05-02-13

SSSPL / 13-14/ 4 / 134/ Panora Group

To,

PANORA GROUP

Kind Attention : Mr. Unmesh

Subject: WATERPROOFING METHODOLOGY FOR OTTERS CLUBS BANDRA (WEST).

Dear Sir,

Thank you very much for the interest shown by you in our organisation.

With respect to above subject please check the following annexure attached herewith,

Annexure I- Methodology for Terrace Waterproofing work.

Feel free to call us in case of any doubts.

Thanking You,

Yours truly,

Dr. Mangesh Joshi

For SSSPL
Methodology for Supporting -

Distance
between two
props is not
more than 3
feet

1) Provide the steel props below the damaged RCC Structure as shown in drawings.

2) While providing steel props care should be taken that work is being carried under the

qualified civil engineer who has the idea of loading pattern of the structure.

3) At the bottom & top of the prop either steel plate (8mm to 12mm thick) or wooden block of

sufficient thickness (50mm to 100mm) should be provided.

Repair Methodology for Excessively damaged RCC Section

A. FOR EXPOSED REINFORCEMENT

Exposing Existing R.C.C Element:

 Marking of the area to be exposed shall be done by contractors engineer and the same shall
be counter approved by engineer in-charge / consultant’s site representative.
 Exposing of concrete cover shall be carried out with the help of light hammer and sharp
chisels.

If the R.C.C elements are found extremely damaged and the reinforcement snapped (Almost
60% damaged) the following procedure shall be followed:
a) Exposed 1/4th of the cross section of columns
b) Remove snapped links
c) Provide new links dipped in epoxy by drilling holes in concrete
d) Remove rust and corrosion
e) Apply required thickness of epoxy mortar

 If junctions are found badly damaged, the possibility of providing propping shall be
considered and the matter shall be discussed with engineer in charge.
 Irregular shapes shall be converted to regular shapes like squares, rectangles etc.

Treatment to corrosion damaged existing steel reinforcement:

a. Remove rust by manually and by using alkaline rust remover:

 Thoroughly clean the corroded reinforcement/ steel rebar by wire brush or rotary grinder.
Remove all the corrosion scales present on the bare and reach up to sound steel.
 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.
b. Application of two coats of IP Net RB anticorrosive epoxy coating on steel rebars:
Application of primer shall be followed with application of two coats of IP Net RB (confirming to
CBRI requirement) anticorrosive epoxy coating for bar protection against future corrosion.
Coating is for old a well as newly provided steel. This system (Interpenetrating polymer network
system for rebars: IP Net RB) once applied on steel shall provide extended protection against
future carbonation and chloride attack.
c. Application of Concrete penetrating corrosion inhibitor on concrete surface
Carry out application of ‘Bi-polar migratory corrosion inhibitor EPCO KP 100 on concrete surface
by brush in two coats. This inhibitor has migratory kind of property which permits the material
to migrate to a virtual extent of 60 mm, through pores of concrete, inhibiting the corrosion and
de-passivating the Electro-chemical reaction. It has property to attack anode as well as cathode,
which is purely alkaline in nature (pH-9.5), so it has no carcinogen activity with concrete.
Material shall have evaluated test reports indicating significant reduction in corrosion rate after
minimum 90 thermal cycles at 60° Centigrade followed by 8 weeks of accelerated corrosion
indicative of its suitability for tropical applications.

B. MAKING UP LOST STRENGTH OF CORE CONCRETE BY LOW VISCOSITY MONOMER

Make up of lost strength of core concrete shall be with grouting of low viscosity ( 2- 5cps- as per
ASTM-D-2196) monomer. This is a low viscous high molecular weight thermo setting polymer.
Due to its low viscosity it effectively fills up all micro-cracks and voids up to full depth of
concrete. Beside enhancing existing binding matrix this shall also enhance in ductility property
of elements.
Description of Grouting:
 Drilling of holes 12mm dia. and about 50mm deep into concrete along the cracks or in
honey combed and deteriorated areas, fix the perforated nozzles and seal the sides with
Epoxy sealant.
 Epoxy sealant: This is a non-shrink sealant. It is built in resilience to absorb impact and
movements in joints.
 Inject very low viscous injection resin into pre- drilled nozzles at a pressure of 2 to 4kg/cm2
using compressed air and injecting gun. Seal the nozzles with epoxy after injection is
completed.
 C. SECTIONAL RECONSTRUCTION IN EXCESSIVELY DAMAGE CONCRETE IN
STRUCTURAL ELEMENTS

Bonding Coat:

Bond between new and old concrete is important aspect for effective participation of total
cross sectional area of concrete. Selection of type of bond coat is based on, type of stresses
bond strata is expected to go and prevailing area where application is to be carried. After the
various pretreatment apply liberal quantity of bond coat-ELMONOBOND on cleaned
concrete surfaces as per the detailed manufacture’s procedure. Ensure that the application
of new concreting is carried out during the pot life of material.

Making up lost –section with latex modified mortar:

Makeup mortar is based on type of structural element and its location. Here following type
of modified mortars are recommended.
Modified mortar:
a) For replacing the carbonated part of concrete and repairing the damaged surface of
concrete up to 20mm thickness usage of following formulated mortar is recommended.

Mix: or Ready-mix PMM bag

 Cement: 50KG
 Sand: 150KG
 MONOBOND: 2.5 to 5KG
 Water: 15-20 Ltrs.

b) For replacing the carbonated part of concrete and repairing the damaged surface of concrete
between 20 to 30mm thickness thixotropic mortar is recommended.

c) For replacing the carbonated part of concrete and repairing the damaged surface of concrete
between above 30mm thickness micro- concrete is recommended.
METHODOLOGY FOR GROUTING

STEP 1- Drilling Holes: -

Drill 12 mm diameter., 40 mm deep holes in structural members at the intervals of 600 mm in
staggered manner or as directed by the consultants in RC structural element.

STEP 2- Cleaning of Holes: -

Clean the holes by air blower prior to fixing nozzles.

STEP 3- Fixing of Nozzles: -

Insert 12 mm diameter Teflon nozzles in cleaned holes, External end of nozzles to be machine to
receive outlet of grouting gun. Fix it inside the holes by applying Epoxy putty to ensure complete
sealing. Cure the system for min. 12 hrs.

STEP 4- Mixing of materials: -

Mixing material components (part A & B) in required quantities as per manufacturer’s instruction
by weigh batching.
STEP 5- Grouting:-

Fill the grouting gun with epoxy resin. Maintain desired pressure in the gun by air compressor;
maintain the pressure at exit (3 to 5 Kg/ cm2) by monitoring pressure gauge at exit or as per
consultant’s instruction. Grout the material through prefixed nozzles in the structural elements still
its refusal. Seal the nozzle with Epoxy putty after the refusal. Monitor leakages through other
nozzles while grouting and seal them as per the requirement. Repeat the process for all the
nozzles. Complete the operation within pot life of the material.

STEP 6- Cutting of Nozzles:-

Cut the nozzles by chisel after completion of grouting without damaging structural elements.

METHODOLOGY FOR CRACK FILLING

STEP 1- Marking the crack:-

Marking the crack in structural element (beam/column/slab/wall).

STEP 2- Cut a V-grove :-

Cut a V-grove by cutting blade, to open the surface up to depth of the crack.

STEP 3- Cleaning of crack :-

Cleaning of crack by water pressure or conventional method for removing dust

STEP 4- Filling the crack:-

Fill the crack with EPCO 1010 putty flush to the concrete surface.

Methodology For Fiber Wrapping

 Level prepared concrete
Apply Primer onto substrate with Putty /
prepared concrete substrate Levelling Mortar (optional)
(optional)

Apply first coat of Apply Fibre

Saturant Reinforcement

Apply second coat of Apply sand Pasting for

Saturant plastering

After sandpasting apply 12 mm thk. Ordinary plaster on wrapped surface.