7203 - Pyrotek - Without OLD PDF

Project No.
7203 Year: 2019-2020
Structural Audit
Report for
‘GRDR and Promag Shed’
Project At
Pyrotek India Pvt. Ltd.
Add: Gate no. 1228 & 1229, Pune-Nagar Road, Sanaswadi, Pune, Maharashtra-412 208
Structural Consultant
Salt Design & Infra Services Pvt . Ltd .
Address : 508, Nyati Emporius, Mumbai – Bangalore Highway, Near the

Orchid Hotel, Baner, Pune, Maharashtra – 411045
Contact No. : +91-9850-005-294 +91-9011-330-588
Email & Web : support@saltinfra.com or log on to: www.saltinfra.com

Structural Audit Report for: Promag and GRDR Shed
Sr.No Content Page No
1 Project Introduction 1
2 Methodology 1-3
3 Visual Inspection 4-8
4 Typical Photo log of observation 9-11
5 Condition Survey 12-19
6 Onsite Activity 20-23
7 Structural Analysis 24-35
8 Non-Destructive Testing 36-40
9 Conclusions 41 -43
10 Recommendations 44-45
11 Priority Actions 46
12 Annexure I
13 Annexure II
Salt Design & Infra Services Pvt. Ltd.

| support@saltinfra.com | Baner Pune-411045 | www.saltinfra.com |
1. Project Introduction
The Project is for Pyrotek India Pvt. Ltd., Pune-Nagar Road, Sanaswadi, Pune, Maharashtra-412 208. The
scope of the project is to carry out Structural Audit of the GRDR and Promag shed. The previous
structural audit of this shed was carried out in March 2017. The previous report is also attached in
Annexure I. So, this report comprises the new findings in Visual Inspection, onsite verification of various
inputs, Non-Destructive testing results, STAADPRO analysis if any change of thickness (after conducting
NDT thickness), conclusions and recommendations based on these findings. The details of the Project are
mentioned in the Table 1
Table 1 Project Information

1 Building Name GRDR and Promag Shed
2 Type of Structure RCC + Steel

3 Type of Building Industrial (2008)
4 Eaves Height 6.100m
5 Date of Inspection October 14, 2019, December 12,2019 and Dec 13, 2019
2. Methodology
This section briefs the inspection procedure adopted and guides the reader to understand the report. The
Detail stages involved under audit report are as follows:
- Visual Inspection
- Onsite work, conducting NDT and Data Collection
- STAADPRO Analysis to find out the Utility ratio.
- Results of NDT’s
- Conclusion.
- Recommendations.
2.1. Visual Inspection
Visual inspection is the first step of understanding the condition of the structure. The purpose of the visual
inspection is to determine if there are observable issues in the considered structure. It is also conducted as
needed before performing a detailed inspection of the structure. Primarily qualitative data is obtained
through this type of survey; it would be most effective if this data could be reflected in performance
evaluations of the structure.

| support@saltinfra.com | Baner Pune-411045 | www.saltinfra.com | Page 1 of 105
Type of Survey Survey Item

Cracking status Cracking location / width
Survey of external Defects Concrete peeling, etc.
appearance Displacement / deformation Overloading if any
Rust fluid, free lime, discoloration, leakage of water
2.1.1 Scope of Visual Inspection
The inspection report should reveal the following listings:

 Any settlements in the foundations.
 Settlement of walls and floors.
 Concrete disintegration and exposed steel reinforcements.
 Extent of corrosion in reinforcement and Structural steel members.
 Overloading of members due to cable trays, pipelines, etc.
 Observable connection issues.
 Any observable deflection in the steel members of the truss or girts or any other steel members.
 Leakages & dampness in walls resulting into cracks and corrosion.
Visual inspection Survey was carried out by our Engineers, to observe Distress/ Damage/ Cracks/
Settlements/ Corrosion / Carbonation/ Leakage at site.
2.2 Drawing Verification
Structural General arrangement drawings of the Promag and the GRDR Shed that were prepared during
the previous structural audit by taking on-site measurements of the shed were checked to see if there
are any changes made or if the strengthening strategy suggested during the previous audit was done or
not.
These records were kept for Internal use purpose (i.e. to keep a record of locations at which the tests
are carried out and to have a general information of the structure). The member properties, dimensions
and the connections of the structural members is checked thoroughly.
2.4 STAADPRO Analysis
The STAAD model is prepared and studied and the following checks are performed
1. Modelling verification.
2. Geometry verification
3. Member verification
4. Loads on the members
5. Utility ratio check.

2.5 Non-Destructive Testing
Non-Destructive Testing is performed on Structural steel members and RCC structures at locations were the
testing was carried out during the previous structural audit and also at new other select locations to
determine the Structural steel and concrete quality of the shed. The details of types of tests carried and test
results of ND testing done are given in section 8 of this report.

‘ViSUAl INSPection’

3. Visual Inspection
Following Table summarize the structure information in consideration for carrying out detailed visual
inspection
1 Building Name GRDR and PROMAG shed
2 Type of Structure RCC + Steel

3 Type of Building Industrial (2008)
4 Eaves Height 6.100m
4 Date of Inspection October 14, 2019, December 12,2019 and Dec 13, 2019
3.1. Visual Inspection Survey
Visual inspection survey was carried out by our Engineers, to observe Distress/ Damage/ Cracks/
Settlements/ Corrosion / Carbonation/ Concrete Defects / Leakage at site.
Foundation:
The Visual inspection for the foundation settlement is performed without excavation. The general criteria
are if there are any cracks in non-structural components at openings, any deflection observed then we can
conclude for uneven settlement of foundations. The tolerance for RCC Structures is up to 25 - 40 mm of
deflection in footings but for load bearing walls no such uneven deflection is acceptable.
Sr. Major /
Elements / Defects Observations Remark Photo
No. Minor
Settlements of column Not
1 - - -
Footings Observed
Not
2 Settlements of wall Footings - - -
Observed
RCC damaged on External faces:
Sr. Major/
Item Description Observations Remarks Photo
No. Minor
1 Columns/Pedestals NO - - -
2 Lintel Beams NO - - -

Defects in Brick Masonry Wall:
Sr. Major/
Item Description Observation Remarks Photo
No Minor
1 Wall mortar joints Loose/ Brittle No - - -
2 Brick work quality NV - - -
3 Large cracks seen on surfaces No - - -
RCC damaged on Internal faces:
Sr. Major/
Item Description Observations Remarks Photo
No. Minor
The Pattern of crack indicates

1 Columns Yes Minor the crack to be due to corrosion. 1
Column No. C5
Cracks were observed in the
Major 4
Column C3
Defects in Rafter members
Sr. Major/
No Minor
There is corrosion observed on
1 Signs of Corrosion YES Major 2
all members after removing tape
Observable Deflection in
2 NO - - -
members
3 Any missing members NO - - -
1. There are many members

above the accessible
locations where taping has
4 Extra Observations YES Major not been done 5 ,7
2. Disjointed members
(member not connected to
column)

Defects in Steel Columns
Sr. Major/
No Minor
There is corrosion observed
1 Signs of Corrosion YES Minor in the short steel columns in 3
promag shed
2 NO - - -
members
Defects in Bracing Members
Sr. Major/
No Minor
Corrosion observed even
1 Signs of Corrosion YES Major -
under the tape
2 NO - - -
members
4 Extra Observation NO
Defects in Other Steel Members (Girts)
Sr. Major/
No Minor
1 Signs of Corrosion YES Minor - -
2 YES Minor - 6
members

Water Seepages:
Sr. Major/
No. Minor
1 Wall surfaces NO - -. -
2 RCC surfaces NO - - -
3 Roof NO - - -

‘TYPIcAL PHOto
LoG Of
OBSERVation’

4. Typical Photo Log of Observation
Photo No. 1 Photo No. 2

| support@saltinfra.com | Baner Pune-411045 | www.saltinfra.com | Page 10 of
105

| support@saltinfra.com | Baner Pune-411045 | www.saltinfra.com | Page 11 of
105
‘ConDition SuRVEY’
Page 12 of 105
5. Condition Survey
5.1 PROMAG SHED (Observations During Last Audit and Current Scenario)
Location:-ISMC Girt below Promag shed truss Location: -Gutter over Lattice Girder Location: -Baseplate for Lattice Girder at
no 6 as per drawing Gable ends of Promag shed
Observation: - Such non tapped members Observation: - The gutter has been Observation: - The baseplate is corroded.
have been drastically affected by the severely corroded and is of no use.
Chlorine/Florine gases. Thickness reduction is
such that our engineer was easily able to punch
the ISMC with screw driver.
Remedy: - Replace / Remove such extra Remedy: - Replace entire gutter. Remedy: - Clean the baseplate from rust
corroded members. For other members and paint with anticorrosive paint.
clean and paint them.
NEW: The same has not been rectified yet. NEW: The same has not been rectified yet. NEW: The same has not been rectified
The gutter is still more corroded yet.
*RED COLOUR INDICATES RECENT AUDIT COMMENTS ON THE OBSERVATIONS OBSERVED DURING PREVIOUS AUDIT
Page 13 of 105
5.1 PROMAG SHED
Location: -Roof Purlin tie bar Location: -Trusses over process area Location: -Truss Exactly over the process
area
Observation: - Due to corrosion tie bars at Observation: - Accumulation of Powder over Observation: - Pipe is suspended from truss.
few locations are disconnected/Broken. trusses this may lead to severe corrosion if
powder penetrates the tape.
Remedy: - Replace such bars. Remedy: - Keep cleaning the trusses at Remedy: - Provide separate arrangement for
regular interval and check the pipe support. Don’t Load truss.
integrity/overlaps of tape.
NEW: The same has not been rectified yet. NEW: The same has been rectified. There NEW: The same has not been rectified
does not seem accumulation of powder. The yet.
photo no. 1 attached below concludes the
same.
*GREEN INDICATES THAT THE ISSUE HAS BEEN RECTIFIED OR CORRECTED
Page 14 of 105
Photo No. 1
Page 15 of 105
5.1 PROMAG SHED
Location: -Gable end truss Location: -Truss 6 Mezzanine floor. Location: - Representative image for tapes
Observation: - Tapping is not done for bottom Observation: - Extensive corrosion of non- Observation: - At few locations it was
chord member over the wall. structural members observed that tapes are not properly wrapped/
overlapped. Chances of corrosion are high at
such locations. Attention required at
junctions, base plates, bolts.
Remedy: -As per section 9 of report Remedy: - Please do remove/replace all the Remedy: - Either provide tapes with proper
(Conclusions) rusted non-structural members. overlapping or else apply anticorrosive paint.
NEW: The same has been done at a few places NEW: The same has been rectified except at NEW: The same has not been rectified
near the gable end. a few places. yet.

5.2 Extension Shed
Location: -All trusses, Purlin and top chord Location: -Gable End Truss and Column Location: -Above rolling shutter
junction junction
Observation: - Improper placement of Observation: - Improper placement of Observation: - Bending of girt member
purlins over the top chord member of truss. column interaction with the bottom chord observed
Such connections are not permitted in truss member of truss. Such connections are not
system permitted in truss system.
Due to corrosive environment peeling of paint
observed
Remedy: - As per section 9 of report Remedy: - As per section 9 of report Remedy: - Replace the member.
NEW: The same has not been rectified yet. NEW: The same has not been rectified
Photo No. 2 is attached below. yet.
Page 17 of 105
Photo No. 2
Page 18 of 105
5.2 Extension Shed
Location: -At opening (rolling shutter) Location: -Truss over Mezzanine Location: -All trusses
Observation: - Excessive corrosion observed. Observation: - Accumulation of powder Observation: - Due to corrosive environment
observed. Possibility of corrosion. peeling of paint observed
Remedy: - Replace the member Remedy: - Keep cleaning the trusses at Remedy: - Clean the members from rust and
regular interval and apply anticorrosive paint. apply anticorrosive paint.
NEW: All the structural steel members are NEW: The remedy suggested has been NEW: All the structural steel members are
painted to avoid corrosion. Photo no.2 is followed and needs to be maintained. painted to avoid corrosion. Photo no.2 is
attached above.(Page No. 18) Photo no.1 is attached.(Page No. 15) attached above.(Page No. 18)
*RED COLOUR INDICATES RECENT AUDIT COMMENTS
Page 19 of 105
‘Onsite ActivitY’

6. Onsite Activity
Firstly, the visual inspection of the shed was done to get a general idea about the condition of the sheds.
Also, as the structural drawings and layout were also available, we checked the member properties and the
dimensions of the structural members.
Later, based on the previous Structural Audit report and accessibility to carry out NDT on structural steel
members, the test locations were prepared by removing the tape wrapped around the member and the
grinding the surface to make it free from oil, grease and dirt.
NDT was carried out on structural steel members at locations mentioned in Annexure II of this report
(Page No. 100). The drawings are attached in Annexure II comparing the thickness obtained in the
previous audit and the recent audit. The concrete cores were also extracted from the columns in the
Promag shed.
Table 2: Date wise Activity
Sr. No Date Activity Carried

1. 14/11/2019 1. Visual Inspection of the Shed
1. Visual Inspection of the shed

2. Finalizing the test locations
2 12/12/2019
3. Preparation of test locations by removing the tape
wrapped and grinding the surface
1. Carry out NDT on steel members

3 13/12/2019
2. To extract core from concrete columns
In the following page, the images of the test locations where the nondestructive testing
of the various types of structural members had been carried out has been elaborated. The
test locations of the same has been shown in the drawings (Page No. 100) for reference.
NDT Tests were carried out at 29 locations which is explained ( Pg. No. 36 /Section * of
this report)

Typical Photo Log of Observation


‘STRUctuRAL
AnALYSIs’

7. Structural Analysis
Sizing of members as per drawings are taken for STAAD model preparation. After Modelling various
structural members, a computer model of the structural frame of the building will be generated to assess the
effects of vertical and lateral loads that have already been estimated to be imposed on the structure.
The building structures will be analysed using STAAD-Pro software for the following computer
models of the building.
a) Analysis for gravity loads – Portal frames in transverse and longitudinal direction.
b) Analysis for Wind load - Portal frame in transverse and longitudinal direction.
The computer analysis will indicate member forces, and utility ratio check of the entire structure as well as
individual members. This data will then be used to check the structural members.
After obtaining the onsite NDT results and then comparing the geometry and member properties of the
STAADPRO model prepared during the previous audit of the shed, we found that the member properties
assigned has to be reduced by 1mm considering an average corrosion effect. So, the STAADPRO model
remains the same, just the member properties have been changed. The analysis results of the edited
STAADPRO model has been elaborated in Section 7.1 below.
The previous audit report is also been attached in ANNEXURE I.
7.1 Analysis Results
As per drawings and test results, the analysis has been performed and result summary is
given in table below and detailed results are attached before the table.
For (DL, DL+LL, and Critical combination with wind Load) following 5 critical trusses have
been identified and listed below.
Location No Description
1. Gable end truss of Existing Promag shed
2. Intermediate truss of Existing Promag shed
3. Intermediate truss of Existing Promag shed with pipe attached.
After carrying out NDT in the Expansion shed, the maximum change of thickness observed was -0.4mm.
After comparing the utility ratio values of the previous audit report and analyzing the current model, it was
found that there is not much difference in the utility ratio. Hence the same is attached in Annexure I of this
report.

1.1 Analysis Results for DL on Gable End truss of Promag Shed
*Values in figure indicates the utilization of section strength for given loading
Green line indicates that section is adequate for given loading.
1.2 Analysis Results for DL+LL on Gable End truss of Promag Shed
1.3 Analysis Results for DL+LL+WL on Gable End truss of Promag Shed
Blue line indicates that section is overstressed but below 1.33 utilization ratio.
Page 26 of 105
Summary Sheet
Gable End Truss of Promag Shed

Critical Load Combination (DL+WL)
Only Dead Load Dead + Live Load
or (DL+LL+WL)
All members are safe considering
Member Status All Members are safe All Members are safe
allowable additional stresses
Gable truss members are sufficient for Gable truss members are sufficient Gable truss members are sufficient for
Comments
Dead load for Dead load + Live Load Critical Load Combination
1.No anticorrosive taping done for bottom chord members above gable end wall.
2.Thickness reduction with holes on bottom chord member observed.
Site Observations
3.Considerable reduction in Nonstructural Members observed without taping.
1. Forthe bottom chord members of this gable end, 5.5 mm average thickness was found as per test. (6mm used).
So, on an average 0.5mm reduction is observed.
Test Observation
1. Reduce the wall height by 600 mm below bottom chord member.

2. Provide extra support as per drawing. (Annexure 2, Page No.104)
Remedial Measures if any 3. Provide anticorrosive tape for bottom chord member above wall.
4. Replace all rusted Non-structural Members.
*For Detailed observation of member result please refer section 1.1, 1.2 and 1.3 above.(page No.26)
*RED COLOUR INDICATES RECENT AUDIT COMMENTS/ OBSERVATIONS
Page 27 of 105
2.1 Analysis Results for DL on Intermediate truss of Promag Shed
2.2 Analysis Results for DL+LL on Intermediate truss of Promag Shed
Indicates additional support of column, hence member is safe.

2.3 Analysis Results for DL+LL+WL on Intermediate truss of Promag Shed
Red line indicates that section is overstressed above 1.33 utilization ratio.
Indicates additional support of column, hence member is safe

Intermediate Truss of Promag Shed
or (DL+LL+WL)
Member Status All Members are safe All Members are safe Bottom chord, Inclined Member Fails
Intermediate truss members are Intermediate truss members are Members are exceeding permissible
Comments
sufficient for Dead load sufficient for Dead load + Live Load stress limit, thus strengthening required.
1. Thickness reduction with holes on bottom chord member observed above the process area.
Site Observations
1. For the bottom chord members of this intermediate truss, 5.6 mm average thickness was found as per test. (6mm
used).
Test Observation
2. Overall reduction in thickness observed due to rusting of members.
3. For Channel sections, flange thickness found between 6.5 to 6.7 mm. (7.3mm)
1. Provide additional ISMC 75 in back to back position with existing ISMC 75 as given is drawings. (Annexure 2, Pg.
Remedial Measures if any no.104)
2. For the trusses exactly over the process area, where concentrated thickness reduction is observed, we recommend
a plate of 6 mm thickness and of width 275 mm to be welded along the length of bottom chord.
*For Detailed observation of member result please refer section 2.1, 2.2 and 2.3 above(Page No.29)
Page 30 of 105
3.1 Analysis Results for DL on Intermediate truss of Promag Shed with pipe attached
3.2 Analysis Results for DL+LL on Intermediate truss of Promag Shed with pipe attached
Indicates additional support of column, hence member is safe

3.3 Analysis Results for DL+LL+WL on Intermediate truss of Promag Shed with pipe
attached

Intermediate Truss of Promag Shed with attached pipes
or (DL+LL+WL)
Bottom chord member fails, other
Member Status All Members are safe Top chord member fails members are passing considering
allowable additional stresses
In case of wind load the addition of
Top Members are failing due to
Intermediate truss members are pipe acts as counteracting load, and
Comments Excessive stress due to attached pipe
sufficient for Dead load hence all other members are within
line
permissible limits.
1. Thickness reduction with holes on bottom chord member observed above the process area.
Site Observations 2. Extra ISA 75 x 75 x 6 mm welded to bottom chord .
3. Promag powder carrying pipe suspended from truss observed. (Input weight data-225kg)
1. For the bottom chord members of this gable end, 5.6 mm average thickness was found as per test. (6mm used).
2. Overall reduction in thickness observed due to rusting of members.
Test Observation
3. For Channel, flange thickness found between 6.5 to 6.7 mm. (7.3mm)
1. Provide additional ISMC 75 in back to back position with existing ISMC 75 as given is drawings. (Page No. 104)
2. For the trusses exactly over the process area, where concentrated thickness reduction is observed, we recommend
a plate of 6 mm thickness and of width 275 mm to be welded along the length of bottom chord. (Page No.104)
Remedial Measures if any
3. Provide independent load carrying system for promag pipe. Do not transfer loads from pipe or any other suspended
objects to the truss.
*For Detailed observation of member result please refer section 3.1,3.2 and 3.3 above.(Page No.32)
Page 33 of 105
Intermediate Truss of Extension shed
Critical Load Combination
Only Dead Dead + Live (DL+WL)
Load Load or (DL+LL+WL)
Member Status All Members are Top chord member fails Top chord member fails
safe
Top Members are failing due to In case of wind load the improper
Intermediate truss members are
Comments Excessive stress due to improper placement of purlins, transfers
sufficient for Dead load
placing of purlin forces critically to top chord.
1. The truss showed considerable vibration and deflection in lateral direction while cleaning of truss with the
Site Observations
grinder. (Has Been rectified by providing Bracing)
2. All the purlins are placed on members instead of junctions. **
1. No reduction in thickness observed (During Previous Audit)

Test Observation
2. Test showed the thicknesses between 7.5 mm to 7.8 mm (Original Thickness -8mm)
1. The purlins should be relocated at the junction points.

2. While locating the purlins at junctions it may happen that the purlins of extended shed would not align
Remedial Measures if
with junctions of promag truss. In this case we have to strengthen the top chord member of truss with 6 mm
any
thick plate.
3. Bottom chord of all trusses in extended shed should be connected with ISA 75 x75 x 6 mm as shown in
drawings.
*For Detailed observation of member result please refer Page

Page 34 of 105
Extended shed Gable End
or (DL+LL+WL)
Bottom chord member with column Bottom chord member with column
Member Status All Members are safe
interaction fails interaction fails
Bottom chord Members are failing Bottom chord Members are failing due
Intermediate truss members are
Comments due to Excessive stress due to to Excessive stress due to improper
sufficient for Dead load
improper alignment of column alignment of column
1. All the purlins are placed on members instead of junctions. **

Site Observations
2. The gable end truss is connected to columns with improper alignment.
1. Test showed the thicknesses between 7.7 mm to 7.8 mm (Reduction of 0.2 to 0.3mm observed)
Test Observation
1. The purlins should be relocated at the junction points.

Remedial Measures if any
2. Provide gable end column connection as per drawings.
*For Detailed observation of member result please refer report attached in Annexures of old report.
Page 35 of 105
‘Non-DestRUctive
testinG’

8. Non-Destructive Testing Procedure

Non-Destructive Testing is performed on Structural Steel members and RCC members of the Shed. By
implementing proper non-destructive assessment of the structural members, it can help in reducing the risk
of member failures.
Basic objective of conducting non-destructive testing includes
- To assess present condition of the structural members and propose its future life
- To decide action plan for repair and maintenance.
Different non-destructive tests are adopted to determine the sub surface defects and its extent in the
structure. Also, it can help to decide the action to be taken regarding repairing, maintenance, or complete
replacement of the structure.
Following test is performed on RCC members of the shed at select and convenient locations as shown in
Annexure II of this report.
1. Concrete Core cutting

And the ND Tests performed on Structural steel members of the shed are mentioned below. The tests are
done at select and convenient locations as shown in Annexure II of this report.
1. Dye Penetrant Testing
2. Magnetic Particle Testing
3. Thickness Measurement
The thickness obtained during the previous structural audit is compared with the thickness
obtained during the NDT done this time. The comparison table of the same is attached in
drawings provided in Annexure II of this report.
A. Concrete Test
1. Diamond Core Cutting
Concrete cores are used for testing of actual properties of concrete in existing structures such as strength,
permeability, chemical analysis, carbonation etc. Sampling of concrete cores and testing its strength is
described. For the present condition we use core test only to get actual strength. Concrete cores are usually
cut by means of a rotary cutting tool with diamond bits. In this manner, a cylindrical specimen is obtained
usually with its ends being uneven, parallel and square.

Photo No. 17
B. Structural Steel NDT Tests
a. Dye Penetrant Test

Dye Penet rant test is a widely applied and low-cost inspection method used to check surface-breaking
defects in all non-porous materials (metals, plastics, or ceramics). The penetrant may be applied to all non-
ferrous m aterials and ferrous materials, although for ferrous components magnetic-particle inspection is
often usedinstead for its subsurface detection capability. LPI is used to detect casting, for ging and welding
surface defects such as hairline cracks, surface porosity, leaks in new products, and fatigue cracks on in-
service components. The surface under test should be clean and smooth. Dirt or other loose material on the
surface can be removed using a grinding prior to the test. Rough surfaces cannot be test ed as they do not
give reliable results. The main steps of this inspection are
1. Pre-cleaning
2. Application of Penetrant
3. Excess penetrant removal
4. Application of developer
5. Inspection and Post cleaning.
b. Magnetic Particle Test

Magnetic Particle Test is a technique used to detect surface and slightly subsurface flaws in most
ferromagnetic materials such as iron, nickel, and cobalt, and some of their alloys. Because it does not
necessitate the degree of surface preparation required by other non-destructive test methods, conducting
MPT is relatively fast and easy. This has made it one of the more commonly utilized NDT techniques.
MPT is a fairly simple process with two variations: Wet Magnetic Particle Testing (WMPT) and Dry
Magnetic Particle Testing (DMPT). In either one, the process begins by running a magnetic current through
the component. Any cracks or defects in the material will interrupt the flow of current and will cause
magnetism to spread out from them. This will create a “flux leakage field” at the site of the damage.

The second step involves spreading metal particles over the component. If there are any flaws on or near the
surface, the flux leakage field will draw the particles to the damage site. This provides a visible indication of
the approximate size and shape of the flaw.
There are several benefits of MPT compared to other NDE methods. It is highly portable, generally
inexpensive, and does not need a stringent pre-cleaning operation. MPT is also one of the best options for
detecting fine, shallow surface cracks. It is fast, easy, and will work through thin coatings. Finally, there are
few limitations regarding the size/shape of test specimens.
c. Thickness Measurement
Ultrasonic thickness measurement (UTM) is a method of performing non-destructive measurement
(gauging) of the local thickness of a solid element (typically made of metal, if using ultrasound testing for
industrial purposes) basing on the time taken by the ultrasound wave to return to the surface. This type of
measurement is typically performed with an ultrasonic thickness gauge.
Procedure
Step No Description of Activity

1. Remove the anticorrosive tape.
2. Clean the Coating with sand paper.

3. Grind the surface thoroughly and evenly.
4. Apply lubricant such that no voids are present between probe and member.
5. Attach the probe and move it around to capture the readings.
5.7 Core Test Results on Concrete

Core Cutting is performed on the RCC Members of the Industrial shed at accessible and convenient
locations as shown in Drawings attached in Annexure II of this report. The core was then sent t o lab for
testing its compressive strength. Original concrete strength that was used during construction was not
available, but in general for industrial structures minimum M30 grade of concrete is used. The results
obtained are as below
Table 3: NDT Results
Sr. No. Test Point Core Strength
N/mm2
1 Pedestal C2 32
2 Pedestal C5 33

5.8 NDT Results on Steel

Following tests were performed on the structural steel members in the industrial shed
1. Magnetic Particle test (MPT)

2. Dye penetrant test (DPT)
3. Ultrasonic thickness measurement.
The results of MPT and DPT have been found to be free from relevant indication of cracks for
the material.
Ultrasonic Thickness Measurement Results
The results of the thickness measurement is shown location wise in Annexure II of this report (Page No.
99 -105) and concluded in the Section 9 of this report.

‘Conclusions’

9. Conclusions
The Project is for Pyrotek India Pvt. Ltd., Pune-Nagar Road, Sanaswadi, Pune, Maharashtra-412 208. The
scope of the project is to carry out Structural Audit and Structural health of the GRDR and Promag shed.
Following are the activity-based Conclusions
a. VISUAL INSPECTION
PROMAG SHED
1. Small hairline cracks was observed in the Promag shed column C5 (Refer to attached
drawings on Page No. 100) as discussed earlier. Monitoring of this crack needs to be done to
see if this crack propagates further.
Whereas major crack was observed on the RCC Column C3 (Refer to attached drawings on
Page No. 100). This column needs to be strengthened by providing RC jacketing to the
column.The section of the column is enlarged by casting a new reinforced concrete/mortar
section over a part or the entire length of the column
2. Many untaped structural members were visible near the Truss no. 5 and 6 in the promag shed.
These untaped structural steel members need to be covered with tape or High temperature
corrosion protection coating needs to be applied.
3. The strengthening strategy recommended in the previous structural audit report has not been
done at site.
EXTENSION SHED
1. Bending or damage of girt member above the rolling shutter is observed. The same needs to be
replaced.
b. ND TESTING
Our team of engineers also performed Non-Destructive testing on the structure at convenient and
accessible location. The results of these tests are tabulated in table 13 above.
Tests on Steel -PROMAG SHED
 Average thickness for angle members was found to be 5.5 mm in Promag shed (6mm thickness
was observed during previous audit) and for channel sections it was found to be 6.6 mm.
 For untaped structural members in general thickness reduction of 0.9-1.3mm was observed.
(Near to Truss 5 and 6 of Promag shed). 
 Average web thickness of the structural steel column above the RCC Column was found to
be 5.2mm.
 The purlin thickness is found to be 5.5mm. (6mm thick originally) 
 The results of MPT and DPT have been found to be free from relevant indication of
cracks for the material.
Tests on Steel -EXTENSION SHED

 Average thickness for angle in extended shed found to be 7.8 mm. (8mm thickness was
observed during previous audit)
 Average web thickness of the structural steel column above the RCC Column is found to be
5.3mm.
 The results of MPT and DPT have been found to be free from relevant indication of
cracks for the material.

Tests on Concrete-PROMAG SHED

 Average concrete compressive strength of RCC columns is found to be 32N/mm2.
(30N/mm2 in general for Industrial Structures)
c. Structural Analysis
After carrying out NDT’s on steel structure, we had come to a conclusion that there is change of
thickness observed due to corrosion in the promag shed. Maximum of -0.7mm change of
thickness due to corrosion is observed in the promag shed.
Change of thickness is also observed in Extension shed, but a maximum of -0.3mm change of
thickness is observed.
Analysis Results -PROMAG SHED

1. The gable end truss of the promag shed are safe for all the critical load combinations.
2. The intermediate truss of promag shed is found to be safe for DL and DL+LL load
combinations, whereas there are overstressed bottom rafter members and a few
overstressed inclined members.
3. The intermediate truss of promag shed with pipe attached is found to be safe for DL only.,
whereas for DL+LL there are overstressed top rafter members near the ridge.
For DL+LL+WL load combination, the bottom rafter members are overstressed whereas
the top rafter members are also overstressed but are within the permissible utilization ratio.
The addition of pipelines acts as counteracting load and hence the top rafter members are
within permissible limits.
Analysis Results -GRDR (EXTENSION) SHED

1. The gable end truss members of the GRDR shed are safe for DL combination, whereas
bottom chord members of the gable end truss are overstressed for DL+LL load combination
due to improper alignment of column.
For DL+LL+WL load combination also bottom chord members are overstressed due to
improper alignment of column.
2. The intermediate truss of GRDR shed is found to be safe for DL only. For DL+LL load
combinations, whereas there are overstressed top rafter members due to improper placing of
purlin.
Similar type of failure is also observed for DL+LL+WL load combination.

‘RecoMMEnDATions’

10.RECOMMENDATIONS
1. Untaped Structural Members

The untaped structural members in the shed needs to be identified and taping of these members needs to be
done or High temperature corrosion protection coating mentioned below needs to be applied at the top most
priority as the rate of reduction in these members is found to be at a fast rate compared to the taped
structural members.
Coating: WINGARD – Glass Flake Epoxy – High Temperature Corrosion Protection Coating or Equivalent
2. Failures of Structural members

Strengthening strategy remains the same as discussed during the previous structural audit carried out. The
strategy is as per drawings attached in Annexure II of this report.

11. PRIORITY ACTIONS

A priority/urgency list of works to be finalized by the client and the consultant is made
PRIORITY 1 Strengthening Strategy of the PROMAG Shed
Taping of Structural members or application of

PRIORITY 2
high temperature corrosion protection coating
Shifting of Purlins and Strengthening strategy of

PRIORITY 3
EXTENSION Shed.
Replacement of the bent Girt Member in the

PRIORITY 4
Extension Shed.

‘ANNEXURE II’

SHEET 1 OF 6
Extension Shed PROMAG SHED
1 2 3 4 5 6
CORE LOCATIONS
TRUSS LAYOUT PLAN
NDT LOCATIONS
PYROTEK INDIA PVT.LTD. STRUCTURAL AUDIT OF PYROTEK INDIA PVT.LTD.

PROMAG & EXTENSION
SHED
Page 100 of 105
SHEET 2 OF 6
TEST NO. PREVIOUS THICKNESS CURRENT THICKNESS

1500 1500
1500 1500
1500 1500
1500 1500
1500 1500
15
68 68
15
2970
1500 1500
1500 1500
15
960 58 58 960
15
606
15
72 72
15
824 1467 1467 1825 2812 2700 2700 2812 1825 1467 1467 824
22246
10 10
ABOVE THE PYROFLUX DEPARTMENT INFRONT OF BLOWER IS POINT NO 24 TRUSS - 6

1500 1500
1500 1500
1500 1500
1500 1500
1500 1500
15
68 68
15
2970
1500 1500
1500 1500
15
960 58 58 960
15
606
15
72 72
15
824 1467 1467 1825 2812 2700 2700 2812 1825 1467 1467 824
22246
10 10
PURLIN SURFACE IS ALSO EXPOSED TO CARRY OUT NDT NEAR TO THE POINT 4 BETWEEN TRUSS 2 AND TRUSS 3 (POINT NO. 26) TRUSS - 3
1500 1500 TEST NO. PREVIOUS THICKNESS CURRENT THICKNESS
1500 1500
1500 1500
1500 1500
1500 1500
15
68 68
15
2970
1500 1500
1500 1500
15
960 58 58 960
15
606
15
72 72
15
824 1467 1467 1825 2812 2700 2700 2812 1825 1467 1467 824
22246
10 10
TRUSS - 2

PROMAG & EXTENSION
SHED
Page 101 of 105
SHEET 3 OF 6
1500 1500
1500 1500
1500 1500
1500 1500
1500 1500
15
15
68 68 11 - 5.2mm
2970
1500 1500
1500 1500
15
960 58 58 960
15
606
15
72 72
15
824 1467 1467 1825 2812 2700 2700 2812 1825 1467 1467 824
22246
10 10
ABOVE ELECTRICAL ROOM, ON CROSS BRACING THERE IS POINT NO.28 TRUSS - 5 EXPOSED SURFACE TO CARRY OUT NDT NEAR POINT NO 15 IS POINT NO 27(SECONDARY TRUSS)
1500
1500
1500 1500
1500 1500
1500 1500
1500 1500
15
68 68
15
2970
1500 1500
1500 1500
15
960 58 58 960
15
606
15
72 72
15
824 1467 1467 1825 2812 2700 2700 2812 1825 1467 1467 824
22246
10 10
TRUSS - 4

PROMAG & EXTENSION
SHED
Page 102 of 105
SHEET 4 OF 6

150
2141
2291
2291
3000
2291
2195
600
2240 2240 2240 2240 2240

22400
TRUSS - 8

150
2141
2291
2291
3000
2291
2195
600
2240 2240 2240 2240 2240

22400
COLUMN IS EXPOSED AT THE BOTTOM TO CARRY OIUT NDT NEAR THE FLOOR LEVEL (POINT NO. 25) TRUSS - 7 ABOVE THE BLOWER IN THE EXTENSION SHED IS POINT NO 26
PROPOSED TEST LOCATION FOR PYROTEK INDIA PVT.LTD. STRUCTURAL AUDIT OF PYROTEK INDIA PVT.LTD.
EXTENSION SHED EXTENSION SHED
Page 103 of 105

SHEET 5 OF 6
1500 1500
1500 1500
1500 1500
1500 1500
1500 1500
15
68 68
15
2970
1500 1500
1500 1500
15
960 58 58 960
15
600
600
606
15
72 72
15
824 1467 1467 1825 1406 1406 2700 2700 1406 1406 1825 1467 1467 824
600
22246
DETAIL TRUSS ELEVATION FOR GABLE END
1500 1500
1500 1500
1500 1500
1500 1500
1500 1500
8 15
6 68
15
2970
1500 1500
1500 1500
15
960 58 58 960
15
606
15
72 72
15
824 1467 1467 1825 1406 1406 2700 2700 1406 1406 1825 1467 1467 824
22246
10 10
DETAIL TRUSS ELEVATION FOR INTERMEDIATE
1500
10
250X6 thk
22246 LONG
580
DETAIL - 3
751
10
87
25
180
10
65 65
180
1467 DETAIL - 4
DETAIL - 1 DETAIL - 2
25
DETAIL TOP & BOTTOM PLATE

DETAIL - 4
PROPOSED STRENGTHENING FOR PYROTEK INDIA PVT.LTD. STRUCTURAL AUDIT OF PYROTEK INDIA PVT.LTD.
PROMAG SHED PROMAG SHED
Page 104 of 105

SHEET 6 OF 6
150
2141
2291
2291
3000
2291
2195
600
2240 2240 2240 2240 2240

22400
DETAIL TRUSS ELEVATION FOR INTERMEDIATE
150
2141
2291
2291
3000
2291
2195
600
700 700
2240 2240 2240 2240 2240

22400
7560
DETAIL TRUSS ELEVATION FOR GABLE END
700
220
100
470
1000
11
87
FRONT VIEW PLAN VIEW

DETAIL - 1
PROPOSED STRENGTHENING FOR PYROTEK INDIA PVT.LTD. STRUCTURAL AUDIT OF PYROTEK INDIA PVT.LTD.
EXTENSION SHED PROMAG SHED
Page 105 of 105

7203 - Pyrotek - Without OLD PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

7203 - Pyrotek - Without OLD PDF

Uploaded by

Copyright:

Available Formats

Project No.

7203 Year: 2019-2020

‘GRDR and Promag Shed’

Address : 508, Nyati Emporius, Mumbai – Bangalore Highway, Near the

Contact No. : +91-9850-005-294 +91-9011-330-588

Email & Web : support@saltinfra.com or log on to: www.saltinfra.com

Sr.No Content Page No

3 Visual Inspection 4-8

4 Typical Photo log of observation 9-11

5 Condition Survey 12-19

6 Onsite Activity 20-23

7 Structural Analysis 24-35

8 Non-Destructive Testing 36-40

Salt Design & Infra Services Pvt. Ltd.

Table 1 Project Information

2 Type of Structure RCC + Steel

- Onsite work, conducting NDT and Data Collection

- STAADPRO Analysis to find out the Utility ratio.

2.1. Visual Inspection

Salt Design & Infra Services Pvt. Ltd.

Type of Survey Survey Item

2.1.1 Scope of Visual Inspection

The inspection report should reveal the following listings:

2.2 Drawing Verification

2.4 STAADPRO Analysis

Salt Design & Infra Services Pvt. Ltd.

2.5 Non-Destructive Testing

Salt Design & Infra Services Pvt. Ltd.

Salt Design & Infra Services Pvt. Ltd.

1 Building Name GRDR and PROMAG shed

2 Type of Structure RCC + Steel

3.1. Visual Inspection Survey

RCC damaged on External faces:

Salt Design & Infra Services Pvt. Ltd.

Defects in Brick Masonry Wall:

1 Wall mortar joints Loose/ Brittle No - - -

2 Brick work quality NV - - -

3 Large cracks seen on surfaces No - - -

RCC damaged on Internal faces:

The Pattern of crack indicates

Defects in Rafter members

3 Any missing members NO - - -

1. There are many members

Salt Design & Infra Services Pvt. Ltd.

Defects in Steel Columns

3 Any missing members NO - - -

Defects in Bracing Members

3 Any missing members NO - - -

Defects in Other Steel Members (Girts)

1 Signs of Corrosion YES Minor - -

3 Any missing members NO - - -

Salt Design & Infra Services Pvt. Ltd.

Salt Design & Infra Services Pvt. Ltd.

Salt Design & Infra Services Pvt. Ltd.

4. Typical Photo Log of Observation

Photo No. 1 Photo No. 2

Photo No. 3 Photo No. 4

Salt Design & Infra Services Pvt. Ltd.

Photo No. 5 Photo No. 6

Photo No. 7 Photo No. 8

Salt Design & Infra Services Pvt. Ltd.

*GREEN INDICATES THAT THE ISSUE HAS BEEN RECTIFIED OR CORRECTED

*GREEN INDICATES THAT THE ISSUE HAS BEEN RECTIFIED OR CORRECTED