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INTRODUCTION
Concrete construction is generally expected to give trouble free service through out its
intended 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 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.
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 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.
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, 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 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
engineering 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.
Item
No.
Description of item
Unit of
Measurement
sqm
cum
cum
cum
cum
cum
cum
Item
No.
Description of item
Unit of
Measurement
metre
metre
metre
metre
metre
metre
Item
Description of item
No.
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.
(a) Bars upto 12 mm diameter
Unit of
Measurement
metre
metre
each
each
each
8.1.8 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
B 16mm dia. 400 mm long@ M.S. shear key
each
each
Item
No.
Description of item
Unit of
Measurement
sqm
sqm
Sqm
each
each
each
each
each
each
each
each
Item
No.
Description of item
Unit of
Measurement
each
Each
kg
kg
kg
kg
Item
Description of item
Unit of
No.
Measurement
8.2.2 Injecting approved grout in appropriate proportion excluding cost
of such grout material covered under item No. 8.2.2a into cracks/
honey-comb area of concrete/masonry 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
b) Masonry Work
Kg
Kg
Kg
Kg
Kg
Kg
a) Concrete/RCC work
b) Masonry work
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
Kg
Kg
Kg
Item
No.
Description of item
Unit of
Measurement
Kg
Kg
Kg
Kg
Kg
Kg
Kg
Kg
Item
No.
Description of item
Unit of
Measurement
litre
Kg
i) Primer coat
ii) Sealer Coat
C
litre
Kg
Kg
4A
Refer Introductory and General Notes along with the following Chapter Notes :
Chapter Notes :
GENERAL :
Structural Rehabilitation is a specialized subject in itself. As such before undertaking the
structural repair of a building, following principles may please be clearly understood.
(i)
(ii)
(iii)
(iv)
These repairs are basically Design Repairs. Like a building is designed before
undertaking construction, these repairs are required to be Designed before
undertaking rehabilitation. As such maximum Data should be collected through visual
inspection, NDT & material testing to prepare design of repair.
(v)
The aim of rehabilitation should be extend the life of structure by at least 30 years
Clean the corroded bars with mechanical means like wire bush, sand paper etc.
(iii)
(iv)
(v)
(vi)
(vii)
The above guideline is very brief and generic. Many other alternatives like rust converters,
migratory corrosion inhibitors, cathodic protection techniques, bond coats of several types, ready mix
polymer mortars etc. are available. Hence, detailed study should be undertaken for deciding the
methodology of repair.
IMPORTANT
There are large number of companies manufacturing construction chemicals. The products
of each company is typical. While approving the product, it should be ascertained that minimum
technical standards as given in Specification are fulfilled. Further necessary tests should be ordered to
ascertain quality as required.
MEASUREMENT
In all cases of repairs by construction chemicals, the required quantity of chemicals shall be
first supplied in depot, which shall be recorded in MB by Sectional / Sr. Sectional Engineer. This shall
be further 100% test checked by ADEN. The quantity then shall be issued back to contractor for repair
work. The day to day consumption record shall be maintained as is done for cement.
PRECAUTIONS
Construction chemicals are manufactured by more than 50 companies and their numbers are
increasing. Every company has its own brand names. Due to this, it is difficult to determine the
product which will be economical as well as technically correct choice. However, some basic
principles can be applied in this regard.
i)
ii)
Generally IS codes/standards are not available for repair chemicals. In such cases,
appropriate ASTM standards/B.S. Standards should be referred. A sample should be got
tested according to these standards. The schedule items for testing is given in the chapter
of Material Testing.
iii)
In no case any acidic base material shall be used as it helps corrosion process. Materials
shall be ALKALINE BASED
iv)
Item
No.
1.
25101
25102
25103
25104
Clear meaning of the terms POLYMER, EPOXY, RUST REMOVER etc. must be
understood. E.g. all epoxys are polymers but a polymer may not be epoxy because
polymer is a Generic name based on the molecular structure of the material. Word
Epoxy is also a generic name. More than 300 (Three Hundred) various formulations of
epoxies are available.
Therefore, it is important to choose the construction chemical after studying various
technical aspects of the material.
Description of work
2.
Unit
3.
Mumbai Other
Division Divisions
of C. Rly.
4.
5.
19.50
14.60
113.60
107.90
319.50
319.50
171.10
171.10
Qty.
of
Ceme
nt
bags
R
e
m
a
r
k
s
6.
7
.
25105
M2
36.50
36.50
M2
99.40
99.40
M3
3230.20
2584.20
25108
25109
25110
18.80
18.80
26.45
26.45
23.30
23.30
25111
25112
25113
25114
Plastering with cement mortar 1:3 using quartz sand (2.36 mm and
down graded) in place of ordinary sand with water cement ratio 0.40
and finishing the surface smooth in proper line, level & plumb in all
positions. The rate includes use of required admixtures as per
manufacture specification for achieving desired water cement ratio:
(Generally to be used in exterior finishing and in areas, which are
subjected to heavy rain lashing or dampness etc.)
a) 15mm Thick
M2
b) 20mm Thick
M2
M2
c) 25mm Thick
Providing and fixing G.I. weld mesh of 12 SWG, 50 mesh of
approved quality on existing concrete surface with the help of nails,
binding wire etc. with all contractors, labour, material, tools & plants,
leads, lifts, scaffolding etc. complete in all respects. The mesh is to be
fixed to concrete surface by drilling holes and fixing U hooks to hold
the mesh and shall not be tied to the corroded reinforcement.
M2
Providing and fixing chicken mesh of 20mm opening and 21 SWG of
approved quality on existing concrete surface with the help of nails,
binding wire etc. with all contractors labour, material, tools & plants,
leads, lift, scaffolding etc. complete in all respects. The mesh shall be
fixed to the concrete surface and not to the existing corroded M2
reinforcement.
Removing existing Nahanis completely including breaking masonry,
flooring iron Nahani trap etc. and removing the debris to the nearest
Municipal Dump Site complete as directed. Care to be taken to ensure
least damage to existing tiles, with all contractors tools & plants, Each
labour, material, leads, lifts etc. (For repairing leaking Toilet floors)
123.15
160.10
209.25
110.80
144.10
188.30
74.50
74.50
30.25
30.25
26.60
21.30
25115
25116
19.00
15.20
18.45
18.45
25117
Kg
235.45
235.45
\
25118
25119
1291.65
1033.30
122.35
110.10
Item
No.
Description of item
Unit of
Measurement
CHAPTER 4 B STRUCTURAL REPAIR ITEMS
8.4.1 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
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
cum
B Grade M30
cum
C Grade M40
cum
D Grade M50
cum
E Grade M60
cum
8.4.2 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 Engineerin-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)
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
b) 50 mm thick in Grade M 20 with cement content not
sqm
less than 320 Kg per Cu M
c) 75 mm thick in Grade M 20 with cement content not
sqm
less than 320 Kg per Cu M
d) 25 mm thick in Grade M 25 with cement content not
sqm
less than 350 Kg per Cu M
e) 50 mm thick in Grade M 25 with cement content not
sqm
less than 350 Kg per Cu M
f) 75 mm thick in Grade M 25 with cement content not
sqm
less than 350 Kg per Cu M
g) 25 mm thick in Grade M 30 with cement content not
sqm
less than 400 Kg per Cu M
Item
No.
Description of item
Unit of
Measurement
sqm
sqm
sqm
sqm
sqm
Item
No.
Description of item
d) 50 mm thick in Grade M 20 with cement content not
less than 320 Kg per Cu M
e) 150 mm thick in Grade M 25 with cement content not
less than 350 Kg per Cu M
f) 100 mm thick in Grade M 25 with cement content not
than 400 Kg per Cu M
g) 75 mm thick in Grade M 25 with cement content not
less than 350 Kg per Cu M
h) 50 mm thick in Grade M 25 with cement content not
less than 350 Kg per Cu M
i) 150 mm thick in Grade M 30 with cement content not less
than 400 Kg per Cu M
j) 100 mm thick in Grade M 30 with cement content not less
than 400 Kg per Cu M
k) 75 mm thick in Grade M 30 with cement content not less
than 400 Kg per Cu M
l) 50 mm thick in Grade M 30 with cement content not less
than 400 Kg per Cu M
Unit of
Measurement
sqm
sqm
sqm
sqm
sqm
sqm
sqm
sqm
sqm
sqm
sqm
sqm
Item
No.
Description of item
Unit of
Measurement
.
Item
No.
Description of item
Unit of
Measurement
sqm
sqm
sqm
sqm
sqm
sqm
sqm
sqm
sqm
sqm
sqm
kg
Item
No.
8.4.8
Description of item
Unit of
Measurement
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)
Rate include labour, scaffolding, material, tools and plants etc
complete the application procedure shall be as per manufacture
directives & approved by engineer in charge
A 25 mm average thickness for slabs
sqm
sqm
sqm
Kg
cum
Item
No.
Description of item
Unit of
Measurement
Item
No.
Description of item
Unit of
Measurement
CHAPTER 5 CURING
8.5.1Wet 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
a) Using non-pigmented wet curing compound
b) Using pigmented wet curing compound
8.5.1a Supplying pretested and approved water based concrete curing
compound
A Non-pigmented wet curing compound
B Pigmented wet curing compound
sqm
sqm
litre
litre
Item
No.
Description of item
Unit of
Measurement
Description of item
Unit of
Measurement
sqm
kg
kg
sqm
sqm
sqm
Item
No.
Description of item
Unit of
Measurement
sqm
sqm
sqm
sqm
Item
Description of item
Unit of
No.
Measurement
8.7.4 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 Engineerin-Charge. The rates shall include cost all materials, labour and
operations but shall exclude the cost of bond coat, which shall
be paid separately
sqm
Item
No.
Description of item
Unit of
Measurement
CHAPTER 8 : MASONRY REPAIR
8.8.1Cutting, removing, and rebuilding the decayed/damaged masonry with
A Brickwork of 2nd sort in superstructure
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)
cum
cum
cum
In situ concrete 1:2: 4 (1-cement: 2-coarse sand : 4-12 mm Per brick or part
and downsized graded stone aggregate) in part section of a
thereof
brick or part there of.
C Build up by guniting in thickness
a) up to 25 mm
sqm
b) Above 25 mm but not exceeding 50 mm
sqm
D Applying bonding coat, providing & fixing GI wire mesh
and building up the masonry section to required thickness
sqm
on existing surface with the help of nails ,binding wire etc.
with all contractor, labour ,material, tools & plant ,all lead &
lift scaffolding etc complete in all respect by providing
polymer mortar 1:3 (1-Cement : 3-Sand Conforming to zone-III
as per IS : 383) in layers not more than 12mm in thickness
or part there of.
Note : The wire mesh shall be fixed to the concrete surface and not to
the existing corroded reinforcement.
8.8.1aSupply of polymer for polymeric bond coat and/or polymer mortar
A Emmulsified Acrylic Polymer (rates shall be in terms of solid
Kg
contents of polymer)
B Emulsified SBR polymer (Rates shall be in terms of solid
contents of polymer
8.8.2 Repair of cracks in 115 mm/230 mm thick masonry wall by
cutting the masonry, and providing and fixing precast RCC runners
Kg
Kg
Each
Item
No.
8.8.4
Description of item
Unit of
Measurement
cum
cum
sqm
8 .8.7 Supply of polymer for polymeric bond coat and/or polymer mortar
A Emmulsified Acrylic Polymer (rates shall be in terms
Kg
of solid contents of polymer)
B
contents of polymer
Kg
sqm
All preparatory works like transportation & installing of equipment at site, providing
staging, scaffolding, Jhoola etc. as required
at site.
(ii)
Carrying out the work during block timing, if required in cases like bridges etc.
Item
No.
Description of item
Unit of
Measurement
sqm
8.9.2
Each
Measuring the Half Cell Potential readings at the nodes of premarked grid on concrete surface for determining the probability
of corrosion activity of embedded steel reinforcement in concrete with
after moistening the concrete surface with water. The rate shall include
surface preparation, moistening concrete surface, marking on structure
with 5 cm size lettering in yellow paint for easy identification all the
operations and materials enumerated above, necessary scaffolding
Each
Item
Description of item
No.
A i) With Copper-Copper Sulphate Half Cell Electrode
Unit of
Measurement
8.9.5
mortar and finished as as per the existing finish. The rate shall
include preparing the sketch indicating the location of the test &
marking on structure with 2 inches size lettering in yellow paint
for easy identification of location and necessary scaffolding &
Each
Each
Each
Each
Item
No.
A
B
A
B
i)
ii)
iii)
iv)
v)
8.9.6
Description of item
Unit of
Measurement
(i)
50 mm diameter
Each
( ii)
75mm diameter
Each
(iii)
100 mm diameter
Each
Testing the extracted concrete cores of any diameter for
i)
Evaluating compressive strength
Each
ii)
Determining density of concrete
Each
(iii)
Determining depth of carbonation with
Each
phenolphthale indicator
iv)
Determining the total acid soluble chloride contents in
concrete as per BS 1881:Part 124
Each
v)
Determining the total sulphate contents in concrete
expressed as sulphate buy mass of concrete as per BS Each
1881:Part 124
T& P and materials etc complete
(i) 50 mm diameter
Each
(ii) 75mm diameter
Each
(iii) 100 mm diameter
Each
Testing the extracted concrete cores of any diameter for
Evaluating compressive strength
Each
Determining density of concrete
Each
Determining depth of carbonation with phenolphthalein
Each
indicator
Determining the total acid soluble chloride contents in
Each
concrete as per BS 1881:Part 124
Determining the total sulphate contents in concrete
Each
expressed as sulphate buy mass of concrete as per BS
1881:Part 124
Determining depth of carbonated cover concrete by spraying
phenolphthalein pH indicator with physicians injection syringe
(or other fine spraying equipment) over freshly broken/drilled
Each
Item
No.
8.9.7
Description of item
Unit of
Measurement
8.9.8
8.9.9
8.9.10
8.9.11
8.9.12
8.9.13
A Plot of reinforcement
sqm
B Cover Thickness
Each
C Bar diameter
Each
Determination of relative density of samples of fluid, Pyknometer
or relative density bottle for polyester resins, etc according to
Annex-F of IS:6746:1994 Part 4) 1992. The test report shall be
prepared and submitted to the Engineer in-charge.
Each
Determination of relative density samples of liquid admixtures
using hydrometer and according to Annex-E of IS:9103:1999
Determination of solid content of samples of polymer according
to IS 13435 (Part 1) 1992
Each
Determination of pH value of sample using pH meter electrode
conforming to IS:2711:1979 and testing done according toIS13435 Each
Determination of viscosity of samples of polyester resin by
Brookfield viscometer, expressed in centipoises according to
Each
Annex-A of IS 6746:1994
Determination of percentage of air entrained in hardened
concrete/mortar due to an admixture with reference to standard
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
Each
8.9.14
Each
8.9.15
Each
Each
Part 124
8.9.16
124
Item
No.
Description of item
Unit of
Measurement
8.9.17
Each
8.9.18
Each
8.9.19
Each
according to Annex E of IS:9103-1999.
Determination of resistance of concrete against freezing and
thawing according to Annex B of IS:9103-1999.
Each
Determination of flow of concrete of high workability concrete
according to Annex C of IS:9103-1999.
No.
Determination of bleeding of concrete according to Annex D of
IS:9103-1999.
No.
content, relative density, chloride ion content &pH) on admixtures
8.9.20
8.9.21
8.9.22
@ the projected length of shear key shall be more than 10 times its
diameter plus half the thickness of cover concrete plus bend l
Description of work
Unit
2.
Carrying out material testing from approved laboratory as per Railways
Specification, relevant I.S. Codes as specified and test procedures
including collecting and labeling samples, transporting to laboratory and
submitting the test reports in 3 copies.
3.
Standard
Rates for
BB & other
than BB
4
Remark
s
5
(I)
CEMENT
Per Test
154.50
154.50
103.00
103.00
515.00
Chemical Analysis
SO2
Tetra Calcium Alumina Fernite (C,AF)
Silica (SiO2)
Alumina (Al2O3)
Magnesia (MgO)
Iron (Fe2O3)
Lime (CaO)
Chloride (CI)
Specific surface
Total Alkalies (N3O + K2O)
Tri Calcium Aluminate (C3A)
Tri Calcium Silicate (C3S)
Di calcium Silicate (C2S)
154.50
154.50
206.00
206.00
206.00
180.25
231.75
103.00
103.00
128.75
309.00
824.00
824.00
(II)
AGGREGATES
(A)
Fine Aggregates
Physical Tests
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(B)
Per Test
103.00
51.50
51.50
51.50
51.50
51.50
Coarse Aggregates
Physical Tests
103.00
103.00
103.00
51.50
51.50
51.50
51.50
51.50
77.25
206.00
154.50
103.00
(III)
(A)
CONCRETE
Per Test
Compressive strength
Moisture content
Water Absorption
Density
Drying Shrinkage
Moisture movement
92.70
41.20
61.80
51.50
154.50
154.50
( B ) Chemical Analysis
(i)
(ii)
(iii)
(iv)
(v)
(C)
103.00
103.00
103.00
154.50
206.00
(IV)
pH
Chloride
Alkalinity
Sulphate
Sulphur Trioxide
77.25
77.25
BRICKS
(i)
(ii)
(iii)
(iv)
Per Test
41.20
61.80
20.60
51.50
Water Absorption
Compressive strength
Density
Efflorescence
(V)
Abrasion
(iii)
(iv)
Transverse
Acid resistance test
(ii)
(VI)
(VII)
(VIII)
Per Test
Crazing
Water Absorption
Impact
103.00
41.20
41.20
WOOD
(i)
(ii)
(iii)
(iv)
Per Test
Moisture Content
Density
Sp. Gravity
Retroactivity
103.00
103.00
103.00
257.50
FLUSH DOOR
(i)
(ii)
(iii)
(iv)
103.00
41.20
41.20
309.00
Water Absorption
CERAMIC TILES
(i)
(ii)
(iii)
Per Test
Per Test
Thickness
End Emerson Test
Glue adhesion test
Knife test
41.20
206.00
206.00
103.00
(IX)
(X)
PLY WOOD
(i)
Density & Moisture Content
(ii)
Water resistance
(iii)
Mycrological Test
(iv)
Tensile strength
(v)
Resistance to dry head
(vi)
Glue shear strength
(vii)
Test for Adhesion of Plies
STEEL
(A)
(i)
(ii)
(iii)
(iv)
(v)
(B)
(i)
(ii)
(iii)
(iv)
(v)
(C )
(i)
(ii)
(iii)
Per Test
Per Test
206.00
206.00
206.00
206.00
103.00
154.50
154.50
51.50
30.90
103.00
61.80
61.80
Density
% Elongation
Tensile strength
Bend
Re-bend
61.80
41.20
154.50
77.25
77.25
Chemical Analysis
Carbon
Sulphur
Phosphoras
103.00
103.00
103.00
(XI)
SOIL
(A) Physical Tests
Per Test
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
(x)
(xi)
(xii)
(xiii)
(xiv)
(xv)
(xvi)
(xvii)
(xviii)
(xix)
Bulk Density
Moisture Content
Specific Gravity
Sieve Analysis
Shrinkage Limit
Hydrometer Analysis
Unconfined Compression
Liquid Limit / Plastic Limit (Both)
Standard Proctor
Modified Proctor AASHO
Consolidation
California Bearing Ratio (Un-soaked)
Triaxial Compression Unconsolidated un-drained
Triaxial Compression unconsolidated drained
Triaxial consolidated drained
California Bearing Ratio (Soaked)
Permeability
Lab vane shear
Direct Shear (Un-drained)
51.50
103.00
103.00
103.00
103.00
206.00
206.00
257.50
721.00
824.00
618.00
618.00
463.50
927.00
1030.00
875.50
226.60
154.50
283.25
(B)
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
Chemical Analysis
PH
Chloride
Silica (SiO2)
Alumina (Al2O3)
Loss of Ignition (LOI)
Sulphate
Calcium Oxide(CaO)
Magnesium Oxide(MgO)
103.00
103.00
103.00
103.00
103.00
154.50
154.50
154.50
(XII) ROCK
Per Test
(A)
Physical Test
(i)
(i)
(ii)
(iii)
(iv)
Density
Specific Gravity
Water Absorption
Unconfined crushing Strength
Porosity
(B)
Chemical Tests
(i)
(ii)
(iii)
Sulphate
Chloride
PH value
(XIII)
51.50
103.00
103.00
257.50
154.50
206.00
103.00
103.00
Per Test
Chemical Tests
Insoluble residue
Silica
Alumina
Lime(CaO)
Magnesia (MgO)
Loss on Ignition (LOI)
Residue by sieve analysis
77.25
128.75
128.75
154.50
154.50
103.00
257.50
Per Test
pH
Chloride
Phosphate
103.00
103.00
103.00
-
Per Test
Alumina (Al2O3)
Silica (SiO2)
Sulphur trioxide(SO3)
Iron Oxide (Fe2O3)
% Loss on Ignition
Chloride (CI)
Sodium Oxide (Na2O)
Potassium Oxide (K2O)
Calcium Oxide (CaO)
Magnesium Oxide (MgO)
206.00
206.00
206.00
154.50
103.00
103.00
133.90
133.90
257.50
257.50
(XVI)
Per Test
309.00
103.00
103.00
103.00
154.50
154.50
103.00
103.00
103.00
103.00
(XVII) PLASTICIZER
(i)
(ii)
(iii)
(iv)
(XVIII)
pH
Chlorides
Sulphates
% total Solids / Concentration
WATER
(i)
(ii)
(iii)
(iv)
(v)
(vi)
Per Test
103.00
103.00
103.00
206.00
Per Test
Chlorides
pH
Alkalinity
Suspended Solids
Sulphates
Total Hardness
103.00
103.00
103.00
103.00
154.50
154.50
Refer Introductory and General Notes along with the following Chapter Notes :
Chapter Notes:(i)
(ii)
This chapter is introduced for repair works only & shall not be used in any new construction work.
The documentation of repair/maintenance work shall be maintained meticulously. The following procedure
shall be adopted for recording the measurement of items included in these chapters:
(a) Sectional Engineer /Sr. Sectional Engineer shall open a numbered separate register called Zonal Petty
Repair/Maintenance Register (ZPRR) which shall be in the following format.
Division ____________
(b) The above Zonal Petty Repair Register shall be maintained in two copies. One with Section Engineer and
the other copy with the Contractor. Occupants/users signature shall be obtained on contractors copy, as it
will be the responsibility of the contractor to obtain the signature in token of satisfactory work done.
(c) The measurements shall be recorded in the MB after completion of the work & the same shall be test
checked as per the extant instructions. However, the recorded measurement shall also be cross-checked with
the ZPRR.
(d) In case the occupant/user refuses to acknowledge the repairs, Section Engineer/Sr. Sectional Engineer in
addition to his usual inspection & certification of work will again satisfy himself about the quality & quantity
of the work and shall pass the remark I have personally inspected the work again in addition to my normal
inspection & satisfied myself with quantity and quality of work done in (name the work and location). The
complaint of the occupant is therefore not genuine & the measurement of the work is to be recorded without
occupant/users signature.
(iii)
As far as possible Sectional Engineer/Sr. Sectional Engineer shall club the repair works planned to be done in a
month and shall give the instructions through register once in a month, for facilitating execution of the work by
the contractor. However, it shall not be binding on the railways to do so and instructions as and when repairs
are required shall be given.
(iv)
It Description of work
e
m
N
o.
1.
2.
2 Repairs to plaster of thickness 12mm to 20mm in
8 patches of area 5.0 sq. meters or less including
CEMENTATIOUS REPAIRS
Unit
Mumbai
division
3.
4.
Other
divisions of
C. Rly.
5.
Qty.
of
Ceme
nt
bags
Remark
s
6.
7.
1
0
1
2
8
1
0
2
2
8
1
0
3
2
8
1
0
4
2
8
1
0
M2
75.05
63.75
M2
196.85
177.15
M2
41.75
37.60
Per hole
60.35
54.30
Per hole
56.55
50.90
5
2
8
1
0
6
2
8
1
0
7
References:
(1)
(2)
(3)
(4)
Per meter
45.90
45.90
M2
210.70
189.65
Concrete Repair Manual-Vol.I & II(2nd edition year 2003) of American Concrete Institute(ACI)
Handbook on repair and rehabilitation of RCC buildings issued by CPWD
Schedule of Rates(2002) of Central Railway
N.S. items of S.C.Rly