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Building No.26
Vartak Nagar, Thane (W)
Due to the age of the structure, there are many areas in the building where deterioration in the
structure is observed. Some members of the society have carried out repair works as and
when required in their respective flats.
However no comprehensive structural repair work has been carried out for the complete
building in the recent past.
The current structural audit work is being carried out to get a better understanding of the
current condition of the building, required rectification measures and to further estimate the
residual life of the building.
a) Carry out visual assessment in each of the flats and in the common areas of the building
to identify the type of distress in the structural members.
b) Ascertain the non-destructive tests that are required to be carried out to get a quantitative
idea about the condition of the building.
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2. Observations
a) Observations for each flat have been presented in the form of drawings, where different
types of defects as identified during visual assessment have been marked.
b) Observations for common area and terrace level have also been shown on drawings.
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3. Photographs
Observation 1 - Cracks in Structural RCC Members (Beam / Columns / Slab) :-
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Observation 2 – Cracks in masonry wall:-
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Observation 3 – Spalling of concrete & Reinforcement Exposed :-
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Observation 4 - Leakage / Dampness in Masonry Walls / Concrete Members:
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Observation 5 - Vegetation Growth :-
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Observation 7 – Plumbing Line Leakage :-
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Observation 7 – Peeling of Paint
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4. Analysis of Test Results & Overall Conclusion :-
Since all of the readings fall under the ‘Doubtful’ category, the quality of concrete can be
considered to be poor in general.
It was seen during visual inspection that the surface concrete has severely deteriorated at
many locations due to corrosion of reinforcement, hence the low reading values for the
UPV test are again an indication of the deteriorated nature of surface concrete.
Hence it is evident that corrosion is present in almost all concrete members which have
been tested.
Cover Meter test was carried out at 3 locations. In most cases the cover has been found to
be between 30 to 35mm range.
This shows that carbonation has occurred to a depth higher than the cover of most
reinforcement bars which indicates that the cover concrete is no longer able to provide
protection to reinforcement bars against corrosion.
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Rebound Hammer Tests:
The rebound hammer test result show a very low strength of concrete. Many readings give
the concrete strength as below 9 MPa which is significantly low compared to an acceptable
concrete strength. This indicates the surface concrete is weak. This is due to the distress in
surface concrete because of corrosion in reinforcement.
To assess that the strength of internal concrete, core cutting tests should be carried out.
Chemical Tests:
The results of pH, chloride and sulphate tests show that these parameters are within the
permissible limits of indian standards.
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Overall Conclusion :-
From the test results & visual observations following conclusions can be arrived at:
Members where addition of new reinforcement is required can be decided during repair
works, once the corroded reinforcement is completely visible.
b) Due to presence of corrosion, the surface concrete has deteriorated and hence the strength
of surface concrete has become lower. Surface concrete will have to be repaired at all
locations where distress has been observed.
c) Leakages from terrace slab and toilets must be arrested to prevent further decay of RCC
members.
After carrying out the required structural and non-structural repairs, the life of the
building can be extended by 3 years.
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DRAWINGS FOR
OBSERVATION
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NDT Test Report
for
Rahul Agarwal
Approved 20-09-17
(M.Tech IIT Bombay)
PROJECT INFORMATION PAGE
UPV 20 HCP 10
UPV HCP
- Floor at which element is present. For columns, the start and end floor levels are indicated.
Level
- In case of industrial buildings, this can be the approximate height from ground level
Columns: whether the test has been done near the Top, Middle or Bottom of the column height
Test Location on Beams: whether the test has been done near the mid-span(MID) or near the supports (END)
Member Slabs: whether the test has been done near any of the slab edges (EDGE) or away from
the
edge (CENTER)
Capstone
CONSULTANTS
Procedure:
• The concrete surface is cleaned properly
• The hammer is pressed against the concrete
surface and released
• Six readings are taken and an average is taken.
• Correlate the average with the compressive
strength
Rebound Hammer Test
Application:
These tests are used to assess the probability of corrosion in reinforcement.
HCP Tests are done in accordance with ASTM C876 standard.
Carbonation tests can also be done on extracted cores by applying the chemical on the
core and measuring the depth till which the carbonation has taken place.
Application:
Rebar mapping is a mechanism to obtain information related to reinforcement in existing
concrete buildings where drawings are missing or reinforcing data needs to be verified.
These tests are carried out to:
• check the size and numbers of reinforcing bars present in concrete members
• determine the concrete cover provided to reinforcement
• prepare structural drawings for RCC structures where original drawings are not
available
Procedure:
• Identify the test locations on each member so that all required reinforcement data
can be captured.
• Clean the surface of the structural member.
• Locate main reinforcement bars and determine number/spacing of the bars.
• Determine diameter of main bars.
• Locate secondary bars (or stirrups) and determine number/spacing of the bars.
• Determine diameter of secondary bars.
• Data obtained for similar members must be correlated to obtain more meaningful
results in terms of rebar diameter.
• This test does not determine grade of reinforcement.
Application:
These tests are used to assess the pH level, Chloride (Cl) content and SO3 content of
concrete.
A higher pH value or a higher content of chloride or SO3 than permitted by Indian standard
codes shows the presence of an environment where corrosion of reinforcement has much
higher probability than normal.
Procedure:
• The chemical tests are conducted on powdered concrete sample collected from the
site.
• The powdered samples are tested in the lab using test kits from reputed
manufacturers.
• The obtained results are correlated with the permissible limits given by IS 456: 2000
code and reported.
Permissible Limits:
3
For PCC, maximum 3.0 kg of Chloride per m3 of concrete.
Cl (kg/m )
For RCC, maximum 0.6 kg of Chloride per m3 of concrete.
HCP Carbonation
Test Location UPV Results Rebound Hammer Results
Results Results
Test Hammer
Performe Equiv. cube
Serial Member Location UPV Concrete Potential Depth Reading Hammer
Unit Level Element Type d on strength
No. ID on (km/s) Quality (mV) (mm) (Rebound Direction
Core? (MPa)
Member Number)
Notes
Name of Person Signature Date a) For calculating cube strength from rebound hammer
Supervisor Vivek Mishra 13-09-17 values, appropriate reduction factors for surface
carbonation of concrete has been considered.
Report prepared Santosh Yadav 20-09-17
Rahul Agarwal
20-09-17
Approved (M.Tech IIT Bombay)
NDT TEST RESULTS (Rebar Cover Meter Test)
NDT RESULTS
Secondary Remarks
Serial Member Dimensions of Concrete Concrete
Unit Level Element Type Main Bars Nos bar spacing
No. ID Member mm Cover mm Cover mm
mm
1 C1 G-1 Column 30
2 C4 G-1 Column 35
3
For PCC, maximum 3.0 kg of Chloride per m3 of concrete.
CL (kg/m )
For RCC, maximum 0.6 kg of Chloride per m3 of concrete.
Repair type 1:
Treatment for Exposed Reinforcement and Spalling of Concrete / Cracks in concrete members due to corroded reinforcement
(When new reinforcement is not required to be added).
When corrosion of reinforcement occurs, it exerts pressure on the concrete leading it to cracks in concrete. When the corrosion is severe, concrete
portions break apart from the main member which is called spalling of concrete. Spalling of concrete will lead to complete exposure of reinforcement,
which becomes susceptible to further corrosion. This makes the reinforcement ineffective and reduces the life of the concrete member.
When the loss in cross sectional area of reinforcement is not considerable, then the repair methodology suggested in this annexure can be adopted.
However if after removal of surface concrete and removal of rust from corroded reinforcement, it is seen that the bar diameter has reduced by more than
20% for beams and slabs, and 25% for columns, then additional rebar will have to be provided. In this case refer Repair Type 2 for repair methodology.
Recommendation:
• Use light chipping hammers to remove concrete from the affected area. Clean the surface thoroughly and remove all dirt & loose dust and
aggregate.
• The reinforcement should then be protected against corrosion by applying Feovert chemical of Krishna Conchem.
• Apply a bonding agent to the existing concrete surface so that proper bonding of the existing concrete to the repair material can take place. The
bonding agent has to be applied as per the manufacturer’s instructions.
• Apply Polymer modified mortar (PMM) to repair the concrete member and bring it to its original shape and size. The PMM should be applied while
the bonding agent is still tacky.
Note:
1) Speed and time for application of any chemical or PMM should be as per manufacturer’s instructions.
2) It is not advisable to place PMM above 30 deg Celsius. Newly prepared surface should be protected from rainfall and other source of water. However
it should be moist cured for 1 to 3 days under ambient temperature or as per manufacturer’s instructions.
Repair Type 2:
Treatment for Exposed Reinforcement and Spalling of Concrete / Cracks in concrete members due to corroded reinforcement
(When new reinforcement is required to be added).
When the reinforcement has corroded considerably and the rebar diameter has reduced by more than 20% for beam & slab, and 25% for columns, the repair
methodology suggested in this annexure shall be adopted.
• Use light chipping hammers to remove concrete from the affected area. Clean the surface thoroughly and remove all dirt & loose dust and
aggregate.
• Clean the exposed steel reinforcement with mechanical wire-brushing and by using a Feovelt.
• Add new reinforcement bars, as per the sketches provided in this annexure.
• The new reinforcement should then be protected against corrosion by applying Krishna Conchenis Feovelt Chemical.
• Apply an bonding agent to the existing concrete surface so that proper bonding of the existing concrete to the repair material can take place. The
bonding agent has to be applied as per the manufacturer’s instructions.
• Apply Polymer modified mortar (PMM) to repair the concrete member and bring it to its original shape and size. The PMM should be applied while
the bonding agent is still tacky.
Note:
• Speed and time for application of any chemical or PMM should be as per manufacturer’s instructions.
• It is not advisable to place PMM above 30 deg Celsius. Newly prepared surface should be protected from rainfall and other source of water.
However it should be moist cured for 1 to 3 days under ambient temperature or as per manufacturer’s instructions.
• Use light chipping hammers to remove concrete from the affected area. Clean the surface thoroughly and remove all dirt & loose dust and
aggregate.
• Clean the exposed steel reinforcement with mechanical wire-brushing and by using a Feovelt.
• Add new reinforcement bars, as per the sketches provided in this annexure.
• The new reinforcement should then be protected against corrosion by Krishna Conchenis Feovelt Chemical.
• MICROCONCRETE : micro-concreting to be done after erection of shuttering around the existing beam/slab. Micro concrete has to be poured
from the top after creation of sufficient number of holes in the existing slab. Since vibration will not be possible after pouring micro-concrete, a
super plasticizer admixture will have to be used.
• Cure the shotcreted surface adequately at least for seven days minimum. Curing can be done using wet burlap and hose pipes.
Retrofitting Details for Slabs:
Retrofitting Details for Beams:
Repair Type 3:
It was observed that water seepage is occurring from external plumbing pipes at certain locations. This may be due to:
• damage in plumbing pipes
• poor workmanship leading to gaps at pipe junctions
• choking of pipes restricting free movement of water
This water seepage is going into the masonry walls and concrete members. Where the seepage is occurring in the concrete members, it will lead to
corrosion of reinforcement which will lead to reduction in strength of the rebar as well as development of cracks in concrete.
Recommendation: All such locations where external plumbing lines are leaking should be identified and the plumbing lines should be checked for damage,
blockages or gaps in connections.
Repair Type 4:
At some places it was observed that leakage is occurring in the slabs through the terrace slab. This is happening due to deterioration in waterproofing.
Recommendation:
1. Chemical waterproofing membrane should be overlaid on the current surface. Products such as Dr. Fixit’s new coat or other similar products can
be used.
Repair Type 5:
Recommendation:
1. Removing live plants from the structure can cause additional damage because it may also tear off surrounding building materials that have been
weakened. To kill the roots, a “cut-and-paint” technique – where the plant is cut and the cut surface is then painted with an herbicide – is usually
recommended.
2. Moss and lower order plants can be effectively removed with an appropriate biocide and a soft bristle brush, being sure to wet the surface prior to
cleaning and to work from the bottom up to minimize streaking.
3. “Glyphosate” which is marketed as a weed killer and seems to be less toxic yet effective can also be used. Initially A 1:1 solution of Glyphosate, in
water can be sprayed over the affected areas.
BILL OF QUANTITY FOR REPAIR
BUILDING NO - 26 , VARTAKNAGAR ,THANE, MUMBAI G+3
I. ENABLING SYSTEM :-
2 MICRO-CONCRETE:
Providing and laying Super Fluid Micro concrete which
shall be single component, non-shrink, free flow, self-compacting,
ready to use after mixing water in specified proportion to the beam 9500.00 Kg 70.00 665,000.00
bottoms, columns, slabs, etc. Including mixing with 05mm to
10mm size aggregates, pouring, temping, Consolidating, curing
etc.
3 PRO & FIX STEEL:
Providing and fabricating, fixing steel as required for column and 5000.00 Kg 80.00 400,000.00
beams. complete as per the direction of Engineer In Charge
4 Anchoring of Rebars & Shear Connector: Providing
and supplying Medium duty injection adhesive
Re - 500 or equivalent for rebar fixing for Rebar dia from 8
mm upto 16mm. Drilling hole into rock or concrete to the
required depth by rotary hammer drill, cleaning with brush and jet
2500.00 Nos. 150.00 375,000.00
of clean air, filling resin and hardener with standard
dispenser in hole and then fixing the re-bar, The system
should be made of two foils consisting of resin and Hardener foil
pack.The installation and the setting instructions should be strictly
followed as per the manufacturers recommendations.
TOTAL 2,415,000.00
III. CIVIL REPAIR WORKS:-
BOQ SUMMARY
ENEABLING SYSTEM 776,700.00
STRUCTURAL REPAIR 2,415,000.00
CIVIL REPAIR WORK 890,500.00
Total 4,082,200.00
The above amount is excluding taxes