1.

1 Cracks in Lining Concrete due to hysteresis

Root cause- Expansion and contraction due to thermal variation and hysteresis,
Earlier PVC strips were provided for the same but due to unpleasant looking cracks, it is
replaced with grove cutting and filling with suitable material.

Crack observed

Crack observed Grove depth is insufficient

1
 1.2 Cracks in Lining Concrete due to hysteresis

Corrective Action-
1. Cracks to be isolated and marked.
2. Removal up to 65mm in depth and 15 mm
width in V -shape.
3. Groove cleaning- free from loose and
foreign material, dust, water or any other
lubricant material etc. by brush, air blower, Grove cutting in Grove filling in lining
clean cotton etc. lining
4. Primer is applied as adhesive to old Grove in lining
concrete and repairing material.
5. In hot weather, water sprinkle is required
to down the surface temperature.
Surface
6. The V-groove shall be filled with PUB prepetition
material. The specification shall be
maintained as specified as per
manufacturer instruction.

2
 1.3 Cracks in Lining Concrete due to hysteresis
Preventive action-
1. PVC water stopper should not be used in
where for paneling in CC lining.
2. Pizza Cutter shall be used to cut groove in
green stage of concrete , just after finishing.
3. Where ever groove cutting could not be
done by pizza cutter in green stage or Grove cutting in
Grove cutting in
desire shape is not found in groove, the lining by pizza cutter
lining by pizza cutter
panel cutting shall be started by concrete
saw cutter machine in 24 hour of concrete
placing.
4. The depth of groove shall be minimum
1/4th to 1/3rd of the thickness and width 5
to 10 mm in single stage cutting.
5. Sealant (hot/cold) shall be filled in groove
as per IRC-57. Grove cutting in
lining by Machine Grove filling in lining
6. Method of used shall be followed by
manufacturer instruction. 3
 2.1 Cracks in CC Lining due to Soil erosion

Root cause- From LBL rain water entered below lining and sandy silty soil eroded below the lining and cracks
developed at bottom panel in slope.

Soil erosion due to rain

Crack in lining Crack in lining

4
 2.2 Cracks in CC Lining due to Soil erosion
Corrective Action- Cleaning by blower
1. Hollow area due to soil erosion should be marked.
2. Lean mix concrete should be filled in hollow area.
3. Crack is marked and identified.
4. Cutting of marked area should be done with the help
of concrete cutter up to 25 mm deep and 15 mm
wide in V shape.
5. Chipped area should be cleaned for loose concrete, Backfilling by LMC
dust and other lubricant material by using wire
brush, blower and cotton.
6. Seal primer is applied on clean surface and patch fix
pub should be used to fill the V shape grove by
pressuring firmly in to place to ensure positive
adhesion and full compaction.
7. Finishing if required should be done with trowel.

Crack repairing done Cleaning by brush

5
 2.3 Cracks in CC Lining due to Soil erosion
Preventive action- For releasing pour pressure
our designer suggested to make weep holes in
lining.
1. Identify location above 200 mm from D/S
crest wall or 1 m from CBL,
2. Another core should be marked 1 m above
previous core and 5 m in up stream.
Core cutting for release
3. Core cutting should be done with 100mm pour pressure
cutting bit. Drawing to fill No fine in hole
4. Core further excavated manually to a depth
of 300mm from lining bottom and in 300
mm dia.
5. Geotextile should be placed in hole so that
no soil can pass threw the hole,
6. The pit should be filled with no fine
concrete of 1:8 ratio and compacted
manually. Core cutting for release
pour pressure
6
 3.1 CC Lining core fail in strength

Root cause- Some of the leading cause of core fail are given below:
1. Delay in unloading,
2. Mixing of excess water (other then mix design),
3. Improper compaction at time of placing in slope portion.

Core cutting done for Core cutting done for

strength strength Core Testing with client Core Testing with client
7
 3.2 CC Lining core fail in strength

Corrective Action-
1. If a single core is fail in strength, with client permission
we cut another core in vicinity of the core, If again core
strength is not acceptable, the panel is removed.
2. If a complete set is fail in strength, then with client
permission we cut another set in same chainage, If
results are not satisfactory, concrete is removed. Core Testing with client

Core Cutting and marking

with client

Dismantling of Lining
8
 3.3 CC Lining core fail in strength
Preventive action-
1. To avoid delay in unloading of TM, proper
access to site, proper illumination in night,
flag mans, are deployed.
2. Slum is checked at site to avoid
unnecessary mixing of water at site,
3. If slum is less at site, admixture is added at
site and mixed to get required slump.
Tool box talk at site Use of needle vibrator
4. If TM is delay more than 2.5 Hr, TM should
be rejected.
5. Proper compaction should be done by using
needle vibrators thoroughly. And
Importance of compaction is conveyed in
tool box talk.

Slump testing at site Cube casting at site

9
 4.1 CC Lining core fail in Thickness

Root cause- CC lining core cutting is done with client representative and Sometimes Due to paver settlement or
by soil undulation in particular panel thickness is not found satisfactory in CC lining.

Thickness checking at Thickness checking at Core cutting at site

Core cutting at site site site
10
 4.2 CC Lining core fail in thickness
Corrective Action-
1. If core thickness is found less then 188 mm in 200
mm slope lining, Another core is cut in same
panel,
2. If both the core having less thickness, the panel is
removed.
3. After dressing lining is done again.

Lining dismantling due to Lining dismantling due to

core thickness is less core thickness is less

11
 4.3 CC Lining core fail in Thickness
Preventive action-
1. Compaction is checked for subgrade of CC lining.
2. Profile length, thickness is checked along the
section ready for concreting by installing of line dori
on level.
3. Paver alignment, rail alignment is checked to
ensuring thickness,
4. During laying of CC, thickness is checked on top Checking of slope lining
level and in bottom level of slope to ensure thickness
and alignment of paver.
5. If, after all the checking bed is disturbed it should
be compacted and checked again.

Checking of slope lining Checking of slope lining

12
 5.1 Improper packing of RR Masonry

Root cause- In RR masonry work

1. Improper size selection of stones,
2. Improper packing of stone,
3. Improper packing of mortar,
4. In single lift, more height is constructed,

Checking for Checking of

Use of shear stone Use of Measuring box
alignment Boundary wall
13
 5.2 Improper packing of RR Masonry
Corrective Action-
1. Defected area is identified and marked,
2. Remove the defected area by manually or
by mechanical mean depends on fresh
work and old work.
3. Re work is done with proper selection and
packing of stones with proper filling of Removing of poorly
Removing of poorly packing packing
mortar.
4. In some cases, if there are minor defect it
can be filled with rich cement mortar with
non shrinkage material.
5. Curing should be done for both the cases.
6. Sand should be checked and approved.

Poorly Workmanship Poorly Workmanship

14
 5.2 Improper packing of RR Masonry
Preventive action-
1. Selection of stone, is an important parameter, stone
should not be too small, or too big,
2. Stone packing should be done properly, stone should
not be fixed vertically, it should be laid horizontally ,
3. If any cavity left, Small stone should be fixed after
putting mortar then after stone should be installed. Training at site Racking in boundary wall
4. Through stone should be used at every 1.5m.
5. In a single lift not more then 200 mm to 300 mm
casted, depends on size of stones available.
6. Curing should be done for at least 7 days.
7. Mortar should not have more then 25 mm thick.

Use of through stone Tool Box talk at site

15
 6.1 Undulation and level difference in CC lining

Root cause- Due to improper finishing, paver settlement, settlement of shuttering, improper supervision are the
main cause of undulation and level difference in CC lining.

Undulation checking in Lining

CC Lining Undulation checking in Lining CBL Slope
16
 6.2 Undulation and level difference in CC lining
Corrective Action- 6.2 CC Lining core fail in thickness
1. Identify and mark undulated area on lining
surface.
2. Use grinder to grind the surface with all the safety
requirement.
3. Check the area during grinding until it reaches up
to desired level.
4. This rectification is in progress.

Undulation in slope Lining Use of grinder for control

undulation

17
 6.3 Undulation and level difference in CC lining
Preventive action-
1. Checking of undulation post cc lining by using
straight edge,
2. If it is not acceptable in undulation, Did
rectification at time by grinding machine,
3. Conduct tool box talk to convey our requirement
to work force to improve finishing and to motivate
them to do continuous improvement.

Undulation checking
Tool Box Talk at site
in slope Lining

18
 7.1 Honeycombing in concrete

Root cause- There are some basic reasons for honeycombing in concrete some of them are listed below
1. Improper compaction in concrete,
2. Segregation in concrete,
3. Improper shuttering packing

Honeycombing in Honeycombing in Honeycombing in

slope Lining slope Lining slope Lining
19
 7.2 Honeycombing in concrete
Corrective Action-
1. Identify the affected area and severity of
honeycombing,
2. Do chipping with suitable tool chisel and hammer
or chipping machine,
3. Clean all the loose material, dust or oil, from the
area,
4. Apply rich cement slurry, Honeycombing repairing in Honeycombing repairing
slope Lining in slope Lining
5. Use GP2 or any approved material of same or
higher strength,
6. Use shuttering if necessary, full compaction should
be done,
7. Use curing compound or water curing,
8. If honeycombing is sever other suitable method
may be used, as suggested by engineer.
Honeycombing in check
Honeycombing repairing in
dam crest wall
Wall
20
 7.3 Honeycombing in concrete
Preventive action-
1. Major cause of honeycombing is improper compaction
and segregation,
2. Segregation can be avoided by measuring slump before
pouring and limiting height of fall to 1m, it can be
eliminated.
3. Compaction should be done by needle vibrators for
thickness more than 150 mm, Good surface Wooden Melting during
4. In a single filing concrete should be filled up to 300 mm finishing at RIICO STP concreting
and then compaction should be done by vibrator,
5. Wooden melting should also be used to avoid air
bubble,
6. Tool box talk is necessary to convey knowledge.

Use of Vibrator in
21 Concreting Tool box talk at site
 8.1 Shrinkage cracks on CC lining surface

Root cause- Inadequate curing just after finishing, Large surface area and extreme hot weather, high wind
velocity increases rate of evaporation form concrete resulting in shrinkage cracks on surface of concrete.

Shrinkage cracks in lining Shrinkage cracks in lining Shrinkage cracks in lining Shrinkage cracks in lining

22
 8.2 Shrinkage cracks on CC lining surface
Corrective Action-
1. Identify location and type of crack,
2. If it is shrinkage crack, cut it in 15 mm depth and
10mm width, with the help of concrete cutter,
3. It should be cleaned for any dust and loose material,
4. It should be filled with GP2 after applying of
cementitious material, or rich slurry of GP2.
5. Finishing should be done up to required degree.
6. Curing should be done up to 7 days. Cutting of groves Curing by ponding

Grove cleaning
23
Grove cleaning
 8.2 Shrinkage cracks on CC lining surface
Preventive action-
1. Use water sprinkling on subgrade,
2. Use wind varication to avoid hot wind,
3. Use curing compound just after finishing,
4. Use ice in concrete to control temperature of
concrete,

Curing Compound Curing Compound

Water Curing applied on time applied on time

Controlling aggregate Curing Compound

temperature applied on time
24
 9.1 Delay in application of curing compound

Root cause- Poor management of material and manpower at site.

Curing done in PCC

Curing done in Lining Curing is in progress in

Lining CBL

Pond curing for

Water Curing in Water Curing in Tool box talk about checkdam curing
progress progress 25
curing
 9.2 Delay in application of curing compound
Corrective Action-
1. Curing done immediately
2. If curing compound is not available, water curing is
done, or wet hessian cloth may be used,
3. At least 7 day curing is required, if we go for water
curing,
4. For slab, bund should be made by 1:10 mortar mix Curing compound
and at least 50 mm water should be maintained, application Curing with water
5. For vertical structure components use curing
compound just after deshuttering, or use wet
hessian cloth,
6. Wax bases curing compound should not be used at
joining of old to new concrete,
7. Resign based curing compound can be used at
junction surface of old and new concrete.

Curing with Curing

Curing with water
Compound
26
 9.3 Delay in application of curing compound
Preventive action-
1. During signing of pour card, curing compound or arrangement
is checked according to quantity of concrete.
2. If arrangement is not proper concrete is not allowed.
3. Before application of curing compound, curing compound Curing with water
should be agitate properly to mix all the settled particles.
4. If curing compound is not available use water curing or wet
hessian cloth can be used,
5. If there is a delay in deshuttering water is used for curing, then
only after curing compound can be applied.
Curing Compound Curing Compound
applied not applied

Curing Compound Curing Compound

not applied applied
27
 10.1 Improper Packing of Stone Pitching

Root cause- Improper selection of stones, poor workmanship, are the leading cause of improper packing of
stone pitching.

Improper stone Tool box talk about Tool box talk about
Proper stone pitching
packing stone pitching 28 stone pitching
 10.2 Improper Packing of Stone Pitching
Corrective Action-
1. Improper Panels should be identified and marked,
2. Remove loose fill and pointed stones,
3. Size of stone should be at least 230mm*150mm,
4. Sharp corners should be chipped of,
5. 15m*25m panel should be sub divided in to 5m*5m
panel to control undulation, Tool box talk about Improper stone
6. Packing should be done by small stones, stone pitching packing

Removing of stone Improper stone

pitching Proper stone pitching
packing

Correction

29
 10.3 Improper Packing of Stone Pitching
Preventive action-
Tool box talk about Proper stone
1. Daily tool box talk is conducted to worker to introduce stone pitching pitching
the work.
2. Stone pitching sample is visualized to workers to know
packing requirement of client.
3. Selection and shorting is done as per requirements of
size of stone,
4. Sharp edges, pointed stones are chipped to make
proper face of stone,
5. In between stones, packing with small stones is done,

Tool box talk about Tool box talk about

stone pitching stone pitching
30
 11.1 Railing alignment and painting issue

Root cause- For Alignment,

For painting,
1. Improper surface preparation,
2. Improper procedure for paint,
3. Improper handling,
4. Improper weather and conditioning
1. Railing alignment damaged by vehicle movement,
2. Railing alignment is damaged during fixing,
3. Improper Fixing of railing ,

Corrosion on hand rail Alignment improper Damaged railing Pathway

31
 11.2 Railing alignment and painting issue
Corrective Action-
1. Identify location of rust in railing on each railing.
2. Railing having rust should be cleaned by sand paper,
3. Now clean all the dirt and rust with clean cotton,
4. Primmer should applied on that area,
5. Paint should applied on that area,
6. Damage railing should be removed by chipping
grouting, and can be replaced by another railing, Hand railing painting
correction
7. If alignment is not correct, it should be corrected by
hammering or at factory with suitable machinery.
Hand railing client
inspection

32
 11.3 Railing alignment and painting issue
Preventive action-
1. Step by step procedure is conveyed to every contractor,
2. Surface preparation should be done,
3. Surface should be clean from rust, dust and oil etc,
4. It should be cleaned by sand paper or may be buffing
wheel,
5. Primmer should be applied consistently and thoroughly, Stage inspection of Stage inspection
6. After 4 hr or as per TDS of primmer and paint, First and hand railing of hand railing
second coat of epoxy paint should be done,

Stage inspection Stage inspection

of railing of hand railing
33
 12.1 Issue in Karauli stone Fixing

Issue- Root cause-

1. Improper packing with grouting
2. Joint miss match,
3. Gaps in between adjacent stone,
4. Horizontal and vertical alignment is not proper,
5. Hollow sound in cladding stone,
1. Use of poor quality sand for grouting,
2. Not cleaning of Saw dust of stone from stone,
3. Not cleaning loose material in boundary wall,
4. Improper Curing,
5. Improper packing of stone,
6. Joint mismatching due to each corners are not in
right-angle,

Improper grouted
Racking of boundary wall Improper fixing of stone stone removed Checking of fixed stone
34
 12.2 Issue in Karauli stone Fixing

Corrective Action-
1. Identification of stone those are not as per
requirement i.e. gap in stone, hollow sounded
stone,
2. Mark those stones for rectification, Checking
Marking of improper grouted stone
3. Rectification can be done by removing stone, of karauli
stone
chipping off the mortar,
4. Cleaning of dust, loose material, oil and grease
from the masonry and stone should be done,
5. Stone again fixed by cement to wall,
6. Filling should be done with 1:3 mortar with the
approved sand, Remove not cleaned stone
7. Curing should be done for at least 7 days.

35 Remove of cladding stone

 12.3 Issue in Karauli stone Fixing

Preventive action-
1. Before starting of work, stone are checked for
thickness and every corner for right angle, if not in
right angle use cutter machine to do the same.
2. Cleaning of stone as well as boundary wall surface
from dust, loose material, and oil by chipping of or Washed stone use for fixing Curing of cladding work
may be b scrubbing,
3. Groves can also be make on fixing side of stone
face to provide key for holding.
4. Vertical and horizontal alignment should be
Fixing of karauli
checked after fixing if not correct rectify and do it
stone with out
again. cleaning of wall
5. Filling of stone should be done by 1:3 from
approved sand and cement,
6. Curing should be done for at least 7 days.
Cleaning of
boundary wall
36 Improper gap in stone by wire brush
 13.1 Issue in Pathway fixing
Issues- Root cause-
1. Level difference in paver, 1. After fixing of paver, heavy vehicle movement
2. Broken tiles from center, leads to undulation and broke tile from center,,
3. Broken tiles from corners, 2. Mishandling of pavers in shifting leads to edge
4. Line mismatch of paver, break,
5. Undulation in pavers, 3. More sand thickness for bedding of paver leads to
undulation,

Damage paver blocks due Pathway Paver and

to vehicle movement railing

Damage paver blocks due

to vehicle movement
37
 13.2 Issue in Pathway fixing
Corrective Action-
1. Broken paver should e identified and marked,
2. Remove the defected paver blocks,
3. Arrange same size and design pavers to replace
broken pavers,
4. Sand should be leveled and compacted,
5. Paver block should be compacted by manually Improper alignment Broken age due to
during fixing paver improper handling
mean to fix position,
6. Soil should be spread to fill gaps in between
pavers to avoid movement of paver.
7. Further movement of vehicle is avoided to
protect paver.

Testing of paver with

Paver damaged by JCB
client

38
 13.3 Issue in Pathway fixing
Preventive action-
1. Stop Heavy vehicle movement,
2. PCC level checked and thickness of sand is checked
it should be 25 to 45 mm not more then that,
3. Paver block is checked for strength,
4. Handling of paver block is improved to avoid edge
break,
5. Thickness of paver is checked if found difference Level Checking of
more then 3 mm, pavers are rejected, pathway PCC
6. Varying thickness causes undulation in surface and Vehicle movement on
ultimately lead break in paver block. paver
7. Paver block should be constrain for lateral
movement as soon as paver is laid, due to tendency
to slip in out-word direction.

Level checking of
Paver blocks after
39 fixing.