HANDBOOK ON REPAIRS & REHABILITATION OF RCC BUILDINGS

l Re-alkalisation of carbonated concrete.

l Electro-chemical removal of chloride from concrete
l Water proofing and/or protective coating.

6.3 Performance Requirements of Repair Systems

l Strength, Serviceability and Durability
l Protection of steel
l Bond with parent surfaxce
l Dimensional stability
l Resistance to environmentally induced damage.
l Ease of application
l Appearance

6.4 Important factors to be considered for selection of repair methods:

l Type and extent of distress
l Location of distress
l Environmental exposure
l Availability of skill
l Availability of time and access for repairs.
l Appearance
6
l Cost

6.5 Repair Stages

l Concrete Removal and Surface Preparation
l Fixing suitable formwork
l Bonding / passivating coat and repair application

6.5.1 Concrete Removal and Surface preparation

The general procedure for marking area to prepare the surface of spalled area for
carrying out repairs is illustrated in Fig 6.1.

BOUNDARY OF LOOSE AND RECOMMENDED LAYOUT

DELAMINATED CONCRETE

Fig 6.1 Recommended Layout of Surface Repairs

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 REHABILITATION AND RETROFITTING METHODS

Prior to preparation of concrete surfaces, exposed reinforcement should be inspected for

access clearance, cross-sectional area and location. Reinforcing bars must be further exposed
if the remaining concrete is de-bonded from the reinforcing steel. Removal must be continued
to completely expose the bar if more than half of a reinforcing bar perimeter has been exposed.
For completely exposed reinforcing bars, a minimum average clearance of 25 mm or nominal
maximum size of aggregate plus 5mm, whichever is greater, must be provided between the
reinforcing bar and surrounding concrete. A structural engineer should be consulted if the
cross-sectional area of an individual bar has been reduced by 15 percent or more or if two
adjacent bars have been reduced by 10 percent or more. Out-of-plane and loose reinforcement
should be secured in its design location.
The process of Surface preparation is illustrated stepwise (Step 1 to 3) in Fig 6.16. The
general procedure in preparing concrete and reinforcement surfaces for optimum
bonding is to sandblast the surfaces and then remove dust and debris by air blasting,
low-pressure water blasting, or brooming. If the damage is due to corrosion, a suitable
coating may be considered after removal of total rust from its surface to protect the
exposed reinforcing steel. Final inspection of the prepared area including remedying
any deficiencies should be completed just prior to batching the repair material.

6.5.2 Form work

If repairs are required on vertical or overhead surfaces and if the repair material is 6
likely to sag, formwork will be required. Prior to installing forms, the concrete surface
must be inspected for any surface contours that could result in air being trapped during
concrete placement or pumping. If air is likely to get trapped, concrete must be removed
to change the contour, or vent tubes must be installed. Formwork should be secured to
the concrete with expansion anchors of standard makes etc. Installed form anchors
should be pre-tested for slippage. Preformed foam gaskets or cast-in-place foam may
be required to provide a watertight seal between the concrete and form
surfaces (Fig 6.2).

TASLA

VENT TUBE TO REMOVE

TRAPPED AIR CONCRETE IS PLACED
THROUGH LETTER-BOX
ENTRY EXPANSION ANCHORS SURFACE CONTOURS TO
TRAPPED AIR
TIMBER OR STEEL FORM ENSURE NON-ENTRAPMENT
OF AIR
OUTLET FOR
FORM WORK TRAPPED AIR

PACKED DRY AGGREGATE

FRESH CONCRETE
INLET FOR REPAIR
MORTAR

RCC COLUMN FORM WORK SCREWED

WITH EXPANSION
ANCHORS
(a) VENT TUBE FOR TRAPPED AIR PACKING WITH PREFORMED
FOAM JACKETS OR
CAST-IN-PLACE FOAM

(b) REMODELLING OF SURFACE CONTOURS OF CONCRETE

TO ENSURE NON-ENTRAPMENT OF AIR

Fig 6.2 Form Work

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 REHABILITATION AND RETROFITTING METHODS

6.6.1.2 Polymer Modified Cement Mortars are used for repairs on old hardened concrete for
repairing defects on exposed concrete surface only. For larger repair areas with thickness
in excess of 50 mm, concrete, as repair material, is a better option. For thicker
applications, over larger areas, it is desirable to use appropriate reinforcing mesh fixed
with U-nails. These shall use Polymers admixed in specified proportions, based on
selection criterion given in Chapter 5. Other materials shall be same as in Portland
Cement Mortars stated above. However, these shall follow the given relevant
specifications, if specified.

6.6.1.3 Epoxy Mortars: These mortars consist of resin, hardener and silica sand and are applied
over an epoxy bonding coat over old hardened concrete surface.. These mortars attain
strength in few hours. These mortars have very high strength and are abrasion resistant,
water resistant and can be used in few millimeter thickness overlays. These are used
for repairs at locations where
l It is difficult to use epoxy bonded concrete,
l Depth of repair is less than 40 mm or
l Repair areas are small (less than 0.1 sqm) and few in number.
When depth of repair exceeds 15 mm but is less than 40 mm, the build up of patch
repair over large areas shall be in layers using appropriate reinforcing mesh fixed with
U-nails or shear keys. 6

6.6.2 Dry Pack and Epoxy Bonded Dry Pack:

The Dry Pack Repair technique is application of dry cement sand mix . It consists of
cement and clean sand (in proportion 1:2.5) with just enough water to be able to form
a ball by hand. It is immediately packed into place before the bond coat has dried or
cured, with suitably shaped hardwood dowel and hammer in 8 to 10 mm thick layers
(Refer Fig 6.3).

DRY PACK MATERIAL PLACED IN LAYERS

HARD WOOD

RESTRAINING FORMWORK HAMMER USED TO

COMPACT DRYPACK
MATERIAL

DRYPACK MATERIAL SHOULD

BE DRY BUT COHESIVE ENOUGH
TO BE FORMED INTO A BALL.

Fig 6.3 Dry Packing

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 HANDBOOK ON REPAIRS & REHABILITATION OF RCC BUILDINGS

If the epoxy is used as bonding material between the repair material and the substrate,
the method is termed as Epoxy Bonded Dry Pack. Its application shall be limited to
areas that are small in width and relatively deep but not less than 25 mm in depth..
The application areas include core holes, holes left by removal of form-ties,
cone-bolts, she bolt holes, narrow slits for critical repairs or for repairs expected to be
exposed to severe service conditions. Dry pack shall neither be used for shallow
depressions where lateral restraint cannot be obtained nor for filling behind steel
reinforcement.

6.6.3 Pre-Placed Aggregate Concrete (PAC):

Pre-placed aggregate concrete (PAC) is concrete that is made by forcing grout into the
voids of a mass of clean, graded coarse aggregate densely pre-packed in formwork
(Refer Fig 6.4). PAC is used where placing conventional concrete is extremely difficult,
such as where massive reinforcing steel and embedded items are present, in underwater
repairs, concrete and masonry repair, or where shrinkage of concrete must be kept to a
minimum.
For the purpose of this repair method, grout typically consists of sand, cement,
pozzolana, plasticiser/ super-plasticiser and an air entraining agent (for anticipated
freeze & thaw problem, if required). The pozzolana and the plasticiser/super plasticiser
6 are used to impart flowability to the grout. The coarse aggregate is washed to remove
all fines and screened just prior to placement. Grout is then injected through forms to
provide the cementing matrix. Grouting is begun at the bottom of the pre-placed
aggregate.
Characteristics of the grout are affected by the water content, sand grading, cement,
pozzolana and the types & amount of admixtures. For each design of grout mixture,

CEMENT GROUT IS PUMPED IN

THROUGH THE INJECTION TUBES

INJECTION TUBES
WITHDRAWN AS GROUT
RISES
WALL FORMWORK WITH
RAKING SUPPORTS

COARSE AGGREGATE PLACED DRY

EXISTING RETAINING WALL

FOUNDATION

Fig 6.4(a) Preplaced Aggregate Concrete Repair to Concrete Wall

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 REHABILITATION AND RETROFITTING METHODS

REINORCEMENT
OVERLOW VENT

GAP GRADED
AGGREGATE INLET FOR GROUTING

STEP-1 STEP-2
GAP GRADED AGGREGATE WASHED,FREE OF FINES FORMS ARE FITTED WITH PIPES AND NIPPLES
AND BOND-INHIBITING MATERIALS ARE PLACED IN AND VALVES FOR PLACEMENT OF GROUT.
CAVITY.

OVERLOW VENT

INLET FOR GROUTING

FLOWABLE GROUT IS MIXED
AND PLACED INTO PUMP.

PUMP

STEP-3
FLOWABLE GROUT IS MIXED AND PUMPED INTO STEP-4
FORAMED CAVITY, FILLING SPACE BETWEEN AGGREGATE. FORMS ARE REMOVED AND SURFACE IS FINISHED
6

Fig 6.4(b) Preplaced Aggregate Concreting

there are optimum amounts of fillers and admixtures to produce the best pumpability or
consistency. Proper proportioning for the structural grout mix components is necessary to get
the required strength and durability of the finished pre-placed aggregate concrete. Trial mix
design is necessary for each job.
In underwater repair, injection of grout at the bottom of the PAC displaces water, leaving a
homogenous mass of concrete with minimum of paste wash out. In such applications, addition
of anti wash admixtures minimizes the paste wash out. For underwater PAC, the quality of
underwater should also be tested to determine its influence on PAC over a period of time for
taking appropriate corrective action.

6.6.4 Shotcrete
Shotcrete is defined as pneumatically applied concrete or mortar placed directly on to a
surface. The shotcrete shall be placed by either the dry mix or wet mix process.
The dry mix process (Fig 6.5) shall consist of
l Thoroughly mixing the dry materials,
l Feeding of these materials into mechanical feeder or gun,
l Carrying the materials by compressed air through a hose to a special nozzle,
l Introducing water at nozzle point and intimately mixing it with other ingredients
at the nozzle;
l Jetting the mixture from the nozzle at high velocity on to the surface to receive
the shotcrete.
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 HANDBOOK ON REPAIRS & REHABILITATION OF RCC BUILDINGS

COMPRESSED AIR IS USED TO

CONVEY REPAIR MATERIAL THROUGH
HOSE

BLENDED DRY (OR DAMP)

REPAIR MATERIAL IS
DEPOSITED INTO PUMP
INTO SHORTCRETE MACHINE

PUMP

NOZZLE
WATER

Fig 6.5 Dry Mix Shortcrete

The wet-mix process (Fig 6.6) shall consist of

l Thoroughly mixing all the ingredients with the exception of the accelerating
6 admixture, if used;
l Feeding the mixture into the delivery equipment;
l Delivering the mixture by positive displacement or compressed air to the nozzle;
l Jetting the mixture from the nozzle at high velocity on to the surface to receive
the shotcrete.
If specified, fibres of steel, poly propylene or other material, as may be specified,
could also be used together with the admixtures to modify the structural properties of
the concrete/mortar being placed in position.

COMPRESSED AIR IS ADDED TO

PROPELL THE MATERIAL OUT OF
THE NOZZLE

MIXED MATERIAL IS
PLACED INTO PUMP

NOZZLE

Fig 6.6 Wet Mix Shortcrete

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 REHABILITATION AND RETROFITTING METHODS

TENSION FACE PLATE

BOLTS

SIDE PLATES

GLUE LINE

(a) ENHANCE FLEXURAL STRENGTH

REINFORCED CONCRETE BEAM

SIDE PLATE

(b) ENHANCE SHEAR AND FLEXURAL (c) L-PLATES

STRENGTH AND DUCTILITY

Fig 6.7 Tension Face Plates 6

by fire, chemical break down, rusting or simply bad workmanship. Since epoxy is prone to
premature debonding, use of mechanical anchorage along with epoxy bonding is considered
more reliable.
Since the steel plates are unobtrusive, with this technique original sizes of the structural members
are not increased significantly. This method is preferred where enlargement of the members
is going to affect the headroom, existing windows, doors and other fixtures.

6.6.16 RCC Jacketing

Reinforced concrete jacketing increases the member size significantly. This has the advantage
of increasing the member stiffness and is useful where deformations are to be controlled. If
columns in a building are found to be slender, RC jacketing provides a better solution for
avoiding buckling problems. Design for strengthening/repair work is based on composite
action between the old and the new work. Strain compatibility calculations may have to be
carried out carefully giving due account to factors such as creep. As the new jacket is to
behave compositely with the parent member, the new jacket can take additional loads only
with the increase in the stresses & strains in the old one. The problem arises if the;
l Old concrete has reached limiting strain and is not likely to sustain any more significant
strain
l Old concrete is weak and porous and started deteriorating due to weathering action
and corrosion of reinforcement.
The question then arises as to whether the composite action should be abandoned and
the new jacket (plate or RC) designed to carry the entire load. It is perhaps best to

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 HANDBOOK ON REPAIRS & REHABILITATION OF RCC BUILDINGS

design the strengthening in this manner, but detailing must be right to ensure transfer of load to
the new jacket, if the old concrete fails. It is however, necessary to ensure perfect bond also
between the old and new concrete by providing shear keys and effective bond coat with the
use of epoxy or polymer modified cement slurry giving strength not less than that of new
concrete.
Plate bonding and RC jacketing are the common methods of strengthening RCC structures
(detail procedure and stages given in Fig 6.8). The cost difference between the two methods
is not significant. A choice has to be made between the two methods based on actual needs
and the suitability of each method with respect to the structural /architectural and other details
of buildings.

6.6.17 Propping and Supporting:

Problem arises in deciding on propping and supporting the structure to give relief in stresses
and strains in some of the existing weak members being strengthened. Mere vertical props

ADDED LONGITUDINAL
REINFORCEMENT

RESIN ADDED WELDED STRRUPS

CONCRETE
SEALING WITH
6 RESIN MIX

Fig 6.8(a) Column Strengthening Concrete Jacket

C.C. JACKETTING

1/2 THE THICKNESS OF PROPOSED

JACKETTING OR 40 MM WHICHEVER
IS MORE PROJECTING BEYOND THE
ORIGINAL COLUMN FACE

SHEAR KEY @ 300 MM C/C

PLACED STAGGERED

INSERTED LENGTH OF SHEAR KEY DIPPED

IN EPOXY EQUAL TO 4 TIMES THE DIA.
OF BARS OR 50 MM WHICHEVER IS MORE

EXISTING COLUMN EXISTING FACE OF DISTRESSED COLUMN

NOTE :- SHEAR KEY SHALL BE PROVIDED IN

LOCATIONS WHERE IT IS TO FUNCTION
AS SUCH i.e. SIDES OF COLS AND BEAMS
ETC.THEY SHALL NOT BE PROVIDED IN
THE SOFFIT OF THE BEAMS OR CEILING OF
SLAB

Fig 6.8(b) Details of Shear Key Bars

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 REHABILITATION AND RETROFITTING METHODS

sitting on some beams & slabs may not be enough.

Diagonal bracing to transmit the loads to the adjacent columns should also be considered.
The first item of schedule in Chapter 8 has been prepared which may be read in conjunction
with its related specifications in Chapter 9 and Fig 6.9

TOPMOST STOREY
4 C4

IMPORTANT
1 FOR PROPPING/SUPPORTING ANY COLUMN AT TOP,LOWEST
OR INTERMEDIATE STOREYS, PROPS SHALL BE PROVIDED AT
ALL STOREYS BELOW ALL BEAMS MEETING AT COLUMN.

PROP/SUPPORT 2 ALL PROPS SHALL BE CONCENTRIC i. e. AT THE SAME

3 C3 LOCATION IN ALL STOREYS.

3 PROPS/SUPPORTS SHALL BE MADE OF BUILT UP STRUCTURAL

SECTIONS OR TUBULAR STEEL OF ADEQUATE CAPACITY TO
BE ABLE TO RESIST TOTAL OF BEAM REACTIONS
FROM ALL UPPER STOREYS. USE OF BALLIES BAMBOOS
ARE TOTALLY PROHIBITED.
COLUMN TO BE REPAIRED
2 C2 4 SEQUENCE OF PROPS/SUPPORTS FIXING WOULD BE 1-2-3-4
WORKINGCLEARANCE i.e. FROM LOWEST TO UPPERMOST STOREY.
(TO BE KEPT MINIMUM) 5. SEQUENCE OF DISMANTLING COLUMNS IF REQUIRED WOULD
BE C4-C3-C2-C1 i.e. FROM TOP TO LOWER STOREY. 6
6. SEQUENCE OF REPAIRING COLUMN WOULD BE C1-C2-C3-C4
7 AEQUENCE OF PROP/SUPPORT REMOVAL WOULD BE 4-3-2-1
i.e. FROM TOP TO LOWER STOREYS.

1 C1

LOWEST STOREY A
ELEVATION
TUBULAR PIPE/BUILT UP PROP

FOOTING DESIGNED TO CARRY THE

TOTAL LOAD COMING ON PROP

PLAN DETAIL AT-A

Fig 6.9 Typical Arrangement For Propping & Supporting a Column to Releive at Form Load

6.6.18 Fibre Wrap Technique:

The fibre wrap technique, also known as Composite Fiber System is a non-intrusive structural
strengthening technique that increases the load carrying capacity (shear, flexural, compressive)
and ductility of reinforced concrete members without causing any destruction or distress to
the existing concrete. (Refer Fig 6.10)
There are two systems followed in adopting this technique:
a. Bi-directional Woven Fabric: This system comprises of woven fabric presoaked in
specially formulated epoxy and applied over prepared surface after application of epoxy
primer. Woven fibre fabric is composed of bi-directional high strength fibers that are
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 HANDBOOK ON REPAIRS & REHABILITATION OF RCC BUILDINGS

FIBRE WRAP

CONCRETE SECTION

TENSION CRACK

Fig 6.10 Fibre wrap technique for improving load carrying capacity of a column.

combined with specially formulated epoxy in a pre-determined proportion to form a

6
composite-Material. This composite material is wrap applied onto the reinforced concrete
or steel member requiring strengthening or protection and left to cure at ambient
temperature. The subsequent layer/s of unidirectional fibre fabric could be applied after
giving the required overlap along the direction of fibres as per design requirements
b. Uni-directional E-glass Fibres: This system comprises of precut unidirectional E-glass
fibre wrapped over epoxy primer applied prepared surface of member requiring structural
strengthening and/or surface protection. Subsequent to its wrapping, it is saturated with
epoxy using rollers and stamping brushes manually to remove air bubbles, if any and left
to cure at ambient temperature. The subsequent layer/s of unidirectional fibre fabric
could be applied after giving the required overlap along the direction of fibres as per
design requirements.
Though the underlying principle of the above two methods is more or less identical, but the
application techniques and basic materials adopted are at slight variance. Each of the above
systems has their own merits.
Enhancement in lateral drift ductility and horizontal shear carrying capacities of a concrete
member can also be obtained by confinement of the member by this method. The flexural,
shear and axial load carrying capacities of the structural members can be enhanced by
appropriate orientation of primary fibres of the composites. The resulting cured membrane
not only strengthens the reinforced concrete member but also acts as an excellent barrier to
corrosive agents, which are detrimental to concrete and the reinforcement. Ingress of water,
oxygen and carbon dioxide through the external surface of concrete member is prevented by
the application of composite jacket.
The system is useful for its structural enhancement and protection capabilities under severe
environmental conditions. It can be used for retrofitting of a wide variety of structures that

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 HANDBOOK ON REPAIRS & REHABILITATION OF RCC BUILDINGS

EXISTING NEW SPECIFIED BOND COAT

SPECIFIED GRADE CONCRETE

METHOD A

BOND COAT OF
SUNEPOXY 368
EXISTING NEW
M20 GRADE CONCRETE

METHOD A

BOND COAT OF
SUNEPOXY 368
EXISTING
6
M20 GRADE CONCRETE

NEW

METHOD A

Fig. 6.11 Column Compressive Strengthening by Section Enlargement

c. Joints: The joints play crucial for resisting earthquake forces. The joints can be
strengthening by enlargement, jacketing by steel collar and fibre wrap.
l Beams: These can be strengthened for:
a. Flexural Strength: The flexural strength of the beam can be enhanced by
i. Section enlargement in compression,
ii. Additional reinforcement in the tension. Caution shall be exercised to
ensure that section is not over reinforced while providing additional
reinforcement to compensate loss of reinforcement due to corrosion
etc.
iii. The provisioning for enhanced tensile strength if being undertaken,
this should be accompanied with corresponding increase in compression
as well .Due to such increased flexural capacities extra shear capacities
required to ensure ductile behaviour during earthquake shall also
considered for provision.
iv. MS plate bonding
v. High Strength Fibre Fabric Wrap Technique (without section
enlargement)

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ORIGINAL SECTION
INCREASED SECTION WITH MICRO CONCRETE/
SHORTCRETE SELF COMPACTION CONCRETE
FIXING OF STRRUP WITH
EPOXY AND QUARTZ SAND
MORTAR AS SPECIFIED

TENSION REINFORCEMENT

BEAM SECTION ENLARGEMENT

INCREASED SECTION WITH MICRO CONCRETE/

SHORTCRETE SELF COMPACTION CONCRETE
ORIGINAL SECTION
SPECIFIED BOND COAT
6

TENSION REINFORCEMENT

COMBINATION SLAB AND BEAM OVERLAY WITH BEAM ENLARGEMENT

Fig. 6.12 Beam Strengthening : Concrete Overlay And Section Enlargement

b. Shear Strength: The shear strength of the beam can be enhanced by any of the
following:
i.Section enlargement
ii.Shear ties anchored in compression zone of beam.
iii.Post tension strap around the section
iv. Diagonally anchored bolts (the holes are drilled perpendicular to the
possible shear cracks)
v. MS Steel plate bonding
vi. Fibre wraps
l Slabs: The performance of the slab can be improved by providing overlays
(in case of negative moment deficiency) or underlay (in case of positive moment
deficiency). The addition of overlay/underlay will also increase the stiffness of
the slabs and control the excessive deflections problems. The slabs are generally
safe in shear and as such no need is likely to occur for shear strengthening except
flat slabs near column capital.

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 HANDBOOK ON REPAIRS & REHABILITATION OF RCC BUILDINGS

NEW REINFORCEMENT OVERLAY WITH MICRO-CONCRETE

SPECIFIED BOND COAT

EXISTING SLAB

OVERLAY ON TOP OF SLAB

SPECIFIED BOND COAT EXISTING SLAB

NEW REINFORCEMENT OVERLAY WITH SHORTCRETE

Fig. 6.13 Slab Strengthening : Concrete Overlay

Structural repairs to Columns/beams/slabs due to corrosion of reinforcement are most

frequented in the normal practice. The step by step sequence of repair stages have been
given in Annexure 6.1 for structural repairs to RCC columns, beams and slabs under
different conditions of deterioration

6.7.3 Compressive Strength of Concrete: The concrete strength can be enhanced substantially
by impregnation with specific polymers. The process has already been explained under section
6.5.9

6.7.4 Cracks/Joints: The concrete and masonry are weak in tension. The cracks indicate the
tensile failure of the material. The cause of cracking should be examined in detail and remedial
measures taken accordingly. Inactive (i.e. non-moving) cracks in masonry can be repaired
by stitching. Grouting with non-shrink grouts also repairs these types of cracks. The active
cracks required for accommodating thermal movements shall be repaired by suitably locating
the expansion joints and filling them with flexible materials like poly-sulphides, bituminous
fillers etc.

6.7.5 Masonry: The masonry may be required to be strengthened for resisting earthquake forces
by external pre-stressing, splint and bandage methods. The techniques are explained in IS:
13935-1993

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REPAIR STEPS :

MARK AND DRILL HOLES ON BOTH

SIDES OF THE CRACK

CHASE A GROOVE BETWEEN

THE DRILLED HOLES

INSERT U-SHAPED M.S. BARS

IN THE HOLES AND SPAN
ACROSS THE CRACK

GROUTING THE HOLES WITH EITHER

EPOXY OR NON-SHRINK GROUT

Fig. 6.14(a) Stitching Method of Rapairing Wall/Slab Cracks

REINFORCED CEMENT
CONCRETE 1:2:4

REINFORCEMENT BARS

CRACK

Fig. 6.14(b) Elevation of Brick Masonry Wall Showing Typical Cracks (Vertical or Diagonal)

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 HANDBOOK ON REPAIRS & REHABILITATION OF RCC BUILDINGS

Appendix 6.1
Structural Repairs to RCC Columns, Beams and Slabs
CASE-I: Crack Repair and Protective Coating for less damaged structural members
like minor/hair cracks or spalling from beams and columns, where
carbonation depth in cover concrete has not reached reinforcement level.
Caution: It may be stated that recommended measures are cosmetic measures.
The distress may continue to take place even after repairs, if the protective coating,
provided as per step no. 7 below, is damaged or ineffective.
Step-1: Measures shall be taken to ensure that no seepage/leakage etc. affects
the RCC columns/beams.
Step-2: The plaster/finishes over the RCC columns/beams shall be removed as
per relevant item in sub head 2 of Chapter 8 and relevant specifications
in Chapter 9. The concrete surface exposed, spalled and loose cover
concrete removed, cracks marked after close examination on the surface
of concrete. Whereas the good surface of concrete shall be hacked and
roughened for receiving the repair as per relevant item in sub heads 4 &
5 of Chapter 8 and relevant specifications in Chapter 9.
Step-3: Wherever loose/spalled cover concrete is removed, it shall be repaired
6
with polymer modified cement mortar, done up in layers as per
nomenclature of items in sub-heads 4 & 5 of Chapter 8 and relevant
specifications in Chapter 9.
Step-4: All cracks in RCC columns/beams wherever noticed shall be sealed by
injection grouting through nipples fixed along the crack line as per
nomenclature of items in sub head 3 of Chapter 8 and relevant
specifications in Chapter 9.
Step-5: Over the prepared surface of RCC columns/beams, 6 mm thick 1:3
cement sand plaster shall be applied with polymer modified cement

NARROW AND DEEP CRACK

FAST-SETTING POLYESTER RESIN PUTTY

PRE-DRILLED INJECTION POINT

ENTRY PORT WITH ONE-WAY NIPPLE CHASE A V-GROOVE ALONG THE CRACKS
FOLLOWED BY WATER-JETTED CLEANING
CL

5 4 3 2 1 6 7 8 9

ALTERNATIVE A
CL

8 6 4 2 1 3 5 7 9

ALTERNATIVE B
SEQUENCE OF INJECTION OPERATION

Fig. 6.15 Crack Sealing with Resin Injection Technique

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Step-5: Fix shear key bars of appropriate diameter at specified spacings in both
directions over the surface to be covered with repair materials as per
the nomenclature of items in subhead 2 of Chapter 8 and relevant
specifications in Chapter 9.
Step-6: The rusted reinforcement shall be cleaned of rust and passivated and
applied bond coating as per the nomenclature and of items in subhead 4
of Chapter 8 and relevant specifications in Chapter 9.
Step-7: The prepared concrete surface shall be covered with appropriate mix of
polymer modified cement sand mortar in layers including behind
reinforcement over a bond coat with polymer modified cement slurry
as per the nomenclature of items in subhead 4 & 5 of Chapter 8 and
relevant specifications in Chapter 9. The mortar cover thickness shall
be not less than 15 mm over the reinforcement. The maximum thickness
shall be not more than 30 mm with each layer not exceeding 10 mm.

CUT AT RIGHT-ANGLE WITH THE

HELP OF DISC TYPE MECHANICAL
CUTTER

REQUIRED OVER-CUT BEYOND REINFORCEMENT

BAR FOR CONCRETE COVER TO REINFORCEMENT 6

STEP-1 REMOVE ALL DEFECTIVE CONCRETE AND PARENT CONCRETE

EXPOSE CORRODED REINFORCING BARS
TO THEIR FULL CIRCUMFERENCE

STEP-4 PATCH WITH REPAIR MORTAR

OR CONCRETE AND RESURFACE
TO REQUIRED THICKNESS
STEP-2 REMOVE THE CORROSION PRODUCT FROM
REINFORCING BARS UNTIL THEY SHINE

STEP-3 APPLY ANTI-CORROSIVE PROTECTIVE PROTECTIVE SURFACE

FINISH FOLLOWED WITH
PASSIVATING COAT TO PROTECT
DECORATIVE FINISH
REINFORCING BARS
STEP-5 APPLY PROTECTIVE COATING
AND FOLLOW UP WITH
DECORATIVE PAINTING

Fig. 6.16 Typical repair procedure for patch repair and corrosion damaged concrete

Step-8: Water curing shall be carried out for a minimum period of 7 days as per the
nomenclature and of items in subhead 6 of Chapter 8 and relevant
specifications in Chapter 9.
Step-9: Necessary white washing /painting of the surface may be carried out
after the curing period is over and the surface gets dried up.

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(ii) Shotcreting: (For repair jobs covering large areas and/ or large magnitude)
Stepwise sequence of methodology to be adopted is given hereunder
Step-1: Step no. 1 to 6 shall be same as in case of no. (i) above.
Step-7: Shotcreting with average thickness of 50 mm shall be done within the
tacking period of epoxy bond coat to be applied over the prepared surface
of concrete.
Step-8: Finishing plaster if necessary, may be provided within 48 hours of
shotcreting without allowing the RCC slab to become dry during the
intervening period.
Step-9: Water curing shall be carried out for a minimum period of 7 days as per
the nomenclature and of items in subhead 6 of Chapter 8 and relevant
specifications in Chapter 9.

STAGE 1 STAGE 2 STAGE 3

FIRST STAGE FIRST STAGE PREVIOUSLY GUNITE/

GUNITE / SHORTCRETE GUNITE / SHORTCRETE SHORTCRETE SURFACE

6
TIMBER FORM WORK AND
CROSS FRAMING SECOND STAGE
GUNITE / SHORTCRETE
SHUTTER FINISHED SURFACE
(A) BEAM REPAIR (TIMBER FORM WORK REMOVED)

TIMBER FORM WORK AND SHUTTER FINISHED SURFACE

CROSS FRAMING (TIMBER FORM WORK REMOVED)

FINISHED GUNITE/
FIRST STAGE SHORTCRETE
GUNITE / SHORTCRETE

a. REMOVE COVER CONCRETE
SECOND STAGE
GUNITE / SHORTCRETE
b. FIXED SCREEDS AND SPRAY TWO SIDES c. SPRAY REMAINING SIDES AND
APPLY FLASH COAT TO FULL AREA
(B) COLUMN REPAIR

Fig. 6.17 Typical Column repair by Guniting

VI-34 Repairs & Rehabilitation Unit

 REHABILITATION AND RETROFITTING METHODS

Appendix 6.2
TREATMENT OF DEPRESSED FLOOR IN TOILETS/KITCHEN
Stepwise sequence of methodology to be adopted is given hereunder
Step-1 Remove all materials /flooring from the sunken floors and expose the drainage
pipes/G.I. water supply lines.
Step-2 Test the G.I. water supply lines less than 6 kg per sq.cm. Water pressure
using the pressure-testing machine with pressure guage, which is readily
available in the market.
Step-3 Test the drainage pipes and other joints for leakages if any, by plugging of
horizontal pipe at tee junction with vertical stack and filling with water upto
the finished floor level for 48 hours. Leakages noticed, if any, shall be attended
to.
Step-4 Provide 40 mm dia G.I.pipe spout and CC flooring with water proofing
compound laid in slope(1:48 minimum) for draining out leaking water, if
any, from the sunken portion in the shaft.
Step-5 Provide 12mm thick cement plaster 1:3(1cement:3 fine sand) mixed with
water proofing compound on the vertical walls of the sunken portion including
providing necessary repair around the drainage spout provided.
6

CEMENT PLASTER
WATER TIGHT JOINT
BRICK WALL
BITUMEN COATING
KHURRA 150 X 150 (MIN.)

"A"

DRAINAGE SPOUT
R.C.C. SLAB R.C.C. BEAM
GRADING CONC. 1:1.5:3
(WITH NEAT CEMENT PUNNING)
STONE AGGREGATE
CEMENT CONC. 1:5:10
FLOORING
DETAIL AT "A"

STEP 1 - PROVIDE DRAINAGE SPOUT

STEP 2 - GRADING CONCRETE 1:1.5:3 LAID TO SLOPE TOWARDS DRAINING SPOUT WITH FLOATING COAT OF NEAT CEMENT

STEP 3 - PROVIDE AND LAY WATER SUPPLY & DRAINING PIPES & TEST FOR LEAKAGE THE DRAINAGE /SANITARY PIPES
SHALL BE LAID TO SLOPE AND A CLEAR GAP UNDERNEATH THE PIPES SHALL BE MADE AVAILABLE BY PROVIDING SUITABLE
C.C. BLOCKS AT APPROPRIATE LOCATION FOR FREE FLOW (OF LEAKED WATER ,IF ANY ) TOWARDS DRAINAGE SPOUT.

STEP 4 - 18 MM TH. CEMENT PLASTER 1:3 ON VERTICAL FACES MIXED WITH POLYMER MODIFIED WITH WATER PROOFING
COMPOUND AND FLOATING COAT OF POLYMER MODIFIED NEAT CEMENT SLURRY & COATED WITH BITUMEN (2 COATS)

STEP 5 - 150 MM TH. 20 MM SINGLE SIZED STONE AGGRAGATE TO PROVIDE A FILTER MEDIA FOR ANY LEAKING WATER TO
TRAVEL TO DRAIN SPOUT BELOW C.C. 1:5:10 ( 1-CEMENT : 5-COARSE SAND : 10-40 MM & DOWN GRADED STONE AGGREGATE )

NOTE :- 1. WATER PROOFING TREATMENT SHALL BE UNDERTAKEN ONLY WHEN ALL DRAINAGE PIPES / SANITARY PIPES /
DRAINAGE SPOUT ETC. HAVE ALL BEEN LAID AND TESTED.

Fig. 6.18 Typical arrangement for treatment of Depressed Floor of Toilets etc.

Central Designs Organisation VI-35