2800 REPAIR OF STRUCTURESRepair of Structures Section 2800 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. Implementation of repair schemes shall also conform to provisions of IRC:SP:40, IRC:SP:74 and IRC:SP:80. 2802 GENERAL (2802.1 Environmental Aspect Care shall be taken to ensure suitable mitigation measures against noise and dust, pollution ‘and damages to the environs whether temporary or permanent. 2802.2 Phasing The sequence of work shall be in accordance with the drawings or as directed by the Engineer. 2802.3 Traffic Management Traffic management, signage, signaling, barricading, ‘and lighting arrangement shall be in accordance with Section 100 of these Specifications. 2802.4 Safety Precautions Adequate precautions shall be taken for safety of personnel, road users and existing services. 2802.5 Dismantling and Removal of Material Dismantling of any bridge component and removal of materials shall conform to Section 200 of these Specifications and as shown on the drawings or as directed by the Engineer. 2803 SEALING OF CRACKS BY INJECTION OF EPOXY RESIN 2803.1 General The work of structural bonding of concrete using epoxy adhesive shall conform to these Specifications. 759Section 2800 Repair of Structures 2803.2 The Contractor shall furnish a method statement giving details of methodology of construction, sources of supply of materials, tools, equipment, and appliances to be used on work, personnel and supervision. 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, The material for epoxy injection shall conform to the following: i) The resin and hardener shall be mixed by weight and the mixing ratio shall generally be between 1 pbw (parts by weight) to 50 pbw subject to manufacturer's recommendation. il) Neither the mixed epoxy adhesives nor their individual component shall contain solvents and thickeners. il) The components shall be free of lumps or foreign material. The viscosity of the individual components shall not change more than +15 percent kept in closed containers at 25°C after two weeks. iv) Consistency of mixed adhesive shall satisfy the requirements given in Table 2800 -1. Table 2800-1: Consistency of Adhesive Standard Version Low Viscosity (cps) Version (cps) i) _ | Viscosity of Mixed Adhesive at 25°C (200-300) (100-190) Pot Life of mixed adhesive at 25°C 1 hour + 15 minutes * iil)_[Set time of mixed adhesive at 25°C 3-6 hours * Inthe 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 minutes + 10 minutes. 2803.5 Equipment for Injection 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 elecirically powered and shall provide in-time metering and mixing. The tolerance 760Repair of Structures Section 2800 ‘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 componentis 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 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, it shall be ensured that the surface seal has gained adequate strength corresponding to concrete strength of the member and to withstand the injection pressure. 2803.7 Epoxy Injection Injection of epoxy adhesive shall begin at the lowest entry port and continue until the epoxy adhesive appears at the next adjacent entry port. The injection shall then be discontinued at the first entry port which shall be sealed. Thereafter, epoxy injection shall be carried out from the next adjacent port and continued successively from each port until the crack is completely filled. If travel of epoxy adhesive from one port to the next does not occur, the work shall be stopped immediately. In case the volume of the injected material exceeds 2 litres for a particular entry port, the work shell be stopped and the specifications may be reviewed. 761Section 2800 2803.8 2803.9 2803.9.1 Repair of Structures Precautions for Application 2) Temperature of components A and B, i.e., resin and hardener shall be between 10°C and 35°C at the time of mixing unless otherwise specified. b) Temperature of structural member during epoxy injection shall be between 10°C and 35°C unless otherwise specified. ©) Immediately prior to use, each component shall be thoroughly mixed with a clean paddle. The paddle shall be of a type that does not propel air into the material. Separate clean paddle must be used for each component. 4) Any heating of the adhesive components shall be done by application of indirect heat, in case the work is to be done in cold climate. ) Just before use, the two components shall be thoroughly mixed in the ratios specified by the manufacturer. The mixing time shall be strictly in accordance with manufacturer's recommendations. When adhesives with different coloured components are mixed, the mixture shall havea uniform colour without streaks, f) The use of solvents and thinners shall not be permitted except for cleaning of equipment. Testing Material Testing Prior to approval of material, the following tests shall be carried out by the Contractor at site or in an authorised laboratory for each batch of resin and hardener and each combination. i) Viscosity test for resin and hardener and the mix: three specimens each, li) 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. Subsequent tests shall be carried out as directed by the Engineer. Procedure for tests shall be as below: i) Pot Life Test a) 500 gm of resin formulation shall be prepared by thoroughly mixing the resin and —_hardener/accelerator /catalyst component in proposed proportion in a 1 kg capacity hemispheric 762Repair of Structures ii) ii Section 2800 porcelain bowl by means of a spatula or any other agitating device and time and the ambient temperature noted. b) The resin formulation shall be applied with a clean dry 25 mm size painter's brush, on a clean dry surface such as cement concrete over 150 mm - 200 mm length, starting immediately after mixing the formulation and repeating the operation every five minutes When it becomes just difficult to spread the resin properly with the brush, the time is noted. The time elapsed since completion of mixing of resin formulation, is taken as its pot life. ©) One pot life test shall be performed on commencement of work and the same shall be repeated every four hours. 4) _ Incase the material fails to satisfy the pot life test, it shall not be used for injection. Where the resin and hardener get mixed at point of injection, the pot life is not important and no tests may be required. Bond Test standard 150 mm diameter and 300 mm long concrete cylinder shall be cast in 2 pieces by providing a separating medium at an axis of 45 degrees to the longer axis of the cylinder as shown in Fig. 1 of Appendix 2800/1. Three such split cylinders shall be prepared. Two pieces of each cylinder shall be joined with epoxy mortar at four points to give a clear gap of about 0.2 mm, which will be injected with epoxy resin at site. After epoxy has been cured, load test shalllbe carried out on the cylinder. The failure shall not take place at the joint injected with epoxy resin. Also the strength of cylinder at failure shall not be less than 80 percent of the 28 days cube strength of the concrete mix. Shear Tests ‘Two steel plates, minimum 3 mm thick, shall be bonded with epoxy at site using the same resin mix as used/proposed to be used for injection. The assembly shall be kept in mechanical clamp till epoxy is cured. A total of six specimens shall be prepared for each batch of materials. Three test specimens shall then be subjected to a shear force along the axis after 24 hours and the minimum shear strength before failure shall not be less than 1 MPa (Refer Fig. 2 of Appendix 2800/1). The remaining test specimens shall be similarly tested after 72 hours of curing. The shear strength before failure shall not be less than 2.5 MPa. 763Section 2800 Repair of Structures 2803.9.2 Core Test If directed by the Engineer, cores shall be tested for the acceptance of the work. The selection of the location of cores shall be as directed by the Engineer in such a way that damage in critical/stressed areas of the structure is avoided. The Contractor shall obtain 50 mm 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, The depth of the core shall normally be less than 200 mm. Tests and Acceptance Criteria shall be as follows: a) _ Penetration- Visual examination of the core should show epoxy adhesive filling a minimum of 90 percent of the crack. b) Bond Strength- When tested for bond, concrete failure should occur before adhesive failure. Also, minimum bond strength of 40 MPa should be developed with no failure of either concrete or adhesive. Ifthe 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 re-tested for acceptance. Filling of Core Holes ‘Two-component bonding agent shall be applied to surfaces of cored holes followed by filing of non-shrink cement grout mix placed by hand trowel, thoroughly rodded and tamped in place. The surface shall be finished to match the finish and texture of existing concrete to the satisfaction of the Engineer. Materials to be used and procedures for filling core holes shall be got approved by the Engineer before proceeding with work. 2803.9.3, Test for Injection Equipment Atall times during the course of the work, the Contractor shall keep complete and accurate records and make available to the Engineer, the results of the pressure and ratio tests ‘specified below so that the efficacy and accuracy of the injection equipment is verified. The Engineer at any time may direct the Contractor to conduct additional tests in his presence. a) Pressure Test The mixing head of the injection equipment shall be disconnected and the two adhesive component delivery lines shall be attached to 764Repair of Structures Section 2800 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. 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. The amounts thus discharged shall be compared to determine whether the volume/discharge conforms to the manufacturer's recommended ratio for applicable material. 2804 REPLACEMENT OF SPALLED CONCRETE BY EPOXY MORTAR! POLYMER MORTAR 2804.1 Epoxy Mortar 2804.1.1 Material The epoxy resins for use in the mortar shall be obtained from a reputed manufacturer and shall conform to the following: Pot Life 60 minutes at 30°C Bond Strength 12 MPa Tensile Strength 16 MPa The Contractorluser shall carry out tests on the samples to demonstrate that the above requirements are met. The sand to be used in the mortar shall be graded quartz sand. 2804.1.2 Proportioning and Mixing The resin and hardener shall be first mixed. Thereafter, dry filler shall be added and again mixed thoroughly. The resultant mix shall be free of lumps of dry filler and shall be of uniform 765Section 2800 Repair of Structures colour. For a total weight of 1kg or less, the components shall be mixed for 3 minutes in a slow speed (400-600 rpm) mixer. The stirrer shall be moved up and down and along the sides until uniform colour without streaks, is obtained. While stirring, it shall be ensured that excessive amount of air is not entrapped. 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. 2804.1.3 Surface Preparation ‘Two general methods of surface preparation shall be followed: @) Mechanical that includes grinding, grit blasting, water blasting and scatification. b) Chemical that includes acid etching with 15 percent by weight of hydrochloric solution, followed by repeated flushing with high pressure stream of water Contaminants, such as oil, grease, tar, asphalt, paint, wax, curing compounds, surface; impregnants like linseed oil or silicons and laitance, loose material and unsound concrete, shall be removed from the surface on which epoxy mortar is to be placed. 2804.1.4 Application The epoxy primer coat which acts as a bonding agent, shall consist of resin and hardener mixed in the proportions as given by the manufacturer. Epoxy bonding agent shall be applied only on a dry surface and shall not be applied when it rains or in standing water. The overlay, whether epoxy or coment based, shall be done within the pot life of the epoxy primer coat, Epoxy primer coat shall be applied with the help of stif 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 24 hours after curing and mild roughening of the surface of the mortar, 2804.1.5 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: a} Primer Coat. An area of 3-6 square metres will be covered by 1 kg of resin hardener mix, depending on the finish of the concrete. 766Repair of Structures Section 2800 b) Epoxy Mortar. One square metre of surface requires approximately 20-24 kg of epoxy mortar, when laid to a thickness of 10 mm. ©) Seal Coat. An area of 4 to 6 square metres will be covered by 1 kg depending on the temperature of application. 2804.16 Cleaning and Maintenance of Equipment 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. Equipment shall always be cleaned before the epoxy 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 2804.1.7 Testing Epoxy used for making mortar shall conform to all requirements and testing procedures as laid down in Clause 2803.9. 2804.1.8 Personnel and Environment Safety 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 at 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 and inhalation of vapours avoided. If materials are sprayed, a respirator shall be used. If contact occurs with the skin, 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 of. 767Section 2800 Repair of Structures 2804.2 Polymer Mortar 2804.2.1 Material The latex acrylic polymer for use in the polymer modified cementitious mortar (PMC) shall be obtained from a reputed manufacturer and shall conform to the following: Pot Life 60 minutes at 30°C Compressive strength at 28 days 18.20 Nimm? Flexural strength at 28 days 3.0 N/mm? to 5.0 N/mm? Addition to concrete (slant shear) 3.0 N/mm? to 5.0 Nimm? The sand to be used in the mortar shall be graded quartz sand and the sand content shall be in accordance with the desired consistency. 2804.2.2 Proportioning and Mixing A dry mortar of quartz sand and cement (OPC) shall be prepared as per the proportions recommended by the manufacturer. The quantity of polymer shall be measured by measuring jars and shall be added to dry mortar. It shalll be mixed with trowel or by hand so that no lumps remain in the mixed mortar. 2804.2.3 Surface Preparation Same as in Clause 2804.1.3, 2804.2.4 Application The polymer bond coat shall consist of a mix of polymer and cement as per recommendations of manufacturer and shall be appliad in the same manner as indicated in Clause 2604.1.4 for epoxy primer coat. The cement and sand shall be dry mixed and then mixed with liquid polymer, adding the required amount of water in prescribed proportions as per manufacturer's recommendation The mortar shall be mixed till it attains a smooth consistency. The mix shall be applied over the polymer bond coat by hand and finished by trowel. 2804.2.5 Coverage a) An area of 3 to 4 square metres will be covered by 1 litre of polymer bond coat, depending on substrata conditions. b) Anarea of 1 square metre of surface will be covered by approximately 21-22 kg of polymer mortar when laid to a thickness of 10 mm. 768Repair of Structures Section 2800 2804,2.6 Testing The polymer used in making polymer mortar, shall be tested for all requirements as indicated by the manufacturer and to satisfy requirements given in Clause 2804.2.1 2805 EPOXY BONDING OF NEW CONCRETE TO OLD CONCRETE 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 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 partices 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 conerete cubes of 10 mm size cast as per approved design mix shall be placed at a distance of 150 mm from each other, as shown in Fig. 3 of Appendix-2800/1. 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. 3 of Appendix 2800/1. 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. 2806 CEMENT GROUTING 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 and strength, with 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 769Section 2800 Repair of Structures 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-mesh and “00-mesh sieves. The proportions of Ordinary Portland coment 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 used and it should seldom be necessary to use more than 36 to 40 litres of water per bag of cement. Where necessary and approved by the Engineer, additives and admixtures may be added to Portland cement grout mixtures for improving impermeability and strength, delaying the setting time, increasing flowability and minimizing segregation and shrinkage. 2806.2 Preparation ‘The surface shall be cleaned with wire brush and compressed air. Thereafter holes of 15 mm dia and 150 mm to 200 mm deep may be drilled along the length of the cracks at a spacing of 500 mm by wet crilling using rotary percussion drills and nipples shall be inserted in these holes. 2806.3 Proportioning, Mixing and Equipment for Grouting 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 put 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 of 100 kPa - 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. Adequate precaution shall be taken to ensure that leakage of grout does not occur. 770Repair of Structures Section 2800 Pressure shall be steady to ensure 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. Should the grout escape from an adjacent nipple, it should be plugged or capped. Any seam, crack or joint through which grout escaves shall be caulked with epoxy mortar as soon as thick grout appears. 2806.5 Cleaning of Equipment After completion of each grouting operation or temporary shutdown, it is advisable to force clear water through the pump until the discharge line shows no colour, after which the pump covers shall be removed and the valve chambers thoroughly cleaned. 2806.6 Testing Percolation test done at the end of grouting operation shall give a value of less than 2 lugions. For specialised treatment like polymer modified cementitious grout injection, manufacturer's literature and specification shall be followed. 2807 GUNITING/SHOTCRETING 2807.1 The gunite shall comprise 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 shotorete shall be used. 2807.2 Ordinary Portland cement conforming to IS:269 shall be used in guniting. 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 moisture content between 3 to 6 percent. The grading of sand shall lie within the limits given below: IS Sieve Percent Passing the Sieve Designation 4.75 mm 95-100 2.36 mm 65-90 1.18mm 45-75 600 micron 30-50 300 micron 10-22 150 micron 2-8 2807.4 For thick sections it may be advantageous to incorporate coarse aggregate in the mix provided adequate guniting equipment is available. Coarse aggregate, when used, m7Section 2800 Repair of Structures shall conform to grading given in Table-1 of IS:9012. The percentage of coarse aggregate may normally be kept as 20 to 40 percent of the total aggregate and the mix shall be suitably designed. 2807.5 Water/cement ratio for guniting shall fall within the range of 0.35 to 0.50 by mass; wet enough to reduce the rebound. Drying shrinkage may be between 0.06 percent and 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 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 shalll not be less than 25 MPa. For effective guniting, the nozzle shall be kept 600 mm to 1500 mm 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 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 conorete 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 sand blasted to make it rough to receive shoterete after applying a coat of epoxy bonding as per recommendation of the manufacturer at the rate of 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. 2807.11 Sufficient clearance shall be provided around the reinforcement to permit encasement with sound gunite. Care shall be taken to avoid sand pockets behind the reinforcement. 772Repair of Structures Section 2800 2807.12 A thickness of 25 mm to 40 mm of gunite can normally be deposited in one operation. If, for some reason, the total thickness is to be built up in successive operations, the previous layer should be allowed to sot but not become hard before the application of the subsequent layer. Guniting shall always be done on a damp concrete surface. 2807.13 Where required, welded wire fabrics 50 mm x 50 mm x No. 10 gauge shall be provided in the first layer of guniting. The fabric shalll be tied properly. In case the damage to the concrete member is very deep, the specifications for guniting as well as requirement of placement of wire mesh, has to be decided as per field conditions. 2807.14 ‘The stipulations given in 1S:9012 regarding application of gunite should be followed so as to keep the rebound to the minimum. The quality of guniting and workmanship shail be such that the percentage of rebound mentioned in [S:9012 can be adhered to. Inno circumstances shall the rebound material be re-used in the work. 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 PROTECTIVE SURFACE COATING OF CONCRETE BY ACRYLIC ELASTOMERIC COATING 2808.1 The acrylic elastomeric coating shall be water based (solvent free), modified with selected mineral filers applied over the prepared surface. The coating should have anti-carbonation and water vapor diffusion property and should be resistant to action of ultra violet (UV) radiation. It should be waterproof and capable of bridging orazings and cracks. The shelf life for such coatings shall not be more than 6 months. 2808.2 Itis necessary that the system should be capable of protecting the surfaces of pre-stressed and reinforced concrete members from all deleterious elements such as chlorides and sulphates. The protective treatment should allow excess water vapour in the concrete to evarorate out (breathing) without rupturing itself due to vapour pressure. The protective system itself should not deteriorate from exposure fo UV rays and weathering. The acrylic elastomeric coating system shall satisfy the requirements given in Table 2800-2. Table 2800-2: Properties of Acrylic Elastomeric Coating SI.No. Parameter Requirement Reference 1)_[Specific Gravity 7420.05 1S:345 2) [Solid contents 7023% 1S:345 3) [UV resistance No colour change ASTM-G-53/DIN-EN- 150-105 773Section 2800 Repair of Structures SI.No. Parameter Requirement Reference 4) [IR-Spectum ‘As per Acrylic Polymer | IR-Spactrometer standards 5) [Adhesion with concrete 1.5 Nim? JASTM-D-4541-02/ DIN500014 6) [Dry film thickness 1200-225 Microns (for minimum 2 coats) 7)_|Coverage [400-450 gm /m? (2 Coats) 8) [Physical properties Diffusion [Equivalent air layer DIN 53122 Part -1 resistance against carbon _| thickness S,CO, shall be dioxide >50 m 9) [Diffusion resistance against {Equivalent air thickness _|DIN 62615 water vapour S,H,0 <4 m 10) [Water proofing characteristics [Percentage reduction in flux should be>50% 11) |Re-coatability Min. 2h to 72h or as per manufactures specification ‘with the approval of the Engineer in charge. The primer shall satisfy the following requirements 2808.3 sealed container. i) System ii) Base iii) Curing iv) Colour v) Shelf life vi) Coverage : 75 gm/m? to 100 gm/m? : Single component universal polymer primer : Acrylic Resin dispersion : Al Curing : Milk white, transparent application : 6 months from date of manufacturing in tightly (depending upon smoothness and absorption of concrete surface) Quality Assurance The Acrylic elastomeric material should be tested in GOI accredited laboratories where such laboratories are available, otherwise in other standard laboratories where similar facilities exist for properties specified above. Random samples during execution shall be taken from consignments brought to site to verify that the test results match with the earlier certificates produced before approval of the product. Both the test results (prior to approval and during execution), shall conform to the requirements as per Table 2800-1, failing which the consignment shall be rejected. It shall be made mandatory that the stock register for the materials are maintained at site and signed by the Engineer periodically. 774Repair of Structures Section 2800 2808.4 ‘Surface Preparation The work shall commence after carrying out any repair to the concrete surface as directed by the Engineer. The concrete surface shall be free from all adhesion inhibiting substances such as oil, grease release agents as well as laitance and dust. The surface shall be cleaned by wire brushing, mechanical scraping and any loose material shall be removed by chiseling with small hammer and washed with clean water. The substrata shall be structurally sound for effective bond of the acrylic polymer with the concrete surface. All pin holes shall be filled with non-shrink polymer modified fine repair mortar. 2808.5 Application After preparing the surface and filling the pin holes, primer coat (75-100 gm/sq.m.) shall be applied with brush/lambskin rollet/spray gun and shall be cured for 60 minutes or as specified by the manufacturer. Subsequently, 1* and 2" coats of polymer coating shall be applied with brushispray gun/ roller keeping the time between coats not less than 2 h and not more than 72 h. Consumption per coat shall be 200-225 gmim?. The total dry film thickness of the protective coating for all coats shall be in the range of 200-225 microns. The wet film thickness shall be measured at a number of selected locations at the time of application with painting gauges. For measuring the dry film thickness, suitably located painting gauge shall be used. Atleast one gauge shall be located on each face of superstructure in each span but not less than one gauge/100 sqm. For the given solid content in the application, the dry film thickness to wet film thickness ratio should be established by prior testing in the laboratory using appropriate panels like glass plates, flat concrete, steel plates (300 x 300 mm)with similar coatings. Alternatively, the dry film thickness may be calculated from the measured wet film thickness by multiplying with the solid contents per unit volume. 2808.6 Performance Guarantee This type of protective coating shall be executed only through authorized technical applicators of standard manufactures who have requisite work experience for having carried out similar type coating works. The Engineer shall take performance guarantee from the agency responsible for the execution of the work for a minimum period of 5 years. 2809 PROTECTIVE SURFACE COATING OF CONCRETE BY, PATENTED SYSTEMS OF COATING Patented system of protective coating like epoxy polyurethane painting system, epoxy phenolic protective system and other systems shall be used only with the approval of Engineer after the assessment of the performance of the product, backed by ceriificates from users, acceptance tests as per published standards, pertinently to cover the material, processes, 775Section 2800 Repair of Structures carbonation resistance, water vapour diffusion property, crack bridging properties, and UV resistance. The Engineer shall take performance guarantee from the agency responsible for the execution of the work for a minimum period of 5 years. 2810 REPLACEMENT OF BEARINGS 2810.1 Necessary repair/replacement of bearings shall be carried out as indicated in the repair plan or as directed by the Engineer. Care shall be taken to plan the execution of repair in the shortest possible time. 2810.2 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 no undue stresses are 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 shall have provision for manual override to control the loads of any particular jack. The jacks should be so synchronized that differential lift between individual jacks does not exceed 1 mm. 2810.3 Precautions during Lifting of Girders for Rectification of Bearings Walkie talkie system or similar audio arrangements should be available for communicating instructions during lifting of girders for rectification/replacement of bearings. In the event of replacement it shall be ensured that the new bearing fits into the available space. 2811 REPAIR AND REPLACEMENT OF WEARING COAT 2811.4 Repair of Wearing Coat Repair of bituminous and cement concrete wearing coat shall be as per Section 3000 of these Specifications. 2811.2 Replacement of Wearing Coat i) The existing wearing coat shall be dismantled before laying fresh wearing coat. ii) Overtay shall not be provided on existing wearing coat on bridge decks unless its structural adequacy to carry extra load of overlay is assured and certified by the Engineer. iii) _ Before commencing dismantling, the nature and condition of the wearing coat shall be ascertained. iv] Dismantling of wearing coat shall be carried out using jack 776Repair of Structures Section 2800 hammers or suitable manual/mechanical methods as approved by the Engineer. Care should be taken to avoid any damage to the existing structure including concrete, reinforcement or pre-stressing anchorages for cables, if any, located in the deck slab. v) The existing expansion joint assemblies shall be removed carefully along the entire width of the carriageway if included under the scope of work or as directed by the Engineer. In such cases, the deck slab for a width of 400 mm on elther side should be removed for placing of reinforcement, anchor rods, anchor bolts and other fixing assemblies for the new expansion joints and pouring of fresh concrete. The gap between the girders over the piers should be cleared of all debris. A temporary platform under the gap at the end of girders shall be erected to collect the materials falling down during concreting and fixing of ‘expansion joints. vi) After dismantling the existing wearing coat fresh wearing coat shall be provided as per Section 2700 of these Specifications. The expansion joint assembly, wherever dismantled shall also be fixed in position true to lines and levels. 2811.3 Precautions during Dismantling Work For general guidelines, reference may be made to Section 100 of these Specifications. Dismantling work shall not be carried out at night, or during storm or heavy rain. A warning device shall be installed in the area for warning the workers in case of mishap/emergency. Safety helmets conforming to I$:2925 shall be used by the workmen engaged in dismantling work. The sheds and tool boxes should be located away from the work site, To protect eyes and face from injuries from flying pieces, dirt, dust etc., celluloid goggles and gas masks shall be worn at the time of dismantling, especially where tools like jack hammers are deployed. 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 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. 2812 EXTERNAL PRESTRESSING 2812.1 Material H.T. Strands/wires shall conform to Section 1000 of these Specifications. 77Section 2800 Repair of Structures HOPE Sheathing shall conform to IS:4984 sultable 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. As necessitated by the profile of the external cable, suitable strand/wire deviator block fabricated from M.S. sections shall be provided and securely fixed at the required locations, The block shall be sand blasted and given a coat of suitable paint (preferably epoxy based). Depending upon the pre-stressing force, suitable anchorages and wedges shall be used conforming to relevant codes and Section 1800 of these Specifications. 2812.2 Workmanship a) — Stressing of cables shall be carried out as per instruction given in the drawings, and conforming to Section 1800 of these Specifications. b) Care should be taken to avoid any damage to the existing structure by way of stress concentration or any other reason during fixing of the deviator blocks and after stressing of cable. The deviator biocks shall be so fixed as not to allow any movement due to pre-stressing forces. Radius of curvature of the surface of the deviator block interfacing with the cable shall be minimum one metre. °) The anchorages shall be sealed with suitable epoxy mortar system after the stressing of cables. A minimum cover of 50 mm shall be provided for the anchor plates and anchorages. 4) Suitable grouting inlet points and vent points shall be provided by way of HDPE “T” vent connections to the sheathing. e) Grouting of cables shall be carried out as per provisions of Section 1800 of these Specifications. 2812.3 itshall be ensured that no part of the existing structure is damaged/distressed due to the external pre-stressing. The behaviour of the girder shall be monitored by measurement of deflection so that ‘only required amount of external pre-stressing is imparted to the girder. Care shall be taken to avoid excess pre-stressing and impairment of the girders. 2813 TESTS AND STANDARS OF ACCEPTANCE The material shall be tested in accordance with these Specifications and shail meet the prescribed criteria. The work shall conform to these Specifications and shall meet the prescribed standards of acceptance. 778Repair of Structures Section 2800 2814 MEASUREMENTS FOR PAYMENT a) For epoxy grouting measurement for sealing of cracks and injection shall be made by weight of epoxy consumed in kg for epoxy grouting. For provision of nipples required for grouting, the payment shall be for number of nipples inserted. b) For cement grouting measurement for sealing of cracks and injection shall be made by weight of cement consumed in kg. c) Measurement for application of epoxy mortar/protective surface coating of concrete for specified thickness shall be in square metre of surface area of application. d) Bonding of old and new concrete by epoxy mortar shall be measured in square metre of surface area of interface. ) Guniting/shotereting shall be measured in square metre of surface area of application. f) _ Replacement/rectification of bearings shall be measured in number of bearing assembly replaced/rectified. 4g) Dismantling of wearing coat shall be measured in square metre of arez of wearing course dismantled. External pre-stressing shall be measured in tones of H.T. steel strand/wire measured from anchorage to anchorage before stressing. 2815 RATE 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 Spectfications. ‘The contract unit rate for application of epoxy mortar/protective surface coating for specified thickness shall include cost of all materials, labour, tools and plant, placing in position, testing and other incidental 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. 779Section 2800 Repair of Structures The contract unit rate for replacementrectification 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 urit 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, if included as a part of the work by the Engineer for the satisfactory completion of the work as per these Specifications. The contract unit rate for external pre-stressing shall include cost of all materials, labour, tools and plant, temporary works, testing, curing and other incidental expenses including careful monitoring of the deflection of girders being externally pre-stressed for the satisfactory completion of the work as per these Specifications and as shown on the drawings. 780