Morth 2800 Repair of Structure
Morth 2800 Repair of Structure
Morth 2800 Repair of Structure
2800
Repair of Structures
Section 2800 Repair of Structures
2801 DESCRIPTION
Repair of structures shall be carried out in accordance with the repair plans and these
Specifications or as directed by the Engineer. Where repair work is not covered by these
Specifications, special Specification may be framed.
2802 GENERAL
Care shall be taken to ensure suitable mitigation measures against noise and dust, pollution
and damages to the environs whether temporary or permanent and shall be taken as
incidental to work.
2802.2 Phasing
The sequence of work shall be in accordance with the drawings or as directed by the
Engineer.
Adequate precautions shall be taken for safety of personnel, road users and existing
services, during execution. These shall be considered as incidental to work.
Dismantling of any bridge component and removal of materials shall conform to Section
200 and this section and as shown on the drawings or as directed by the Engineer.
2803.1 General
The work of epoxy adhesive utilizing the Structural Concrete Bonding Process shall conform
to these Specifications.
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Repair of Structures Section 2800
2803.3 Personnel
The Contractor’s personnel shall be qualified and experienced in epoxy injection process.
2803.4 Material
The material for injection shall be suitable two-component low viscosity epoxy resin, having
the required characteristics of bonding with concrete and resistance to moisture penetration.
Epoxy mortar or polysulphide resin may be used for sealing the surface.
* In the case of two component injection system where resin and hardener get mixed at
point of injection pot life at 25°C shall be not greater than 15 min + 10 minutes.
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Section 2800 Repair of Structures
The equipment shall be portable, positive displacement type pumps with interlock to provide
positive ratio control of exact proportions of the two components at nozzle. The pumps
shall be generally electrically powered and shall provide in-time metering and mixing. The
tolerance on mix ratio shall be 5 percent by volume. The injection equipment shall have
automatic pressure control capable of discharging mixed adhesive at any pre-set pressure
within the prescribed limits and shall be additionally equipped with a manual pressure
control.
The injection equipment shall be equipped with sensors on both the components A and B
reservoirs that will automatically stop the machine when only one component is being
pumped to the mixing head.
If considered appropriate, suitable compressed air operated epoxy injection gun can be
used with prior approval of the Engineer for manual injection of mix when resin and hardener
had been mixed in a separate unit.
2803.6 Preparation
Surfaces adjacent to cracks or other areas of application shall be cleaned of dirt, dust,
grease, oil efflorescence or other foreign matter by brushing/water jetting/sand blasting.
Acids and corrosives shall not be permitted for cleaning.
Entry ports shall be provided along the crack at intervals of not more than the thickness of
concrete at the location.
Surface seal material shall be applied to the face of the crack between the entry ports. For
through cracks, surface seal shall be applied to both faces.
Before proceeding with the injection, the surface seal material must gain adequate strength
with respect to concrete strength of the member/injection pressure.
Injection of epoxy adhesive shall begin at lowest entry port and continue until there is an
appearance of epoxy adhesive at the next entry port adjacent to the entry port being pumped.
When epoxy adhesive travel is indicated by appearance at the next adjacent port, injection
shall be discontinued on the entry port being pumped and entry port shall be sealed.
Thereafter, epoxy injection shall be transferred to next adjacent port where epoxy adhesive
has appeared.
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Repair of Structures Section 2800
Epoxy adhesive injection shall be performed continuously until cracks are completely filled.
If port to port travel of epoxy adhesive is not indicated, the work shall immediately be
stopped. In case the volume of the injected material exceeds 2 litres for a particular entry
port, the work shall be stopped and the specifications may be reviewed.
2803.9 Testing
2803.9.1 Material Testing : Prior to approval of the material, the following tests shall
be carried out at site or in an authorized laboratory for each batch of resin and hardener
and each combination thereof at the cost of the Contractor.
i) Viscosity test for resin and hardener and the mix – three specimens
each.
ii) Pot life test - three specimens each.
iii) Bond test – three specimens each.
iv) Shear test – six specimens each, 3 after 24 hours and the other three
after 72 hours of curing.
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Section 2800 Repair of Structures
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150 mm
STANDARD CONCRETE
CYLINDER CAST IN 2
PARTS
300 mm
SEPARATING MEDIUM
Fig. 2800/1
Fig. 2800/2
2803.9.2 Core test : If directed by the Engineer, core tests shall be conducted for
the acceptance of the work. The selection of the location of cores shall be made under the
direction of the Engineer in such a way that damage in critical/stressed areas of the structure
is avoided. The procedure for the test shall be as under.
The Contractor shall obtain 5 cm diameter initial core samples in the first 50 linear metres.
Thereafter, frequency of core sampling shall be as specified or as agreed by the Engineer.
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Section 2800 Repair of Structures
If the cores taken in first 50 m length pass tests as specified above, epoxy adhesive injection
work at area represented by cores will be accepted.
If cores fail either by lack of penetration or bond strength, work shall not proceed further
until the areas represented by the cores are re-injected and retested for acceptance.
2803.9.3 Test for injection equipment : At all times during the course of the work
the Contractor shall keep complete and accurate records and make available to the
Engineer of the pressure and ratio tests specified above so that the efficacy and accuracy
of the injection equipment is verified.
In addition, the Engineer at any time without prior intimation of the Contractor may request
the Contractor to conduct the tests specified below, in the presence of the Engineer.
a) Pressure Test
The mixing head of the injection equipment shall be disconnected
and the two adhesive component delivery lines shall be attached to
the pressure check device, which shall consist of two independent
valved nozzles capable of sensing the pressure. The check device
shall be closed and equipment operated until the gauge pressure in
each line reads 5 MPa. The pumps shall be stopped and the gauge
pressure shall not drop below 4 MPa within 2 minutes.
The pressure test shall be run for each injection unit at the beginning
and after break of every shift.
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Repair of Structures Section 2800
b) Ratio Test
The mixing head of the injection equipment shall be disconnected
and the two adhesive components shall be pumped simultaneously
through the ratio check device, which shall consist of two independent
valved nozzles. There shall be a pressure gauge capable of controlling
back pressure by opening or closing valved nozzles capable of
sensing the back pressure behind each valve. The discharge
pressure shall be adjusted to read 5 bar for both adhesive
components, which shall be simultaneously discharged into separate
calibrated containers during the same time period and the amounts
discharged into the calibrated containers simultaneously during the
same period shall be compared to determine that the volume/
discharge conforms to the manufacturer’s recommended ratio for
applicable material.
2804.1 Material
The epoxy resins for use in the mortar shall be obtained from a reputed manufacturer and
the mortar shall be prepared in conformity with the manufacturer’s recommendations.
The Contractor shall carry out tests on the samples made and meet requirements indicated
above.
The sand content in the mortar shall be in accordance with the desired consistency.
The resin and hardener shall be mixed before adding the dry filler. The mixed ready to use
mortar should not contain lumps of unwetted filler and should be uniform in colour. For a
total weight of 1 kg or less, hand mixing will be sufficient. For quantities in excess of 1 kg,
the component shall be mixed for 3 minutes with a slow speed 400-600 rpm electric drill
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Section 2800 Repair of Structures
with a Jiffy mixer. The stirrer shall be moved up and down and along the sides until an even
streak free colour is obtained. Whipping in an excessive amount of air shall be avoided. If
no power is available, a flat putty knife may be used to reach into the corners of the can
and hand mixing done for at least 5 minutes.
Surface upon which epoxy is to be placed shall be free of rust, grease, oil, paint, asphalt,
loose material, unsound concrete, dust or any other deleterious material.
Since cured epoxy does not provide adequate bond with any material, all overlay, whether
epoxy or cement based, shall be done within pot life of the base epoxy layer.
2804.4 Contaminants, such as oil, grease, tar, asphalt, paint, wax, curing compounds
or surface impregnants like linseed oil or silicons, including laitance and weak or loose
concrete shall be removed. When bonding to asphalt, the surface should be roughened
so that clean aggregate is exposed. Epoxy bonding agents shall not be applied when it
rains, or in standing water. The surface must be dry.
Epoxy primer coat shall be applied with the help of stiff nylon bristle brushes or hard rubber
rollers or spray gun depending upon the nature of surface and extent of work area. As far
as possible, the coating shall be uniformly thick.
Before the primer coat is fully cured, epoxy mortar shall be applied by means of trowels
and floats. The interval between the application of primer coat and epoxy mortar shall be
approximately 15/30 minutes depending upon the ambient temperature.
Seal Coat shall be applied after 24 hours curing, after mild roughening of the surface of the
mortar.
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Repair of Structures Section 2800
2804.6 Coverage
The coverage of resin mix would depend on the system of resin used. However, as a
general guideline the coverage area shall be as under :
Tools and equipment are best cleaned immediately after use since the removal of cured
resin is difficult and time consuming. The bulk of resin shall be removed using a scraper
and remainder washed away completely using solvents such as toluene, xylene or acetone.
Equipments used for epoxy shall always be cleaned before it hardens. Solvents used for
this purpose may be Acetone (flammable), Methyl Ethyl Kethone (flammable), Methyl
Chloride (non-flammable). Cured epoxies may be removed using Methylene Chloride.
2804.8 Testing
Epoxy used for making mortar shall conform to all requirements and testing procedures as
laid down in Clause 2803.9.
Epoxy resins can cause irritation of skin in sensitive persons if incorrectly handled. The
resin and hardener should not be allowed to come into direct contact with skin. The most
effective protection is achieved by wearing rubber or polythene gloves.
Any skin contact with epoxy materials, solvents and epoxy strippers should be avoided.
Epoxy resins and particularly epoxy hardeners (B component) may cause a rash on the
skin. The official toxicity classification on the container labels may be looked for before
starting work.
Rubber gloves, with a cloth liner, and protective clothing shall be worn. Barrier creams are
recommended but are not substitutes for protective clothing. Eyes shall be protected
where splashing could occur while spraying or mixing. Good ventilation shall be ensured
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Section 2800 Repair of Structures
and inhalation of vapours avoided. If materials are sprayed, a respirator shall be used.
If skin contact occurs, it shall be immediately washed with a cleaner, followed by soap and
water. Should eye contact occur, it shall be flushed immediately with plenty of water for
15 minutes and a doctor called for.
If contact occurs with the clothing, it shall be immediately changed to prevent further skin
contact, and if the contact occurs with components A or B, the clothing shall be thrown
away. Hardened epoxy is not harmful but will break the clothing.
All emptied, used buckets, rags and containers shall be removed from site. These shall
be stored in waste disposal bags and suitably disposed.
2805.1 Epoxy resin used for bonding shall be obtained from a reputed manufacturer.
The pot life of such bonding epoxy shall not be less than 60-90 minutes at normal
temperature.
2805.2 The entire surface of the existing concrete member should be thoroughly
cleaned by wire brush and then with compressed air to remove dust and loose particles
from the surface. Any crack or spalling of concrete shall be sealed by epoxy injection/
epoxy mortar/grouting as decided by the Engineer. A coating of suitable epoxy resin at the
rate of 0.8 kg/sq.m (minimum) should then be applied on the surface of the existing concrete
members. Fresh concrete shall then be placed within the pot life of the resin system.
2805.3 Testing
2805.3.1 Epoxy used for bonding work shall satisfy the criteria mentioned in
Clause 2803.9.
2805.3.2 Two concrete cubes 150 mm size cast as per approved design mix shall be
placed, as shown in Fig. 2800/3 at a distance of 150 mm from each other. Epoxy resin
system suggested for bonding new to old concrete shall be applied on the opposite faces
of the cubes.
Fresh cement concrete cube of grade as per approved design mix shall be cast with water
cement ratio of 0.4 or less in the manner shown in Fig. 2800/3. The assembly shall be
cured in water for 28 days and steel spacer removed thereafter.
The cube assembly shall be subjected to compression load after 28 days of curing, thereby
subjecting the bond to shearing load. Failure must not occur at this joint.
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Repair of Structures Section 2800
M 35 M 35 M 35
C.C. CUBE FRESH C.C. C.C. CUBE
'OLD' 'NEW' 'OLD'
Fig. 2800/3
2806.1 Material
Grouting shall normally be performed with a mixture of neat Portland Cement and water.
Other additives and admixtures may be added to improve the impermeability, strength,
etc. on the approval of the Engineer. The size of the particles and the consistency of the
grout must be suited to the passageways it must follow. Neat grout will not flow freely into
holes smaller than about three times the largest cement particle. Except in large cavities
where thick mortar can be placed, the sand should all pass the 28-mesh sieve and have a
large portion passing the 50 and the 100 mesh sieves. The proportions of Ordinary Portland
Cement to sand will depend upon the size of the spaces to be filled and will vary from a
neat grout to about 1:1 mix. The amount of water to be added depends upon the consistency
required. Grouts with as little as 16 litres of water per bag of cement could be handled and
it should seldom be necessary to use more than 35 to 40 litres of water per bag of cement.
Where necessary and approved by the Engineer, admixtures to Portland Cement grout
mixtures may be added for delaying the setting time, increasing flow ability, minimizing
segregation and shrinkage.
2806.2 Preparation
The surface shall be cleaned with wire brush and compressed air, 15 m dia and 150 to
200 mm deep holes along the length of the cracks at a spacing of 500 mm may be drilled
by wet drilling using rotary percussion drills and nipples inserted in these holes.
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Section 2800 Repair of Structures
The cement grout shall be mechanically mixed using a system of power-driven paddles of
high speed centrifugal pump. The grout pump to be used shall permit close control of
pressures to allow a flexible rate of injection with minimum clogging of valves and ports.
The most satisfactory equipment for injecting grout is a pump of the double-acting flexible
reciprocating type giving a steady flow. The grout pump shall be so placed as to reduce
the waste in cleaning lines. It is preferable to add 50 percent or more of the mixing water
into the mixer before adding the dry ingredients and then the remaining water. A continuous
supply of grout is preferable to an intermittent one. Consistency of the grout may be
determined by trials starting with thin grout i.e. about 40 litres of water per bag of cement
and progressively decreasing the water content to about 15 litres per bag of cement.
Where the mixer and pump are combined in one unit, the dry material shall be screened
before mixing. If the mixer and pump are in separate units, the grout shall pass through a
screen before it enters the pump.
2806.4 Application
Highest practical pressure within the limits 100-400 kPa should be used in order to force
the surplus water from the grout. As the pressure may be distributed hydraulically over
considerable areas, vigilance must be exercised to prevent damage or needless waste of
grout. Grouting is to be done by attaching a packer (consisting of expansible tube of
rubber) to the end of the grout supply pump through the holes and nipples.
Pressure shall be steady to ensure a continuous flow of grout. Grouting shall not be
continued till the hole consumes mix at the rate of not less than 30 litres in 20 minutes or
until refusal at the grouting pressure of 400 kPa at any hole until refusal. Should the grout
escape from an adjacent nipple, it should be plugged or capped. Any seam, crack or joint
through which grout escapes shall be caulked with epoxy mortar as soon as thick grout
appears.
2806.6 Testing
Percolation test done at the end of grouting operation shall give a value of less than 2
lugions.
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NOTE : For specialised treatment like polymer modified cementitious grout injection,
manufacturer’s literature and specifications shall be followed.
2807 GUNITING/SHOTCRETE
2807.1 The gunite is a mixture of cement, sand and water. It comprises 100 parts
by weight of cement, 300 parts by weight quartz sand, 35-50 parts by weight water and
2 parts by weight approved quick setting compound. In general, dry mix shotcrete shall be
used.
2807.3 Sand for guniting shall comply with the requirements stipulated in IS:383. In
general, sand should neither be too coarse to increase the rebound nor too fine to increase
the slump. Sand should preferably have a moisture content between 3 to 6 percent.
The grading of sand shall lie within the limits given below :
4.75 mm 95 – 100
2.36 mm 65 – 90
1.18 mm 45 – 75
600 micron 30 – 50
300 micron 10 – 22
150 micron 2 -8
2807.5 Water/cement ratio for guniting shall fall within the range 0.35 to 0.50 by
mass, wet enough to reduce the rebound. Drying shrinkage may be between
0.06 percent to 0.10 percent. The quick setting compound shall be added at the nozzle
with water just before guniting.
2807.6 Workmanship
The cement and sand shall be batched and mixed and conveyed through a hose pipe with
the help of compressed air. A separate line shall bring the water under pressure. The
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Section 2800 Repair of Structures
cement, sand and water mix shall be passed through and intimately mixed in a special
manifold and then projected at high velocity to the surface being repaired. The density of
gunite shall not be less than 2000 kg/cu.m. The strength of gunite shall not be less than
25 MPa. For effective guniting, the nozzle shall be kept 60 to 150 cm away from the
surface, preferably normal to that surface. While enclosing reinforcement bars during
repairs, the nozzle shall be held closer at a slight angle and the mix shall be wetter than the
normal.
2807.7 Test panels simulating actual field conditions shall be fabricated for conducting
preconstruction testing. The procedure for testing the cubes or cylinders taken from the
panels stipulated in clause 6 of IS:9012 shall be followed.
2807.8 It should be ensured from tests that a strength of about 25 MPa at 28 days is
available for the mortar/concrete mix.
2807.9 The defective concrete shall be cut out to the full depth till sound concrete
surface is reached. Under no circumstances should the thickness of concrete to be
removed be less than clear cover to the main reinforcement. No square shoulders shall be
left at the perimeter of the cut-off portion and all edges shall be tapered. Thereafter, all
loose and foreign materials should be removed and the surface be sandblasted to make
it rough to receive shotcrete after applying a coat of bonding epoxy as per recommendation
of the manufacturer @ 1.0 kg per 1.5 sq.m of surface area.
2807.10 The exposed reinforcement shall be thoroughly cleaned free of rust, scales
etc. by wire brushing. Wherever the reinforcements have been corroded, the same shall
be removed and replaced by additional reinforcement. Before application of gunite, a
coat of neat cement slurry should be applied on the surface of the reinforcement.
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2807.15 It would be desirable that green gunite is moistened for at least 7 days.
Guniting work shall not be done during windy or rainy conditions.
2808.2 Lifting of superstructure spans may be carried out by jacking up from below
or by lifting the span from top. Where jacks are employed, their location/number and size
shall be selected in such a manner so that there are no undue stresses created in the
structure. Jacks may be placed on piers/pier caps or specially erected trestles in
accordance with the approved methodology for lifting of superstructure. All jacks shall be
operated from one control panel by a single control lever. The system will have provision
for manual over ride to control the loads of any particular jack. The jacks should be so
synchronized that differential lift between individual jacks shall not exceed 1 mm.
Walkie talkies system or similar audio arrangements should be available for communicating
instructions regarding lifting, stopping, starting etc. The operator shall have a clear view
of the jacks and the lifting of each girder controlled by reading the dial gauges.
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Section 2800 Repair of Structures
Dismantling work shall not be carried out at night, or during storm or heavy rain. A warning
device shall be installed in the area to be used to warn the workers in case of mishap/
emergency.
Safety helmets conforming to IS:2925 shall be used by the workmen engaged in dismantling
work. The sheds and tool boxes should be located away from the work site. Goggles
preferably made up of celluloids and gas masks shall be worn at the time of dismantling,
especially where tools like jack hammers are deployed to protect eyes from injuries from
flying pieces, dirt, dust etc. Leather or rubber gloves shall be worn by the workers during
the demolition of RCC work. Screens made of GI sheets shall be placed wherever
necessary to prevent the flying pieces from injuring the workers.
Water should be sprayed to reduce the dust while removing concrete wearing course with
jack hammer. No work shall be taken up under the span when dismantling work is in
progress.
H.T. Strands/Wires, HDPE Sheathing, Deviator Blocks, Anchor Plates, Anchorages and
grouting material.
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2810.2 Material
HDPE Sheathing : HDPE Sheathing shall conform to IS:4984 suitable for a working
pressure of 6 bars. Its density shall be 955 kg/cu.m, shore hardness D63, yield stress 24
MPa and ultimate tensile strength 35 MPa.
Deviator Blocks : As necessitated by the profile of the external cable, suitable strand/
wire deviator block fabricated from M.S. Sections shall be provided. The deviator block
shall be given a coat of suitable paint (preferably epoxy based) after sand blasting.
Anchorages : Depending upon the prestressing force, suitable anchorages and wedges
shall be used conforming to relevant codes and section 1800.
2810.3 Workmanship
The behaviour of the girder shall be monitored by measurement of deflection so that only
required amount of external prestressing is imparted to the girder. Care shall be taken to
avoid excess prestressing and impairment to the girders.
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Section 2800 Repair of Structures
The materials shall be tested in accordance with these Specifications and shall meet the
prescribed criteria.
The work shall conform to these Specifications and shall meet the prescribed standards of
acceptance.
The contract unit rate for sealing of cracks and injection of cement grout shall include cost
of all materials, labour, tools and plant, placing in position, testing, curing and other incidental
expenses for the satisfactory completion of the work as per these Specifications.
The contract unit rate for application of epoxy mortar for specified thickness shall include
cost of all materials, labour, tools and plant, placing in position, testing and other incidental
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Repair of Structures Section 2800
expenses including surface preparation for the satisfactory completion of the work as per
these Specifications and as shown on the drawings.
The contract unit rate for guniting/shotcreting shall include cost of all materials, labour,
tools and plant, placing in position, testing, curing, surface preparation and other incidental
expenses including the provision of nipples for the satisfactory completion of the work as
per these Specifications.
The contract unit rate for replacement/rectification of bearings shall include cost of all
materials, labour, tools and plant, placing in position, site welding/riveting/bolt connections,
operation of jacks and other incidental expenses for the satisfactory completion of the
work as per these Specifications and as shown on the drawings.
The contract unit rate for dismantling of wearing coat shall include cost of all materials,
labour, tools and plant, traffic management, signages, safety precautions and other
incidental expenses including removal of existing expansion joints for the satisfactory
completion of the work as per these Specifications.
The contract unit rate for external prestressing shall include cost of all materials, labour,
tools and plant, temporary works, testing, curing and other incidental expenses including
the careful monitoring of the deflection of girders being externally prestressed for the
satisfactory completion of the work as per these Specifications and as shown on the
drawings.
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