PRESENTING

YOU
POWER POINT PRESENTATION
ON

MATERIALS AND TECHNIQUES A PART OF:

MAINTENANCE AND
FOR REPAIR REHABILITATION OF
STRUCTURES
SELECTION OF REPAIR MATERIALS
The repair material should have following properties:
Low shrinkage and expansion properties
Good Workability and Durability
Good bond strength
Good hardening and setting properties
Good Mechanical Properties
Less permeable
Economical
Non-hazardous
Good Aesthetics
 REPAIR
MORTARS
Portland Cement Mortar

As the name suggests in this type of material a mixture of

cement, sand and water is used. This type of mortar is used for
repairing defects on exposed new concrete surfaces only. This method
is used only when the defect is small and too shallow for concrete
replacement. The mortar generally used is of 1:3 or 1:4 (C:S)
Polymer Modified Cement Mortar The polymers used
may be in the form of
:
These mortars are used for repair on old hardened concrete
for repairing defects on exposed concrete surface only. The mortars
shall consists of cement, sand, polymer and water in specified  Polymer latexes
proportions.  Water soluble
polymers
For preparing polymer modified mortar, first of all the cement and  Liquid resins
sand are mixed in the proportion of 1:2 to 1:3 and then polymers at  Re-dispersible
the rate of 5 to 20% of the weight of cement are added. W/C ratio shall polymer powders
be 0.3 to 0.6.
Epoxy Mortar The advantages of
epoxy mortar are:
Epoxy mortars consists of epoxy resins, hardener and silica sand and
are applied over an epoxy bonding coat over the old hardened  Very High Strength
concrete surface. These mortars attain strength in few hours.  Abrasion
These mortars are used for repairs where it is difficult to use epoxy Resistance
bonded concrete, when depth of repair is less than 40mm or when the  Good Water
repair areas are small i.e. less than 0.1 sq.m. Resistance
 CLASSIFICATION OF REPAIR
MATERIALS
A. Patch Repair Materials
 Cementatious Mortar/Concrete
 Polymer Modified Mortar/Concrete
 Polymer Mortar/Concrete

B. Injection Grouts
 Polymer Grouts
 Gas Forming Grouts
 Sulpho-Aluminate Grouts

C. Bonding Materials
 Polymer Emulsion Type
 Polymer Resin Type

D. Resurfacing Materials
E. Sealing Materials
F. Water Proofing Materials
 CONCRETE REPAIR CHEMICALS:
EPOXIES
Epoxies belong to the epoxy group of organic chemicals. In case of
epoxies, the polymerization process takes place when two materials
 Epoxy Resin
 Curing Agent
Come in contact by thoroughly mixing in specified proportions.
EPOXY RESIN:
Epoxy resins are the substances of low viscosity and can be
injected into small cracks too. The higher viscosity can be used for
surface coating or filling of large cracks or holes.
EPOXY RESIN AND
HARDENER
 PROPERTIES OF EPOXY
 Good Mechanical Strength
 Good Chemical Resistance
 Good Workability
 High Tensile Strength

USES OF EPOXY RESIN

 Epoxy Grouts, Mortars and Coatings are extensively used for repair. They
develop excellent strength and adhesive properties rapidly and provide
toughness that give both durability and crack resistance.
 Epoxy coated steel bars are used for corrosion resistance in RC works.
 Epoxy Group of chemicals are used for stopping leakages.
Other materials used for concrete repair are:
Polymer and Latex
Acrylic Polymer
Polyester resins
Chemicals Used in Concrete Construction are:
Corrosion Inhibitors
Plasticizers
Shrinkage Reducing Compounds
Retarders
Accelerators
Curing Compounds
Air-entraining Agents
Bonding agents
Quick settings compounds
ADMIXTURES-ACCELERATORS
Accelerator is an admixture that causes an increase in the rate
of hydration of the cement and thus shortens the time of setting,
increases the rate of strength development, or both.
Accelerating admixtures are added to concrete either to
increase the rate of early strength development or to shorten the time
of setting, or both. Chemical compositions of accelerators include
some of inorganic compounds such as soluble chlorides, carbonates,
silicates, fluosilicates, and some organic compounds such as
triethanolamine. The accelerators also reduce the risk of damage by
freezing when concreting in cold weather.
HYDRO SET
TYPES OF ACCELERATING
ADMIXTURES
Accelerating admixtures can be divided into groups based on their
performance and application:
1. Set Accelerating Admixtures: Reduce the time for the mix to change
from the plastic to the hardened state. Set accelerators have relatively
limited use, mainly to produce an early set.
2.Hardening Admixtures: Which increase the strength at 24 hours by at
least 120% at 20ºC and at 5ºC by at least 130% at 48 hours. Hardening
accelerators find use where early stripping of shuttering or very early
access to pavements is required. They are often used in combination with a
high range water reducer, especially in cold conditions.
 The most commonly used accelerator is calcium chloride
(CaCl2). When it is used under normal conditions, and in regular
amounts 2% by weight of cement. IS : 7861 (1981) recommends a
maximum of 1.5 percent of CaCl2 for plain and reinforced concrete
works in cold weather conditions. CaCl2 can be used with ordinary
Portland cement or rapid hardening cement.
The use of calcium chloride in form of accelerating admixtures
should not be done as it results into the corrosion of the
reinforcement.
The accelerators suitable for reinforced concrete one can find are:
Sodium thiocyanates and other thiocyanate salts
Triethanolamine and other alkanolamines
Products based on sulfates, nitrates and formats
 Advantages of accelerators
1. Quick setting of concrete.
2. The formwork can be removed early.
3. The concrete gains strength at early stage.
4. Reduces the segregation of concrete.
5. The hydration of heat is increased therefore suitable for the cold regions
as it stops the water in concrete from freezing.
6.The repairing of structures can be done rapidly and can be subjected to
load early.

Dis-Advantages of accelerators
1. The excess use of accelerators may lead to drying shrinkage and swelling.
2. The excess use may result into flash set of concrete.
3. The excess use of accelerators containing chloride result into corrosion of
concrete.
4. The excess use of admixtures reduce the resistance of concrete against
ADMIXTURE: RETARDERS
Retarders are added to the concrete to slow down the process
of hydration of cement to delay or prolong the setting of cement in
concrete. Retarders keep the concrete workable for a longer period.
Purpose of Retarders:
To overcome the accelerating effect of high temperature on setting
properties of concrete in hot weather concreting.
To delay setting. of cement. when concrete 15 to he placed in t
conditions.
When concrete is required to be transported for a long distance.
In grouting oil wells, where at a depth of about ()0le meter
temperature may be about 200°C and cement grout is required to be
in mobile condition for about 3 to 4 hours.
RETARDER
Commonly used retarders are:
Calcium sulphate (Gypsum).
Starches.
Sugars.
Cellulose products.
Acids or salts of acids like lingo, sulphonic acid, hydroxylated
carboxylic acid, mucic acid calcium acetate, tannic acid.
Calcium sulphate in the form of gypsum is generally added
during the manufacture of cement to retard the setting. Normally 2 to
3% gypsum is used. Calcium sulphate in the form of plaster of Paris
can also be used. Addition of excess amount of gypsum may cause
undesirable expansion and indefinite delay in the setting of concrete.
At normal temperature, 0.2% addition of sugar can delay the
final setting time to about 72 hours or more.
ADMIXTURE: PLASTICIZER
Workability is an important property of concrete. The optimum workability of
fresh concrete varies from situation to situation. A high degree of workability is
required in situations like deep beams, this walls with congested reinforcement. beam
column Junctions, tremie concreting, hot weather concreting, pumping of concrete etc.
The conventional methods adopted to obtain high workability are use of higher
percentage of fine aggregate, using good grading of aggregates, or by increasing
cement content. Sometimes, unengineered contractors use extra water to improve
workability of concrete.
Use of plasticizers for improving workability without using excess of water is
becoming popular practice all over the world.Calcium, sodium and ammonium lingo-
sulphonates are the most commonly mad plasticizers. They are used in the amount of
0.1% to 0.4% by weight of cement.
The action of plasticizers is to fluidify the mix and to improve the workability
of mix. Portland cement will have a tendency to flocculate in wet concrete. These
flocculation entraps certain amount of water used in the mix. When plasticizers are
added, they get absorbed on the cement particles. The absorption of charged polymer
PLASTICIZER
SUPER PLASTICIZER
Japan was the first country to develop super—plasticizers in 1960 and
subsequently Germany in 1970. The use of Super-plasticizers permit the reduction of
water to the extent of 30 percent without reducing workability of the mix. They are
also called high range water reducers. They are chemically different from the normal
plasticizers. They are more powerful as dispersing agents.
Advantages of using Super—plasticizers :
Very high workability can be achieved. Hence, self levelling, self-compacting,
flowing concrete can be produced.
For the same workability, it has made possible to use w/c ratio as W 0.28 to obtain
strength of the order of 100 MPa.,
With low w/c ratio, it also permits a reduction of cement content.
The use of Super—plasticizers has made it possible to use fly ash. 513% “n silica
fume to make high performance concrete.
The Super—plasticizers produce a homogeneous, cohesive concrete general without
ADMIXTURE: WATER PROOFING
The leakage of roofs, bathrooms, toilets, walls, kitchens, water
tanks,basements etc. is still a headache for civil engineers. There are
various materials and methods available in our country for
waterproofing purposes. But most of them fail due to one or the other
reasons. The success of waterproofing depends upon the quality of
materials durability of materials, workmanship, environment etc.
A waterproof concrete has to fulfil two separate and distinct functions:
To be impervious to the water under pressure.
To resist the absorption of water.
Waterproofing admixtures amy be obtained in powder, paste or
liquid form. There are two types of materials available namely, pore
filling and water repellent materials.
The Pore filling materials are chemically active pore fillers. In
addition they also accelerate the setting time of concrete. Examples of
pore filling materials are silicate of soda, aluminium and zinc
WATER-PROOFING
 The water repelling materials are soda, potash soaps, calcium
soaps vegetable oils, Waxes, fats and coal tar residues. Butyl stearate,
heavy mineral oil free from fatty or Vegetable oil may also be used as
waterproofing materials.
The chemical available for waterproofing concrete structures are :
Integral waterproofing compounds
Acrylic based polymer coatings.
Mineral based polymer coatings.
Silicon based water repellent materials.
Waterproofing adhesives for marble, granite and tiles.
EXPANSIVE CEMENT
Concrete shrinks while setting due to loss of free water. This is
known as drying shrinkage. The important property of expansive
cement is that it suffers no overall change in volume on drying. Such
type of cement is used by adding an expansive compound known as
Sulpho-aluminate in the form of clinker at the time of grounding
cement clinkers. Generally 8-20 parts of clinkers of Sulpho-aluminate
are added to 100 parts of Portland cement and 15 parts of the
stabilizer.
There are two types of Expansive Cement:
Shrinkage compensating cement
Self stressing cement
 Uses of Expansive Cement
are:

EXPANSIVE CEMENT  Grouting anchor bolts

 Grouting machine
foundations
 Grouting Pre-stress
Concrete Ducts
POLYMER CONCRETE
Polymer concrete can be classified into three groups:
Polymer-impregnated concrete
Polymer Portland Cement Concrete
Polymer Concrete
POLYMER IMPREGNATED
CONCRETE
Polymer impregnated concrete is produced by impregnating or
infiltrating a hardened Portland cement concrete with a monomer and
subsequently polymerizing the monomer in situ. It is one of the widely
used polymer composite.
The partial or surface impregnation improves durability and
chemical resistance while total or in depth impregnation improves
structural properties of concrete
The monomers used for impregnation are:
Methyl methacrylate
Styrene
Acrylonitrile
T-Butyle stryene
Epoxy
STEPS FOR IMPREGNATION
Casting Conventional Concrete Elements
Curing of Elements
Drying and Evacuation
Soaking the dried concrete in monomer
Sealing the monomer
Polymerizing the monomer
polymerization is carried out by thermal-catalyst technique. In
this method after monomer-catalyst mixture penetration and then
heating the concrete to 70 to 90 degree Celsius for few hours.
 Application of Polymer-
impregnated concrete:
 Prefabricated structural
elements

POLYMER IMPREGNATED  Surface impregnation of

bridge decks
 Hydraulic structures
CONCRETE  Marine works
 Desalination plants
 Nuclear power plants
 POLYMER PORTLAND CEMENT
CONCRETE
Polymer Portland cement concrete is a conventional Portland cement concrete
which is usually made by replacing a part of the mixing water with a
latex/polymer emulsion. Earlier latexes were based on polyvinyl acetate or
polyvinylidene chloride, but these are now not used because of the risk of
corrosion of steel in concrete.
Two types of polymers are generally used:
1. Elastrometric polymers
2. Glassy polymers
1. Elastrometric polymers:
they are characterized by their rubber like elongation and low
modulus of elasticity.
Examples are:
Natural rubber latex
Styrene butadiene rubber latex
Neoprene
2. Glassy polymers:
they are characterized by higher strength, higher modulus of elasticity
and relatively brittle type of failure.
Examples are:
Polyester-styrene
Epoxy-styrene
Furans
Vinylidene Chloride
POLYMER CONCRETE
Polymer concrete is a mixture of aggregates with polymer as the sole
binder. There is no other bonding material present i.e. Portland cement is not
used.
It is manufactured in manner similar to that of cement concrete.
Monomers or pre polymers are added to graded aggregates and the mixture
is thoroughly mixed by hand or machine. The thoroughly mixed polymer
concrete material is cast in moulds of wood, steel or aluminum etc.
To minimize the amount of expensive binder it is very important to
achieve the maximum possible dry packed density of the aggregates. For
example, using two different size fractions of 20mm maximum coarse
aggregates and 5 different size fractions of sand, higher density can be
achieved.
The polymerization can be achieved by any of the below methods:
Thermal-catalytic reaction
Catalyst-promoter reaction
SULPHUR INFILTRATED CONCRETE
In the past, attempts have been made to use Sulphur as a binding material
instead of cement.
Sulphur is heated to bring it into molten condition to which coarse and fine
aggregates are poured and mixed thoroughly.
On cooling, this mixture gave fairly good strength, exhibited acid resistance and
chemical resistance, but it proved to be costlier than ordinary cement concrete.
Recent studies shows that Sulphur impregnation into lean porous concrete
improve its strength and other properties.
It is reported that compressive strength of about 100 MPa could be achieved in
about 2 days time.
The quantity of Sulphur used in this method is also comparatively less making
the process economical.
A coarse aggregate of size 10mm and down well graded, natural fine aggregate
and commercial Sulphur of purity 99.9% are used. A w/c ratio of 0.7 or more may
 PROCEDURE-A
In procedure ‘A’, the test specimens after 24 hours of moist curing,
dried in heating cabinet for 24 hours at 121˚ C. Then the dried
specimens are placed in a container of molten Sulphur at 121˚C for 3
hours. Specimens are removed from the container, wiped clean of
Sulphur and cooled to room temperature for 1 hour and weighed to
determine the weight of Sulphur infiltrated concrete.

PROCEDURE-B
In procedure ‘B’, the dried concrete specimen is placed in an
airtight container and subjected to vacuum pressure of 2 mm
mercury for two hours. After removing the vacuum, the specimens
are soaked in the molten Sulphur for half an hour. The specimens are
removed, wiped clean of Sulphur and cooled at room temperature.
APPLICATION

 Precast roofing elements, fencing posts, sewer pipes.

 Railway sleeper.
 For industrial applications.
 Precast concrete units are cheaper than commercial concrete.
FERRO CEMENT
In 1943 pier luigi nervi tested and presented and in his paper, a new
structural elements, an extremely thin plate of concrete made of layers of small
diameter wire mesh and cement mortar with sand used as the binder.
Ferro cement is a type of thin wall reinforced concrete, commonly
constructed of hydraulic cement mortar, reinforced with closely spaced layers of
continuous and relatively small size wire mesh. The mesh may be made of
metallic or other suitable materials.
FERRO CEMENT
TECHNIQUES OF
MATERIALS USED IN FERRO CEMENT
MANUFACTURES
 Cement mortar mix
 Hand plastering
 Semi- mechanized process Skeleton steel
 Centrifuging and Guniting  Steel mesh reinforcement or Fiber -
reinforcement polymeric meshes
CONTENTS OF FERRO CEMENT
Cement Mortar:
Normally Portland cement and fine aggregate matrix is used in
Ferro cement. The matrix constitutes about 95% of the Ferro cement.
The cement mortar is in the ratio of 1:2 or 1:3 with w/c ratio of 0.4 to
0.45. The fine aggregates conforming to Zone 2 and 3 are used. The
fine aggregates greater than 2.36mm are used, i.e. coarse sand is
used. The fine sand is not recommended to be used in Ferro cement.
Plasticizers and other admixtures can be used to improve
workability, increase durability, reduce permeability and increase
strength. Fly ash can be added up to 30% as cement replacement to
increase the durability.
Reinforcement
There are two types of reinforcement
Skeleton Steel
The skeleton steel consists of large diameter steel bars upto
8mm dia spaced at 75 to 100mm. It may be tied reinforcement or
welded wire fabric.
Wire Mesh
The wire mesh consists of galvanized wire of 0.5 to 1.5mm
diameter and 6 to 20mm c/c spacing. The wire mesh are formed by
welding, weaving or twisting the wires. The welded wire mesh can be
square or hexagonal in shape. The meshes with hexagonal opening
are known as chicken wire mesh. The square woven meshes consists
of 1-1.5mm dia wire spaced at 12mm c/c spacing.
ADVANTAGES OF FERRO CEMENT
 It is highly versatile and can be formed in to almost any shape for a
wide wire range of used
 20% saving on materials and cost
 Suitability for pre – casting
 Flexibility in cutting, drilling and jointing
 Good fire resistance
 Good impermeability
 Low maintains cost
Disadvantages of Ferro cement
low shear strength
 Low durability
 stress rupture failure
 corrosion of reinforcement materials
 large number of labors required
 high time consuming
FIBER REINFORCED CONCRETE
Fiber-reinforced concrete (FRC) is concrete containing fibrous
material which increases its structural integrity. It contains short discrete
fibers that are uniformly distributed and randomly oriented.
Fibers include steel fibers, glass fibers, synthetic fibers and
natural fibers – each of which lend varying properties to the concrete.
Fiber reinforced concrete (FRC) is a new structural material which
is gaining increasing importance.
Addition of fiber reinforcement in discrete form improves many
engineering properties of concrete.
Uses of Ferro Cement
 Water tight structures
 Silos and bins
 Biogas plants
 Pipes
 Wind tunnel
 Swimming pool
 STEEL FIBER REINFORCED CONCRETE
Steel fiber-reinforced concrete is basically a cheaper and easier to use form of
rebar reinforced concrete. Rebar reinforced concrete uses steel bars that are laid within
the liquid cement, which requires a great deal of prep work but make for a much
stronger concrete. The steel fibers have diameter ranging from 0.25mm to 0.75mm. The
use of steel fibers make significant improvement in the flexural strength of concrete.

Steel fiber reinforced concrete is used in construction of roads, air fields,

bridges etc surfaces subjected to wear and tear
GLASS FIBER REINFORCED CONCRETE(G.F.R.C .)
Glass fiber-reinforced concrete uses fiberglass, much like you would find in
fiberglass insulation, to reinforce the concrete. Major problem with the glass fibers is
breaking of fibers and surface degradation by high alkalinity.

The commonly used glass fibers are E-Glass fibers and AR-Glass fibers. Glass
fibers are made from 2000 to 4000 filaments which are lightly bonded to make up a
strand. These strands can be chopped or combined to make cloth or mate.
PLASTIC FIBER REINFORCED
CONCRETE
Plastic fiber reinforced concrete uses plastic fibers such as
nylon, polypropylene, polyethylene to increase the tensile strength of
concrete. The nylon and polypropylene and nylon fibers are found to
increase the impact strength of concrete and thus reduce the tendency
of cracking and their propagation. Generally 0.25-1% of fibers by
volume are added to concrete.
CARBON FIBER REINFORCED
CONCRETE
Carbon fibers possess high tensile strength and high youngs
modulus. The modulus of rupture of an aligned carbon reinforced
concrete cement composite with 8% fiber volume can be as high as
1623 N/mm2.
 ASBESTOS FIBER
REINFORCED CONCRETE
Asbestos is a mineral fiber and has proved to be the most successful
fiber, which can be mixed with OPC. The minimum length of asbestos
is 10cm. The asbestos fiber reinforced concrete has high flexural
strength. Tensile strength of asbestos fiber is 500-980 N/mm2
CORROSION PROTECTION OF
REINFORCEMENT
Methods used are:
Use of corrosion resistant steel
Coating to reinforcement
Cathodic protection
Hot dip galvanizing
Electrochemical chloride removal
Improving the cover to reinforcement
USE OF CORROSION RESISTANT
STEEL
Stainless steel is the name given to a family of corrosion
resistant steels containing a minimum of 12% chromium. On contact
with air, the chromium forms a thin oxide layer on the surface of
steel. This layer is inert and resists corrosion.
The use of corrosion resistant steel is done where humidity is
more and where the concrete is subjected to chemical attacks.
COATING TO REINFORCEMENT:
CEMENT SLURRY
The purpose of coating of steel bar is to provide a sufficiently durable
barrier to aggressive materials such as chloride.
This method was developed by CECRI, Karaikudi, Tamilnadu. It
consists of application of two coats of cement slurry to rebars.
The entire process of coating is :
De—rusting : Removal of rust, dirt and oil from steel surface.
Phosphating : Phosphatization of steel surface by phosphating jelly offers
temporary protection during time lag between de—rusting and application of
first coat of inhibited cement slurry.
Cement slurry : Two coats of cement slurry made by OPC cement and
inhibitor solution to protect steel surface from the attack of sulphate and
chloride ions and to keep the steel surface in high pH environment. (
Sealing : Two coats of sealing solution to increase the adhesion between
steel and cement coating and to seal the surface. Sealing coat is applied
after each application of slurry coat.
COATING TO REINFORCEMENT:
EPOXY COATING
The Fusion Bonded Epoxy Coating (FBEC) is a process where epoxy powder is
applied by electrostatic spray on hot steel at pre-set temperature level The powder,
when in contact with the hot bar, melts, flows, gels, cures, cools and produces a well
adhered continuous corrosion resistant protective coating. The coating thickness
typically varies from 130 micron to 300 micron
Advantages :
As the technique is factory based, it gives uniform thickness and better quality
control.
It has excellent adhesive property.
The coating is flexible not broken due to bending of bars during fabrication.
Disadvantages:
There is reduction in bond strength between coated rebars and concrete.
Patching may not always be effective.
Even the smallest damage in coating can initiate corrosion in severe environment.
EPOXY COATED BARS
CORROSION INHIBITORS
A corrosion inhibitor is defined as a chemical substance that
reduces the corrosion of metals without a reduction in the
concentration of corrosion agents, i.e. chlorides.
Corrosion inhibitors work by reducing the rate of the anodic
and/or Cathodic reactions thereby Suppressing the overall corrosion
rate.
The examples of corrosion inhibiters are
The addition of calcium nitrate extends the time of corrosion
initiation, and also reduces the rate of corrosion once started.
Organic corrosion inhibitors such as amino-alcohols are believed to
suppress corrosion by primarily being absorbed on to the steel
surface thereby displacing corrosive ions such as chlorides.
CATHODIC PROTECTION
Cathodic protection is a technique by which the electrical
potential of the steel is decreased to level at which corrosion cannot
take place. It is widely used for concrete offshore structure and steel
structures, while on land it has been used for the protection of
pipelines.
Two methods are used:
Impressed current method
Sacrificial anode system
CATHODIC PROTECTION:
IMPRESSED CURRENT
The Cathodic protection comprises of application of impressed
current from an external power source to an electrode laid on the
concrete above steel reinforcement. This electrode serves as anode
and the steel reinforcement which is connected to the negative
terminal of a DC source acts as a cathode. In this process the external
anode is subjected to corrosion and the Cathodic reinforcement is
protected against corrosion and hence the name ‘Cathodic Protection’
.
In this process the negative chloride ions which are responsible
for the damage to “it passivating layer are drawn away from the
vicinity of steel towards the anode where they are oxidized to form
chlorine gas. The environment around the steel reinforcement reverts
back to alkaline condition which protects the steel.
CATHODIC PROTECTION:
SACRIFICIAL ANODE
In this system the reinforcement is connected to anodes with a
more negative corrosion potential than steel, such as zinc and
aluminium. The external anode corrodes preferentially to the steel and
supplies electrons to the Cathodic steel surface. Sacrificial anode
system are more effective in submerged structures where the concrete
is wet and resistivity is low. Warm temperature i.e. above 20˚C is
generally required for this system.
 DRY PACK
TECHNIQUE
In this technique , dry cement sand mix in proportion of 1:2.5 is
used and sufficient amount of water is added to it so as to form a
ball by hand. The ball should neither slump nor crumble.
 DRY PACK PROCESS
Before actual operation the hole should be thoroughly cleaned and ensured
free from broken pieces of aggregates, washed and dried.
A thin layer of cement grout is applied on the surface. The mix for bonding
grout is the mixture of cement and fine sand in ratio of 1:1 to a consistency
like thick cream.
After this, the dry pack material is put into place before the bonding grout
has dried up. Packing material consists of the volume or by weight a mix of 1
part of cement to 2.5 parts of sand.
Water requirement for mix is such as to produce a mortar which, when
used, will stick together on being molded into a ball, and will not exude
water but will leave the hands damp. If less water is added, it will not make
sound solid pack. If more water is added excessive shrinkage will occur and
the material becomes loose.
Dry pack material is not to be filled at a time, but should be filled in
layers and properly compacted having compacted thickness of about
1 cm.
Each layer is scratched & finished to secure bond for succeeding
layer and is compacted over its entire surface by use of hardwood
stick and hammer. The size of such stick is about 20 to 30 cm in
length and not over 2.5 cm in diameter. Wooden sticks will not polish
the surface of each layer and thus better bonding surface is formed.
Last layer is finished to match the surroundings.
For better results and when water tightness is a requisite, the holes
should be sharp and square at the surface edges, but corners within
holes should be rounded. Holes for dry pack should have a minimum
depth of 2.5 cm
VACUUM CONCRETE
Higher water-cement ratio is damaging for concrete. We always try to
restrict the water-cement ratio in order to achieve higher strength. the
adopted water-cement ratio is much more than that mainly because of the
requirement of workability. Workability is also important for concrete, so it
can be placed in the formwork easily without honeycombing.
After the requirement of workability is over, this excess water will
eventually evaporate leaving capillary pores in the concrete. These pores
result into high permeability and less strength in the concrete. Therefore,
workability and high strength don’t go together as their requirements are
contradictory to each other.
Vacuum concrete is the effective technique used to overcome this
contradiction of opposite requirements of workability and high strength.
In this technique, the excess water after placement and compaction of
concrete is sucked out with the help of vacuum pumps. This technique
is effectively used in industrial floors, parking lots and deck slabs of
bridges etc. The magnitude of applied vacuum is usually about 0.08 MPa
and the water content is reduced by up to 20-25%. The reduction is effective
 COMPONENTS REQUIRED FOR
VACUUM CONCRETING
Mainly, four components are required in vacuum dewatering of
concrete, which are given below:
 Vacuum pump
 Water separator
 Filtering pad
 Screed board vibrator
Vacuum Pump: Vacuum pump is a small but strong pump of 5 to 10
HP.
Water Extractor: Water is extracted by vacuum and stored in the
water separator.
Filtering Pad: Filtering pad consists of rigid backing sheet, expanded
metal, wire gauge or muslin cloth sheet. A rubber seal is also fitted
around the filtering pad. Filtering pad should have minimum
dimension of 90cm x 60cm. The mats are placed over fine filter pads,
which prevent the removal of cement with water.
Screed Board Vibrator: To force the excess water to get collected at
the top.
 Effect of Vacuum
Concreting
ADVANTAGES OF VACUUM CONCRETING

Due to dewatering through vacuum, both workability and high

strength are achieved simultaneously.
Reduction in water-cement ratio may increase the compressive
strength by 10 to 50% and lowers the permeability.
It enhances the wear resistance of concrete surface.
The surface obtained after vacuum dewatering is plain and smooth
due to reduced shrinkage.
The formwork can be removed early and surface can be put to use
early
 ASPHALT
SHEETING
Bitumen sheets are watertight. They are used for water
proofing of concrete. They can be laid easily on any surface. These
sheets cannot resist excessive pressure and temperature. They are
available in thickness of 3mm, and applied hot on the surfaces. At the
junction of two sheets minimum lap of 100mm is required.
GROUTING
Grouting is a process of injecting mixture of cement, sand and
water at a high pressure in the cracks , joints, voids.
Materials generally used for grouting are:
Cement + Water
Cement + Stone Dust + Water
Cement + Clay + Water
Cement + Clay + Sand + Water
Chemicals, For example: Epoxy
PROCEDURE OF GROUTING
Drilling of grouting holes:
For drilling the holes equipment's like jack hammer or shot drill can
be used depending on the diameter of hole and the depth of hole
required.
Arrangement of grout pipes
Grout pipes of 4-5cm dia and 45 to 90cm length are inserted in the
grout holes. The space surrounding the pipes is filled with cement
mortar
Cleaning of cracks
Before injecting grout mixture in the cracks, it is necessary to clean
the cracks. The loose materials in the cracks can be removed by
injecting air-water mixture by pressure in the cracks.
Inserting the grout in the holes
Grout is inserted in the holes at a pressure of 0.65 kg/cm2.
SOIL GROUTING
GROUTING IN TUNNELS
SCHEMATIC PLAN OF
GROUT PLANT
GUNITING
Guniting is the process of pneumatically transporting the
mortar or fine concrete through a hose on to a surface at a high
velocity.
Guniting is an effective technique, which has been extensively
used in the rehabilitation of structurally distressed R.C.C members.
Gunite is also known as shotcrete or pneumatically applied mortar.
The various applications of shotcrete are:
Thin overhead, vertical or horizontal surfaces
Swimming pools and prestressed tanks
Canal and tunnel lining
Repair of damaged concrete
Refractory lining works
Overlays on concrete roads
METHODS OF GUNITING
Dry-mix process shotcrete
In this process, cement and moist aggregate are mixed and then
placed into a device that meters the mixed material into a stream of
compressed air.
Material is carried by the compressed air through a delivery hose to
the nozzle where water is added under pressure through a perforated
ring.
The water thoroughly wets the other ingredients as the mixture is
jetted from the nozzle at high velocity onto the surface to be
shotcrete.
The amount of water added is under the control of the nozzle man
or placing operator and can be varied by means of a valve to produce
 DRY MIX
PROCESS
DRY MIX PROCESS
Wet-mix shotcrete
In the wet-mix process, all ingredients are first mixed to produce
mortar or concrete.
The mortar or concrete is then placed into delivery equipment which
can be of a squeeze tube, pneumatic-feed or positive-displacement
type.
In any c a s e, the material is forced thro u g h a delivery hose to the
nozzle where compressed air is injected to increase velocity.
The nozzle man can vary the amount of air introduced but has no
direct control over the other properties of the concrete or mortar
being placed.
WET MIX PROCESS
JACKETING
Jacketing is the most popularly used method for strengthening of
building columns. The most common types of jackets are steel jacket,
reinforced concrete jacket, fibre reinforced polymer composite jacket,
jacket with high tension materials like carbon fibre, glass fibre etc.
The main purposes of jacketing are:
To increase concrete confinement by transverse fibre reinforcement,
especially for circular cross-sectional columns,
To increase shear strength by transverse reinforcement,
To increase flexural strength by longitudinal reinforcement
provided.
To increase the seismic capacity of the structure
COLUMN JACKETING
Jacketing of columns consists of added concrete with
longitudinal and transverse reinforcement around the existing
columns.
This type of strengthening improves the axial and shear
strength of columns while the flexural strength of column and
strength of the beam-column joints remain the same. It is also
observed that the jacketing of columns is not successful for improving
the ductility. A major advantage of column jacketing is that it
improves the lateral load capacity of the building in a reasonably
uniform and distributed way and hence avoiding the concentration of
stiffness as in the case of shear walls.
PROCEDURE OF COLUMN
JACKETING
Open the footing of columns by excavating around it and provide
the supports to the slab with the help of the hydraulic jack and
vertical posts.
Remove the plaster from the surface of the columns.
Make the surface of the concrete rough by sand blasting.
Add new bars to the column externally from footing to the column
as per engineer guides.
Apply the bonding agent on the old concrete for proper bonding
between the old and mew concrete.
Erect necessary shuttering around the columns.
Pour Minimum of M-25 grade of Concrete, compact and cure it.
COLUMN JACKETING
COLUMN JACKETING
BEAM JACKETING
Jacketing of beams is recommended for several purposes as it
gives continuity to the columns and increases the strength and
stiffness of the structure. While jacketing a beam, its flexural
resistance must be carefully computed to avoid the creation of a
strong beam-weak column system. The location of the beam critical
section and the participation of the existing reinforcement should be
taken into consideration.

Jacketing of beam may be carried out under different ways, the

most common are one-sided jackets or 3- and 4-sided jackets. At
several occasions, the slab has been perforated to allow the ties to go
through and to enable the casting of concrete. The beam should be
jacketed through its whole length. The reinforcement has also been
added to increase beam flexural capacity moderately and to produce
high joint shear stresses.
PROCEDURE OF BEAM JACKETING
Reduce the load on the beam by removing the tiles and bed mortar
from the slab.
Erect the props to support the slab
Remove the plaster on the beam and then plsce the longitudinal bars
along with the stirrups to the beam.
Stirrups are inserted by making the holes through the slab.
The longitudinal bars are either passed through the column or in
case if column is also to be jacketed they are attached to the external
reinforcement of the columns.
The old concrete surface is cleaned by air jetting. To allow good
bonding between old concrete and new concrete epoxy bond coat is
applied.
The formwork is erected around the beam and the concrete is
BEAM JACKETING
SHORING
Shoring is the construction of a temporary structure "to support
temporarily an unsafe structure.
The main objects of shoring are :
When the walls of a building shows signs of bulging or leaning
outwards, shoring is necessary.
When an adjacent structure is to be dismantled.
When openings are to be made or enlarged in the wall.
When a wall cracks due to wall needs repairs.
 Components of raking
shores
RAKING SHORES  Rakers
This is system of giving the temporary supports to an unsafe  Wall plate
wall. The construction of raking shore, varies with the condition at the  Needles
site. In this method the incline members known as rakers are used to  Cleats
give support to the wall.  Bracing
 Sole plate
PROCESS OF ERECTION
The wall plate, about 20 to 25 mm wide and 5 to 7.5 cm thick is placed
vertically along the face of the wall and is secured by means of needles of 10
cm x 7.5 cm section.
The needles penetrate the wall by about 10 cm.
In order that the needles do not get sheared ,, oil due to the thrust of the
raker; the needles are further strengthened by means of cleats which are
nailed directly to the wall plate.
Rakers abut against the needles in such a way that the Centre line of the
raker and the wall meet at the floor level. Thus there will be one raker
corresponding to each floor.
These takers are inter-connected by struts to prevent their buckling. The
feet of takers are connected to an inclined sole plate, embedded into the
ground by means of iron dogs.
POINTS TO BE KEPT IN MIND
Rakers should be inclined to the ground by 45°, to make them move effective
However. in practice, the angle may vary from 45° to 75°.
Rakers should be properly braced at intervals.
For tall buildings, the length of raker can be reduced by introducing rider
raker.
The Centre line of raker and the wall should meet at floor level.
The size of the raker should be decided on the basis of anticipated thrust
from the wall.
The longer length of the wall needs support, shoring may be spaced at 3 to
4.5 m spacing. depending upon the need.
The sole plate should be properly embedded into the ground, at inclination.
and should be of proper section.
Wedges should not be used on sole plates since they are likely to give way
under vibrations which are likely to occur.
 FLYING
SHORES/HORIZONTAL
SHORES Types of flying shore:
In this type of shoring, horizontal supports are provided for
supporting temporarily the parallel walls of the two adjacent buildings,  Single flying shore
which may tend to collapse or damage when one of the intermediate  Double flying shore
buildings has to be pulled down and rebuilt.
 If the walls are quite near to each other (distance up to 9 m),
single flying shore can be constructed. It consists of wall plates, needles,
cleats, struts, horizontal shore, straining pieces and folding wedges.

When the distance between two parallel walls is more than 9 m,

a double flying shore having a trussed formwork
 POINTS TO BE KEPT IN MIND
The Centre lines of flying shore and struts and those of the walls should
meet the floor levels of the two buildings. If the floor levels are different, the
horizontal shore should be placed either mid-way between the levels of the
two floor of equal strength, or it should be placed at the level of weaker
floor.
The struts should preferably be inclined at 45°. This inclination should not
exceed 60°.
The flying shores should be spaced at 3 to 4.5 m centres along the two
walls, and horizontal braces should be introduced between adjacent shores.
Single flying shores should be used only up 0 9 m distance between two
walls. For greater distance, double flying shores should be provided.
Flying shores are introduced when old building is being removed and
should be kept in position till the new unit is constructed.
DEAD SHORE/VERTICAL
SHORES
This type of shoring consists of vertical members known as
dead shores supporting horizontal members known as needles. The
needles transfer the load of the wall etc. to the dead shores.
 Process of Erection
Holes are made in the wall at suitable height.
Needles, which are made of thick wooden sections or of steel, are
inserted in the holes.
Each needle is supported at its two ends; by vertical posts or dead
shores.
The dead shores stand away from the walls so that repair work is not
obstructed.
The dead shores are supported on sole plates and folding Wedges

Purpose of Dead shores

To rebuild the defective lower part of the wall.
To rebuild or deepen the existing foundation.
To make large opening in the existing wall at lower level.
POINTS TO BE KEPT IN MIND
The needles are spaced at l to 2 m. A minimum of three needles should beused for
an opening.
The needles should be suitably braced.
The section of needles and dead shores should be adequate to transfer the which
can be estimated with fair degree of accuracy.
If the opening is made in an external wall, the length of the outer dead shore will
be greater than the inner ones.
The floors should be supported from inside.
The dead shores are supported on sole plates. Folding wedges should be inserted
between the two.
If the external wall is weak, raking shores may be provided, in addition to the dead
shores.
Shores should be removed only when the new work has gained sufficient strength.
 UNDER
PINNING
The term underpinning is applied to the construction of a
new foundation underneath the existing one for strengthening
purposes, without endangering the stability of the existing
structure.
Underpinning may be necessary for a variety of reasons:
The original foundation is simply not strong or stable enough.
The usage of the structure has changed.
The properties of the soil supporting the foundation may have
changed (possibly through subsidence) or were mischaracterized
during design.
The construction of nearby structures necessitates the excavation of
soil supporting existing foundations.
To increase the depth or load capacity of existing foundations to
support the addition of another storey to the building (above or
below grade).
It is more economical, due to land price or otherwise, to work on the
present structure's foundation than to build a new one.
Earthquake, flood, drought or other natural causes have caused the
structure to move, thereby requiring stabilization of foundation soils
and/or footings.
UNDERPINNING: PIT METHOD
In this method existing wall over the foundation is divided into
various sections generally 1.2 to 1.5 m in length. Holes are then made
at adequate height in the existing wall. In these holes steel needle
beams with bearing plates are inserted and supported on either side
of the wall by means of crib supports (wooden blocks) and screw
jacks.
The pit is now excavated up to the desired level of the
proposed new foundation in sections. The old foundation may be
extended up to level of foundation directly or by cutting the lower part
of old foundation as desired.
PIT METHOD
The following points regarding pit method of under pinning may be
noted:
The entire wall foundation can be replaced or deepened by this
method in sections.
In case of underpinning the large sections of walls, the work is
started from the centre and progress is made side ways.
Proper timbering to the excavated trenches should be provided.
Alternate sections are taken up in the first round. The remaining
intermediate sections are then taken up. Only one section should be
taken at a time.
The needle beams etc. should be removed only when the new
foundation hag gained sufficient strength.
It is desirable to do the new foundation work in concrete.
The needle holes, etc. should be closed in masonry using cement
mortar.
UNDERPINNING: PILE METHOD
Sometimes, pit method may be impracticable or uneconomical
under certain circumstances, for example, pit method cannot be used
for underpinning in water-logged areas, or when the heavy loads of
existing structure are to be transferred to the ground at a great depth.
the cost of underpinning by pit method may be excessive and hence
uneconomical. Under such situations, the use of precast piles or steel
piles is made for underpinning of foundations.
In this method the piles are driven at regular interval along both the
sides of the wall.
Generally bore hole piles or under reamed piles are used. The piles
are connected by concrete or steel needles, penetrating through the
wall. These needles act as pile caps also.
This method is very much useful in clays soil and in water logged
PILE/PIER METHOD
 CREATED BY
DHAWANI LAVISH 136510306026
GAYAKWAD TEJAS 136510306029
GORASIYA MAYUR 136510306031
HIRANI YATIN 136510306034
KATARMAL DARSHAN 136510306037
LALWANI PIYUSH 136510306039
MALI VISHNU 136510306041
PATEL PARTH 136510306044
PRAJAPATI JAYESH 136510306045
PRAJAPATI KALPESH 136510306046
THANK YOU!!!