1.

3 METHODOLOGIES FOR REPAIR OF RCC ELEMENTS

1.5.1 The methodology for the repair of spalled/distressed concrete members/areas is as
follows:
1. Surface Preparation: The loose dilapidated concrete shall be removed from the substrate
using mechanical breakers. The concrete shall be removed up to a minimum depth of 10mm
beyond steel reinforcement. The Chipping should continue till sound concrete is available.
The chipped concrete shall be cleaned using high pressure water jet with clean potable water.
This would make the substrate free from all impurities and unwanted organic deposits. In
case of slabs the edges shall be cut to a minimum depth of 20mm to avoid formation of
feather edges.

2. Reinforcement Treatment: The corroded steel bars shall be cleaned mechanically or

using high pressure water jet to remove all loose materials. The rust scales shall be cleaned
using rust remover. The surfaces shall be brought to bright condition. The cross- sectional
area of the bars shall be checked for loss and wherever it is found that the loss of section is
more than 25% the same needs to be marked for retrofitting. The prepared bars shall be
given a coat of zinc rich epoxy primer to a dry film thickness of 50 microns. The application of
primer shall be carefully done covering the surfaces behind the bars.

3. Provision of Additional Reinforcement: Wherever the reinforcement loss is heavy or

reinforcement is lost completely, additional rebar of same diameter shall be provided with the
help of shear connectors. The shear connectors are provided in the repair area in a grid
pattern of 200mm X 200mm by drilling holes of 12mm diameter to a depth of 150mm. The
drilled holes shall be grouted with epoxy acrylate based anchoring material.

4. Injection Grouting to arrest porosity: Holes should be drilled in the concrete where the leakage
and cracks are observed to fix injection packers. The packers are fixed using Epoxy Putty on
the surface. Injection is done using hydro swelling, water based, low-viscous, thermo-setting
resin based on vinyl metha-acrylate chemistry, to fill the pores within the concrete.

5. Application of bonding agent: The prepared and treated concrete substrate to be repaired
shall be given a bonding coat using two components, epoxy bonding agent having a long
open time. The bonding agent is applied using either brush or roller. The bonding agent
application shall be done to only that much area that can be covered within the open time.
Under normal conditions, the bonding agent has an open time of at least 3hrs before it looses
its tackiness. However a small patch shall be applied to confirm the same before applying
over the entire area since the open time varies with ambient conditions. In case the bonding
agent is found to be dried, a further coat of bonding agent shall be given.

6. Refurbishment of Damaged concrete: The primed concrete substrate shall be repaired with
single component, fibre reinforced, dual shrinkage compensated, cementations, thinxotropic
repair mortar by hand trowel application.
The mortar shall be prepared by mixing the powder with water at the recommended water
powder ratio. Initially add 80% of the water in the mixing bucket slowly adding powder
component using slow speed paddle mixer. Add remaining amount of water and continue
mixing for2 minutes till lump free paste is achieved.

The mixed mortar shall be used within its workable time and no further addition of water for
workability is allowed. To enable this mix only required amount of powder which can be
applied within its workable time.
 The mixed mortar shall be applied initially by hand carefully pressing the same against the
concrete surface and filling all the corners of the repair area starting from centre of damaged
area.

The mortar shall be applied in layers of 50mm on vertical and 30mm on overhead surfaces.
The final layer shall be finished with steel trowel to make it in line with existing concrete
surface.
In case further layers of mortar were not applied immediately. Then the surface shall be made
rough using steel trowel to provide mechanical key further layers of mortars. The initial dried
layer shall be saturated with water prior to application of further layers.
7 Curing: the repaired area shall be kept wet by covering with wet hessian cloth for a minimum
7 days. For ceiling its after should be sprinkled continuously for minimum 7 days.
8 Polymer based plaster over repaired mortar: The entire surface shall be plastered with
polymer mix with cement mortar of 1:5:15 ratios

1.5.1.2 MATERIAL SPECIFICATIONS

The following is the list of materials recommended for repair.
Application Product/Make

S. No.
Rust cleaner for reinforcement. BASF/Sika/Pilite/ Fosroc/

1 Sunanda/ Krishna
Anti-Corrosive Primer for Reinforcement. BASF/Sika/Pilite/ Fosroc/

2 Sunanda/ Krishna
Anchorage Material for fixing rebar’s. BASF/Sika/Pilite/ Fosroc/

3 Sunanda/ Krishna
Injection Grouting to arrest porosity BASF/Sika/Pilite/ Fosroc/

4 Sunanda/ Krishna
Bonding Agent for Concrete BASF/Sika/Pilite/ Fosroc/

5 Sunanda/ Krishna
Repair Mortar for Concrete BASF/Sika/Pilite/ Fosroc/

6 Sunanda/ Krishna
Polymer for plastering over repaired mortar BASF/Sika/Pilite/ Fosroc/

7 Sunanda/ Krishna

The specifications for the materials to be used shall be as follows:

1 Rust cleaner for reinforcement: Treat all the rusted reinforcement using single component,
water based, rust converter before treating with anti- corrosive primer. The rust converter shall
be capable of forming tough protective layer of iron phosphate
Typical Properties of rust Cleaner:
Aspect : Pale yellow liquid
Mixed Density : 1.45 Kg/litre
Drying time : 20minutes
Over coating time : 18hours

Anti- corrosive Primer for Rebars: The primer shall be a two component, epoxy zinc rich. It
shall be formulated to meet the requirement of BS 4652 Type 2. The primer shall be an active
type having zinc content of greater than 90% in dry film state which is capable of generation of
incipient anodes in the areas surrounding the repairs. The product shall have mix density not
less than 2.25 Kg/litre. It shall be fully compatible with wide range of repair mortars’.
 Typical Properties of primer
Aspect : Thick grey suspension
Mixed density :2.3 Kg/litre
Volume Solids,% :50 + 3
Mixing Ratio, by weight :96(B):04(H)
Pot Life : >2 Hours at 250C
Tack free time :20 Minutes at250C
5 Minutes at 40oC
Recoat time :5 Hours at 25oC
:2 Hours at 40oC
Total zinc content in dry film : >90% by volume
D.F.T per coat : > 50 microns
Application temperature : Minimum 10oC
Maximum 40oC
3 Anchorage Material for fixing rebars:
The material for fixing rebars shall be two-component, thixotropic, pure epoxy resin based
chemical anchoring mortar. The product is specially designed for applications where heavy
loads under critical conditions are to be fixed in concrete. Both components shall be packed in a
single with separate components, are correctly mixed in the mixing nozzle during application.
4 Injection Grouting to arrest Porosity:
Injection resin shall be hydro welling, water based, low-viscous, thermo-setting resin based on
vinyl metha-acrylate chemistry. The Injection resin shall have re-swelling capacity up to 2.5
times by volume in potable water. The injection resin shall contain accelerator to regulate the
setting times and shall not of expanding foaming type product or non-swelling formulation. The
injection resin shall be effective in saline water by exhibiting positive expansion.
Typical Material Properties:
Chemical base :Acryl ate polymer
Mixed Density :1.065 Kg/litre
Viscosity : < 40cps at 20oC
Application temperatures :+5oC to 40oC
Pot life :20 – 60 Minutes at 20oC
(See mixing Chart)
Setting time :1- 2 Hours

5 Bonding Agent for Repair: The structural grade bonding shall be a two Component, solvent less
epoxy resin based. It shall be formulated to meet the requirement of ASTM C881 Type 2, Grade
2, and Class B &C. The Bonding agent shall exhibit minimum open time of 6 Hours and shall
exceed the tensile strength. It shall be fully compatible with EMACO Range of repair mortars.

Typical Material Properties:

Aspect: Grey viscous dispersion
Mixed density 1.48 Kg/litre
Mixed Viscosity: 2450 + cps at 25oC
Mixing Ratio, by weight: 83(Base):17(Hardener)
Compressive Strength: 65 MP a at 7 Days
Tensile Strength: 25 MP a at 7 Days
Adhesive bond strength to
Concrete (ASTM D4541): >2.5 MPa
(Substrate failure)
Slant Shear bond Strength
(BS 6319, Part 4): > 11MPa
(Concrete failure)
Pot life: 2 Hours at 25oC
1 Hours at 40oC
Overlay time (Open time): 8 Hours at 25oC
6 Hours at 40oC
Setting time: 150 minutes at 25oC
Full cure 7 days
 6 Repair Mortar for Refurbishment: The dual shrinkage-compensated, cementitious patch repair
mortar shall be EMACO S48C T / Polymer modified mortar / equivalent, single component
mortar modified with fibres. The repair mortar shall exceed compressive strength of 35 MPa at 7
day and 45MPa at 28 days. The repair mortar shall not require polymer bonding agent as primer
and shall be thixotropic consistency, capable of applying 50mm thick in single layer.
Typical Material Properties:
Aspect :Grey powder
W/P ratio, by weight :0.16
Fresh wet density :2250 Kg/m3

Compressive strength, 15 MPa at 1 day

(ASTM C 109, 7cm cube) :25 MPa at 3 days
:35 MPa at 7 days
45 Pa at 28 days

1.5.1.3 Repair of RCC elements using Micro Concrete

Alternatively: The repair of RCC elements using Micro Concrete in place of Polymer Modified
Mortar is also recommended for making of concrete more than 25mm.
 FLOW CHART FOR REPAIRING OF RCC MEMBERS
JACKKETING OF RCC MEMBER USING MICROCONCRETE

Remove loose rust from reinforcement by

Light tapping or hammering

Apply RUSTICIDE by brush to the rusted

After 24 hours apply first coat of POLYALK FIXOPRIME and cement slurry in
the weight ratio 1:1.25 to the steel

After 4-6 hours apply second coat of POLYALK FIXOPRIME and cement slurry in
the weight ratio 1:1.25 to the steel

After 4-6 hours clean the surface and apply a bonding coat of SUNPOXY 368 by mixing Resin
and Hardener in the weight proportion of 1:0.5 and apply it by brush to the entire broken
concrete surface

Within 60 minutes of application of bonding Coat prepare and fix in position watertight shuttering
and pour micro-concrete-POLYCRETE-A. This has to be a wet on application

POLYCRETE-A is prepared by mixing 12.5% to 13% of water by weight of POLYCRETE and

mixing it thoroughly using a mechanical mixer.

Pour the POLYCRETE in the watertight shuttering up to desired heights.

De-shutter after 24 hours and start curing of the RCC member

 STRUCTURAL REPAIRS TO RCC MEMBERS

STRUCTURAL REPAIRS TO RCC MEMBERS

Break open the loose and damaged

concrete

Remove loose rust from reinforcing by light

tapping or hammering

Apply RUSTICIDE by brush to the rusted steel

After 24 hours apply first coat of POLYALK FIXOPRIME and cement

Slurry in the weight ratio 1:1.25 to the steel

After 4-6 hours moisten the surface and apply a Bonding Coat of POLYALK EP and cement
slurry in the weight ratio 1:0.5 to the entire broken concrete

Within 30 minutes of application of Bonding Coat prepare and apply by

hand POLYMER MODIFIED MORTAR using 1 Kg POLYALK EP, 5 Kg Cement,
15 Kg Graded Quartz Sand. Add little water (@ 1 litre) for Dough like
consistency. This has to be a wet on application in layers of 15mm.

If the broken concrete

Finish the surface with steel trowel
thickness is above 15 mm
after 24 hours

Air Cure the surface for 48 Hrs.

Sprinkle Water for 3-4 days.

Plaster surface as usual adding SUNPLEX (330 gms) pouch per 50 Kg bag of

Cement. Cure as usual.