Structural Health Assessment Internship Report PDF

Structural health assessment of Indian Rayon, Veraval
An Internship report
on
“Structural health assessment

of Indian Rayon, Veraval”
By
Jaykumar J. Bavarva
Trainee- Design Engineer
UICCPL, Vadodara
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2015-2016
Ushta Infinity Construction Co. Pvt. Ltd.

Preface
The golden opportunity for any Structural engineering student is to know about
the actual technical work of any industry. “Practice makes man perfect.” In this
perspective it is the necessity of practical training for every M.Tech student to
support and to expand the deep sense of practical engineering work. The aim
and purpose behind this industrial training is to lead the students to get more
efficiently skills and the knowledge of real technical work/practices which may
help them to become a successful engineer. Forensic structural engineering
field is like a coin. It has two sides one is theoretical and another is practical
engineering approach. Both are very necessary aspects to learn for engineering
students.
As a Part of practical approach, industrial training is very important for the

structural engineering students. As a trainee, I worked under Ushta Infinity
Construction Company Pvt. Ltd., Vadodara. As a trainee design engineer of
UICCPL I worked on project of structural health assessment of Indian Rayon (A
unit of Aditya Birla Nuvo Ltd.) Veraval, Gujarat. It was great opportunity for me
to explore such a big and vibrant company. And I tried my level best to make
this training most successful. I got very cordial support from all the employees
who shared their working experience with me, as such a way this training period
has become a precious reminiscence for me.
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Acknowledgement
I am thankful to the management of “Ushta Infinity Construction Company Pvt.

Ltd., Vadodara.” Who permitted me for doing the training within and exposure
of functioning of big corporate for the period of 90 days. A project of this nature
calls for intellectual nourishment and professional help from many people.
I therefore, deeply express my gratitude to all the employees of UICCPL and

special Mr. Kaizaad Engineer and Mr. Harish Sheth who guided me and support
me.
I would like to thank Ms. Behnaaz Panthaki, HR manager, for providing me this
opportunity to learn the basic nitty-gritty’s of structural assessment in the
prestigious company of UICCPL.
I am also thankful to Mr.Anindya Chatterji and Mr. Sourav Maity (Librarian)

for his cooperation to provide relevant help that made my task smooth.
I finally express my gratitude to all those who directly or indirectly rendered the
assistance, guidance and support for the internship done by me in the company.
Last but not the least, I am greatly indebted to my God, my parents, my family
members and my friends without whose blessing and guidance I think I could
not have reached this moment in my life.
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CONTENTS
1 Preamble 5
2 Visual Inspection 6
2.1 Cracks 6
2.2 Chemical attack 22
2.3 Honeycombing 25
2.4 Delamination 25
3 Non Destructive Test 28
3.1 Caustic_HCL 28
3.2 Packing Section 30
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Chapter 1
Preamble
A study on overall structure assessment has been conducted in Indian Rayon,

one of the blue chip units of the Aditya Birla Group of Companies. Indian Rayon,
the VFY unit of Aditya Birla Nuvo, is a major player in the Indian viscose filament
yarn business. The unit enjoys a 30 per cent domestic market share, making it
the second largest producer of viscose filament yarn in India. The report
discusses the brief overview of visual inspection, Non Destructive Testing of
various structure.
This document covers observations of primary evaluation and present condition

of structure, details of Non-destructive/Partial destructive tests and condition of
concrete. Report is divided into following points:
 Conditional Assessment of existing building

 Observations and conclusions based on Non Destructive/Partial
Destructive tests.
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Chapter 2
Visual Inspetion
Following are the main defects shown during visual inspection of various section
of Indian Rayon:
 Cracks
 Corrosion of embedded metals
 Bulging/ buckling of section
 Delamination of paint
 Spalling of concrete cover
 Chemical erosion
 Honeycombing in concrete
2.1 Cracks
Concrete cracks. In fact, it is designed to crack to be able to fully engage the
reinforcing steel. Concerns with concrete cracking come up when owners and
maintenance workers are unsure of what to look for or are unaware of the
implications of certain cracks. Some types of cracking indicate a structural issue,
when others do not indicate any type of issue other than normal weathering.
There are many different causes of cracks, which can lead to different types of
cracking patterns. Each type of cracking pattern can be associated with a likely
cause. If this cause is recognized, it can be identified as structurally vital or non-
vital. It is of particular interest in discerning between these two so that the
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failure and damage of these can be avoided or at least predetermined to

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minimize economic damage, future deterioration, and in severe cases the loss
of human life.

2.1.1 Why cracks form in concrete structures

Concrete provides structures with strength, rigidity, and resilience from
deformation. These characteristics, however, result in concrete structures
lacking the flexibility to move in response to environmental or volume changes.
Cracking is usually the first sign of distress in concrete. It is, however, possible
for deterioration to exist before cracks appear. Cracking can occur in both
hardened and fresh, or plastic, concrete as a result of volume changes and
repeated loading. This involves tensile stresses being loaded onto the concrete,
the cracks occurring when the force exceeds its maximum tensile strength.
It is important to understand the reasons why cracking occurs, the type of crack
formed, and cracks’ effects on structural stability. Once you understand these
points you can take the appropriate action. This may mean leaving the crack
alone, injecting the crack with an appropriate material, or applying other
suitable repair methods.
2.1.2 Causes of Cracking
 Overloading
The cross section of concrete is designed with both calculated and estimated
loads, determined from building codes. Design includes such factors as the
strength of the concrete, the number, sizing, and placement of reinforcing bars,
and size and shape of the concrete cross section. When a structure is
overloaded to the extent not covered in safety factors, concrete may be
7
damaged or fail. Overloading may be in shear, flexure, or tension, or may be a

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result of fatigue or cyclic loading. Each of these has a different cracking pattern
to look for (see Loading Cracks below).

 Corrosion
Corrosion of the reinforcing steel in concrete can be a major structural issue.
Under normal conditions, the pH level of concrete is high (above 12.5). The high
pH of concrete allows an inactive layer of ferric oxide to form around the
reinforcement, preventing rust (Khan 2006, p. 14).
There are two major causes of corrosion in the reinforcing steel: chloride
penetration and carbonation. Chloride penetration reduces the pH level of the
concrete when oxygen, chlorides, and moisture all penetrate the concrete (Pirro
2012, p. 20). Chlorides can be found in potable water, which should never be
used to mix concrete. They are also an environmental factor that may add up
over the lifespan of a structure. For instance, buildings exposed to salt water or
de-icing salts may experience faster chloride build up from the salts (Emmons
1993, p. 12). The chloride penetration process can be viewed in Figure 1.
Carbonation occurs when carbon dioxide and moisture infiltrate the concrete,
reducing the pH level of the concrete (Pirro 2012, p. 29). This process can be
seen illustrated in Figure 2. Both causes of corrosion end similarly. The pH level
is the concrete’s last barrier against corrosion, so the reinforcement begins to
rust (Khan 2006, p. 14). Rust expands the steel to 10 times the volume, which
can cause major problems in the structure (see Spalling below).
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Fig. 1: Process of chloride penetration

Fig. 2: Process of carbonation
 Freeze/Thaw
When water freezes, it expands about 9%. As the water in moist concrete
freezes, it produces pressure in the capillaries and pores of the concrete. If the
pressure exceeds the tensile strength of the concrete, the cavity will dilate and
rupture. The accumulative effect of successive freeze-thaw cycles and
disruption of paste and aggregate can eventually cause significant expansion
and cracking, scaling, and crumbling of the concrete. Local weather records can
also be referenced to more precisely determine the severity of exposure. The
resistance of concrete to freezing and thawing in a moist condition is
significantly improved by the use of intentionally entrained air. Entrained air
voids act as empty chambers in the paste for the freezing and migrating water
to enter, thus relieving the pressure in the capillaries and pores and preventing
damage to the concrete
Concrete with low permeability is also better able resist the penetration of
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water and, as a result, performs better when exposed to freeze-thaw cycles.

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The permeability of concrete is directly related to its water-to-cement ratio—

the lower the water to cement ratio, the lower the permeability of the
concrete.

Freezing and thawing cycles can be very detrimental to concrete over time.
Unless a protective coating is applied to the concrete, each cycle allows more
moisture to penetrate into the concrete. The stress of the moisture freezing
inside the concrete causes larger defects with each cycle. Air-entrained
concrete can be used to help alleviate some of the expansive stresses of harsh
temperature changes. However, not all freeze/thaw effects can be assuaged in
this way and many structures may succumb to cracking either caused or
worsened by these cycles. Manufacturers of crack repair kits suggest that cracks
less than 1/16" in thickness can be repaired without professional contractors
("Types" 2012). However, tolerable crack widths may be significantly less than
this (0.016" and less depending on the environment) because cracks may allow
deteriorating chemicals to damage the concrete in other ways (Emmons 1993,
p.13).
 Alkali-Aggregate Reaction (AAR)

AAR refers to chemical reactions taking place within the concrete mix. Certain
aggregates inside the concrete may react with alkalis, causing concrete
expansion. The alkalis may be also be from within the concrete mix, or may be
from outside sources like sea or ground water, or deicing salts. Depending on
the type of aggregate, AAR also goes by other names. In siliceous aggregates,
the reactions are called "alklali silica reactivity" (ASR). In dolomitic carbonate
rocks, the reactions are called "alkali-carbonate reactivity" (ACR) (Khan 2006,
p.15).
When these types of ractions occur, they create a gel-like substance that swells
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when moisture reaches it. The stresses from the swelling create internal tensile
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forces, which may crack the concrete from within (Khan 2006, p.15).

 Shrinkage
Concrete shrinkage may occur throughout a structure’s life cycle for different
reasons with the majority occurring within the first few months or years after
casting. There are two primary categories of shrinkage: plastic (before
hardening), and drying (after hardening). Immediately after concrete is poured,
there can be settlement shrinkage, construction movement (e.g. formwork
movement or removal), and drying shrinkage. After the concrete has fully
hardened, a structure will undergo temperature, volume and chemical changes
throughout the years (Winterbottom, p. 2). Each of these may also cause
concrete shrinkage.
This is the main cause of cracking in hardened concrete. This cracking takes
place near the restraints due to volume changes in the concrete. When
concrete is exposed to moisture it swells and when it is exposed to air with
relatively low humidity it shrinks, such air drawing water out of its cement
paste, which is cement and water. If the shrinkage could occur without restraint
no cracking would result, but in most cases the requirements of structural
support makes this impossible. This cracking is the result of a combination of
factors that influence the magnitude of the tensile stresses that cause it. These
factors include the amount and rate of shrinkage, the degree of restraint, the
modulus of elasticity, and the amount of creep. Additional factors to be aware
of include the type of aggregate, water content, binder type, and the concrete’s
mix proportions and mechanical properties. The amount and type of aggregate
and the cement paste are the main influences on the amount of drying
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shrinkage. To minimise the amount of shrinkage it is best to use a stiff

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aggregate in high volumes relative to the cement paste. The rate of shrinkage
increases with the volume of cement paste. The aggregate provides internal

restraints to shrinkage. Similarly, increases in the ratio of water to cement in the

cement paste increase the level of shrinkage by increasing the potential for
volume loss through water evaporation.
A greater volume of stiff aggregate

reduces concrete shrinkage, as the
aggregate provides restraints. This
reduces the tensile stresses and thereby
minimises concrete cracking.
Reducing the volume of aggregate

increases the movement in the
concrete during shrinking, as the
aggregate provides less restraint.
This increases drying shrinkage and
consequently the tensile stresses
causing concrete cracking.
Fig. 3: The effects of aggregate volume on concrete shrinkage
Shrinkage is an expected phenomenon in a concrete structure, and can often be

controlled with stress-relieving joints and properly placed reinforcing steel. The
optimum condition for preventing drying shrinkage is a relative humidity of
100%. This is rarely possible, so sealing the concrete surface to prevent
moisture loss can control the amount of shrinkage, and the use of suitably
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spaced contraction joints and proper steel detailing allows shrinkage to occur in
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a controlled manner.

 Poor Workmanship
Concrete itself is so variable that properly constructing a concrete structure can

be difficult. Some issues related to workmanship are as follows: over/under
consolidated aggregates, improper location of rebar, over watering for
workability, finishing surface before bleeding occurs. Each of these may end up
not mattering overall, or may contribute to a structural failure.
2.1.3 Types of Cracks

Concrete cracking and defect patterns can often indicate its cause or causes and
can help to define whether the crack is architectural (affecting aesthetics only)
or structural (may affect the load carrying capacity). Some of the main types of
cracking are described below.
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Fig. 4: Types of cracks

 Crazing
Crazing is a web-like series of fine cracks, usually at the surface of the concrete.
These can be caused by surface shrinkage, which can occur in low humidity, hot
air or sun, and wind (PCA 2001, p. 3). Since these cracks occur on the surface
and do not penetrate deeper into the concrete, they do not indicate a deeper
structural issue. A general pattern of crazing can be seen below in Figure 3.
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Fig. 5: Crazing pattern (Caustic_New Chlorine Filling)

 Disintegration
Concrete disintegration can be a result of freeze/thaw cycles on the surface.
Moisture enters concrete pores and expands. The expansions can cause
microcracking or they may force off a small amount of the surface. Figures 4
and 5 depict disintegration on concrete surfaces. When tiny pieces of the
surface come off, it is called disintigration (Pirro 2012, p. 38).
Fig. 6: Concrete disintegration around column joint (Caustiuc_ HCL)
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Fig. 7: Base disintegration (Caustic_ Salt Unloading Area)

 Scaling
Scaling appears as small divets in the concrete surface in which aggregate may
be exposed. Scaling is often caused by freeze/thaw cycles (PCA 2001, p. 10).
Because scaling is a surface defect, it does not generally indicate a more serious
structural issue.
 Delamination
Delamination occurs when the surface of a slab is finished prematurely. When
concrete cures, it is necessary for the excess water to escape to the surface (a
process called “bleeding”). If a slab is finished before bleeding has occurred, it
can trap the water below the surface. When the water does escape, it leaves
hollow patches just below the surface. These patches may break open,
resembling shattering, to expose the aggregate below as seen in Figure 8 (PCA
2001, p. 12). This type of defect occurs near the surface, and does not indicate a
structural threat (unless over a cantilever, where the reinforcing steel is near
top portion of the slab).
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Fig. 8: Delamination of concrete caused by premature finishing

(Caustic_Salt Yard)

 Overloading Cracks
Overloading a concrete member may cause several types of cracks. Depending
on the direction and location of the crack (vertical, diagonal, top, bottom, etc),
the type of loading stress can be identified. For example, vertical cracks at the
bottom of a simply supported beam and in the center indicate positive flexural
cracks. Negative flexural cracks show up over the supports on the top of the
beam, also as vertical cracks (Pirro 2012, p. 47). It should be noted that flexural
cracks may be related to longitudinal splitting cracks. This relationship is based
on splitting cracks allowing moisture to reach the steel pieces in the concrete
and corrode them, reducing their ability to resist flexure cracks. Reduction in
resistance may cause additional flexural cracks (Giuriani 1998, p. 1). Shear
cracks may appear as diagonal cracks at quarter points along the beam member
(Pirro 2012, p. 47). See the diagram below in Figure 9 for better understanding
of locations of cracking. These cracks can indicate a deeper structural issue if
the crack width or lateral displacement exceeds 1/4" (CFA 2005, p. 3).
Fig. 9: Diagram of locations and directions of overloading cracks

[Diagram Credit: Robert Pirro]
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Fig. 10: Flexural crack (Caustic_Salt Yard)
 Spalling
Spalling is primarily a result from the corrosion of the reinforcing steel and/or
embedded objects such as clips, chairs, anchors, etc. When the steel corrodes,
the rust expands to 10 times the original volume, creating internal tension
forces in the concrete . Concrete is unable to handle the tension forces, and the
pieces between the corroded steel and the nearest surface will break off, called
"spalling" (PCA 2001, p. 12). Even just a small spall can indicate a much larger
issue for two main reasons. First, a small spall can expose the steel, leaving it
ultra-vulnerable to more corrosive elements. This can been seen in Figure 10. If
the steel corrodes more, there will be more spalling, as seen in Figure 11.
Second, a spall in one area may be the first piece of a larger issue beneath the
surface. It is likely that other rebar in the immediate area has also been affected
by the corrosive effects and will begin to spall soon. Small spalls are relatively
simple and inexpensive to fix, and repairing these early on can help to avoid
large spalling areas. A large spall area in a slab may indicate immediate danger
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to a structure. If enough concrete has spalled off of the bottom, exposing the
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reinforcing grid, then the concrete and steel are no longer working together to
handle the compressive and tension forces. Essentially, when the concrete

reaches its tensile limit, it will fail. The steel is not engaged by the concrete to
take the excess tensile forces, and is only acting as a cage to hold up the
concrete. At this stage, repairs may be enormously expensive. Figure 12 shows
a whole building spalling failure.
Fig. 11: Small spall area caused by corrosion of

reinforcment (Old AT GF)
2.1.4 The Position and Characteristics of the Concrete Construction cracks
The cracks in the concrete walls mainly occur as: vertical cracks, horizontal
cracks and other cracks and cracks normally occur on the surface layer,
sometimes it causes entire wall surface crack, even cracks through the wall. The
position and characteristics of the cracks in the concrete wall:
1. There are horizontal and diagonal cracks around door and window
openings, below lintel. And around the hole drilled for buried electrical
equipment, fire hydrants and other equipment often appear extended
upward cracks along the top corner of hole.
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Fig. 12 Cracks around window opening

2. The connections between wall and beam often appear horizontal cracks;
the cracks normally penetrate through the wall. The connections
between wall and column often appear vertical cracks; the cracks
normally penetrate through the wall. The walls below the beam also
easily appear vertical and diagonal crack.
Fig. 13 Cracks on the column (Spinning Hall)
3. Cracks in the middle of wall normally appear as horizontal cracks and

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vertical cracks, those cracks caused by destruction of mortar, and the

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length of cracks are big.

2.1.5 Precaution of Concrete Construction Cracks
1. During the concrete elements deliver from factory to building site, should
use cover to protect; put wooden batten under concrete elements; keep
distance between two elements in order to have ventilation cap between
each other; avoid being wet in building site.
2. Better to be used after two month of maintenance, never use before
28days since produced. If the concrete elements haven’t dry yet, should
use some measures to make them dry in order to reduce shrinkage of
concrete wall.
4. Try to avoid working in hot day or cold day, if it has to be work in such
days, should sprinkle water on concrete in hot days or use insulation
protect concrete in cold days.
5. If the wall longer than 5m, should set load bearing column in the wall,
and set around 100mm reinforcement concrete beams under windows.
6. Set expansion joints in every certain distance (depends on the regulation)

according building regulation.
7. Should not erect concrete elements more than 1.8m high every day, if
the wall is higher than 3m, leave the top 2 layers of concrete element for
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next day in order to finish settlement on bottom layer.

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8. Keep in touch with electrician, plumber in order to make sure where the
electricity wire and sewer pipe is, avoid recessing again on the finished
wall.
2.2 Chemical attack
Concrete performs well when exposed to various atmospheric conditions,

water, soil, and many other chemical exposures. However, some chemical
environments can deteriorate even high-quality concrete. The deleterious
effects of some common chemicals on concrete are shown in the fig. 13.
Fig. 13 Chemical erosion in beam (Spinning hall)
Concrete is rarely, if ever, attacked by solid, dry chemicals. To produce

significant attack on concrete, aggressive chemicals must be in solution and
above some minimum concentration.
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Acids
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In general, portland cement concrete does not have good resistance to acids. In
act, no hydraulic cement concrete, regardless of its composition, will hold up for
long if exposed to a solution with a pH of 3 or lower. However, some weak acids

can be tolerated, particularly if the exposure is occasional. Acids react with the
calcium hydroxide of the hydrated Portland cement. In most cases, the chemical
reaction forms water-soluble calcium compounds, which are then leached away
by aqueous solutions.
The products of combustion of many fuels contain sulfurous gases which

combine with moisture to form sulfuric acid. Also, certain bacteria convert
sewage into sulfuric acid. Sulfuric acid is particularly aggressive to concrete
because the calcium sulfate formed from the acid reaction will also deteriorate
concrete via sulfate attack.
In addition to individual organic and mineral acids which may attack concrete,
acid-containing or acid-producing substances, such as acidic industrial wastes,
silage, fruit juices, and sour milk, will also cause damage. Animal wastes contain
substances which may oxidize in air to form acids which attack concrete. The
saponification reaction between animal fats and the hydration products of
Portland cement consumes these hydration products, producing salts and
alcohols, in a reaction analogous to that of acids.
Acid rain, which often has a pH of 4 to 4.5, can slightly etch concrete, usually
without affecting the performance of the exposed surface. Any water that
contains bicarbonate ion also contains free carbon dioxide, a part of which can
dissolve calcium carbonate unless saturation already exists. This part is called
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the “aggressive carbon dioxide.” Water with aggressive carbon dioxide acts by
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acid reaction and can attack concrete and other portland cement products
whether or not they are carbonated. Calcium-absorptive acidic soil can attack
concrete, especially porous concrete. Even slightly acidic solutions that are lime

deficient can attack concrete by dissolving calcium from the paste, leaving
behind a deteriorated paste consisting primarily of silica gel.
To prevent deterioration from acid attack, portland cement concrete generally

must be protected from acidic environments with surface protective
treatments. Unlike limestone and dolomitic aggregates, siliceous aggregates are
acid-resistant and are sometimes specified to improve the chemical resistance
of concrete, especially with the use of chemical-resistant cement. Properly
cured concrete with reduced permeability experience a slightly lower rate of
attack from acids.
Salts and Alkalis

The chlorides and nitrates of ammonium, magnesium, aluminum, and iron all
cause concrete deterioration, with those of ammonium producing the most
damage. Most ammonium salts are destructive because, in the alkaline
environment of concrete, they release ammonia gas and hydrogen ions. These
are replaced by dissolving calcium hydroxide from the concrete. The result is a
leaching action, much like acid attack. Strong alkalies (over 20 percent) can also
cause concrete disintegration.
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Fig. 14 Chemical erosion (Spinning hall)

2.3 Honeycombing
Honeycomb occurs when mortar fails to fill the spaces between coarse
aggregates (Fig. 15). Congested reinforcement, segregation, and insufficient fine
aggregate contents can contribute to honeycombing. Higher concrete slumps
and vibration may assist in preventing honeycombing by increasing the flow
ability of the concrete.
Fig. 15 Honeycombing (Caustic_ Salt Yard)
2.4 Delamination
Delaminations occur when air and bleed water become trapped under a
prematurely closed (densified) mortar surface. The trapped air and bleed water
separate the upper 3- to 6-mm (1⁄8- to 1⁄4-inch) layer of mortar from the
underlying concrete.
Delaminations are very difficult to detect during finishing and become apparent
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after the concrete surface has dried and the delaminated area is crushed under
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traffic. A smaller and more noticeable form of delamination is a blister, a bump

that forms at the concrete surface from trapped air and bleed water (Fig. 16).

Fig. 16 Delamination of paint(Caustic_Chlorine filling area new)
The primary cause of delaminations is finishing the surface before bleeding is

complete. Delaminations are more likely to occur when factors that extend the
bleeding time of concrete are combined with factors that accelerate surface
setting.
Observations of visual inspection

 Water leakaging spots observed at various locations.
 Minor and major cracks observed in structural members.
 Cracks running parallel to main reinforcement observed in several beams
and columns.
 50 to 100 mm thick jacketing/plastering observed in some of the columns
up to some height.
 Corrosion observed in corner angles inserted inside column.
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 Openings are provided in slab at various locations for passing of duct.

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Concrete cover has been lost near some of these openings and
reinforcement found corroded.

 Loss of concrete cover has been observed in several beams and slabs and
exposed reinforcement found corroded.
 Local repair patches observed in various structural members.
 Some of the structural members coated with PU paint.
Note: Observation of each structural member noted during visual inspection are
already given to Mr. Harish Seth.
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Chapter 3
Non Destructive Test
Various Non Destructive Test name as Rebound Hammer, UPV, Half Cell, Cover
meter and partial NDT core cutter done during training in various section. NDT
done on various section such as Old AT GF, Old AT Basement, Dryer room,
Packing Section, New AT GF & FF, Caustic_HCL, Caustic_Salt Unloading Yard, Salt
Yard etc.
Following are two section such as Packing section & Caustic_HCL consider for
analysis of NDT result.
Caustic_HCL
UPV Test & Rebound Hammer Test
UPV (km/s) test (Caustic_HCL)

<=3 km/s
4%
>4.5 km/s 3 to 3.5 km/s

27% 13% <=3 km/s
3 to 3.5 km/s
3.5 to 4 km/s
3.5 to 4 km/s 4 to 4.5 km/s
29%
>4.5 km/s
4 to 4.5 km/s
27%
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Fig. 17 UPV Test result of Caustic_HCL Section

Rebound Hammer (Caustic_HCL)

70<RH
0% 30<=RH<40
2%
40<=RH<50
14%
30<=RH<40
40<=RH<50
50<=RH<60
60<=RH<70
51% 60<=RH<70
50<=RH<60
33% 70<RH
Fig. 18 Rebound hammer test result of Caustic_HCL Section
UPV Test results suggest 4% quality of concrete is doubtful, 13% portion is of

medium quality, 82% is of good quality. Higher value of rebound numbers
suggests presence of carbonation in concrete. Based on the UPV and Rebound
hammer results, it can be concluded that concrete is in good condition.
Rebar cover test

In case of columns, concrete cover to reinforcement ranges between 27 mm to
120 mm.
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Packing Section
UPV Test & Rebound Hammer Test
UPV (km/s) test (Packing Section)

>4.5 km/s
6%
4 to 4.5 km/s
9%
<=3 km/s
3 to 3.5 km/s
3.5 to 4 km/s <=3 km/s
48% 3.5 to 4 km/s
17%
4 to 4.5 km/s
>4.5 km/s
3 to 3.5 km/s
20%
Fig. 19 UPV Test result for packing section
Rebound Hammer (Packing Section)

60<=RH<70 70<RH
3% 0%
20<=RH<30
RH<20 6%
8%
RH<20
50<=RH<60 20<=RH<30
23%
30<=RH<40
40<=RH<50
50<=RH<60
30<=RH<40
40<=RH<50 37% 60<=RH<70
23% 70<RH
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Fig. 20 Rebound hammer test result for Packing section

UPV Test results suggest 48% quality of concrete is doubtful, 20% portion is of
medium quality, 32% is of good quality. Higher value of rebound numbers
suggests presence of carbonation in concrete. Based on the UPV and Rebound
hammer results, it can be concluded that concrete is distressed.
Rebar cover test

In case of columns, concrete cover to reinforcement ranges between 16 mm to
86 mm.
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Structural health assessment of Indian Rayon, Veraval

“Structural health assessment

Ushta Infinity Construction Co. Pvt. Ltd.

As a Part of practical approach, industrial training is very important for the

Ushta Infinity Construction Co. Pvt. Ltd.

I am thankful to the management of “Ushta Infinity Construction Company Pvt.

I therefore, deeply express my gratitude to all the employees of UICCPL and

I am also thankful to Mr.Anindya Chatterji and Mr. Sourav Maity (Librarian)

Ushta Infinity Construction Co. Pvt. Ltd.

Ushta Infinity Construction Co. Pvt. Ltd.

A study on overall structure assessment has been conducted in Indian Rayon,

This document covers observations of primary evaluation and present condition

 Conditional Assessment of existing building

Ushta Infinity Construction Co. Pvt. Ltd.

failure and damage of these can be avoided or at least predetermined to

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2.1.1 Why cracks form in concrete structures

2.1.2 Causes of Cracking

damaged or fail. Overloading may be in shear, flexure, or tension, or may be a

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Fig. 1: Process of chloride penetration

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Fig. 2: Process of carbonation

water and, as a result, performs better when exposed to freeze-thaw cycles.

The permeability of concrete is directly related to its water-to-cement ratio—

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 Alkali-Aggregate Reaction (AAR)

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shrinkage. To minimise the amount of shrinkage it is best to use a stiff

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restraints to shrinkage. Similarly, increases in the ratio of water to cement in the

A greater volume of stiff aggregate

Reducing the volume of aggregate

Fig. 3: The effects of aggregate volume on concrete shrinkage

Shrinkage is an expected phenomenon in a concrete structure, and can often be

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Concrete itself is so variable that properly constructing a concrete structure can

2.1.3 Types of Cracks

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Fig. 4: Types of cracks

Fig. 5: Crazing pattern (Caustic_New Chlorine Filling)

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Fig. 6: Concrete disintegration around column joint (Caustiuc_ HCL)

Fig. 7: Base disintegration (Caustic_ Salt Unloading Area)

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Fig. 8: Delamination of concrete caused by premature finishing

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Fig. 9: Diagram of locations and directions of overloading cracks

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Fig. 10: Flexural crack (Caustic_Salt Yard)

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Fig. 11: Small spall area caused by corrosion of

2.1.4 The Position and Characteristics of the Concrete Construction cracks

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Fig. 12 Cracks around window opening

Fig. 13 Cracks on the column (Spinning Hall)

3. Cracks in the middle of wall normally appear as horizontal cracks and

vertical cracks, those cracks caused by destruction of mortar, and the

length of cracks are big.

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2.1.5 Precaution of Concrete Construction Cracks

6. Set expansion joints in every certain distance (depends on the regulation)

next day in order to finish settlement on bottom layer.