1 Repair Methodology Along With Cost Analis-SEPL LOW COST

1 Introduction 11 1.1 Summary 11 1.2 Need for study 11 2 Identification and characterisation of defects 12 2.1 Leakage through reservoir roofs 12 2.2 Reasons for investigation 12 2.3 Reservoir roof construction groups 13 2.4 Drainage provisions 16 2.5 Defect categories, causes and effects 18 3 Investigation and testing methods 29 3.1 Review of the existing plans 30 3.2 Visual survey 30 3.3 Detailed investigation 31 4 Methods of repair and performance requirements 36 4.1 Method of repair 36 4.2 Material categories 51 4.3 Material performance requirements 71 4.4 Roof insulation 78 5 Defects which may rise as a result of repair activity and their avoidance 80 5.1 Problems arising through repair activity 80 5.2 Problems that occur with repair methods and materials 80 6 Waterproofing and repairing reservoir walls 87 6.1 Reservoir wall construction groups 87 6.2 Defect categories 87 7 Selection of method of repair - a consideration of durability, maintenance and cost 89 7.1 Durability of repairs and waterproofing 89 7.2 Maintenance 90 7.3 Cost 90 8 Contract documentation 96 8.1 Preprinted documentation 96 8.2 Contract procedures 96 9 Quality assurance 97 9.1 Introduction 97 9.2 During the investigation and condition assessment 97 9.3 During design of the repair 99 9.4 During materials selection and testing 100 9.5 During the repair 101 9.6 Quality assurance scheme for repair contractors 102 10 Feedback for future design 103 10.1 Drainage 103 10.2 Corrosion of structural metalwork 103 10.3 Concrete deterioration 103 10.4 Cracking (other than formed joints) 103 10.5 Corrosion of reinforcement 104 10.6 Joint failure 104 10.7 Breakdown of waterproofing membranes 104 10.8 Access, ventilation and ancillary openings 105

REPAIR METHODOLOGY No. 1 (RM-1)

Treatment of opened construction joints in walls – Non-leaking but showing efflorescence marks (It means it has leaked earlier.)

POLYMER MODIFIED CEMENT GROUT FOR INJECTION OF CONSTRUCTION JOINTS AFTER SURFACE SEALING– Cement admixed with Cebex 100 can be used for injection Grouting. The dosage of Cebex 100 is 225 gms per 50Kg of cement. The injection is carried out as per standard applications detailed below. Application instructions: Mixing

For best results a mechanically powered grout mixer must be used. For quantities upto 50kg, a slow speed drill fitted with a shear paddle is suitable. Large quantities will require a high volume drum mixer. It is essential that machine mixing capacity and labour availability is adequate to enable the grouting operation to be carried out continuously. This may require the use of a holding tank with provision for gentle agitation to maintain fluidity. The selected water content should be accurately measured into the mixer. Then add cement along with Cebex 100 shall be slowly added to mixing drum. Mixing shall be continued for 5 minutes, making sure that a smooth even consistency is obtained.ApplicationIt shall be ensured that areas to be grouted are clean, sound, and then pre-wetted. The unrestrained surface area of the grout must be kept to a minimum. The grout shall be placed within 20 minutes of mixing to gain the full benefit of the expansion process. Usual placing or pumping procedures shall be adopted ensuring a continuous operation.Dosage-50Kg Cement + 23-25Ltrs of Water+ 225gm Cebex 100 will Yield Approx 36ltrs of grouting Slurry

Steps for Pressure grouting The process consists of the following steps:

Drill holes in the concrete upto 70% depth of concrete section/thickness using Electric drill for fixing PVC nozzles at specific location with spacing of 500 mm C/C.

The depth of the nozzles shall be adequate to pump the grout to the intended locations in predetermined areas.

Packers/Nozzles shall be fixed in the holes drilled using fast setting mortar Renderoc plug. The mixed grout shall be injected through the prefixed nozzles under pressure using grout

pump to fill all possible pores and gaps left within the concrete mass. When the flow of grout stops, or when the grout flows out of the adjacent nozzle, mains shall be disconnected, the nozzle is locked and allowed to set for 24 hours.

Grouting operation is carried out through the next nozzle till the entire area is covered. The PVC nozzles shall be removed after completion of process and sealed off with Polymer

mortar Renderoc S2.UNIT TOTAL COST (RM) = Cement-1.4Kg @ 7.00 =9.80, Cebex 100-1/15 pouch @60.00 = 4.00, Renderoc Plug-500gm @ 60.00=30.00, Material Total = 43.80T & P Cost = 2 Nos @ 50.00 =100.00, Labour = 2Nos @ 50.00 =100.00Total Cost = 44+100+100 = Rs. 244.00(INR)


Treatment of leaking construction joints in Tanks walls.

The leaking construction joints shall be treated by cutting a V groove, followed by

Stage 1.-Injection grouting with Microfine cement admixed with CEBEX 100, plasticizing and expansive cementitious grout additive and Stage 2.- Injection grouting of PU Grout finishing with

FOSROC RENDEROC S2 Polymer, two component modified mortar, applied over FOSROC NITOBOND AR, Acrylic bonding agent and cured.

Stage 1-POLYMER MODIFIED MICRO FINE CEMENT GROUT FOR INJECTION OF LEAKING AREAS /CONSTRUCTION JOINTS AFTER SURFACE SEALING– Microfine cement along with Nitobond SBR (Latex) and Cebex 100 can be used for injection Grouting. The dosage of Nitobond SBR (Latex) is 3 Ltr and that of Cebex 100 is 225 gms per 50Kg of microfine cement. The injection is carried out as per standard applications detailed below. Application instructions: MixingFor best results a mechanically powered grout mixer must be used. For quantities upto 50kg, a slow speed drill fitted with a shear paddle is suitable. Large quantities will require a high volume drum mixer. It is essential that machine mixing capacity and labour availability is adequate to enable the grouting operation to be carried out continuously. This may require the use of a holding tank with provision for gentle agitation to maintain fluidity. The selected water content should be accurately measured into the mixer. Then add the specified quantity of Nitobond SBR Latex. The micro fine cement along with Cebex 100 shall be slowly added to mixing drum. Mixing shall be continued for 5 minutes, making sure that a smooth even consistency is obtained.ApplicationIt shall be ensured that areas to be grouted are clean, sound, and then pre-wetted. The unrestrained surface area of the grout must be kept to a minimum. The grout shall be placed within 20 minutes of mixing to gain the full benefit of the expansion process. Usual placing or pumping procedures shall be adopted ensuring a continuous operation.Dosage-50Kg OPC + 3Ltr of Nitobond SBR Latex + 20-22Ltrs of Water+ 225gm Cebex 100 will Yield Approx 36ltrs of grouting SlurrySteps for Pressure grouting of construction joints and honey combed concrete The process consists of the following steps:

Drill holes in the concrete upto 70% depth of concrete section/thickness using Electric drill for fixing PVC nozzles at specific location with spacing of 500 mm C/C.

The depth of the nozzles shall be adequate to pump the grout to the intended locations in predetermined areas. Packers/Nozzles shall be fixed in the holes drilled using fast setting mortar Renderoc plug. The mixed Polymer grout shall be injected through the prefixed nozzles under pressure using grout pump to fill

all possible pores and gaps left within the concrete mass. When the flow of grout stops, or when the grout flows out of the adjacent nozzle, mains shall be disconnected, the nozzle is locked and allowed to set for 24 hours.

Grouting operation is carried out through the next nozzle till the entire area is covered. The PVC nozzles shall be removed after completion of process and sealed off with Polymer mortar Renderoc S2.


Treatment of isolated leakages in water retaining unit due to construction defects.


Treatment of vertical/diagonal cracks in walls and radial cracks in bottom of OHSR.

Treatment of vertical /diagonal cracks in walls and bottom slab: These cracks shall be treated by cutting a V groove, injecting FOSROC CONBEXTRA EP 10M, structural epoxy resin grout through PVC nozzles and sealing with FOSROC RENDEROC S2, two component ,structural grade, polymer modified mortar, applied over FOSROC NITOBOND AR, Acrylic bonding agent and cured.

PRESSURE INJECTION WITH LOW VISCOSITY EPOXY GROUT OF CRACKS

The process consists of the following steps: Drill holes in the concrete upto 70% depth of concrete section/thickness using Electric drill

for fixing PVC nozzles at specific location with spacing of 500 mm C/C. The depth of the nozzles shall be adequate to pump the grout to the intended locations in

predetermined areas. Packers/Nozzles shall be fixed in the holes drilled using fast setting epoxy mortar Nitocote

VF. Mix the Base and Hardener of Conbextra EP 10(M) Low Viscosity Grouting Material just

before starting the pressure grouting process. The mixed resin shall be injected through the prefixed nozzles under pressure using grout

pump to fill all possible pores and gaps left within the concrete mass. When the flow of grout stops, or when the grout flows out of the adjacent nozzle, mains shall be disconnected, the nozzle is tied up and allowed to set for 24 hours.

Grouting operation is carried out through the next nozzle till the entire area is covered. The PVC nozzles shall be removed after completion of process and sealed off with Epoxy

mortar Nitocote VF.WORK SEQUENCE OF PU GROUT INJECTION: 1. IDENTIFICATION & MARKING OF CRACKS 2. CONSTRUCTION JOINTS/CRACK ROUTING 3. INSERTION PORTS 4. USING HIGH INJECTION PRESSURES EQUIPMENT

UNIT TOTAL COST –RM UNIT TOTAL COST = Each Location (Nos)

Renderoc S2-0.5kg @30.00 =15.00, Renderoc Plug-0.5kg @ 60.00=30.00, Low Viscosity Epoxy Resin- 0.6Ltr @ Rs. 600.00 =360.00Material Total = 405.00T & P Cost = 2 Nos @ 150.00 =300.00, Total =300.00 Labour = 2Nos @ 50.00 =100.00,Total =100.00Total Cost = 405+300+100 = Rs. 805.00(INR)


Treatment of corrosion, spalling & leakages in Ring Beam & walking platform at the bottom level of water containing units in OHSR’s.

mailto:[email protected]

Treatment of Corroded rebars and spalling of cover concrete:

i) The spalled and loosely bonded cover concrete shall be chipped out to expose the corroded rebars and sound substrate of the RCC member of the service reservoir to be restored.

ii) The fully corroded and distressed rebars shall be replaced with the new rebars of the same grade and dia.

iii) The exposed surface of the RC member shall be water jet to remove the lose particles and allowed to dry.

iv) The partially corroded and the new rebars shall be treated with FOSROC NITOZINC PRIMER, two component , zinc rich epoxy based , anticorrosive primer , brush applied to a dft of 45 microns after removal of the corrosion deposits and exposing the bright surface of the rebars.

v) Polymer modified Cement Silica sand Mortar, patch repair mortar for localised reinstatement over a polymeric bonding agent.

vi) Curing of the repaired surfaces by application of Polymeric Slurry Coat.

UNIT COST ANALYSIS-SQMMaterials-Thickness of Structural grade Mortar assumed = 60mmi) Nitozinc Primer-125gm@ 800.00 = 100.00ii) Reinforcement-2.00 @ 70.00=140.00iii) Polymer modified Cement Silica sand Mortar [email protected] = 1875.00iv)Acrylic Polymer-600ml @300.00 = 180.00 Total = 100+140+1875+180=2295.00T & PMachines like chipper, mixer etc = 200.00Temporary Supports and Staging = 200.00 Total = 400.00Labour = 1000.00Gross Total = 2295 + 400 + 1000 = 3695.00


Treatment of cracks because of distress in structures in columns & tie beams (staging of OHSR).

Further Analysis & Redesign of Elements is advised. Based on revised design only; the Cost analysis of repair can be taken up.


Treatment of staging columns & tie beams of OHSR because of cracks due to corrosion in columns &

tie beams

Treatment of Corroded rebars and spalling of cover concrete: Scope of Work:1. The spalled and loosely bonded cover concrete shall be chipped out to expose the corroded rebars and sound substrate of the RCC member of the service reservoir (existing columns & Beams) to be restored. 2. Cleaning the existing reinforcement bars with wire brushes and cleaning brushes. The fully corroded and distressed rebars shall be replaced with the new rebars of the same grade and dia. 3. The exposed surface of the RC member shall be water jet to remove the lose particles and allowed to dry.

4. The partially corroded and the new rebars shall be treated with FOSROC NITOZINC PRIMER, two component , zinc rich epoxy based , anticorrosive primer, brush applied to a dft of 45 microns after removal of the corrosion deposits and exposing the bright surface of the rebars. 5. Fixing 8 mm dia shear connectors with Lokfix (of Fosroc) with 250 mm c/c spacing both ways.6. Pre soaking the existing RCC with water and fixing cement slurry proof centering and shuttering.7. Preparation of site prepared M25 concrete with addition of superplasticisers and non shrink compound and mixing with slow speed mechanical mixer. 8. Pouring the micro concrete with shuttering for reinstatement of all the faces of the RC member micro-concrete in the columns. 9. Removal of centering / shuttering from the columns. 10. Curing by application of Nitobond AR Slurry Coat.UNIT COST ANALYSIS-SQMMaterials-Thickness of Micro concrete assumed = 100mmi) Nitozinc Primer-125gm@ 800.00 = 100.00ii) [email protected] = 65.00iii) Reinforcement-5.00 @ 70.00=350.00iv) Concrete =0.1cum@6000=600.00v) Curing Compound -200ml @100.00 = 20.00 Total = 100+65+350+600+20=1135.00T & PForm Work -1Sqm @ 350.00 = 350.00Machines like chipper, mixer etc = 200.00Temporary Supports and Staging = 200.00 Total = 750.00Labour = 600.00Gross Total = 1135 + 750+600 = 2485


Treatment of honeycomb areas in columns & tie beams (staging of OHSR).-Cement Grouting with polymer

The affected area shall be treated by sealing the surface and finishing with FOSROC RENDEROC S2 Polymer, two components modified mortar, applied over FOSROC NITOBOND AR, Acrylic bonding agent and cured. After the surface is sealed than drilling holes and fixing specially designed Nipple/Packer to facilitate Injection grouting with FOSROC CONBEXTRA EP 10M, structural epoxy resin grout through PVC nozzles.

PRESSURE INJECTION WITH LOW VISCOSITY EPOXY GROUT


The process consists of the following steps: Drill holes in the concrete upto 70% depth of concrete section/thickness using Electric drill

for fixing PVC nozzles at specific location. The depth of the nozzles shall be adequate to pump the grout to the intended locations in

predetermined areas. Packers/Nozzles shall be fixed in the holes drilled using fast setting epoxy mortar Nitocote

VF. Mix the Base and Hardener of Conbextra EP 10(M) Low Viscosity Grouting Material just

before starting the pressure grouting process. The mixed resin shall be injected through the prefixed nozzles under pressure using grout

pump to fill all possible pores and gaps left within the concrete mass. When the flow of grout stops, or when the grout flows out of the adjacent nozzle, mains shall be disconnected, the nozzle is tied up and allowed to set for 24 hours.

Grouting operation is carried out through the next nozzle till the entire area is covered. The PVC nozzles shall be removed after completion of process and sealed off with Epoxy

mortar Nitocote VF.WORK SEQUENCE OF PU GROUT INJECTION: 1. IDENTIFICATION & MARKING OF CRACKS 2. CONSTRUCTION JOINTS/CRACK ROUTING 3. INSERTION PORTS 4. USING HIGH INJECTION PRESSURES EQUIPMENT

UNIT TOTAL COST –SQM

2.5Ltr @ Rs. 150.00 = 375.00, Renderoc S2 -25Kg @30.00 =750.00 Renderoc Plug-3.0Kg @ 60.00=180.00, Total Material Cost = 3430.00T & P Cost = 5Nos @ 250.00 =1250.00, Labour = 5Nos @ 50.00 =250.00Total Cost =3430+1250+250 = Rs.4930.00 (INR)


REBUILDING OF DAMAGED STAIRCASE WAIST SLAB AND CONNECTION DETAILS WITH STAGING.

1. Dismantling. 2. Provision of Reinforcement Connection to Staging of Tank(Beams and Columns) by drilling

holes and REBARRING WITH LOKFIX3. Erection of suitable Form work4. Providing and placing in position Reinforcement as per design5. RECASTING with M25 grade Concrete6. Curing with Concure WB7. Providing Safety Railing


UNIT TOTAL COST –LUMPSUM-PER METRE OF HEIGHT OF TANK

Estimated Cost per metre of height of tank for all above specifications = Rs 25000.00Revised Break up along civil lines= Approx cost per M height=15000.00


Treatment of corrosion on inside face in domes of various water tanks

TECHNICAL SPECIFICATIONS FOR GUNITING(Dry Shotcrete)

Furnishing and placing of ‘ Pneumatically Placed Concrete of 50mm average thickness for strengthening of inside face of existing dome after removing the damaged concrete, treating existing reinforcement with Nitozinc primer and after placing welded wire mesh of size 100mm x 100mm x 3mm fixed into the structural members with the help of fasteners. The mortar for Guniting will comprise of Cement: Coarse Sand in the ratio of 1:3.5 admixed with Conplast X 421 IC

The process consists of following steps:1. Surface Preparation it includes removing all loose materials, laitance etc. to ensure proper adhesion.

2. FASTENING WELDED WIRE MESH: Putting in position welded wire mesh of size 3 mm x 100mm x 100 with the help of nails.

3. Preparation of the GUNITE MIX: Dry mixing all the ingredient of Gunite mix viz cement, sand aggregates thoroughly.

4. The grout mix is fed into at special mechanical feeder/ gun and then the mixture is forced into the delivery hose by a feed wheel/ distributor.

5. Carrying mixed material in suspension by compressed air through the delivery hose to a nozzle, introducing water mixed with admixture under pressure of nozzle.

6. Jetting Mortar from the nozzle at high velocity on to surface to guniting.7. Plastering of the gunite surface with Cement Mortar (1:4) to smoothen the surface.

UNIT COST =SQM (Full Area to be treated)Nitozinc Primer@ 100.00Reinforcement welded wire mesh (100 x 100 x3mm)-1.1Sqm @ 120 per Sqm=132.00Shear Connectors for welded wire mesh at Dome surface -4 Nos @ 150.00 =Rs. 600.00 Material Cost =832.00Shotcrete in one layers of 50mm each @ [email protected] for working platform@ 200.00Total T & P=1600.00Labour Dismantling& others = 150.00Total Cost =Rs. 2582.00 per sqm


Treatment of corrosion on outer face in domes of various water tanks exposed to nature.

TECHNICAL SPECIFICATIONS FOR GUNITING(Dry Shotcrete)

Furnishing and placing of ‘ Pneumatically Placed Concrete of 100mm average thickness in two layers of 50mm each for recasting of Dome on outer face of existing dome after placing and providing new reinforcement as per drawing. The

reinforcement will be connected to periphery wall section with the help of shear connectors of 12mm dia @ 150mm c/c. The mortar for Guniting will comprise of Cement: Coarse Sand in the ratio of 1:3.5 admixed with Conplast X 421 IC

The process consists of following steps:1. Providing MS pipes and coupler support system to the dome from inside the tank.2. Surface Preparation it includes removing all loose materials, laitance etc. to ensure proper adhesion. 3. Putting in position reinforcement and shear connectors as per drawing.4. Preparation of the GUNITE MIX: Dry mixing all the ingredient of Gunite mix viz cements, sand aggregates

thoroughly.5. The grout mix is fed into at special mechanical feeder/ gun and then the mixture is forced into the delivery hose

by a feed wheel/ distributor.6. Carrying mixed material in suspension by compressed air through the delivery hose to a nozzle, introducing

water mixed with admixture under pressure of nozzle. 7. Jetting Mortar from the nozzle at high velocity on to surface to guniting.8. Plastering of the gunite surface with Cement Mortar (1:4) to smoothen the surface.

UNIT COST =SQM(Full Area to be treated)Reinforcement = 20.00 Kg per Sqm @ 70=1400.00Shear Connectors at Dome-Wall junction 3 Nos@ 250.00 =Rs. 750.00 Material Cost =2150.00Shotcrete in two layers of 50mm each @ 2000=2000.00Labour-Steel Scaffolding Cost /Supporting system for DOME from Inside @ 500.00= 500.00Total Cost = 2150+ 2000+500 =Rs. 4650.00(INR) per sqm


Waterproofing of the Roof tops of Tanks:

The roof tops of the RC service reservoirs shall be waterproofed with FOSROC BRUSHBOND RFX, two component, elastomeric, acrylic polymer modified, cementitious waterproofing system and protected with a protective waterproof plaster(walls) / PCC screed(bottom slab), admixed with FOSROC CONPLAST X421IC, Integral waterproofing compound conforming to IS 2645 @ 125 ml per bag of cement and cured.

Specifications for Waterproofing Coatings -Inside the tanks

Step1.- Surface Preparation: Wire brushing of the whole surface and cleaning all dust by cleaning brush to make the surface must be free from oil, grease, wax, dirt or any other form of foreign matter.Step 2. - Application of Three Coat system of Acrylic polymer modified cementitious coating Brushbond RFX of FOSROC on the inner surface of the tanks as per manufacturer’s specifications.

i) Primer coat: Primer coat is done after diluting Brushbond RFX with extra amount of water as per the details below

Nitobond BBX : Water : Brushbond RFX Powder 4.8 Ltr. : 4.8 ltr. : 15 Kg.

ii)Two top coats of Brushbond RFX – Acrylic polymer modified cementitious coating on the primed surface as per manufacturers specifications.

Nitobond BBX : Water : Brushbond RFX Powder 4.8 Ltr. : 2.5Ltr. : 15 Kg. UNIT COST PER SQMBrushbond RFX-15Kg Powder & 4.8Ltr pack of Nitobond BBX –0.15 Pack @2800.00=420.00T & P = 40.00Labour = 80.00

UNIT COST= Rs. 540.00 per sqm

REPAIR METHODOLOGY No.13 (RM-13)

Waterproofing treatment on inside faces of Water Tanks including the supporting Columns & Beams.

The interior surfaces of the RC service reservoirs shall be waterproofed with FOSROC- BRUSHBOND two components, elastomeric, acrylic polymer modified, and cementitious waterproofing system.

Specifications for Waterproofing Coatings -Inside the tanks

Step1.- Preparing a Gola /Coving of size 150mm x 150mm with concrete, admixed with Conplast X 421 IC at the intersection of Base and walls.Step2. -Surface Preparation: Wire brushing of the whole surface and cleaning all dust by cleaning brush to make the surface must be free from oil, grease, wax, dirt or any other form of foreign matter.Step 3. - Application of Three Coat system of Acrylic polymer modified cementitious coating Brushbond of FOSROC on the inner surface of the tanks as per manufacturer’s specifications.

ii) Primer coat: Primer coat is done after diluting Brushbond with extra amount of water as per the details below

Nitobond BB : Water : Brushbond Powder 4 Ltr. : 12 ltr. : 23 Kg.

ii)Two top coats of Brushbond – Acrylic polymer modified cementitious coating on the primed surface as per manufacturers specifications.

Nitobond BB : Water : Brushbond Powder 4 Ltr. : 4 ltr. : 23 Kg. UNIT COST PER SQMMaterials: Concrete for Gola M 25 -0.01@ 3600.00= 36.00 Brushbond-23Kg Powder & 4Ltr pack of Nitobond BB –0.085Pack @2400.00=204.00 Total = 240.00T & P = 40.00Labour = 80.00 Total Cost= Rs. 360.00 per sqm


Step 1. Surface Preparation: Wire brushing of the whole surface and cleaning all dust by cleaning brush to make the surface must be free from oil, grease, wax, dirt or any other form of foreign matter.Step 2. Application of bonding coat of Nitobond SBR Latex on the cleaned & prepared surface. Step 3. Providing Waterproof plaster in desired thickness of 15-18mm of cement mortar of ratio 1:4 admixed with CONPLAST X421IC, Integral waterproofing compound conforming to IS 2645 @ 125 ml per bag of cement in desired thickness to attain line and level and cured with traditional method of water curing.

UNIT COST ANALYSIS-SQMMaterials-Thickness of Mortar assumed = 20-25mm i) Mortar M 10-0.030 cum @ 2600.00 = 78.00ii)Nitobond SBR Latex -200ml @250.00 = 50.00

iii) Conplast X 421 IC-0.02Ltr @ 100.00=2.00 Material Total = 130.00T & P=40.00Labour = 100.00Gross Total = 130 + 40 + 100 = 270.00


Providing Portable grade Epoxy Coating on all inside concrete surfaces.

The interior surfaces of the RC service reservoirs post repair and waterproofing, shall be protected by brush/roller application of 2 coats of FOSROC Nitocote EP 405- Solvent free epoxy resin coating for potable water tanks after application of acrylic putty to smoothen the surface.

WORKING METHODOLOGY FOR COATING OF WATER TANKS

TECHNICAL SPECIFICATIONS

Step-1. Surface Preparation

Step- 2. Providing and Application of Acrylic based Cement Primer on the cleaned surface.

Step -3 Providing and Application of Acrylic Putty Superfine Grade on the primed surface.

Step-4. Providing two coat system of Nitocote EP 405- Solvent free epoxy resin coating for potable water retaining structures to achieve DFT of 200 microns as per as manufacturers specification.

Unit Cost PER SQM

Acrylic Putty-2Kg @30.00 =60.00

Nitocote EP 405-0.3Ltr @ 750.00= 225.00

Materials Total = 285.00

T & P =50.00

Labour = 75.00

Total = 285 + 50+ 75= Rs. 410.00 per SQM

REPAIR METHODOLOGY No.16 (RM-16)

Protective coatings on the outer faces of structures coming in contact with atmosphere The exterior surfaces of the RC service reservoirs post repair shall be protected by brush application of 2 coats of FOSROC DEKGUARD WB 300, water based, aliphatic acrylate based, protective coating system, applied over one coat of FOSROC DEKGUARD WB, Acrylic Primer @ dft of 300 microns.

Dekguard WB 300

Section B : Application Method1.0 Preparation-Clean all contamination such as oil, grease, algae, laitance etc from the surface by

sanding and wire brushing.2.0 Priming

Use knapsack type spray equipment for applying Dekguard WB Primer and it will give a continuous and uniform surface appearance.

3.0 Application 3.1 Apply Dekguard WB 300 using a suitable brush or roller or airless spray equipment.3.2 The first coat of Dekguard WB 300 should be applied to all areas of the substrate to achieve uniform

coating, with a w.f.t of not less than 175 microns and not more than 225 microns.3.3 Allow the first coat to dry and then proceed with the application of the second coat. Also ensure by

means of visual inspection that the surface is free of pinholes or any such irregularities, which if present should be filled with Dekguard Filler.

3.4 The second coat of Dekguard WB 300 should be applied at 90° to the first ensuring that a final unbroken coating of the substrate is achieved.

Unit Cost PER SQMDekguard WB Primer - 0.15Ltr@200= 30.00Dekguard WB 300 - 0.4Ltr @350.00 = 140.00Materials Total=170.00T & P =40.00Labour = 70.00

UNIT COST @ Rs. 280.00 per SQM


Treatment of de bonded surfaces (initial stage of delamination).

POLYMER MODIFIED MICRO FINE CEMENT GROUT FOR INJECTION Microfine cement along with Nitobond SBR (Latex) and Cebex 100 can be used for injection Grouting. The dosage of Nitobond SBR (Latex) is 3 ltr and that of Cebex 100 is 225 gms per 50Kg of microfine cement. The injection is carried out as per standard applications detailed below. Application instructions: MixingFor best results a mechanically powered grout mixer must be used. For quantities upto 50kg, a slow speed drill fitted with a shear paddle is suitable. Large quantities will require a high volume drum mixer. It is essential that machine mixing

capacity and labour availability is adequate to enable the grouting operation to be carried out continuously. This may require the use of a holding tank with provision for gentle agitation to maintain fluidity. The selected water content should be accurately measured into the mixer. Then add the specified quantity of Nitobond SBR Latex. The micro fine cement along with Cebex 100 shall be slowly added to mixing drum. Mixing shall be continued for 5 minutes, making sure that a smooth even consistency is obtained.ApplicationIt shall be ensured that areas to be grouted are clean, sound, and then pre-wetted. The unrestrained surface area of the grout must be kept to a minimum. The grout shall be placed within 20 minutes of mixing to gain the full benefit of the expansion process. Usual placing or pumping procedures shall be adopted ensuring a continuous operation.Dosage-50Kg Microfine Cement + 3Ltr of Nitobond SBR Latex + 20-22Ltrs of Water+ 225gm Cebex 100 will Yield Approx 36ltrs of grouting Slurry

Steps for Pressure grouting The process consists of the following steps:

Drill holes in the concrete upto 70% depth of concrete section/thickness using Electric drill for fixing PVC nozzles at specific location.


Packers/Nozzles shall be fixed in the holes drilled using fast setting mortar Renderoc plug. The mixed Polymer grout shall be injected through the prefixed nozzles under pressure using

grout pump to fill all possible pores and gaps left within the concrete mass. When the flow of grout stops, or when the grout flows out of the adjacent nozzle, mains shall be disconnected, the nozzle is locked and allowed to set for 24 hours.


mortar Renderoc S2.UNIT TOTAL COST (SQM) =

Microfine Cement-3Kg @ 90.00 =270.00, Nitobond SBR Latex-0.2@250 = 50.00 Cebex 100-1/12 pouch @60.00 = 5.00, Renderoc S2-0.5Kg @30.00 =15.00Renderoc Plug-1.0Kg @ 60.00=60.00, Material Total = 400.00 T & P Cost = 3 Nos @ 150.00 =450.00, Labour = 3Nos @ 50.00 =150.00Total Cost = 400+450+150 = 1000.00(INR)

REPAIR METHODOLOGY No. 18 (RM-18)Treatment of bottom slabs & walls embedded below ground level for reported leakages.

Treatment of starter/kicker joints for leakage by injection grouting and preparation of gola/vatas followed by treatment of the interior surfaces of the RC service reservoirs with FOSROC- BRUSHBOND two component, elastomeric, acrylic polymer modified, cementitious waterproofing system.

Specifications


Step1. Steps for Pressure grouting The process consists of the following steps:

Drill holes in the concrete upto 70% depth of concrete section/thickness using Electric drill for fixing PVC nozzles at specific location at the rate 500mm c/c.


Packers/Nozzles shall be fixed in the holes drilled using fast setting mortar Renderoc plug. The mixed Polymer grout shall be injected through the prefixed nozzles under pressure using

grout pump to fill all possible pores and gaps left within the concrete mass. When the flow of grout stops, or when the grout flows out of the adjacent nozzle, mains shall be disconnected, the nozzle is locked and allowed to set for 24 hours.


mortar Renderoc S2.Step2- Making of Gola: Preparing a Gola/Coving of size 150mm x 150mm with concrete, admixed with Conplast X 421 IC at the intersection of Base and walls.Step3. -Surface Preparation: Wire brushing of the whole surface and cleaning all dust by cleaning brush to make the surface must be free from oil, grease, wax, dirt or any other form of foreign matter.Step 4. - Application of Three Coat system of Acrylic polymer modified cementitious coating Brushbond of FOSROC on the inner surface of the tanks as per manufacturer’s specifications.

i) Primer coat: Primer coat is done after diluting Brushbond with extra amount of water as per the details below


ii)Two top coats of Brushbond – Acrylic polymer modified cementitious coating on the primed surface as per manufacturers specifications.


UNIT TOTAL COST (SQM) =

Microfine Cement-1.5Kg @ 90.00 =135.00, Nitobond SBR Latex-0.2@250 = 50.00 Cebex 100-1/12 pouch @60.00 = 5.00, Renderoc S2-0.5Kg @30.00 =15.00Renderoc Plug-1.0Kg @ 60.00=60.00, Brush bond [email protected] = 204.00Concrete M 25-0.01 @ 3600.00 = 36.00Material Total = 505.00 T & P Cost = 2 Nos @ 150.00 =300.00, +40.00=340.00Labour = 2Nos @ 50.00 =100.00 + 80.00= 180.00Total Cost = 505+340+180 = 1025.00(INR)



REPAIR METHODOLOGY No. 19 (RM-19)Treatment of Crumbling/buckling of columns in OHSR because of earthquake shocks.

SECTION ENLARGEMENT as per redesign-Additional 100mm on each face with Additional reinforcement as per design and Placing Micro concrete as per earlier procedure.

Scope of Work:1. The loosely bonded cover concrete shall be chipped out to expose the corroded rebars and sound substrate of the RCC member of the service reservoir (existing columns & Beams) to be restored. 2. Cleaning the existing reinforcement bars with wire brushes and cleaning brushes. The fully corroded and distressed rebars shall be replaced with the new rebars of the same grade and dia.

3. The exposed surface of the RC member shall be water jet to remove the lose particles and allowed to dry. 4. The partially corroded and the new rebars shall be treated with FOSROC NITOZINC PRIMER, two component , zinc rich epoxy based , anticorrosive primer, brush applied to a dft of 45 microns after removal of the corrosion deposits and exposing the bright surface of the rebars. 5. Fixing 8 mm dia shear connectors with Lokfix (of Fosroc) with 250 mm c/c spacing both ways.6. Pre soaking the existing RCC with water and fixing cement slurry proof centering and shuttering.7. Preparation of micro-concrete from Renderoc RG (of Fosroc) admixed with 10 mm down aggregate and making mixing with slow speed mechanical mixer. 8. Pouring the RENDEROC RG, micro concrete with shuttering for reinstatement of all the faces of the RC member micro-concrete in the columns. 9. Removal of centering / shuttering from the columns. 10. Curing by application of Nitobond AR Slurry Coat.

UNIT COST ANALYSIS-SQMMaterials-Thickness of Micro concrete assumed = 100mmi)Nitozinc Primer-125gm@ 800.00 = 100.00ii) [email protected] = 65.00iii) Reinforcement-20.00 @ 70.00=1400.00iv) Renderoc [email protected] = 3000.00v) Nitobond AR-200ml @500.00 = 100.00 Total = 4665.00T & PForm Work -1Sqm @ 500.00 = 500.00Machines like chipper, mixer etc = 300.00Temporary Supports and Staging = 500.00 Total = 1300.00Labour = 1200.00Gross Total = 4665 + 1300 + 1200 = Rs. 7165.00



1 Repair Methodology Along With Cost Analis-SEPL LOW COST

Documents

Transcript of 1 Repair Methodology Along With Cost Analis-SEPL LOW COST