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Sr.

No

Particular

Volume 1
Concession Agreement ,Schedules and SPV
Details for DS Toll Road Limited

Volume 2
RFP, Response to Queries and Addendum for
DS Toll Road Limited

Volume 3
DPR for DS Toll Road Limited

National Highways Authority of India


Consultancy Services for Feasibility study and Detailed Project Report
for 46 Laning of Karur- Madurai section of NH-7 from Km 30518 to 42616
in the State of Tamil Nadu (Consuttancy Package CmllAlll)

CONTRACT PACKAGE NS 82 (TN)

VOLUME 11(A) :APPENDIX D


BRIDGE REPAIR AND REHABILITATION REPORT
January 2005

BCEQM

F i w w ~ ~ c o H 6 u T ~

4sD

bint venture With

aarvee assoc~ates
I

,.

,,

..

IFL E Z , " ' d Y E E ' H

G Rol

REHABILITATION OF EXISTING BRIDGES FROM


KARUR TO MADURAI IN BANGALORE- KANNIYAKUMARI
SECTION OF NH7 IN TAMILNADU
PACKAGE 3

NS 82 (km 381 km 426.6)

NH 7 (Karur - Madurai) Rehabilitation of Existing Bridges


Package NS 82 (TN) (km 381 - km 426.6)

REPAIR, REHABILITATION, RETROFITTING AND WIDENING OF


BRIDGES (NH7)
INTRODUCTION
The Ministry of Road Transport and Highways (MoRT&H), Govt. of India has decided
to take up the development of various National Highway Corridors where the traffic
intensity has increased significantly thereby necessitating capacity augmentation for safe
and efficient movement of traffic. One set of such corridors is North - South (From
Srinagar in J&K State to Kanyakumari in Tamil Nadu State) and East - West (Silchar in
Assarn to Porbander in Gujarat) for a total length of about 7300 Km. National Highways
Authority of India (NHAI) has been entrusted to implement the development projects for
these corridors. NHAI has accordingly taken up project preparation of certain stretches
on North - South, East - West corridors under Phase I1 of NHDP. NHAI issued RFP in
June 2003 for these stretches. The work of conducting Feasibility Studies and Preparation
of Detailed Project Report for Four / Six laning from Karur (Km 306) to Madhurai (Km.
427) in NH 7 has been entrusted to the Joint Venture of BCEOM - Aarvee Associates in
association with ORG.
The section has been divided into three packages as shown below:
Package 1 (NS - 80 ) from km 305.8 to krn 345
Package 2 (NS - 8 1 ) from km 345 to km 38 1
Package 3 (NS - 82 ) from km 38 1 to km 426.6
The existing 2-lane bridges are to be rehabilitated and widened to 3-lane, and a new 3-lane
bridge shall be constructed adjacent to the existing one. The following report pertains to the
rehabilitation and widening scheme that has been proposed for NS 82, the specifications for
the rehabilitation work and the schedule of work. The proposal can be summarized as follows:
1) Widening of existing 2-lane bridges to 3-lane.
2) Replacement of handrail with crash barrier, in the median side
3) Replacement of wearing coat.
4) Repair of the defects in the superstructures and the substructures

NH 7 (Karur - Madurai) Rehabilitation of Existing Bridges


Package NS 82 (TN) (km 381 - km 426.6)
WIDENING METHODOLOGY:

It is intended to convert certain existing 2-lane bridges to 3-lane, the deck


widths of which are not the same. However, after widening it shall be 12.7m with a
carriageway of llm. The new camber provided after widening shall be 1 in 60 unidirectionally. The profile of the deck slab after widening and application of the new wearing
coat shall be as shown in the figure. The thickness of the widened portion of the new slab will

be slightly more than the existing slab. The bottom of the new slab is to be kept flat as shown
in the figure. The new wearing coat is to be laid with a uni-directional camber of 1 in 60 with
the higher side towards the median side. Reference can be made to the detailed drawings for
better appraisal of the methodology.
REPLACEMENT OF HANDRAIL WITH CRASH BARRIER IN THE MEDIAN
SIDE:
A new crash barrier solid type will be provided on the central verge side. The base

width of the crash barrier will be 450 mm instead of the standard 500 mm (change the
spacing of bars with the internal dimensions).
Step 1: Remove the railings along with post upto kerb level. The kerb is roughly 275 x

450 mm.
Step 2: The existing kerb of size, say 300 x 450mm, which is about 275 to 300mm above

the old concrete structural slab, is to be dismantled without breaking or removing the
vertical rebars which go inside the steel slab.
Step 3: The new kerb will be of (275 + 200) x 450 size and should have reinforcement of

16 dia bars 4 numbers on either side. These bars are vertical. In addition, the
reinforcement of the crash barrier should be provided inside the available depth of 475
mm. If required the end of the reinforcements of the crash barrier can be suitably bent
inside this depth of 475mm.
Step 4: Before concreting the new kerb, a suitable bonding coat should be provided

between the top of old structural slab and the new concreting of the kerb.
On the outer side, a safety kerb of 750 H x 250 V (clear) is to be provided.

NH 7 (Karur - Madurai) Rehabilitation of Existing Bridges


Package NS 82 (TN) (km 38 1 - km 426.6)

RE-LAYING OF WEARING COAT:


The existing wearing coat of cement concrete is assumed to have been laid with a bidirectional camber of 1 in 75, the condition of which is likely to be bad because of the age, and
the wncrete wearing coat might have been overlaid with bituminous material. In view of the
bad condition of the wearing course, it is proposed to remove completely, the old wncrete
wearing coat, so that the old structural slab can be exposed. On removal of the old wearing
coat, the top of the old concrete structural slab shall be examined to determine whether a cover
plate was provided or not over the expansion joint. This steel plate over the expansionjoint is
to be replaced by means of 100 x 10 mm new cover plate. The new cover plate should have
diamond shaped BRC fabrics, welded on one side and the reverse side should have 10 mm dia
long 50mm long rods welded at the centre line.

REPAIR OF THE DEFECTS IN THE SUPERSTRUCTURES AND THE


SUBSTRUCTURES
The following defects have been detected in the existing bridges.
1) Cracking in superstructureand substructure,

2) Spalling of Concrete with/without exposure of reinforcement,


3) Leaching,
4) Honeycombing withiwithout exposure of reinforcement,
5) Loss of pointing,

6) Hollow sound in weblsoffit of girder.


7) Growth of vegetation.
The repair methodologies for the defects mentioned shall be as per MORTH specifications
and certain additional specifications brought for this project that have been given in the

'Specifications for Repair and Rehabilitation of Bridges' part of this document.

Existin handraillkerbto be removed (16)

Pro osed Crash barrier 500 wide

P
4

Proposed Safety kerb 750 wide

Existing handrail to be w a n t l e d with


reinforcements intact

(Refer to Detailed drawing)

12 thk MA
4
-

50 thk BC\

1 in 60

Profile corrective course (SDBC)


N concrete slab

11000 (Carriageway)

450
C,

12700 (Deck width)

TYPICAL CROSS-SECTIONAL PROFILE OF DECK SLAB AFTER WIDENING

MEDIAN SIDE

NH 7 (Karur - Madurai) Rehabilitation of Existing Bridges


Package NS 82 (TN) (krn 38 1 - krn 426.6)

m
n

,*
a

*
n

Pic.1 Spalling of Concrete with exposure of reinforcement due to inadequate provision


of cover

Pie2 Spalling of Concrete with exposure of reinforcement near drainage spouts due to
inadequate length of drainpipe
/

..' ..

n
m

:.- --

'
'\

4- 1

/'

.*

T #

..
-.'
C

NH 7 (Karur - Madurai) Rehabilitation of Existing Bridges


Package NS 82 (TN) (km38 1 - km 426.6)

Pic3 Spalling of Concrete in pier caps due to growth of vegetation

Pic.4 Handrails missing

NH 7 (Karur - Madurai) Rehabilitation of Existing Bridges


Package NS 82 (TN) (km 381 - km 426.6)
A

.IThe following table gives the details of existing bridges and the proposed rehabilitation

works to be carried out.


6

CC -Camber Correction: WDN - Widening: NA -No Action

As indicated above, certain bridges are getting eliminated and no action is taken owing to
different reasons, which are mentioned in the remarks column. Bridge no: 40511 is a
single span slab bridge with a carriageway of 1 lm. This bridge need not be widened and
only camber correction is to be done. It shall be a uni-directional camber as indicated in
the drawings. The repair works to the defects found shall be canied out as mentioned in
the specifications. The schedule of the work for each bridge is given in the following
table.

) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) Z ) ) ) ) ) l )
bh

N,%? (Karur Madural) Rehabllltatlon of Exlstlng Bridgesi$


Package NS 82(TN) km 381 - km426 6

Item
I

BRlDGENo:
38711
SPAN ARRANGEMENT 4 x 6.6
DESCRIPTION OF WORK
Dlsmantllng the ra~l~nglparapet
and kerb of the exlstlng br~dges
for prov~dlngnew crash barrler wthout causlng any structural
damage to other parts of the br~dgelncludlng all labour tool and
~ t sd~sposalas per drawlng and MORTH spec~ftcat~ons
2802 and
add~t~onal
spec~f~cat~on
2814

la

Central Verge s~de

lb

W~den~ng
s~de

Removal of exlstlng b~tumtnous wearlng coat and concrete


wearlng coat e~thermanually or w~thjack hammers lncludlng ~ t s
dlsposal wlthout causlng any detr~mentaleffect to any part of the
br~dgecomplete as per deta~lsglven and MORTH spec~f~catlo'l
2809
Careful cutt~nglremovalld~smantl~ng
of exlstlng constructton
mater~alIn order to achleve proper connection between the
exlstlng and new structure requlred for wdenlng the exlstlng
br~dgeand dlsposal of the dismantled materlal clearlng the area
as per add~t~onal
spec~flcat~on
2814

3a

RCC ~nd~rtwall pler cap, abutment cap

Prov~d~ng
pla~ncement concrete M I 5 grade as levelling course
(100mm thlck) below the new floor slab for wdened portlon of
fpundatlon slablfloor slab cncludlng center~ng shuttering as per
,MQRTH cpec~f~cat~on
1700
Pla~nCement Concrete M I 5 grade In Open Foundat~onas per
drawlng and MORTH spectflcattons 1500,1700,2100

'6,

Schedule of work

38Nl 1 3 8 W
2 x 5.7
3 x 5.1

39SH
2 x 7.2

40311
2 x 3.4

MI
1 x 10.6

*
*

t.

*
*

40511
1 x 6.0

40512
2 x 5.8

40611
4 x 8.7

40711
1 x 10.0

40N1
2 x 8.4

40812
2 x 8.4

*
*

*
*

41012
2 x 6.0

*
*

390H
2 x 6.5

*
*

N)4? (Karur Madurai) Rehabilitation of Existing Bridges'


Package NS 82(TN) km 381 - km426.6

N%J
zm No1
II
21
-

22

23
24

25

26

BRIDGE NO:^
SPAN ARRANGE MEN^

DESCRIPTION
- -- -. ... ..-. . OF
-. WORK
.. -. . ~ .

38711
4x6.6

1
1

II

II

[Plain Cement Concrete of M15 arade 100mm thick for levellinal


course below approach slab complete as per drawing and
MORTH specification 1700
Providing RCC M30 grade approach slab including formwork
and reinforcement complete as per drawing and MORTH
specification clauses 1500, 1700. 2700 and addditional
lspeclfication 2828
I
IHYSD bars in approach slabs confirming to MORTHI
specification I600
Providing and fixing in position "Buried" type of Expansion joints
to be installed under supervision of the approved manufacturer
complete as per drawing and MORTH specifications 2600 and
additional specification 2830
Providing profile corrective course of semidense bituminous
concrete in specified thickness and camber at the appropriate
points over the slab along the transverse direction of the bridge
deck after application of tack coat as per drawing and MORTH
specifications 503,508 and additional specification 2815
I
I
Bituminous wearing coat 62 mm thick consisting of 50 mm thic
bituminous concrete (BCIlaid in two lavers, overlaid by 12 m
thick mastic asphalt 'layer with a prime coat as per-^^^^^
specifications 515, 2700 and additional specification 2815

*
*
*

38811
2 x 5.7

1
I

.,

38911
3 x 5.1

II
I

1
1

*
*

*
I

390H
2x65

)
L'

I
1

II

II

(Karur Madurai) Rehabilitationof Existing Bridges'


Packaae NS 82(TN) km 381 - krn426.6
3991
2x72

Reinstating the existing handrail In the damaged portion as per

27

specifications 2816
28

29
30
..

32

Repairs to leached1 honey combed and spalled concrete surface


and exposed reinforcement complete as per drawing, MORTH
specifications 2804, additional specification 2818 and special
lons 1.1.4 and 1.1.5
I
IGunitina for repair of substructures as per specification 2821
and spiclal specification 1.1.6a)
Sealing of fine cracks (less than 0.5mm) by application of PMC
mortar after making grooves 10 x 20mm in size complete as per
MORTH specification 2803 additional specification 2819 and
l s ~ e c spec~f~cat~ons
~a~
1.1.1
I
SBollng of wde cracks (more than 0 5mm) wlth cement grout b
lnlectlon process through nipples complete as per MORT
&eclflcatlbns 2803 aditlonal spec~f~cat~ons
2819, 2823 and1
IRepalrs to volds In glrders as per speclficatlon 2822 and speclall

Schedule of work

*
I

*
I

*
I

*
*

*
I

*
I

*
I

*
I

*
I

'T

\p

I
A

l " 1 - 1 -

Schedule of work

Package NS 82(TN) km 381 - km426.6

Providing plain cement concrete M15 grade as levelling cours


f100mm
thick) below the new floor slab for widened oortion
,
foundat~onslablfloor slab including centering, shuttering as pe
MORTH spectfication 1700
IPlain Cement Concrete M I 5 grade in Open Foundation as per(
drawing and MORTH speclficatlons 1500, 1700,2100
/Pr&vldlng new substructure of plain cement concrete M20 grad!
i n oler abutment return walllwna wall ~otnedto old exlsttna sub

II labour, tools,scaffolding as per drawing an

N , s (Karur Madurai) Rehabilitation of Existing Bridges '

~~

)
LA

>

eat, and or straightening of bar, cutting of reinforcement and

Schedule of work

Nr?$ (Karur Madurai) Rehabilitation of Existing Bridges


Package NS 82(TN) krn 381 km426.6

)
b1

'I

concrete in specified thickness and camber at the appropriat


ck after application of tack coat as per drawing and MORT

ituminous concrete (BC) laid in two layers, overlaid by 12 rn

Schedule of work

NVL7 (Karur Madurai) Rehabilitation of Existing Bridges


Package NS 82(TN) km 381 - krn426.6

)
LI

SPECIFICATIONS FOR REPAIR AND


REHABILITATION OF BRIDGES

416 Laning of Kamr-Maduni Section of NH-7


Consultancy Services for Feasibility study and P~.cparationof DPR

Clause

SECTION 2800 - REPAIR OF STRUCTURES


2809

DISMANTLING OF CONCRETE W A R I N G COAT


Rename the clause as:
Dismantling of Existing Concrete/Bituminous Wearing Coat, Expansion
Joints

2809.1

Commencement of dismantling
Add as sub para (i) as below
(i)

The concrete wearing coat as well as the bituminous overlay shall be


removed from the existing bridges.

Renumber the sub para (i), (ii), (iii) as (ii), (iii) & (iv)
2809.2

This Clause shall read as follows:


The removal operations shall be carried out mechanically using pavement
breakers and compressors. Removal shall be done carefully to avoid damage to
any part of the existing structure. In delicate locations for example around spouts,
which will continue to serve as rain water spouts, removal shall be done by
manual methods. After removal, the concrete deck surface shall be closely
inspected for identifying any distress such as cracks, pockets of loose or
honeycombed concrete etc. The deck surface shall be thoroughly cleaned with
special efforts to remove any loose material. Expansion joints and spouts shall be
removed carefully so that deck concrete is not damaged.

2809.3

Precautions during dismantling work


Add the following at the end.
Dismantled material shall not be stacked on the deck nor shall it be thrown below
the bridge. It shall be neatly piled at points designated by the Engineer with all
lifts and lead upto 1000m. Materials, which can be used or auctioned, shall be
stored in neat piles at locations designated by the Engineer with all lifts and lead
upto 2000m.
Measurement for Payment
Add the following to the end of the Clause.
g) Dismantling of wearing coat shall be measured in cubic metre of volume of the
wearing coat dismantled.
Rate
Add the following to the end of the Clause.
The contract unit rate for dismantling the wearing coat shall include the
materials, labour, tools and plant, traffic management, signage, safety

-T e c h n ~ ~Spec~ficat~ons
al
Contract Package NS 82

Rchab~llbt~on.&W ~ d & ~ no'f


g Exlstlng %dgs

\A/
, ,.A' /

4/6 Laning of Karur-Madurai Sectionof NH-7


Consultancy Services for Feasibility study and Preparation of DPR

Clause
and other incidental expenses including removal of existing expansion joints for
the satisfactory completion of the work as per these specifications.

The following new clauses shall be added.


2814

DISMANTLING OF DAMAGED STRUCTURES AND/OR PART OF


EXISTING STRUCTURES
The work shall be executed in accordance with Standard Specifications section
200 clause 202. All damaged concrete brick worMstone work in coping wing
walls, returns, piers and abutment and caps shall be thoroughly inspected to
identify the extent of dismantling. The decision of the Engineer shall be final.
Care shall be taken to avoid damage to any part of the existing structure.
Dismantling work for part of deck slab railing and kerbs shall be done carefully
such that the existing reinforcement, which will project into the new work, is not
damaged or lost. Reinforcement shall be cleaned thoroughly.
Dismantled material shall not be stacked on the deck nor shall it be thrown below
the bridge. It shall be neatly piled at points designated by the Engineer with all
lifts and lead upto 1000m. Materials, which can be used or auctioned, shall be
stored in neat piles at locations designated by the Engineer with all lifts and lead
upto 2000m.
Water shall be sprayed to reduce the dust while the dismantling work is in
progress. Dismantling work shall not be carried out at night, during storms or
heavy rain.
Goggles and gas masks shall be worn at the time of dismantling. Leather gloves
shall be worn by the workers. Screens made of G.I. sheets shall be placed
wherever necessary to prevent the disintegrated pieces from flying.
Damage caused to any component of the bridge structure during removal
operations shall be restored by the Contractor at his cost. The service lines, if any,
shall be disconnected/diverted before dismantling work commences.

2814.1

Dismantling of existing railings, kerbs, footpath slabs, approach slabs and


damaged concrete in wing wallslreturns, piers and abutments
Railing, kerbs, concrete (P.C.C.) parapet erected in place of damaged railing,
footpath slabs, approach slabs and damaged concrete in wing walls/retums, piers
and abutments of the existing structures shall be dismantled as shown in drawing
or as directed by the Engineer.

2814.2

Dismantling of existing deck slab


The depth of cutting of the existing deck slab shall be as shown in the drawings.
Dismantling shall be done in accordance with Standard Specification section
200.

Technical Specifications
Contract Package NS 82

416 Laning of Ka~r-MaduraiSection of NH-7


Consultancy Services for Feasibility study and Prepamtion of DPR

Clause

2814.3

Dismantling of existing damaged stonelbrick masonry in pier, abutment,


wing wallslreturns, parapet, etc.
Damaged stonebricks masonry in pier, abutment, wing wallslreturns and all
stonebrick parapets shall be dismantled as shown in drawings or as directed by
the Engineer.

2814.4

Dismantling of existing wing wall for construction of adjacent one lane


bridge - a) StoneIBrick masonry, b) Concrete
Part of existing stonebrick masonrylconcrete wing wall shall be dismantled for
construction of adjacent 1 lane bridge as shown in drawings and Specification
clause 2814 above or as directed by the Engineer.

Measurement for Payment


The work of dismantling structures shall be paid for in units by taking
measurements before and after as applicable
linear metre
1)
Railing and kerb together
ii)
Footpath slab
square metre
ii)
Approach slab
cubic metre
iii)
Dismantling bricWstone masonry/
cubic metre
concrete (plain & reinforced)
Rate
The contract unit rate for the various items of dismantling shall be paid in fill for
canying out the required operations including full compensation for all labour,
materials, tools, equipment, safeguards and incidentals necessary to complete the
work. These will also include excavation and backfilling where necessaq to the
required compaction and for handling, salvaging, piling and disposing of the
dismantled materials within all lifts and up to a lead of lOOOm

PROVIDING NEW WEARING COAT WITH PROFILE CORRECTIVE


COURSE FOR NEW CROSS CAMBER 1/60
In order to have a cross slope of 1/60 in all existing bridges whether the crosssection is retained or widened, profile corrective course of Semi-Dense
Bituminous Concrete (SDBC) shall be laid over the structural deck slab after the
top has been exposed by removing the existing wearing coat (refer to clause
2809). The existing wearing coat will be basically of PCC with or without surface
reinforcement, but can also have top bituminous overlay, which had been
provided subsequently as a leveling course.
The profile corrective course of SDBC of variable thickness has to be laid over
the existing caniageway. For T girder bridges, which are not being widened, the
maximum thickness of profile corrective course will be at the existing Centre
Line. For slab bridges, which are being widened, the maximum thickness of
profile corrective course will be at the kerb toward the cent-ge
because of
.. . .
unidirectional camber.
.,'. .., - ..
.i.

Technical Specifications
Contnct Package NS 82

'4

416 Laning of Kamr-Madurai Section of NH-7


Consultancy Services for Feasibility study and Preparation of DPR

Clause
Slab bridges are being widened with slab extensions. The top of extended slab
will have a cross slope of 1/60 and no profile corrective course will be required
for the widenedlextended portion of the slab bridge.

A tack coat confuming to standard specification clause 503 shall be applied over
the exposed surface of deck slab before the application of SDBC. In addition,
tack coat has to be provided on new concrete surface of widened portion.
The SDBC shall follow standard specification clause 508.
Bituminous concrete confirming to standard specification clause 509 shall be laid
as component of wearing coat over the SDBC in the existing bridge portion and
directly over concrete on the new widened concrete slab. Tack coat has to be
provided on new concrete surface.
The Mastic Asphalt (MORTH specification clause no. 515) shall be overlaid as
the other component of wearing coat on the bituminous concrete.

Measurement for Payment


The profile corrective course (PCC) shall be measured in cubic metres, as running
continuously through. The tack coat shall not be measured. The work of wearing
coat shall be measured in square metres.

Rate
The contract unit rate for profile corrective course shall include the cost of tack
coat and shall also cover cost of all materials, labour, tools, plant and equipment
required for mixing, transporting and placing in position, vibrating and
compacting and finishing as per this section or as directed by the Engineer,
including all incidental expenses, sampling and testing, quality assurance and
supervision.
2816

REINSTATING THE EXISTING DAMAGED HANDRAILS, KERBS, etc


For repair of kerb, railhailing post etc., cement sand mortar (1 :3) shall be applied.
Missing reinforcement if any shall be compensated before application of mortar.
Damaged rails of the railing shall be replaced by rails of same size and
reinforcement as given in MORTH drawings. Both the above operations shall be
done as per relevant provisions of MORTH specification clause 27033 &
2703.4

Measurement for Payment


The measurement shall be done in linear metres of railings repaired.

Rate
The contract unit rate shall include the cost of all labour, materials, tools and
plant, scaffolding and all incidental expenses,
supervision as described in these specifications.

Technical Specifications
Contract Package NS 82

Rehabilitation &wjdi,q+"gqf;~x&ting Bridges

.._._.I

416 Laning of Kamr-Madurai Sectioli of NH-7


Consultancy Services for Feasibility study and Preparation of DPR

Clause
2817

PROVISION OF NEW DRAINAGE SPOUTS AND REPAIR OF


EXISTING DRAINAGE SPOUTS
a) Provision of new drainage spouts:
For all existing bridges that are being widened and changed to uni-directional
camber drainage spouts shall be provided as shown in the drawings.
The work of new drainage spout shall be executed in accordance with Standard
Specification Section 2700 Clause 2705

Measurement for payment


The measurement for provision of new drainage spouts shall be done in number
of drainage spouts provided.
Rate
The contract unit rate for each drainage spout shall include the cost of all labour,
material, tools and plant required for completing the work as per the
specifications. It shall also include the cost of closure of existing drainage spouts
and providing flow drainpipes with all fixtures up to the point of ground drains
wherever shown on the drawings.
b) Closure and sealing of existing drainage spouts:
The work shall be done after the wearing coat is removed. The grating shall be
dismantled and the existing spouts shall be removed carefully with minimum
damage to surrounding concrete.
The pocket formed shall be sufficiently large to ensure good flow and compaction
of concrete in the hole. The area around the spout covered by the grating shall be
provided with PMC slurry.
Before commencing application of PMC slurry brush topping, the prepared
concrete substrata shall be thoroughly soaked with clean water. Before priming it
should be ensured that any free surface water is removed. The material shall be
applied in accordance with manufacturer's recommendations. Suitable steel rods
shall be placed vertically in the drainage spout and then concreting shall be done
in the hole. And then the steel shall be embedded in the concrete poured over the
grating area.
The specifications for polymer modified cementitious topping & mortar shall be
as per of Special Specifications A-3 (1.7)

Measurement for payment


The closure of drainage spouts shall not be measured.
Rate
The rate for such closing shall be deemed to have been included in the cost of
..
new drainage spouts provided in the widened portion.
----<--; . ,

Technical Spscifications
Contract Package NS 82

416 Laning of Ka~r-MaduraiSection of NH-7


Consultancy Smices for Feasibility study and Prepantion of DPR

Clause
c) Extension of existing drainage spouts
For bridges that are not being widened, the existing drainage spouts are to be
retained with minor repairs. The work shall be carried out as shown in the
drawing. The concrete surrounding the spout in the soffit of the slab shall be
chipped out. An extension collar of specified size shall be attached to the existing
pipe as shown in the drawing. The chipped out area shall then be filled with 1:4
cement sand mortar over which a lOmm thick layer of PMC repair mortar shall
be applied.

Measurement for Payment


Drainage spout repair shall be measured in numbers.

Rate
The contract unit rate for each drainage spout shall include the cost of all labour,
material, tools and plant required for completing the work as per these
Specifications. It shall also include the cost of providing flow drainpipes in girder
bridges with all fixtures up to the point of ground drains wherever shown on the
drawings.

2818

REPAIR TO HONEYCOMBED, SPALLED CONCRETE


Honey combed, spalled concrete should be cleaned and cleared (plaster removed)
before the start of repair operation. If necessary, should be cleaned vigorously
with wire brush.
The work shall be executed in accordance with standard Specification Section
2800 and special Specification A-3 (1.4 & 1.5).

Measurement for Payment


Measurement for application of PMC mortar for specified thickness shall be per
square metre of surface area of application.

Rate
The contract unit rate for application of PMC mortar for specified thickness
including cement mortar 1:4 wherever required, shall include cost of all materials,
labour, tools and plant, placing in position, testing and other incidental expenses
including surface preparation for the satisfactory completion of the work as per
these specifications and as shown in the drawings.

2819

SEALING OF CRACKS IN CONCRETE


The work is to seal all cracks in slab, girders and substructures.
The work shall be executed in accordance with
2800 Clause 2803,2804 and Special

. ..
Technical Specifications
Contract Package NS 82

.,

416 Laning of Kamr-Madurai Section of NH-7


Consultancy Sewices for Feasibility study and Preparation of DPR

Clause
Measurement for Payment
Fine Crack: Measurement for sealing of fine crack by application of PMC
mortar for specified thickness along with application of PMC slurry for proper
bondage of old concrete and PMC mortar shall be linear metre of crack.
Wide crack: Measurement for sealing of cracks and injection shall be made by
weight of cement consumed in kg for cement grouting.
For provision of nipples required for grouting, the payment shall be for number of
nipples inserted.

Rate
Fine crack:The contract unit rate for application of PMC mortar for specified
thickness shall include cost of all materials, labour, tools and plant, placing in
position, testing and other incidental expenses including surface preparation for
the satisfactory completion of the work as per these specifications and as shown
in the drawings.
Wide crack: The contract unit rate for sealing of cracks and injection of cement
grout shall include cost of all materials, labour, tools and plant, placing in
position, testing, curing and other incidental expenses for the satisfactory
completion of the work as per these specifications.
Injection nipples are being paid separately.

VOIDS IN SOFFIT OF GIRDER


Portions of the soffits of the girder wherever voids are anticipated shall be
chipped off so that films forming external soffit surface are removed exposing the
reinforcement. Loose concrete sticking with the reinforcement shall be removed
thick
using appropriate tool and equipment. Polymer modified concrete 15shall be applied and after that cement plaster 1:4 shall be applied so as to have the
entire soffit in one straight line.
The work shall be executed in accordance with Special Specification A-3 (1.3)

Measurement for Payment


Measurements for reshaping of soffit of girder with PMC and Cement Plaster
(1 :4) shall be square metre of surface area of application.

Rate
The contract unit rate for application of PMC mortar for specified thickness shall
include cost of all materials, labour, tools and plant, placing in position, testing
and other incidental expenses including surface preparation for the satisfactory
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Contract Package NS 82

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Rehabilitation m n i n g of Existing Bridges

416 Laning of Karur-Madurai Section of NH-7


Consultancy Services for Feasibility study and Preparation of DPR

Clause
2821

SEALING OF WIDE CRACKS AT JUNCTION OF WING WALL AND


ABUTMENT WITH BRICK BATS AND FINISHING WITH 1:3 CEMENT
MORTAR
Wide cracks of different degreelextent due to separation of masonryPCC
substructure such as wing wall abutments etc. shall be sealed by cement grout
after filling the gap followed by the application of sealing material. The work
shall be executed in conformity with Standard Specification Section 2800
Clause 2806 and Special Specification A-3 (1.2). Gaps shall be sealed by filling
sized stones/brickbats and finishing with cement plaster (1:3).

Measurement for Payment


Measurements for sealing of cracks and injection shall be made by weight of
cement consumed in kg for cement grouting. For provision of nipples required for
grouting, the payment shall be for number of nipples inserted.

Rate
The contract unit rate for sealing of gap, cracks and injection of cement grout
shall include cost of all material including the gap filling material, labour, tools
and plant, placing in position, testing, curing and other incidental expenses for the
satisfactory completion of the work as per these specifications.

The work is to repair spalls or loss of cover in abutment, pier substructure and
gaps. This shall be executed in accordance with standard Specification Section
2807 and special Specification A-3 (1.6 (a) & @)) and 1.7

Measurement for Payment


Measurement for guniting shall be square metre of area of application.
Rate
The contract unit rate for guniting shall cover cost of all materials, labour, tools,
plant, placing in position, testing, curing and surface preparation and other
incidental expenses for the satisfactory completion of work as per specification. It
shall also include the cost of the provision of steel weld mesh as per specification.
2823

PROVIDING AND INSERTING NIPPLES FOR CEMENT INJECTIONS


The work shall include providing and inserting nipples with approved fming
compound after drilling holes, and after operation, cutting and removing nipples
and sealing the holes.

Measurement for Payment


Measurement for Payment for making provision of nipples reqGed for grouting
6 . .. ..
shall be for number of nipples inserted.
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Contract Package NS 82

Rehabilitation & Widening of Existing Bridges

416 Laning of Kamr-Madurai Section of NH-7


Consultancy Services for Feasibility study and Preparation of DPR

Clause
Rate
The rate will include cost of cement nipples, admixture fixing compound, all
material and labour in drilling fixing and cutting after the job and removal and
sealing the holes including the cost of drilling equipment, cost of drill, bits and
spares wastage etc.

CASTING OF APPROACH SLAB WITH M-30 GRADE CONCRETE


Approach slabs are to be provided for the new widened carriageway of bridges.
In addition, approach slabs, which are cracked or otherwise damaged, shall be
recast.
The work shall be executed in accordance with Standard Specification Section
2700 Clause 2704. The approach slab shall be laid over lean concrete as per
drawing. The base shall be consolidated by ramming with water.

Measurement for Payment


The measurement shall be in cubic metre.

Rate
The contract unit rate for approach slab shall include the cost of all labour,
material, tools and plant and other cost necessary for completion of the work as
per these Specifications. The rate for base shall include cost of all labour,
material, tools and plant required, including preparation of surface and
consolidation complete in all respects

EXPANDED METAL SHEET


Expanded metal sheet of size 75 mm x 200 mm, 3.25 mm wide and 3.15 rnrn
thick @ 2.141 kg1sq.m shall be provided over the steel plate placed at the
expansion joint and welded.

Measurement for Payment


This provision of expanded metal sheet shall not be measured and shall be
deemed to have been included in the cost of provision of expansion joints.
Rate
The contract unit rate shall include provision, placing in position of the sheet as
per drawing and specifications, and welding also.

Technical Specifications
Contract Package NS 82

Rehabilitation & Widening of Existing Bridges

416 Laning of Kamr-Madurai Section of NH-7


Consultancy Services for Feasibility study and Preparation of DPR

Clause

SPECIAL SPECIFICATIONS
A-3

REPAIR
PROCEDURE,
SPECIFICATION.

UPGRADATION

AND

MATERIAL

Various types of distress in concrete superstructure and substructure manifesting in


the formation of horizontal cracks, vertical cracks and spalling are generally
observed. The constructional inadequacy in the form of honeycombing and spalling
of soffit concrete near drainage spout outlet are also found.
Apart from these, the bridges are to be provided with uni-directional camber, crash
barriers in lieu of railing and new expansion joints specially when the slab bridges are
widened.
For various types of defects, the repair methodology, its procedure and the material
specification and the specification and procedure for providing new expansion joint,
crash barrier and wearing coat are outlined in the succeeding Para.
1.1

FINE CRACKS
There can be fme visible cracks in bridges. If the cracks are 0.5mm wide or less, these
cracks are to be repaired with PMC mortar. The location of the cracks can be seen
during repair and widening works. , In order to avoid increase in corrosion,
rectification of the cracks by cutting grooves in the concrete and sealing the grooves
with PMC repair mortar after cleaning and applying PMC slurry on the freshly cut
surfaces at all locations is recommended.
Procedure

The size of the groove, which should be cut along the whole length of visible cracks,
shall be 20 x 1Omm. Depth of the groove is lOmm while the width of the groove is
2 0 m n which however, should be symmetrically placed along the crack. In case
reinforcement is met within a depth of 6mm, the depth should be limited to the depth
of the reinforcement from the surface. It is preferable to cut the groove
perpendicularly to the surface but a deviation of 15 degrees in either direction may be
permitted.
After cutting the groove it shall be cleaned properly to ensure a dust free clean
surface and a coating of PMC sluny be applied over the freshly cut surfaces.
The PMC repair mortar shall be used to fill the 20 x lOmm groove while the sluny
coating is still wet, after a lapse of 30 minutes from the time of application of the
slurry, the PMC repair mortar shall be applied and compacted to ensure complete
filling of the groove.' The filling up of the groove shall be finished flush with the
existing concrete surface. After the finishing operation, the filled up groove should
be properly covered with impermeable sheet whose edges are to be sealed by taping.
Curing of the finished surface will be the same as that stated for curing of PMC
mortar (See C1.1.7). Care should be taken to cut the groove with sharp
instrument to avoid damage to the structure.
1 .

Techn~calSpec~ficat~ons
Contract Package NS 82

+'a"/

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~ e h a b d q ~&my & n g of'Ex~stlngBndges

10

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416 Laning of Karur-Madurai Sectionof NH-7


Consultancy Services for Feasibility study and Preparation of DPR

Clause

Material Specification
Specification of PMC material is provided at 1.1.7.

1.2

WIDE CRACKS
Wide cracks having width more than 0.5 m m have been found in some of the bridge
components. Moreover, these wide cracks are also found in MasonryPCC
substructure, such as wing walls, abutments and piers. While locating them and to
repair specially the wing walls, it is to be decided whether the old wing wall will be
functional after widening, if so they need to be repaired.
The basic repair methodology consists of injection of cement grout in the wide cracks
after most of the visible gaps have been sealed by applying sealing mortars. The
repair should be in conformation with clause 2806 of MORTH specification.
However, the general procedure is briefly described.

Procedure
The wide gaps should be chased so that grooves are formed which may be 10 x 5 mm
in size. AAer cleaning the surface with wire brush and compressed air, 15mm dia
nipples are to be fixed in 150 - 200mm deep holes with suitable sealing material.
The nipples should have maximum spacing 500 - 600mm. The chased groove also
should be filled up with suitable sealing material. Neat cement along with soluble
glass (Sodium Nitrate) forms excellent quick setting sealing compounds.
Grouting of cement slurry should be done by mechanical pumps. The details of
procedure should be in conformity with clause 2806 of MORTH specification except
for sub clause 2806.6.

Material Specification
- Material specification should be in accordance with clause 2806.1 of MORTH
specification.
1.3

REPAIR OF VOIDS IN GIRDER SOFFIT


In case of voids in the girder soffits are identified, the repair technique shall be as
follows. The repair shall be done by low permeability polymer modified cement
repair mortar. The thickness of the PMC repair mortar shall be limited to 15 mm. For
repairing voids more than 15 mm, the lowerlinner layer should be filled with cementsand mortar 1:4 prior to application of PMC repair mortar.
Portions of the soffits of the girders to be repaired are to be chipped off, so that the
film forming the external soffit surface are removed exposing the reinforcement. All
loose concrete sticking with the reinforcement shall be removed using appropriate
tools and equipment.
Depending on the depth of voids, cement sand mortar 1:4 is to be applied,
application of PMC mortar 15mm thick so that the soffit of the girder is
line i.e., the soffit should not have protrusion or depressions.
All concrete film in the soffit of girders and weak c
reinforcement will be removed by using appropriate tools anif-

Technical Specifications
Contmct Package NS 82

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Bridges

416 Laning of Kamr-Madurai Section of NH-7


Consultancy Services for Feasibility study and Preparation of DPR

Clause
reinforcement bars are exposed, the breaking shall continue so as to expose half the
diameter prior to further treatment.
Reinforcement Preparation

All exposed reinforcement shall be cleaned in accordance with the following:


a)

Where exposed reinforcement is sound and does not show any signs of heavy
corrosion or pitting other than typical rusting, it shall be mechanically
cleaned to remove rust and loose mill scale.

b)

Where exposed reinforcement shows signs of heavy corrosion deterioration,


it shall be cleaned by grit blasting or by proprietary rust removing compound.

Reinforcement Priming

Within one hour of preparing and cleaning, the reinforcement shall be coated with a
primer. The primer shall be PMC slurry using Tapecrete PI51 as polymer latex or
approved equivalent polymer latex.
The primer shall be brush applied on to the cleaned reinforcement ensuring that the
full surface area is in accordance with the manufacturer's recommendation.
Concrete Su$ace Primingfor Bond

Before commencing to apply PMC repair mortar or the inner cement sand mortar, the
prepared concrete substrata shall be thoroughly soaked with clean water. Free surface
water shall be removed before priming. The primer shall be PMC slurry using M/s
CICO Technologies Ltd.'s Tapecrete P151 polymer latex or approved equivalent.
The priming agent shall be well worked into the irregularities according to the
manufacturer's recommendations.
The repair material should be applied before the priming agent sets. The area coated
as one time must be restricted to allow for this provision and any area, which
becomes set shall be recoated as per manufacturer's instruction.
Cementitious Repair Mortar

The repair mortar shall be high build polymer modified cementitious repair mortar.
The PMC repair mortar shall be of appropriate general specification for use in vertical
and overhead application.
The total thickness of mortar shall be applied in one layer not exceeding lSmm
without sagging or slumping. The material shall be applied in accordance with the
manufacturer's recommendations.
The mixing shall be carried out using forces action mixes or with slow speed drive
mixer (400 - 500 rpm) fitted with a spiral paddle. In no circumstances shall water be
used in the PMC repair mortar mix. Re-mixing and re-tampering shall not be
permitted.
The material shall be applied by gloved hand or trowel to the prepared and
surface of the substructure and be well worked inside paying pakicular

.
Technical Specilications
Conttact Package NS 82

12
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416 Laning of Kamr-Madumi Section of NH-7


Consultancy Services for Feasibility study and Preparation of DPR

Clause
packing behind and between the reinforcement. In order to make up the total height
of the girder up to the original soffit level, the balance portion of the girder depth
shall be made up with 1:4 cement sand plaster. Refer to Para 1.7.1 for specifications
of PMC mortar i.e., special specification 1.7

1.4

SPALLING OR HONEYCOMBING IN DECK SLAB WITH LIGHT


EXPOSURE OF REINFORCEMENT
(Less than half the diameter of reinforcement visible or discolouration of soffit)
For some bridges, spalling and honeycombing have been observed specially near the
drainage waterspout. The basic repair for this defect is to provide a 5 to 8 mm thick
PMC repair mortar layer after removing the loose concrete, plaster etc. The peripheral
edge may be cut upto lOmm deep and the material removed to give a proper
demarcation line. If such spalling or honeycombing is observed in the cantilevered
portion of deck of girder bridges, a drip course covered with PMC repair mortar may
be provided to stop the back flow of rainwater.
Procedure
The honeycombed/spalled surface after removing plaster, if any, should be cleaned
vigorously with steel wire brush. PMC sluny coat should be provided on the
prepared surface after the surface has been pre-wetted with water. The surface should
be moist but without any free water. For further details refer to "Concrete surface
priming for Bond" and "Cementitious Repair Mortar" under Para 1.7 ante.
A drip course 10 x 12 mm size is to be formed at the outer edge of the soffit of the
cantilevered deck slab. PMC repair mortar 5mm thick shall be applied on the drip
course. Refer to Para 1.7 for details of specification of PMC materials.

1.5

SPALLING OR HONEYCOMBING IN DECK SLAB WITH HEAVY


EXPOSURE OF REINFORCEMENT
(More than half the diameter of reinforcement visible)
This type of distress has been observed in couple of bridges. The large spalling might
have been initiated due to honeycombing, a bad construction defect. In many cases,
inadequate length of drainage spout has been responsible for wetting the locality with
drained rainwater and in addition due to the growth of vegetation. This happens
particularly in pier caps.
The repair technique suggested is the application of Cement Sand mortar 1:4, before
the application of PMC mortar 15mm thick so that the soffit is in a straight line.
Procedure for Repair
All concrete film in the soffit and weak concrete sticking to the reinforcement shall be
removed by using appropriate tools and equipment. Where the reinforcement bars are
exposed, the breaking shall continue so as to expose half the diameter prior to further
treatment. PMC slurry shall be applied over the prepared surface. After application of
PMC slurry, the repair shall be canied out as per section 1.3

Techn~calSpeclficatlons
Contract Package NS 82

~ehab~hdl&
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13

g of Exlstlng Bndges

416 Laning of Kamr-Madumi Section of NH-7


Consultancy Services for Feasibility study and Preparation of DPR

Clause
PIER AND ABUTMENT SUBSTRUCTURE AFFECTED BY WEATHERING
1.6
AND LOSS OF POINTING/PLASTER
Generally, there are no cases where these defects have been identified. However,
during the construction period, if the defects are noticed, the following methodology
shall be used for repairing the same.

Case (a) Weathering


Basic Principles
Guniting or shotcreting of affected portion of masonry of abutment and pier is being
suggested in such cases. (Guniting and shotcreting are the two different names for the
same operation)
The purpose of guniting of the bridge is to increase its life from general weathering
and for counteracting weathering effects also. There are distinct weathering signs in
the old masonry/cement concrete substructure portion.
The guniting thickness for vertical faces of substructure should be at least 40mm and
should be strengthened by providing a steel weld mesh 50 x 50 x 10 gauge all along
vertical faces of substructure.
Procedure
The steel wire mesh has to be placed in position keeping the mesh within 10 - 15mm
from the surface, which will be curved for the cutwater portion. Suitable fixing pins
are to be inserted between the masonry mortar joint so that the mesh can be kept in
proper position. The inserts can even be spaced quite apart but ensuring that the weld
mesh is not disturbed during guniting, which is also termed as shotcreting.
Depending on the expertise of the guniting personnel, the thickness of 40mm may be
built in one layer but it must be ensured that no void is created behind the gunite built
up thickness. The presence of void can be found by hollow hammering sound after
the gunite has attained strength say after 3 days.
Material Specijkation
For details and specification of gunite refer to clause 1.8

Case (b) Loss of PointingIPlaster


For loss of pointinglplaster cement mortar 1:3 will be used on exposed surface after
removal of old plasterfpointing and preparation of surface thereof.

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Techn~calSpecrficat~ons
Contract Package NS 82

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~ehab111tatl;n&Wtdetungof Ex~stlngBndgs

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Consultancy Services for Feasibility study and Preparation of DPR

Clause
1.7
SPECIFICATION FOR MATERIALS AND MIX FORMULATIONS FOR
PMC MATERIAL SYSTEM
The acrylic polymer latex to be used for system shall be TAPECRETE P 151
manufactured by MIS CICO Technologies Ltd. Equivalent products of MIS FOSROC
and MIS SIKA are also acceptable.
1.7.1

Specification for Acrylic Polymer Latex


The polymer latex, which is to be used, should consist of water based acrylic and
copolymer dispersion and special purpose chemicals. (TAPECRETE P151 of M/s
FRC Composites (I) Pvt. Ltd. or any approved equivalent may be used for this
purpose). The polymer solid contents shall be 30 1 percent. The particles shall be
nearly spherical shape with a diameter of 0.35 0.05 micrometer. The manufacturer
shall certify to the above requirements about solid content and grain size. In order to
keep control over the quality, the manufacturer shall provide infrared absorption
spectrum analysis for the materials (polymer latex) to be supplied to them.

The integral waterproofing compound which is to be used for underlying layer of


cement sand mortar shall conform to IS: 2645 No. 1 manufactured by M/s Structural
Waterproofing Co. Pvt. Ltd. or approved equipment.
Portland Cement conforming to IS: 81 12 shall be used for production of polymer
modified cement repair mortar and polymer modified cementitious coating system,
which is to be used as a bonding medium with concrete substrate.
Tapecrete P151, an acrylic polymer latex shall be used as the polymer for modifying
and improving the properties of cement. The same product is to be used for various
purposes such as in a sluny form with cement to form a bondinglpriming medium and
with sand to firm PMC repair mortar. However, no additional water is to be added to
PMC slurry or PMC repair mortar as the water which is present in the latex is
sufficient for cement hydration and for this reason the latex cement ratio remains
constant for all applications.
The sand, which is to be used for constituting the PMC repair mortar, should be Silica
sand as the basic material, which is categorized in two groups:
a)
b)

Coarse Silica Sand


Fine Silica

The grading of the above groups should follow the limits provided below: IS Sieve No.
10 mm
4.75mm
2.361nm
1.18mm
600 micron
300 micron
150 micron
75 micron

Techn~calSpecificat~ons
Contract Package NS 82

Percentage
Coarse
100
95 - 100
90 - 100
40 - 60
0 - 10
0-4
0-3
3 max

Passing
Fine
100
100
100
100
90 - 100
40 - 60
0-10
0-3

15

by weight
Combined
100
98 - 100
80 - 100
70 - 80
45 - 55
0-5

-.
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Consultancy Services for Feasibility study and Preparation of DPR

Clause

In the event of using local sand, the sand to be used must satisfy the limits of
deleterious materials and the requirements of soundness as given in Clause. 3.2.1 and
3.6 of IS: 383 respectively. Confirmatoly tests shall be conducted by the contractor
and sample kept for comparison by the Public Works Department.
Cement - Sand Mortar
For repair of spallings, where the depth of spalling exceeds 15mm cement-sand
mortar 1:4 layer have been recommended after the application of PMC repair mortar,
15mm thick.
The composition of the cement sand mortar shall be as follows:

COMPOSITION
Cement
Sand
CICO No. 1 or equivalent
Water

PARTS BY WEIGHT
100
400
3
Variable

The amount of water will depend on the environment condition and is therefore
variable.

In case where two layers of cement-sand mortar are to be used, the second layer shall
be provided after a lapse of 24 hours from the time of application of the first layer.
Conventional practice or surface preparation for good bonding shall be adopted for all
layers.
Conventional curing of the cement sand mortar layer by application of water spray
should be followed for at least 2 days.

Component
Cement
Tapecrete P 151 or equivalent
Cement
Tapecrete P 151
Fine Silica Sand
Cement
Tapecrete P 15 1
Coarse Silica Sand
Fine Silica Sand
Cement
Tapecrete P15 1
Concrete Sand

Mix Formations
PMC SLURRY
Parts by Weight
100
50

PMC BRUSH TOP COATING


100
50
100
PMC REPAIR MORTAR
100
50
150
150
PMC FILLER
100
50
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Technical Specifications
Contract Package NS 82

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Rehabilitation & Widening of Existing Bridges

16

12,

416 Laning of Kamr-Madurai Section of NH-7


Consultancy Services for FeasibiliIy study and Preparation of DPR

Clause

Curing of PMC Work


This specification describes the curing procedures to be followed for various PMC
systems.
The curing procedures outlined apply to normal weather conditions. Take precautions
to avoid drymg. PMC work should be carried out a temperature below 35C.
Under unusual weather conditions e.g. high humidity and/or high wind velocity or
imposed constraints special curing procedures shall be followed. Approval, therefore,
shall be obtained from the Engineer-in-charge.
Air-drying shall be considered to take place only during unfavourable uninterrupted
weather conditions existing throughout the recommended drying period. Some
judgement shall be made in this respect and if conditions are deemed unfavourable
for drying to occur, then drying must be prolonged for the full-recommended period
after the weather clears.

Curing of PMC Repair Mortar and Filler


As PMC work proceeds, precautions shall be taken to prevent rapid drying of the
PMC repair mortar and PMC filler. This is usually accomplished by covering the
filled surfaces with an impermeable sheet shortly after the work has been done. The
edges of the impermeable sheet should be suitably taped.
The sheet shall be kept in place until further work is carried on over the filler or in the
case where the filler will be exposed to heavy abuse, the sheet shall be kept in place
for 24 hours.
No foot traffic or m h e r work shall be allowed over the filler until 12 hours from the
time of the completion of the work.
All the areas repaired using cementitious materials specified above shall be fully
cured in accordance with good practice for PMC application as given under general
specifications for PMC material systems.

No curing compound shall be used as a curing membrane. Care shall be taken to


ensure complete coverage particularly around the interface with the host concrete.
For the first day the repaired concrete patch shall be protected from harsh
environment by laying a polythene sheet over it taping down the edges.

Curing PMC Brush top Coatings and PMC Slurry


In unexposed and exposed areas the initial air-drying of 2 to 12 hours shall be
followed by moist curing for 24 hours by spraying or another approved curing
method. No curing compound is to be used.

Following moist curing, the coating shall be allowed to air dry for at least 3 days
to the application of finishing coat.
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Technical Specifications
Contract Package NS 82

RehabllltaUon & Wldemng of Existlng Bndges

17

33

416 Laning of Kamr-Madurai Section of NH-7


Consultancy Services for Feasibility study and Preparation of DPR

Clause
1.8

SPECIFICATION FOR GUNITING (SHOTCRETING)

The gunite is a mixture of cement, sand and water. It comprises 100 parts by weight
of cement, 300 parts by weight quartz sand, 35-50 parts by weight water and 2 parts
by weight approved quick setting compound. In general, dry mix shotcrete shall be
used.
Ordinary Portland cement conforming to IS: 269 shall be used for guniting.
Sand for guniting shall comply with the requirements stipulated in IS: 383. In general,
sand should neither be too coarse to increase the rebound nor too fine to increase the
slump. Sand should preferably have a moisture content between 3 and 6%.

The grading of sand shall lie within the limits given below:
IS Sieve Designation
4.75 mm
2.36mm
1.18mm
600 microns
300 microns
150 microns

% Passing the Sieve


95 - 100
65 - 90
45 - 75
30 - 50
10-22
2-8

For thick sections it may be advantageous to incorporate coarse aggregate in the mix
provided adequate guniting equipment is available. Coarse aggregate, when used
shall conform to grading given in Table 1 of IS 9012. The percentage of coarse
aggregate may normally be kept as 20 to 40% of the total aggregate and the mix shall
be suitably designed. Waterlcement ratio for guniting shall fall within the range 0.35
to 0.50 by mass, wet enough to reduce the rebound. Drying shrinkage may be
between 0.06% and 0.1%. The quick setting compound shall be added at the nozzle
with water just before guniting.
The cement and sand shall be batched and mixed and conveyed through a hosepipe
with the help of compressed air. A separate line shall bring the water under pressure.
The cement, sand water mix shall be passed through and intimately mixed in a special
manifold and then projected at high velocity to the surface being repaired. The
density of gunite shall not be less than 2000 kglcum. The strength of gunite shall not
be less than 25 Mpa. For effective guniting the nozzle shall be kept 60 to 150 cm
away from the surface, preferably normal to that surface. While enclosing
reinforcement bars during repairs the nozzle shall be held closer at a slight angle and
the mix shall be wetter than the normal.
Test panels simulating actual field conditions shall be fabricated for conducting preconstruction testing. The procedure for testing the cubes or cylinders taken from the
panels stipulated in clause 6 of IS: 9012 shall be followed. It should be ensured from
tests that a strength of about 30 MPa at 28 days is available for the mortar/concrete
mix.
The defective concrete shall be cut out to the full depth till sound concrete
reached. Under no circumstances should the thickness of concrete to be
less than clear cover to the main reinforcement. No square shoulders
the perimeter of the cut-off portion and all edges shall be tapered. Thereafter,
loose and foreign matenals should be removed and the surface be
.

Technical Specifications
Contract Package NS 82

Rehabilitation &

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416 Laning of Kamr-Madurai Section of NH-7


Consultancy Services for Feasibility study and Preparation of DPR

Clause
make it rough to receive shotcrete after applying a coat of bonding epoxy as per
recommendation of the manufacturer @ 1.0 kg per 1.5 sqm of surface area.
The exposed reinforcement shall be thoroughly cleaned free of rust etc. by wire
brushing. Wherever the reinforcements have been corroded the same shall be
removed ad replaced by additional reinforcement. Before application of gunite a
coat of neat cement slurry should be applied on the surface of the reinforcement.
Sufficient clearance shall be provided around the reinforcement to permit encasement
with sound gunite. Care shall be taken to avoid sand pockets behind the
reinforcements.

A thickness of 25 to 40mm of gunite can normally be deposited in one operation. It


would always be necessary to apply guniting on a damp concrete surface.
Where required, welded wire fabrics 5 an x 5 cm x No. 10 gauge shall be provided in
the first layer of guniting. The fabric shall be tied properly. In case the damage to the
concrete member is too deep, the specifications for guniting as well as requirement of
placement of wire mesh has to be decided as per field conditions.
The stipulations given in IS: 9012 regarding applications of gunite should be followed
so as to keep the rebound to the minimum. The quality of guniting and workmanship
shall be such that the percentage of rebound mentioned in IS: 9012 can be adhered to.
In no circumstances shall the rebound material be reused in the work. It would be
desirable that green gunite is moistened as curing requirement for at least 7 days.
Guniting work shall not be done during windy or rainy conditions.

Contract Package NS 82

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