Final Report Wo NDT

STRUCTURAL AUDIT REPORT
FOR
M/s RUBICON RESEARCH PVT LTD.

BHANDUP (W), MUMBAI
BY
G N SYSTECH CONSULTING ENGINEERS PVT. LTD

1, Basement, Arihant Tower, B Cabin, Near Lagu Bandhu Showroom
Naupada, THANE (W)-400 601
TEL: 25363015, 25364473, (M) 9920748772
E-MAIL: mail@gnsystech.com
ARCHITECT
R.V.Dalvi & Associates
346 / 348 Kaliandas Udyog Bhavan,
Near Century Bazar, Prabhadevi.
PREPARED BY REVIEWED BY APPROVED BY
-------------------------------- ------------------------------- ---------------------------------------

MUKESH KUMAR ASHISH P PAWAR N.J.SINGH
(Sr. Engineer) (Sr Engineer) Director (B.E M.Tech (Civil)
BMC L.No. STR/S/105
TMC L.No.1019
Pg 1 of 70
GN SYSTECH CONSULTING ENGINEERS PVT. LTD.
TABLE OF CONTENTS
SR NO. DESCRIPTION OF CONTENT PAGE NO
1. STRUCTURAL AUDIT / CIVIL SURVEY REPORT 2
• INTRODUCTION 3
• SUMMARY OF NDT 4
• OBSERVATIONS 8
• ANALYSIS & DESIGN SUMMARY 10
• RECOMMENDATIONS & METHODOLOGY 12
• GENERAL SPECIFICATIONS 17
2. PHOTOGRAPHS 18
3. GA DRAWINGS SHOWING STRENGTHENING MARKUPS 34
4. ANEXURE 39
• NDT REPORT
This document is property of GN SYSTECH CEPL, and shall not be copied or reproduced without written permission
Pg 2 of 70
1. STRUCTURAL AUDIT / CIVIL SURVEY REPORT
Pg 3 of 70
SURVEY REPORT FOR
STRUCTURAL REPAIR WORKS FOR M/s RUBICON RESEARCH PVT. LTD

BASED ON THE SURVEY DATED 17TH MAY, 2017.
1. GENERAL
The building structure in reference belongs to M/s RUBICON RESEARCH PVT.

LTD. The building in reference is a Ground + 2 upper storied RCC framed
Industrial building situated at Indira Nagar, Near Spectra Motors, Waghle Estate,
Thane (W). The building was constructed around 15 years back.
Visual inspection was done to asses the structural status of the building. The
building structure was not completely constructed and has remained unoccupied till
date. As this was not finished and remained unoccupied, many problems
(structural or otherwise) have cropped up over the years and they have remained
unattended too.
Following are the observation headers based on Visual Inspection
A. Cracks & Corrosion in RCC members (Column, beam & slab).
B. Incomplete & Deteriorated Plumbing.
C. Honeycombing in structural members and Lift shaft walls.
D. Leakage in external walls & Terrace
E. Brickwork done on Staircase Tread & Riser.
The above observations at various locations have to be attended to make the

structure usable.
A detail survey of the building is done and all the observations are recorded to
ascertain the type and extent of repairs and maintenance work to be taken up. The
repair works will make the structure stronger and better for use. Non Destructive
Testing is done recently with the same intention in mind and as guidance for
preparation of repair scheme (Refer Annexure for Detailed NDT report).
Pg 4 of 70
The site survey brings out the type of problems, locations and the extent of it and
thus the type of solutions and application method. The quantities of various items
and budgetary cost estimate are arrived at. The specifications of various items to
be done (materials and workmanship) are also decided. The observations are
recorded by the engineers keeping in mind the method and type of repairs to be
done (its feasibility and cost) subsequently. Generally the inference is drawn
based on the observations and the NDT report.
2. Summary of NDT Report (Refer Annexure for detailed report)
Types of test carried out
1. UPSV & Rebound Hammer test for Column, beam & Slab
2. Carbonation Test
3. Half cell Potentiometer Test
4. Concrete Core test
5. Rebar survey
Test conclusions as mentioned below.
a) The Average concrete core Test Results is M15 Grade i.e. compressive
strength of 15 N/mm2, however certain structural elements considered
for tests show strength even less.
b) The USPV & REBOUND HAMMER TEST results show poor and
medium quality of concrete for the structural elements considered in the
tests.
c) The Electromagnetic Detection test results show that the slab thickness
is approx. 120mm
The markup drawings showing the locations of NDT tests are shown
below.
Pg 5 of 70
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Pg 8 of 70
3. OBSERVATIONS
A. Cracks in RCC members
The columns at the ground and upper floors show signs of distress mainly
because of corrosion and poor concrete. The problem is acute at many
places and needs urgent attention. Cracks are observed on the column,
beam & slab at ground floor, First floor & Second floor. The columns & slab
concrete cover have fallen at all floor levels.
B. Incomplete & Deteriorated Plumbing.
The old C.I. Pipes, C.I. fittings, P.V.C. Pipes & P.V.C. fittings are seen
damaged & leaking at the joints in both the duct areas & external area. The
Pipes are installed touching the walls.
C. Honeycombing in Lift duct wall
Concrete segregation/honeycombing are visible in the Lift duct RCC wall

adjacent with external face of building.
Plaster cracks are observed on the external wall of the entire building. Moss
formation is observed at south side entire external wall, indicating that the
plaster is not sound. The plaster behind the plumbing pipes is severely
deteriorated. Separation cracks between brick work and R.C.C. members
are found externally at some places. The terrace has been waterproofed
with brick bat coba, finished with china chips. Leakage is seen in certain
portion of the terrace slab & minor cracks are observed at some locations
with hollow sound on china chips.
Pg 9 of 70
Brickwork (damaged) is visible on the staircase step instead of RCC.
F. Damaged Flooring
The flooring at all levels is severely damaged and need to be redone.
Pg 10 of 70
4. STRUCTURAL ANALYSIS AND DESIGN SUMMARY
1. INTORDUCTION:
• We have carried out Linear static analysis & design for the structure based
on the dimensions taken during the survey.
• Design is Based on Indian Standards
2. STRUCTURAL COMPONENTS
• Columns
• Beams
• Slabs
• Shear wall
3. Codes & Standards

• IS 456:2000 - Indian Standard code of Practice for Plain and Reinforced
concrete.
• IS 1893 - Indian Standard code of Practice for Earthquake resistance
design of structures.
4. Material Grade
• Concrete M15 Grade
• Reinforced steel: Fe-250(Mild steel)
• Concrete density 25kN/m³
5. Design Loads
a) Dead Load –
• Self weight of structural components
• 3.75Kn/m² (150mm Slab)
• SDL for floor finishes – 1.5kN/m²
• SLD – Waterproofing – 1.5kN/m²
b) Live Load – 5kN/m²

c) Wind Load
• Basic wind Speed – 39m/sec for Thane region
d) Seismic Load
• Zone III
• Soil Type – Medium
e) Load combinations as per IS:456 2000
Pg 11 of 70
OBSERVATIONS:
In the analysis & Design, it was noted that NDT tested columns will require
strengthening as the steel required in them is more than the steel present
(Steel present is taken from NDT Report for the respective columns).
Apart from these columns (tested in NDT); there are few other columns
which show the need for additional reinforcement based on Analysis and
design (Refer GA drawings for Jacketed column markup at all leves)
Struds Analysis & Design
NDT Report
requirement
Ast%
Main Ast %
Colum Concrete Based on Main Stirrup
SR. Column Steel & prov. Fym/
Floor‐ n size Fe 415 = Steel Steel Ast % Governing Load
Tested Stirrup (A) Fyt
Level (A*B) req. Combination
For NDT (B)
NO
(mm) Grade Grade Grade Grade
.
GROU 1.50 DL + 1.50
1 C39 Ø400 M15 Fe250 1.27 0.60 0.756 Fe415 Fe250 3.125
ND LL
GROU 300X7 0.90 DL + 1.50
2 C9 M15 Fe250 1.14 0.60 0.684 Fe415 Fe250 0.918
ND 00 WL Y‐
350X3 0.90 DL + 1.50
3 C37 1ST M15 Fe250 1.3 0.60 0.780 Fe415 Fe250 0.867
50 EQL X‐
1.50 DL + 1.50
4 C26 1ST Ø400 M15 Fe250 1.27 0.60 0.762 Fe415 Fe250 1.28
LL
1.50 DL + 1.50
5 C21 2ND Ø300 M15 Fe250 1.28 0.60 0.768 Fe415 Fe250 1.707
EQL Y+
300X5 1.20 DL + 1.20
6 C30 2ND M15 Fe250 1.06 0.60 0.636 Fe415 Fe250 1.395
00 LL + 1.20 EQL Y+
Conclusion:
As the Seismic Load combination is governing the design of structural

members, we recommend extending 4 reinforcement bars from column
jacketing into the slab/beam to improve the structural integrity at nodes to
resist seismic loads.
Pg 12 of 70
5. RECOMMENDATIONS
A. Structural Works:
The columns at the ground and upper floors show signs of severe distress
mainly because of corrosion and bad concrete. The problem is acute at
many places and needs urgent attention. It is desired that micro concrete is
used at these places in the form of jacketing and additional reinforcement be
provided at some locations Due to urgency to meet project deadlines we
recommend using micro concrete, also the cover required for micro concrete
is 60mm as compared to normal concrete which needs 100mm, hence we
can reduce the overall size for jacketing as well (see other advantages
below).
The structural works to be attended with polymer modified mortar as per the
method given herein at other places. If necessary, the severely damaged
beams may also be treated with super fluid micro concrete / jacketing
process. Slab surfaces are unfinished and it’s recommended to provide
plaster to them, however while hacking if more deteriorated areas are
observed polymer treatment is recommended.
The defects and deterioration of the structural members need to be rectified
using polymer treatment, Jacketing & Micro concrete.
Advantages of Micro concrete Over Normal concrete
• Quick setting – It dries quickly and the finished surface can be functional
within a day
• Pumpable – Can be pumped or poured into restricted locations
• Flowable – Flowable mortar hence does not require compaction
• Shrinkage compensation – Controlled expansion system which
compensates for shrinkage and settlement in the plastic state
• Strength – Develops high initial and ultimate compressive strength
• Moisture resistant – Offers excellent resistance to moisture ingress
• Durability – Makes repaired sections highly durable & compatible to parent
concrete
Pg 13 of 70
METHODOLOGY:
Preparation:-
• Propping of members wherever Jacketing is required. The propping to be in

all the floors and to all the surrounding beams & slabs.
• Cleaning of surface to remove plaster and any loose material, use blower /
vacuum pump.
• Adding of new reinforcement by welding / fixing by U - nails, if required.
• Applying antirust chemical to reinforcement.
• Nitobond EP Mix the two components and apply the bonding coat over
entire surface.
JACKETING WORKS TO COLUMNS:
• New reinforcement to be provided as per drawing / instructions.

• Concrete mix to be used - (1:1.5:1:5) (Cement: Sand: Metal – below 10 mm
size).
• Plasticizers - Fosroc (Conplast P2 11) 200 ml / bag of cement to be used.
Follow the instructions as given by the manufacturer.
• Water to be used should be @ 18-20 liters / bag of cement, so that the
concrete is homogeneous mix and flows into the form work.
• Shuttering to be water tight.
• Concrete poured and compacted properly.
• Concrete to be used within 20minute of adding of water.
POLYMER MODIFIED MORTAR WORK:
• Preparation of the surface as given above.

• Bond coat to be applied to the existing concrete and reinforcement just as
given above before application of mortar.
• Applying of polymer modified mortar in proportion CM 1: 2.5 and 1 lt of
polymer for every 5Kg of cement.
• The mixed mortar should form an elastic and stiff ball / roll which should not
break when tossed in hand.
Pg 14 of 70
• The mortar should be applied for about 20mm thickness at one time.
• Only sieved sand having silt content below 3% and zero salinity to be used
in works. Quartz sand to be used for mortar.
• Plastering of the area to match with existing plaster.
• The Sika SBR 100, Dr. Fixit Pidicrete URP, Fosroc ‘Nitobond SBR”,
Choksey “Mastercrete URP”can be used as polymer.
B. Incomplete & Deteriorated Plumbing
The rainwater down take pipes are in bad condition and need replacement /
rectification. The new pipe line (inlet & outlet) for toilet areas will be required
as per architect revised drawing. Also the pipes which are touching the walls
need to be fixed away from the walls (40-50mm) with suitable clamps and
seats.
METHODOLOGY:
• All damaged pipes to be removed.

• UPVC pipes (4 Kg/cm2) to be used for sewer down take pipes
• Proper connectors to be fixed for traps, outlets etc.
• Area of pipelines to be plastered in double coat with waterproofing
admixture. Connector holes to be properly filled with waterproofing material.
• Pipes to fix in true plumb and joints should be firmly secured. UPVC pipes
to be placed at least 50mm away from wall.
• Pipes should be properly clamped just below joints and in between the
length of pipes.
• Horizontal length of pipes along wall should be avoided as possible.
• Any cracks arising during clamping should be immediately treated.
• Area of pipelines to be plastered in double coat with waterproofing
admixture. Connector holes to be properly filled with waterproofing material.
• Pipes to fix in true plumb and joints should be firmly secured. UPVC pipes
to be placed at least 50mm away from wall.
Pg 15 of 70
C. Honeycombing in Lift duct wall
Honeycombing in Lift duct wall will be treated with Polymer based on the
structural works methodology as mentioned above.
External walls
The building to be treated with double coat sand plaster with first coat in CM
1:3 and second coat in CM 1:4. Only river sand / washed sand (Gujarat
sand) is recommended to be used for the work. The wall surface then can
be treated with two coats of elastomeric paint on one coat of primer. This
paint will ensure water tightness. A Guarantee of 6 - 10 years for water
proofing can be obtained for this paint from both the manufacturer and the
contractor to ensure proper material / workmanship.
TERRACE BRICK BAT WATERPROOFING:
• Waterproofing to be broken locally at affected areas and slab to be cleaned.

• Sealing of gaps with sealing materials.
• Applying polymer base coat with waterproofing admixture.
• Curing for two days.
• Applying brickbat waterproofing in C. M. 1:5 with waterproofing admixtures
laid to proper slope and joints less than 10mm and with khurras at downtake
locations.
• Water logging of minimum depth of 0.10 m for 3 days.
• Providing of proper watas and nosing on walls.
• Applying of topcoat of China Mosaic Tiles.
The existing brickwork done on staircase slab needs to be removed to

check the stair slab thickness.
Pg 16 of 70
F. Damaged Flooring
The floorings at all levels to be removed and properly redone based on the
clients requirement.
6. ADDITIONAL WORKS
a) FOOTING INSPECTION.
Excavation near Footings (2no’s as marked in Plan dwgs.) must be done for
inspection & recommendations will be given accordingly.
b) EXTERNAL PAINTING:
The entire external surface of the building need to be treated with Painting
will also increase the life of plaster by controlling the rate of increase of
cracks. New painting is essential every 2-3 years in case of cement-based
paints, 4-5 years in case of external acrylic paints to fill up minor cracks
and stop leakage through them. Alternatively elastomeric paint can also be
used. This type of paint has waterproofing and elastic properties and has a
life of 6-10 years (depending on thickness of paint) and comes with a
guarantee from the manufacturer and contractor to ensure proper material
/ workmanship.
c) INTERNAL PLASTER:
Internal Replastering is required. The building to be treated with 12mm

thk. Single coat plaster with in C: M 1:4. Only river sand / washed sand /
Gujrat sand is recommended to be used for the work.
d) INTERNAL PAINTING:
Suitable paint to be used after plastering is done to suit the requirement.
e) New Slab near Staircase ducts at 1st & second Floor Level:
New slab to be cast for proposed waiting/Reception area near staircase

based on the Architectural & RCC drawings.
Pg 17 of 70
f) New Brickwork for Internal walls & openings:
Light weight blocks to be used for internal additional walls & openings based
on the Architectural & RCC drawings.
GENERAL SPECIFICATIONS
1. All polymers to be checked for their correctness and manufacturers date

before applying polymers to be strictly applied as specified.
2. Additional Props to be provided as and when required for supporting the

RCC beams while doing jacketing.
3. Light weight blocks are recommended to be used for internal & external
walls.
4. Cement for structural repairs to be 43 grades OPC and of Ultratech, ACC or

Birla make. Cement for waterproofing to be 43 grade of same make.
5. Sieved sand to be used for structural repairs and plaster having silt content
below 3% and zero salinity. All sand to be washed.
6. Well burnt Brick bats to be used for water proofing
Pg 18 of 70
2. PHOTOGRAPHS
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3. GA DRAWINGS
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4. ANNEXURE -NDT REPORT

Final Report Wo NDT

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Final Report Wo NDT

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STRUCTURAL AUDIT REPORT

M/s RUBICON RESEARCH PVT LTD.

G N SYSTECH CONSULTING ENGINEERS PVT. LTD

PREPARED BY REVIEWED BY APPROVED BY

-------------------------------- ------------------------------- ---------------------------------------

GN SYSTECH CONSULTING ENGINEERS PVT. LTD.

SR NO. DESCRIPTION OF CONTENT PAGE NO

1. STRUCTURAL AUDIT / CIVIL SURVEY REPORT 2

• ANALYSIS & DESIGN SUMMARY 10

• RECOMMENDATIONS & METHODOLOGY 12

3. GA DRAWINGS SHOWING STRENGTHENING MARKUPS 34

GN SYSTECH CONSULTING ENGINEERS PVT. LTD.

1. STRUCTURAL AUDIT / CIVIL SURVEY REPORT

GN SYSTECH CONSULTING ENGINEERS PVT. LTD.

SURVEY REPORT FOR

STRUCTURAL REPAIR WORKS FOR M/s RUBICON RESEARCH PVT. LTD

The building structure in reference belongs to M/s RUBICON RESEARCH PVT.

Following are the observation headers based on Visual Inspection

A. Cracks & Corrosion in RCC members (Column, beam & slab).

B. Incomplete & Deteriorated Plumbing.

C. Honeycombing in structural members and Lift shaft walls.

D. Leakage in external walls & Terrace

E. Brickwork done on Staircase Tread & Riser.

The above observations at various locations have to be attended to make the

GN SYSTECH CONSULTING ENGINEERS PVT. LTD.

2. Summary of NDT Report (Refer Annexure for detailed report)

Types of test carried out

Test conclusions as mentioned below.

GN SYSTECH CONSULTING ENGINEERS PVT. LTD.

GN SYSTECH CONSULTING ENGINEERS PVT. LTD.

GN SYSTECH CONSULTING ENGINEERS PVT. LTD.

GN SYSTECH CONSULTING ENGINEERS PVT. LTD.

A. Cracks in RCC members

B. Incomplete & Deteriorated Plumbing.

C. Honeycombing in Lift duct wall

Concrete segregation/honeycombing are visible in the Lift duct RCC wall

D. Leakage in external walls & Terrace

GN SYSTECH CONSULTING ENGINEERS PVT. LTD.

E. Brickwork done on Staircase Tread & Riser.

Brickwork (damaged) is visible on the staircase step instead of RCC.

The flooring at all levels is severely damaged and need to be redone.

GN SYSTECH CONSULTING ENGINEERS PVT. LTD.

4. STRUCTURAL ANALYSIS AND DESIGN SUMMARY

3. Codes & Standards

b) Live Load – 5kN/m²

e) Load combinations as per IS:456 2000

GN SYSTECH CONSULTING ENGINEERS PVT. LTD.

As the Seismic Load combination is governing the design of structural

GN SYSTECH CONSULTING ENGINEERS PVT. LTD.

Advantages of Micro concrete Over Normal concrete

GN SYSTECH CONSULTING ENGINEERS PVT. LTD.

• Propping of members wherever Jacketing is required. The propping to be in

JACKETING WORKS TO COLUMNS:

• New reinforcement to be provided as per drawing / instructions.

POLYMER MODIFIED MORTAR WORK:

• Preparation of the surface as given above.

GN SYSTECH CONSULTING ENGINEERS PVT. LTD.

B. Incomplete & Deteriorated Plumbing

• All damaged pipes to be removed.

GN SYSTECH CONSULTING ENGINEERS PVT. LTD.

C. Honeycombing in Lift duct wall

D. Leakage in external walls & Terrace