Civil Structural Repairs of Sea water Jetty of Dhruva, BARC, Trombay-85.

Amount

Suspended Working Scaffold with Platform for Jetty: Design, preparation of drawing, providing and fixing adequately designed hanging/suspended steel scaffolding with working platform (more than one type of construction for different locations) using standard frames / members & suitable hoisting arrangement to approach civil structural components like piers, beams, slabs etc. located below the jetty road over its entire length of 975 mtr & also jetty head for executing structural repairs and protective coating etc., Scaffolding made with standard steel structural members and maintaining it in a serviceable condition for the required duration as approved and removing it thereafter. The suspended scaffolding system shall be stiffened with bracings, runners, connection with structure etc. with essential safety features for the workmen and should not hinder movement of vehicular traffic on jetty road etc. complete as per directions and as approved by the Engineer-in-charge. The payment shall be made once irrespective of duration of scaffolding.

Epoxy Repair (Surface Preparation): Repairs of cracked, damaged, spalled, portion of RCC of beams, slabs, piers below jetty road, jetty head, pump room, cable tray supporting ribs by epoxy formulation of approved manufactures as per the specification and as directed by the Engr-in-Charge including, cleaning of reinforcement, surface- preparation as per specifications, applying bonding coat to reinforcement & exposed prepared surfaces with Epoxy formulation and various thickness of Epoxy mortar/concrete as specified, finishing smooth to match the existing shape and dimensions using suitable scaffolding & hoisting arrangement, preparation etc. complete to the satisfaction of Engineer-in-Charge and all as per the specification. Surface Preparation: Chipping/removal of damaged / spalled/cracked concrete carefully upto hard core concrete, roughning thoroughly entire surface area of all concrete components such as Piers, beams, Deck Slab etc. Clean the area with sweep sand blasting to open the micro cracks, remove surface contaminated/ carbonated/chlorinated concrete and wash the concrete surface with high pressure water jet of 100 bar pressure to remove all salts deposits and make the surface ready to receive further treatment.

Epoxy Repair: Cleaning Cum Passivation of re-bars: Re-bar cleaning / rust removal using sand blasting / electrically operated angle grinders/ wire brushes etc complete and drying the surface by hot air blow near damp areas if formed and providing, applying Rust Remover cum Passivator with Rustoff 100 of Sika or BASF/Dr.Fixit/Huntsman or approved equivalent and a coat of Two Component, Low Solvent, Zinc rich Epoxy Resin based primer Friazinc-R of Sika or BASF/Dr.Fixit/Huntsman or approved equivalent over the existing cleaned reinforcement surfaces before structural repair as per site requirement and as directed at the site.

Epoxy Repair: Epoxy Bond Coat: Providing & applying one coat of Epoxy Bond coat to concrete surfaces/ protective coat to reinforcement bars using Sikadur 32 LP of Sika or BASF/Dr.Fixit/Huntsman or approved equivalent make for bonding on the existing concrete surface with new materials as per manufacturers specifications, data sheet and as directed at site. Note: Epoxy Bonding agent should pass the requirement of ASTM C 881 and should have compressive strength of min 55N/sq.mm, flexural strength of min 30 N/sq.mm as per IS 9162-1979 and bond strength of 2.5-3N/sq.mm as per ASTM C 882.

Epoxy Repair: Epoxy Application: Repairing epsoxy repair mortar using moisture insensitive epoxy putty/mortar namely Sikagard-694 F(I) of SIKA or BASF/Dr.Fixit/Huntsman or approved equivalent makes as per manufacturers recommendations, applying this mortar on damaged surfaces in 5 mm thick layers so as to mend the damaged surfaces to the required thickness etc complete including one coat of primer coat between epoxy mortar layers consisting of resin: hardner as per manufacturer recommendation by brush and sprinkling of Quartz Sand when the coat is tacky etc complete. Note: 1) Epoxy putty should have compres sive strength of min 50 N/sq.mm 2) Area of each coat of 5mm thick mortar shall be measured for payment. 3) Priming coat shall be applied after each layer of 5mm mortar.

Epoxy Repair: Sealer Coat: Applying 2 coats of sealer epoxy coats using epoxy resin, hardener, silica flour & flow control agent in the ratio as mentioned by manufacturer of SIKA/BASF/Dr Fixit/Huntsman by brush to have even surface etc. complete

Structural strengthening of piers/beams and other members: New reinforcement: Providing new reinforcement for repair work of RCC work including cutting, bending, straightening, binding with annealed steel wires of 0.9 to 1.6mm thickness and placing in position and /or welding with the existing re-bars wherever the loss of cross sectional area is less than 15% of its original area. Note: 1) Steel shall be TMT bars of sizes as required . Binding wire required for the work will have to be supplied by the contractor at their own cost and will not be measured for payment.

Structural strengthening of piers/beams and other members: Shear Key: Drilling and providing reinforcement by anchoring 12 mm dia shear key / bars in 14 mm dia holes or size of holes as recommended by the manufacturer of SikaRefix of Sika in existing RCC structures like Piers, Pier caps, walls, beams etc by drilling specified dia upto 10 times of diameters of bars and anchoring with SikaRefix of Sika or Anchorfix-S of Dr fixit or BASF/HILTI/ Huntsman or approved equivalent make after cleaning the holes to make dust free complete as per site requirement and as directed at site. Note: only Number of anchors will be measured and paid and reinforcement will be paid under relevant item. Rate shall include cost of labour, all materials, T & P for power drilling in concrete, epoxy cartridges, plastic nozzle etc complete including cleaning the drilled holes of loose dust by blowing air.

Structural strengthening of piers/beams and other members: Shuttering: Providing & fixing special water tight centering and shuttering including bolting, shuttering, propping etc so as to withstand a pressure of 0.1 Mpa including removal of forms after microconcreting /R.C.C for all locations etc., complete.

Structural strengthening of piers/beams and other members: Microconcrete: Providing and laying free flow, shrinkage compensated, corrosion inhibiting, high strength Cementitious ready to use Super Fluid microconcrete (SFMC) of Sika Rep Microcrete 4 of Sika or Dr.Fixit/BASF/ Roffe or approved equivalent make high early strength flowable mortar and adding premeasured water to make the mix flowable & admixed with 10 mm down cleaned washed aggregates 50% by weight of microconcrete for confining the columns, column top, beams etc including curing etc complete all as per site requirement and as directed at the site by the E-I-C. (Shuttering and form work will be measured and paid under relevant item) Note: 1) Microconcrete should pass the requirement of BS 6463(part 3&4)-1987 for foowability and BS 4551 -1980 for compressive strength and permeability as per manufacturer's data shee. 2) Microconcrete at 28 days curing should have compressive strength of min 65 N/sq.mm as per ASTM C-1107-99 and flexural strength of 5 N/sq.mm as per ASTM-C-293-79 and Tensile strength of 3 N/sq.mm as per ASTM-D-412-87 . 2) Actual quantity of SFMC used alone in the work will be paid.

Corrosion Protection and Protective coating: Providing & application of High performance Protective coating Providing and applying protective coating of Sika/Dr.Fixit/BASF/ Roffe /Karaikote-6545 of KCPPL or approved equivalent on the entire concrete structural components such as RCC Piers, Pier caps, beam, racker piers, Jetty head structure, Pump house, chlorination room, Deck slab etc. Protective coating shall be moisture copatible/ insensitive, corrosion resitant and suitable for marine environment in two coats for a DFT of 160 microns. The rate shall be inclusive of all tools and tackles of Airless spraying machine etc including required skilled labour. Note: Coating should pass the requirement of ASTM B 117 for 2000 hours of Salt spray and resistance to seawater and 10^9 Ohm for coating resistance. 2. Coating should pass the requirement of ASTM D 4541 for 4.5 N /Sq mm for Adhesion; Impact as per ASTM G 14-04 and Flexibility as per ASTM D 522

Treatment/repair of Cracks: Groove Cutting: Cutting V groove 10 mm wide 15 mm deep along with the cracks

Treatment/repair of Cracks: Groove Sealing: Filling & sealing the grooves with with epoxy putty crack filler using Dr. Fixit or BASF/SIKA/ Huntsman or approved equivalent make as per site requirements and manufacturers specifications.

Treatment/repair of Cracks: Fixing of Nozzles: Drilling and fixing 12 mm Φ x 100 mm long nozzles by drilling upto 200 mm depth in brick masonry wall & 50 mm depth in RCC; removing the nozzles after completing of grouting job, filling/repairing the holes with polymer modified mortar etc.

Treatment/repair of Cracks: Injection of low viscosity Epoxy Injection Grout - two components low viscous high strength (7 days comp strength 800 kg/sqcm) epoxy resin based injection grout complies with BS 6319 / ASTM C -881 or Dr. Fixit or BASF/SIKA/ Huntsman or approved equivalent make through the above nozzles to fill the cracks/ voids using compressor machine as per manufacturetres specification, actual site requirements and as directed at site.

Polymer modified mortar: Providing structural repairs in old damaged concrete structures/surfaces with approved Polymer modified mortar of SIKA/Rofee/BASF/Fosroc or approved equivalent make suitable for Structural repair with following operations; 1) Removal of loose/Spalled or damaged concrete by chipping and cleaning the concrete surface and reinforcement steel with wire brush and with water 2) Cleaning the re-bars with Acetone for complete rust removal and washing with water to make the surface clean. 3) Applying protective coat/bond coat using polymer and cement in the proportion of 1;1.5 (1part of polymer and 1.5 parts of cement in synthetic enamal paint like consistancy with brush 4) Reinstate the area with polymer modified mortar in layers of maximum 20 mm with the proportion of Cement 50 Kg : washed and dried river sand 87.50 kg; silica sand 37.50 Kg. mixed with 10 litres of Polymer (or 1 Kg cement: 1.75 kg washed and dried river sand ; 0.75 Kg silica sand : 200 ml polymer) 5) If thickness of repair exceeds 20 mm,after every 20 mm thick repair, bond coat as per 3 above to be applied and further thick of repair to be continued for each layer.

Disposal of civil Scrap: Lifting, shifting and disposal assorted Civil debris and scrap mechanical items by mechanical transport Up to 4 Km.

Gubbi Civil Engineers

STANDARD REHABILITATORS PVT.LTD

Dynasoure Concrete Treatement Pvt.Ltd.