WTP WATER TANK REFURBISHMENT

PLAN AT GRASIM RENUKOOT CHEMICAL

DIVISION

5, 2021
PROSAVA PVT. LTD.
  Project Introduction

Grasim Industries Ltd has placed an order no. 59600001217 on Prosava Private Ltd for
structural rehabilitation of 10 KL RCC water tank at its premises.
This water tank was commissioned in ---- and RCC structural members have suffered
extensive damage and detoriation from its design strength due to site aging and chemical
exposure as per conditions prevailing at site.

Initial Project inspection & Management of uncertainties

Structural design engineer and rehabilitation expert visited the site to inspect the
current conditions of key structural members, review the current conditions followed by
development of detailed working methodology of repair.

Extensive surface cracks were noticed and initial Chipping of loose concrete was carried
out by using light hammer ( max weight 1 Kg) to find out the extent and nature of
damage.

Key observations post inspection were as follows:

1. After chipping with light hammer, it was noted that cracks have percolated inside he
surface of columns and beams, main and secondary reinforcement is exposed with
clear indication of rusting of reinforcement.

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2. There is major loss of concrete cover leading to loss of bonding between concrete
and reinforcement.

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3. The nature of defects indicates that, water percolation in concrete has lead to
formation of cracks which in turn has resulted in carbon dioxide from air attacking
Calcium hydroxide present in concrete due to cement. As a result of consequent
chemical reaction, the concrete has converted into calcium carbonate and lost its
surface strength.

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4. The travel path and location of cracks does not indicate that they are due to excess
shear or moment due to imposed loads.

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5. The reinforcement bar has undergone extensive rusting due to water and air
exposure, however the effective thickness if still available. The rusting of
reinforcement is extensive however damage to reinforcement is not very much and
is still mostly restricted to surface

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Working methodology
Based on inspection report following working methodology as per stages
elaborated below has been agreed to be carried out for rehabilitation
works.

Stages Item description Product used

Light hammering of detoriated surfaces fo identification of
damaged concrete. Subsequent removal and dismantling of
Stage 1 1 KG Hammer
all loose concrete by light hammering/chisel till good
concrete is exposed.
Cleaning the surface to remove all the rust and loose filler
Stage II Wire Brush
material
Cleaning the surface with Rust remover and expose
Stage III Cons Rust R
reinforcement
In case original reinforcement is corroded more than 25%.
Stage IV Consgrout ELV
New reinforcement to be fixed to lapping length of 56D

Stage V Cleaning the existing and new reinforcement with wire brush Zinc Rich epoxy based primer; Make-Berg
/ cloth and application of two coats of Zinc rich Primer
Bonding coat with bonding agent to be applied over the
Stage VI surface. The coat must be touch dry for application of Consbond SBR
concrete

Concreting with M 25 Nominal mix with addition of Arcylic Cons Fibre (125 gm per bag of cement), C
Stage
polymer and fibre and super plasticiser maintaining w/c ratio ( 500 ml ltr per bag of cement), Consflo S (
VII
0.35-0.4 of cement) WC ratio 0.35 to 0.4

Stage Providing hard concrete surface by microconcreting using

High strength micro concrete where only surface repair less CONSCRETE
VIII
than 50 mm thickness is to be done
Stage IX Application of curing agent on concrete surface CONSCURE C
Stage X Pressure grouting with epoxy based grouting material Consgrout ELV

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Key Site Plan and phases of execution of rehabilitation project

The entire repair and rehabilitation work shall be carried out in following
steps:

Step I : Tie beam at level 2.5 Mtr

Step II : Main columns upto 7 Mtr
Step III : Tie Beam at level 7 Mtr
Step IV : Main column upto 10 Mtr
Step V : Inspection and Grouting of tank

The responsibility of carrying out repair work is to be carried out by Site

supervisor assisted by specialized and experienced work force.
Responsibility of implementation of this work plan shall be with Design
engineer.
The responsibility of completion of work and handover to operations shall 8
be carried out by Grasim Civil team