MAS Final Report PDF

Project : MAS Linea Aqua- Canteen Building Doc.
No : CSEC/MAS /01
Client : MAS Linea Aqua (Pvt) Ltd, No. 01, Naiwala Watta, Rev. No : 00
Naiwala, Sri Lanka.
Date : 10 August 2018
Consultant : Civil and Structural Engineering Consultants (Pvt.) Ltd.
Report on
Structural Strengthening and Repair for Canteen Building of MAS Linea
Aqua Premises at Naiwala
Reference sheet
Document number Description
Revision History
00 Afsar FOR REFERENCE SM SF

Revision Date Prepared by Description Checked Approved Project
10 August by by Approved
2018
Total pages
© CSE
Table of Contents
List of Tables ........................................................................................................................................... 3
List of Figures .......................................................................................................................................... 4
1 Objective ......................................................................................................................................... 5
2 Introduction .................................................................................................................................... 5
2.1 Building and function .............................................................................................................. 5
2.2 Procedure of assessment and repair ...................................................................................... 6
3 Review of the structure and its elements ....................................................................................... 8
3.1 General.................................................................................................................................... 8
3.2 Design, Detailing and Workmanship ....................................................................................... 9
3.2.1 Element Design ............................................................................................................... 9
3.2.2 Detailing and Workmanship............................................................................................ 9
4 Assessment of damage to concrete and reinforcement............................................................... 10
4.1 Damages to the concrete ...................................................................................................... 10
4.2 Damages to the reinforcement ............................................................................................. 13
5 Assessment of the structure ......................................................................................................... 14
5.1 Diagnosis ............................................................................................................................... 14
5.1.1 Structural Element Survey ............................................................................................ 15
5.1.2 Concrete Quality ........................................................................................................... 15
5.1.3 Concrete Cover.............................................................................................................. 15
5.1.4 Position and diameter of the reinforcement ................................................................ 15
5.1.5 Cracks ............................................................................................................................ 16
5.2 Danger of reinforcement corrosion ...................................................................................... 19
6 Evaluation of current and future conditions of the structure ...................................................... 20
6.1 Concrete corrosion................................................................................................................ 21
6.2 Crack investigation ................................................................................................................ 21
6.3 Reinforcement corrosion ...................................................................................................... 21
Date : 10 August 2018 Document Title : Report on Structural Strengthening & Repair for Canteen Revision : 00
Building of MAS Linea Aqua Premises at Naiwala
Project : MAS Linea Aqua Document Name : CSEC/MAS/01 Page :1
7 Structural Evaluation..................................................................................................................... 21
7.1 Structural Design Criteria ...................................................................................................... 21
7.1.1 Design Codes & Standards ............................................................................................ 21
7.1.2 Material Properties ....................................................................................................... 22
7.1.3 Element Geometry ........................................................................................................ 24
7.1.4 Loading .......................................................................................................................... 25
7.1.5 Load Combination ......................................................................................................... 26
7.1.6 Durability & Fire Resistance Criteria ............................................................................. 26
7.1.7 Deflection Limits ........................................................................................................... 27
7.2 Capacity Assessment & Evaluation of Structural Elements .................................................. 27
7.2.1 Foundation .................................................................................................................... 27
7.2.2 Columns ........................................................................................................................ 28
7.2.3 Beams ............................................................................................................................ 28
7.2.4 Slabs .............................................................................................................................. 28
7.3 Assumptions & Limitations ................................................................................................... 29
7.4 Analysis Results and Interpretation ...................................................................................... 29
7.4.1 Foundation .................................................................................................................... 29
7.4.2 Column .......................................................................................................................... 30
7.4.3 Beam ............................................................................................................................. 30
7.4.4 Slab ................................................................................................................................ 32
8 Structural Concrete Repair and Strengthening ............................................................................. 33
8.1 General.................................................................................................................................. 33
8.1.1 Principles for repair and protection for damages of the concrete ............................... 34
8.1.2 Principle for protection against reinforcement corrosion ............................................ 39
8.2 Surface Preparation .............................................................................................................. 41
8.3 Structural Concrete Element Repair ..................................................................................... 42
8.3.1 Beams ............................................................................................................................ 42
8.3.2 Slab ................................................................................................................................ 42
8.3.3 Columns ........................................................................................................................ 43
8.3.4 Roof structure ............................................................................................................... 43
8.3.5 Foundation .................................................................................................................... 43
8.4 Structural Strengthening ....................................................................................................... 44
8.4.1 Proposed Rectification Method for Slab ....................................................................... 44
8.4.2 Proposed Rectification Method for Beam and Slab...................................................... 45
9 Execution and Quality Control ...................................................................................................... 46
10 Maintenance of Concrete Structures ........................................................................................ 47
ANNEXURE A - Load Maps .................................................................................................................... 49
ANNEXURE B – Test Results .................................................................................................................. 50
ANNEXURE C – Column Design ............................................................................................................. 51
ANNEXURE D – Beam Design ................................................................................................................ 52
ANNEXURE E – Slab Design ................................................................................................................... 53
ANNEXURE F - Suggested Materials, typical method statements and technical data sheets and test
reports................................................................................................................................................... 54
List of Tables
Table 1 Principles for repair and protection for damages of the concrete ............................................ 7
Table 2 Principles for protection against reinforcement corrosion........................................................ 8
Table 3 Different types of cracks: causes, appearance, and short description .................................... 17
Table 4 Strength of New Concrete ........................................................................................................ 23
Table 5 Test results values of concrete and reinforcement strength ................................................... 24
Table 6 Material unit weight ................................................................................................................. 25
Table 7 Super Imposed Dead & Live Loads ........................................................................................... 26
Table 8 Load Combinations................................................................................................................... 26
Table 9 Exposure Class for Concrete Elements ..................................................................................... 26
Table 10 Fire rating for Concrete Elements .......................................................................................... 27
Table 11 Overview of selected and most commonly used methods for surface preparation according
to RL-SIB (2001)..................................................................................................................................... 41
List of Figures
Figure 1 Location and satellite view of MAS Linea Aqua Premises ........................................................................ 5
Figure 2 View of canteen building .......................................................................................................................... 6
Figure 3 Phases of repair project ............................................................................................................................ 7
Figure 4 Systematics of planning according to EN 1504-9...................................................................................... 8
Figure 5 Unsound concrete of slab ......................................................................................................................... 9
Figure 6 Base Plate connected by only two bolts .................................................................................................. 9
Figure 7 No/Un-tightened bracings ...................................................................................................................... 10
Figure 8 Exposed Shear Links ................................................................................................................................ 10
Figure 9 Poor Workmanship ................................................................................................................................. 10
Figure 10 Crack Pattern observed in slabs ............................................................................................................ 11
Figure 11 Vertical cracks in beams ....................................................................................................................... 11
Figure 13 Continuation of cracks through beam and slab .................................................................................... 12
Figure 12 Timber pieces and debris in concrete ................................................................................................... 12
Figure 15 Flexural cracks in mid span of Beams ................................................................................................... 12
Figure 14 Shear crack in beams near support ...................................................................................................... 12
Figure 16 Existing Reinforcement in Beams ......................................................................................................... 13
Figure 17 Reinforcements without/inadequate cover ......................................................................................... 14
Figure 18 Mapping of cracks in slabs and beams ................................................................................................. 18
Figure 20 Depth of crack approx. 10 mm in slabs................................................................................................. 19
Figure 19 Depth of crack more than 15 mm in beams ......................................................................................... 19
Figure 21 Bending Moment on beams for Load Comb.2 ...................................................................................... 30
Figure 22 Shear Forces on Beams for Load Comb.2 ............................................................................................. 31
Figure 23 Schematic representation of Method 1.3 before and after application .............................................. 34
Figure 24 Schematic representation of Method 2.3 before and after application............................................... 35
Figure 25 Schematic representation of Method 4.1 after application ................................................................ 36
Figure 26 Schematic representation of Method 4.5 before and after application .............................................. 38
Figure 27 Schematic representation of Method 7.2 for carbonation- induced corrosion according to the actual
draft of the German guideline for maintenance of concrete structures (RL- SiB 2013). ...................................... 39
Figure 28 Schematic representation of Method 11.1 before and after application ............................................ 40
Figure 29 Cross section of Edge Beam with repair detail ..................................................................................... 42
Figure 30 Typical Slab and Beam Strengthening Details....................................................................................... 45
Figure 31 Cross section of Beam with repair and strengthening detail ................................................................ 46
Figure 32 Time- dependent development of the status of a structure due to different maintenance concepts 48
1 Objective
The main objective of this report is to propose the structural rectification and repair works to restore
the structure. This will ensure functional and performance requirements considering the stability and
integrity of the structure as whole and its structural and non-structural elements. This is achieved by
a preliminary structural investigation of the building based on the visual observations followed by
secondary investigation with series of test included. Further, this report discusses on most rational
and effective methodologies in overcoming identified structural defects giving concerns to
serviceability & durability aspects based on BS EN 1504- Products and systems for the protection and
repair of concrete structures.
2 Introduction
2.1 Building and function
The location of the MAS Linea Aqua premises and the position of canteen building are shown in Figure
1 below.
Figure 1 Location and satellite view of MAS Linea Aqua Premises
The two storey canteen building which is said to be about 30 years old functioning the ground floor
for factory operation work while the upper floor serving for the canteen area. The ground floor area
is occupied with sewing machineries and kept as open area without any internal partitions. The access
to the first floor is provided by an external staircase.
The upper floor is also kept as open area without internal partitions while the food serving area located
at one end of the building both ground and first floor. The view of canteen building is shown in Figure
2 below.
Figure 2 View of canteen building
2.2 Procedure of assessment and repair

The rectification options and repair methods to rehabilitate the structure were selected based on the
rectification principles and methods according to BS EN 1504.
A preliminary investigation followed by a secondary investigation along with series of selected tests
are conducted together the materials required for structural assessment and evaluation. The
rectification and repair methods are proposed.
The phases of repair projects follow a logical sequence, which is dominated by engineering aspects.
Figure 3 gives a general scheme followed according to BS EN 1504-9.
Figure 3 Phases of repair project
For protection and repair, different principles have been defined, separately for repair and protection
of damages to the concrete and damages induced by reinforcement corrosion. Tables 1 and 2 show
the six principles for protection and repair of concrete and the five principles to prevent damages due
to rein for cement corrosion, respectively.
Table 1 Principles for repair and protection for damages of the concrete
Table 2 Principles for protection against reinforcement corrosion
The rules for the use of products and systems for protection and repair of concrete structures are
based on a hierarchy of different levels, namely, options, principles, and methods. Figure 4 shows the
systematics of planning according to EN 1504-9.
Figure 4 Systematics of planning according to EN 1504-9
3 Review of the structure and its elements

3.1 General
The structural system of the building was found to be with reinforced concrete column beam frame
work with in-situ reinforced concrete slab panels up to first floor. The upper floor roof structure and
columns are of structural steel with Zn-Al sheet cover. Masonry wall have been used as the perimeter
cladding.
3.2 Design, Detailing and Workmanship
3.2.1 Element Design
NOTE: The structural element sizes were quoted from the report ‘Rehabilitation of cracks appeared
1st floor reinforced concrete structure (Canteen floor) of factory building at Naiwala’
The following is a general comment on the element design and it does not reveal any acceptance or
non-acceptance of the structure as a whole or elements unless it has been proven and justified by the
detail analysis given in this report.
The beam and column elements are found to be fairly sized with regard to the structural geometry.
However, thickness of slab element was found to be undersized with regard to the basic structural
engineering guidelines. The reinforcement design were separately considered under detail analysis.
Further, the upper floor structural steel element sizing were found to be acceptable with respect to
basic structural engineering guideline.
3.2.2 Detailing and Workmanship

For reinforced concrete beams it was found that the shear links were not fully covered with concrete
at the casting and however later had been covered up with cement sand mortar or putty application.
For slabs and beams, the soffit and sides were found to be with non-homogeneous concrete due to
non-consolidation and poor workmanship. The upper floor steel columns were found to be fixed to
concrete column below by using only two anchor bolts instead of four number of anchor bolts which
is the general engineering practice. The roof and side wall wind bracings were observed not properly
tightened. It was found that wind bracings were only provided at one long side of the building. The
following images show few of the observed defects.
Figure 5 Unsound concrete of slab Figure 6 Base Plate connected by only two bolts
Figure 7 No/Un-tightened bracings
Figure 9 Exposed Shear Links Figure 8 Poor Workmanship
4 Assessment of damage to concrete and reinforcement

4.1 Damages to the concrete
There are several ways the concrete could be attacked by and however it was found that the observed
defects had been initiated by mechanical and physical attack only.
Mechanical attack
Project : MAS Linea Aqua Document Name : CSEC/MAS/01 Page : 10
The cracks observed in beams and slabs may have been due to the following reasons as could be
predicted from preliminary investigation and the information received.
1. Possible overload of the upper floor

2. Substandard material quality
3. Substandard workmanship
4. Vibration due to functional activity on the upper floor
Physical attack
Some shrinkage cracks were observed under this category and these are common in concrete
structures however, frequency and severity are related to quality of the material used at fresh state
along with workmanship.
The following images depicts few of the observed defects in the building.
Figure 10 Crack Pattern observed in slabs
Figure 11 Vertical cracks in beams
Figure 13 Timber pieces and debris in concrete
Figure 12 Continuation of cracks through beam and slab
Figure 15 Shear crack in beams near support Figure 14 Flexural cracks in mid span of Beams
Further Assessment and Evaluation on Concrete
The following structural elements are considered for further assessment and evaluation with required
testing.
a) Slab
b) Beam
c) Column
d) Foundation
The observed cracks of the above elements were proposed to be further investigated to differentiate
the type of cracks and their extent. Further, structural evaluation was also proposed to compare the
action forces under present loading condition with existing member capacity and then to design for
new loading condition. This necessitate some selected testing to be carried out such as strength of
concrete and reinforcement, position and diameter of reinforcement provided.
Figure 16 Existing Reinforcement in Beams
4.2 Damages to the reinforcement

As per the preliminary investigation there was visible damage observed to reinforcement though the
concrete age is about 30 years.
Figure 17 Reinforcements without/inadequate cover
Further Assessment and Evaluation on Concrete
Since some construction defects were found including poor material quality the corrosion on the
reinforcement induced by carbonation proposed to be probed. However, the chloride level
determination is not proposed since it is unlikely in the environment the building is exposed.
Since, the workmanship problems are observed while considering the age of concrete determination
of cover to reinforcement is proposed.
Hence, it is expected that deterioration of concrete elements will continue to occur in future. The
following images show the status of the existing reinforcements. However, the decision must be
supported by the carbonation test results of each structural elements.
5 Assessment of the structure

The significance of the assessment is in general based on the overall condition of the structure and
the environment. The extent of the assessment was decided based on the preliminary investigation
carried out along with the experience of the authors in handling similar situations.
5.1 Diagnosis
The process of assessment of the structure include but not limited to the following (EN 1504):
a) The visible condition of the existing concrete structure;

b) Testing to determine the condition of the structure and reinforcing steel;
c) The original design approach;
d) The environment, including exposure to contamination;
e) The history of the concrete structure, including environmental exposure;
f) The conditions of use, e.g., loading or other actions;
g) Requirements for future use.
5.1.1 Structural Element Survey

A structural element survey was conducted due to the absence of as built structural drawings to get
the details of structural elements, layout plan etc. The details of the structural element such as floor
layouts, element section dimensions are taken from the report ‘Rehabilitation of cracks appeared 1 st
floor reinforced concrete structure (Canteen floor) of factory building at Naiwala’ and discussed in
detailed under Section 7.1.3 in this report.
The deflection of the structural members are proposed to be measured under secondary investigation.
5.1.2 Concrete Quality

The judgment of the concrete quality is to be done under consideration of the function of the concrete
within a structure. The concrete’s core is mainly responsible for the load- bearing capacity of the
structural element. Since there are many quality related issues regarding the material and
workmanship prevail it is proposed to conduct tests and checks to determine the properties of the
structural elements.
Proposed tests
 Concrete quality - compressive strength and surface strength
5.1.3 Concrete Cover

A detailed information about the location of the reinforcement in an element is a key parameter
regarding any analysis of the load bearing behavior. Regarding corrosion protection, the location of
the reinforcement is also a key parameter, which has to be known because adequate cover depths are
essential to ensure a sufficient durability of a construction.
Proposed tests
 Concrete cover for beams and slabs
5.1.4 Position and diameter of the reinforcement

The preliminary investigation included exposing of beams and column reinforcement the details are
covered under structural evaluation the slab bottom reinforcement are taken from the report
‘Rehabilitation of cracks appeared 1st floor reinforced concrete structure (Canteen floor) of factory
building at Naiwala’. Further it is proposed to verify beam and slab top layer reinforcement under
secondary investigation to provide strengthening detail optimized.
5.1.5 Cracks
Cracks in constructions occur due to many different reasons. Table 3 gives an overview of the most
common cracks in concrete structures following the German concrete association (DBV 2006).
Table 3 Different types of cracks: causes, appearance, and short description
The crack mapping, determination of depth and crack movements are essential for correct diagnosis
to lead in to a suitable strengthening and repair procedure.
Crack mapping done at site previously were considered for further analysis and however the crack
depth were investigated under the preliminary investigation to determine the extent in to the
concrete. Further, it is essentially required to differentiate structural and non-structural cracks for
effective and optimum repair system and therefore further observation on top surface of the floor
were proposed under secondary investigation. The movement of the cracks need to be monitored
after repair to decide for live cracks.
The Figure 18 below shows the crack patterns in the slabs and the beams.
Figure 18 Mapping of cracks in slabs and beams
Structural Cracks
Some flexural cracks were observed on the beam soffit running perpendicular to the direction of
reinforcement. The shear cracks running diagonal on side surface of the beams were observed close
to columns, some are starting from bending cracks. The depth of the flexural cracks were investigated
to see the severity of damage and to decide on repair system.
The cracks on the soffit of the slab panels may be a combination of flexural and shrinkage cracks. The
flexural cracks may have occurred due to under capacity of the slab section. Further there The depths
of these selected flexural cracks were further investigated and found terminating at about 10 mm
from the surface in the cover region.
Figure 19 & Figure 20 shows the depth of cracks in beam and slab element.
Figure 20 Depth of crack more than 15 mm in beams Figure 19 Depth of crack approx. 10 mm in slabs
Non-Structural Cracks
Some shrinkage cracks running in the full depth of the beam were observed and which should have
been prevented if laser bars were provided. These may be drying shrinkage cracks which are generally
following the weaker zone of the concrete.
The shrinkage cracks on the slabs may be due to plastic shrinkage, early thermal contraction or drying
shrinkage. This could be differentiated further after the observation from the top surface of the slab
in the secondary investigation.
The following procedure is to be carried out to assess the cracks.
1. Slab Cracks depth to be checked to differentiate drying shrinkage cracks with flexural
cracking. Drying shrinkage cracks run through section depth
2. Beam crack depth to be checked for extension of cracks above reinforcement to decide if
injection repair needed.
3. Inspection to be done on top surface of the floor after tile removal to finalize treatment
options to cracks. eg. if the same crack appears on top as on the bottom, it may be a
shrinkage crack and need only swelling type treatment to prevent ingress. Also, it should
identify top surface only cracks too to provide same type of treatment.
4. Vertical cracks in beams surface due to inadequate cover (plastic shrinkage)
5.2 Danger of reinforcement corrosion

As indicated previously since there is no indication on the corrosion of the reinforcement the following
tests are proposed to assess the existing condition.
The depth of carbonation test is proposed to determine the reason for the corrosion of reinforcement
and cover meter test to identify whether sufficient cover is provided to protect the reinforcement on
following structural elements.
1. Carbonation test on beam

2. Carbonation test on column
3. Cover meter test on column
4. Cover meter test on beam
6 Evaluation of current and future conditions of the structure

The evaluation of the current condition of the structure and the prognosis of the further development
is an essential task in the rehabilitation of the structure for future use. It provides a decisive basis for
the owner and engineer to select the optimal repair options for the structure.
The followings were considered based on the results from preliminary and secondary investigations
and testing.
 The adequacy of actual load bearing capacity of each structural element and its
development
 The acceptability of usability and safety and its development
 The effect to concrete due to corrosion and its deterioration
 The corrosion on the reinforcement and its deterioration
For the above items it was analyzed and decided the critical conditions that will be reached and the
critical limit states. There the followings were considered for each element as appropriate prior to
decide on management strategy.
1. The critical conditions suffered like severe cracking and deflection

2. Safety against failure of existing structural members
3. Limiting further carbonation, etc. before reaching critical situations like corrosion of
reinforcement.
In choosing the management strategy with the above conditions the following aspects were analyzed.
1) General
a) The intended use as continuing with the canteen floor and remaining service life of the
structure
b) The performance requirement like fire resistance and water tightness on the top surface of
the floor
c) The likely service life of 10 years more from the protection and repair works
d) The required availability of the structure, permissible interruption to its use and
opportunities for additional protection, repair and monitoring work
e) The number and cost of repair cycles acceptable during the design life of the concrete
structure
f) The comparative whole life cost of the alternative management strategies, including future
inspection and maintenance or further repair cycles
g) Properties and possible methods of preparation of the existing substrate
h) The appearance of the protected and repaired concrete structure
2) Structural
a) The actions and how they will be resisted, including during and after implementation of
the strategy
3) Health and Safety
a) the consequences of structural failure
b) health and safety requirements
c) the effect of occupiers or users of the concrete structure and on third parties
4) Environmental
a) The exposure environment of the structure and whether it can be changed locally
b) The need or opportunity to protect part or all of the concrete structure, from weather,
pollution, etc., including protection of the substrate during the repair work
6.1 Concrete corrosion

At the time of investigation concrete corrosion was not found and hence not considered for further
assessment.
6.2 Crack investigation

Included in the secondary investigation
6.3 Reinforcement corrosion

Included in the secondary investigation
7 Structural Evaluation
7.1 Structural Design Criteria
7.1.1 Design Codes & Standards
British and Euro codes and standards are adopted in the structural analysis and member capacity
evaluation of the building. Appropriate internationally accepted standards for structural work are
listed below and referred wherever required:
The main European Standards used are listed as follows;
 BS EN 1990:2002 - Euro code, Basis of Structural Design

 BS EN 1991-1-1: 2002 - Eurocode-1, part 1-1, Actions on structures, General Actions –
Densities, self-weight, imposed loads for buildings
 BS 648:1964 - Weights of building materials
 BS 6399: Part 1 - Code of Practice for Dead and Imposed Loads: 1996
 BS EN 1992-1-1: 2004 - Eurocode-2, part 1-1, Design of concrete structures, General rules
and rules for buildings
 BS EN 1992-1-2: 2004 - Eurocode-1, part 1-2, Design of concrete structures, Structural fire
design
 BS 8110 part-1 (1997) - Structural use of Concrete, Code of practice for design and
construction
 BS 8110 part-2 (1985) - Code of practice for special circumstances
 BS 8500-1:2006 - Concrete – Complementary British Standard to BS EN 206-1,
Method of specifying and guidance for the specifier
 BS 8500-2:2006 - Concrete – Complementary British Standard to BS EN 206-1,
Specification for constituent materials and concrete
 BS EN 1997-1:2004 - Eurocode-7, Geotechnical design, General rules
 BS 8004 - Code of Practice for Foundations: 1986
 BS 8002 - 2015 Code of Practice for Earth Retaining Structures
 BS 4449 (2009) - Reinforcing steel bars for the reinforcement of concrete
 BS 4466 (1989) - Bending dimension and scheduling of bars for the reinforcement of
concrete
 BS 12 - Specification for Portland Cement: 1991
 C part 1 (1997) - Guide to specifying concrete
 BS 5328 part 2 (1997) - Method for specifying concrete mixes
 BS 5328 part 3 (1990) - Specification for the procedures to be used in producing and
transporting concrete
 BS 5328 part 4 (1990) - Specification for the procedures to be used in sampling, testing and
assessing compliance of concrete
Apart from the above for rectification and protection of concrete structures the following code will be
used
 BS EN 1504 part 1-10 - Products and Systems for the protection and repair of
concrete structures – Definitions, requirements, quality control and evaluation of conformity
7.1.2 Material Properties

The new materials listed in this section are the selected materials for the purpose of structural
strengthening and repair. Hence, it is recommended to refer the sketches, drawings and specifications
(as applicable).
The properties of the materials of the existing structure have been obtained from the results of the
tests conducted.
7.1.2.1 Proposed New Materials
7.1.2.1.1 Reinforced Concrete

Properties of new concrete to be used shall comply with BS EN 1992:2004 and BS 5328. Selected
structural concrete types as defined in BS standards are listed in Table 1.
Table 4 Strength of New Concrete
Structural Element Fcu (MPa)
Beam (For widening) C30

Slab (Topping) C30
It is suggested that Self Compacting Concrete (SCC) is to be utilized for slab topping and micro concrete
is to be used for beam widening as per manufacture’s manual. The purpose of use is mainly due to its
flow which ensures completely filling the narrow formwork and achieving full compaction with the
presence of congested reinforcement. The fluidity and segregation resistance of these concrete
ensures a high level of homogeneity, minimum concrete voids and uniform concrete strength.
The filling ability and stability of self-compacting concrete in the fresh state can be defined by four key
characteristics. Each characteristic can be addressed by one or more test methods:
Characteristics Test Methods

Flowability Slump-flow test
Viscosity T500 Slump flow test/ V-funnel test
Passing ability L-box test
Segregation Segregation resistance (Sieve) test
 Slump-flow class - SF2 (660 – 750 mm)

 Passing Ability - PA 2 ( Gap of 60 to 80 mm)
A quality control procedure shall be documented and followed on the job site for acceptance of self-
compacting concrete. Use of other cement replacements shall be subject to Designer’s approval.
7.1.2.1.2 Steel Reinforcement

Reinforcing steel shall comply with BS 4449:2009 and SLS 375: 2009. Hot rolled high yield deformed
type reinforcement bars of Grade B500B (Yield strength = 500 MPa) are specified for the
reinforcement of the strengthening of structural element. Preferred bar sizes are 8, 10, 12, 16, and
20mm.
7.1.2.2 Existing Material Properties

For the analysis of the existing structure the results obtained from tests carried out are used.
The derivation and interpretation of test results to a design value are to be considered in two aspects,
which are
a) The probability of representing the test results value for the selected element type
considering the number of tests.
b) Safety factor for the material to be used as appropriate to the standards governed at the
time of construction of the building.
It is assumed that the test results represent the overall material quality of the structural elements
being based on testing done. To validate this assumption, it is importantly required to review the test
results with respect to number of tests, tested element types, location, variation in the values of the
results, etc. Further, surface deterioration and hardening with age due to chemical process undergone
with the environmental factors are considered in interpreting these test results for the use as design
values.
7.1.2.3 Existing Reinforcement

As per the visual inspection the reinforcements are not corroded. This has to be further confirmed by
carbonation tests where depth of carbonation has reached the concrete cover. To ascertain the
amount of corrosion occurred in beam reinforcement visual observation on corroded reinforcement
were carefully carried out. The reinforcement was found to be tor steel having a characteristic
strength of 460N/mm2 and 0.87 was used as the material safety factor as per BS 4449:1988
Specification for the carbon steel bars for the reinforcement of concrete. Mild steel having a grade of
250 N/mm2 had been used for the shear links.
7.1.2.3.1 Existing Concrete

The test results of concrete elements are obtained from the report ‘Rehabilitation of cracks appeared
1st floor reinforced concrete structure (Canteen floor) of factory building at Naiwala’ and are
presented in Table 2 along with steel reinforcement strength values.
Table 5 Test results values of concrete and reinforcement strength
Average In-situ Cube Strength

Structural Element Strength of reinforcement (N/mm2)
(N/mm2)
Slab 17 460
Beam 20 460
Those results were interpreted as stated above to derive design values for the use of analysis and
capacity evaluation of structural elements.
7.1.3 Element Geometry

It was not observed substantial deterioration of structural elements. According to the drawings
presented in previous report the reinforced concrete columns (300 mm × 300/400 mm) have located
at 6.0 m × 7.7 m grid and extended up to the first-floor level. The slab panels are supported on two
main beams that have spanned on to the columns. The main beam sizes are 725 mm (depth) × 300
mm (width) and 625 mm × 300 mm that have span length of approximately 7.7 m and 6.0 m,
respectively. The reinforced concrete slab thickness is about 125 mm.
7.1.4 Loading
Loads are a primary consideration in any building design because they define external forces that a
building must resist to provide reasonable performance (i.e., safety and serviceability) throughout the
structure’s useful life. The anticipated loads are influenced by a building’s intended use (occupancy
and function), configuration (size and shape), location (climate and site conditions), material selection
etc. Thus, to optimize the value (i.e., performance versus economy) of the finished product, it is
essential to apply design loads realistically.
7.1.4.1 Gravity Loads

Dead loads consist of the permanent construction material loads comprising the roof, floor, wall, and
foundation systems, including claddings, finishes, and fixed equipment. The values for dead loads in
Table 3 are for commonly used materials.
Table 6 Material unit weight
Material Unit weight (kN/m3)

Reinforced Concrete 25
Mass Concrete 24
Structural Steel 78.5
Brick 21
Solid Block 24
Hollow Block 14
Plaster/ Screed 22
Light weight concrete 15
Water 10
Soil in planters 18
Glass 26
7.1.4.2 Super Imposed Dead Loads & Live Loads

Table 4 shows super imposed dead and imposed loads allocated for different floor areas according to
the floor function. Super imposed dead loads and imposed loads comply with BS EN 1991-1-1:2002
and BS 6399- 1:1996. Maps indicating loads allocated for each floor level are attached in Appendix A
Table 7 Super Imposed Dead & Live Loads
Super imposed dead load kN/m2 Live load

Description
Finishes Partitions Ceilings & kN/m2
Services
Canteen 1.50 - 0.50 4.00
Roof 1.50 - 1.50 0.60
7.1.5 Load Combination

Combination of different loads will take in to account as per section 6.4 of EN 1990:2002 and section.
Basic load combinations to be used in the design is presented in Table 5. In special cases additional
combination of relevant loading effects will be considered as per above stated code recommendations
Table 8 Load Combinations
Load Combination Abbreviation Description

Comb 1 1.0 D + 1.0 S.D. + 1.0 L
Comb 2 1.35 D + 1.35 S.D. + 1.5 L
D.- Dead Load, S.D.- Super Imposed Dead Load, L.- Live Load
7.1.6 Durability & Fire Resistance Criteria

The exposure classes and fire ratings, which will be considered in designing the structural system are
tabulated in Table 6 (as per BS 8110 Table 3.2 and section 4.2 of BS EN 1992-1-1:2004) and Table 7.
Table 9 Exposure Class for Concrete Elements

Location Exposure Condition
Concrete Work underground

Very severe
& contact with ground
Elements inside the building Mild
External building surface Severe
As per the exposure condition appropriate to each element a minimum cover of 30 mm found in
existing element was satisfactory. Further, new reinforcement for strengthening is also provided with
30 mm cover.
Table 10 Fire rating for Concrete Elements
Location Fire rating
Floor elements (Beams & Slab) 1.5 hours
Vertical elements 3 hours
All steel elements 2 hours
As per the fire rating requirements appropriate to each element a minimum cover of 30 mm found in
existing element was satisfactory. Further, new reinforcement for strengthening is also provided with
30 mm cover.
7.1.7 Deflection Limits

7.1.7.1 Reinforced Concrete Deflection Limits
Horizontal concrete elements (slabs and beams) shall be designed in compliance with a maximum
vertical deflection limited to:
 L/250 for the total deflection

 L/350, L/500 or 20mm for the remaining deflection after construction of finishes and
partitions depending on the characteristics of the materials above (brittle or non-brittle).
Where L is the span of the element.
7.2 Capacity Assessment & Evaluation of Structural Elements

Evaluation and assessment of capacity of the structural element is carried out based on results
obtained from the comprehensive structural analysis to verify the design criteria explained in previous
sections. In addition to hand calculations internationally accepted element design software (E.g.
ETABS, Prokon, SAFE, etc.) and series of approved software developed by CSEC or others in the form
of spreadsheets as a design tool shall be used for the design. The following structural elements are
considered for evaluation and assessment.
a) Foundation
b) Columns
c) Beams
d) Slabs
7.2.1 Foundation
Under preliminary investigation it could not be inspected the foundations and hence it was included
under secondary investigation. Further, there was no sign of distress or settlement issues observed at
site due to a possible settlement of foundation.
7.2.2 Columns
The proposed structure consists of 400mmx300mm and 300mmx300mm columns and they are
categorized according to the dimensions.
Column loads were obtained from the 3D model developed for the building and detailed designing
was done using PROKON and excel spread sheets in accordance with BS EN 1992-1, Design of concrete
structures.
Combinations of different load cases were taken in to account as per section 6.4 of EN 1990:2002.
Basic load combination used in the assessment is presented in Table 8. The columns are assessed for
the available cross-sectional area, provided reinforcement and quality of the concrete.
Since the corrosion level in columns found to be negligible the complete area of reinforcement was
considered in the assessment. It is assumed that the both 400mmx300mm column (C1) and
300mx300mm column have 4T16 bars based on the observation done with one column exposed. Refer
ANNEXURE C – Column Design for calculations.
7.2.3 Beams
Design calculations of beams were carried out for first floor beams. Beams have been analyzed using
a 3D finite element model of the building in accordance with BS 8110-1:1997 Structural use of
concrete. Deflection, shear and moment calculations were done using excel spread sheets. The
respective loadings were used as shown in the loading diagrams annexed herewith. The beams are
checked for the cross-sectional area, concrete quality, and available cover and provided
reinforcements.
When assessing beams minimum concrete cover for reinforcement was taken as 25mm while the
concrete grade is assumed to be C15 for existing concrete structure. In the absence of test results for
strength evaluation, however the strength evaluation was included in the secondary investigation.
The existing bottom reinforcement was inspected by exposing them and used the details found for
the design. Beam 725mmx300m (B1) was found with 5T20 bars at bottom and Beam (B2)
625mmx300mm with 3T16 bars at the bottom. The grade of steel is taken as 460 N/mm2 and 0.87 is
taken as the material safety factor considering the time of the construction.
7.2.4 Slabs
The first-floor slabs of this structure are two-way spanning. The two-way slabs were analyzed and
assessed as panels for the maximum effects of factored loads. The deflections were determined for
serviceability situation. Sample calculations were carried out for selected slab panels and strips, and
design summaries of each member are annexed herewith.
The concrete grade utilized for the slabs are C20 and loads were assigned on floors as per given in the
basis of design report. CSI SAFE and excel spreadsheets were used for the calculations for respective
panels of slab.
The minimum thickness of the slab is taken as 125 mm and the reinforcement arrangement of the
slabs are taken from previous reports as, the main reinforcement of the slab laid in the spacing of
about 150 mm and it was about 250 mm for other direction n. During core sampling, it was identified
that main reinforcement are provided with T12 bars and bars in other directions are provided using
T10 steel.
7.3 Assumptions & Limitations

The following assumptions and idealizations were adhered in this assessment.
 No further loading will be added other than the specified floor functional loads
 The minimum value for the strength of concrete obtained through test results was taken
while carrying out the analysis for each element.
7.4 Analysis Results and Interpretation
7.4.1 Foundation
The details of the footing such as the thickness of the pad, reinforcement arrangements, concrete
grade and other relevant details were included under secondary investigation.
Thus, the building has not shown any signs of serious distress that could lead to settlements of the
foundation throughout its lifespan and hence it can be concluded that the foundation of the building
is good. Since no any major dead load addition would occur after the rehabilitation it can be concluded
that the building would be safe under the existing foundation with respect to the strength and
performance of the foundation.
7.4.2 Column
The total axial loads on columns were determined for the ultimate condition and used for the analysis.
The detailed designing was done using PROKON and excel spread in accordance with BS 8110-1:1997
Structural use of concrete. It is concluded that the provided reinforcement for columns are adequate
given that the grade of the concrete is C25. Refer ANNEXURE C – Column Design.
7.4.3 Beam
A Comprehensive structural evaluation was carried out. The beams are checked for moment, shear
for ultimate limit state and the deflection of the beams for the serviceability limit state.
The figures below show the bending moment and shear force diagrams obtained using the 3D model
developed for canteen building using CSI ETABS.
Figure 21 Bending Moment on beams for Load Comb.2
Figure 22 Shear Forces on Beams for Load Comb.2
The analysis results show that the existing beams are structurally insufficient to carry the new design
loads hence strengthening is required. Further the existing reinforcements must be prevented from
further corrosion where the reinforcements are exposed.
Respective calculations of beams are given in ANNEXURE D – Beam Design for modified sections.
7.4.4 Slab
The slabs are modelled in SAFE and analysis were carried out. The immediate deflections considering
all loads, elastic deflection and long term deflections were determined for cracked surface. Nonlinear
crack analysis was carried for existing slab and it reveal that for the design loads the slab possess
insufficient structural capacity and the slab thickness is insufficient as per rule of thumb. The figure
below shows the analysis results for the deflection.
Refer ANNEXURE E – Slab Design for results of slab design for proposed modification. The figure below
show the comparison of deflection and human induced vibration of slab before and after the
modification. It is evident that the deflection is vastly reduced. The satisfactory magnitudes of floor
vibration with respect to human response is 4Hz given by ISO 2631-2:1989 hence, the vibration
sensitivity is also hugely enhanced after the rectification which is very close to 4Hz as per existing
condition.
8 Structural Concrete Repair and Strengthening
8.1 General
The following principles are adopted for this building to repair and protection of damages to the
concrete and damages induced by reinforcement corrosion. These principles are considered in two
main categories as principles for concrete repair and principles for protection against reinforcement
corrosion according to BS EN 1504:
a) Principles for repair and protection for damages of the concrete

• Principle 1 – Protection against ingress
• Principle 2- Moisture Control
• Principle 3 – Concrete Restoration
• Principle 4 – Structural Strengthening
b) Principle for protection against reinforcement corrosion
• Principle 7 – Preserving or restoring passivity
• Principle 8 – Increasing resistivity
• Principle 11 – Control of anodic areas
8.1.1 Principles for repair and protection for damages of the concrete
8.1.1.1 Principle 1 -Protection against ingress
To reduce or prevent the ingress of adverse substances into the concrete Method 1.3 Coating for
protection against ingress is recommended. This method also reduce the rate of carbonation to
negligible values.
Summary of Method 1.3
 Method 1.3: Coating.

 Principle 1: Protection against ingress.
 Approach: Application of a coating that prevents ingress of adverse agents.
 Typical applications: All types of concrete structures.
 Special attention should be paid to:
o Design: Requirements have to be specified in detail (EN 1504-2).
o Product requirements: According to EN 1504-2 (Refer Annexure F for product
details)
o Execution: Careful surface preparation; concrete surface must have the required
wetness; minimum thickness must be ensured.
o Quality control: Adhesion to concrete, coating thickness, etc.
 Durability/ maintenance: Inspections are recommended, depending on use.
 Complementary methods: Usually Methods 1.5 and 3.1 to 3.3.
Figure 23 Schematic representation of Method 1.3 before and after application
8.1.1.2 Principle 2 - Moisture Control
The approach of Principle 2 is to adjust and maintain the moisture content in the concrete within a
specified range of values to control adverse reactions. The concrete is allowed to dry and moisture
build up is prevented. Method 2.3 coating system is been proposed for moisture control in the slabs
horizontal top surface. Figure 24 shows schematically the application of this method. After the
preparation of concrete surface, concrete topping and crack filling the coating should be done.
 Method 2.3: Coating.

 Principle 2: Moisture control.
 Approach: Application of a coating that prevents water ingress and allows evaporation of
water from the concrete.
 Typical applications: Concrete corrosion like alkali- silica reaction, sulphate attack in an early
stage.
o Design: Requirements have to be specified according to EN 1504-2.
o Product requirements: According to EN 1504-2.
o Execution: Careful surface preparation; concrete surface must have the required
wetness; minimum thickness must be ensured.
o Quality control: Adhesion to concrete, coating thickness, etc.
 Durability/ maintenance: Inspections are recommended, depending on use.
 Complementary methods: Usually Methods 1.5 and 3.1 to 3.3.
8.1.1.3 Principle 3 - Concrete Restoration
The approach of Principle 3 is to restore the original concrete of an element of the structure to the
originally specified shape and function or to restore the concrete structure by replacing part of it.
Concrete restoration is proposed to be carried out recasting with concrete or alkaline mortar.
 Method 3.2: Recasting with concrete or mortar.

 Principle 3: Concrete restoration.
 Approach: Replace defective concrete with mortar or concrete by casting.
 Typical applications: All types of concrete surfaces except soffits.
o Design: Force transmission from old to new concrete, etc.
o Product requirements: According to EN 1504-3.
o Execution: Surface preparation; complete removal of defective concrete.
o Quality control: Visual control, etc.
 Durability/ maintenance: —.
 Complementary methods: Often Method 1.8 (horizontal surface) or 1.3; Method 8.3 (vertical
surface) or others, e.g., 1.1, 5.1, 6.1, 8.1.
8.1.1.4 Principle 4 - Structural Strengthening

According to Principle 4 Structural strengthening is increasing the load bearing capacity of the element
of the concrete structure. Method 4.1 addition of rebars outside of the existing structural element
into a new external concrete layer increasing its cross sectional area Method 4.2 Adding
reinforcement anchored in preformed or drilled holes, Method 4.4 Adding mortar or concrete and
Method 4.5 injecting cracks and voids in beams and slabs are adhered. The Figure 25 shows the
schematic representation of method 4.1.
Figure 25 Schematic representation of Method 4.1 after application
 Method 4.1: Adding or replacing embedded or external reinforcing bars.

 Principle 4: Structural strengthening.
 Approach: Adding or replacing damaged reinforcing bars.
 Typical applications: Structures with insufficient load- bearing capacity, e.g., due to
corrosion.
o Design: Structural analysis required.
o Product requirements: Like for new construction.
o Execution: Like for new construction.
o Quality control: Like for new construction.
 Durability/ maintenance: —.
 Complementary methods: Method 4.2.
 Method 4.2: Adding reinforcement anchored in preformed or drilled holes.

 Approach: Preparation of a hole, inserting a rebar and embedding with mortar.
 Typical applications: Connections between new and old concrete elements.
o Product requirements: According to EN 1504-6 and approvals.
o Execution: Careful preparation of the hole; complete filling with mortar.
o Quality control: Pull- out tests, etc.
 Durability/ maintenance:
 Complementary methods: Method 4.1 or 4.4.
 Method 4.4: Adding mortar or concrete.

 Approach: Increasing the thickness of a structural element.
 Typical applications: All types of concrete structures.
o Product requirements: EN 1504-3 and –4 standards for new constructions.
o Execution: Careful surface preparation.
o Quality control: Adhesion, strength, etc.
 Durability/ maintenance: No special requirements.
 Complementary methods: Method 1.5, 4.2, 4.5, or 4.6.
The standard method for strengthening concrete in the area of cracks, voids or interstices is injection
with filling materials that are able to transfer loads like epoxy resins, cement- based mortars. Injection
can be carried out using packers on top of the crack at the concrete surface or by drilling holes into
the concrete crossing the crack about in the center of the concrete, as shown in Figure 26. The
injection parameters like pressure, etc., have to be set in a way that the water within the cracks is
displaced and the cracks, voids, or interstices are filled as completely as possible with the injection
material.
 Method 4.5: Injecting cracks, voids, or interstices.

 Approach: Complete filling of defect areas with a hardening material by injection to achieve
load bearing like in defect- free concrete.
 Typical applications: Cracks, voids, or interstices in areas with high requirements to load-
bearing capacity.
o Design: Moisture condition in the crack, crack movements, etc.
o Product requirements: Basic requirements according to EN 1504-5.
o Execution: High degree of filling.
o Quality control: Degree of filling, etc.
 Complementary methods: Method 3.1 or coating to improve appearance.
8.1.2 Principle for protection against reinforcement corrosion
8.1.2.1 Preserving or restoring passivity
Principle 7- Preserving or restoring passivity is to create the chemical conditions in which the surface
of the reinforcement is maintained in or is returned to a passive state. Method 7.2 Replacing
contaminated or carbonated concrete is considered to restore the passivity. All carbonated concrete
is removed, the reinforcement is cleaned, and the breakout area is filled with concrete or alkaline
mortar.
 Method 7.2: Replacing contaminated or carbonated concrete.

 Principle 7: Preserving or restoring passivity.
 Approach: Removing all carbonated concrete and placement of alkaline concrete to re-
passivize the reinforcement.
 Typical applications: Traditional method for all types of concrete structures.
o Design: Structural analysis of the system or element, etc.
o Product requirements: Basic requirements according to EN 1504-3 (Refer Annexure
F for product details)
o Execution: Careful surface preparation.
o Quality control: Adhesion, strength, etc.
 Complementary methods: Methods 4.1, 1.3 as protective coating system.
Since the depth of carbonation is high for beams in first and second floor as per test results , not all
the carbonated concrete behind the reinforcement needs to be removed, but within a distance of 10
mm when the steel diameter ds is <16 mm or 15 mm, when ds is thicker than 16 mm.
Figure 27 Schematic representation of Method 7.2 for carbonation- induced corrosion according to
the actual draft of the German guideline for maintenance of concrete structures (RL- SiB 2013).
8.1.2.2 Control of anodic areas
Under controlling of anodic areas Method 11.1 Active coating of the reinforcement is adopted since
existing reinforcement is already corroded and may not be fully covered by coating during the
rectification process. At first the reinforcement needs to be uncovered so far that sufficient space is
available around the rebar to apply an active coating. Before coating the surface of the rebar must be
cleaned carefully from rust and loose particles. This method is adopted to enhance the durability after
repair and to reduce the risk from adopted repair methods.
 Method 11.1: Active coating of the reinforcement.

 Principle 11: Control of anodic areas.
 Approach: Corrosion protection of the reinforcement by an active coating.
 Typical applications: When not sufficient, concrete cover is available or can be provided;
temporary protection of exposed reinforcement.
o Design: Unknown durability, etc.
o Product requirements: According to EN 1504-7 (Refer Annexure F for product
details)
o Execution: Careful cleaning of the reinforcement; careful application.
o Quality control: Thickness of the active coating, etc.
 Durability/ maintenance: Regular inspections recommended.
 Complementary methods: Additionally, Method 1.3 recommended.
Based on the above principles and methods the structural elements are suggested to be repaired. The
repair mechanism are provided in detail specific to each element in the following section. The specific
requirements, e.g., roughness, adhesion strength, or moisture content, are usually given in the specific
data sheet of the repair material that will be used for the concrete repair.
8.2 Surface Preparation
The preparation of the concrete surface is one of the most important steps in making a successful
concrete repair. The primary goal of the surface preparation is a good and durable bond between the
repair material and the substrate. As a rule of thumb, the substrate has to be sound, clean, rough
textured, and dry after the surface preparation. Depending on the boundary conditions, the following
steps are done to prepare the surface:
• Dry cleaning, e.g., sweeping

• Removal of thin layers with low strength, e.g., cement slurry
• Removal of concrete or mortar
• Removal of old coatings or impregnations
• Removal of rust located on the reinforcement
In order to achieve a sufficient surface preparation, various methods can be used. Table 11 Overview
of selected and most commonly used methods for surface preparation according to RL-SIB (2001) gives
an overview of selected and most commonly used methods.
Table 11 Overview of selected and most commonly used methods for surface preparation according to RL-SIB (2001)
8.3 Structural Concrete Element Repair
8.3.1 Beams
Repair and protection for damage of concrete
 Protection against ingress by filling structural and non-structural cracks

 Structural Strengthening by section enlargement and filling the structural cracks
 Concrete restoration by Replacing weaker concrete
Protection against reinforcement corrosion
 Increasing cover with additional concrete

 Control of anodic areas by application of active reinforcement coating
Figure 29 Cross section of Edge Beam with repair detail
8.3.2 Slab
Repair and protection for damage of concrete
 Protection against ingress by filling structural and non-structural cracks also to avoid
moisture intrusion in to the slab
 Protection against ingress by coating
 Application of water proofing layer on the new concrete for moisture control
 Cracks at the bottom surface is to be repaired with V groove cut or injection of epoxy resin
for cracks and voids
 Structural Strengthening by overlay and filling and repairing the structural cracks
 Concrete restoration by replacing weaker concrete with repair mortar
 Adding of reinforcement anchored in drilled holes
Protection against reinforcement corrosion
 Increasing the resistivity by application of coating.

 Restoration of passivity by anti-carbonation coating and filling cracks, voids.
 Control of anodic areas by application of active reinforcement coating
8.3.3 Columns
Strengthening requirements to be decided after evaluation of secondary investigation results.
8.3.4 Roof structure

For the roof structure the following should be adhered to avoid any structural defects in to the future.
 It is strongly recommended to provide adequate wind bracing for the roof structure. The
bracing arrangement need to be continued for the walls at both sides of the building. This
will ensure adequate performance of the steel roof structure especially under lateral loads
such as wind.
 Provide diagonal reinforcement trimmers around
 It is required remove the corrosion in the base plate and treated with the anti-corrosive
paints
8.3.5 Foundation
The capacity assessment of the foundation with respect to geotechnical and strength requirements
was not carried out due to absence of sufficient detail and however it was assumed existing
foundations could carry the design load safely considering the following:
 There is no addition of floor or substantial dead weight of structure

 There were no signs of any kind of settlement of foundation in the past leading to structural
distress or alike.
Material Specifications
 Repair material – Alkaline mortar or micro concrete – Refer Annexure

 Active reinforcement coating – Refer Annexure
 Bonding Agent for fresh concrete – Refer Annexure
 Crack repair material – Refer Annexure
 Water proofing coating for new slab – Refer Annexure
 Suggested complementary method – Protective coating for concrete surface – Refer
Annexure (This should be applied on cementitious skim coat which is used to achieve
smooth surface for slab soffit. This coating will act as the finishing surface or use liquid
concrete protection systems suitable for soffit application)
 Crack injection as structural repair – use epoxy resin – Refer Annexure
 Crack filling for non- structural repair – use silicate based compound – Refer Annexure
 Reinforcement anchoring – HILTI HIT
8.4 Structural Strengthening
Structural strengthening needs very careful consideration by engineers experienced in the repair
process.
 Weakening at the point of repair (e.g. due to loss of concrete section in a compression member,
or loss in cross-section of reinforcing bar due to corrosion) can be calculated through a standard
structural appraisal to give the residual structural capacity. Therefore, supporting system has to
be adopted to temporarily hold the slabs while substantially limiting the transferred load to the
beams.
 Weakening post-repair is less obvious and the following factors must be considered:
o The physical and structural properties of the repair products and systems to be used at
the applicable service temperatures, in particular the elastic modulus, creep and
shrinkage of the materials. Where the repair is to take compressive loads, consider the
effects of creep at elevated service temperatures.
o 'Locked-out stress' occurs where tensioned reinforcement is broken out and repaired,
thereby losing its tensioned state. This weakening effect can only be reduced by removing
load from the structure prior to repair (e.g. propping and load restrictions) and/or
minimising the area of concrete to be broken out, even if new bar is added to replace the
bar sectional area lost due to corrosion. Even then it is doubtful that the repaired area will
fully adopt the initial structural capacity of the undamaged structure.
o Maximum service temperature of structural repair materials. Some organic material, such
as epoxy resin and other adhesives, may have a glass transition temperature of less than
60°C, meaning that they are unsuitable for structural use if service temperatures exceed
this value. (The 'glass transition temperature' of a polymer is the approximate
temperature at which it changes from a relatively stiff and brittle material to a viscous
material)
Strengthening may be required where structures are assessed to be below their original structural
capacity or require an increase in capacity due to a change in use or change in applicable standards.
Methods include:
 adding extra reinforcement and casting additional concrete

 adding externally bonded reinforcement to Increase tensile and/or shear capacity
 adding external structural elements
It must be noted that the other structural elements which have not been covered in the analysis must
be inspected for any structural or serviceability issues and the same repair and rectification treatments
must be carried out with prior consultation and approval from the engineer.
8.4.1 Proposed Rectification Method for Slab

The first-floor slab has to be strengthened for flexure, deflection and for vibration control. A 50 mm
topping has to be added over the existing slab surface to increase the flexural capacity and to reduce
the deflection. The following rectification and repair works were proposed for the first-floor slab.
 Concrete restoration
 Filling of non-structural pass through cracks.
 Reinforcement top and bottom layer
 (Fabric Mesh) to be provided fully for concrete topping to reduce further extension of drying
shrinkage cracks after repair.
8.4.2 Proposed Rectification Method for Beam and Slab

The structural strengthening for shear and flexure is carried out by introducing external reinforcement
added outside of the existing structure into a new external concrete layer to enhance the structural
capacity of the beams. The cracks are filled or repaired based on the crack width and depth and any
voids are filled for shear improvement. The thickness of the slab is increased in order to enhance the
deflection capacity and to increase the flexural capacity of the slab section.
The figure and details below show typical details of slab and beam modification.
Figure 30 Typical Slab and Beam Strengthening Details
Material Specification
 Concrete –C30
 Reinforcement – Grade B500B
 Bonded reinforcement – HILTI HIT- RE 500
 Active reinforcement coating – Refer Annexure
 Bonding Agent for fresh concrete – Refer Annexure
 Suggested complementary method – Protective coating for concrete surface – Refer
Annexure for material
NOTE:
 Contractor to measure & verify all the dimensions at the site

 All dimensions are given in metric units unless otherwise specified
 Unless otherwise indicated nominal cover to reinforcement to be as follows
o Beam-bottom 30 mm, sides 30mm
 Exiting concrete surface roughening & cleaning methods should be approved by the
engineer
 Bonding agent according to specified application method approved by the engineer.
 Grade of concrete mix shall be C30 Self-Compacting to BS EN-206-1 with a nominal
maximum aggregate size of 15mm
 Concreting to be done by use of cores through the slab
 No concrete is to be poured until the reinforcement has been inspected and approved by
the engineer
 Anchoring of reinforcement to be done using HILTI HIT
Figure 31 Cross section of Beam with repair and strengthening detail
9 Execution and Quality Control

This section elaborates the test that must be carried out to ensure an execution of works are according
the technical standards. It has to be noted that the general requirements for the quality control are
given in EN 1504-10.
Consideration shall be given to the chemical, electrochemical and physical condition of the substrate
and any contaminants, the ability of the structure to accept loading, movement and vibration during
protection and repair, ambient conditions, and the characteristic of the materials contained in the
structure and those of the protection and repair products and systems:
The following requirements shall be met:
 The achievement of the required condition of the substrate regarding cleanliness,
roughness, micro cracking, cracking, tensile and compressive strength, chloride or other
contaminant and their penetration, depth of carbonation, moisture content, temperature
and degree of corrosion of reinforcement.
 The achievement of the compatibility of the original concrete and reinforcement with the
protection or repair products and systems and compatibility between any different products
and systems, including avoiding the risk of creating conditions which may cause corrosion.
 The achievement of the specified properties of products and systems when applied and in
their hardened condition regarding the fulfilment of their purpose for protection and repair
of the structure.
 The achievement of the required storage and application conditions regarding ambient
temperature, humidity and dew point, wind force and precipitation and any temporary
protection which is needed.
10 Maintenance of Concrete Structures

In order to achieve the desired lifetime after a repair of a structure, it is necessary to define a
maintenance plan. The maintenance plan is thus an essential element of the repair of a structure and
should not be neglected.
Some parts of the protected or repaired concrete structure may have an expected service life which
is short compared with that of the rest of the concrete structure. Familiar examples are surface
coatings, sealants, and weather proofing materials. If the integrity of the protection or repair depends
on such parts, it is essential that they be regularly inspected, tested and renewed if necessary.
It is also states that “a structure management strategy is not chosen on technical grounds alone, but
also on economic, functional, environmental and other factors, and most importantly the owner’s
requirements for the structure.”
A maintenance management system should also be implemented to ensure that the required
maintenance is carried out properly, because a “correct monitoring and maintenance of the
protection and repair works will result in a longer service life for both the works and the structure.”
There are three different strategies proposed by Frangopol 2000
1. Reactive maintenance strategy
This features the repair only at the point when the actual status of the structures reaches the
limit state, and not before. After reaching the desired level of structural status at the time
being, the process begins again.
2. Preventive maintenance strategy
The preventive maintenance plan features the repair of the structure without any visible
damages, e.g., renewal of a surface protection system after 5 or 10 years even though the
surface protection system might still fulfil its requirements.
3. Combination of both
Combination of both strategies also feasible as appropriately considered.
Figure 32 Time- dependent development of the status of a structure due to

different maintenance concepts
ANNEXURE A - Load Maps
FIRST FLOOR
Colour code
Live Load 4
(kN/m2)
Super Imposed
Dead Load 2
(kN/m2)
Remark Canteen
ANNEXURE B – Test Results
ANNEXURE C – Column Design
Layout of Columns
C1 C2 C1
Column C1-400mm x 300mm
C1 C2 C1
C1 C2 C1
C1 C2 C1
C1 C2 C1
C1 C2 C1
Column Design using Prokon
From stocky Equation
Required - 4T16
Existing - 6T16
From stocky Equation
Required - 5T20
Existing - 6T20
ANNEXURE D – Beam Design
Layout of Beams
(Beam annotation units are in mm)

Analysis of Beams
Beam Vibration Analysis
Beam Deflection (mm) - Comb. 1 (1.0Gk + 1.0Qk) Allowable Min. Vibration = 4 Hz
1.8 1.1
B1a B1a
1.0 0.6
1.3 1.0
B1 B1
2.5 B1 1.8 B1
B2a B2a
B2a B2 B2a B2
B1 B1
0.7 0.6
B1 B1
B1a B1a
Allowable deflection - L/500

Natural Vibration frequency = 18/(δ)0.50
B1, B1a = 15.5 mm = 18/(1.8)^0.5
B2, B2a = 11.27 mm = 13.4 Hz
Analysis results of proposed beam sections
Moment M33 - Comb.2 (1.35 Gk + 1.5 Qk)

Loading SUPPORT
Grade of Steel - 460 N/mm2 SPAN
SDead - 2 kN/m2
Live - 4 kN/m2 1/γs = 0.87
B1
Existing Section - 725x300
Max. Support Moment = 596 kNm

B1a Max. Span Moment = 435 kNm
Existing Bottom R/f - 5T20

Assumed Existing Top R/f - 3T20
Existing 5T20 Existing 3T20
Modified Section - 850x450 mm
B1 Required Nil Required 5T20
B2 - Type 1
B1 B2a
B2a
Max. Span Moment = 264 kNm
B2
Existing Bottom tension R/f - 5T16
B1 Assumed Top tension R/f - 3T16

B1 Required - Nil Required 3T16
B1a B2 - Type 2

Existing Bottom tension R/f - 3T16

Assumed Top tension R/f - 3T16

Required Nil Required 2T16
Moment M33 - Comb.2 (1.35 Gk + 1.5Qk) - Continued
B1a B1a

B1
Assumed Bottom tension R/f - 3T20
Existing 2T20
Modified Section - 850x375 Existing 3T20 Required 3T20
B1 B2a
Required Nil
B2a
B2a
B2 Existing Section - 625x300
B1 Max. Support Moment = 181 kNm

Assumed Bottom tension R/f - 3T16

B1
B1a Modified Section - 750x375
Existing 2T16
Required 2T16
Existing 3T16
Required 1T16
Requirement of Lazer Bars for surface crack controlling
Min. bar diameter for 150mm spacing = (sbb/fy)0.5

= (150x400/500)^0.5
=11 mm
Provide T12@150 c/c

Shear S22 - Comb.2 (1.35 Gk + 1.5 Qk)
B2
B1a
B1a
B1
Existing R6@200
Required T10@200
Existing R6@200 B1
Required T10@150 for 2.55 m
from support then T10@200 B1
B2a B2 B2a
B2a
B1
B1
B1a
Existing R6@200
Required T10@200
Existing R6@200
Required T10@200
Diameter of lazer bars at 150 c/c = (sb*b/fy)0.5

= (150x400/500)0.5
= 10.95
Provide T12@150 mm c/c

ANNEXURE E – Slab Design
Existing Slab - Crack Analysis
Slab Thickness - 125 mm Max. Allowable Deflection = Lx/250

Loading : = 5675/250
- SDead - 2 kN/m2 = 22.7
- Live - 4 kN/m2
Elastic Deflection Immediate Cracked Deflection Long Term Cracked Deflection

Comb.1 (1.0Gk + 1.0 Qk) (Load Case- D+SDead+Live) (Load Case - 1.0D+1.0SDead+0.25Live)
Max Deflection 8.72 mm Max Deflection 27.8 mm Max Deflection 49.3 mm

Proposed Slab - Deflection
Eold = 20 kN/mm2, Enew = 24.6 kN/mm2 , Creep factor = 0.5
Slab Thickness - 275 mm Max. Allowable Deflection = Lx/250
Loading : = 5675/250 Effective Elastic Modulus = (Eoldx0.5x125 + Enewx150)/275
- SDead - 2 kN/m2 = 22.7 = (20*0.5*125 + 24.6*150)/275
- Live - 4 kN/m2 = 17.96 kN/mm2
Proposed Slab -Elastic Deflection Immediate Cracked Deflection Long Term Cracked Deflection
Comb.1 (1.0Gk + 1.0 Qk) (Load Case- D+SDead+Live) (Load Case - 1.0D+1.0SDead+0.25Live)
Max Deflection 10.41 mm Max Deflection 18.31 mm

Max Deflection 5.4 mm
Vibration Analysis -
Load Case (Dead + SDead + 10%Live)
Allowable Min. Vibration = 4 Hz
Existing Slab (Thk. = 125 mm) Proposed Slab (Thk. = 275 mm)
Max. Deflection = 9.98 mm

Max. Deflection = 5.8 mm
Natural Vibration frequency = 18/(δ)0.50 Natural Vibration frequency = 18/(δ)0.50
= 18/(9.98)^0.5 = 18/(5.8)^0.5
= 5.7 Hz = 7.47 Hz
Proposed Slab Analysis
Assumptions :
Loading :
1. The main reinforcement in the existing slab has yielded
- SDead - 2 kN/m2
2. The reinforcement in the other direction is not considered in the analysis
- Live - 4 kN/m2
M11 (kNm/m) - Comb.2 (1.35Gk+1.5Qk)
34.2 35.7
Provide T12 @ 125 = 905 mm2/m

M22 (kNm/m) - Comb.2 (1.35Gk+1.5Qk)
33.1
29.0
F11 (kNm/m) - Comb.2 (1.4Gk+1.6Qk) F22 (kNm/m) - Comb.2 (1.4Gk+1.6Qk)
Max. Shear = 29 kN/m

Max. Shear = 13 kN/m
Slab Reinforcement Yield Check
Project: Canteen Building-MAS Date : 09.08.2018 Rev: 00
Client: MAS Linea Aqua (Pvt.) Ltd. Sheet No: 1 Job No:-
Location: Overlay Deasign - Beams-B1 Designed by: Afsar
Checked by: SM
Reference Description Results
Loads Concrete R/f

Sdead = 2 kN/m2 Old Concrete = C15/20 fy,old = 460 N/mm2
Live = 4 kN/m2 New concrete = C25/30 fy,new = 500 N/mm2
3.06 m 4.665 m
As,top = 1571 mm2/m

As,bot = 1797 mm2/m
Location: Overlay Deasign - Beams Designed by: Afsar
Checked by: SM
Top Overlay Design
At Span:
Neutral Axis Xa = 1797x(460/1.15)
0.8x0.85x(25/1.5)x1531
= 41.4 mm
Vcd =
= 0.8x41.4x1.531x0.85x(25/1.5)
= 718.34 kN
= 718.34x2x1000
3060x(1531-450)
= 0.43 N/mm2
At internal Support
Vtd =
= 1571x(500/1.15)/1000
= 683 kN
= (718.34+683)x2x1000
4665x(1531-450)
= 0.56 N/mm2
d
d
0.45N/mm2 0.56N/mm2
0.33N/mm2
0.43N/mm2
3.06 m 4.665 m
d = 788 mm
Checked by: SM
Surface Treatment - sand blasted
At Span
= 0.33 N/mm2 From Diagram r = 0.145%
At Intermediate support
At Edge - cracking
Ved =
= 125x1531x0.8x3/1000
= 459 kN
Strip width = 0.75b

le = 0.75x1531 = 1150 mm
= 459x1000
1150x(1531-450)
d=788 mm
d=788 mm
0.45N/mm2 0.56N/mm2
0.33N/mm2
S1 S2 S3
0.33N/mm2
0.43N/mm2
1.15 m 3.82 m 2.755m
3.06 m 4.665 m
S1 = 0.16x1150x1531/100 = 2817 mm2 T10-200 Both direction

Checked by: SM
Forces to be anchored
For T10
Nd =
= 0.5x79x(500/1.15)/1000
= 17.2 kN
For T12
Nd =
= 0.5x113x(500/1.15)/1000
= 24.56 kN
Anchoring depth = 100 mm
For 10 Nrd = 23.6 kN (HILTI Manual)

For T12 Nrd = 32.4 kN (HILTI Manual)
Edge distance
c = 150 mm
Tensile force from resisited moment
Ned = Ved/6
= 459/6
= 76.5 kN/m
Nrd = 23.6/0.2
= 118 kN/m > Ned OK
Shear force to be anchored

Ved = 459 kN/m
Asv = 459/(500/1.15)
= 1056 mm2/m
Provide 2 legs T10-150
Location: Overlay Deasign - Beams B2 Designed by: Afsar
Checked by: SM
Loads Concrete R/f

Sdead = 2 kN/m2 Old Concrete = C15/20 fy,old = 460 N/mm2
Live = 4 kN/m2 New concrete = C25/30 fy,new = 500 N/mm2
2.99 m 2.99 m
As,top = 603 mm2/m

As,bot = 1005 mm2/m
Checked by: SM
Top Overlay Design
At Span:
0.8x0.85x(25/1.5)x1286
= 27.6mm
Vcd =
= 0.8x27.6x1.286x0.85x(25/1.5)
= 402.3 kN
= 402.3x2x1000
2990x(1286-450)
= 0.32 N/mm2
At internal Support
Vtd =
= 603x(500/1.15)/1000
= 201 kN
= (402.3+201)x2x1000
2985x(1286-450)
= 0.48 N/mm2
d
d
0.39N/mm2 0.48N/mm2
0.23N/mm2
0.32N/mm2
2.42 m 3.56 m
d = 702 mm
Checked by: SM
At Span
At Edge - cracking
Ved =
= 125x1286x0.8x3/1000
= 386 kN
Strip width = 0.75b

le = 0.75x1286 = 965 mm
= 386x1000
965x(1286-450)
d=702 mm
d=702 mm
0.39N/mm2 0.481N/mm2
0.23N/mm2
S1 S2 S3
0.23N/mm2
0.32N/mm2
1m 2.84 m 2.14m
2.42 m 3.56 m

Checked by: SM
For T10
Nd =
= 0.5x79x(500/1.15)/1000
= 17.2 kN
For T12
Nd =
= 0.5x113x(500/1.15)/1000
= 24.56 kN

Edge distance
c = 150 mm
Ned = Ved/6
= 386/6
= 64.3 kN/m
Nrd = 23.6/0.2
= 118 kN/m > Ned OK

Ved = 386 kN/m
Asv = 386/(500/1.15)
= 888 mm2/m
Location: Overlay Deasign - Slab Short span Designed by: Afsar
Checked by: SM
Loads Concrete R/f

Sdead = 2 kN/m2 Old Concrete = C20 fy,old = 460 N/mm2
Live = 4 kN/m2 New concrete = C30 fy,new = 500 N/mm2
Consider 1 m strip of the slab
BMD
SFD
2.99 m 2.99 m
As,top = 393 mm2/m

As,bot = 754 mm2/m
Distribution bars to be T8- 250

Location: Overlay Deasign - Slab Designed by: Afsar
Checked by: SM
Top overlay design
At Span:
0.8x0.85x(25/1.5)x1000
= 35.2 mm
Vcd =
= 0.8x35.2x1x0.85x(25/1.5)
= 399 kN
= 399x2x1000
2985x1000
= 0.27 N/mm2
At internal Support
Vtd =
= 393x(500/1.15)/1000
= 171 kN
= (399+171)x2x1000
4665x1000
= 0.244 N/mm2
d
d
0.23N/mm2 0.244N/mm2
0.25N/mm2
0.27N/mm2
3.14 m 2.84 m
d = 219 mm
Checked by: SM
At Span
At Edge - cracking
Ved =
= 125x1000x0.8x3/1000
= 300 kN
Strip width = 6tnew

le = 6x125 = 750 mm
= 300x1000
750x1000
d=219 mm
d=219 mm
0.23N/mm2 0.244N/mm2
0.21N/mm2
S1 S2 S3
0.21N/mm2
0.27N/mm2
0.75 m 4.78 m 0.5m
3.14 m 2.84 m

Checked by: SM
For T10
Nd =
= 0.5x79x(500/1.15)/1000
= 17.2 kN
For T12
Nd =
= 0.5x113x(500/1.15)/1000
= 24.56 kN

Edge distance
c = 150 mm
Ned = Ved/6
= 300/6
= 50 kN/m
Nrd = 23.6/0.2
= 118 kN/m > Ned OK

Ved = 300 kN/m
Asv = 300/(500/1.15)
= 690 mm2/m
Location: Overlay Deasign - Slab Long span Designed by: Afsar
Checked by: SM
Loads Concrete R/f

Sdead = 2 kN/m2 Old Concrete = C20 fy,old = 460 N/mm2
Live = 4 kN/m2 New concrete = C30 fy,new = 500 N/mm2
Consider 1 m strip of the slab
BMD
SFD
3.06 m 4.665 m
As,top = 393 mm2/m

As,bot = 410 mm2/m
Distribution bars to be T8- 250

Checked by: SM
At Span:
0.8x0.85x(25/1.5)x1000
= 14.5 mm
Vcd =
= 0.8x14.5x1x0.85x(25/1.5)
= 214 kN
= 214x2x1000
3060x1000
= 0.14 N/mm2
At internal Support
Vtd =
= 393x(500/1.15)/1000
= 171 kN
= (399+171)x2x1000
4665x1000
= 0.244 N/mm2
d
d
0.23N/mm2 0.244N/mm2
0.25N/mm2
0.26N/mm2
3.06 m 4.665 m
d = 208 mm
Checked by: SM
At Span
At Edge - cracking
Ved =
= 125x1000x0.8x3/1000
= 300 kN
Strip width = 6tnew

le = 6x125 = 750 mm
= 300x1000
750x1000
d=208 mm
d=208 mm
0.23N/mm2 0.244N/mm2
0.21N/mm2
S1 S2 S3
0.21N/mm2
0.26N/mm2
0.75 m 6.48 m 0.5m
3.06 m 4.665 m

Checked by: SM
For T10
Nd =
= 0.5x79x(500/1.15)/1000
= 17.2 kN
For T12
Nd =
= 0.5x113x(500/1.15)/1000
= 24.56 kN

Edge distance
c = 150 mm
Ned = Ved/6
= 300/6
= 50 kN/m
Nrd = 23.6/0.2
= 118 kN/m > Ned OK

Ved = 300 kN/m
Asv = 300/(500/1.15)
= 690 mm2/m
Zoning of Areas and required shear connectors
ANNEXURE F - Suggested Materials, typical method statements
and technical data sheets and test reports
Conpatch 600 ®
ONE PART POLYMER MODIFIED FINE CONCRETE STRUCTURAL REPAIR MORTAR

DESCRIPTION PRIMING
A ready to use economical one component polymer Priming is not normally required. Surfaces to receive
modified repair mortar containing fibres and silica fume. Conpatch 600 should be well saturated with water first.
Conpatch 600 contains specially selected materials to MIXING
provide a fine, smooth repair material. Complies with class Conpatch 600 is simply mixed with water to yield a stiff
R4 of EN 1504-3. easily workable compound with shrinkage compensating
properties.
USES & ADVANTAGES The quantity of water depends on the desired consistency
Conpatch 600 is a fine, ready to use repair mortar for but as a guide we recommend 16-18% by weight of
Conpatch 600.
repairing concrete surfaces including small honeycombs, Mix with a paddle mixer or trowel for at least 3 minutes to
surface defects, blowholes and minor damage. It can also ensure a homogenous lump free material is achieved.
be used to repair corrosive damage to concrete surfaces. Do not try to remix the product after losing workability by
Conpatch 600 is suitable for structural repairs in buildings, the addition of more water.
marine structures, bridges and other infrastructure. It is Typical Procedure for Concrete Repair
suitable for structural strengthening and preserving/restoring Using Conpatch Repair Mortars
passivity according to EN 1504-9 principle 3, 4 and 7.
Advantages include:- Remove damaged concrete and prepare
• Structural repair mortar. exposed steel reinforcement.
• Easy to apply. Excellent workability.
• Non shrink. Non toxic. Non corrosive.
• Water & weatherproof.
• Reduces carbonation significantly. Thoroughly clean area of repair using high
• Excellent adhesion and mechanical strengths. pressure water jet to remove all loose debris
• Contains no chlorides or salts that may cause corrosion. and contamination. Fingers should be able
• Gives better control than two part systems. to be fitted behind rebar.
• Provides cost saving over two part systems.
• Good colour matching to concrete.
Mix and apply Congard Zinc to rebar allow
• Non sagging.
to dry. Apply Conmix Latex bonding bridge
• Good resistance to chlorides & sulphates.
if required. Apply repair material WET ON WET
• Contains fibres to reduce micro cracking and improve
to bonding bridge.
durability.
• Complies with class R4 of EN 1504-3 repair mortar.
Replace damaged concrete using Conpatch
PROPERTIES AND COMPLIANCES 600 one component polymer modified
Appearance: Grey powder mortar, build up in layers if necessary.
Compressive Strength: 55 - 65 N/mm2
ASTM C109 after 28 days at 25oC
Flexural Strength: 12 - 15 N/mm2 Once set firm, the repair and surrounding area
ASTM C348 after 28 days at 25oC coat with Corcure 90 or Corcure 75
Bond Strength to Concrete: 2.5 - 3 N/mm2 curing compound.
ASTM D4541 after 28 days at 25oC
Drying Shrinkage: <400 microstrain at 7 days
ASTM C490 <560 micron strain at 28 days Remove any remaining Corcure 90 from
Coefficient of Thermal Expansion: 11 x 10 -6 /o C treated area if to overcoat.
Water Absorption ISAT: 10 mms < 0.007 ml/m2 /sec
BS 1881 Part 5 : 2 hours < 0.0045 ml/m2 /sec
Note: Properties depend on water content and are typical

Any further leveling may be achieved with
under laboratory conditions.
fairing material.
SUBSTRATE PREPARATION A final coat of Elastoclad decorative
The substrate should be clean & sound. Remove dirt, elastomeric, anti-carbonation coating will
dust, oil, grease, laitance, sealers, release agents, curing prevent the ingress of water chlorides and
compounds & paints. other aggressive influences, effectively halt-
Exposed rebar should be cleaned & protected with ing the carbonation process. Elastoclad is
Congard Zinc. water vapour permeable, allowing the sub-
The concrete should be presaturated for preferably 6 hours strate to breathe, and has excellent elastic-
with water before application. ity, bridging dynamically moving cracks even
at low temperatures.
Rev. 012 : Dec 2013

Conpatch 600 ®
ONE PART POLYMER MODIFIED FINE CONCRETE STRUCTURAL REPAIR MORTAR

METHOD OF USE QUALITY ASSURANCE
Apply Conpatch 600 with a trowel, spatula, float or by ISO 9001 : 2008 verified by TUV Nord.
spray. By hand press hard. Work up to 20 mm. in one
layer. Thicker repairs may be achieved by working in
layers.
CURING 1012
To prevent rapid surface drying and crazing, use a suitable
Cormix International Limited Compressive Strength: >45 MPa
curing compound from Cormix ‘s Corcure range e.g.
89 Romklao Rd., Sansab, Chloride ion Content: < 0.05 %
Corcure 90. Minburi Bangkok 10510 Adhesive bond: > 2.0 MPa
09 Restrained shrinkage: > 2.0 MPa
CONSUMPTION 1012-CPD-0103 Carbonation resistance: dk < control
Approx. 2 kg/m2/mm. EN 1504-3 (R4) concrete
Structural and non- Elastic modulus: > 20 GPa
structural repair Capillary absorption : < 0.5 kg/m-2/h-0.5
PACKAGING
25 kg. 4 ply plastic lined bags.
CONTACT DETAILS
STORAGE & SHELF LIFE Cormix International Limited
Conpatch 600 has a shelf-life of up to 12 months in Regional Office,
unopened packs kept in a dry store. If high humidity is 89 Romklao Rd., Sansab, Minburi, Bangkok 10510
apparent the life may be reduced to 6-8 months. Tel. (66 2) 917 3955-8, 543 8890
Fax. (66 2) 917 3959, 543 8891
HEALTH & SAFETY http://www.cormix.com E-mail : info@cormix.com
Conpatch 600 is non-toxic but is alkaline in its nature.
When applying gloves & goggles should be worn. Wash
off splashes to skin with water. If in eyes wash out with
plenty of clean water and seek medical attention.
Conpatch 600 is non-flammable.
TECHNICAL SERVICE
The Cormix International Technical Service Department
is available to assist you in the correct use of our products
and its resources are at your disposal entirely without
obligation.
NOTE : Every reasonable precaution is taken in the manufacture of all CORMIX-products to ensure that they comply with CORMIX‘s high standard of quality.
The recommendations and properties of the product are based upon what is believed to be the most reliable information available, and are not intended as
recommendations which infringe on other patents. Although all CORMIX-products are subject to rigid quality tests, no specific guarantee can be given, because
results depend, not only on quality, but also on other factors beyond our control. We welcome therefore consultation in the event of doubt concerning application,
or performance, and point out that oral recommendations, which vary from the instructions contained herein, are not binding without written confirmation by
CORMIX. All transactions shall be subject to our terms and conditions of sale-delivery-and-service. This data sheet supersedes the previous one and a reprint may
be issued without notice to supersede this edition, as and when deemed necessary. The information given in this leaflet is to the best of our knowledge true and
reliable. Field service where provided does not constitute supervisory responsibility.Our guarantee is therefore limited to the quality of materials delivered.
Contite ®
LIQUID CONCRETE PROTECTION & WATERPROOFING BY CRYSTALLIZATION SYSTEM

DESCRIPTION • Cracks developing on treated surfaces up to 1 mm.
Contite is a clear sealing and waterproofing subsurface may be sealed avoiding leakage through the slabs.
membrane which is solvent free, non-toxic, odourless and • Non toxic, odorless, safe for potable water tanks.
eco friendly. It is a spray applied colloidal liquid that • Fast tracks projects.
penetrates the concrete’s surface and reacts with the • Remains active for life of concrete.
• Overlays of asphalt do not delaminate, Ballast will not
cement paste matrix to form an insoluble gel sealing pores,
damage system.
capillaries and cracks creating a below surface barrier
• No protection boards required when backfilling.
against water and water borne salts ingress. As long as
• Hairline cracks that may develop reseal on contact
water is present Contite remains active and will seal with water (self healing).
hairline cracks both present and future. Contite allows • Can use with concrete containing PFA, GBFS, or
the passage of water vapour from the inside of the structure Silica fume.
(the concrete breathes) whilst waterproofing/sealing the • Withstands thermal stresses.
surface against sea water, aggressive ground waters, • Increases useful life of structure.
waste water and certain chemical solutions. • Provides additional resistance to dilute acid & alkali attack.
• Increases concrete’s surface hardness.
USES & ADVANTAGES • Very easy to apply and cannot be damaged during
Contite can be used to protect various concrete structures construction.
including marine and coastal structures, water storage How Contite Seals Concrete & Cracks (Not to Scale)
tanks, highways, runways, roofs, decks, bridges, cut &
cover tunnels, silos, car parks, swimming pools, precast Contite penetration is
panels, pipes, etc. Unlike solvent-based, membrane determined by concrete grade
& porosity
forming sealers Contite is environmentally friendly.
Since Contite penetrates into the concrete, it won’t
scratch, peel or damage. 0-0.5
mm
Advantages include:-
0-0.5 mm. crack
• Reduces porosity & permeability.
Stresses develop & cause crack.
• 100% Trafficable. Slip resistance improved. Crack sealed by Contite.
• Reduces Chloride & sulphate penetration by up to 90%.
• Prevents concrete cancer/corrosion.
• Improves concrete durability.
2mm Crack s >0.5 mm.
• UV resistant no topping or protection required. Heat The surrounding area of the
0.5mm
reflective membranes may be applied over the top. cracks mouth is sealed. As the
• Cannot be damaged, no debond as subsurface crack narrows it is sealed by
Contite. The cracks mouth
membrane. may be sealed via a combination
• Existing cracks up to 2 mm. width may be sealed. of calcium acetate & Contite
or Contite on its own.
Crystals Forming Through A Void 350-400 µm in Width. Some damage is shown to the crystal through the coring
process of the Sample. (Photograph has been taken 15 cm into the concrete)
Rev. 016 : Dec 2013
Contite ®

STANDARDS finished with an open textured finish or after finishing by
Conforms to: Water Permeability Test JIS 1404 acid etching, waterblasting or grinding to provide an open
ISAT BS1881 Part 5 1970 pore structure.
BS 6920 Contact with Potable Water
Construction Joints, Parapets, and Penetrations:
PROPERTIES AND COMPLIANCE Ensure all construction joints are roughened, clean & well
Appearance: Transparent Liquid prepared with exposed aggregate. Install Contite
Specific Gravity: 1.22 + 0.02 kg/ltr Waterstop. At parapets either pour insitu or treat surface
ASTM D1475
before installing the parapet with Contite Seal and install
Toxicity: Non Toxic
Contite Waterstop in the joint.
BS 6920-1
pH: 11-12 All drains, pipes, penetrations shall be sealed with
BS 1377-3 Contite Waterstop or Conflex LM polyurethane joint
Drying Time: min. 2 hrs
sealant. Design detailing is important, Contite seals
ASTM D2939
Recoat Time: 5-6 hrs cracks, capillaries and pores in concrete. It does not fill
Paintability: Excellent major honeycombs, voids or large structural cracks.
% Non Volatile Content: Approx. 28 + 2%
Surface Hardness: >15% increase over APPLICATION & SURFACE PREPARATION
ASTM C805 (Impact test) untreated surface • It is desireable to apply Contite at least 2 weeks after
Explosion Hazard: None pouring concrete, 4 weeks is recommended. It may be
Flash Point: None applied at any later time and is especially effective on
Water Permeability: >85% improvement over
old concrete.
JIS 1404 control
• Contite may be applied to concrete immediately after
Relationship of water absorption as function of time forms are stripped acting as a curing compound and
0.80 sealing material. Performance is not as effective as
0.70 when applied after 2 weeks. A second treatment is
0.60
recommended 28 days later.
ce • Contite may be applied to concrete treated with other
rfa
Su 0.50
ted compounds providing, these are removed properly,
t rea
Un 0.40
however, oils or paints may prevent penetration.
ce • Existing cracks up to 2 mm. may be sealed by flooding
d Surfa 0.30
Treate
0.20
on to the crack and in conjunction with calcium acetate
in some circumstances.
0.10
0.00
Before any concrete is treated the area must be thoroughly
0 50 100 150 200 250 300 350 400
cleaned. The surface should be first swept with a broom to
Contite treated concrete shows dramatic reduction of
water absorption over plain concrete (AIT2003). remove loose dirt. Then wet and scrub with soap or cleaning
compound wash off and ensure clean. Allow concrete to dry
thoroughly for at least 24 hours depending on humidity
COVERAGE RATES
5 m2 / Litre applied by spray. before applying Contite.
Contite can be applied by spray, brush and roller
DESIGN CRITERIA AND SPECIFICATION applications.
The waterproofing system shall penetrate the concrete A back pack spray will achieve 100-150 m2 per hour. Eye
and become an integral part of it forming insoluble protection should be used when spraying.
complexes of calcium silicate hydrate gel in the pores, Contite should be flooded onto the concrete surface. If
cracks and capillaries. applied by brush or roller the product must be flooded on
The material shall be non toxic and clear. It shall reactivate first. For vertical surfaces spray equipment is only
to seal hairline cracks which develop in the future. appropriate.
The concrete shall be placed and compacted to avoid Agitate material in drum before application. Apply only
honeycombs and shall be cured for up to 28 days prior to to concrete which is dry to touch (no damp patches). If it
application. Falls shall be to drains and the concrete rains before Contite has dried reapplication is required.
Contite ®

Sealing of joints etc should be carried out before STORAGE AND SHELF LIFE
application. Apply with low pressure in low wind conditions Store in the shade do not allow to freeze. Shelf life is 12 months
and allow to dry for 2-6 hours before flooding with water. in original sealed containers. Stir before application.
Re-spray water/flood with water on the second and third HEALTH AND SAFETY
day. If swallowed increase liquid intake for 24 hours. Consult a
In below ground backfilled concrete surface applications doctor. Eye contact should be avoided by the use of eye
ensure concrete surfaces are dry before application. If protection if contact is made flush with large amounts of
high hydrostatic pressure is anticipated consult Cormix water continue for several hours. Where in contact with
first in these instances. skin remove with water. Avoid direct contact with eyes
Contite should not be applied at temperatures below at all times. In enclosed environment use breathing
5oC (in high temperatures apply in the morning or late apparatus.
afternoon) if it is about to rain or in high wind conditions.
Cracks must be located & flooded with material at one TECHNICAL SERVICE
litre per 3-4 linear metres. The Cormix International Technical Service Department
Pond testing will determine if leaks are apparent and is available to assist you in the correct use of our products
should be continued for at least 12 hours. Retreat the and its resources are at your disposal entirely without
area if leaks are found. obligation.
Equipment:
Use simple hand spraying knapsack for small areas or QUALITY ASSURANCE
motorized sprayers for large 2areas. A simple knapsack ISO 9001 : 2008 verified by TUV Nord.
spray can achieve 100-150 m per hour.
IMPORTANT NOTES AND LIMITATIONS

Contite should not come into contact with glass. Paint in
general will not be effected by Contite, however, if
Contite comes into contact with paintwork remove with 1012
water. Before applying Contite where tiles or other
Cormix International Limited Abrasion resistance: at least
material may come into contact with Contite consult
89 Romklao Rd., Sansab, 30%
Cormix’s technical department.
Minburi Bangkok 10510 Capillary absorption and
Contite is not designed to be highly resistant to strong 09 permeability to water: < 0.1 kg/
acid or alkali attack. It is not a repellent surface coating. 1012-CPD-0102 m2.h0.5
The ability of Contite to seal concrete does not include EN 1504-2 Impact resistance: >20 Nm
leaks due to structural faults or mechanical damage. The Protection and repair Pull-off: > 0,8
repair of leaking structures will generally take 3 days to of concrete structures : Depth of penetration: > 5 mm.
achieve a seal, however, the seal may take longer. Surface protection system Dangerous substances: Comply
If other waterproofing additives have been used in the for concrete (Impregnation) with 5.4
concrete or mortar consult Cormix. If curing compounds Reaction to fire: Class A1
are used they should be degradeable and removable.
The concrete or mortar surface to receive Contite must
be clean and free of all oils and grease. If floor hardening CONTACT DETAILS
is the main consideration use Contop S. Contite should Cormix International Limited
not be used on the negative side of structures which are Regional Office,
continuously damp. Consult with Cormix if to be used with 89 Romklao Rd., Sansab, Minburi, Bangkok 10510
pigmented concrete. Roof details eg. construction joints, Tel. (66 2) 917 3955-8, 543 8890
penetrations, fixtures, expansion joints etc. must be Fax. (66 2) 917 3959, 543 8891
adequately sealed. Contact Cormix for details. http://www.cormix.com E-mail : info@cormix.com
The surface treatment of the concrete by power floating or
vacuum dewatering can make the surface of the concrete
very dense and impermeable. After such treatment it is
advisable to test a small area of concrete prior to the
application of Contite to ensure that impregnation occurs
and that the surface is not made glassy or white.
Consult Cormix before application in cases of high
hydrostatic pressure.
Agitate material in drum before application.
PACKAGING
25 litre plastic pails or 200 litre drums.
NOTE : Every reasonable precaution is taken in the manufacture of all CORMIX-products to ensure that they comply with CORMIX‘s high standard of quality.
The recommendations and properties of the product are based upon what is believed to be the most reliable information available, and are not intended as
recommendations which infringe on other patents. Although all CORMIX-products are subject to rigid quality tests, no specific guarantee can be given, because
results depend, not only on quality, but also on other factors beyond our control. We welcome therefore consultation in the event of doubt concerning application,
or performance, and point out that oral recommendations, which vary from the instructions contained herein, are not binding without written confirmation by
CORMIX. All transactions shall be subject to our terms and conditions of sale-delivery-and-service. This data sheet supersedes the previous one and a reprint may
be issued without notice to supersede this edition, as and when deemed necessary. The information given in this leaflet is to the best of our knowledge true and
Condur ® SC
LOW VISCOSITY 2 COMPONENT INJECTION RESIN
DESCRIPTION APPLICATION
A two component, low viscosity, injectable high strength Several application methods may be used to apply
epoxy resin to be injected into cracks & cavities in Condur SC. We recommend you consult Cormix
Technical Service Department for assistance. When
concrete where it cures to a rigid high strength material.
used to fill cracks Condur SC may be gravity fed (or)
Condur SC complies with ASTM C881-78 Type 1 Grade pressure injected for horizontal surfaces only pressure
1 Class B + C and BS 6319. injection is suitable for vertical (or) overhead cracks.
Crack, should be between 0-15 mm.
USES & ADVANTAGES
TYPICAL INJECTION
Condur SC is used as a structural binder to repair
cracked and damaged concrete. It has a proven history
for use as a structural repair epoxy and bonds Crack
depth 1. Mark position of nipple on concrete surface.
tenaciously to concrete and steel. (Distance between flange should not be more
It can be used for sealing cavities and cracks in structural than depth of crack.)
components such as columns, beams, foundations,
decks, and water retaining structures.
It not only forms an effective barrier against water
2. Press fixing nail through plastic injection
infiltration but also bonds the concrete sections together port.
restoring the original structural strength.
Advantages include:-
• Waterproofs structure.
• Deep penetration. 3. Apply Condur EA1 Paste epoxy to underside
• Excellent adhesive quality. of plastic injection port.
• Suitable for both dry & damp conditions.
• High mechanical & adhesive strength.
• Shrinkage free hardening.
• Prevents corrosion of rebar. 4. Place plastic injection port on position
Condur SC can also be used as a structural patching marked in step 1 and press firmly onto
concrete.
repair compound for spalled concrete, as a grouting
compound for anchoring bolts and anchors in concrete
and as bridge deck nosing compound by mixing with
5. Seal flanges and surface of crack with
Condur aggregates. Condur EA1 Paste.
PROPERTIES
Colour: Yellow to light brown (mixed)
6. Inject bottom flange using Condur SC until
Viscosity (mixed): 200-300 cPs@ 25oC Clean material flows from next flange above.
Specific Gravity: A + B = 1.06 + 0.02 Resin
Tensile Strength: > 25 N/mm2 Inject
Flexural Strength: > 50 N/mm2

Potlife: 50-70 min
7. Seal flange.
Bond Strength:
To Concrete 3-4 N/mm2 (Concrete Failure)
To Steel 10 - 15 N/mm2 (Sand Blasted)
(35oC, 65% r.H., 10 days)
Clean
Resin 8. Repeat process working from bottom to top
MIXING Inject until crack is filled.
Condur SC is supplied in factory proportioned units
comprising correct quantities of comp A (resin) and
comp B (hardener). Decant all of comp B into comp A
and mix thorough for approx 3 min, still homogenous 9. After curing, remove flanges and grind off
material achieved. This material is now ready to be crack sealant.
injected in horizontal and vertical cracks.
Rev.014 Oct 2015

Condur ® SC
LOW VISCOSITY 2 COMPONENT INJECTION RESIN
IMPORTTANT NOTES TECHNICAL SERVICE

The maximum width of a crack to be injected should be The Cormix International Technical Service Department
no more than 15 mm. The concrete should be at least 3 is available to assist you in the correct use of our
weeks old. To obtain characteristics stated in the data products and its resources are at your disposal entirely
sheet the mixing ratio must be maintained. without obligation.
LIMITATIONS
QUALITY ASSURANCE
Condur SC should not be used to seal cracks where
ISO 9001: 2008 verified by TUV Nord.
future movement is expected. Other solutions should be
undertaken to rectify this problem e.g. creating a
CONTACT DETAILS
movement joint.
Cormix International Limited
MIX RATIO 89 Romklao Rd., Sansab, Minburi, Bangkok 10510
Tel. (66 2) 917 3955-8, 543 8890
A : B = 4 : 1 by weight.
Fax. (66 2) 917 3959, 543 8891
A : B = 3 : 1 by volume.
http://www.cormix.com
PACKAGING E-mail: info@cormix.com
Condur SC is supplied in 2 kg. or 20 kg. packs.
STORAGE & SHELF LIFE

Condur SC has a shelf life of 12 months when unopened
and stored in a cool, dry environment.
HEALTH & SAFETY

Cormix International Limited recommends that
protective clothing, gloves, eye protection and mask be
worn.
Condur SC contains resins which upon contact with the
skin, may cause irritation. Avoid inhalation of vapour. In
case of contact with skin, do NOT use solvent, remove
immediately with resin removing cream, followed by
soap and water. In the instance of contact with eyes
rinse thoroughly with clean water and seek medical
advice. In the instance of swallowing, do NOT induce
vomiting, seek medical attention.
NOTE : Every reasonable precaution is taken in the manufacture of all CORMIX-products to ensure that they comply with CORMIX‘s high standard of quality. The recommendations and
properties of the product are based upon what is believed to be the most reliable information available, and are not intended as recommendations which infringe on other patents. Although
all CORMIX-products are subject to rigid quality tests, no specific guarantee can be given, because results depend, not only on quality, but also on other factors beyond our control. We
welcome therefore consultation in the event of doubt concerning application, or performance, and point out those oral recommendations, which vary from the instructions contained herein,
are not binding without written confirmation by CORMIX. All transactions shall be subject to our terms and conditions of sale-delivery-and-service. This data sheet supersedes the previous
one and a reprint may be issued without notice to supersede this edition, as and when deemed necessary. The information given in this leaflet is to the best of our knowledge true and
Elastoclad ®
A ONE COMPONENT LIQUID, 100% ACRYLIC ELASTOMERIC WATERPROOFING MEMBRANE
DESCRIPTION • Suitable for protection against ingress (Principle 1,

method 1.3 of EN 1504-9),
The Elastoclad system comprises a single com- • Suitable for moisture control (Principle 2, method
ponent water based, high solids, 100% acrylic 2.3 of EN 1504-9)
copolymer waterproof membrane coating applied • Suitable for increasing the resistivity (Principle 8,
over a range of primers dependent on the substrate method 8.3 of EN 1504-9)
type. Elastoclad is a crack accommodating coating
containing additives to inhibit the growth of mould PROPERTIES AND COMPLIANCES
and resist bacterial growth and resists aggressive
Colour: 4 standard colours plus special
elements.
colours made to order.
Elastoclad complies with the requirements of EN
Volume solids: 45% (ASTM D2697)
1504-2 as protective coating.
Specific Gravity: Approx. 1.26
USES & ADVANTAGES Physical or Chemical
Change: Dries through loss of water.
Use as a decorative, waterproofing membrane to Drying Tack free: 40 minutes (30oC, 50% RH)
most types of building facades, walls, roofs and Recoat: 2 hours
gutters after the recommended primer/sealer appli- Fully dried: 7 days
cation. Elastoclad has approval for the safe encap- Application temp: 5 - 40oC
sulation of asbestos and for use in “wet areas” such Hardness: 55-65 shore A (ASTM D2240)
as bathrooms. It provides a protective waterproofing Elongation: >500 % (ASTM D412)
skin over polyurethane foam, protecting the PU foam Permeance: 1.95 metric perm @ 500 microns
from UV and weather attack. On roofs and balconies, (ASTM E96)
Elastoclad provides a durable, non skid, waterproof Bond Strength: Exceeds cohesive strength of
finish which will accept regular foot traffic. Coating. (ASTM C297)
When applied as a multi-layer system incorporating UV Resistance: No effect after 5,000 hours
reinforcement fabric, Elastoclad is also suitable for (ASTM D822)
waterproofing concrete decks subject to light Tear Resistance: >21 kN/mm (ASTM D624)
vehicular traffic. Accelerated Weathering: No cracking.
Elastoclad is suitable for application to many (ASTM D471)
common substrates including concrete, fibrous Carbon dioxide diffusion resistance:
cement products, metals, timber and bituminous (Klopfer criterion R >50 m) – R = 266 m
membranes. Some special priming may be required. Water vapour diffusion resistance:
Advantages include:- (Klopfer criterion SD<4 m) - SD = 1.65 m
• Proven track record over 30 years. Water permeability: Highest resistance
• Safe to use, water based acrylic formulation. (Class E ASTM E514-7A) to water penetration
• Easy water cleanup. Chemical resistance: Unaffected by a range of
• One component - readily applied direct from pail. mild acids, alkalis, and is resistant to bio deterioration.
• Excellent resistance to UV, weathering and CO2. Cormix International should be consulted in respect of
• Excellent build properties enable application to other chemicals.
both horizontal and vertical surfaces. Lightweight Heat Reflectance
no topping required. White Elastoclad offers 80% reflection of solar energy
• Can be applied to a wide range of substrates. providing the following advantages:-
• Various colours available. Colour fast. • Minimises surface temperature gain.
• Highly flexible - accommodates movement and • Prevents roof degradation of existing substrate.
minor cracking of substrates. • Minimises expansion/contraction experienced with
• No solvents or fire hazard. No pungent smell. • temperature changes extending the life of the
• Acoustic dampening properties. roofing system.
• Excellent long term durability. • Decreases energy consumption.
• Fast application.
• High solids & resin content. APPLICATION INSTRUCTIONS
• Remains flexible through use of high grade 100% Due to the wide range of applications for which
elastomer acrylic polymers. Elastoclad is suitable, several system brochures have
• Low maintenance costs. been produced to explain specific surface preparation
• Reduced energy cost due to heat reflectivity. and application details for each type of application.
• Resistant to foot traffic. These system brochures are available from Cormix
• Excellent dirt releasing ability. International Ltd.
• No need to remove existing system in maintenance System 1: General facade waterproofing including:
situation e.g. existing sheet membrane, therefore walls, brick, masonry render, block work and con-
reduces programme time, noise, dirt, debris etc. crete.
Rev.018 May 2018

Elastoclad ®
System 2: Waterproofing and refurbishment of This followed by a minimum of 2 coats of Elastoclad

corrugated roof materials including: fibrous cement, over the entire surface.
steel and aluminium.
Mould infested surfaces
System 3: Waterproofing of concrete roofs, masonry
Scrape or clean thoroughly; all finishes lifting or badly
tiles and concrete decks.
infested should be removed. Wash down with a water
System 4: Waterproofing of wet areas including:
soluble fungicide or one part of domestic bleach to
showers, laundries and bathroom floors.
eight parts of water and then rinse off residues. Make
Cormix will provide application advise for main-
good any defects and allow walls and repairs to
tenance when applying Elastoclad over existing
completely dry.
systems such as sheet membranes, or built up roofs.
Notes : All sealer/primer applications to be allowed to
SURFACE PREPARATION & PRIMING dry prior to the application of the first coat of
Surfaces shall be sound, clean, dry and free from oil Elastoclad.
or grease. Moisture shall not be escaping from the
substrate. APPLICATION
If moisture is escaping seal with 2 coats of Floorgard
Prior to applying Elastoclad to the roof surface all
Moisture Barrier.
detailing work must be completed on seams, splits,
Concrete & masonary surfaces protrusions, fixings, drains, flashings, fasteners etc.
Floorgard Moisture Barrier, Elastoclad Clear Sealer. The detailing shall be completed using Conflex LM or
Elastoclothe reinforcement embedded in Elastoclad.
Steel, aluminium, galvanised steel & zinc Primers shall have been applied and dried. Elastoclad
Elastoclad Primer 2 shall be extended up & over pipes, parapets, vents &
Bituminious or asphalt surfaces fixings to finish at least 10 cm. above the substrate.
Consult Cormix. The coating should be extended under flashings.
Coats of Elastoclad shall be installed in a direction
Timber perpendicular to the last one except if coating metal
Elastoclad Acrylic Sealer. roof panels.
Previously coated substrates Surfaces shall be uniformly coated & free from voids,
Elastoclad Clear Sealer blisters or pin holes. Before recoating previous coats
must have adequately cured. Several hours are
Sound, previously coated or primed surfaces required to achieve resistance to rain or dew. Long
The old surface should be thoroughly scrubbed with term resistance will take longer depending on weather
detergent and water, then sanded or wire brushed to conditions, resistance to ponding shall require 24-48
ensure mechanical adhesion. Seal with Elasto Coat hours.
Clear Sealer. All dirt, dust or pollution that falls on the coating
between coats shall be removed before applying the
Crumbling walls
The application of Elastoclad will prevent the erosion next coat. Film thickness may be checked with a wet
of weak, crumbling walls and will readily bridge film gauge.
hairline cracks. In high temperatures Elastoclad in opened containers
may skin over, remove the skin before mixing. To
Overcoating old Elastoclad prevent skinning cover the container with plastic.
Clean the surface, then apply a single coat of Elasto Diluting Elastoclad with water is not recommended as
Coat Clear Sealer and allow to dry for one to two its properties will be effected. Do not leave Elastoclad
hours. in equipment, purge with water. Spraying material with
temperatures below 15oC will become more difficult
Expanded plastics, polystyrene and polyurethane
due to its cohesive nature.
foam etc.
Spraying by airless spray is prefered over flat
Apply 2 coats of Elastoclad directly over clean
surfaces, a heavy to medium nap roller can be used
surfaces.
and brush or roller for touch up or detail work.
The treatment of joints liable to movement The application using brush or roller requires laying
These must be bridged with Elastoclothe the material onto the surface, avoiding brushing out,
reinforcement. to achieve the required film thickness per coat. A
The reinforcement should be laid and stippled flat on minimum of two coats are required on vertical
a very thin coat of wet Elastoclad and allowed to dry. surfaces to achieve a total dry film thickness of
It should then be covered with a thin layer of approximately 350 microns. On horizontal surfaces a
Elastoclad with a generous overlay on each side of minimum of three coats are required to achieve a total
the mesh and allowed to dry. d.f.t. of approximately 500 microns.
Elastoclad ®
REINFORCEMENT & ROOF DECKS Old Systems

Elastoclad can be applied over built up & modified
Polyester fabric or mesh can be incorporated into the bitumen roofs, cracked and deteriorated concrete
Elastoclad film to reinforce the membrane. roofs, steel roofs and single ply membranes such as
Reinforcement is recommended for various EPDM, Hypalon, PVC, Neoprene etc.
applications, cracked concrete decks, old sheeted Ensure moisture movement is sealed off.
and bitumen membranes and trafficable areas. Once
the reinforcement is embedded into the Elastoclad CLEANING
and dry, apply a minimum of 500 microns D.F.T. of
Tools and equipment should be cleaned with water
Elastoclad over these areas.
immediately after use.
On roof decks, balconies etc., Elastoclad is
reinforced with polyester fabric or mesh embedded APPROXIMATE COVERAGE RATES
into the first coat of Elastoclad whilst wet. Apply a
Elastoclad: 2.8 m2/litre per coat*
further coat ensuring there are no bubbles or wrinkles
Elasto Coat Clear Sealer: 7 m2/litre per coat
in the reinforcement to completely saturate the
Floorgard Moisture Barrier: 3 m2/litre per coat
reinforcement. Application of this reinforcing will
Elastoclad Acrylic Sealer: 12 m2/litre per coat
require the use of approximately 0.5 litre Elastoclad,
The coverage figures are theoretical - due to wastage
additional to the final membrane materials per m2 of
factors and the variety and nature of possible
area. Apply an additional three (3) coats of Elastoclad
substrates, practical coverage figures may be
to achieve a total d.f.t. of approximately 1000 microns
substantially reduced.
(1 mm).
For profiled steel roofs multiplication factors of 1.2-1.3
The product will be touch dry in approximately 40
are normally required.
minutes and may be overcoated after 2 hours drying
* 150 microns dry film thickness.
under normal conditions. This can be assessed at the
time of application and is influenced by ambient MAINTENANCE
temperature, humidity, airflow and type of surface
There are no special requirements for maintenance,
treated.
any damage identified during normal inspections
GENERAL INFORMATION should be repaired or material replaced as
Fabric Reinforcement appropriate. Regular maintenance should be carried
Fabric reinforcement is required on roofs that have a out & the roof cleaned at least once a year to prevent
large amount of cracks, splits, seams, joints etc. buildup of dirt, leaves, chemicals, bird dropping &
These may be individually addressed using Conflex other contaminations that may adversely effect the
LM and Elastoclothe if the numbers are limited. coating.
Ponding
Ponding should be avoided on roofs, and good SPECIFICATION CLAUSES
slopes to drains provided, however, Elastoclad with- Waterproofing membrane for concrete roof slabs and
stands minor ponding found on many roofs. deckings.
Product Life Prior to applying Elastoclad on flat concrete roof slabs
The life of Elastoclad depends on initial applied and decking areas initially prepare and prime the
thickness, UV levels, temperatures, abrasion, foot substrate in accordance with manufacturer’s surface
traffic, rain, ponding & wind. Elastoclad will typically preparation details.
wear at a low rate of 10-15 microns per year. Over the prepared area, apply one coat of Elastoclad
The thickness of Elastoclad is related to the required and while still wet embed polyester reinforced fabric
life and anticipated crack widths. The thicker the or mesh overlapping edges and ends by a minimum
coating the longer the life and greater the crack of 50 mm. Ensure that all bubbles and wrinkles in the
bridging capacity. reinforcement are removed prior to further over-
Typically the coating is installed to last 5-10 years coating.
before recoating. It is recommended that the base Apply multiple coats of Elastoclad (min. 3 coats) to
coat shall be light grey before applying the white top provide an additional dry film thickness of
coat as the top coat wears the base coat will approximately 500 microns over the reinforced area.
eventually show through. Allow between 2 and 4 hours between coats.
Application shall be by airless spray or roller.
Recoating
Note : the total thickness of the system should be
Before recoating Elastoclad shall be cleaned with
approx.1 mm. requiring at least 1.5 litre of Elastoclad/m2
water & detergent, high pressure washed off & all over the reinforced completed system.
necessary repairs made.
Elastoclad ®
Decorative waterproofing facade coating. Elastoclad is not recommended for surfaces sub-
The decorative waterproofing coating shall comprise jected to hydrostatic pressure. Protect from rainfall
a suitable primer system overcoated with Elastoclad, whilst curing.
a single component elastomeric coating suitable for Elastoclad should only be tiled over after drying for 7
application by brush, roller or spray. The total dry film days. For applications where faster turnaround is
thickness of the coating shall be not less than 350 required, consult Cormix International Limited.
microns and shall be capable of providing carbon
dioxide diffusion resistance equivalent to not less WARRANTIES
than 50 metres of air. It must exhibit a water vapour Elastoclad warranties are available for five, ten or
transmission resistance S D not more than 1.65 fifteen year periods. The warranties guarantee the
metres (Klopfer criterion) and achieve a Class E performance of the material against leaks caused by
water permeability when tested to ASTM E514-74. normal weathering. Refer to the individual warranty
Waterproofing membrane system for bathroom and documents for additional information.
wet areas. PACKAGING
Prior to applying Elastoclad in wet areas prepare and
prime the substrate in accordance with manufac- Elastoclad Acrylic Sealer: 20 litre pails
turer’s surface preparation details. Elasto Coat Clear Sealer: 20 litre pails
Once this has been completed, a fillet of Conflex LM Elastoclad Primer 2: 20 litre pails
polyurethane joint sealant should be applied at the Floorgard Moisture Barrier: 20 litre pails
junction of the wall and floor (perimeter seal). A base
coat of Elastoclad should be layer and a layer of STORAGE & SHELF LIFE
polyester reinforcing fabric or mesh placed over all
joints and where the walls and floor meet. Where All products have a shelf life of 12 months if kept in a
subject to flooding reinforcement should be used dry store.
over the entire area. Apply multiple coats of Elasto- Storage conditions:
clad to achieve a dry film thickness of at least 500 Store in dry conditions at temperatures between 5oC
microns. and 30oC in the original, unopened containers. If
stored at high temperatures, the shelf life may be
LIMITATIONS reduced.
Elastoclad should be applied to sound substrates Fire:
either new or old. Unsound surfaces must be re- Elastoclad Clear Sealer is flammable. Keep away
paired or removed. Cracks must be detailed. from sources of ignition. No smoking. In the event of
Elastoclad should not be applied over surfaces con- fire, extinguish with CO2 or foam. Do not use a water
taining moisture, insulation that is saturated should jet.
be replaced. Existing waterproofing systems left in
place must be sealed to avoid moisture movement. HEALTH & SAFETY
To avoid potential bubbling of the system concrete Elastoclad Primer 2 is acidic and appropriate eye and
containing moisture should be treated with 2 coats of skin protection must be taken to avoid contact.
Floorgard Moisture Barrier to a minimum d.f.t. of 300 Elastoclad is non-flammable and is classified as
microns. The concrete’s moisture content should be nonhazardous, however, all manufactured products
< 4%. All detailing must be attended to prior to the should be handled with care. If swallowed, do NOT
application of Elastoclad, it is not designed to bridge induce vomiting, give a glass of water. If in eyes, hold
expansion joints, and will only crack bridge if applied eyes open, flush with water for at least 15 minutes. If
at the correct coverage rates to accommodate the skin contact occurs, remove contaminated clothing
crack size. Elastoclad is not manufactured to seal and wash skin thoroughly. Do not use solvents on
structural cracks. Reinforce when subject to light skin. If poisoning occurs, contact a doctor or Poisons
traffic. Information Centre.
Extreme ambient or surface heat temperatures will
have a detrimental effect on Elastoclad during TECHNICAL SERVICE
installation. Cormix International Limited offers a comprehensive
Under high temperatures work should be performed range of high performance, high quality products
early in the morning, late in the day or in shaded suitable for use within all aspects of the concrete
sections. repair and protection industry. In addition, the
Application under direct sunlight during the heat of company offers a technical support package to speci-
the day should be avoided. fiers, end users and contractors, as well as on-site
Do not use as a vapour barrier coating or over cold assistance. The Cormix International Technical Ser-
storage tanks. Do not apply to uncured concrete or vice Department is available to assist you in the
while rain threatens, or at temperatures below or correct use of our products and its resources are at
which may fall below 10oC during the drying period. your disposal entirely without obligation.
Elastoclad ®
QUALITY ASSURANCE
ISO 9001 : 2008 verified by TUV Nord
1012
Cormix International Limited Permeability to CO2: SD > 50 m

89 Romklao Rd, Sansab, Permeabillity to water
Minburi, Bangkok 10150 vapour: < 0.1kg.m2.h0.5
09 Capilliary absorption
1012-CPD-0102 permeability to water: SD < 5 m (class I)
EN 1504-2 Pull-off test: > 0.8 N/mm2
Protection and repair of
concrete structures: Surface
Dangerous substances: Comply with 5.3
protection systems for Reaction to fire: Class F
concrete coating (PI, MC,IR)
DISCLAIMER
Performance data is achieved testing in accordance
with International Standards. Testing by others may
result in different results from those published as a
result of external factors such as poor sampling,
incorrect mixing, varying temperatures, curing,
crushing procedures etc.
Cormix does not take responsibility nor need to
defend others testing that does not achieve the
published data.
The user must test the products suitability for the
intended application and purpose. Cormix reserves
the right to change the properties of the product.
Site conditions and differences in materials are such
that no warranty or fitness for a particular purpose,
nor liability can be inferred from the published data
sheet, written recommendations or from other advise
offered.
CONTACT DETAILS
Cormix International Limited
89 Romklao Rd., Sansab, Minburi, Bangkok 10510
Tel. (66 2) 917 3955-8, 543 8890
Fax. (66 2) 917 3959, 543 8891
http://www.cormix.com
E-mail: info@cormix.com
one and a reprint may be issued without notice to supersede this edition, as and when deemed necessary. The information given in this leaflet is to the best of our knowledge true and reliable.
Field service where provided does not constitute supervisory responsibility. Our guarantee is therefore limited to the quality of materials delivered.
Technical Data Sheet
X-Roc GalZinc
Single component zinc rich anti corrosion primer 10280507
Product Description after initial application. Once priming is complete and

X-Roc GalZinc is a single component zinc rich epoxy has fully dried, it is essential that the repair mortar is
primer. applied as soon as possible.
Uses Clean up
As an anti-corrosion primer for reinforcing steel to Clean hands and skin immediately with soap and water
extend the life of repairs made to reinforced concrete. or industrial hand cleaner, not solvents. Remove X-Roc
GalZinc from tools, equipment and mixers with xylene
Advantages immediately after use.
• Single component
• High zinc content Limitations
• Combats corrosion Do not leave the primed surface exposed to the
• Compatible with all cementitious mortars elements for longer than 7 days before overcoating or
• Protects adjacent areas of the repair applying repair mortar.
• Easy to use
• Fast drying Do not apply X-Roc GalZinc when the ambient or
substrate temperature is below 4ºC (40ºF) or if the
Application Properties temperature is within 3ºC (5ºF) of the dew point. When
Typical wet film thickness: 135 microns (5.4mils) the temperature is above 35ºC (95ºF) the following
Typical dry film thickness: 40 microns (2mils) guidelines are adopted as good working practice.
Coverage Store unmixed materials in a cool (preferably

Typically 8m2 per liter (86ft² per quart) temperature controlled) environment, avoiding exposure
to direct sunlight. Keep equipment cool, arranging shade
Packaging protection if necessary. It is especially important to keep
1 and 5 liters cool those surfaces of the equipment which will come
1 quart and 1 gallon tins (USA) into direct contact with the material itself. Try to avoid
application during the hottest times of the day, arrange
Shelf Life temporary shading as necessary. Make sufficient
7 months when stored at below 25°C (77oF) under material, plant and labour available to ensure that
shade in a dry environment. application is a continuous process.
Installation Guidelines Health and Safety

Surface Preparation This product is for industrial use only by trained
The reinforcing steel should be abrasion blasted operatives. It is potentially hazardous if not used
completely to bright metal to remove all scale and correctly. Please refer to the Material Safety Data
corrosion deposits. Sheet (MSDS) prior to the purchase and use of
this product. The MSDS can be obtained via our
Application website www.x-calibur.us
Apply within one hour of preparing the reinforcing steel.
The product should be applied by brushing, to ensure Authorized Technical Specialist
continuous coverage over the total surface Please note that only X-Calibur Authorized Technical
area of the exposed steel. It may be necessary to apply Specialists (‘ATSs’) are permitted to change any of the
a second coat if it is felt that some holidays may exist in information in this data sheet or to provide written
the first coat. Allow the first coat to dry fully before recommendations concerning the use of this product.
application of the second coat. X-Roc GalZinc is Visit www.x-calibur.us for a full list of X-Calibur ATSs.
recoatable generally between 30 minutes and one hour
28
Datasheet Validity
X-Calibur makes modifications to its product datasheets
on a continuous basis. Please check the datasheet
update section on www.x-calibur.us to ensure you have
the latest version.
Warranties
X-Calibur supplies products that comply with the
properties shown on the current datasheets. In the
unlikely event that products supplied are proved not to
comply with these properties, then we will replace the
non-compliant product or refund the purchase price.
X-Calibur does not warrant or guarantee the installation
of the products as it does not have control over the
installation or end use of the products. Any suspected
defects must be reported to X-Calibur in writing within
five working days of being detected. X-Calibur
Construction Systems Inc. makes no warranty as to
merchantability or fitness for a particular purpose
and this warranty is in lieu of all other warranties
express or implied. X-Calibur Construction Systems
Inc. shall not be liable for damages of any sort including
remote or consequential damages, down time, or delay.
www.x-calibur.us
Cormix ® Latex
POLYMER BONDING AID & WATERPROOFING ADMIXTURE
DESCRIPTION SUBSTRATE PREPARATION

Cormix Latex is an aqueous emulsion especially Saw cut or cut back the extremities of the repair locations
formulated for use with cementitious mixes. It is used in to a depth of at least 10 mm. to avoid feather-edging and
mortar and concrete to improve the waterproofing, wear to provide a square edge. Break out the complete repair
resistance, durability and bonding properties. Mortars area to minimum depth of 6 mm. up to the sawn edge.
containing Cormix Latex may be used for vertical,
horizontal and overhead repair work. REBAR PRIMING
Prime rebar with Congard Zinc or Congard ST.
USES & ADVANTAGES
Cormix Latex is used to substantially improve the MATERIALS
qualities of cement mixes, for example: thin layer patch Aggregates and sand should be clean and well graded.
mortars, renders, floor screeds, concrete repair mortar, Sand particle size should relate to applied thickness of
abrasion resistant linings, fixing mortars, bonding slurry mortars and required surface finish.
etc. SUBSTRATE PRIMING
Advantages include:- The substrate should be thoroughly soaked with clean
• Excellent water resistance. water and any excess removed prior to commen-
• Increased durability. cement.
• Plasticising effect and reduces shrinkage. A slurry primer should be prepared consisting of 1
• Improved corrosion protection. volume Cormix Latex to 1 volume clean water to 1-3
• Economical. volumes fresh cement. The slurry should be stirred
• Higher flexibility. frequently during use to offset settlement & worked well
• Good resistance to many salts and chemicals. into the surface.
• Excellent adhesion to concrete, mortar, stonework, Avoid ponding. The repair mortar, topping or render must
plaster & blockboard. be applied on the wet slurry primer. If the slurry primer
• Thermal expansion and elastic modulus similar to dries before application of the mortar, it must be
concrete. removed and the area reprimed before continuing.
• Non toxic.
• Improves cohesion & workability. MIXING
• Single component easily gauged. Hand mixing is not recommended. Preferably a forced
• Improved flexural & tensile properties allow for thin action mixer or low speed drill with appropriate paddle
application. should be used. Hand mixing should only be undertaken
PROPERTIES with small quantities. Weigh the cement, sand and,
where required, aggregate into the mixer and dry blend
The below results are approximated and achieved by together for one minute. With the machine in operation,
considering the properties of a sand : cement mortar at add the pre-mixed Cormix Latex and clean water.
3:1 combined with Cormix Latex at 10 litres per 50 kg of Continue mixing for 3 minutes to ensure complete
cement. dispersal into the sand and cement. Make any small
Appearance: Milky White Liquid adjustment to the quantity of clean water but do not
Specific Gravity: Approx. 1.02 + 0.02 kg/litre
significantly exceed the dosage shown below. Mix until
Compressive Strength: 10-15% increase over control
BS 6319, Part 2 lump free with creamy consistency.
Tensile Strength: 5-10% increase over control
METHOD OF USE
BS 6319, Part 7
Flexural Strength: 5-10% increase over control In all situations the surface must be in a clean, laitance
BS 6319, Part 3 free and roughened state. Absorbent surfaces should be
Shear Bond Strength: > 8.6 N/mm2 saturated thoroughly with water, but avoid ponding. Oil
by Slant Shear Method, ASTM C1042
or grease deposits should be cleaned away. Pull off tests
Toxicity: Non-toxic
Complies to ASTM 1059, Type II and ASTM C932 should be conducted to assess decontamination.
Chemical resistance: Expose rebar & clean to bright condition. Grit or sand
Adding Cormix Latex to cement mortars reduces blast.
permeability and therefore helps reduce the rate of Remove any corrosive agents such as chloride by high
attack by aggressive chemicals, acid gases and water. pressure water blasting.
Rev.012 Feb 2015

Cormix ® Latex
POLYMER BONDING AID & WATERPROOFING ADMIXTURE
APPLICATION CURING
Cormix Latex mortars, toppings and renders must be Cure with Corcure 180 or Corcure 90.
well-compacted on to the primed substrate by trowel.
Exposed steel reinforcement should be completely SUBSEQUENT FINISHES
encapsulated by the mortar. Cormix Latex mortars can
be applied at a minimum thickness of 6 mm. and up to Cormix Latex can be finished with a steel, plastic or
40 mm. thickness, dependent on the location and wood float, or by a damp sponge technique, to achieve
configuration of the repair zone. Where thick sections up the desired surface texture. The completed surface
to a total thickness of 40 mm. are to be built up by hand should not be overworked.
or trowel application, the surface of the inter-mediate
layers should be scratch-keyed. Application of the slurry PACKAGING
primer and a further application Cormix Latex mortar 25 litre pails; 200 litre drums.
may proceed as soon as this layer has set.
MIX DESIGN STORAGE & SHELF LIFE
Repair Mortar - Mix Design Cormix Latex should be stored protected from sunlight
Thickness : 6 mm. - 40 mm. and frost. The shelf life is at least 9 months in original
10 litres of Cormix Latex unopened containers.
8 litres of Clean water.
50 kgs. of Ordinary Portland Cement. HEALTH & SAFETY
150 kgs. of Sand - fine to coarse depending on Wear suitable protective clothing, gloves and eye
layer thickness. protection. The use of barrier creams provide additional
Floor Screeds - Mix Design skin protection. In case of contact with skin, rinse with
Thickness : 10 mm. - 40 mm. plenty of clean water, then cleanse with soap and water.
10 litres of Cormix Latex If poisoning occurs, contact a doctor or Poisons
6 litres of Clean water. Information Centre. If swallowed, DO NOT induce
50 kgs. of Ordinary Portland Cement. vomiting - give a glass of water. If in eyes, hold eyes
150 kgs. of sand - coarse sand up to 6 mm. open, flush with water for at least 15 minutes and see a
depending on coat thickness. doctor. If skin contact occurs, remove contaminated
The screed should be semi dry. clothing and wash skin thoroughly with soap and water.
Renders - Mix Design
Thickness : 6 mm. - 9 mm. TECHNICAL SERVICE
10 litres of Cormix Latex
The Cormix International Technical Service Department
6 litres of clean water.
is available to assist you in the correct use of our
50 kgs. of Ordinary Portland Cement.
products and its resources are at your disposal entirely
150 kgs. of Fine sand.
without obligation.
The render should be semi dry & cohesive.
Bonding Coat for Rendering / Bonding between old &
new concrete
QUALITY ASSURANCE
Cormix Latex : Water - 1 : 1 ISO 9001 : 2008 verified by TUV Nord
Dry mix : Cement : Fine sand - 1 : 1 or cement only.
Mix as mixing instruction above. CONTACT DETAILS
Apply slurry to prewetted substrate in 1 - 2 mm.
thickness & place new concrete or water immediately Cormix International Limited
before the slurry dries. Place Wet on Wet. 89 Romklao Rd., Sansab, Minburi, Bangkok 10510
The above mixes are based on dry sand & aggregate. Tel. (66 2) 917 3955-8, 543 8890
Site conditions & varying moisture contents will effect Fax. (66 2) 917 3959, 543 8891
final performance. http://www.cormix.com
Dry mix cement, sand and aggregate (if needed) for at E-mail: info@cormix.com
least 1 minute before adding the premixed Cormix Latex
& water. Mix for at least another 5 minutes. Do not use
excessive amounts of water. Allowance must be made
for the water content in the sand.
one and a reprint may be issued without notice to supersede this edition, as and when deemed necessary. The information given in this leaflet is to the best of our knowledge true and
reliable. Field service where provided does not constitute supervisory responsibility. Our guarantee is therefore limited to the quality of materials delivered.

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Project : MAS Linea Aqua- Canteen Building Doc.

00 Afsar FOR REFERENCE SM SF

List of Tables ........................................................................................................................................... 3

List of Figures .......................................................................................................................................... 4

2.1 Building and function .............................................................................................................. 5

2.2 Procedure of assessment and repair ...................................................................................... 6

3 Review of the structure and its elements ....................................................................................... 8

3.2 Design, Detailing and Workmanship ....................................................................................... 9

3.2.1 Element Design ............................................................................................................... 9

3.2.2 Detailing and Workmanship............................................................................................ 9

4 Assessment of damage to concrete and reinforcement............................................................... 10

4.1 Damages to the concrete ...................................................................................................... 10

4.2 Damages to the reinforcement ............................................................................................. 13

5 Assessment of the structure ......................................................................................................... 14

5.1 Diagnosis ............................................................................................................................... 14

5.1.1 Structural Element Survey ............................................................................................ 15

5.1.2 Concrete Quality ........................................................................................................... 15

5.1.3 Concrete Cover.............................................................................................................. 15

5.1.4 Position and diameter of the reinforcement ................................................................ 15

5.1.5 Cracks ............................................................................................................................ 16

5.2 Danger of reinforcement corrosion ...................................................................................... 19

6 Evaluation of current and future conditions of the structure ...................................................... 20

6.1 Concrete corrosion................................................................................................................ 21

6.2 Crack investigation ................................................................................................................ 21

6.3 Reinforcement corrosion ...................................................................................................... 21

7.1 Structural Design Criteria ...................................................................................................... 21

7.1.1 Design Codes & Standards ............................................................................................ 21

7.1.2 Material Properties ....................................................................................................... 22

7.1.3 Element Geometry ........................................................................................................ 24

7.1.4 Loading .......................................................................................................................... 25

7.1.5 Load Combination ......................................................................................................... 26

7.1.6 Durability & Fire Resistance Criteria ............................................................................. 26

7.1.7 Deflection Limits ........................................................................................................... 27

7.2 Capacity Assessment & Evaluation of Structural Elements .................................................. 27

7.2.1 Foundation .................................................................................................................... 27

7.2.2 Columns ........................................................................................................................ 28

7.2.3 Beams ............................................................................................................................ 28

7.2.4 Slabs .............................................................................................................................. 28

7.3 Assumptions & Limitations ................................................................................................... 29

7.4 Analysis Results and Interpretation ...................................................................................... 29

7.4.1 Foundation .................................................................................................................... 29

7.4.2 Column .......................................................................................................................... 30

7.4.3 Beam ............................................................................................................................. 30

7.4.4 Slab ................................................................................................................................ 32

8 Structural Concrete Repair and Strengthening ............................................................................. 33

8.1.2 Principle for protection against reinforcement corrosion ............................................ 39

8.2 Surface Preparation .............................................................................................................. 41

8.3 Structural Concrete Element Repair ..................................................................................... 42

8.3.1 Beams ............................................................................................................................ 42

8.3.2 Slab ................................................................................................................................ 42

8.3.4 Roof structure ............................................................................................................... 43

8.3.5 Foundation .................................................................................................................... 43

8.4 Structural Strengthening ....................................................................................................... 44

8.4.1 Proposed Rectification Method for Slab ....................................................................... 44

8.4.2 Proposed Rectification Method for Beam and Slab...................................................... 45

9 Execution and Quality Control ...................................................................................................... 46

10 Maintenance of Concrete Structures ........................................................................................ 47

ANNEXURE A - Load Maps .................................................................................................................... 49

ANNEXURE B – Test Results .................................................................................................................. 50

ANNEXURE C – Column Design ............................................................................................................. 51

ANNEXURE D – Beam Design ................................................................................................................ 52

ANNEXURE E – Slab Design ................................................................................................................... 53

Figure 1 Location and satellite view of MAS Linea Aqua Premises