
20 28 29.74 32.71 35.68 40.15 44.61 49.07 55.01 59.47 66.91 74.34 75.58 75.58
25 32 42.92 47.69 52.45 58.81 63.58 71.53 79.48 95.37 118.09
Partial Safety Factor for Steel = 1.15, for Variable actions = 1.5
IX-45
9
9
IX-46
Table 9.9
Concrete Grade M25; Yield Strength of Steel 415 N/mm2

Dia Dia of
Hole

(in (in 100 120 140 160 180 200 220 240 270 300 330 370 400 450 500 600 850
mm) mm)
8 12 9.87 11.85 12.09 12.09 12.09 12.09 12.09 12.09 12.09 12.09 12.09 12.09 12.09 12.09 12.09 12.09 12.09
10 14 11.04 13.25 15.45 17.66 18.90 18.90 13.90 18.90 18.90 18.90 18.90 18.90 18.90 18.90 18.90 18.90 18.90
12 16 14.51 16.93 19.35 21.77 24.18 26.60 27.21 27.21 27.21 27.21 27.21 27.21 27.21 27.21 27.21 27.21
14 18 18.29 20.90 23.51 26.12 28.73 31.35 35.26 37.03 37.03 37.03 37.03 37.03 37.03 37.03 37.03
16 22 22.34 25.13 27.93 30.72 33.51 37.70 41.89 46.08 48.37 48.37 48.37 48.37 48.37 48.37
20 28 31.22 34.34 37.47 42.15 46.83 51.52 57.76 62.44 70.25 75.58 75.58 75.58
25 32 47.12 52.36 57.60 64.58 69.81 78.54 87.27 104.72 118.09
Partial Safety Factor for Steel = 1.15 for Variable actions = 1.5
Values for the above table remain same for all subsequent higher grade of concrete.
Table 9.10
Concrete Grade M30; Yield Strength of Steel 415 N/mm2

Dia Dia of
Hole
(in (in 100 120 140 160 180 200 220 240 270 300 330 370 400 450 500 600 850
mm) mm)
8 12 9.87 11.85 12.09 12.09 12.09 12.09 12.09 12.09 12.09 12.09 12.09 12.09 12.09 12.09 12.09 12.09 12.09
10 14 11.04 13.25 15.45 17.66 18.90 18.90 18.90 18.90 18.90 18.90 18.90 18.90 18.90 18.90 18.90 18.90 18.90
12 16 14.51 16.93 19.35 21.77 24.18 26.60 27.21 27.21 27.21 27.21 27.21 27.21 27.21 27.21 27.21 27.21
14 18 18.29 20.90 23.51 26.12 28.73 31.35 35.26 37.03 37.03 37.03 37.03 37.03 37.03 37.03 37.03
16 22 22.34 25.13 27.93 30.72 33.51 37.70 41.89 46.08 48.37 48.37 48.37 48.37 48.37 48.37
20 28 31.22 34.34 37.47 42.15 46.83 51.52 57.76 62.44 70.25 75.58 75.58 75.58
25 32 47.12 52.36 57.60 64.58 69.81 78.54 87.27 104.72 118.09
Partial Safety Factor for Steel = 1.15 for variable actions -= 1.5
IX-47
9
9
IX-48
Table 9.11
Epoxy Requirement for Rebar Embedment
Rebar Hole Depth REBAR APPLICATION

Dia Dia of Consumption in cm3 (ml)
Hole

(in (in 100 120 140 160 180 200 220 240 270 300 330 370 400 450 500 600 850
mm) mm)
8 12 9 10 12 14 16 17 19 21 23 26 29 32 36 39 43 52 74
10 14 10 12 14 16 18 20 22 24 27 30 33 37 40 45 51 61 86
12 16 12 14 16 18 21 23 25 28 31 35 38 43 46 52 58 69 98
14 18 13 16 18 21 23 26 29 31 35 39 43 48 52 58 65 78 110
16 22 24 29 33 38 43 48 52 57 64 71 79 88 95 107 119 143 203
20 28 40 49 57 65 73 81 89 97 109 121 133 150 162 182 202 243 344
25 32 40 49 57 65 73 81 89 97 109 121 133 150 162 182 202 243 344
described above.
9.2.9 SPECIFICATION FOR PROVIDING AND INSERTING SHEAR KEY BARS

(Schedule Item No. 8.2.9):
PURPOSE: Shear key bars are used for providing a structural connection of the applied
repair material with the substrate/parent surface for transfer of forces occurring at
the interface.

1. Epoxy cartridges and specified lengths and diameter of steel reinforcement.
2. Standard Power driven drilling/hammering equipment
Hand operated blow out pump, brushes, epoxy dispenser, epoxy cartridge holder,
disposable PVC mixing nozzle for epoxy, and any other incidental accessories and
T&P items.
9.2.9.2 Procedure
Step 1: Mark the locations of shear keys and get the same approved for structural
connection from the Engineer-in-charge.
Step 2: Drill holes to specified depth and diameter in concrete at marked locations
for the specified dia of shear key bars.
Step 3: The drilled hole in dry state shall be cleaned with round brushes and by
blowing air through a tube inserted in the hole and connected to hand operated
blow out pump (Fig. 9.1).
Step 4: Inject epoxy from the foil pack with the help of epoxy dispenser, epoxy 9
cartridge holder and disposable PVC mixing nozzle inserted inside the drilled
hole to fill it from bottom of the hole and upwards. The approximate
consumption of the epoxy in cubic cm. is given in Table 9.11 as a general
guide.
Step 5: Insert the reinforcing bar and allow the epoxy adhesive to cure.
Measurements shall be done in number of specified bars introduced in two separate
groups for shear key bars of 12 mm dia and 16mm dia bars.
9.2.9.4 Rates:
described above.
9.2.10 SPECIFICATION FOR CLEANING EXPOSED CONCRETE SURFACE OF
LOOSE AND FOREIGN MATERIALS BY MEANS OF SAND BLASTING
PURPOSE: To clean the prepared concrete surface of all-loose, lightly sticking
materials, including the foreign materials, loose concrete, aggregates etc so as to
provide a good bond with the applied repair material.


Coarse sand conforming to Zone I or II as per IS: 383, Air compressor of a minimum 35
Kilowatt capacity, spray gun for sand, all related accessories for sand blasting, hand tools
like wire brushes, chisels, etc
9.2.10.2 Testing of Materials and T&P:
The sand shall be tested to conform to the specification.
The air compressor shall be tested to perform to the required standards as laid down in Para
9.5.2.1.2 subsequently.
9.2.10.3 Safety:
Safety shall be ensured in accordance with Para 9.0.5.
9.2.10.4 Procedure:
Step-1: Specified tested coarse sand shall be collected at site in required quantity for
sand blasting.
Step-2: Make available mechanical power driven air compressor in working condition
at site with all required accessories for carrying out sand blasting as well as air
blasting operations.
Step-3: Clean the final chipped off concrete surface and exposed reinforcement, if any,
of all loose and foreign materials to be subsequently followed with oil free air blast.
Length and breadth of the area cleaned by sand blasting shall be recorded correct to a
9 centimeter and area worked out in square metres correct to second place of decimal.
9.2.10.6 Rates:
described above.
9.2.11 PROVIDING AND FIXING ANCHOR FASTNER SYSTEM MECHANICAL/

EPOXY BASED (Schedule Item No. 8.2.11):
PURPOSE: To provide an anchor fastner to be able to resist a known pull out force.
The anchor fastner system shall be standard system with minimum guaranteed load
carrying capacities for a given substrate.

As per the proprietary firm and as specified.
9.2.11.2 Testing:
The designated capacity of the mechanical/epoxy based anchor fastener shall be tested
by appropriate pull out strength measurement device.
9.2.11.3 Procedure:
As per the proprietary firm and as specified.

Measurements shall be done in number of fastners complete for each category, diameter
wise of the anchor fastner system separately for mechanical and epoxy based system.
9.2.11.5 Rates:
described above.
9.3 CRACK/HONEYCOMB AREA REPAIR

9.3.1 SPECIFICATION FOR PROVIDING DRILLING AND INSERTING NIPPLES
ALONG CRACK LINES (Schedule Item No. 8.3.1):
PURPOSE: To fix injection nipples and seal the remaining portion of honey combed
or cracked concrete /masonry for grout injection.
12 mm diameter approved aluminium /Galvanised Iron nipples, Chisel, hammer, power
driven tool for chase cutting & drilling, hand operated blow out pump, sealing putty of
polyester/epoxy/polymer modified mortar etc. and all related accessories and materials.
9.3.1.2 Testing:
The sealing putty and the nipples shall be tested to conform to the manufacturers
specifications.
The power driven tools shall be test driven and their drill/cutting bits shall be tested for
effectiveness before taking up the repair operation.
9.3.1.3 Procedure:
Step-1: Follow the guidelines for Safety, Quality Assurance, Environmental
9
Protection, Personnel, Supervision, Product delivery, Storage and Handling
etc given in Para 9.0.
Step-2: Identify the Cracks and mark the area for injection grouting.
Step-3: Prop & support the structural member, if required, to relieve it of stress and
strains (Refer Para 9.1.1)
Step-4: Open up cracked surface by making ‘V’ notch or groove of size 12 mm x
12mm.
Step-5: Remove plaster, if required, to identify and mark the honey combed area
(Refer 9.2.1).
Step-6: Drill holes at least 25 mm diameter and 40mm deep
l along crack lines at spacing of 300 mm or thickness of the structural
member, whichever is less.
l In honey combed area @ 9 nos per sqm. as directed by Engineer-in-Charge
and upto 30 mm to 40 mm depth.
Step-7: Remove coarse debris and dust in opened up cracks and drilled holes by
blowing oil free compressed air, if available with air compressor, otherwise
with hand operated blow out pump. Concrete surfaces required to be grouted
shall be free from all loose and unsound materials by means of mechanical
abrasion using stiff wire brushes, after removing all loose areas with chissel

and hammer. Area shall be made free from any deleterious materials, such as oil
dust dirt etc. by means of oil free jet of compressed air.
All prepared concrete surfaces shall be thoroughly inspected and got approved
by the contractor.
Step-8: Insert 12mm dia specified injection nipples in holes drilled along crack
lines and fix them by sealing only its sides with epoxy or polymer modified
mortar.
Step-9: Seal the crack or the honey combed surface between the nipples by means
of epoxy mortar after applying epoxy primer or polymer modified mortar as
may be approved by Engineer-in charge. The epoxy/polymer used shall be of
approved grade and applied as per specifications mentioned separately
elsewhere. The epoxy mortar shall be air cured for 24 hours, whereas the
polymer-modified mortar shall be moist cured for 1-3 days and allowed to
gain strength before actual grouting commences.
For payment purposes, number of nipples fixed shall be separately measured for concrete
and masonry work.
9.3.1.5 Rates:
described above except those involved in above mentioned steps 3 and 5.
9.3.2 SEALING OF CRACKS BY INJECTION OF APPROVED GROUT (Schedule

9 Item No. No. 8.3.2):
PURPOSE: To inject the specified grout into honeycombed or cracked concrete/
masonry
a. Specified grout
i. Cementitious Grout shall have following components:
Cement: The cement used shall be ordinary Portland cement of the specified
grade and conforming the relevant BIS code of Practice.
Sand: The sand shall be sharp washed well graded generally falling in Zone
IV of IS 383
Water: Water used for grout shall conform to the requirements of IS 456.
Admixture: If required, admixture shall be used only after the approval of Engineer-
in-Charge, who shall be furnished with all the required literature pertaining to its
efficacy. The mixture shall meet the requirement of IS 456 and IS 9103. Payment
for admixture shall be made separately.
Polymer: It shall be as specified and shall conform to ASTM-C-1059 The physical
and mechanical properties of polymers shall conform to Tables 5.4 and 5.5.

ii. Epoxy Grout shall conform to ASTM C-882 and have following properties:
Viscosity at 25oC maximum - 2 Pas
Minimum Gel time - 30 minutes
o
14 days bond strength at 25 C min. - 3.5 MPa
Min. compressive strength - 60 MPA at 7 days.
Tensile strength 7 days min. - 45 MPa
b. Hand/power operated grouting pressure pump/gun with pressure gauge.
The grouting equipment shall be capable of supplying, mixing, stirring and
pumping grout to the satisfaction of the Engineer-in-Charge. The equipment shall
have the capacity to inject grout at a pressure upto 7 kg per square centimeter
measured at the grout connections. It shall be capable of mixing and pumping of
cement sand grout 1:2 with water cement ratio ranging from 0.5 to 1.
c. Air compressor with all related accessories for carrying compressed air to the
required location. Hand operated blow out pump may be allowed by Engineer-in-
Charge for small crack depths/areas.
d. Calibrated Spring Balance (for accurately weighing different components of
materials in required proportions),
e. Mechanical blender for mixing
f. Spray equipment/brush for application of epoxy/ polymer modified/ bonding
cement slurry
9.3.2.2 Execution:
Step-1 Follow the guidelines for Safety, Quality Assurance, Environmental
Protection, Product delivery, Personnel, Supervision, Storage and Handling,
etc given in Para 9.0. 9
Step-2 Full quantity of manufactured material (e.g. specified resin, hardener,
polymer, cement, etc as may be required) shall be received at site in factory
sealed containers with labels legible and intact provided that the shelf life so
permits. Otherwise substantial quantity as could be consumed within the
storage period shall be received as per quantity approved by Engineer-in-
Charge. Full quantity shall be worked out as theoretically required for
consumption in the whole work.
Step-3 Collect random samples of materials for test and send to approved
laboratories so as to ensure that they satisfy the physical and mechanical
properties.
The grout pump and the pressure gauge shall be tested before taking up the
repair operation.
Step-4 Identify the Cracks and mark the area for injection grouting.
Step-5 Surface Preparation: The appropriate propping/supporting,
surface preparation and crack sealing as per site requirements shall be
completed, which may sequentially cover one or more of the following items
of work:
a) Prop & support the structural member to relieve it of stress and strains
(Refer Para 9.1.1)

b) Provide grouting nipples (Refer Para 9.3.1).

Step-6 Blow the compressed air followed by washing with water through nipples located
at the highest level and downwards to ensure removal of even fine dust particles
from the cracked surface, which could obstruct the free flow of grout material and
impede its bonding with cracked surface (and drying with air blast wherever epoxy
injection grout is to be used).
Step-7 Saturate the cracked surface in the vicinity of crack/honeycombed concrete/
masonry with water (but without excess water), only if the cementitious grout
is to be injected. Otherwise, this step may be skipped.
Step-8 Prepare the injection grout as under:
A EPOXY GROUT
Epoxy component shall be mixed in a clean container free from harmful
residue or foreign particles. Epoxy component shall be thoroughly blended
in a mechanical mixer to a uniform and homogeneous mixture. Small
batches (upto 1 litre) however may be allowed for manual mixing using
spatulas, pallattes, knives, etc.
B. CEMENT SLURRY
Mixes consisting of cement, water, sand and admixture like fluidifiers
(of approved type) in the proportions directed by the Engineer-in-Charge
who will, from time to time make changes to suit the conditions
encountered in the particular grout work. The water cement ratio shall
be varied to meet the characteristics of each hole as revealed by the
9 grouting operations and will range between 0.5 and 1.0.
Shrinkage compensating cement slurry mixed to a lump free creamy
consistency shall be made by thoroughly blending in a mechanical mixer
and shall be continuously stirred mechanically to keep the cement particles
in suspension to retain uniform consistency till the grout is injected. Only
small batches (upto 1 litre) be allowed by manual mixing with spatulas,
pallattes, knives, etc.
C. SBR/ACRYLIC POLYMER CEMENT SLURRY
Shrinkage compensating cement mixed with polymer and water, in
specified proportion in conformity with Table 5.4. For other details it
would be similar to preparation of cement slurry as given in preceding
paragraph above.
Step-9 Inject the approved & specified grout into the cracks by means of suitable
gun or pump at a pressure of 1- 2 kg./cm2 for epoxy grout and 4-7 kg./cm2 for
cementitious grout.
In case of vertical cracks injection shall be started at the lowest nipple and
continued until the injected grout begins to flow out at the next higher nipple.
Whereas in other cases of horizontal locations, the injection shall be started
from one nipple and continued until the injected grout begins to flow out at

the other nipple.

The first nipple shall then be closed off and injection continued at the second
until the grout flows out at the third. The process shall be repeated until the
whole of the crack has been sealed. As soon as the system is cured, the nipples
shall be cut.
In case of Honeycombed Area, each grout hole shall be grouted individually.
Grouting pressures to be used in the work will vary with the conditions
encountered and different areas and the pressure used shall be between 1 to 4
kg/cm2. The sequence of injection shall be as per the direction of Engineer-
in-Charge
Step-10 Pre and Post Repair Evaluation
As per directions of the Engineer-in-Charge, the contractor shall carry out
Ultrasonic Pulse Velocity Test (UPV) and core test in an approved manner
prior to injection grouting and after injection and cure of the grout to ascertain
the quality and efficacy of the grouting work. Cores from the post-repaired
area shall be extracted only when UPV test results are reported satisfactory.
For UPV test and Core test. Nomenclature of relevant items given in Sub
Head- X of Chapter 8. Such tests carried out at one location prior to and after
the grouting shall be considered as one test only and shall be carried out with
at least one test for every 100 square metre of injection grouted surface area.
The UPV and core tests shall be carried out only by experienced personnel/
agency.
Step-11 Re-grout, based on test results, if in the opinion of Engineer-in-Charge the
condition of concrete along the path of grouting is not satisfactory, the 9
contractor shall drill more holes at the locations as required by Engineer-
in-Charge and re-grout the member according to the procedure laid down as
above. The grouting operation shall be followed till the results of ultrasonic
pulse velocity test and core test are satisfactory.
(a) Material supplied: The quantities of specified resin and hardener, polymers,
cements etc supplied shall be recorded after satisfying acceptability criteria. The
solid contents of Acrylic/SBR polymer shall be determined in field laboratory or
designated laboratory for each batch of supply of latex received and recorded
separately batch wise for determining the solid contents for the purpose of payment.
The measurements of weight of the grouting materials supplied shall be weight
of resin plus hardener for epoxy; solid contents of polymer, cement for each batch
of supplies received:
(b) Grout Material Consumed: The weight of the grout material shall include the gross
weight of injected material for:
(i) Epoxy grout - weight of resin, hardener & silica sand
(ii) Polymer modified or plain cement sand slurry- weight of cement, sand, and solid
contents of polymer & plasticiser, if any, but excluding the weight of mixed water.
(iii) Cement slurry- excluding the weight of mixed water.

The weight of grout shall exclude the quantity of water added directly or through the polymer
emulsion.
Pre-measurements of the quantities of such grouting materials available or brought at site and
the balance quantities remaining at the end of grouting application shall be recorded separately,
which will determine the quantity of grout materials actually injected in to the crack/honeycomb
area.
The quantities of grout material wasted, discarded, hardened shall not count for payment and
shall be recorded for deduction at the end of each operation.
The measurements shall be separately recorded for concrete and masonry work.
9.3.2.4 Rates:
described above except those covered by step-5. Cost of admixture shall be paid
separately.
Note : In respect of materials supplies, two stage payment shall be made. In the
first stage 75 % of the rates quoted be released after the materials are brought
to site of work and tested satisfactorily. Balance 25 % of the rates quoted
shall be released in the second stage, which will be after their consumption
in the work.
9.4 BONDING COATS
9.4.1 BONDING COAT FOR HARDENED CONCRETE WITH REPAIR

CONCRETE/ SHOTCRETE/ CEMENT MORTAR (Schedule Item No. 8.4.1):
9
PURPOSE: To provide adequately strong adhesion of parent concrete with applied
repair concrete or mortar.

Specified bonding materials e.g. epoxy or polymer and cement, mixing water, necessary
T&P for mixing and applying bond coat e.g. brush, spray gun, mixer, mechanical
stirrer, etc
Product:
A) Epoxy Adhesives shall conform to ASTM C-882.
B) Polymer Latex shall conform to ASTM C-1059
C) Cement shall be ordinary Portland cement conforming to IS: 269
9.4.1.2 Execution:
Step-2 Full quantity of manufactured repair materials shall be received at site in
factory sealed containers with labels legible and intact, if the shelf life so
permits. Otherwise substantial quantity as could be consumed within the shelf

life shall be received as per quantity approved by Engineer-

in-Charge. Full quantity shall be worked out as theoretically required for
Step-3 Prepare the surface for treatment (Refer Para 9.2.1, 9.2.2, 9.2.6 and 9.2.7 as
may be applicable).
Step-4 Saturate the surface with water but shall be free of excess surface water,
debris and dust, where cementitious bond coat is to be applied. Otherwise,
surface to remain dry and clean of debris and dust.
Step-5 Thoroughly inspect all the concrete surfaces prior to applications of adhesive
and get approved from the Engineer-in-Charge.
Step-6 Test the materials by taking random samples and testing in approved
laboratories so as to check whether they satisfy the physical and mechanical
properties.
Step-7 Make available at site all necessary mechanical equipment as under :
a. Calibrated Spring Balance (for accurately weighing different components of
materials in required proportions),
b. Mechanical blender for mixing
c. Spray equipment/brush for application of epoxy/ polymer modified/ bonding
cement slurry
Step-8 Bond Coat Mixing: Components of the bonding coat mix shall be weigh
batched and mixed in specified proportions in a clear container free from
harmful residue or foreign particles. The components shall be thoroughly
9
blended with a mechanical mixer to a uniform and homogeneous mixture.
Small batches (upto 1 litre) may however be allowed by manual mixing using
spatulas, palette, knives etc.
Step-9 Bond coat application for jacket concrete/ shotcrete/ Mortar placement:
The specified adhesive shall be applied to concrete surface at atmospheric
temperatures below 40oC for epoxy adhesive and below 30oC for polymer
modified cement or cement-sand slurry adhesive. Bonding coat shall be applied
by spray equipment or stiff nylon bristle brush as approved by Engineer-in-
Charge. The bonding material shall be worked well into the surface of the
parent body ensuring that no pinholes are visible.
Polymer modified bonding cement slurry shall be applied to a thickness not
in excess of 2 mm.
If necessary, a second coat shall be applied at right angles to the first to ensure
complete coverage and absence of pin holes.
All concrete surface shall be well protected beyond limits of surface receiving
adhesive against spillage.
Step-10 Repair Material Application: Fresh plastic concrete/ shotcrete/ mortar shall
be applied while adhesive is still tacky and well within the pot-life/ setting
period. If adhesive cures to the extent of loosing its tack or has set before

plastic concrete/shotcrete/mortar is placed, the same shall be removed or slightly

abraded and second coat of adhesive applied.
Freshly placed plastic concrete shall be thoroughly consolidated to ensure full
bonding of new concrete with the substrate.
Step-11 Bond of repair shall be tested in accordance with 9.4.1.3 given hereinafter.
9.4.1.3 Field Quality Performance Requirement:

Bond of repair with parent concrete
i) Evaluate bonding of fresh concrete/ shotcrete/ mortar to existing concrete after
the fresh material has cured for not less than 7 days by sounding and tapping fresh
concrete with a blunt metal instrument to the satisfaction of Engineer-in-charge.
Suspect inadequate bonding, if a hollow sound is detected in any area. In case of
conflicted location contractor shall extract one core from the repaired surface
area at the end of 28 days.
ii) Conduct one core test at random for checking the bond, for every 100 square
metre or part thereof. The contractor shall core each area after 28 days of application
of concreting/ shortcreting/ repair mortar application for determination of bonding
adequacy.
iii) Core drilling shall be done through applied repair material and into the existing
concrete. Core diameter shall be not less than three times the nominal size of the
coarse aggregate used in repair material or as required by the Engineer-in-Charge.
Length of cylindrical cores shall preferably be twice the core diameter or twice
the thickness of applied repair material or as instructed by Engineer-in-Charge
but in any case not less than the dia of the core.
9
iv) Cores shall be visually inspected by Engineer-in-Charge for evidence of poor
workmanship.
v) Cores shall be tested in tension to evaluate the quality of bond between
new concrete/shotcrete/mortar and the parent concrete. If the failure is
in the parent concrete the bond of new repair material shall be deemed to be
satisfactory.
vi) Failure at the bond line or in the repair material shall be concluded as lack of
proper bond or inadequate strength of repair mortar
vii) Dismantle such areas of work failed in bond or repair material and re-prepare
the surface after chipping off new concrete/mortar work and abrading the epoxy/
polymer/cement slurry interface. Nothing for testing concrete for bond between
old and new concrete shall be paid separately.
a) Materials supplied: The quantities of specified resin and hardener, polymers etc supplied
shall be recorded after satisfying acceptability criteria. The solid
contents of Acrylic/SBR polymer shall be determined in field laboratory or
designated laboratory for each batch of supply of latex received and
recorded separately batch wise for determining the solid contents for the purpose
of payment.

The measurements of weight of the bonding materials supplied shall be weight of resin
plus hardener for epoxy; solid contents of polymer for each batch of supply received;
b) Materials Consumed: Pre-measurements of the quantities of bonding materials (e.g.
epoxy, Acrylic/SBR polymer) available or brought at site and the balance quantities
remaining at the end of bonding coat application shall be recorded separately, which
will determine the quantity of bonding materials actually consumed.
c) Materials wasted: The quantities of bond material wasted, discarded, hardened shall
not count for payment and shall be recorded for deduction at the end of each operation.
For proper control so that the wastage is separately accounted, a register shall be
maintained to get the cumulative quantity of material received as supply, consumed
in the work, net balance in the store.
Bond Coat Application: The concrete surface, over which bond coat has been
applied, shall be measured correct to a centimeter and area of surface worked out
in square meters correct to second place of decimal.
Measurements shall be separately recorded for the supplies of material received,
material consumed and area over which bond coat applied from time to time.
9.4.1.5 Rates:
described above but shall not cover those involved in step 3 & 10.
to site of work and test results found satisfactory. Balance 25 % of the rates
quoted shall be released in the second stage, which will be after their
consumption in the work.. 9
9.4.2 ALKALINE PASSIVATING BOND COAT OVER REINFORCEMENT

PURPOSE: To protect steel reinforcement with a passivating alkaline layer provided
all around its circumference along the length with strong adhesive to bond with applied
repair concrete or mortar.
Specified alkaline passivating & bonding materials e.g. CPCC material, epoxy, epoxy
phenolic IPN-RB or specified polymer and cement, mixing water, necessary T&P for
mixing and applying bond coat e.g. brush, mechanical mixer, mechanical stirrer, etc.
Product:
A) Epoxy Adhesives shall conform to ASTM C-882.
B) Polymer Latex shall conform to ASTM C-1059
C) Cement shall be ordinary Portland cement conforming to IS: 269
D) Patented materials e.g. CPCC or epoxy-phenolic IPN-RB as per licensee’s
specifications
9.4.2.2 Execution:

Step-1 Follow the guidelines for Safety, Quality Assurance, Environmental Protection,
Product delivery, Personnel, Supervision, Storage and Handling, etc given in Para
9.0.
factory sealed containers with labels legible and intact, if the shelf life so
permits. Full quantity shall be worked out as theoretically required for
consumption in the whole work .
Step-3 Prepare the surface for treatment (Refer Para 9.2.1, 9.2.2, 9.2.6 and 9.2.7 as
may be applicable).
Step-4 Thoroughly inspect all the concrete surfaces prior to applications of
passivating/bond coat and get approved from the Engineer-in-Charge.
Step-5 Test the materials by taking random samples and testing in approved
laboratories so as to check whether they satisfy the physical and mechanical
properties.
Step-6 Make available at site all necessary mechanical equipment as under :
a. Calibrated Spring Balance (for accurately weighing different
components of materials in required proportions),
b. Mechanical blender for mixing
c. Brush for application of specified and approved passivating/bond
coat.
Step-7 Material Mixing: Components of the passivating/ bond coat mix shall be
weigh batched and mixed in specified proportions in a clear container free
9 from harmful residue or foreign particles. The components shall be thoroughly
blended with a mechanical mixer to a uniform and homogeneous mixture.
Small batches (upto 1 litre) may however be allowed by manual mixing using
spatulas, palette, knives etc.
Step-8 Material Application: The alkaline passivating & bonding material shall be
applied to prepared reinforcement substrate after tying in new reinforcement
wherever specified in the form of bars or welded wire fabric. It shall be applied
to reinforcement surfaces by stiff nylon bristle brush. The coating material
shall be worked well all round the periphery and along its exposed length
using a stiff brush ensuring that no pinholes are remaining. The second coat,
if required, the same shall be applied as per manufacturer’s recommendation
after the first coat is touch dry.
a) Material supplied: The quantities of specified resin and hardener, polymers,
patented materials etc supplied shall be recorded after satisfying acceptability
criteria. The solid contents of Acrylic/SBR polymer shall be determined in field
laboratory or designated laboratory for each batch of supply of latex received and
recorded separately batch wise for determining the solid contents for the purpose
of payment.
The measurements of weight of the passivating and bonding materials supplied

shall be weight of resin plus hardener for epoxy; solid contents of polymer for each
batch of supply received;
b) Material Consumed: Pre-measurements of the quantities of passivating and bonding
materials (e.g. epoxy, Acrylic/SBR polymer/patented material) available or brought at
site and the balance quantities remaining at the end of passivating & bonding coat
application shall be recorded separately, which will determine the quantity of bonding
materials actually consumed.
c) Materials wasted: The quantities of bond material wasted, discarded, hardened shall
not count for payment and shall be recorded for deduction at the end of each operation.
For proper control so that the wastage is separately accounted, a register shall be
maintained to get the cumulative quantity of material received as supply, consumed
in the work and net balance in the store.
Passivating Coat Application: For the purpose of payment, the reinforcing bars
coated with passivating and bond coat shall be grouped in two diawise categories,
with one being upto and including 12 mm and the other above 12 mm. For each
of such categories, length of bars coated all around, shall be separately measured.
The length shall be measured in metres correct to second place of decimal
Measurements shall be separately recorded for the supplies of material received,
actual quantity of material consumed from time to time.
9.4.2.4 Rates:
described above except those involved in step-3.
9
to site of work and test results found satisfactory. Balance 25 % of the rates
quoted shall be released in the second stage, which will be after their
consumption in the work.
9.5 REPAIR ITEMS

9.5.1 SPECIFICATION FOR MICRO-CONCRETE (Schedule Item No. 8.5.1):
PURPOSE: A manufactured cementitious concrete mix for use in constricted locations,
which is received in pre batched, prepackaged, single component dry mix of specified
grade. When mixed with specified quantity of water, it is to have free flowing and self
compacting characteristics in plastic state and on hardening it shall have non-shrink
and impervious characteristics.
Specified grade of micro-concrete, mixing water, mechanical mixer, transportation
and handling equipment, all necessary T&P for surface preparation, reinforcement
bars, shear key bars, epoxy, power drilling equipment, props & supports, waterproof
shuttering, specified passivating & bond coats for reinforcement and concrete, the
ingredients as per design of concrete mix including super-plasticiser, micro-silica, other
mineral admixtures to achieve concrete of specified grade and workability.

9.5.1.2 Procedure:
9.0.
factory sealed containers with labels legible and intact provided that the shelf
life so permits. Otherwise substantial quantity as could be consumed within
the shelf life shall be received as per quantity approved by Engineer-in-Charge.
Full quantity shall be worked out as theoretically required for consumption in
the whole work.
Step-3 Testing of Material: The requisite number of test specimens of micro-concrete
shall be cast from each batch of manufacture or supply received (whichever
is less) for these to be tested for conformance to the specified requirements of
7 and 28-day cube crushing strength, surface absorption of water, permissible
limits of shrinkage, etc before use on the work.
Step-4 Surface Preparation: The appropriate surface preparation and crack sealing
as per site requirements shall be completed, which may sequentially cover
one or more of the following items of work:
(Refer Para 9.1.1)
b) Removal of existing surface plaster shall be done according to Para
9.2.1.
c) Chipping unsound/weak concrete material shall be done according to
9
Para 9.2.2.
d) Removing concrete all around embedded rusted reinforcement shall be
done according to Para 9.2.6.
e) Removing and cleaning reinforcement of rust from its surface to give it
a shining bright metal shall be done according to Para 9.2.7.
f) Sealing the cracked or honeycombed concrete with injection grouting
shall be done according to Para 9.3.1 and 9.3.2
g) Providing and inserting mild steel shear keys shall be done according
to Para 9.2.9.
h) Cleaning of lightly sticking materials and foreign matter from the
exposed concrete surface and steel reinforcement by suitable means
shall be done according to Para 9.2.10.
Step-5: Additional reinforcement, if required, shall be tied with required overlaps
or welded. (Refer Para No 9.5.5).
Step-6 Apply Passivating & bonding coat over the cleaned reinforcement according
to Para 9.4.2.
Step-7 Apply bond coat on the cleaned concrete substrate according to Para 9.4.1.
Step-8 Erect pre-fabricated watertight shuttering, if required, while the bond coat
is still tacky according to Para 9.1.2 to receive the self compacting free flowing

micro concrete
Step-9 Prepare self compacting, free flowing micro-concrete simultaneously along
with step-8 so as to have a uniform consistency and texture in a mechanical
concrete mixer by adding a specified proportion of water in the preweighed
dry mix of pre-batched, prepackaged, single component micro concrete .
Step-10 Pour the fresh micro-concrete in the shuttering mould or over the surface
prepared to receive it, while the bond coat is still tacky.
Step-11 Wet cure the micro-concrete according to Para 9.6.1
Step-12 Field Quality Performance shall be culculated as per Para 9.4.13
After surface preparation, if necessary for working out volume of applied repair material,
pre-measurements of dimensions of the substrate shall be recorded. For the purpose of
payment, measurements of the finished surface shall be recorded only after wet curing
is done and surface evaluated satisfactorily. The dimensions shall be recorded correct
to a centimeter and volume shall be worked out in cubic metres correct to second place
of decimal.
9.5.1.4 Rates:
described above except for those involved in steps 4, 5, 6, 7, 8 and 11.
to site of work and tested satisfactorily. Balance 25 % of the rates quoted 9
in the work.
9.5.2 SPECIFICATION FOR SHOTCRETE (Schedule Item No.. 9.5.2):

PURPOSE: Application of repair concrete of specified mix proportions by spraying
it under pressure in layers over prepared substrate.
9.5.2.1.1 Materials:
Cement:
The cement shall be ordinary Portland cement of 43 grade conforming to relevant
B.I.S. Code of Practice.
Aggregates:
Sand for shotcrete shall comply with the requirements given in IS 383 and graded
evenly from fine to coarse as per Zone-II and Zone III grading. Sand failing to satisfy
this grading may, however, be used only if pre-construction testing establishes that it
gives good results.
Coarse aggregate when used shall comply with the requirements of IS 383. It shall,
generally conform to the grading given below:

GRADING OF COARSE AGGREGATES

IS Sieve Designation, mm Percentage Passing by mass for
aggregate of nominal maximum size
10 100
4.75 10-30
2.36 0-10
1.18 0-5
All over sized pieces of aggregate shall be rejected by screening.

Gradation of the combined coarse and fine aggregate mixture used for shotcrete shall
generally lie between the following limits.
I.s.sieve Percent passing by Weight

Gradation
10 mm 100 -100
4.75 mm 72- 85
2.36 mm 52-73
1.18 mm 36-55
600 microns 28-38
300 microns 7-20
9
150 microns 0-8
Water
Water used for shotcrete shall conform to the requirement of I.S. 456-2000
Admixture
Admixture shall only be used if approved by the Engineer-in-Charge who shall be
furnished with all required literature pertaining to its efficacy. Guniting admixtures &
quick setting agents may be used to minimise the rebound loss and increase the bond
& enable thicker layers per coat. The admixture shall meet the requirement of I.S. 456
and I.S. 9103 .
Reinforcement
Reinforcement bars if used shall conform to I.S. 432 (Part-I) or I.S. 1786. Welded
wire fabric where used shall conform to I.S. 1566.
Concrete
The grade of concrete shall be as specified i.e. the characteristic compressive strength
of 15 cm cube at 28 days should be as specified. The water cement ratio for shotcrete
shall be within the range 0.45- 0.50 by mass.

9.5.2.1.2 Equipment
For Dry mix process:
Batching and mixing equipment- Batching shall be done by mass. The moisture content of
the sand shall be such that the sand cement mixture will flow at a uniform rate through the
delivery hose. The sand shall be moistened or dried as required to bring the moisture content
to a satisfactory level. Fluctuations in moisture content shall be avoided.
The mixing equipment shall be capable of thoroughly mixing the sand and cement in sufficient
quantity to maintain continuity of placing. The mixing time shall be not less than 1 minute in a
drum type mixer, where other mixers are proposed, satisfactory evidence shall be presented
to the Engineer-in-Charge that they are capable of thorough mixing. The mixer shall be self
cleaning capable of discharging all mix material without any carry over from one batch to the
next. It shall be inspected and thoroughly cleaned at least once in a day and more often if
instructed by Engineer-in-Charge to prevent accumulations of batched material.
Delivery equipment or guniting equipment- The delivery equipment shall comply with
requirements given in I.S. 6433.
Air Supply - The compressor shall be fitted with a moisture extractor to keep up a
supply of clean, dry air adequate for maintaining a sufficient nozzle velocity for all
parts of the work while simultaneously operating a blow pipe for clearing away re-
bound material.
A gauge near the material outlet of the gun shall measure the operating pressure. The
air pressure shall be uniformly steady (non pulsating).
For lengths of hose upto 30m, air pressure at the gun shall be 0.3 N/Sq.mm or more.
Where length exceeds 30m the pressure shall be increased by 0.035 N/Sq.mm for each
additional 15 m of hose required & by 0.035 N/sq.mm for each 7.5 M that the nozzle 9
is raised above the gun.
Water supply -The water pressure at the discharge nozzle shall be sufficiently greater
than the operating air pressure to ensure that the water is intimately mixed with the
other materials. If the line water pressure is inadequate, a water pump shall be introduced
into the line. The water pressure shall be uniformly steady (non pulsating).
9.5.2.2 Procedure:
the storage period shall be received as per quantity approved by Engineer-in-
Charge. Full quantity shall be worked out as theoretically required for
Step-3 Mix Design: The shotcrete mix design shall be developed by laboratory tests
and field trials and got approved from Engineer-in-charge.
Step-4 Pre-construction testing- A laboratory trial and testing shall be carried out
prior to the commencement of the work in order to check the operation of the
equipment, the skill of the operating staff and also to verify that the specified quality
of shotcrete would be expected in the structure. The procedure for pre-construction
testing shall be as below;
A. The operating staff, using the equipment, materials and mix proportions
proposed for the job, shall fabricate test panels simulating actual job
conditions.
B. For the dry mix process, the amount of water added at the nozzle shall be
adjusted so that in place shotcrete shall be adequately compacted and
will neither sag nor show excessive rebound. At least, two mixes shall
be tested before deciding on the final mix proportion.
C. The panels shall be fabricated by gunning on to a back form of plywood.
A separate panel shall be fabricated for each gunning position to be
encountered in the structure. At least part of the panel shall contain the
same reinforcement as the structure to show whether sound shotcrete is
obtained behind the reinforcing rods. The panel shall be large enough to
obtain all the tests specimen needed, and also to indicate quality and
uniformity that may be expected in the structure. Generally the size of
panel shall be not less than 75cm x 75 cm. The thickness shall be the
same as in the structure except that it shall be not less than 50mm.
D. Cores shall be taken from the panels for testing. The cores shall preferably
have a diameter of 7.5 cm but not less than 50 mm and a length to diameter
ratio of at least 1. The specimen shall be tested in compression at the age
of 7 or 28 days or both as directed by Engineer-in-Charge. The result of
9 the tests shall be compared with the cube strength taken earlier. Nothing
extra shall be paid for core testing of concrete for pre construction testing.
E. The cut surface of the specimen shall be carefully examined and additional
surfaces shall be exposed by sawing or breaking the panel, if it is
considered necessary by Engineer-in-Charge to check soundness and
uniformity of the material. All cut and broken surfaces shall be dense
and free from laminations and sand pockets.
Step-5 Surface Preparation: The appropriate surface preparation and crack sealing
as per site requirements shall be completed, which may sequentially cover
one or more of the following items of work:
(Refer Para 9.1.1)
b) Scaffolding & working platforms for the exterior members (Refer Para
9.1.3), if not already done and if necessary, shall be erected for working
upon the area.
c) Working Platforms for interior members, if not already done and if
necessary, shall be erected suitably or provided as mobile.
d) Provide Protective Screen (Refer Para 9.1.8), if not already done and if
necessary.
e) Removal of existing surface plaster (Refer Para no 9.2.1)

f)Chipping unsound/weak concrete material (Refer Para no 9.2.2). However,

no square shoulders shall be left at the perimeter of the cavity, all edges shall
be tapered. The final cut surface shall be critically examined to make sure that
it is sound and properly shaped.
g) Removing concrete all around embedded rusted reinforcement (Refer
Para no 9.2.6).
h) Removing and cleaning reinforcement of rust from its surface to give it
a shining bright metal (Refer Para no 9.2.7).
i) Sealing the cracked or honeycombed concrete with injection grouting
(Refer Para no 9.3.1 and 9.3.2),
j) Providing and inserting mild steel shear keys, also to act as depth gauge
for controlling thickness of gunite/shotcrete (Refer Para no 2.9)
k) Cleaning of lightly sticking materials and foreign matter from the exposed
concrete surface and steel reinforcement by suitable means followed by
an oil free dry air blast(Refer Para no 2.10)
Step-6 Additional reinforcement, if required, and welded wire fabric shall be
tied with required overlaps or welded. (Refer Para No 9.5.5).
Step-7 Adequate and safe working platform, as approved as per Para 9.1.3, shall
be provided so that the gunite/shotcrete operator can hold the nozzle at optimum
angle and distance from the surface for all parts of work.
Step-8 Suitable formwork of plywood sheeting or other suitable material shall be
fixed true to lines and dimension to get finished sides and edges of the gunited/
shotcreted surface. Refer Specifications of form work (centering and
shuttering)’ contained in Para 5.2 of CPWD Specifications 1996 9
(Vol-II).
They shall be adequately braced to protect against excessive vibration and
shall be constructed so as to permit the escape of air and rebound during the
gunning operation. Forms shall be oiled or dampened and they shall be cleaned
just before gunning.
Formwork shall be necessarily required for first stage application of shotcrete/
gunite on two opposite faces of rectangular columns and beams, whereas in
second stage of application of repair material on the remaining faces, gunited/
shotcreted surface at edges/corners shall serve the purpose without requiring
further formwork.
The minimum clearance between the reinforcement and the formwork or other
back up material shall be provided as per detailed drawing.
Step-9 Alignment & thickness Control- Adequate ground wires shall be installed
to establish thickness and surface planes of the shotcrete build up. Both
horizontal and vertical ground wires shall be installed at the corners and offsets
not clearly fixed by the formwork, i.e. at exterior corners of columns and
beams and other such locations. Ground wires shall be tight and true to line
and placed in such a manner that they may be further tightened.
Step-10 Passivating/bond coat shall be applied to the reinforcement and the welded

wire fabric (Refer Para no 4.2)

Step-11 Bond coat over the prepared concrete and reinforcement substrate as above shall
be applied (Refer Para no 4.1)
Step-12 Gunite/Shotcrete Application: Fresh gunite/shotcrete shall be applied at the earliest
possible, when bond coat, as applied in Step-11 above, is still tacky.
Maximum thickness to be applied in one pass will be, in general, limited to 25
mm for overhead application and 50 mm on sides. Where gunite is to be placed to
a thickness of more than 50 mm on sides or 25 mm overhead, it is preferable for it
to be built up in more than one application.
Each layer of shotcrete shall be built-up by making several passes or loops of
the nozzle over the working area. This will be done by moving the nozzle rythmetically
in series of loops from side to side and up and down. The shotcrete shall emerge
from the nozzle in a steady, uninterrupted flow. If the flow becomes intermittent due
to any cause, the Operator shall direct it away from the work until it again becomes
constant. The distance of nozzle from work (usually between 0.5 and 1.5 m) shall
be such as to give the best results for the working conditions. The nozzle shall be
held perpendicular to the surface of application. However, when gunning through
and encasing reinforcing bars the nozzle shall be held closer and at a slight angle to
the perpendicular. Also the mix shall be little wetter than normal but not so wet as
to cause sloughing behind the bars.
Application shall begin at the bottom for columns and beams and for slabs,
the nozzle shall be held at a slight angle to the perpendicular so that the rebound is
blown on to complete portion from where it shall be removed.
9
Embed reinforcement atleast adjacent to the form in the first layer completely.
The thickness of layers shall be adjusted so that shotcrete does not sag. Where
thick layers are applied, top surface shall be maintained at a 45 degree slope.
Rebound material, ricocheting off the surface, shall not be worked back into
the construction. If it does not fall clear of the work, it shall be removed. Rebound
shall not be salvaged and included in later batches.
Theoretical consumption of cement - For working out the theoretical consumption
of cement in shotcreting, following coefficients shall be added for accounting for the
concrete wasted as loss due to rebound in various items.
1. Ceiling of RCC slab - 40%
2. Vertical faces of R.C.C. beams
columns & R.C.C. walls
a. with face width not
exceeding 450 mm - 50%
b. with face width
exceeding 450 mm - 45%
Construction joints- Construction joints shall generally be tapered to a thin
edge over a width of 300 mm. However, in case of joints, which in the opinion
of the Engineer-in-Charge, are likely to be subjected to compressive stresses,

square joints shall be provided by temporarily fixing the batten formwork of required
thickness. In case of square joints, steps shall be taken by the Contractor to avoid
or remove trapped rebound in the joint. The entire joint shall be thoroughly cleaned
and the approved bonding coat applied prior to the application of additional
shotcrete.
Preparation for succeeding layers- When a layer of shotcrete is to be covered
by a succeeding layer, it shall first be allowed to take its initial set. Then all
laitance, loose materials and rebound shall be removed by brooming. Any
laitance that has attained final set shall be removed by sand blasting and the
surface cleaned with an air jet. In addition the surface shall be thoroughly
sounded with a hammer for drummy areas, sags or any other defects, which
shall be carefully cut out and replaced with succeeding layer as instructed by
Engineer-in-Charge. Succeeding layers shall be shot within 4 to 8 hours to
attain the required thickness. In case application of succeeding layer is delayed
beyond 24 hours, then the bond coat shall be applied at the interface for which
no extra payment shall be made to the contractor.(Refer Para No 9.4.1).
Suspension of work: The application of shotcrete shall be suspended in
condition of likely exposure to high winds, freezing or rain.
At the end of each day of work, or on stopping work for any other reason, the
shotcrete shall be sloped off to a thin edge and then the work shall be resumed
on next day after cleaning the surface of joint and applying a bond coat of
approved formulation.
Inspection- The shotcreting shall be continuously inspected by a qualified
supervisor, who shall check material, forms, reinforcement, ground wires,
9
delivery equipment, application of material, curing, protection against high
or low temperatures. Each layer of concrete shall be systematically sounded
with a hammer to check for drummy areas.
Permissible Tolerances: The permissible tolerance on the thickness of work
executed by shotcrete shall be (-) 3 mm to (+) 8 mm.
Quality control: Small un-reinforced test panels, at least 30 cm square and
75 mm thick shall be periodically gunned, and cores shall be extracted and
compressive tests shall be performed periodically in the same manner as at
step-4 above. The frequency of samples shall be one sample for every 10 cum
of gunite/shotcrete.
In addition, concrete cubes prepared by directly gunning into 15 cm cube mould,
shall also be used for day-to-day quality control tests. One sample comprising of
three test specimens for testing at 28 days, shall be taken for every 5.0 cubic metre
of concrete. Additional cubes if instructed by Engineer-in-Charge shall also be
taken for each sample to determine the strength of gunite/ shotcrete at seven days.
All the specimen shall be tested as described in IS 516.
The gunite shall be deemed to comply with the strength requirements if the test
results satisfies the acceptance criteria as per IS 456
Step-13 Wet cure the shotcreted/gunited surface (Refer 9.6.1).

Step-14 Field Quality Performance shall be evaluated as per Para 9.4.1.3:

Shotcreting upto 50 mm thickness shall be measured in square metre of finished surface area.
9.5.2.4 Rates:
Rate includes cost of all T & P material, labour and T&P involved in all the operations
described above except specifically mentioned and those involved in steps 5, 6, 8, 10,
11 and 13.
in the work.
9.5.3 PLAIN/REINFORCED CONCRETE JACKET FOR THE STRUCTURAL

MEMBERS e.g. COLUMNS, PILLARS, PIERS, BEAMS ETC. (Schedule Item
No. 8.5.3):
PURPOSE: To provide a thin walled RCC element structurally bonded to the substrate
of an existing stress-relieved structural member either to increase its structural size &
strength or to restore the reduced structural size due to chipping.

All necessary T&P for surface preparation, mechanical mixer, transportation and
9 handling equipment, reinforcement bars, shear key bars, epoxy, power drilling
equipment, props & supports, waterproof shuttering, specified passivating & bond
coats for reinforcement and concrete, mixing water, the ingredients as per design of
concrete mix including super-plasticiser, micro-silica, other mineral admixtures to
achieve concrete of specified grade and workability.
9.5.3.2 Procedure:
the shelf life shall be received as per quantity approved by Engineer-in-Charge.
Full quantity shall be worked out as theoretically required for consumption in
the whole work.
Step-3 Testing of Material: The requisite number of test specimens of concrete shall
be cast from each batch of manufactured or supplied materials received
(whichever is less) for these to be tested for conformance to the specified
requirements of 7 and 28-day cube crushing strength, surface absorption of
water, permissible limits of shrinkage, etc before use on the work.

Step-4 Surface Preparation: The appropriate propping, surface preparation and crack
sealing as per site requirements shall be completed, which may sequentially
cover one or more of the following items of work:
(Refer Para 9.1.1)
b) Removal of existing surface plaster shall be done according to Para 9.2.1.
Para 9.2.2.
e) Removing rust scales and cleaning reinforcement of rust from its
surface to give it a shining bright metal shall be done according to
Para 9.2.7.
g) Providing and inserting mild steel shear keys shall be done according to
Para 9.2.9.
h) Additional reinforcement, if required, shall be tied with required overlaps
i) Cleaning of lightly sticking materials and foreign matter from the exposed
concrete surface and steel reinforcement by suitable means shall be done
according to Para 9.2.10.
9
Step-5 Drill holes in RCC Slabs of appropriate diameter at appropriate locations
for pouring concrete in the jacket close to beam and slab soffits.
Step-6 Apply Passivating & bonding coat over the reinforcement according to Para
9.4.2.
Step-8 Fabricate and erect watertight shuttering, if required, while the bond coat
is still tacky according to Para 9.1.2 to receive the self compacting free flow
concrete
Step-9 The specified concrete (self compacting and free flow) shall be prepared,
poured and compacted well within the tacky period of bond coat. The CPWD
specifications for manufacture and placing of concrete shall generally be
followed.
Step-10 Wet cure the concrete jacket according to Para 9.6.1
Step-11 Test the Surface of 7-day cured concrete for soundness.
Step-12 Field Quality Performance shall be evaluated as per Para 9.4.1.3:
Dimensions of area of finished surface shall measured correct to a centimeter and area

worked out in square metres correct to second place of decimal for payment purposes.
9.5.3.4 Rates:
described above except for those involved in steps 4, 5, 6, 7, 8 and 10.
in the work.
9.5.4 PROVIDING AND LAYING AN OVERLAY OF REINFORCED CONCRETE

OVER PREPARED SURFACE OF EXISTING RCC SLAB/BEAM ETC.
PURPOSE: To provide specified additional thickness of RCC over an existing stress-
relieved RCC slab/beam, bonded structurally to the substrate either to increase the
structural thickness and/or additional reinforcement to enhance the load carrying
capacity or to restore the reduced thickness of RCC slab due to removed weak and/or
carbonated concrete.
All necessary T&P for surface preparation, reinforcement bars, shear key bars, epoxy,
power drilling equipment, props & supports, specified passivating & bond coats for
reinforcement and concrete, mechanical mixer, transportation and handling equipment,
the ingredients as per design of concrete mix including mixing water, super-plasticiser,
9 micro-silica, other mineral admixtures to achieve concrete of specified grade and
workability.
9.5.4.2 Procedure
the self life shall be received as per quantity approved by Engineer-in-Charge.
Full quantity shall be worked out as theoretically required for consumption in the
whole work.
Step-3 Testing of Material: The requisite number of test specimens of concrete shall be
cast from each batch of manufactured or supplied materials received (whichever is
less) for these to be tested for conformance to the specified requirements of 7 and
28-day cube crushing strength, surface absorption of water, permissible limits of
shrinkage, etc before use on the work.
Step-4 Mark the area of overlay over the RCC slab/beam.
Step-5 Surface Preparation: The appropriate propping/supporting, surface preparation
and crack sealing as per site requirements shall be completed, which may sequentially
cover one or more of the following items of work:

a) Prop & support the structural member to relieve it of stress and strains (Refer
Para 9.1.1)
b) Removal of existing surface plaster/treatment shall be done according
to Para 9.2.1 or 9.2.3 as the case may be.
Para 9.2.2.
g) Providing and inserting mild steel shear key bars shall be done with
minimum 3 nos per square meter of surface area of substrate according
to Para 9.2.9, which may also be used as depth measuring gauge.
i) The rust, if any, persisting over the existing exposed reinforcement or
the new reinforcement shall be removed mechanically or chemically,
as per Para no 8.2.7 and Para 9.2.7
j) Cleaning of lightly sticking materials and foreign matter from the
exposed concrete surface and steel reinforcement by suitable means
shall be done according to Para 9.2.10
k) Provide shuttering along sides of overlay as per Para 5.2 of CPWD 9
Specifications 1996Vol-II.
Step-6 Clean the dust from the prepared surface of concrete and reinforcement
wth a clean oil free air blast.
Step-7 Alignment & thickness Control- Ground wires shall be fixed at reference
points to measure and control the thickness of overlay. Shear keys fixed earlier
could also function as depth gauges. Adequate ground wires shall be installed
to establish thickness and surface planes of the overlay build up. Ground wires
shall be tight and true to line and placed in such a manner that they may be
further tightened.
Step-8 Apply Passivating & bonding coat over the existing and new reinforcement
according to Para 9.4.2.
Step-9 Apply bond coat on the concrete substrate according to Para 9.4.1.
Step-10 Prepare self compacting, free flowing concrete for overlay as per design
mix so as to have a uniform consistency and texture in a mechanical concrete
mixer by adding a specified proportion of water to the weigh batched
ingredients of the design mix including necessary super plasticisers.
Step-11 Pour the fresh concrete over the surface prepared to receive it, while the
bond coat is still tacky.

Step-12 Wet cure the concrete overlay according to Para 9.6.1

Step-13 Test the Surface of 7-day cured concrete overlay for soundness by tapping or
sounding with hard blunt surface.
Length and width of the specified thickness of overlay concrete shall be measured correct to
a centimeter and area worked out in square metres correct to second place of decimal. This
item shall be measured only after proper wet curing has been done and surface has been
satisfactorily .
9.5.4.4 Rates:
described above except for those involved in step nos 5, 8, 9 and 12.
in the work.
9.5.5 REINFORCEMENT FOR RCC WORK ETC. (Schedule Item No. 8.5.5):
PURPOSE: To provide reinforcement in repair concrete for structural purposes,
controlling effects of thermal variation or holding shotcrete/gunite material in position.
The reinforcement material may comprise specified grade and quality with or without
9
zinc coating.
9.5.5.1 Material & T&P:
Specified reinforcing material, necessary hand or power driven tools for cutting, bending,
binding, transportation, handling and placement, etc Reinforcement bars if used shall
conform to I.S. 432 (Part-I) or I.S. 1786. Welded wire fabric where used shall conform
to I.S. 1566.
9.5.5.2 Procedure:
The general requirements, placing in position, measurement etc. shall be generally
followed as in Para 5.3 of CPWD specifications 1996 Vol-II excepting those
specifications provided in the following clauses.
9.0.
Step-2 Testing of Material: The requisite number of test specimens of specified reinforcing
material shall be collected from each batch of manufacture or supply received
(whichever is less) for these to be tested for conformance to the specified requirements
before use on the work.
Step-3 Execution:
The required reinforcement as per detailed drawings in the form of round bars or

welded wire fabric in such a way so as to cause the least interference with placement
of repair material.
Overlaps: Lapped reinforcing bars shall not be tied together. They shall be
separated by at least 50 mm wherever possible. Wire mesh shall be lapped by
1-1/2 squares in all direction. Minimum requirement of lap length of bars
shall be as specified in I.S. 456.
Clearance around reinforcement: Sufficient clearance shall be provided
around the existing exposed and additional reinforcement to permit complete
encasement with sound repair material.
Cover: Minimum cover to reinforcement shall be as per I.S. 456. As far as
possible the bars shall be arranged so as to permit shooting from opposite
side.
Fixing: Reinforcement shall be fixed to existing shear key bars and depth
gauges driven into the concrete with wires and secured rigidly so that the
vibration resulting from the deposition of repair material shall not impair or
displace them.
Where gunite /shotcrete to be done in more than one layer: In such cases,
the additional reinforcement should be so fixed that it is encased in succeeding
layer. No additional reinforcement is required to be fixed in first layer of
gunite.
Mesh reinforcement shall be fixed in the manner so that it is firmly held at
least 12 mm away from the parent concrete surface as well as from the final
finished surface. It shall be ensured that it is stiffened enough and cannot
belly out during the guniting / jacketing / concrete overlays with consequent
lack of cover. It shall be done by tying with parent concrete surface through 9
shear key bars or depth gauges. GI-wire mesh fabric will add sacrificial “Zinc”
coating & shall reduce corrosion process in the reinforcement. The wire mesh
spacing shall be as specified in the drawings.
For the purpose of measurement for payment, length of specified reinforcing bars/
wires shall be measured correct to a centimeter and that of wire fabric, length and
width shall be measured correct to a centimeter to work out area in square metres
correct to second place of decimal. Overlaps shall be accounted for in the length/area
measurements.
For each batch of supply of steel reinforcement or the wire fabric, weight coefficients
shall be worked out per meter length for bars and wires and per square meter for wire
fabric. The weight coefficients shall be calculated correct to third place of decimal in
each batch by weighing three randomly taken samples from the lot of supply and
taking an arithmetical mean of the weights per unit length/area.The total weight shall
be worked out in Kilograms correct to second place of decimal
9.5.5.4 Rates:
Rates shall cover the costs of all labour, material and T&P involved in all operations

detailed above.
Note : In respect of materials supplies, two stage payment shall be made. In the first
stage 75 % of the rates quoted be released after the materials are brought to site
of work and tested satisfactorily. Balance 25 % of the rates quoted shall be released
in the second stage, which will be after their consumption in the work.
9.5.6 PROVIDING STRUCTURAL CONNECTION (Schedule Item No. 8.5.6):

PURPOSE: To establish a structural connection for a new RCC member to be
connected with the existing structural member for transfer of the end forces between
the members.
9.5.6.1 Specifications:
This item is a combination of various other items of work, specifications of which are
distinctly given under relevant items. Hence no separate specification of materials,
T&P, execution procedure is being given.
The Cross-sectional area at the interface of the structural connections shall be
measured and area shall be worked out in square metres correct to second place of
decimal.
9.5.6.3 Rates:
Rates shall cover all incidental cost of labour, material and T&P involved in all
operations other than those items of work distinctly mentioned in the nomenclature
payable separately.
9
9.5.7 CEMENT BASED POLYMER MODIFIED MORTAR (Schedule Item No. 8.5.7):
PURPOSE: To carry out structural repairs to prepared patches of spalled concrete
with an alkaline impervious repair material comprised of polymer admixed cement-
sand mortar.
Polymers in emulsion or powder forms as may be specified conforming to ASTM C-
1059, Ordinary Portland Cement of 43 grade conforming to relevant BIS code, Sand
conforming to Zone-II or Zone-III grade of IS: 383, Mixing water conforming to IS:
456-2000, mortar mixer with mechanical water dozer, spatulas, trowels, etc.
9.5.7.2 Procedure:
Step-2 Full quantity of specified polymers shall be received at site in factory sealed
containers with labels legible and intact provided that the shelf life so permits.
Otherwise substantial quantity as could be consumed within the shelf life
shall be received as per quantity approved by Engineer-in-Charge. Full quantity
shall be worked out as theoretically required for consumption in the whole

work.
Step-3 Testing of Material: The requisite number of test specimens of mortar shall be
cast from each batch of manufactured or supplied materials received (whichever is
less). These are to be tested for conformance to the specified requirements contained
in Table 5.5 before use on the work. Polymer modified cement mortar with cement:
sand proportion by weight as (1:3 ) shall have the following properties
Minimum compressive strength - 20N/sq.mm after 28 days at 27oC
Minimum tensile strength - 6.5 N/sq.mm after 28 days at 27oC
Step-4 Identify and mark the area for Polymer modified mortar repair.
Step-5 Surface Preparation: The appropriate propping/supporting, surface
preparation and crack sealing as per site requirements shall be completed,
which may sequentially cover one or more of the following items of work:
(Refer Para 9.1.1)
b) Removal of existing surface plaster/treatment shall be done according to
Para 9.2.1 or 9.2.3 as the case may be.
Para 9.2.2.
f) Sealing the cracked or honeycombed concrete with injection grouting 9
h) Additional fresh reinforcement, if required, shall be tied with required
overlaps or welded. (Refer Para No 5.5).
the new reinforcement shall be removed mechanically or chemically, as
per Para no 8.2.7 and Para 9.2.7
j) Cleaning of lightly sticking materials and foreign matter from the exposed
according to Para 9.2.10
Step-6 Clean the dust and saturate the prepared surface of concrete and
reinforcement with a clean oil free air blast and water fit for construction.
Step-7 Inspection of concrete surface prior to adhesive application shall be
thoroughly inspected and got approved by the Engineer-in-Charge. Surfaces
shall be ensured to be free from any deleterious materials such as oil, dust,
dirt etc. using oil free air blast.

Step-8 Alignment & thickness Control- Ground wires shall be fixed at reference points
to measure and control the thickness of overlay. Shear keys fixed earlier could also
function as depth gauges. Adequate ground wires shall be installed to establish
thickness and surface planes of the overlay build up. Ground wires shall be tight and
true to line and placed in such a manner that they may be further tightened.
Step-9 Apply Passivating & bonding coat over the cleaned existing and new
reinforcement according to Para 9.4.2.
Step-11 Mix and Prepare Polymer Modified Mortar to have a uniform consistency
and texture by adding cement sand and polymer as weigh batched ingredients
of the design mix, a specified proportion of water through water dozer.
Use of prepacked ready to use components supplied by manufacturers in
containers may be allowed subject to approval of Engineer-in-Charge. In case
where prepacked ready to use materials are to be used, the contractor shall
submit the manufacturer’s certificate verifying conformance to material
specification as specified, manufacturer’s mixing and application procedure
for approval by Engineer-in-charge.
Plastering with cement based polymer modified mortar shall be done
immediately after applying the bonding slurry to the prepared surfaces,
preferably in coats of approximately 10mm thickness with thickness of
trowelling not to exceed the range given in Table 5.6 as greater thickness may
lead to delamination/collapse. However, coats shall be applied in fairly rapid
successions within 15 to 30 minutes. After applications of mortar the surface
9
shall be finished using a wooden float.
The guidelines on mortar mix proportioning & application, available in
Table 5.6, Para 5.3.2.8 and 5.3.2.9 are generally applicable
. Step-12 Moist cure the polymer modified mortar surface for 1-3 days followed by
air curing at ambient temperature or as per manufacturer’s specification, if
specified otherwise. Use of flowing water or ponding of water shall not be
done for curing. Steam curing shall not be permitted.
Step-13 Test the Surface of 7-day cured concrete overlay for soundness by tapping
or sounding with hard blunt surface.
9.5.7.3 Inspection & Quality control:
The mortar application work shall be continuously inspected by a qualified supervisor who
shall check materials, application of mortar, curing stoppage of work during low temperatures
(minimum working temperature being 80C in most of the polymer modified mortar or as per
manufacturer direction) and high winds etc. Each completed work of mortar shall be
systematically sounded with a hammer to check for drummy areas after hardening.
In suspect areas or whenever directed by Engineer-in-Charge, the contractor shall drill the
cores from the finished work and in to the host concrete after 28 days of mortar application.
The cores shall be examined for evidence of poor workmanship by the Engineer-in-Charge,
and if he is satisfied that either the bonding work or the subsequent layer of mortar are not of
the required workmanship, the contractor at the instruction of Engineer-in-Charge shall

dismantle such areas of work as required by the Engineer-in-Charge and re-do the same
after re-preparing the surface by chipping off mortar work and abrading the bonding slurry
interface.
Pre-measurement of dimensions of plaster patches shall be measured correct to a centimeter
and area worked out in square metres correct to second place of decimal. The pre-
measurement of the average thickness shall be done by taking an average of five thickness
readings recorded with one reading each at corner and at the point of intersection of wires
stretched diagonally from corner points of the rectangular area chipped.
9.5.7.5 Rates
described above. The payment shall be made on the actual consumption of cement on
kilograms basis.
in the work.
9.5.8 EPOXY MORTAR ((Schedule Item No. 8.5.8):

PURPOSE: To carry out structural repairs to prepared patches of spalled c
oncrete with an epoxy repair mortar comprised of resin, hardener and specified silica
sand.
9.5.8.1 Materials and T&P: 9
Epoxy comprising of resin and hardener in proportions as specified by manufacturer
and shall conform to ASTM C-882, Silica sand falling in Zone-II as per IS:383,
mechanical mortar mixer, spatulas, trowels, etc.
9.5.8.2 Procedure:
Step-2 Full quantity of specified resin, hardener and silica sand shall be received
at site in factory sealed containers with labels legible and intact provided that
the shelf life so permits. Otherwise substantial quantity as could be consumed
within the storage period shall be received as per quantity approved by
Engineer-in-Charge. Full quantity shall be worked out as theoretically required
for consumption in the whole work.
Step-3 Testing of Material: The requisite number of test specimens of mortar shall
be cast from each batch of manufactured or supplied materials received
(whichever is less) for these to be tested for conformance to the specified
requirements contained in Table 5.8 before use on the work in general. Epoxy
Mortar of Resin: Silica sand proportion as 1:7 shall have the following
properties

Specific gravity 1.87+ 0.05

Minimum gel time 30 minutes
0
Bond strength after 7 days curing at 25 C 75-100 Kg/sqcm
0
Compressive strength at 7 days curing at 25 C 800-1200 kg/sqcm
0
Split Tensile strength after 7 days curing at 25 C100 -130 kg./sqcm
Flexural Strength after 7 days curing at 25 0C 295 Kg/sqcm
Step-4 Identify and mark the area for epoxy mortar repair.
Step-5 Surface Preparation: The appropriate propping/supporting, surface
preparation and crack sealing as per site requirements shall be completed,
which may sequentially cover one or more of the following items of work:
(Refer Para 9.1.1)
b) Removal of existing surface plaster/treatment shall be done according to
Para 9.2.1 or 9.2.3 as the case may be.
Para 9.2.2.
9
or welded. (Refer Para No 5.5).
the new reinforcement shall be removed mechanically or chemically, as
per Para no 8.2.7 and Para 9.2.7
j) Cleaning of lightly sticking materials and foreign matter from the exposed
according to Para 9.2.10
Step-6 Inspection of concrete surface prior to adhesive application shall be
thoroughly inspected and got approved by the Engineer-in-Charge. Surfaces
shall be ensured to be free from any deleterious materials such as oil, dust,
dirt etc. using oil free air blast.
Step-7 Alignment & thickness Control- Ground wires shall be fixed at reference
points to measure and control the thickness of repair mortar. Shear keys fixed
earlier could also function as depth gauges. Adequate ground wires shall be
installed to establish thickness and surface planes before application of repair
mortar. Ground wires shall be tight and true to line and placed in such a

manner that they may be further tightened.

Step-8 Apply Passivating & bonding coat over the cleaned existing and new
reinforcement according to Para 9.4.2.
Step-9 Apply epoxy bond coat on the cleaned concrete substrate according to Para
9.4.2. Work of application of primer coat shall not be allowed to be performed
beyond 400C atmospheric temperature and/or pot life of epoxy.
Step-10 Mix and Prepare Epoxy Mortar to have a uniform consistency and texture
in a mechanical mixer by adding resin, hardener and silica sand as weigh
batched ingredients of the mix.
Use of pre-packed ready to use components supplied by manufacturers in
containers may be allowed subject to approval of Engineer-in-Charge. In case
where pre-packed ready to use materials are to be used, the contractor shall
submit the manufacturer’s certificate verifying conformance to material
specification as specified, manufacturer’s mixing and application procedure
for approval by Engineer-in-charge.
Plastering with epoxy mortar immediately after applying the epoxy bonding
coat (Refer 9.4.2) to the prepared surfaces shall be done by trowel, roller or
spray equipment, at a thickness not less than, nor more than that recommended
by manufacturer,
The mortar shall be worked into place and consolidated so that all contact
surfaces are wet by the mortar and the surfaces shall be finished by wooden
floats or steel trowels.
The guidelines on mortar mix proportioning & application, available in 9
Table 5.8, Para 5.3.3.2-E and 5.3.3.3 are generally applicable
All concrete surfaces shall be well protected beyond limits of surface receiving
primer coat or mortar, against spillage.
. Step-11 Air cure the epoxy mortar surface for 24 hrs at ambient temperature or as
per manufacturer’s specification, if specified otherwise.
Step-12 Test the Surface after 24 hrs days cured epoxy mortar for soundness by
tapping or sounding with hard blunt surface.
9.5.8.3 Inspection & Quality control:
The mortar application work shall be continuously inspected by a qualified supervisor
who shall check materials, application of mortar, curing, stoppage of work during low
temperatures and high winds etc. Each completed work of mortar shall be systematically
sounded with a hammer to check for drummy areas after hardening.
In suspect areas or whenever directed by Engineer-in-Charge, the contractor shall drill
the cores from the finished work and in to the host concrete after 24 hrs of mortar
application. The cores shall be examined for evidence of poor workmanship by the
Engineer-in-Charge, and if he is satisfied that either the bonding work or the subsequent
layer of mortar are not of the required workmanship, the contractor at the instruction of
Engineer-in-Charge shall dismantle such areas of work as required by the Engineer-in-

Charge and re-do the same after re-preparing the surface by chipping off mortar work and
abrading the epoxy interface.
Pre-measurement of dimensions of plaster patches shall be measured correct to a centimeter
and area worked out in square metres correct to second place of decimal. The pre-
measurement of the average thickness shall be done by taking an average of five thickness
readings recorded with one reading each at corner and at the point of intersection of wires
stretched diagonally from corner points of the rectangular area chipped.
10.5.8.5 Rates
described above. The payment shall be made on the actual consumption of resin plus
hardener on kilograms basis.
9.5.9 DRY PACK AND EPOXY BONDED DRY PACK (Schedule Item No. 8.5.9):
PURPOSE: To carry out structural repairs to prepared patches of spalled concrete
with an epoxy repair mortar comprised of resin, hardener and specified silica sand.
9.5.9.1 General: The work shall be carried out as per description of the item of work given in
Para 8.5.9, general guidelines & description given Para 6.5.2 and directions of the
Engineer-in-Charge
Pre-measurement of dimensions of patches shall be measured correct to a centimetre
9
and volume worked out in Cubic metres correct to second place of decimal. The pre-
measurement of the average thickness shall be done by taking an average of fibre
thickness readings recorded with one reading each at corner and at the point of
intersection of wires stretched diagonally from corner points of the rectangular area
clipped.
9.5.9.3 Rates
described above.
9.5.10 PREPLACED AGGREGATE CONCRETE (Schedule Item No 8.5.10):
PURPOSE: To carry out structural strengthening of concrete.
9.5.10.1 General: The work shall be carried out as per Para 6.5.3 in general and as per specification
and directions of the Engineer-in-Charge
Pre-measurement of dimensions of surface shall be measured correct to a cm. and
volume worked out in square metres per layer correct to second place of decimal.
9.5.10.3 Rates
The rates shall be cover cost of all materials, labour and T&P including grout pump
etc. involved in all the operations describd above. Shuttering and priming/bonding
coat, if applied, shall be paid separately as per the relevent item.
9.5.11 STRENGTHENING WITH HYBRID ORTHOGONAL WOVEN FABRIC

SYSTEM SOAKED IN EPOXY (Schedule Item No. No 8.5.11):
PURPOSE: To increase the load carrying capacity (shear, flexural, compressive) and
ductility of reinforced concrete members through a non-intrusive structural
strengthening technique comprised of the Composite Fiber System, without causing
any destruction or distress to the existing concrete.
9.5.11.1 General: The work shall be carried out as per Para 6.5.18 in general and as per
specification and directions of the Engineer-in-Charge
9.5.12 STRENGTHENING WITH UNIDIRECTIONAL HIGH STRENGTH FIBRES
OVER EPOXY COATED SURFACE (Schedule Item No. No 8.5.12)
PURPOSE: To increase the load carrying capacity (shear, flexural, compressive) and
ductility of reinforced concrete members through a non-intrusive structural
strengthening technique comprising of unidirectional E-glass fiber and 0.4 mm effective
thickness, complete
9.5.12.1 General: The work shall be carried out as per Para 6.5.18 in general and as per
specification and directions of the Engineer-in-Charge.
9.6 CURING
9.6.1 CURING OF SHOTCRETED, PLASTERED AND/OR RCC SURFACES ETC.
(Schedule Item No 8.6.1):
PURPOSE: To ensure satisfactory hydration of cement by retaining or replenishing
the mixing water lost due to natural drying and evaporation process for a specified
period through exposed cementitious surfaces of the freshly placed cement mortar/
concrete. 9
9.6.1.0 General:
Importance of wet curing to all items of work involving use of cement need not be
over emphasised. It is important to note that the measurement and payment of all relevant
items involving use of cement such as shotcrete, plaster, RCC etc. is subject to the
precondition of successful execution of the item of curing.
Any surface experiencing discontinuity of dampness of surface with any patch having
dried out during the specified period of curing, it shall be prominently marked with
lime or other suitable prominent colour. Measurement and payment of such portion
shall neither be made under the item of curing nor under the relevant items of shotcrete,
plaster or RCC etc but rejected & redone.
9.6.1.1 Materials and T&P
Curing compound, brush or hand operated spraying gun and all other related accessories
for application on Concrete/Plastered Surface.
9.6.1.2 Procedure:

Step-2 Full quantity of specified manufactured material shall be received at site in

factory sealed containers with labels legible and intact provided that the shelf life so
permits. Otherwise substantial quantity as could be consumed within the shelf life
shall be received as per quantity approved by Engineer-in-Charge. Full quantity
shall be worked out theoretically for consumption in the whole work.
Step-3 (A) Moist Curing:
Cover all exposed surface of concrete, when the concrete begins to harden
i.e. two to three hours after compaction with moist gunny bags or any other
material approved by the Engineer-in-Charge.
Keep the exposed surfaces continuously damp after its final setting (i.e.
after a maximum of 8 hours of concreting) by ponding with a sheet of water or
by covering with a layer of sacks, canvass, hessian or similar water absorbent
materials constantly kept wet by water sprinkling for at least 7 days, where
ordinary portland cement is used and 10 days, where portland pozzolana
cement is used from the date of placing of concrete. For concrete work with
other types of cement, curing period shall be as per manufacturer’s
recommendations or as directed by the Engineer-in-Charge.
(B) Using Curing compound:
Testing of Materials: It must be ensured that curing compound should neither
affect the strength nor the surface of concrete. It shall not leave any undesirable
stains on surface to affect the bond of plaster or other finishes to be applied
later. It should be soluble in water, so that it can be removed by splashing or
washing with water without scrubbing the surface.
9
Test for Efficacy: The testing of curing compounds shall be done from each
lot of curing compound received at site by casting two sets of 15 cm cubes
with each set having 6 cubes. One set shall be moist cured by covering with
damp gunny bags and subsequently by immersing under water and the other
set by applying curing compound on top after 2 to 3 hours of casting and
subsequently on de-moulding apply on the remaining faces all around. The
cubes shall be kept in an environment similar to which the actual structure is
exposed for a period of 7 days after its casting. Three concrete cubes each
from both sets shall be tested after 7 days for their crushing strength as per test
procedure specified in clause 5.4.9.1 of CPWD specification 1996 Vol-II
under identical condition. The average crushing strength of cubes cured with
curing compound shall be not less than 95% of the crushing strength of cubes
cured under damp or immersion curing.
Test for Staining: The set of three sample cubes applied with curing compound,
remaining after 7-day cube crushing strength test, shall be washed with water
with soft brush scrubbing with nylon bristles and allowed to dry for a period of
seven days in an atmosphere with relative humidity not exceeding 40% at
ambient temperature. The other set of three cubes cured for seven days
under damp or immersion conditions shall also be kept for another seven days
under identical humidity and temperature conditions. The surface of the two

sets of such cubes shall be compared by closely observing for any visible stain
and texture that may detrimentally affect its bond with subsequently applied
plain plaster or aesthetic appearance. Such observations shall be recorded in
three categories as no effect, slight effect and moderate effect. The curing
compound shall be considered as acceptable in the ‘no effect’ category and
unacceptable in the ‘moderate’ category. The decision of Engineer-in-Charge,
which shall be final and binding, based on the likely use of finished surface of
concrete/plaster shall determine the acceptability of the ‘slight effect’ category.
Concrete curing compounds, after testing satisfactorily for efficacy, may be
used in lieu of moist curing with the permission of the Engineer-in-Charge.
Such compounds shall be applied to all exposed surfaces of the concrete by
spraying or brushing within two to three hours of casting and well within an
hour of removal of formwork.
Dimensions of exposed surface of concrete wet cured shall be measured correct to a centimeter
and areas worked out in square metres correct to second place of decimal.
9.6.1.4 Rate:
described above.
9
in the work.
9.7 CHHAJJA/SUN SHADES

9.7.1. SPECIFIED SAND STONE CHHAJJA (Schedule Item No. 8.7.1):
PURPOSE: To protect the windows/ doors, etc located on the exterior of the building
from heat and water due to sun or rain etc.
9.7.1.1 Materials and T&P
Specified angle iron, sand stone, zinc rich and tar-epoxy resins and hardeners, cement
concrete, all applicable T & P complete with necessary accessories.
9.7.1.1 Procedure:
Angle iron frame for chhajja shall be fabricated correct to required size at ground &
fixed in position in the wall as per the standard drawing.
Steel work in frame shall conform to the provisions of Para 10.4 of CPWD specifications
1996 Vol.-III. However, steel frame work shall be given priming coat Zinc rich epoxy
coating followed with two coats of tar-epoxy paint.
The specified sand stone shall conform in general to the provisions of Para 7.8 of
CPWD specifications 1996 Vol-II. Size of stone shall, however, be as specified.
Frame shall be tightly embedded into the masonry with cement concrete 1:3:6

(1 cement: 3 coarse sand : 6 graded stone aggregate 20 mm) blocks 150 mm x 115mm x 230
mm.
Junction of wall & the chajja shall be finished with cement concrete gola for proper drainage
of rain water. Gola shall conform to the provisions in Para 12.15 of CPWD specification
1996-Vol-IV.
The exposed surfaces of the angle iron frame and chajja shall be finished with two or more
coats of tar epoxy paint.
The projected length & breadth of the chajja shall be measured correct to a
centimeter & area shall be worked out in square metres correct to second place of
decimal.
9.7.1.4 Rates:
Rate for the item includes the cost of all labour, materials & T&P involved in operations
stated above except for the scaffolding, which shall be payable separately.
9.7.2 AVERAGE 25 MM THICK FERRO-CEMENT CHAJJA/WEATHER SHADE
ETC. (Schedule Item No. 8.7.2):
PURPOSE: To protect the windows/ doors, etc located on the exterior of the
building from heat and water due to Sun or rain etc with a suitably formed chhajja
projection.
9.7.2.1 General: In most of the cases the ferrocement chhajjas are factory made and they are
fixed at site using partially cast in situ ferrocement components using existing embedded
steel reinforcement or with suitable structural steel framework. However precautions
9 are to be taken against seepage of water by providing Gola above the Chhajja at junction
with wall as per CPWD specifications. Work shall be carried as per the specifications
and directions of Engineer-in-Charge.
9.8 WATER PROOFING & PROTECTIVE COATINGS

9.8.1 POLYMER MODIFIED CEMENT SLURRY WATERPROOFING AND
ANTICARBONATION COATING (Schedule Item No. 8.8.1):
PURPOSE: To protect the RCC surface against ingress of aggressive environmental
deteriorating agents like carbon dioxide, water vapours, etc to substantially reduce
the rate of carbonation of concrete and ingress of water.
9.8.1.1 General: The Para 9.4.1 generally applies for this item. The work shall accordingly be
carried out as per nomenclature of Item and directions of Engineer-in-Charge.
9.8.2 UV RESISTANT ACRYLIC POLYMER BASED WATER PROOF COATINGS:
PURPOSE: To protect the exposed surface of RCC roof against ingress of, water
vapours, etc to provide a UV resistant, flexible, elastic, water proofing membrane.
9.8.2.1 General: It is a thin water proofing membrane applied with brush comprised of UV
resistant Acrylic Emulsion to be applied over a primer coat. The work shall be carried
out as per manufacturer’s specifications and as per directions of Engineer-in-Charge.
9.8.3 FERRO-CEMENT WATER PROOFING TREATMENT (Schedule Item

No. 8.8.3):

PURPOSE: To provide protection against ingress of water, etc through RCC surface
with a structural membrane of cement matrix reinforced with layers of small diameter
steel wire mesh and structurally connected to the exposed surface of RCC.
9.8.3.1 General
The ferrocement being a structural membrane is gainfully utilised as a stiff membrane
to resist ingress of water from exposed RCC terraces. It is also used as inside tanking
membrane for RCC raft and walls to arrest leakage of water in existing basements.
Materials used for the work shall be strictly according to specification. Utmost care
shall be taken to ensure good workmanship. On extremely hot days, the work shall be
carried out only in the late afternoon or early morning.
Cement shall be Ordinary Portland Cement of 33 grade conforming to IS:269 or 43
grade conforming to IS:1489 as may be specified.
Sand shall conform to grading Zone-II as per IS:383
Admixtures shall be used to improve workability, reduce water demand and to retard
the mortar setting time.
Reinforcement: 22 gauge orthogonal woven G.I. wire mesh, 4mm dia G I wires
In most cases, hand mixing is satisfactory. If mixing is to be done for large structures
or factory made components, horizontal paddle bladed mixer shall be required.
9.8.3.3 Procedure:
Step-1 Remove & scrap all treatment including non-cementitious tarfelt, bitumen,
etc from the surface to be treated (Refer Para 9.2.3 payable separately). 9
Step-2 Repair the exposed roofing and its junctions with parapets, including
sealing of cracks & honey combed area (Refer Para 9.3.2 payable separately).
Step-3 Regrade the roofing, if required and re-lay the Khurrahs (Refer Appendix
6.3). Provide adequate slope towards the rainwater spouts.
Step-4 Cut a chase of 75 mm X 75 mm in parapet at the junction with roofing for
taking the Ferrocement water proofing treatment inside the chase.
Step-5 Fix hot dip galvanised wire nails 50 mm to 60 mm long & 4 mm dia to
roofing along marked grid points at a spacing of 450 mm as shown in the Fig
9.8.3.1. The fixing shall be done by drilling 25 mm deep holes of appropriate
diameter with high speed drill, blowing away the dust from drilled holes with
a hand operated blow out pump or air compressor, injecting epoxy from the
cartridges with epoxy dispenser/cartridge holder through PVC mixing nozzle
and inserting the nails in vertical position with remaining length as projecting
above the roof surface. The epoxy shall be allowed to air cure for 24 hours.
Step-6 Lay over the roofing, 4 mm dia galvanised steel wires laid parallel to each
other spaced at 450mm c/c along the layout of GI wire nails. Wires shall be
taken alternately along the either side of GI nails in order to fix their position.
Step-7 Apply a coat of bonding slurry (Refer Para 9.4.1 and payable separately)

after saturating the surface with water but without excess water. The area to be
covered with bond coat shall be in parts and just enough for all the operations of
ferrocement to be finished by close of the day.
Step-8 Lay the first layer of specified woven wire mesh and tightly stretch over roof
surface from one end so that the nails are inserted in the meshes to keep it in tightly
stretched condition. The woven mesh shall be orthogonally woven with 22 gauge
hot dip galvanised wires spaced at 12 mm c/c. The mesh shall be seated over 4 mm
dia GI wires laid in step-6. In the laid woven wire mesh, the over laps of 100 mm
shall be given along the sides and ends.
Step-9 Weigh batch Cement and specified sand (while operations of Steps-6,7, 8 & 9
are in progress), in proportion 1: 2 (1-cement: 2-sand) and dry mixed before adding
a measured quantity of admixture and water. The water to cement ratio shall be
maintained not more than 0.4. Mixing, if done in a mechanical mixer, shall be done
for about three minutes to form a plastic mortar of uniform colour and texture.
Step-10 Lay another set of 4 mm dia wires at right angle to lower layer of GI wires at
450 mm c/c in same manner as at Step 4. This shall be done to provide a 4 mm
clear gap between the first woven wire mesh & the next one yet to be laid. For 25
mm thickness of ferrocement the top 5 mm thickness shall only be made up by
PARAPET WALL
MM G.I.WIRE PLACED @ 450 MM C/C IN

EACH DIRECTION WITH 22 GAUGE G.I.
WOVEN WIRE MESH 12 MM X12 MM
STRETCHED BETWEEN TWO LAYER
9
PARAPET WALL
GLAZED TERRACING
3MM DIA 80 MM LONG G.I. WIRE NAILS
A A
PLAN SHOWING FIXING ARRANGEMENT OF

G.I. WOOVEN WIRE MESH
INSERT & ACCOMODATE STRETCHED
40X40 MM CHASE CUTTING TO
COPING
CEMENT PLASTER TO BE DONE

AFTER THE FERROCEMENT TREATMENT
ON TERRACE
WIRE MESH
22 GAUGE G.I. WIRE MESH 12X12MM

1:2 CEMENT MORTER FILLED UNDER FORCE
AND COMPACTED WITH PLATE VIBRATOR
4MM DIA WIRE PLACED @450 MMC/C
EXISTING TERRACING
G.I.NAIL
EXISTING GOLA TO LIME CONCRETE LAID TO SLOPE
BE RETAINED
SECTION A-A

increasing the cover thickness in only mortar.

Step-11 Spread second layer of woven square mesh of 22 gauge hot dipped galvanised
wire with wires spaced at 12 mm c/c as per procedure explained in Step-8.
Step-12 Provide Levelling/Thickness gauges by bending the projected nails to U shape,
which will also ensure that the mesh is fixed in position. Mortar gauges of specified
thickness shall also be provided in a square grid at an interval of about one metre c/
c.
Step-13 Apply the mortar using trowels by force, rubbing and pressing down with trowels
so as to ensure penetration in the wire meshes. There shall be a minimum mortar
cover of 4 mm below the mesh, between the meshes and over it. The mortar shall
be compacted thoroughly using a vibrating trowel or an orbital vibrator and finished
smooth to specified thickness. The surface shall be finished semi smooth and to the
required slope.
Step-14 Provide Cement Concrete Gola in the Chase provided earlier at Step-4 as per
CPWD Specifications 1996.
Step-15 Curing: Refer Para 9.6.1 But the period of wet curing shall be 14 days. For the
next two weeks, it shall be gradually allowed to dry. Care shall be taken to ensure
that ferrocement does not dry up in the first two weeks.
Dimensions of the area covered with ferrocement treatment shall be measured correct to a
centimeter and area worked out in square metres correct to second place of decimal.
9.8.3.5 Rates:
9
described above except step 15.
9.8.4 CEMENT PLASTER WITH POLYMERIC WATER PROOFING COMPOUND:
PURPOSE: To provide a barrier against ingress of water/dampness through RCC/
Brickwork etc with plaster in cement matrix made impervious or hydrophobic by
addition of polymeric pore sealants.
9.8.4.1 Materials, Procedure, Measurements and Rates
The polymeric water proofing compound shall conform to the requirements given in
Chapter-5. Others shall generally conform to the description of the item given in Para
8.8.5 of Chapter-8 and CPWD Specifications 96 Vol-IV.
9.8.5 INJECTION TYPE POST CONSTRUCTION WATER PROOFING TO
CONCRETE STRUCTURES (Schedule Item o. 8.8.5)
PURPOSE: To seal pores of existing concrete structures against ingress of water and
moisture by pressure injection of pore sealing compounds through nipples fixed for the
purpose.
9.8.5.1 Materials, Procedure, Measurements and Rates
These shall generally conform to the description of the item given in Para 8.8.6 of
Chapter-8 and Para 9.3.2.

9.9 MASONRY REPAIR

9.9.1 General:
Masonry repair is done by various types of repair material. Of those covered in sub paras of
para 8.9, cement mortar and cement concrete the relevant sections of CPWD Specifications
1996 Vol-I & II may be referred. Whereas for gunite/ shotcrete, polymer modified cement
mortar, bond coat relevant respective Paras at 9.5.2, 9.5.4, 9.4.1 are required to be referred.
The work is required to be executed, measured and paid as per nomenclature of items of
work. The individual specifications are not being given for the sake of brevity. The item of
curing covered in Para 9.6.1 is required to be executed, measured before measuring and
making payment of any of the items of masonry repair.
10.0 TESTING OF MATERIALS AND PRE / POST REPAIR STRUCTURE
The pre and post repair testing of a structure for evaluation purposes shall generally be
carried out in accordance with sub paras of Para 8.10 and relevant standards mentioned
therein and relevant tests indicated in Chapter-3 of this Handbook.
✯ ✯ ✯

Appendix 9.1
TEST METHODS FOR EXECUTION OF THE WORKS
A9.1.1 General
(1) Table A9.1-1 given hereinafter reviews the test methods to be used during execution of
the works in accordance with these specifications.
(2) Column 1 shows the property to be tested for which requirements are specified Tables
9.1 to 9.7.
(3) Column 2 indicates whether the test can be performed using resources available on the
construction site or whether a testing agency must be called in. The construction site
and the testing agency cooperate in cases where specimens are taken on the site and
tested at the testing agency. A specialist laboratory must be employed in cases where
neither the construction site nor the testing agency possesses adequate facilities.
(4) Column 3 indicates the section of this Handbook or BIS code of practices in which the
description of the method is given.
Table A9.1-1: Test methods for execution of the works
Property To be tested by Description of test method,

see section/BIS Code of
Practice.
Concrete substrate
1. Apparent nature Construction site A9.2.1.
2. Concrete compressive strength Construction site and testing agency 3.2.1 9
3. Surface tensile strength Construction site and testing agency 3.2.1.4
4. Carbonation depth Construction site 3.2.2.1
5. Concrete cover, position and Construction site
diameter of reinforcement A9.2.2
6. Chloride content Construction site and testing agency 3.2.2.2
Moisture content of the concrete

7. - by heating surface Construction site A9.2.3
8. - with CM apparatus Construction site A9.2.4
9. - Gravimetrically Specialist Laboratory –
10. Water penetration Testing agency A9.2.5
11. Wettability Construction site A9.2.6.
Roughness
12. - sand area method Construction site A9.2.7
13. -With inductivement
-displacement sensor Specialist Laboratory –
Crack State
14. - Crack-width rule, crack magnifier, Construction site A9.2.8
plaster mark
15. Crack propagation- Glass Strip Construction site –
marker

Property To be tested by Description of test method,

see section/BIS Code of
Practice.
16 Crack- indicating caliper and induc- Specialist laboratory –

tive displacement sensor
Processing Conditions
17. Air temperature and atmospheric Construction site A9.2.9
humidity, component temperature,
dew-point temperature
2. Repair concretes or mortars

2.1 Aggregate
18. Granulometric composition Construction site IS:383
19. Inherent moisture, surface moisture, Construction site IS:383
core moisture
2.2 Mortar
19. Consistency, apparent specific Construction site –
density, air content
20. Flexural tensile and compressive Construction site and testing agency. IS:516
strength and apparent specific
density
2.3 Concrete (IS:456)

21. Consistency, apparent specific Construction site –
density, air content
9 22. Concrete composition Testing agency –
23. Water content (dehydration test) Testing agency –
24. Compressive strength Construction site Testing agency IS:516
25. Impermeability to water Construction site and testing agency –
2.4 Shotcrete
26 Consistency Construction site 9.5.3
27 Apparent specific density Construction site –
28 Water/cement ratio Testing agency –
29 Concrete composition Testing agency –
30 Compressive strength Construction site and testing agency 9.5.3
3. Surface protection systems

Coating thickness
31 - Wedge-cut method Testing agency –
32. - Drilled core Testing agency A9.4.1
33. Adhesive strength Construction site and testing agency A9.4.2
34. Voids content (SP 9 and 10) Testing agency A9.4.3
35. Leakage resistance Testing agency –
36. Grid test with tape test Specialist laboratory A9.4.4
4. Treatment of cracks
37. Degree of filling Testing agency A9.5.1.
38. Cement paste Testing agency A9.5.2

A9.2 Concrete Substrate

A9.2.1 Visual Checks
(1) Visual checking of the surface is done for the presence of:
- Hardened cement slurry, loose particles such as dust, etc
- Original Construction Defects e.g. gravel pockets, ridges, honey-comb, segregated
concrete surface, powdering & sanding, etc
- Efflorescence, leaching and weathering of the fine mortar layer
- Concrete spalling (e.g. above reinforcement),
- Moisture penetration and its entry points,
- Growths (e.g. mosses, higher plant organisms).
- Contamination by foreign matter, e.g. oil, grease, paraffin, rubber particles, parting
agents, after-treatment agents and residues of old coatings.
- Cracks (crack width, crack type and appearance).
(2) Near surface cavities can be detected by hollow sounds on percussion. Powdering,
sanding and dust coatings can be quantified by applying an adhesive strip of defined size
to the surface and pulling it off.
A9.2.2. Determination of Concrete Cover, Position and Diameter of the Reinforcement
(0) The concrete cover, position and diameter of the reinforcement are to be measured and
recorded non – destructively using an electronic tester called rebar locator or profometer.
The directions for use, as per manufacturer’s instruction manual, govern the way in
which the test instruments are used. The accuracy of the instruments is to be checked
periodically for example on already exposed reinforcement or by exposing a localized
area of the reinforcement.
(1) Destructive measurement of the concrete cover should be used only in exceptional
9
cases.
A9.2.3 Testing the Moisture Content of the Concrete Surface Zone by Heating the Surface.
Concrete surface is termed as “dry”, “moist” and “wet” as follows:
- “Dry” – A freshly created fracture of concrete surface with depth of about 20 mm must
not become visibly lighter in colour as a result of drying out than before. In case concrete
contains equilibrium moisture for the environment, it is deemed to be dry.
- “Moist”- When the surface of concrete has a matt appearance without any shiny water
film and the concrete surface absorbs fresh drops of water applied to its surface, leaving
the surface matt again in a short time (i.e. the surface pore structure is not saturated), the
surface is termed as moist.
- “Wet”- When the pore structure of concrete surface is water saturated, there may be a
surface shine on the concrete but no excess surface water film
The surface of the concrete or of a roughly 2 cm deep freshly reptured surface may be
heated, for example with a hot air dryer (i.e. hair dryer), to indicate the presence of concrete
moisture exceeding the definition “dry”. The moist concretes appear significantly lighter after
heating.
A9.2.4 Testing the Moisture Content of the Concrete Surface Zone with a CM Device.
a) Purpose and Use:
The method may be used to determine the moisture content of the concrete substrate.

b) Brief Description:
(1) Pieces of concrete removed from the concrete surface zone are crushed rapidly
with a pestle in a porcelain bowl and weighed. The sample (Table A9.2) is
placed in a pressure bottle together with a quantity of calcium carbide (5 g
glass ampoule). The bottle is shaken vigorously several times, so that previously
added steel shot breaks the glass ampoule. The mixing of the sample and the
calcium carbide allows a chemical reaction between the water in the sample
and the calcium carbide, releasing acetylene gas. The resulting gas pressure is
proportional to the moisture content of the sample, and is read off via a pressure
gauge.
(2) The moisture content associated with a particular pressure reading is given in
Tables A9.3. to A9.5
Table A9.2: Required weight
Estimated moisture content Required weight

1 2
Mortar Concrete
1. 1.05% to 2.5 % 50 g 50 g
2. 3.0 % to 5.0 % 20 g 20 g
3. 5.5% to 7.0 % 20 g 10 g
4. More than 7 % 10 g 10 g
9
Table A9.3: Pressure in bar for maximum grain size up to 4 mm
Pressure for 50 g weight Moisture content [%]

1 2 3 4
after 15 min after 20 min after 25 min
1. — — 0.330 1.0
2. — — 0.495 1.5
3. — — 0.655 2.0
4. — — 0.820 2.5
Pressure for 20 g weight

ater 15 min after 20 min after 25 min
5 — 0.380 0.390 3.0
6 — 0.500 0.510 3.5
7 — 0.615 0.625 4.0
8 — 0.735 0.745 4.5
9 — 0.855 0.865 5.0
10 — 0.970 0.980 5.5
11 — 1.090 1.100 6.0
12 — 1.325 1.335 7.0


1 2 3 4

1 — — 0.335 1.0
2 — — 0.510 1.5
3 — — 0.685 2.0
4 — — 0.860 2.5

5 — 0.405 0.415 3.0
6 — 0.550 0.560 3.5
7 — 0.690 0.700 4.0
8 — 0.835 0.845 4.5
9 — 0.975 0.985 5.0
10 — 1.120 1.130 5.5

11 0.475 0.480 0.485 5.5
12 0.530 0.535 6.0

9

1 2 3 4

1 — — 0.340 1.0
2 — — 0.605 1.5
3 — — 0.870 2.0
4 — — 1.130 2.5

5 — 0.580 0.585 3.0
6 — 0.750 0.755 3.5
7 — 0.915 0.925 4.0
8 — 0.085 1.095 4.5
9 — 1.255 1.270 5.0
10 0.715 0.725 0.730 5.5
11 0.845 0.850 0.855 6.0

c) Test apparatus and other materials required

- CM pressure bottle with pressure gauge.
- Electronic scales (accuracy 0.1 g)
- Analytical sieve with 2 mm mesh size
- Porcelain Bowl (with collar ring to prevent portions of the sample escaping) with
a pestle
- Steel shot, calcium carbide ampoules, stopwatch
- Hammer and chisel
- Other accessories.
d) Procedure
Step-1 Use the hammer and chisel to remove fragments of the concrete under test to
a depth of 2 cm (10 to 50 g).
Step-2 Use the hammer to crush the fragments in the porcelain mortar (do not crush
individual aggregate grains)
Step-3 Pass the sample through an analytical sieve (mesh size 2 mm).
Step-4 Weigh out the required sample (see Table A9.2) on the electronic scales.
Step-5 Place first the steel shot and then the weighed sample in the bottle, without
losing any of the sample.
Step-6 Tilt the bottle slightly and carefully slide in an ampoule of calcium carbide.
Step-7 Place the cap with pressure gauge on the bottle and secure it with the tightening
levers.
9 The above operations must be carried out quickly, to avoid loss of moisture.
Step-8 Break the glass ampoule by shaking the bottle with a vigorous rotary motion.
Step-9 Repeat the shaking operation once every 5 minutes up to the final reading.
Step-10 Determine the moisture content ( in W.%) as a function of sample weight and
maximum grain size associated with the final pressure reading from Tables
A9.3. to A9.5
Step-11 On completion of the test, open the bottle carefully (Caution : the bottle is
under pressure) and allow the acetylene gas to escape (Caution : no naked
flames).
Step-12 Carefully pour away the contents (Caution : un-hydrated lime and glass
fragments) and clean the bottle with a clean bottle brush.
Step-13 Clean the steel shot with a dry cloth. Clean the bottom of the pressure gauge
(rubber washer).
e) Likely sources of error
1) A substantial difference in temperature between the pressure bottle and the
surroundings.
2) Bottle not gas-tight sealed (e.g. damaged washer, material residues under the
rubber washer).
3) Calcium carbide ampoule leaking before insertion (light brown stain).
A9.2.5 Testing Construction Materials or Components for Water Penetration Using a Water
Penetration Gauge
a) Purpose and Use
The water penetration test with a water penetration gauge indicates the behaviour of a
construction material or component in response to the effects of water, it measures the
volume of water penetrating per unit time in a construction material which is air-dry at
the beginning of the test.
b) Test Apparatus and other materials required
(1) The penetration gauge is supplied in two versions, for vertical and horizontal test
surfaces. It consists of a glass measuring tube with a calibrated ml scale, opening
at the bottom into a bell with a diameter of 30 mm.
(2) The water penetration gauge is sealed water tight to the test surface, using a plastic
sealant (e.g. Plastellin, butyl rubber). For tests over a lengthy period, it is advisable
to use an elastic curing sealant (e.g. silicon rubber).
c) Measuring Points
- The measuring points must be positioned in such a way that the test results are
representative for the concrete under test. The measuring points must therefore
be distributed throughout the test area or must be determined on statistical
principles. The measuring points must be marked and the markings recorded in
the test report.
- At least 6 measuring points must be used for each test area.
d) Procedure 9
Step-1: The sealant is placed in a collar round the edge of the bell. The bell is pressed on to
the measuring point to form a watertight seal with the component surface. The
sealant inside the bell should leave a circular area of the component with a diameter
of roughly 20 mm exposed.
Step-2: To carry out the test, tap water is poured into the tube up to the zero mark, so that
water in contact with concrete surface remains under a pressure of approximately
100 mm water column.
Step-3: The fall in the water level is measured at appropriate intervals. As soon as 1 ml to
2 ml of water have penetrated the concrete, the tube is refilled with water to the
zero mark, to maintain approximately constant water pressure. The times of
measurement, fall in the water level, temperature conditions and moisture state of
the concrete surface are to be recorded in the report.
e) Test Report
The following items are to be recorded in the test report:
Quantity of penetrating water per unit time
Temperature conditions
Moisture state of the test area.

A9.2.6 Testing the Wet-ability of Concrete Surfaces

a) Purpose and Use:
The method supplies indicative values for assessing the absorptive capacity of concrete
surfaces.
b) Brief Description:
The wettability of a concrete surface is tested by spraying it with water and assessing
the pearling effect (no pearling, slight pearling or strong pearling).
c) Procedure:
- A spray bottle is used to place a few drops of water on the test surface. The result
may be penetration of the surface zone, recognizable through the formation of
dark stains, or more or less pronounced droplet formation (pearling).
- The pearling effect is influenced by the nature of the surface – chiefly its porosity
and the degree of contamination – and, where relevant, by the type of surface
treatment and the materials employed. It does not usually constitute a sufficiently
reliable means of assessing the efficacy of impregnation measures.
A9.2.7 Determination of Surface Roughness Using the Sand Area Method.

a) Purpose and Use:
The method is used to determine the mean peak to valley height of a horizontal substrate
surface. The test is carried out after pretreatment of the substrate.
b) Brief Description
(1) A defined volume of sand (Volume V) is distributed in a circular configuration on
9 the test surface, in such a way that the dips are just filled.
(2) The mean peak to valley height Rt is defined as the height of an imaginary cylinder
with a diameter d and a sand volume V.
c) Equipment and ancillary materials
- Vessel with a known internal volume V, e.g. 50 cm3.
- Dry quartz sand, grain size 0.2 – 0.5 mm
- Hardwood disc (diameter 5 cm, thickness 1 cm) with a handle in the top center.
- Rule.
d) Measuring points
The measuring points must be positioned in such a way that the test results are representative
for the test concrete. The measuring points must therefore be distributed over the test area or
selected according to statistical principles. The measuring points must be marked and the
markings recorded in the report. At least 3 measuring points must be used for each test area.
e) Execution of the test
- Fill the vessel with quartz sand and pour the contents on to the dry, clean surface.
- Rub the sand into the dips in the surface without applying pressure and using a
spiral rotary motion until the dips are just filled.
- Measure the diameter of the circle.

The mean peak to valley height is obtained from the sand volume V (cm3) and the diameter
d (cm) of the roughly circular sand distribution using the formula:
40 V
Rt = —————————————— (mm)
pd2
f) Test report
The mean peak-to-valley height in mm must be given in the report.
A9.2.8 Establishing crack characteristics:

a) General
(1) Special care must be taken when establishing the characteristics of cracks, in
order to allow qualified assessment of the need for and type of crack – filling.
(2) On exposed structures, the most important crack characteristics (crack width and
changes in crack width) are subject to weather – related changes. When these
characteristics are established, at least the following additional data must therefore
be recorded:
- date, time
- whether conditions, i.e. air temperature, cloud cover / rain (including values on
preceding days)
- component temperature in the crack-influencing zone, both in the interior and
on the surface of the component.
(3) Whether the change in crack width during the course of the day is observed, the
relevant data must be recorded several times each day. Where changes in crack-
width are traffic related, characterization of the traffic may be necessary in order
to allow more effective analysis of the results. The selected measuring periods 9
should be such that adequate conclusions on short term and daily changes in crack
width at the planned filling time can be inferred from the results.
b) Measurement of crack width and changes in crack width
(1) Crack widths should be given to an accuracy of 0.1 mm. It will usually be sufficient
to compare the crack width visually with a calibrated line on a line-width rule
(draughtsman’s rule). Experience is needed to use a crack magnifier; it does not
invariably ensure greater accuracy and is not usually essential.
(2) Methods with differing sensitivity can be used to measure the changes in distance
associated with changes in crack width:
Crack magnifier.
Thin plaster markers are applied by brush to the concrete surface. When the
cracks in the concrete widen, cracks also appear in the plaster. Their width can
readily be determined with the crack magnifier. Repeated readings to an accuracy
of 0.01 mm can be used to follow slow changes in crack width, including long –
term alterations. If necessary, a number of plaster markers may be applied at
intervals to the same crack.
Laboratory methods:
These mechanically or electrically based methods can be used only by properly
trained and experienced personnel. They register even extremely short-term
changes to an accuracy of 0.001 mm.
(3) On superstructures of monolithic bridges and similar structures exposed to direct

weathering, there are daily changes in crack width, in some cases dependent on
insulation. The maximum changes are to be expected on cloudless days in the
summer months, but not on days with high cloud cover and high air temperatures.
At the maximum crack width, influences of traffic also usually lead to the extreme
values of short-term changes in crack width.
c) Drilled cores
Drilled cores can be used to determine type of crack, the state of the crack and crack
edges and any previous measures. Drilling cores invariably represents a disturbance,
and should therefore be restricted to exceptional cases. Appropriately experienced
personnel can often avoid the removal of drilled cores.
3.2.9. Testing the Processing Conditions
A9.2.9.1. Air Temperature
a) Apparatus and Instruments
(1) The following instruments may be used to measure the temperature of the air.:
- mercury thermometers
- bimetallic strip thermometers
- electrical digital thermometers
- thermographs.
(2) Automatic temperature recorders should be used in the open air and where there
are severe fluctuations in temperature.
(3) the accuracy of reading should be at least 1O C.
9
b) Performance of the measurements
(1) the measurements should be made in the immediate vicinity of the works..
(2) the temperature sensor should not be exposed to direct solar radiation.
(3) The intervals between measurements must be such that temperature change
> 2ºC are detected.
A9.2.9.2. Relative Atmospheric Humidity
a) Apparatus & Instruments
(1) The following instruments may be used to measure relative atmospheric humidity:
- hair hygrometers
- electrical digital hygrometers
- hygrographs.
(2) The accuracy of reading must be at least 1% relative atmospheric humidity (5%
relative atmospheric humidity in the case of hygrographs). The instruments must
be checked prior to commencement of the work, and adjusted as necessary. For
this purpose, the senor is to be wrapped in damp cloths, avoiding any direct
moistening. The instrument must then read 95-98% relative atmospheric humidity.
The instruments must not be exposed to direct solar radiation.

A9.2.9.3. Component Temperature

a) Apparatus & Instruments
The instruments specified in A9.2.9.1. a) may also be used to measure component
temperatures; the use of electrical digital thermometers is preferred.
(1) Measurements of surface temperature should preferably be made on components
whose temperature may be lower than that of the air, as a result of their position
and size, and taking into account the preceding weather conditions. Thermometers
with contact sensors must be used. The intervals between measurements must be
such that any impending drop in temperature below the dew-point can be detected
in good time.
(2) Measurements of temperature in the interior of components must be made in drilled
holes with a diameter of approximately 8 mm and a depth of at least 50 mm. The
holes must be sealed at the component surface with a heat insulating material.
A9.2.9.4 Dew-Point Temperature

(1) The dew-point temperatures corresponding to the measured air temperatures and relative
atmospheric humidities may be taken from standard tables.
(2) The dew-point temperature determined in this way must be compared with the component
temperature.
A9.3. Repair Concretes or Mortars

Testing the Inherent Moisture, Surface Moisture and Core Moisture of Aggregate.
(1) Inherent moisture is generally determined by the dehydration test. To determine the 9
surface moisture, it will then generally be sufficient to employ the recommended core
moisture values, which are measured during determination of inherent moisture normally
vary from 0.5 to 2.2 % depending upon the type of aggregate for 0 to 32 mm aggregate,.
(2) The dehydration test is usually made with the samples envisaged for the sieve test, as
the aggregates must in any case be dried for sieving.
(3) A quantity of roughly 3500 g is weighed out from an average sample and heated under
continuous agitation until the surfaces of the individual grains are dry and the grains no
longer adhere to one another. The sample is re-weighed after cooling. The inherent
moisture is calculated from the loss in weight by reference to the dried materials.
(4) Para A9.2.4 can be used to determine the surface moisture of aggregate with a maximum
grain size of upto 4 mm quickly, and, if used properly, with sufficient accuracy. The
larger device holding 200 gm of aggregate is to be preferred, owing to its greater accuracy.
(5) The surface moisture of aggregate of any maximum grain size can also be determined by
the flame method, using the AM device. The moist aggregate is weighed and an
inflammable liquid is poured over it and ignited. The resulting heat causes the water to
evaporate. The difference between the moist and dry weights indicates the water content;
the surface moisture is determined by reference to the dry weight.
(6) The Thaulow test provided a further means of determining surface moisture. The core
moisture of aggregate with a maximum grain size exceeding 4 mm is determined by
immersed storage and subsequent drying of the grain surface. Approximately 1000 g

of the relevant grain class is kept immersed in water for at least 24 hours. The aggregate
grains are then dried with a moist cloth and filter paper. The aggregate treated in this
way is poured on to a 2 mm sieve and turned while being heated from below by a
current of air, for example from a hairdryer or a fan heater, until the surface moisture has
apparently dried out. The sample is then weighed to an accuracy of 1 g (mg.k),
dehydrated and re-weighed (mg.0d). The difference between the two weights is the
core water quantity of the sample. The core moisture is then
hg,k = 100mgk -mg Od

_______________________ (M.%)
mg.0d
(7) If the sand is of the same mineral composition as the coarse grains examined, the same
core moisture may be assumed.
(8) The same test can be employed to estimate the influence of dry aggregate on the stiffening
of green concrete. In this case, however, immersed storage is for 30 minutes only.
A9.4 Surface Protection Systems
A9.4.1. Testing the Thickness of Coatings on a Drilled Core
(1) Small-diameter drilled cores (50 mm or less) are removed. Local changes in layer
thickness due to drilling must be taken into account, and where necessary counteracted
by appropriate measures. The layer thickness is determined on the surface area, using
a measuring magnifier or microscope.
(2) The measurement is not non – destructive, and must therefore be restricted to justified
cases, e.g. irregularities during performance of the works. Sections are required in
order to determine the exact thickness of thin layers and of sub-layers in multi-layer
systems. The work must be entrusted to a specialist laboratory.
9 A9.4.2. Testing Adhesive Strength
a) Terminology
The term adhesive strength denotes the tensile force, which must be applied perpendicular
to the coating plane over a defined test area in order to detach a coating from its
substrate. This definition means that specimens, which rupture in the substrate concrete
or within the coating rather than at the interface may not be taken into account when
calculating adhesive strength.
b) Test dies and test equipment
(1) Steel test dies (pulling plates) with a circular bonding face and a diameter of ds=50
mm + 2 mm are employed. The test die must be at last 25 mm in thickness; the
thickness remaining below central drillings or recesses must be not less than 15
mm.
(2) The tests may be carried out with portable or fixed tensile strength testing equipment.
The measured value must be indicated with a resolution of 2% of the force range
being measured. The equipment must possess a device for maintaining a constant
loading velocity.
(3) Simpler equipment may be used for internal supervision.
(4) The equipment must be designed in such a way that the tensile force can be applied
to the test surface free of shear forces and moments. It must be possible to adjust

the equipment above the test die in such a way that the axes of the test die and the
working piston are in a straight line.
c) Performance of the tests

(1) The test areas must be selected in such a way that the distances of the test surface
edges from one another or from the edge of the component are at least equal to
the diameter of the test area.
(2) The test area must be freed of loosely – adhering dirt before the test die is bonded
to it. The test surface must be bounded by a ring groove and must be sufficiently
dry for bonding.
(3) On hard coatings, the ring groove is drilled wet or dry with a diamond – charged
bore-crown. The bore-crown should drill through the coating and penetrate 5 to
10 mm into the concrete. The inside diameter of the ring groove and the outside
diameter of the test die must be matched with one another in such a way that the
die can be bonded flush to the exposed cylinder. A bore-crown in good cutting
condition with rounded cutting edges must be used, to avoid notching of the ring
groove root. The exposed cylinder may not be damaged in any way prior to the
test. Drilling dust or sludge must be removed thoroughly.
(4) On soft coatings, the test area must be parted through to the concrete after the test
die has been bonded on. The cut must be made flush with the circumference of
the test die. A sharp knife can be used for cutting.
(5) In general, rapid hardening cold-curing resin adhesives in paste form should be
used. The temperature range specified by the manufacturer is to be maintained 9
during the bonding process.
(6) The test die must be placed on the surface in such a way that excess adhesive is
pressed out of the joint and air entrapments are avoided. Any adhesive squeezed
out of the joint or penetrating into the ring groove must be removed.
(7) After bonding, the die face must be parallel with the test face; the bonding layer
must be as thin as possible.
(8) The tensile strength testing machine must be arranged and centred in such a way
that the taxes of the test die and the piston lie in a straight line.
(9) On hard coatings, the force should be increased continuously in such a way that
the tensile stress in the bonded joint rises by roughly 0.05 N/mm2 per second. For
ds = 50 mm, this is equivalent to a force increase of approximately 100 N/s.
On soft coatings, the tensile stress should increase by roughly 0.15 N/mm2 per
(10)
second. For ds= 50mm, this is equivalent to a force increase of approximately
300 N/s.
d) Evaluation of the results
(1) The visual appearance of the rupture surface is to be evaluated, distinguishing
between the following seven cases:

B - rupture in the concrete

B/D - rupture in the concrete /coating interface
D1/D2 - rupture in the coating 1/coating 2 interface
D - rupture in the coating
D/K - rupture in the coating/adhesive interface.
K - rupture in the adhesive.
K/S - rupture in the adhesive / steel interface.
(2) Only cases B/D and D1/D2 are used in calculating adhesive strength. Supplementary
consideration of cases B and D is permitted for estimation of a definitely exceeded
adhesive strength in cases where concrete or coating strengths are relatively low.
(3) Where rupture takes place at various levels, the proportions of the different rupture
surfaces are to be estimated. The relatively largest component area determines
which case the rupture is assigned to.
(4) The adhesive strength is calculated from the maximum attained force F:
4. F
BHZ = ________________ (N/mm 2)
2
pd
The adhesive strength must be given to an accuracy of 0.1 N/mm2
e) Test report
The test report must cite:
- the test date
- construction site, component
- position and marking of the test area
9 - type of coating
- diameter of the test die
- weather conditions during preparation and execution of the tests
- preparation of the test area, type and depth of pre-drilling or cutting
- course of the rupture or description of the parting case
- maximum force and calculated adhesive strength (single values, mean value).
- Where relevant, the definitely exceeded adhesive strength.
A9.4.3 Voids Content of Surface Protection system

(1) At the beginning of, during and at the end of each days work, and at least once for every
250 m² of area treated, sprayed specimens distributed uniformly over the area must be
taken. The specimens must be taken under sealant spraying conditions directly at the
point of use. The specimens are sprayed onto a foil or plate measuring at least 50 cm x
50 cm, with a thickness of approximately 3 mm.
(2) A small specimen of the hardened coating material is cut out of the sprayed specimen
and placed in a material – specific test liquid (corresponding to the density for the value
Hmax determined in the basic test minus 3% absolute; the test liquid is supplied by the
manufacturer).
(3) The specimen piece must sink immediately to the bottom of the test vessel (e.g. 1 glass
cylinder with measuring scale). If the specimen piece does not fall to the bottom, the
test must be repeated with a number of specimen pieces. If the result remains the same,
the precise value of the actual voids content must be determined.
(4) The mean value of the 3 single measurements must not exceed the maximum voids
content Hmax established in the basic test.
A9.4.4. Grid Test with Tape Test

(1) The coating under test and its substrate should have largely smooth surfaces. Textured
shells and rough sawn shuttering without filling are unsuitable.
(2) At each measuring point, 4 cuts perpendicular to one another are made with Cutter, so
that a grid with 9 squares are produced. The distance between the parallel cuts should
be 4 mm. After the grid has been cut, the measuring point is assessed according to the
grid test parameters.
(3) A commercial transparent adhesive tape with a width of 30 mm is then applied to the
grid made for the grid test, keeping the pressure as even as possible (with a finger or a
soft rubber roller), and is pulled off sharply after roughly 1 minute (tape test).
(4) Following each individual test (grid test plus tape test) the measuring point is assessed
with the aid of an illuminated magnifier (magnification 6x) according to the grid test
parameters.
A9.5. Treatment of Cracks

A9.5.1 Testing the Degree of Crack-Filling on Drilled Cores
(1) Drilled cores provide the only reliable means of determining the completeness of filling.
A check should therefore be made only in justified cases, i.e. where there have been
irregularities during execution of the works where faults in the filling are visible externally.
(2) Small-diameter drilled cores (50mm or less) are taken from characteristic sections of
the filled cracks. The degree of crack-filling is determined from the visual appearance
of the drilled core surface, where necessary with the aid of a magnifier or a microscope. 9
(3) the crack width and the lengths of the filled and un-filled sections of the cracks are
determined on the surface of the drilled core.

10
CASE STUDIES
Life is a series of expriences, each one of which makes us bigger, even though sometimes it is hard to realise this.
..Henry Ford
CONTENTS
PAGE NO.
CASE STUDY
10.1 Four Storeyed RCC Framed Residential Quarters at Mumbai X-1
10.2 Four Storeyed Load bearing Residential Quarters at New Delhi X-7
10.3 Four Storeyed Load bearing Residential with RCC Columns
at corners at New Delhi X-9
10.4 Four Storeyed RCC Framed Hostel Building at New Delhi X-15
10.5 An Over Head Tank with RCC Framed Staging at Delhi X-20
10.6 A Double Storeyed Load Bearing Residential Building at Mumbai X-22
10.7 A Hotel Building at Seychelles X-26
10.8 A Public Building at Porbunder X-28
10.9 Rehabilitation of Counter Fort Retaining Wall X-31
10.10 Office Building Facing Sea at Mumbai X-35
10.11 Dome of A Church, Building at Delhi X-44
10.12 A VIP Monumental Building at Delhi X-48
10.13 Ten Storeyed RCC Framed Office Building at Delhi X-51
10.14 Institution Building at Muscat X-60
10.15 An Industrial Shell Structure X-62
10.16 Four Storeyed RCC Framed Residential Quarters at Banglore X-67
10.17 Auditorium Portion of an Institutional Building at Delhi X-71
10.18 A VIP Conference Centre at Delhi X-74
10.19 Multi-Storeyed Office Building X-79
CASE STUDY - 10.1
FOUR STOREYED RCC FRAMED
RESIDENTIAL QUARTERS AT MUMBAI
10
(Source: Repairs & Rehabilitation Unit, CDO, CPWD, New Delhi)
SALIENT FEATURES
l Period of construction : 1964 – 68
l Investigation done : 1997
l Type of structure : Four storied RCC frame structure.
l Location : At 1.0 km from sea shore. Chemical and petroleum industries
located in the immediate vicinity of the building.
l Number of quarters : 5000
VISUAL OBSERVATIONS
1. Excessive cracking, spalling of concrete in RCC elements.
2. At many locations the diameter of steel reinforcement reduced by more than 15% of the original
area provided.
3. Concrete cover on reinforcement was mostly less than the specified.
4. The diagonal cracks observed in brick masonry walls at many places.
5. Gunited RCC columns and slabs heavily cracked and damaged.
6. The quality of repairs already carried out is not very good.
7. Few of declared dangerous building collapsed and few other on the verge of collapse.
IN-SITU EVALUATION AND LABORATORY TESTING
Core Test
The test results were as under-
Test Average Value
Equivalent compressive cube strength 73.29 kg/cm2
Density of concrete 2231 kg/m3
Carbonation Test
Carbonation has taken place beyond the reinforcement levels in columns, beams and slabs. However, in
case of slab top portion covered with flooring/terracing is generally not affected due to carbonation.
Rebound Hammer Test

The rebound numbers measured on concrete surfaces of RCC columns, beams and slab. Rebound
values were as under-
Central Designs Organisation X-1

Member Rebound Value Number of Reading (in %)
Columns 10-20 65
20-25 35
25-30 Nil
Beam 10-20 22
20-25 56
25-30 22
Ultrasonic Pulse Velocity Test

Values of the pulse velocity recorded by directed method varied mostly in the range of from 0.64 to
2.50 km/sec. The tests results were as under-
Pulse Velocity (km/sec) Number of reading (in %)
0.0-2.0 60
2.0-2.5 25
2.5-3.0 15
Half- Cell Potential Test

Large numbers of observation were taken and it was observed that the range of corrosion potential
measured from (-) 83 mV to (-) 530 mV. The test values were as below-
Electric potential No of Reading (in %) Probability of corrosion

10
< -200 mV 20 <10%
> -200 mV but < -350 mV 57 10% to 90%
> -350 mV 23 >90%
Chemical Analysis of Concrete

a) Water soluble sulphate ions express by weight of cement were within the permissible value of 4%
by weight of cement.
b) Water soluble chloride ions expressed by weight of cement were 0.45% and exceeded permissible
limits.
CONCLUSIONS
The main cause for early distress to RCC structures of the building is.
a) Excessive chloride content in concrete.
b) High level of humidity in air combined with hot climate throughout the year
X-2 Repairs & Rehabilitation Unit

CASE STUDIES
c) Presence of atmospheric CO2 combined with other industrial polluting gases (like
CO2,SO2,CO,SO3,H2S etc), environment is highly acidic causing accelerated carbonation of
concrete and corrosion of reinforcement. Even, rainwater becomes acidic due to dissolution of
such gases and adds to accelerated carbonation.
d) Quality of cover concrete and inadequacy of its thickness is another important factor for early
deterioration of the structures under aggressive environment.
RECOMMENDED REPAIR METHODS
A) Slabs
Provide alternate structural system comprising of RSJ’s spaced at about 1.00 Metre to Support
RCC slabs as per Appendix 6.1.
B) RCC Beams
Carry out structural Repairs to RCC beams as per Appendix 6.1
C) RCC Columns
Carry out structural Repairs to RCC columns as per Appendix 6.1
10

Plate 1: Typical View of one Block of è

Type-III Qrs
è Plate 2: Typical View of one Block of

Type-I Qrs
Plate 3: Earlier repaired Column Damaged è

again due to corrosion
10
è Plate 4: Reduction of clear bay width due

to increased volume of corroded
reinforcement of RCC columns causing
compression of balcony railing

CASE STUDIES
Plate 5: Damaged RCC Chhajja è
è Plate 6: Cracked RCC column near plinth protection
Plate 7: Cracked RCC Column at corner due to Corrosion of è 10

steel reinforcement
è Plate 8: Repaired column

è Plate 9: Structural Repairs in progress
è Plate 10: Structurally repaired block before

finishingbefore finishing
10

CASE STUDIES
CASE STUDY - 10.2

FOUR STOREYED LOAD BEARING
RESIDENTIAL QUARTERS AT NEW DELHI
( Source: Repairs & Rehabilitation Unit, CDO, CPWD, New Delhi)
SALIENT FEATURES
l Period of construction : 1979-84
l Investigations done : 1996
l Type of super-structure : Load bearing
l Type of foundation : Spread footing
l Total no.of quarters in colony : 2115
VISUAL OBSERVATIONS
1. Extensive cracking and spalling of concrte in slab, chajjas.
2. At some places reinforcement is exposed and corroded.
3. Cover of reinforcement was not proper.
4. Visual inspection of core reflect that concrete is porous in bottom portion of slab.
5. Reinforcement in chajjas is seen near bottom instead of top.
6. Terracing done with mud-phuska was having depression at places with joints of tiles opened up

Rebound Hammer Test
Rebound numbers were measured on concrete surfaces of RCC slabs. Rebound values were as
under— 10
Rebound Value Number of Reading (in %)

10-20 nil
21-25 46
26-30 54
30-35 nil
36-40 nil
Evaluation of Carbonation Depth of Concrete

Carbonation depth of concrete in slab measured and bottom 40 to 60 mm depth observed as carbonated,
whereas top is unaffected.
Bar Diameter
Bar dia was checked with verniers caliper and it is found that reduction in dia of reinforcement is about
10 to 40% of the original.

Core Test
Cores were cut at random and tested in laboratory. The test results reveal that concrete is of poor
quality.
The chemical analysis was carried out to examine the chlorides and sulphates contents and it is observed
that these are within permissible limits.
CONCLUSIONS
1. Inadequate thickness and poor quality of cover concrete, carbonation depths from bottom face of
RCC slabs were invariably beyond reinforcement level whereas from top face, the concrete was
generally uncarbonated.
2. At many locations steel reinforcement reduced to less than 85% of cross sectional area.
3. Most distressed portions were the chajjas, terrace slabs, sunken slabs in kitchen and toilet areas,
connecting corridor directly exposed to atmosphere and frequented by wetting/drying.
4. In projected portion of terrace steel reinforcement is provided at top level.

a) Slabs
Provide alternate structural system comprising of RSJ’s spaced at about 1.00 Metre to support
RCC slabs as per Appendix 6.1.
b) Beams
c) RCC projection at terrace level
10
Reduction of large terrace level slab projection to about 200 mm beyond the outer face of wall
with drip course at its end as under:
1. RCC slab to be cut/broken along notch made with diamond cutter to a depth of 40 mm or
more at 200 mm beyond outer face of wall.
2. Polymer modified cement plaster 12 mm thick to be applied over a bond coat of polymer
modified cement slurry to seal the exposed cut face of slab.
3. The disturbed mud phuska to be restored.
d) RCC Chhajjas
1. RCC chajjas to be restored as per Fig 8.1.
2. Additional chajjas to be provided over the doors/windows at top floor wherever not provided
originally.
e) Terracing
Redo the terracing after cleaning the RCC slab, application of Kerosene primer and application of
bituminous coating, laid to adequate slope and joints of tiles properly sealed with cement mortar
admixed with water proofing compound.

CASE STUDIES
CASE STUDY – 10.3

FOUR STOREYED LOAD BEARING
RESIDENTIAL QUARTERS WITH RCC COLUMNS AT
CORNERS AT NEW DELHI
SALIENT FEATURES
l Period of construction : 1979
l Type of structure : Four storeyed load bearing brick masonry buildings with
RCC columns at corners without any connecting beams.
VISUAL OBSERVATIONS
1. Extensive cracking and spalling of cover concrete in RCC elements.
2. The projection of the main roof slab at terrace level either pulled down or collapsed at places due
to wrong placement of steel, porous concrete and due to excessive thickness of mud phuska at
free edge.
3. At some places reinforcement exposed and corroded.
4. Many RCC balcony slabs and end beams were in seriously unsafe condition. Deflection was
observed to be excessive at places.
5. The cross sectional area of some reinforcement reduced to the extent of 50% and in many columns
ties on external face totally vanished due to corrosion.
6. In many flats, longitudinal cracks observed in door/ windows lintels.
7. Bathrooms, W.C. and kitchen slabs damp and distressed. 10
8. The floors of bathrooms, W.C. and kitchen in ground floor flats generally settled and damaged due
to leakage from floor traps and poor compaction of plinth.
9. The external plaster damaged at places.
10. Horizontal cracks observed running at bedding level of RCC slabs and RCC shelves in all single
storyed scooter/ cycle garages.
IN – SITU EVALUATION AND LABORATORY TESTING
Core Test
Test Average Value
Equivalent Compressive Cube Strength 124 kg / cm2
Density of Concrete 2271 kg / m3
Carbonation Test
Carbonation has taken place beyond the reinforcements levels in almost all the cases.

Rebound Hammer Test

The rebound values on concrete surface of column, beams and slab were as under-
Rebound Value Number of Reading (in %)

11-15 31
16-20 43
21-25 14
26-30 12

The test was carried out extensively and values observed are given below-
Pulse Velocity (km/s) Number of Readings (in %)

Below 2.50 84
2.50-3.00 5
3.00-3.50 11
Half-Cell Potential Test

Test results were as under-

< -200 mV 42 <10%
> -200 mV but < -350 mV 50 10% to 90%
10
> -350 mV 8 >90%

Water-soluble chloride and sulphate ions expressed by weight of cement were within permissible limit.
CONCLUSIONS
1. The main cause for distress to RCC elements was poor quality of concrete
a) Inadequate thickness of cover concrete.
b) Highly permeable and porous cover concrete.
c) Inadequate curing or improper proportioning of concrete.
2. Early corrosion of reinforcement and spalling of concrete due to carbonation of concrete.
RCC Slabs
Provide alternate structural system comprising of RSJ’s spaced at about 1.00 Metre to support RCC
slabs as per Appendix 6.1

CASE STUDIES
Terrace Projections
Reduction of large terrace level slab projection to about 200 mm beyond the outer face of wall with drip
course at its end as under:
1. RCC slab to be cut/broken along notch made with diamond cutter to a depth of 40 mm or more at
200 mm beyond outer face of wall.
2. Polymer modified cement plaster 12 mm thick to be applied over a bond coat of polymer modified
cement slurry to seal the exposed cut face of slab.
3. The disturbed mud phuska to be restored.
RCC Chajjas
ALTERNATIVE I –
RCC chajjas to be restored as per Fig 8.1.
ALTERNATIVE II -
1. Existing RCC chajjas to be dismantled, without removing the steel.
2. The rust to be removed from existing reinforcement.
3. Additional reinforcement if required to be embedded in existing beams/ lintels.
4. Casting of RCC chajjas to be carried out with M 20 concrete.
5. RCC chajjas to be finished with cement plaster in cement mortar1: 3 (1cement: 3 fine sand).
RCC Beams of Cantilever Balcony

Carry out structural Repairs to RCC beams as per Annexure 6.1
RCC Columns
Carry out structural Repairs to RCC beams as per Annexure 6.1
10
Terracing
1. Reduce the dead load due to excessive earth at locations.
2. Redo the terracing after cleaning the RCC slab, application of Kerosene primer and application of
bituminous coating, laid to adequate slope and joints of tiles properly sealed with cement mortar
admixed with water proofing compound.
3. Correct the expansion joints.

Fig 10.3.1: Lay out of 248 nos Type-II Residential Qrs under Distress
2.5
10
GARAGE 3.50
C3 W C4 C4 W C3
D D
C2 W.C. W W W.C. C2
KITCHEN KITCHEN
B4
B4
2.45
B3
B3
B2 B2
B1
B1
0.23 D D C5 C5 D D
BED ROOM
2.70 BED ROOM

BED ROOM
BED ROOM
0.23 C1 D D C1
W W
1.10
B5
B5
0.23 BALCONY BALCONY

W C6 C6 W
R.S.JOIST
1.75
SIZES OF BEAMS & COLUMNS IN m
3.40 2.94 2.65 C1,C2,C3,C4,C5,C6 - 230 x 230

0.23 0.23 0.23 B1 - 115 x 250
B2 - 115 X 200
NOTE: ALL DIMENSIONS IN METRES B3 - 115 x 480
B4 - 115 x 200
B5 - 230 x 230
Fig 10.3.2: Typical Floor Plan of a Pair of Residential Type-II Qrs

CASE STUDIES
Plate 1: Typical Front View of two Top Storey Qrs è
Plate 2: Typical Rear View of Top Storey Qrs è
è Plate 3: Typical Side View of Qrs

10
Plate 4: Cracked Column at Rear è

Plate 5: Cracked Column and Vegetation Growth è
è Plate 6: Spalled cover concrete and exposed corroded

reinforcement
10
Plate 7: Spalled Cover Concrete of RCC Slab è
Plate 8: Horizontal cracks in Masonry è

Walls of Single storeyed Garages

CASE STUDIES
CASE STUDY - 10.4

SIX STOREYED RCC FRAMED
HOSTEL BUILDING AT NEW DELHI
SALIENT FEATURES
l Type of structure : Six storeyed RCC framed structure with four wings
having residential suites and a central portion comprising
of staircase and lift lobby.
l No of residential suits : 132
VISUAL OBSERVATIONS
1. Spalling, cracking and splitting of concrete in RCC elements like columns, beams, slabs etc.
2. 4-6 mm wide cracks in columns at lower most storey near the ground level.
3. Cracks noticed along the reinforcement in RCC structural members and at the junction of RCC
and brickwork.
4. At some locations, the diameter of reinforcement reduced due to corrosion.
5. RCC columns gunited earlier, developed heavy cracks.
6. The water tank at terrace had earlier leaked continuously.
7. Spalling of concrete observed at bottom of RCC tank and on walls of tank
8. Seepage in the building observed at several places.
9. Leakage observed in G.I pipelines to supply the water to kitchen
10. GI water supply pipe lines passing through the garbage chute damaged due to impact of falling 10
garbage, causing dampness in walls.
11. Vertical Stacks of rain water pipes were observed missing from some places.
12. Washed stone grit plaster fell at many places.
11. Grooves of washed stone grit were not finished properly and allowed water to seep in.
IN- SITU EVALUATION AND LABORATORY TESTING
Carbonation Test
Carbonation has taken place beyond the reinforcement levels.
Rebound Hammer Test

The rebound values were as under-
Rebound Value Number of readings (in %)

15-20 9
21-30 72
31-40 19

Pulse Velocity (km/sec) Number of reading (in %)

0.0-2.5 47
2.5-3.0 29
3.0-3.5 12
3.5-4.5 12

Half Cell potential values were as below-

< -200 mV 77 <10%
> -200 mV but < -350 mV 23 10% to 90%
> -350 mV nil >90%

a) Soluble chlorides ions expressed by weight of cement was 0.213% and exceeded permissible
limit.
b) Sulphate content in mix was 1.293%, which was within permissible limit.
CONCLUSIONS
1. Poor quality of RCC.
2. Inadequate and permeable cover concrete.
3. Excessive chloride content in concrete.
10
4. Inadequate level of maintenance.
5. Improper workmanship of external finish.
1. Improvement and repair to Civil Services

a) Replace the broken/ damaged drainage and water pipes.
b) Replace the worn out GI pipelines.
c) Relocating of service lines from garbage chute to protect them from damage.
2. Structural Repairs
A) Slabs
Provide alternate structural system comprising of RSJ’s spaced at about 1.00 Metre to
support RCC slabs as per Appendix 6.1.
B) RCC Beams

CASE STUDIES
C) RCC Columns
Carry out structural Repairs to RCC columns as per Appendix 6.1
D) RCC Parapet Wall

The wall to be reconstructed by using super plasticizer admixed concrete of mix 1:1.5: 3 with
w/c ratio not exceeding 0.45.
3. Non Structural Repairs

a) Remove the vegetation growth from roof and other places to avoid further deterioration of
building.
b) Routine maintenance defects to be attended to.
c) Concealed service pipes to be shifted to external face of walls.
10

Plate 1: Front view of F Block è
è Plate 2: Cracks in column earlier repaired by guniting
Plate 3: Crushed cover concrete and cracking along è

main reinforcement
10
è Plate 4: Signs of leakage and seepage

CASE STUDIES
Plate 5: Spalled cover concrete in RCC slab è
Plate 6: Spalled concrete in RCC parapets è
10
Plate 7: Broken & missing rainwater pipe è
è
Plate 8: Inaccessible and inadequately sized
Service Shafts

CASE STUDY – 10.5

AN OVER HEAD TANK WITH RCC FRAMED
STAGING AT DELHI
SALIENT FEATURES
l Year of construction : 1972
l Distressed reported : May 1998
l Period of investigation : January 1999
VISUAL OBSERVATIONS
1. No signs of distress observed in RCC container
2. Signs of initial leakage at the bottom slab of tank could be noticed but no leakage history was
reported for the known past.
3. Spalling of concrete cover in bracing beams and columns of staging.
4. Bottom reinforcement of bracing beams exposed and corroded.
5. Congestion of reinforcement in bracing beams was observed to be responsible for honeycombed
and hollow bottom cover concrete.
6. Cracks running along the reinforcement were observed in bracing beams and columns.
7. Spalling of concrete also observed in the soffit of stair case slab.
8. Corrosion stains and cracks observed in slab of gallery around water container.
Carbonation Test
10 Depth of Carbonation in columns and bracing beams, wherever tested, was beyond reinforcement
level.

a) The soluble chlorides are within permissible limit of 0.15%.
b) The sulphate content in mix exceeding the permissible limit of 4% but no signs of sulphate related
distress observed visually.
CONCLUSIONS
1. Corrosion of reinforcement was due to carbonation of concrete cover.

I) Structural Repairs to RCC columns, bracing beams and slabs
Carry out structural Repairs as per Appendix 6.1
X-20 Repairs
Repairs &
& Rehabilitation
Rehabilitation Unit
Unit
CASE STUDIES
Plate 1: General view of OH Tank Plate 2: Spalled cover concrete and cracks in waist
slab and bracing beams.
10
Plate 3: Spalled cover concrete and exposed cor- Plate 4: Spalled and honey combed cover concrete
roded reinforcement of beam. Longitudinal and congested bottom reinforcement of
crack in the top cover concrete. bracing beam.

CASE STUDY – 10.6

A DOUBLE STOREYED LOAD BEARING
RESIDENTIAL BUILDING AT MUMBAI
(Source: Shri. J. Bhattacharjee, Additional Chief Engineer, MES)
SALIENT FEATURES
l Type of strucutre : Double-storeyed load bearing strucutre
l Type of foundation : Spread footing .
VISUAL OBSERVATIONS
1. Extensive cracking and spalling of concrete in sunshades, chajja, staircase, beams etc.
2. At some places reinforcement was exposed and corroded heavily.
3. Minor crazing observed on plastering on all faces.
4. Severe seepage seen in most of the roof slab and external walls.
5. Waist-slab of staircase and soffit of beams exhibited delamination over 50%.
IN-SITU EVALUATION AND NON-DESTRUCTIVE TESTS
Delam Survey
Every column and beam was tapped by three different type of hammers. Most effective was the
medium hammer, which gave, delams for 15 mm to 25 mm depth. The hollow sound was recorded
as hollow and the results of each strucutural members recorded on to observation sheet and that area
10 evaluated for remedial measures.
Rebound Hammer Test

The rebound numbers measured on concrete surfaces.

Values of the pulse velocity varied in the range of from 3.00 km/sec. to 4.8 km/sec.

Electrical potential values indicate that severe corrosion had taken place in some area, as observed
during the visual survey.
Carbonation Test
Carbonation has taken place beyond the reinforcement levels.
CONCLUSIONS
1. The main cause for distress to RCC element -

CASE STUDIES
b) Highly permeable and porous cover concrete

c) Carbonation of concrete
2. Most distressed portions were the chajjas along with lintel / beam, which is directly exposed to
marine atmosphere and frequented by alternate wetting and drying.
3. Seepage observed in roof slab was due to leekage from pipe line.

1. All sunshades/chajjas including balcony wall, side wall of steps and slab (partly) to be dismantled.
To be rebuilt using richer mix of concrete (minimum grade M-25) and adequate reinforcement
cover (atleast 10 mm more than normal cover).
2. In the joints between old and new concrete, epoxy based bonding material to be applied on old
concrete surfaces.
3. Before removing affected RCC portion, temporary support to the structure to be provided properly.
4. The use of lightweight pre-cast lintels/chajjas in lieu of cast-in-situ was suggested. Accordingly
corrugated sheets were provided.
5. For RCC members, where overall integrity found good, cracks to be filled by putting epoxy
grouting under pressure. For spalled concrete, polymer modified mortar/concrete with epoxy
bond coat to be provided.
The painting to complete surface to be applied with ceemnt based paint with addition of polymeric
compound.
10

Plate 1 : Part view of quarters before repair
Plate 1(a)
10
Plate 1(b)
Plate 1(c)

CASE STUDIES
Plate 2 : Part view of quarters before repair
Plate 1(a)
10
Plate 1(b)
Plate 1(c)

CASE STUDY – 10.7

A HOTEL BUILDING AT SEYCHELLES
(Source: Shri H. S. Bakshi, Consultant, Engineering Development and Consultant)
SALIENT FEATURES
l Type of super-structure : Load bearing / RCC framed construction
l Type of foundation : Spread footing
l Total no. of blocks in hotel : 7 blocks and one main central block
l Location : Sea coast
VISUAL OBSERVATIONS
It was evident from visual inspection that there was a very serious and widespread problem relating to
degradation of the reinforced concrete structures in the hotel complex. Based on experience, it was
emphasized that it is highly desirable, to identify accurately the cause of the deterioration before embarking
upon expensive remedial work. Therefore it was recommended a programme of concrete sampling and
laboratory testing. It was reported that there had been previous attempts at fixing the problem by
patching the concrete with sand cement mix. These had retarded the deterioration, but not contained it,
and problems had reappeared.
Core Test
Over 38 cores were taken. They were drilled in columns, beams and slabs either horizontally or
10 vertically as appropriate. The number of cores was kept large as the initial cores indicated
very weak concrete. The strength results showed a wide scatter ranging from 10 Mpa concrete
to 20 Mpa.
Carbonation Test
The depth of carbonation was generally extensive. The poor quality concrete resulted in rapid carbonation
with the consequence of depassivation of the reinforcement and resultant deterioration of the concrete.
The cover to the reinforcement was inadequate in many instances and this would have compounded the
problem.
Chloride Test
Chloride content was the order 0.04 to 1 % of the mass of cement in the sample. The chloride
concentration showed no definite trend of concentration near the concrete surface. It appeared that
chloride was present in the material used in the concrete. It is also probable that in addition to chlorides
present in the aggregates etc. chloride ingress occurred relatively easily because of the weak and
permeable properties of the concrete. This could explain the variability of chloride concentration in core
specimens.
X-26 Central
RepairsDesigns Organisation
& Rehabilitation Unit X-26
CASE STUDIES

Basically all loose unsound concrete at spalled, cracked and hollow sounding areas were carefully
removed until sound concrete was reached. Breaking out of concrete continued to expose the full
circumference of corroded reinforcing bars and to a further depth as directed. All exposed reinforcement
was cleaned of corrosion products by an approved manual method or sand blasting. The reinforcement
was treated with a pacifier immediately following preparation and cleaning. The repair to reinstate the
concrete was effected by shotcrete or a proprietary mortar or fluid micro concrete either rendered or
placed behind shuttering respectively. It was considered essential that the work be done to the highest
possible specifications and standards. The finished surfaces was cured as specified. In addition an
effective membrane such as a saline or high build alkyd was applied to surfaces to prevent the ingress of
water vapour.
Plate 1: Rehabilitation work in progress.

10
Plate 2: Rehabilitation work of beam in progress.

CASE STUDY - 10.8

A PUBLIC BUILDING AT PORBUNDER
(Source: Shri A. K. Gupta, Chief Engineer, Bharat Sanchar Nigam Limited)
SALIENT FEATURES
l Type of foundation : Isolated and combined RCC footings
l Type of super structure : Three storeyed RCC framed structure
l Location : 200 metre from sea shore
VISUAL OBSERVATIONS
1. Extensive cracking and spalling of concrete in columns, beams, extension brackets, cantilevers,
slabs etc.
2. Reinforcements in most of the external members were found to be severely corroded.
3. Cover of reinforcement was not adequate which was varying from 10-30 mm depending upon the
RCC elements.
4. Reinforcement in columns was found to be twisted along the axis.
5. Inspection of concrete shows that though it may not have been deficient in cement content but it
was porous in character because of inadequate compaction.
6. The cross-sectional area in some of the reinforcement bars has been reduced to just10% and
some other reinforcement bars had completley snapped. Reduction in area of the beam/column
reinforcement was of the order of 25-30 percent.
7. The concrete was found to be in friable mass having whitish deposits, which indicated presence of
ettringite.
10
REPAIR STRATEGY
1. Mechanical cleaning of reinforcement and thorough cleaning of damaged concrete surface after
removal of spalled concrete and weak concrete.
2. The reinforcement augmented where severe deterioration had taken place with the help of additional
reinforcement fixed with ‘U’ clips and also supporting reinforcement on shear anchors fixed with
expansive cement (shrinkomp)
3. The visible cracks were grouted either with cement injection or epoxy injection.
4. The exposed concrete surface and the reinforcement bars were covered with epoxy mortar made
of epoxy and cement (acting as filler material). This provided an imperious membrane against
further ingress of corrosive agents.
5. In some columns concrete was jacketed with richer reinforced cement concrete and low water
cement ratio.
6. The repaired surface was treated with rich cement plaster with low water cement ratio.
7. Some of the badly damaged concrete elements such as extension bracket etc. were recast in richer
reinforced cement concrete.
8. The steel windows were changed to wooden windows to avoid rusting.
X-28 Central Designs

Repairs Organisation
& Rehabilitation Unit X-28
CASE STUDIES
Plate 1 : Concrete Spalling in Columns and Beams è
è Plate 2 : Rusting of reinforcement
10
Plate 3 : Honeycombed Concrete and Corrosion of

Steel
è

Plate 4 : Rehabilitation work in progress è
è Plate 5 : Injection Grouting
10
Plate 6 : Concrete Repair with Epoxy Mortar è
è Plate 7 : Building after rehabilitation

CASE STUDIES
CASE STUDY – 10.9

REHABILITATION OF COUNTER FORT RETAINING WALL
SALIENT FEATURES
l Type of structure : Counter fort retaining wall for approach to a
Road Over Bridge (Fig 10.9.1).
VISUAL OBSERVATIONS
1. The concrete cover to main reinforcement of retaining wall was delaminated, cracked and spalled.
2. Steel reinforcement was found exposed and rusted. The diameter of bars reduced considerably
due to corrosion.
3. Walls found bulged at places apparently due to swelling of corroded rebars.
4. Thickness of concrete cover over steel reinforcement was not uniform.
5. The damage to exposed surface was mostly on Northern side of the approaches.
6. The damage to RCC on southern side observed only near ground level, apparently due to its
frequented misuse by passers as ‘Public Urinal’ due to ingress of harmful chemicals.
7. RCC railing on both sides of the bridge was damaged and steel reinforcement bars were broken
due to corrosion.
8. Vegetation growth observed in the wall.
LABORATORY TESTING
No laboratory testing on concrete could be performed, however the carbonation of concrete was
found to be beyond reinforcement level at most of the places. The work was to be executed after 10
ascertaining through laboratory tests as to whether chloride/sulphate contents were within permissible
limits or not.
CONCLUSIONS
1. The major deterioration due to corrosion of steel reinforcement was on account of alternate wetting
and drying of poor quality of cover concrete. The deterioration was observed mainly on the
retaining wall that was exposed to the direction most likely to be wetted during rains due to most
favourable wind direction during monsoon.
2. Accelerated carbonation of inadequate cover concrete for RCC.
3. Penetration of chlorides and chemicals in to concrete due to urination by passers by.
4. RCC Railing was observed to be beyond economical repairs.

1. RCC Railing
Replacement of side railing of bridge with durable material like structural steel protected with
primer and paint or by precast RCC railing with protective coating.
2. Retaining Walls
The repair to required height of the RCC retaining wall between the two counter forts shall be

done in alternate horizontal strips of one metre height starting from the lower most strip in a
sequence of steps as under:
Step-1: Design and fabricate the adequate number of ‘stress relieving girders’ to span
between the two counter forts to be able to safely transfer the maximum earth
pressure on a one metre wide horizontal strip.
Step-2: Provide and fix anchor fastener system, mechanical/epoxy based of standard
make at vertical spacing of 0.5 metre on each of the two exposed faces of
adjacent counter forts. This fastener system shall be designed to hold the stress
relieving Girders and transfer tensile force reactions safely to counter forts from
such portions of one metre wide strip of wall (Fig 10.9.2) due to lateral earth
pressure.
Step-3: The aforesaid specially designed stress relieving girders shall be fixed on counter
forts at one metre c/c vertical spacing with a clear gap from the face of such
retaining wall panel, which is to be relieved of stress. The clear gap shall be
enough to accommodate reaction jacks to be used for transfer of load to the
stress-relieving girder.
Step-4: The stress relieving shall be done by putting the reaction pressure on wall through
jacks horizontally spaced at least at one metre c/c.
Step-5: The RCC slab in a width of middle 0.5 m vertical width between the stress
relieving girders as above and the two counter forts shall be carefully repaired by
method of structural repairs explained for RCC slabs in Appendix 6.1.
Step-6: Allow the structurally repaired slab to be cured for the requisite period and attain
strength.
Step-7: Shift the stress relieving girders by 0.50 metre so as to be at centre line of the
earlier repaired horizontal strip and repeat the steps 3 to 6 as above and remove
the stress relieving girders.
10 Step-8: Repeat the above steps for all the panels between the counterforts.
Step-9: Provide anti-carbonation protective coating over the entire concrete surface,
whether repaired or not repaired, as per nomenclature of item and related speci-
fication as given in Chapter 8 & 9.

CASE STUDIES
3.5m c/c
Counterforts
(Typical)
STAGE III
Staggered holes for fixing bolts to dash fasteners

Portion to be structurally repaired STAGE II
Wall supporting girder as per details
TYPICAL 500 500 STAGE I
Fig 10.9.1 ELEVATION OF RETAINING WALL
Fig. 10.9.1 : Typical arrangement of counter fort retaining wall
15 MC 150x75x6mm (Tentative)
X Key
50mm
Bolts
Dash Fasteners 15MC

X
500mm SEC X-X
Typical
10
Fig. 10.9.2 : Details of fastner system and stress relieving girder
Plate 1: General View of the Counter-fort è

Retaining Wall

Plate 2: Typical damage of the Counter-fort è

Retaining Wall
è
Plate 3: Typical damage of the Counter-for
Retaining Wall
10
Plate 4: Damage due to urination near
ground level of Counter-fort
è
Retaining Wall
è
Plate 5: Counter-forts of Retaining Wall
and RCC railing as visible from top

CASE STUDIES
CASE STUDY - 10.10

OFFICE BUILDING FACING SEA AT MUMBAI
SALIENT FEATURES
l Type of structure : Seven storied RCC framed structure as per framing plan
shown in Fig 10.10.1. Glazed windows provided at edge
of cantilevered slab. In front face of RCC columns of
main structure protected by 1.02 metre cantilevered
projections (Fig 10.10.2). No such protection to structure
available along sides and back of building.
l Location : Facing sea
VISUAL OBSERVATIONS
A. RCC
a. Columns, beams and lintels cracked at places.
b. Spalling of cover concrete also noticed at other places.
c. 1.02 metre cantilever slab (Fig 10.10.2) along the length of the building deflected to
varying degree.
d. Front masonry facia at edge of cantilevered slab tilted out.
B. Flooring
a. Tiles flooring upheaved at several places.
b. At the location of floor upheaval, the bed mortar was checked and found loose, weak 10
and powdery.
C. Terracing
a. Air bubbles observed in bituminous felt waterproofing treatment at terrace and slope
was found inadequate.
b. Marks of leakage and seepage of water observed in the ceiling of RCC slab and ter-
race level beams
IN-SITU EVALUATION AND LABORATORY TESTS
Core Test
Test results were as under:
Test Average value
Equivalent compressive cube strength 142.43 kg/cm2
Density of concrete 2179 kg/m3
Rebound Hammer Test

Rebound values at 3rd and 4th floor level slab and beams were as under-
Rebound Value No of Reading (in %)

11-15 5
16-20 46
21-25 49

This test was carried out on selective members and found that values varied from 0.88 to 2.76.
Carbonation Test
Top 35mm thickness in cantilevered slab observed as carbonated at third and fourth floor.
Half- Cell Potential Meter Test

It was observed that the range of corrosion potential measured from (-) 50mv to (-) 405mv. Electrical
potential values were as below –

< -200 mV 31 <10%
> -200 mV but < -350 mV 66 10% to 90%
> -350 mV 3 >90%
CONCLUSIONS
a) The cantilevered slab (Fig 10.10.2) had unduly deflected and was susceptible to collapse in view
of reduced cross-sectional area of main reinforcement due to corrosion. It needed immediate
attention.
10 b) Restoration of cantilevered slab necessitated additional reinforcement to supplement the loss of
cross-sectional area due to corrosion. Whereas it did not meet serviceability and deflection criteria.
c) The level of carbonation and consequential corrosion of reinforcement was more than permissible.
d) The water proofing treatment on terrace failed and permitted penetration of rainwater to cause
alternate wetting and drying and consequential accelerated carbonation and corrosion of
reinforcement of terrace level beams and slabs.
e) Upheaval of tiles in cantilevered portion in front and also near column supports were due to
upheaval of top cover concrete owing to corrosion of top reinforcement.

1. In view of the reduced cross-sectional area of reinforcement due to corrosion and necessity to
stiffen the cantilevered slab at floor level from serviceability considerations, it was recommended
to structurally connect it with another RCC slab at lintel level and form a boxed cantilever with
stiffening diaphragms as per the Fig 10.10.3 and procedure given as under:
Sequence of steps:
a) The cantilevered slab be got temporarily vacated and separated from occupied area by
erecting temporary 115 mm brick masonry wall in weak mortar as safety barrier [Fig
10.10.4(a)].

CASE STUDIES
b) Brick masonry wall supporting the glazing be removed.

c) Projecting cantilevered slabs one at floor level and the other at lintel level below be demolished
beyond the beam/column faces but their reinforcement to be retained in position [Fig
10.10.4(b)].
d) After dismantling the two slabs, all rusted bars to be cleaned of rust including even traces of
rust.
e) Deficiency in steel reinforcement to be made up with additional reinforcing bars.
f) The reinforcement of the two cantilevered slabs, one at floor level and the other at lintel level
below to be connected with RCC vertical facia with proper designed over laps [Fig
10.10.4(c)].
g) Stiffen the proposed boxed cantilever as above with 100 mm thick RCC diaphragm provided
at column support as well as at mid span[Fig 10.10.4(d) and (e)].
h) Re-cast with M 20 grade concrete in stages as shown in Fig 10.10.4
i) The RCC facia and other exposed structural elements to be covered with suitable weather
resistant permanent finish material and internal face to be finished with synthetic enamel paint
or acrylic emulsion.
j) After structural rehabilitation is completed, the temporary masonry wall shall be removed
and area merged with rest of building.
2. Improvements of water proofing treatment and drainage of roof.

Sequence of steps:
a) Existing water proofing treatment to be removed and condition including the slope of terrac-
ing to be assessed.
b) The whole terrace to be re-graded, to rectify depressions. If necessary, the existing terracing
could be re-laid to achieve proper slope.
c) Number of rain water pipes to be increased commensurate with the area to be drained to
ensure efficient disposal of rainwater. 10
d) Surface cracks in existing terracing to be identified and marked. Polymer modified cement
slurry to be injected through nipples fixed along crack lines.
e) Regraded roof to be covered with two coats of polymer modified cement slurry coating
containing 20 % acrylic polymer by weight of cement. Subsequently cover this coating with
20mm thick polymer modified non shrink cement plaster with 300x300mm sized square
thread indentation thereon.
f) The adequacy of the water proofness of roofing to be checked by ponding of water after the
curing period is over.
3. Improvement of structural strength of columns/ beams/ slabs at fourth floor level

Stepwise sequence of steps and method of structural restoration and strengthening of RCC col-
umns, beams and slabs shall be as given in Annexure 6.1.
4. Removal of floor tiles and relaying with cement mortar as below

Sequence of steps:
a) Tiles to be removed carefully and stacked, bed mortar to be removed and surface to be
totally cleaned with wire brushes.

b) RCC slab to be tapped and checked for hollow sound. If found hollow, the slab to be
propped and supported as per item 1.1 in Chapter-8.
c) The top cover concrete to be removed and rusted reinforcement exposed all around. The
exposed reinforcement to be cleaned of concrete and rust as per item no 2.6 and 2.7 in
Chapter-8.
d) A bond coat of polymer modified cement slurry as per items 4.1 and 4.2 in Chapter-8 to be
applied over the surfaces of concrete and reinforcement before covering it with repair mate-
rial.
e) This to be covered in layers as per item 5.7 in Chapter-8 with polymer modified mortar 1:2.5
modified with 5 % SBR by weight of cement.
f) The finished surface as well as surrounding sound but un-repaired surface to be coated with
two coats of polymer modified cement slurry containing 20 % SBR polymer by weight of
cement.
g) Flooring tiles to be re-laid as per standard specifications.
10

CASE STUDIES
Fig. 10.10.1(a): Layout Plan
10
Fig. 10.10.1(b): SectionA-A showing cantilevered portion in front

Fig. 10.10.2: Existing Arrangement in Front Cantilevered Portion
INTERNAL FACE FINISHED WITH

PROTECTIVE COATING OF
SYNTHETIC ENAMEL PAINT
SLIDING WINDOW
R.C.C.
PERMANENT FINISH TO BE PROVIDED

IN CUNSULTATION WITH ARCHITECT
VOID
20 CM PORTION TO BE
REMOVED
0.9M DRIP COURSE
10 1.2M
COLUMN BRICK MASONARY
Fig. 10.10.3: Proposed Arrangement Stiffened Cantilevered Portion in Front
Fig. 10.10.4(a): Area Isolated

CASE STUDIES
Fig. 10.10.4(b): Concrete of Cantilevered slabs dismantled
10
Fig. 10.10.4(c): Lintel level Slab cast
Fig. 10.10.4 (d): Vertical front facia and diaphragms cast

Fig. 10.10.4(e):Sectional Elevation through cantilevered box showing diaphragms/filler walls
10
Fig. 10.10.4(f): Floor level slab cast
Fig. 10.10.4(g): Shuttering Removed & boxed Cantilever in position

CASE STUDIES
Plate 1: Front View è
Plate 2: Upheaved Flooring è
Plate 3: Corroded top reinforcement 10

causing in-plane splitting of
cantilever slab and de- è
bonding of reinforcement
è
Plate 4: Cracked terrace level
Beams and slabs

CASE STUDY –10.11

DOME OF A CHURCH BUILDING AT DELHI
(Source: Shri. P.C. Sharma, Former Senior Scientist, SERC, Ghaziabad)
SALIENT FEATURES
l Referred for investigationn : 1995-96
l Investigation carried out : 1996-97
l Type of construction : Brick masonry dome structure in lime surkhi mortar
with embedded steel sections as horizontal bands at few
locations in dome.
VISUAL OBSERVATIONS
1. The dome consists of two shells, the inner and the outer. The outer shell, called as Florentine
dome, is ribbed and rests on eight octagonal columns.
2. The dome was plastered in cement mortar on both inner and outer faces. This plaster was done at
a later date.
3. Extensive spalling of plaster in soffits of the outer-most dome observed. Plaster had no bond with
masonry at most of the places.
4. Cracks on soffits of the outer-most dome along the construction joints and along vertical, ribs.
Few bricks have fallen out from horizontal and vertical joints exposing embedded steel sections.
5. Mortar from brick masonry was ending and degraded due to seepage from outsides.
10 Determination of Geometry
The geometry of dome was determined using Wild T1000 Electronic Theodolite fitted with DI 3000
timed – pulse EDM (Electronic Distance Measuring Equipment with effective least count of 0.001M)
Mapping of Cracks
The loose plaster from inner surface was removed by tapping and all visible major cracks on soffits of
the outer dome were marked and plotted.
Rebound Hammer Test

The average compressive strength assessed as follows:
Bricks 4.848 and 5.208 Mpa on outer and inner surfaces respectively.
Mortar 2.895 and 1.466 Mpa in lower and upper portions of dome respectively
Core Test
Core of both bricks and mortars were taken to evaluate the properties like compressive strength, water
absorption and density.
X-44 Repairs
Central Designs
& Rehabilitation
Organisation
Unit 44
CASE STUDIES
The core tests revealed the compressive strength of the masonry was 3.20 Mpa, which shows bricks
are generally, not affected strength wise.
Determination of Steel
A cover meter was used to ascertain the presence and position of steel sections in the dome. The steel
sections were about 3mm thick and 40 to 45 mm wide and were embedded circumferentially at every
junction of two lifts about 10 mm away from the inner surface. The steel had almost completely cor-
roded.
Chemical Analysis
Mortar was crushed to get fine powder and its chemical analysis was done. The mortar found to be
made up of lime and surkhi in the ratio 1:8.
Theoretical Analysis
The dome was analysed by Finite element method and checked for stability. Changes in stresses due to
different temperatures were also studied.
CONCLUSIONS
1. The steel sections provided in the dome are completely corroded leading to cracks in the masonry.
2. The mortar in upper portion has degraded due to seepage of water from upper surface.
3. Brick strength is low compared to present standards and bricks show higher porosity.
4. Mortar is porous and poor in strength.
5. The dome is stable from tension and stresses point of view
External Surface of Dome 10

1. Entire old plaster to be removed and all visible cracks sealed.
2. Fix grouting ripples and using cement base non-shrink slurry grout all the joints.
3. Provide first layer of Ferrocement as per specifications.
4. Lay second layer and level upto required level.
5. Cure for 14 days.
6. Apply anti-carbonation treatment in two layers.
Internal Surface of Dome

1. Remove old plaster and repack old joints after raking up the joints and clearing with wire brushes.
2. Remove corroded steel in such a way that unsupported length is not more than 1 m. Pack with
non-shrink concrete produced using Portland cement 53 grade.
3. Repack all exposed masonry joints with non-shrink cement sand mortar.
4. At the Dome junction with bottom drum , provide grouting nozzles and pressure grout with non
shrink cement slurry.
5. Provide specified layer of ferrocement as per specification.
6. Cure for 10 days.
7. Apply two coats of polymer cement water proofing.

Fig. 10.11.1: Plan of the Dome of Church
10
Fig. 10.11.2: Front Elevation

CASE STUDIES
Fig 10.11.3: Sectional Elevation of the Octagonal Outer

Dome of Church
10
Fig. 10.11.4: Cracks on three sides of inner octagonal upper Dome

CASE STUDY – 10.12

A VIP MONUMENTAL BUILDING AT DELHI
SALIENT FEATURES
· Period of construction : 1929
· Investigation done : 1997
· Type of structure : Load bearing brick & stone masonry historical structure
having very thick walls with lime concrete terracing
· Problem referred to Investigators: Leakage in to the rooms below roof, Seepage in
stone masonry walls and damage caused to ornamental
Chhajjas due to spalling of cover concrete and exposure
of reinforcement
VISUAL OBSERVATIONS
A) AT ROOF
1. Lime concrete terracing is provided with proper slope. Tarfelt treatment is laid over the terracing.
Drains, laid to proper slope, were covered with steel gratings.
2. In the tarfelt treatment, at some places
a) air bubbles were observed
b) it had debonded with its base.
c) water was observed to have been trapped below the felt.
3. No thermal expansion joints were provided in the structure, whereas size of the building necessitated
such provision as per present codal practice.
10 4. Cracks were seen along corners at junction of roofing and parapet.
5. Cracks were present in lime terracing at some places.
6. Dome over library room had cracked at the junction of ring beam.
7. Cracks were observed in ceiling of North Block Room, Dwarka Suite.
8. Parapet plaster had cracked at some places.
B) JOINTS OF STONE MASONRY AND FOUNTAIN BOWL
1. Pointing of stone masonry joints had got weathered and joints had become hollow at places due to
removal of disintegrated mortar.
2. Mild steel nails fixed in the joints for electrical lighting caused loosening/opening up of joints due to
expansive forces caused due to increased dia of rusted nails.
3. Crazy cracks in bowl type tank of fountain were observed.
C) RCC CHAJJAS IN FRONT COURT
1. Ornamental RCC chhajjas’s reinforcement had corroded and spalling has taken place.
CONCLUSIONS
1. Cracks at the junctions of roof and parapet, lime terracing, other places and disintegration of joint
mortar at exposed locations are due to cyclic nature of diurnal and seasonal temperature variations
X-48 RepairsDesigns
Central & Rehabilitation Unit
Organisation 48
CASE STUDIES
over a long period on account of direct exposure to environment and consequential thermal
expansions and contractions of the structure.
2. Cracks at the junctions of roof and parapet and other places are the most probable areas for
ingress of rainwater.
3. The quality of lime terracing is very good except that it has cracked at few locations. It needed to
be retained but with crack treatment.
4. Being an old and historical structure, it is advisable that no additional loads due to any water
proofing treatment are put over roof.
5. The exposed joints of stone/brick masonry had opened up, mortar disintegrated and became
hollow due to rusting of mild steel nails fixed in the joints and extreme temperature variations.
6. Carbonation of concrete caused the corrosion of reinforcement and the spalling of the concrete in
ornamental RCC chhajjas.
A) Water proofing treatment

1. Existing plaster on inner face of parapet and from other walls to be removed to expose the masonry.
2. Existing tar felt and all rubbish to be removed completely and surface to be cleaned of bitumen
properly.
3. Cracked and damaged terracing, terrace-parapet junctions, etc to be identified and
marked.
4. The nipples for injection grouting to be fixed at a close spacing not farther than 300 mm along the
crack line and crack sealed with putty.
5. Water to be injected through nipples for cleaning the cracks of any debris and saturating the
cracked surface with water.
6. Polymer modified cement slurry grout to be injected into all cracks in RCC/ lime terracing/
terrace-parapet junctions, etc as per nomenclature of item and related specification given in 10
Chapter 8 & 9.
7. Depressions and undulations, if any, to be repaired.
8. 15 mm thick Ferro-cement water proofing teatment to be done over lime concrete terracing with
appropriate expansion joints and laid to proper slope as per nomenclature of item and related
specification given in Chapter 8 & 9. The water proofing treatment to be taken into 75X75 mm cut
chases in the parapet walls.
9. Surface of the finished ferro-cement waterproofing treatment to be kept wet continuously for a
period of seven days.
10. After completion of water proofing treatment, walls to be replastered.
B) Leakage/ seepage from masonry joints of terrace fountains and parapet.

1. Water supply lines for the fountain to be checked thoroughly and leaking pipes to be
replaced.
(a) For vertical sides of fountains and masonry
1. Joints to be raked and all loose material to be removed.
2. Joints to be plugged and made impermeable by injecting polymer modified cement
slurry through aluminium nipples which to be driven into the joints without damaging the
stones.

(b) Horizontal surface of fountain

1. All containers to be thoroughly cleaned of existing water proofing teatment.
2. Containers to be treated by injecting non shrink cementitious slurry with pigment of
matching shade through aluminium nipples which is to be driven into the joints without
damaging the stones.
C) Leakage into the basement below from stone cobbled court yard
1. The leakage to be controlled by pressure grouting of stone cobbled joints and repair of covered
drains.
2. Cement slurry for grouting to be made of polymer modified cement, which to be made by using 1
part of O.P.C with 1 part of water and 20% polymer (solid contents) by weight of cement as per
directions of Engineer in charge/ manufacturer.
D) Repair to Ornamental RCC chhajja

Repair to RCC chhajja shall be carried out as per procedure described in Annexure 6.1 but after
matching the shade of finished colour with that of existing colour
10

CASE STUDIES

TEN STOREYED RCC FRAMED
OFFICE BUILDING AT DELHI
(Source: Shri D S Sachdeva, Chief Engineer, CPWD, Siliguri)
SALIENT FEATURES
l Year of construction : 1981-82.
l Investigation done : Building, when taken over for repairs and modifications
in 1998, it was an unfinished, unprotected and uncared
structure.
l Type of super-structure &
its usage : Ten storeyed R.C.C. framed structure. Originally planned
and constructed as a hotel and now its use was envisaged
as office building.
Total plinth area of the building 38900 sq.m. Ground
coverage 9000 sq. m having 1600 floor columns, 3200
main beams and 1200 slab panels.
l Type of foundation : Pile foundation
VISUAL OBSERVATIONS
i) The central core of building was mostly unaffected, and practically no distress was observed in the
area except honey-combs in coffer beams and segregated concrete in columns.
ii) Relatively more number of structural elements above 30.75 m and 37.9 m levels at the top and
8.15 m and 5.0 m levels at bottom were distressed compared to other levels.
iii) Longitudinal cracks observed in columns and beams. Typical crack pattern corresponds to rebar
corrosion. 10
iv) Spalling of concrete noticed at places.
v) Exposed reinforcement exhibited signs of rusting.
vi) External column elements were distressed more as compared to internal structural elements.
vii) Among the internal elements, those beams, which were near vertical openings, expansion joints
and sunken floors, were distressed more as compared to internal beams located at other places
internally.
viii) Upper floor slabs were more severely affected.
ix) Ponding of water observed in sunken slabs.
x) Expansion joint beams distressed due to seepage of rainwater from terrace of various floors and
consequential wetting/drying cycle.
IN-SITU EVALUATION AND LABORATORY TEST
Rebound Hammer, UPV and Core Test

A) Slabs
i) From UPV test, quality of concrete of slabs at 27.05m level was found to be of doubtful
category. The mean rebound number index was 32 and strength of concrete obtained

12 Mpa. Panels were recommended to be recast with reinforcement as per design

requirements.
ii) Generally the slab concrete marginally satisfied the requirement of M 15 grade of concrete.
B) Beams
i) UPV results generally indicated medium or better than medium quality of concrete. At few
locations it was doubtful and at some other, it marginally failed to satisfy the requirements of
medium grade concrete.
ii) At 30.75/27.05m levels, UPV tests identified quality of concrete as doubtful, which could be
due to existing fine corrosion cracks.
iii) From the results of above tests, it was concluded that concrete in some beams at 8.15 m,
27.05 m and 37.9 m levels was of poorer grade than M15 and required recasting.
C) Columns
i) UPV tests indicated that few columns at 37.9 m level were of doubtful quality.
ii) In columns, mostly medium or better than medium quality concrete was assessed through
UPV tests.
iii) Average characteristic strength of concrete in columns was 16.4 Mpa
Carbonation Test
Out of 33 tests, it was found that depth of carbonation was more than the concrete cover in 11 cases.
Though significant carbonation was observed, but corrosion of rebar was not attributed to carbonation
due to its depth generally being less than cover by and large.

Large number of observations were taken where visible cracks were yet to appear. The results indi-
cated high chances of corrosion in future.
10
Chloride Content
Free chloride content of the entire 13 test-samples test exceeded the permissible limit.
CONCLUSIONS
1. Service floor, located at the second floor level of the building had a number of inverted beams,
which caused ponding, for water collected from various shafts and open sides. The intermittent
collection of water and its evaporation caused accelerated carbonation and consequential damage
to large number of structural members viz columns, beams and slabs due to corrosion of
reinforcement.
2. Reinforcement at bases of columns was corroded due to accumulated water, which rose up in
cover concrete through capillary action from the bases of columns at unfinished & unlevelled floor
level, where it had accumulated due to its entry from open sides.
3. External columns and beams: The building was originally planned for bay windows. The water
accumulated in pot like structure formed between the window sill, which was curved in plan and
the straight faces of the building. Due to this reason, almost all the columns and beams adjacent to
this pot formation were affected.
4. Slabs, beams and columns around the shafts and the sunken slabs were also affected because of
accumulation of water.
CASE STUDIES
5. Large number of slabs affected due to corrosion on account of inadequate concrete cover and
exposed surface being not plastered.
6. Columns and beams adjacent to expansion joints were also severely affected due to unfinished
expansion joints and through which the rainwater traveled unhindered.
STRATEGY FOR REHABILITATION

Two pronged strategy was suggested:
1. Strategy-I: Repair of distressed structure.
The structural system of the building is basically an RCC framed with in filled masonary walls.
Based on the field and laboratory test results, residual strength calculations were done. Despite the
loss in strength of concrete and steel, the building was capable to sustain normal office loading.
The some locations, strengthening measures were suggested. Since, majority of structural members,
some to small extent and others to large extent, were affected by corrosion, mass scale replacement
was discouraged. Instead it was decided to carry out localized repairs to the damaged areas using
latest repair materials available. The process also helped in minimizing chipping off of healthy
concrete. The full circumference of corroded reinforcing bars were exposed by chipping, and
were cleaned of corrosion products by approved manual methods, mechanical brushes and/or
sand lasting. The reinforcing bars were then treated with rust passivators soon after their cleaning.
After application of bond coat over the old concrete surface, micro concrete was poured.
Appropriate designed formwork for the columns & beams were provided. At places particularly
in beams, proprietary repair mortars were also applied.
2. Strategy-II: Load Reduction
Due to change of its use from residential to office purpose, it was felt necessary to plan reduction
of dead loads during remodelling with the use of:
i. Aerated cellular concrete blocks, gypsum blocks in walls to substitute bricks.
ii. Lightweight SMC panel water tanks at terraces.
iii. Light weight flooring, like ceramic tiles in large areas. 10
iv. Lightweight false ceiling of gypsum board, metallic and mineral fibre tile ceilings.
v. Light weight weather proof, composite aluminium sheet cladding as external façade,
vi. Adoption of open plan modular office system.
vii. Elimination of sunken floors in toilets.
viii. Full bay large window openings reducing brick work in jambs and cills.
ix. Additional four bays added at 9th floor in each wing during 1987-88 were removed to reduce**
the imposed load.
RECOMMENDED REPAIR STRATEGY

I. All structural members, which were distressed, identified.
II. The repair priorities were assigned first to all columns and were treated first, then all beams
and slabs in the last.
III. The surface preparation started from visible signs of distress like opening of cracks, expose
the corroded reinforcement and proceed along corroded reinforcement till good steel was
reached.
IV. The reinforcement was cleaned of rust, coated with zinc rich epoxy to check further corrosion.
V. It was decided to provide concrete richer than parent concrete of the structural member
being repaired.
VI.
For columns, epoxy was selected as bonding coat, where as for beams and slabs acylic
based bonding coat was selected from importance and cost considerations.
VII. Beams were repaired with polymers modified cement mortar where as columns were treated
with flowable non-shrink micro concrete.
VIII. Areas affected with honey combed concrete were repaired by injection grouting with either
cement admixed with non-shrink compounds or epoxy grout. Most of the honeycomb was
found at beam-column junction.
10

CASE STUDIES
Plate 1: Building As Taken Over Plate 2: Closer Look
è Plate 3: Corrosion cracked column
10
Plate 4: Rust Signs in RCC column è

è
Plate 5: Inverted Beams on Service Floor
responsible for ponding of water
Plate 6: Honey combed Column-Beam è

Junction
10
Plate 7: Beam at Expansion Joint Location è
Plate 8: Hollow Voided RCC Slab due to

loosened cover concrete on è
account of corrosion of reinforcement

CASE STUDIES
Plate 9: Rusted Shear Stirrups in Beam è
è
Plate 10: Chipped Column with exposed
reinforcement being cleaned by
sand blasting
Plate 11: Exposed reinforcement and chipped è

concrete after sand blasting
10
è Plate 12: Micro-concreting being done to RCC

jacket

Prepared Surface of steel and concrete è

Plate 13: Passivating and Bond Coat Applied over
in a Beam
è
Plate 14: Repair material application to Soffit of
RCC Beam
10
Plate 15: Repaired Beam è
Plate 16: Cement Grouting in Honey Combed

Concrete è

CASE STUDIES
Plate 17: Epoxy Grouting è
Plate 18: Chipping of Loose Cover Concrete è

of RCC slab
10
è
Plate 19: Reinforcement and shear key after
sand-blasting
Plate 20: Recasting of RCC slab è


INSTITUTION BUILDING AT MUSCAT
(Source: Shri H. S. Bakshi, Consultant, Engineering Development and Consultant)
SALIENT FEATURES
l Type of foundation : Isolated footings
l Type of superstructure : Two storeyed RCC framed construction
VISUAL OBSERVATIONS
No sooner the building was completed in the year 1994 cracks started appearing in the beams. Inves-
tigations were undertaken by local consultants and Sultan Qaboos University at Muscat. Repairs were
carried out using bonded steel plate concept, which were later found to be inadequate and problem
further investigated.
1. Steel plates, which were used to strengthen beams, were not well bounded to the bottom of
beams. In fact at some places one could move the plate by gentle push of hand.
2. The grout used between concrete beam face and steel plate was not uniformly dense and as such
unreliable.
3. The bottom steel plates used were too thick for use in such systems. Normally thin plates were
used for complete transfer as composite system on the interface.
4. Some beams required strengthening for hogging moments. These beams had not been attended.
5. There were no signs of foundation settlement and associated cracking of the in-fill walls.
6. There were some separation cracks on concrete face of the column and the block walls. These
cracks were of no consequence, structurally.
10 7. There was no sign of any corrosion setting-in.
8. The quality of concrete was tested and the strength was found to be more than adequate. In fact
inspection of concrete showed strength results more than 25% of the required value.
9. The slabs had been checked and found adequate.
10. Foundations were checked with Soil bearing capacity 35 t/m2 and were found to be adequate.
REPAIR STRATEGY
The repairs required can be classified into three different categories..
Type – 1
Beams, which were not repaired earlier with steel plates, but on examination now, needed to be strength-
ened for sagging moment and shear.
Type – II
Beams, which already had strengthening steel plates for sagging and shear but the bonding to concrete
was poor and the adhesive grout not dense.
Type – III
Strengthening was required for hogging moment.
60
X-60 Repairs &
Repairs & Rehabilitation
Rehabilitation Unit
Unit
CASE STUDIES
(a) The steps followed in strengthening for sagging moment and shear were as follows:
(i) All loose concrete from beams were chipped off and the surface was kept wet for 24 hours.
Using repair mortar, the beam surfaces were also made even for Type 1 beams. This was not
possible in Type II beams.
(ii) Holes were drilled for epoxy grouted bolts at bottom of beams through concrete for type 1
beams. Steel plate was then fixed to beam bottom by bolts. In case of Type II beams holes
had to be driven through existing steel plate.
(iii) Finally epoxy grout was injected between beam bottom and steel plate for Type 1 beams.
Whereas for Type II beams the existing poor quality grout was made dense by injecting
epoxy grout.
(b) The steps followed to overcome the problem of hogging moment were as follows:
(i) Part of the existing flooring was dismantled to expose R.C.C. in this portion.
(ii) The R.C.C. slab was cut to a depth of 85 mm without damaging existing reinforcement bars
in this area.
(iii) New bars were inserted in this portion and welded to existing reinforcement bars in this area.
(iv) A coat of epoxy bonding agent was applied for joining old concrete to new concrete.
(v) Concrete M-35 was poured and finished to the existing level of RCC in slab.
10


AN INDUSTRIAL SHELL STRUCTURE
SALIENT FEATURES
Period of construction : 1964-70
Distress noticed : 1992 and worsened in 1996-97
Investigated done : 1998
Type of super-structure : 4.90 m high single storeyed shutter finished RCC framed
shell structure with 80 mm thick shell roof.(For lay out
plan refer Fig 10.15.1 and typical cross-section refer Fig
10.15.2) The expansion joints are provided in form of GI
Sheet cradle filled with bituminous board and top sealant
(Fig 10.15.3).
VISUAL OBSERVATIONS
1. Rusting stains were observed at few locations, which gave an impression of onset of corrosion.
2. A number of cracks were seen on the soffit of shell roof. The width of cracks varied from hair
cracks to 3mm(Fig 10.15.4).
3. Leakage signs through construction joints were seen.
4. Existing tar felt treatment was cracked/debonded at several places and had out lived its life. The
tar felt treatment had been damaged at locations by dash fasteners of lightning fixtures.
10 5. Expansion joints have failed due to rusting of GI sheet cradle.At some places, expansion joints
were filled with unwanted concrete material.
6. Leakages were also noticed from bay windows through joint of masonry and window frames.
7. Mild steel reinforcement exposed at few locations and found to be in passivated and good condition
REVALIDATION OF STRUCTURAL DESIGNS

The stuctural analysis for the shell roof was carried out which indicated that the existing provisions are
satisfactory.
NON-DESTRUCTIVE TESTS
Carbonation Test
Carbonation depth of concrete in shell roof measured and top 3 to 6 mm thickness observed as carbon-
ated and had not reached reinforcement level.
It was observed that the range of corrosion potential measured from (-) 69mV to (-) 161mV indicative
of 90% probability that corrosion is not active.

CASE STUDIES
CONCLUSIONS
The distress is at initial stage and following are the most probable causes:
1. Failure of expansion joints due to corrosion and damage to GI sheet cradle caused ingress of rain
water
2. Failure of existing tarfelt treatment and exposure of concrete surface of shell roof at places.
3. Entry of rain water through overlaps and leakage through cracked and/or honey combed RCC
shell roof at shuttering joints of shutter finished surface.

A. Remove tarfelt treatment and injection grout all cracks and honey combed concrete with non-
shrink polymer modified cement grout.
B. Replace the tarfelt water proofing treatment with UV ray & abrasion resistant thin water proofing
polymeric membrane after cleaning surface and preparing the same by filling the depressions,
preparing slopes of valley drains, etc.
C. North light windows to be treated with silicon sealants
D. Provide a remodelled and improved the expansion joint(Refer Fig 10.15.5)
The repairs to be done as under :
1. Existing tarfelt treatment to be removed and roof surface to be cleaned.
2. The roof surface to be carefully inspected and all affected area to be marked.
3. All fasteners and fittings to be removed and replaced by small size fasteners and fitings.
4. Holes of fasteners and fittings to be plugged with polymer modified cement mortar.
5. V- grooves to be made along the cracks and aluminium nipples to be fixed along the grooves and
on honeycombed RCC surface, if any.
6. Non-shrink polymer modified cement grout to be injected through nipples and nipples to be cut
and sealed with nonshrink suitable compound.
7. Then entire roof to be cleaned by wire brushes and depressions to be filled with polymer modified 10
cement mortar over a bonding coat of polymer modified cement slurry.
8. After curing, specified waterproofing treatment to be applied to the surface.
9. Expansion joints shall cleaned properly improved to work effectively.
10. Drain between the two shells to be treated with water proofing treatment as explained above and
wearing surface to be treated with 10mm thick 1:3 polymer modified cement mortar, upto a height
of 150mm above the bed level of drain.
11. The gap of windows and walls to be filled with suitable polymer compound.
12. Proper checks on quality / progress to be maintained.

Fig 10.15.1: Lay Out Plan
12.85m
75mm Th. R.C.C.

Shell Roof
R.C.C. R.C.C.
Beams Beams
Beams at Expansion Joint

& on Columns
North Light
Windows
(Fixed Glazed)
R.C.C. Columns
0.43m 0.43m 4.90m
10 75mm Thick Flooring
9.00m 9.00m
Fig. 10.15.2: Typical cross-section of Shell Roof
G.I. Sheet
C.C.
25mm Thick
Expansion Joints
Fig. 10.15.3: Typical detail of Existing Expansion Joint

CASE STUDIES
0.45m
T-Beam (RCC) Size 0.44x0.64
0.075m (RCC Slab)
3.205m
3.485m
3.635m
1.39m
2.17m
2.75m
3.69m
0.4m
1m 1m 1m 1m 1m 1m 1m 1.42m 0.84m
0.4m
8.82m
R.C.C. Column Size 0.44x0.64
0.64m
Expansion Joint R.C.C. Beam (T)

0.44m
0.60m
6.00m 6.00m
4.00m 3.60m
0.60m
0.35m
0.30m 0.45m
Beam Size 0.84x0.44m
1.85m 1.85m 1.85m 1.85m 1.85m 1.85m 1.85m 1.85m 1.85m 1.85m
0.44m
0.91m Fig 10.15.4 CRACKS DEVELOPED ON CEILING
Fig. 10.15.4(a): Typical curved profile of shell roof as per site measurement
Fig. 10.15.4(b): Typical pattern of cracks observed in soffit of shell slab
10
Fig 10.15.5: Detail of improved Expansion Joint

Plate 1: Inside view of a typical shell è
Plate 2: Damage caused to water proofing

Treatment by fixtures for Electrical è
lighting
Plate 3: Expansion Joint as provided originally.

The outlived tarfelt visible. è
10
Plate 4: Seepage through cracks in RCC

è Shell roof

CASE STUDIES

FOUR STOREYED RCC FRAMED
RESIDENTIAL QUARTERS AT BANGLORE
SALIENT FEATURES
l Type of Superstructure : Four storied RCC framed structure with masonry filler
walls
l Type of foundation : Isolated footing
OBSERVATIONS
Based on Structural Drawings & Soil Investrigation Report:

1. Filled- up soil extends to about 1.8-2.0 metre below ground level. The natural sub-soil water level
was reportedly more than 100 metres below GL.
2. The foundation was resting on clayey soil strata.
3. The depth of RCC footing was observed at 1.80 metre below GL.
4. Internal partition walls at ground floor were without grade beams and supported direct on flooring.
5. The outer walls were supported on grade beams.
6. The outer RCC footings were having lower foundation pressures as compared to internal RCC
footings
Based on Visual Observations:

Linked to Damage at Ground Floor 10
1. About five years back, diagonal cracks reportedly developed in the internal masonry walls at
ground floor only.
2. Cement concrete flooring and internal partition walls on ground floor developed more severe
settlement cracks with horizontal cracks in the walls and skirting.
3. A storm water drain existed with dry masonry lining outside the complex at a distance of above 2.0
metre from the two blocks of quarters. The drain is cut off during road construction about five
years back and has no disposal point. No complaint was ever heard of stagnant storm water in
such a dead end drain. Naturally, the rainwater continued to seep intermittently into foundation of
quarters.
Linked to Damage at other floors
4. The two blocks under distress were located at the lowest ground surface level in the complex.
5. Diagonal cracks were indicative of relative settlement of internal columns. The pattern of cracks in
panel walls observed identical on all the upper floor. These cracks were observed only in the
recent past.
6. No damage to or cracking of RCC beams or columns due to over loading was observed.
7. The crack pattern was symmetrical and mirror-image about the central axis drawn through the
connecting stair lobby.

8. Across the road, which was constructed over filled up soil, a low-lying park is located. In the
recent past, this park is in disuse and being used as dumping ground, which resulted in blockade of
drainage points to the adjoining nallah. This caused continued ponding of water at a level higher
than the foundation level.
Linked to Corrosion Damage
9. The thickness of concrete cover to RCC columns found non-uniform and inadequate at places.
10. Some RCC chajjas and facias damaged and a few others split along the reinforcement, apparently
due to corrosion of embedded steel.
FIELD TESTS
Trial Pits
1. Though, the natural sub-soil water level was reported to be much deeper, sub soil water was
encountered even above foundation level understandably due to seepage of water through filled up
soil from a water pond recently developed across the road.
2. It was all filled up soil strata above foundation level and the foundation was resting on pure clayey
soil.
Carbonation Depth of RCC Columns

The carbonation test on all the external columns of the buildings were carried out. It was observed that
concrete in columns had carbonated in the range of 5mm to beyond reinforcement.
Carbonation depth Number of Reading (in %)

Upto 10mm 26%
11mm-25mm 18%
10
26mm-40mm 11%
Beyond reinforcement 45%
CONCLUSIONS
1. Damage at ground floor in the form of cracks in internal panel walls and floor settlement noticed
about five years back occurred due to settlement of filled up soil underneath the floors and walls on
account of intermittent seepage of storm water from dry pitched masonry drain around the buildings.
2. Cracks in internal panel walls at upper stories including ground floor and settlement of floors in the
recent past is attributed to:
a) Percolation of water in clayey sub-soil strata below foundation level due to continuous
ponding in the nearby low lying ground and consequent differential settlement on account of
highly varying bearing pressures below the footings.
b) Poor drainage of rainwater due to non-functioning of surface/storm water drains in the complex,
responsible for percolation of rainwater into foundations below.
3) The main cause for early distress of RCC members in the building attributed to
b) Accelerated carbonation of cover concrete due to alternate wetting and drying of concrete
in exposed RCC members.

CASE STUDIES
REHABILITATION MEASURES
1) Arresting further differential settlement of footing.
a) PVC sheet barrier as per the arrangement shown in the figure to be provided near the building
upto the level below the footing of columns to prevent flow of rain/subsoil water from sides to
save the buildings from damage due to settlement.
b) The ground surface in the complex to be dressed and provided with adequate slope to discharge
the rain water as quickly as possible. The plinth protection provided all round the building to
be repaired and made pucca to ensure that no rain/surface water accumulates or percolates
into the soil near the building.
c) After allowing the settlement to stabilize for a period of at least 12 months, the repair to
masonry to be carried out as specified. Flooring to be redone wherever damaged.
2) Repairs to distressed RCC columns, beams and slabs
Carry out structural Repairs as per Appendix 6.1
10

(a) Stage-I
10
(b) Stage-II
(c) Stage-III
Fig. 10.16.1: Operation for Providing Moisture/water Cut off Barrier

CASE STUDIES

AUDITORIUM PORTION OF AN INSTITUTIONAL
BUILDING AT DELHI
SALIENT FEATURES
l Year of consrtuction : 1994
l Distress noticed : 1997
l Year of investigation : 1999
l Type of structure : An RCC Framed Auditorium on stilts with circular-curved
shape in plan at two ends (Refer isometric framing view
at Fig 10.17.1).
VISUAL OBSERVATIONS
1. Sagging of the curved beams in plan viz 52-59 and 12-19 of ground floor roof supporting 230 mm
thick brick wall.
2. Brick masonry wall resting on left beam showed horizontal and inclined cracks at chhajjas level.
3. Cracks became wide and out ward deflection of wall increased after the earthquake in February’
99.
4. Gola on the roof separated from the beam/ parapet walland waterproofing treatment also
delaminated and failed.
5. The size of curved beam provided was 230x900 mm for span of 12m to take a load of brick
masonry 230mm thick and about 5m high.
6. There was no sign of distress at site due to loss of structural integrity of curved beam at its junction
with RCC column.
10
CONCLUSIONS
1. Failure of curved beam in combined bending, shear and torsion due to its inadequate size and
insufficient reinforcement.
2. The structure without additional supports below curved beams is unsafe and could collapse over a
period of time.

1. Provide two additional columns located at ¼ span of curved beams
2. The rehabilitation and strengthening of RCC curved beams by jacketing.
The above repairs/ strengthening shall be done in the following steps: -
(i) Removal of masonry wall over curved beams.
(ii) Jacking up curved beam and RCC slab at first floor level.
(iii) Provision of column supports below curved beams at first floor level.
(iv) Strengthening of curved beam by additional reinforcement and increasing its size.
(v) Extending column supports beyond curved beams at first floor level up to roof level.
(vi) Removal of props and supports below curved beam at first floor level and reconstruction of
masonry wall.

(vii) Jacking up the curved beam and sagged RCC slab, at terrace level.
(viii) Concreting of the left over height of column.
(ix) Strengthening of curved beam at terrace.
(x) Rectifying the gola on roof wherever damaged or detached from wall / beams as per the
normal practice.
Fig 10.17.1: Isometric View of Framing System of the

Auditorium Hall
10

CASE STUDIES
Plate 1: View of curved wall supported

è
over inverted beam
è Plate 2: Separation gap between the curved wall and the

straight wall
10
Plate 3: View of cracked curved masonry Wall showing è

outward deflection of lower portion.
è Plate 4: Cracks in curved wall resting on circular beam


A VIP CONFERENCE CENTRE AT DELHI
(Source: Central Designs Organisation, CPWD, New Delhi)
SALIENT FEATURES
l Year of constrution : 1957, large scale renovation and modification in 1983
l Type of structure : Building with a total plinth area of 6500 sq.m. and consisted
of three components
a) Auditorium: RCC framed construction with
foundation consisting of isolated/combined footings. The
floor slab supported over the columns with the basement
below. The roof slab was with C.G.I. Sheet roofing
supported over steel roof trusses.
b) Administrative Block: The three storeyed load
bearing structure with RCC floor slab/roofs and load
bearing walls, supported over RCC strip footing.
c) Rear Block: The three storeyed RCC framed
construction with beam/slab arrangements for intermediate
floors and C.G.I. sheet roofing supported over steel
trusses.
l History of Fire : The fire started from false ceiling of the room on second
floor of rear block. The fire soon spread to other parts of
the rear block. Later ,it gutted the roof of the auditorium
which was completely burnt down.The fire had caused
10 severe and extensive damage to the building and its
content.
l Duration of fire : More than 1 hour.
VISUAL OBSERVATIONS
1. Collapse of the roof trusses.
2. Severe and significant cracks observed in a few concrete members.
3. Minor to considerable spalling of concrete noticed in columns, beams and slabs.
4. Reinforcement exposed in some columns, beams and slabs.
5. Minor peeling to total loss of plaster seen in the filler walls, RCC columns, beams and slabs.
6. Excessive distortion observed in a few columns.

a) Estimation of Temperature
Based on the inspection of debris like charring wood, softened glass panes, bitumastic layered
coatings, molten CGI sheets, PVC material, aluminium frames, damaged/destroyed false ceiling
and wall panels, plaster on walls etc, estimation temperature at floor level was 200O C and at roof
level 1100O C at specific locations,
74
X-74 Repairs
Repairs &
& Rehabilitation
Rehabilitation Unit
Unit
CASE STUDIES
b) Non-destructive Test
Core Test
Sl. Member No of Equivalent Cube Strength of Concrete in N/sq mm
No Classification cores Min. Max. Av. s
1 Columns 23 8.64 26.60 16.10 4.78
2 Beams 12 13.16 25.06 18.90 4.39
3 Slab 18 11.75 23.96 17.27 3.06

The results were as under-
Pulse Velocity (km/sec) Number of reading (in %) for Quality of
Concrete
Column Beam Slab
0.0-2.5 22 12 33 Poor
2.5-3.0 14 64 40 Doubtful
3.0-3.5 32 18 17 Medium
3.5-4.5 32 6 - Good
Rebound Hammer Test

The rebound values as under-
Sl. Member No of Equivalent Cube Strength of Concrete in N/sq mm
No Classification cores Min. Max. Av. s
10
1 Columns 12 34 to 39 38 to 56 37 to 52 2.62-5.00
2 Beams 2 28 to 50 39 to 50 33 to 50 -
3 Slab 5 30 to 37 40 to 45 34 to 40 3.88-3.55
c) Laboratory Testing
Thermogravimetric Analysis (TGA)
The results were as under-
Number of samples Estimated temperature range Residual strength
27 100-2000C 80-90%
12 200-3000C 70-80%
2 > 3000C 60-70%
Differential Thermal Analysis (DTA)

This test was carried out on the samples taken from bottom of balcony slab and beam, slab of the main
foyer and some columns. It was found that slab and beam were not subjected to temperature higher
than 5000C but columns were subjected to temperature more than 5000C but less than 5700C.

X-ray Differaction (XRD)

The test was carried out on selective members and found that the main foyer beam was subjected to
temperature higher than 5000C while balcony slab, beam and adjacent slabs were not subjected to
temerature more than 5000C.
CONCLUSIONS
The various fire damaged structural members were classifed into class of damage 1, 2, 3 & 4. This
damage classification was based on the visual inspection and non-destructive tests conducted on the
members. The residual strength of concrete was assessed on the basis of the results of various tests
done on the damaged strucutre.

For the purpose of formulating the recommendations, the extent of damage and their repair, measures
were classified into four major categories.
1. For class of damage-1 (Superficial repairs), consisting of
(i) Cement plaster application over treated surfaces.
2. For class of damage-2 (General non structural or minor strucutral repairs) consisting of
(i) Cement based polymer modified mortar over cement slurry bonding coat.
(ii) Epoxy mortar treatment over epoxy primer coating with or without wiremesh reinforcement.
3. For class of damage -3 (Principal repairs on members with significant strength reduction)
consisting of
(i) Shotcreting on slabs/beams/columns by providing steel wire mesh reinforcement.
(ii) RCC jacketing of column members.
10 (iii) Sealing of structural cracks by epoxy grout injection
(iv) Sealing of honey combed portions by cement grouting.
4. Class of damage -4 (major structural repairs),consisting of
(i) Demolishing the heavily damaged members and recasting with fresh concrete with or without
additional reinforcement.
(ii) Strengthening existing or addition of new structural members.

CASE STUDIES
è Plate 1: Main Auditorium after Fire
è Plate 2: Other part of building after fire
Plate 3: Main Auditorium after repairs and

finishing
è
10
è
Plate 4: Columm Jacketting.

Plate 5 : Nipples fixed and cracks sealed è

for injection grout.
è Plate 6 : Injection grouting in progres.
10
Plate 7 : Epoxy mortar repairs in progress. è
Plate 8 :Shotcreting in progress.

CASE STUDIES

MULTI-STOREYED OFFICE BUILDING
(Source: Dr. K. Mani, Scientist, SERC)
SALIENT FEATURES
● Type of stucture : Ten storeyed RCC framed structure having a plan
dimension 35.0 m x 15.0 m, 7 bays of 5.0 m in the
longitudinal direction and 3 bays of 5.0 m in the transvese
direction.
● Investigation done : 1994
● Fire duration : 2 to 4 hours
VISUAL OBSERVATIONS
1. Fire occured in the 9th floor.
2. Extensive spalling of plaster in slab, beam and columns of that floor.
3. Surface cracking observed in slabs.
4. Leaching of lime through cold joints.
IN-SITU EVALUATION AND NON DESTRUCTIVE TEST
Estimation of Temperature
600 to 7000C based on the visual observation of the materials burnt. Aluminium parts were on the verge
of melting. The temperature of the concrete members was around 300 to 5000C.

10
Sl. Member No. of Statistical parameters of UPV values No. of
No Classification Members Min. Max. Av. s points
Km/sec Km/sec Km/sec
1 Columns 7 0.49 to 3.31 3.88 to 4.42 3.25 0.88 579
2 Beams 13 0.47 to 3.83 2.37 to 4.55 3.23 0.93 1332
The UPV values were relatively low in the bottom portion of the beam in the fire affected area.
Rebound Hammer Test

Sl. Member No. of Statistical parameters of UPV values No. of
No Classification Members Min. Max. Av. s readings
1 Columns 7 24 to 45 45 to 64 31.85 5.84 1214
2 Beams 20 23 to 39 45 to 70 39.27 4.83 1542
3 Slabs 11 27 to 43 51 to 64 44.54 5.76 2985

Carbonation Test
Carbonation has taken place beyond the reinforcement level.
CONCLUSIONS
1. The structural members had not been very seriously affected by fire but a few members had certain
amount of deficiencies by way of loss of integrity and carbonation .
2. The high hammer test values were due to the carbonation of concrete surface.

1. Members with low UPV values were to be repaired by grouting with neat cement. Remove cover
concrete to the required depth and gunite in layers with high strength gunite over a layer of welded
mesh, 10G– 100mm x 100mm in each layer.
2. Members with exposure of steel reinforcement were repaired by grouting with neat cement. Remove
cover concrete to the required depth, adding extra steel reinforcement if required and guniting in
layers with high strength gunite over a layer of welded mesh, 10G– 100mm x 100mm in each layer.
3. The unaffected members were recommended for replastering with cement mortar.
10

CASE STUDIES
Plate 1: Damaged Column & Beam Junction
10
Plate 2: Damaged Beam

GLOSSARY
GLOSSARY
Abrasion The wearing away of material by friction. Surface particles become detached by a
combined action of shearing and tearing.
Absorption The surface penetration of fluid in small pores of a material.
Adhesion The force acting on the interface of two solid materials
Admixture A material other than water ,aggregates and cement used as a component of concrete
or mortar and added to the batch during its mixing
Air Entraining The capability of material or process to infuse air in the cement paste,mortar or
concrete through a system of minute air bubbles.
Alkalinity The condition of having or containing alkaline substances with hydroxyl(OH-) ions
to cause its pH more than 7.
Ambient Temperature The environmental temperature surrounding an object
Anode The positive electrode where oxidation occurs due to electrons moving in to the
electrode.
Capillary Action Rise of fluid in a small diameter ( capillary ) tube due to surface tension of the
fluids.
Carbonation The process of conversion of calcium hydroxide in hardened cementitious material
in to calcium carbonate due to reaction with atmospheric carbon dioxide
Cathode At negative potential, electron are drawn away from it and chemical reduction
reaction occurs.
Cathodic protection The method of protection of a metal from corrosion by making it a cathode by
impressed currant of by introduction of a lesser noble metal.
Chloride Content The total amount of chloride ions including the fixed chlorides (non-soluble in pore
water) present in concrete or mortar
Cold Joint A construction joint formed due to setting of concrete/mortar before placing of next
bach of material
Condition Survey Condition survey is an examination of structure for the purpose of identifying and
defining area of distress.
Corrosion The process of deterioration of concrete or reinforcement due to chemical or
electrochemical change caused in presence of moisture.
Corrosion Inhibitors The chemical, when added to concrete in small proportions, checks or retards the
process of corrosion of embedded steel reinforcement.
Cover The least distance between the surface of the reinforcement and the outer surface of
the concrete.
Creep The irrecoverable strain caused to a material subjected to constant stress for a long
duration.
Curing The process of maintaining sufficient moisture and temperature in the concrete after
its placing in position, which is absolutely necessary for its complete hydration.
Delamination A separation, splitting or cracking roughly parralel and near to surface.
Depassivation The loss of alkalinity in the immediate vicinity of steel reinforcement due to
carbonation process so as to cause dissolution of its protective passive layer.
Design Service Life The life specified for the structure at its design stage for it to adequately perform its
functions.
Central Designs Organisation G-1

Disintegration Breaking into small fragments.

Dry Pack Concrete Stiff mix of concrete / mortar usually compacted by ramming
Drying Shrinkage The shrinkage caused due to loss of water from concrete after its hardening.
Durability The characteristic of a structure to resist gradual degradation of its serviceability in
a given environment for the design service life.
Electrolyte Any substance which when dissolved in water or other suitable solvent forms a
solution that conducts electricity, due to ionic dissociation of the dissolved substance
in a solvent .
Environment of The surrounding conditions of temperature, humidity, chemicals etc of
a structure or structural member to which it is exposed to.
Epoxy It is a high strength adhesive compound formed as a result of polyerisation of resin
at ambient tempearture in presence of a specified proportion of hardener.
Ettringite The expansive crystals that swell due to adsorption of water in alkaline environment.
These crystals are formed due to reaction of alumina containing hydrates in hardened
cement paste with sulphate ions in presence of calcium hydroxide.
Feather Edge The bevelled edge of a repair concrete or mortar which is at an acute angle from
the surface.
Ferrocement It is thin walled reinforced cementitious construction using more than one layer of
continuous small diameter metallic wire mesh.
Fibre Wrap Integrating woven or non-woven high strength fibre ( e.g. E-Glass fibre,
Techniques Carbon Fibre,Aramid, Polyester etc.) with epoxy, around structural element to protect
and/or enhence its structural capacity.
Gel A semisolid jelly like condition of matter.
Grouting Pumping of a fluid cementitious material in to crevices of a cracked material or the
interconnected pores of a porous material with a view to enhence the density/
strength of the material.
Hydrophobic Property of non-wetting or repelling water.
Joint Sealant Compressible material used to exclude water and solid foreign materials from entering
the joints
Latex Natural or synthic rubber emulsion in water phase.
Leaching The draining out of water soluble salts from concrete due to movement of water.
Load carrying The capacity of a structural member to carry loads based on non-
capacity destructive evaluation results and their analysis.
Maintenance A general term for actions taken to ensure that a structure conforms to its original
functional performance above a given level of acceptance.
Non Destructive The sampling/testing in laboratory/field without affecting the functional
Evaluation (NDE) utility of structure.
Original Construction Defects inherent in the original construction due to improper design,
Defects (OCDs) material selection or workmanship.
Passivation Formation of a protective layer of ferric oxide around embedded reinforcement
under highly alkaline environment.
G-2 Repairs & Rehabilitation Unit

GLOSSARY
Patch Repair The repair to a portion of a structural member to restore it to its original state
pH Hydrogen ion concentration of a solution expressed as negative of logarithm to the
base 10
Polymer It is a long chain of molecules formed by combination of molecules of monomers
in presence of an initiator.
Polymer A process of filling the interstices of a cracked/porous material with
Impregnation polymeric compounds.
Polymerisation Polymerisation is the process of formation of long chain molecules at desired
temperature from monomers in presence of an initiator.
Seepage Uncontrolled admittance of water through interconnected pores.
Re-alkanisation The electro-chemical process of infusing alkaline environment in a carbonated
concrete around steel reinforcement by converting calcium carbonate in to calcium
hydroxide
Rebound Aggregate & cement or wet shotcrete that bounces away from a surface against
which it is being projected.
Rehabilitation The process of repairing or modifying a structure to a desired useful condition.
Repairs To replace or correct deteriorated, damaged or faulty materials, components, or
elements of a structure.
Restoration The process of re-establishing the original appearance, shape and materials of a
structure.
Retrofitting Upgrading the existing structure to meet the enhanced structural requirements in
terms of load carrying capacity of existing structural element or by introducing
additional structural members integral to the existing structure.
Service life The time taken from the completion of a structure till the structure is no longer
usable due to the deterioration process.
Serviceability The necessary performance requirement of a structure to meet its intended function.
Shotcrete Process of application of concrete by spraying under pneumatic pressure.
Spalling Loss of strength and integrity of cover concrete with the interior of concrete due to
expansive force.
Sulphate Attack Dis-integration of concrete due to formation of expansive compounds as a result of
chemical reaction of the constituents of hydrated cement with sulphates ions, present
internally or from ingressed from external source.
Strengthening Measures taken for a deteriorated structure or any of its structural member to restore
its design load carrying capacity.
Workability A property of freshly mixed mortar or concrete, which measures the ease of working
upon it duiring its placement including compaction and finishing.
Bond Breaker Material used to facilitate independent movement between two units, which would
otherwise behave monolithically.
Burlap Vurlap a course fabric of jute, hemp, or flax for use as a water retaining cover when
curing cementitious materials.
Erosion Progressive disintegration of a solid by the abasive or cavitation action of gases,
fluids or solid motion.
Fatigue The weakening of a material by repeated or alternating loads.
Central Designs Organisation G-3

Hardener A substane that enters into a chemical combination with other substances to form a
new, more solid material.
Laitance A layer of weak and non durable material containing cement and finds from
aggregates, brought to the top of oval-wet concrete by bleeding water.
Shelf life The useful life of the material.
Permeability The property of the material which allows the fluid through a solid material.
Membrane/Coating A thin, waterproof barrier consisting of polymeric material which may be
prefabricated or applied as a liquid.
Plastic Shrinkage Shrinkage that takes place before cement plaste, mortar, grout, or concrete sets.
Polymer Concrete/ Concrete or mortar in which a resin serves as a binder.
Mortar
Porosity The ratio, usually expressed as a percentage of the volume of voids in a materials, to
the total volume of a material, including the voids.
Pop Out A shallow, corical depression on the surface of concrete.
Pot life Storage time interval after mixing, during which a liquid material can be used without
difficulty.
Quality Assurance A system of proceeding that ensures that the intended levels of quality on a project
are obtained.
Restraint Restriction of free movement of fresh or hardened concrete, mortar, or grout; restraint
can be internal and external and may act in one or more directions.
Retardation A reduction on the rate of hardening or setting, I.e., an increase in the time required
to reach initial and final set, or to develop early strength of fresh concrete, mortar,
or grout.
Scaling Local cracking or peeling away of the surface concrete or mortar.
Silicafume/Microsilica Highly reactive pozzolana, a by-product of ferrosilicon production.
Siloxane A silicon and oxygen-based compound, also containing carbon and hydrogen used
as penetrating sealer for concrete surfaces.
Silane A solution of a low molecular weight compsition of silicon and hydrogen used as
penetrating sealer for concrete surfaces.
G-4 Repairs & Rehabilitation Unit

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HANDBOOK ON

REPAIR AND REHABILITATION

First published in 2002

(ER. KRISHAN KUMAR),

Chairman : Shri S L Karunakaran, Consultant to Govt of India and ADG(Retd.),

A. Encouragement, Guidance and Support:

❐ CHAPTER 1.................................................................... I-1 to I-4

1.1 An Overview of Present Repair Practices I-1

1.2 Distress Identification I-2

1.3 Repair Management I-3

1.1 An Overview of Present Repair Practices

Central Designs Organisation I-1

1.2 Distress Identification

I-2 Repairs & Rehabilitation Unit

Concrete normally provides excellent protection to reinforcing steel. Notwithstanding this, a

1.3 Repair Management

Central Designs Organisation I-3

I-4 Repairs & Rehabilitation Unit

CAUSES OF DETERIORATION AND

Suggested further reading Material and References II-14

Appendix 2.1 II-15

Central Designs Organisation II-1

2.1 Holistic Model of Deterioration of RCC

Fig 2.2: Holistic Model-I of Concrete Deterioration from environmental effects

II-2 Repairs & Rehabilitation Unit

Fig. 2.3: Holistic Model-II of Deterioration of RCC

Central Designs Organisation II-3

Fig. 2.4: Ternary Representation of the Damage to RCC

2.2 Permeability Of Concrete

1. Capillary Porosity -High w/c ratio

II-4 Repairs & Rehabilitation Unit

4. Macro cracks -Placement,

Fig. 2.5: Permeability of cement paste is a function of water-cement ratio

For understanding the permeable character of concrete, it is necessary to understand the

Fig. 2.6(a): Changes in capillary porosity with varying degree of hydration

Fig. 2.6(b): Changes in capillary porosity with varying w/c ratio

II-6 Repairs & Rehabilitation Unit

Table 2.1: Curing Time required Table 2.2: Typical Reduction in

Fig. 2.7 Crack propagation in tensile zone of an RCC beam.

Central Designs Organisation II-7

l Differential Thermal Exposure: The structural members having different thermal

Fig. 2.8 Cyclic process of thermal loading of a structural member.

II-8 Repairs & Rehabilitation Unit

- Improper placement of concrete,

(a) Corrosion of reinforcing bar - Due to carbonation of concrete

Central Designs Organisation II-9

Fig. 2.9 Corrosion of reinforcement due to environmental elements

Carbonation: The alkalinity in concrete is provided by hydroxides of calcium, sodium and

II-10 Repairs & Rehabilitation Unit

Central Designs Organisation II-11

II-12 Repairs & Rehabilitation Unit

contain gypsum which forms as a result of progressive decomposition of calcium hydroxide

2.4 Durability Aspects:

II-14 Repairs & Rehabilitation Unit

SUGGESTED FURTHER READING MATERIAL AND REFERENCES

1. Mehta, P. Kumar and Monteiro,Paulo J.M., CONCRETE-MICROSTRUCTURE,

5. Concrete Society Technical Report No 26, “Repair of concrete damaged by

Central Designs Organisation II-15

INTRINSIC & EXTRINSIC CAUSES AND STAGES OF DISTRESS