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SPECIFICATION AND TENDER SCHEDULE FOR VARIOUS

TYPES OF REPAIR OF CONCRETE


INTRODUCTION

1.1 An Overview of Present Repair Practices


1.2 Distress Identification
1.3 Repair Management

INTRODUCTION
Concrete construction is generally expected to give trouble free service through out its
intended design life. However, these expectations are not realized in many constructions because of
structural deficiency, material deterioration, unanticipated over loadings or physical damage.
Premature material deterioration can arise from a number of causes, the most common being when
the construction specifications are violated or when the facility is exposed to harsher service
environment than those expected during the planning and design stages. Physical damage can also
arise from fire, explosion - as well as from restraints, both internal and external, against structural
movement. Except in extreme cases, most of the structures require restoration to meet its functional
requirements by appropriate repair techniques.
1 An Overview of Present Repair Practices
Since 1950s, the construction activity in India has been increasing geometrically without matching
increase in the availability of quality inputs, in terms of materials and skilled workmen. The gap
between the quality planned and the quality achieved continues to become wider. The factors
contributing to damages/distresses in buildings have, thus, become intrinsic right from the construction
stage. Often these are concealed under external renderings and the defect takes time to manifest itself.
Construction documents contain adequate specifications and instructions required to execute quality
works. However, they remain as written document without achieving the desired level of results,
because of lack of understanding of their significance by the field engineers. Standard cube test results
are taken as a measure of quality in the construction. Whereas the factors such as method of placing,
compaction and curing of concrete, which have significant influence on the quality achieved in the
hardened concrete, are given scant attention. Many a times, the quality of concrete as placed and
hardened in position has no correlation to the cube test results, which are used for quality control
measures.
Procedures, mandatory or otherwise, for periodic inspection of buildings and structures and
documenting defects, like cracks, excessive deflections, corrosion of reinforcement etc., in logical
manner, and recording of structural repairs already carried out, are generally not followed or
maintained. In some buildings, only visual inspection is carried out for preparing maintenance budget
estimates and this exercise is often left to the engineers who have no experience in such problems.
Concrete constructions require proper care in the form of regular maintenance. Buildings remain
for several years without getting due attention. Water stagnation, paint pealing, plaster break- off,
fungus growth, cracking of external rendering and cover concrete are common and widespread.
Penetration of moisture into reinforced
Concrete components promotes corrosion process and further damages the concrete cover.
The engineers responsible for maintaining buildings often begin repair activity without adequate
understanding of the factors responsible for the defects. The repairs strategy adopted is replacement of
damaged materials without dealing with the real problems. Many engineers unintentionally attempt
treating the symptoms, instead of dealing with the cause and effect phenomenon. Such an approach
may offer a quick action with minimum inconvenience to the occupants. But in this process, there is a
strong possibility that the source and cause for the distress remain unattended and continue to cause
problem even after the superficial repairs have been executed. If structural defects are dealt with in this
fashion, it remains only as defects camouflaged beneath finishes, which gives a false sense of safety to
the occupants allowing the problem to continue without getting treated. A rational approach to any
repair and rehabilitation work is to consider the source of the problem and the symptoms together.

1.2

Distress Identification
Before attempting any repair procedure it is necessary to have a planned approach to investigate
the condition of concrete and reinforcement. While the diagnosis of damage or deterioration in some
cases is reasonably straightforward, it may not be so in many cases. Particularly difficult are cases in
which the cause and effect phenomenon cannot be readily explained or when prognosis in terms of
long-term performance of restored structure is to be made.
This will require a thorough technical inspection and an understanding of the behaviour of the
structural component, which is being repaired. Inspection calls for detailed mapping of affected areas,
documentation of type and location of symptoms and their history and photographic evidences. It may
also include the environmental factors, which are likely to accelerate the damage process. Existence of
concealed ducts, water lines, wet areas require special attention. Some areas impose severe limitations
on access to damaged areas. A comprehensive inspection data helps in making an effective strategy for
repair and rehabilitation.
Non-destructive evaluation (NDE) of concrete and components are well known and extensively
used. While they are very good tools for establishing quality levels in new constructions, applying
these techniques to damaged structures requires certain level of experience and understanding of
limitations of these methods. Solving the problem successfully is entirely dependent on the ability of a
team of experts engaged to do this job. Both field and laboratory tests are available. It is important to
select the appropriate Non Destructive Evaluation (NDE) techniques and location of investigation.
This is a specialised job and requires sophisticated instruments and trained personnel. A single
technique may not be adequate and a combination of techniques has to be adopted to get a truly
representative data on the condition of the building.
Concrete normally provides excellent protection to reinforcing steel. Notwithstanding this, a large
number of cases have been reported in which corrosion of reinforcement has caused damage to
concrete structures within a few years from the time of construction. One of the most difficult
problems in repairing a reinforced concrete element is to handle corrosion damage. Reinforcement
corrosion caused by carbonation is arrested to a great extent through repairs executed in a sound
manner. However, the treatment of chloride-induced corrosion is more difficult and more often the
problem continues even after extensive repairs have been carried out. It invariably re-occurs in a short
period of time. Repairing reinforcement corrosion involves a number of steps, namely, removal of
carbonated concrete, cleaning of reinforcement,
application of protection coat, making good the reduced steel area, applying bond coat and cover
replacement. Each step has to be executed with utmost care. When chlorides are present in concrete, it
is extremely difficult to protect reinforcing steel from chloride attack, particularly in cases where
chlorides have entered through materials used in construction and residing in the hardened concrete.
For such cases, new technologies are available which require specialists to execute the job.
1.3 Repair Management
Three distinct stages are to be recognized while taking up a repair job. The first stage involves
documentation of damage, its type and extent, prognosis of repaired structure and recommendations on
repair methodology. For major jobs it will be worth while to engage an independent consultant to do
this job. The second stage requires preparation of detailed drawings, sketches, execution guidelines and
notes, material and works specifications and tender document. The tender document should adequately
cover various elements to the extent possible. Specific provisions in terms of material specifications
should be included. It should clearly define modalities of payment, works measurements and records.

This will facilitate in receiving a fair and competitive proposal for the repair works. Guidelines
prepared for executing the job should be practical and flexible so as to encourage the ingenuity of the
contractor executing the job. The third stage is actual execution of repairs. This is a specialised
job and those who have the necessary expertise and resources in terms of tools and plants should be
engaged. The supervising engineer should have a good understanding of the procedures and give an
attentive supervision. In some cases it may become necessary to monitor the effectiveness of repairs by
various tests before and after the repairs have been executed.
Various options in terms of techniques and repair materials are available for executing repair jobs.
Selecting a most appropriate material and repair methodology is very important to achieve durable,
effective and economic repairs. Matching the response of repaired sections with the main structure is
an important task. Compatibility of materials and matching specifications are essential in any repair
job. Just as building durable construction requires understanding of structural engineering, material
science, and environment/ exposure conditions, repair jobs also require the same level of attention in
these areas.
The buildings taken up for repair may have structural deficiency and in such cases it is necessary to
consider provisions for strengthening through bracing and creating alternative load transfer framing to
give additional reserve strength to the structure for adequate safety and serviceability response. If this
aspect is overlooked, the symptoms are likely to reappear even after repairs have been carried out.
Familiarity with repair methodology and repair materials is very essential. General civil
engineering practice does not offer much scope in this area. The engineer undertaking such specialised
jobs should have good knowledge of new materials, repair methodologies, its limitation and the
fundamentals of structural engineering to ensure safety and serviceability of the buildings during repair
and thereafter.

CHAPTER 1 : SURFACE PREPARATION

Item
No.

Description of item

Unit of
Measurement

8.1.1 Removing of all types and thickness of existing plaster carefully


and exposing existing masonry surface including raking out of
joints 15 mm deep

sqm

8.1.2 Dismantling & removing existing treatment over RCC slabs at


all heights including stacking of serviceable material for reuse as
per direction of Engineer-in-Charge & disposal of balance
unserviceable material within a lead of 50 metre

cum

A. Extra for disposal of unserviceable material beyond 50 metres


and up to 1 kilometer

cum

B. Extra for disposal of unserviceable material beyond 1


kilometer and up to 5 Kilometers

cum

8.1.3 Dismantling existing RCC work but excluding cutting of


reinforcement bars at all heights including disposal of
unserviceable material as per site in-charge within a lead
of 50 metre.
A. Manually using chisel and hammer

cum

B. Mechanically using power driver/pneumatic percussion


chisels/hammers

cum

C. Extra for disposal of unserviceable material beyond 50 metres


and up to 1 kilometer
cum
D. Extra for disposal of unserviceable material beyond 1
kilometer and up to 5 Kilometers

cum

Item
No.

Description of item

Unit of
Measurement

8.1.4 Cutting of reinforcement bars in RCC or reinforced brickwork.


carefully without damaging the existing structure and its finishes
as per site in-charge
A Bars of dia 12mm or less
Each
B Bars of dia more than 12 mm but not exceeding 20 mm
Each
C All bars of dia more than 20 mm
Each
8.1.5 Removing concrete all around reinforcement including from
behind the reinforcing bars to give an average 25mm (but not less
than 15mm )clear air gap as per site in-charge. Length of
reinforcement bars cleared of concrete all around shall be
measured for payment. The rate also include the removing of all
rust around the reinforcement.
A By manual methods (hammering the rebar, using wire brushes,
chiseling etc.)
(a) Bars up to and including 12mm diameter
(b) Bars above 12mm diameter
B Extra for using standard power driven or pneumatic abrading
tools/chisel of standard make.

metre
metre

(a) Bars up to and including 12mm diameter

metre

(b) Bars above 12 mm diameter

metre

8.1.6 Cleaning reinforcement of total rust including from behind


the reinforcing bars to give it a totally rust free finished steel surface.
Length of reinforcement bars cleaned of rust all around shall be
measured for payment
A By manual methods (hammering the rebar, using wirebrushes,
chiseling etc.)
(a) Bars up to and including 12mm diameter

metre

(b) Bars above 12mm diameter

metre

Item
Description of item
No.
B Extra for using sand blasting
C Extra for using alkaline chemical rust remover with paint
brush and removing loose particles after 24 hours of its
application with wire brush and thoroughly washing with
water and allowing it to dry.
(a) Bars upto 12 mm diameter

Unit of
Measurement
metre

metre

(b) Bars above 12 mm diameter


metre
8.1.7 Introducing new reinforcement bars for structural connections
in RCC beams, lintels, columns and slabs including power drilling
holes of appropriate diameters in reinforced or plain cement
concrete to a minimum depth of 150mm and upto 200 mm, fixing
the reinforcement in position using epoxy. (Rate shall include cost
of all materials like reinforcements,cements etc. labour, T&P for
power drilling in concrete, epoxy cartridges, plastic nozzle etc
complete including cleaning the drilled holes of loose dust by
blowing air).
A Upto and including for 12 mm dia reinforcing bar

each

B Bars of dia more than 12 mm but not exceeding 20 mm

each

C All bars of dia more than 20 mm

each

8.1.8 Providing and inserting mild steel shear key bars/ leveling
gauges (for shotcreting) of required length and diameter in
reinforced/plain concrete as per drawing and directions of
Engineer-in-charge including power drilling holes of appropriate
diameters to a minimum depth of equal to 12 times the diameter
of shear key bar/levelling gauge, cleaning the drilled holes of loose
dust by blowing, insertion of epoxy from cartridge, placing the
shear key bar in position and allowing it to stay undisturbed for 24
hours. (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.
A 12mm dia. 300 mm long@ M.S. shear key
B 16mm dia. 400 mm long@ M.S. shear key

each
each

Item
No.

Description of item

Unit of
Measurement

8.1.9 Cleaning exposed concrete surface of lightly sticking materials


including foreign materials, loose concrete/aggregates, etc. The
rates shall include cost of movable scaffolding & working platform
@ The projected length of shear key shall be more than 10 times its
diameter plus half the thickness of cover concrete plus bend length.
(Rate also includes the cost of working platform). Disposing
of all debris up to a lead of 50 metres and complete in all respects.
A

With wire brush, chisel etc for all heights

sqm

By sand blasting with coarse sand followed by and including


cleaning with oil free air blast
i) Up to a height of 15metre above plinth level

sqm

ii) Extra for every additional height of 3 metre or part


thereof beyond 15 metre height above plinth level.

Sqm

8.1.10 Providing and fixing anchor fastener system, mechanical/epoxy


based of standard make for connections in concrete as per design
and drawings and/or as directed by Engineer-in-charge. ( Rate shall
include cost of bolts, labour, all materials including epoxy
cartridges ( wherever required), T&P for power drilling, cleaning
the drilled holes of loose dust by blowing air, insertion of epoxy
from cartridge with plastic nozzles as may be required, placing
internally threaded sleeve, driving of bolts, 2 nos-4mm thick (hot
dip galvanized/epoxy coated ) washers, fastening screw and
tightening with nuts and check nuts etc. as may be required
A. Mechanical Anchor fastener:
a) 8mm dia anchor fasteners
a) 10 mm dia anchor fasteners
b) 12 mm dia anchor fasteners
c) 16 mm dia anchor fasteners
B Extra for epoxy in mechanical anchor fasteners, if used
a) 8 mm dia anchor fasteners
b) 10 mm dia anchor fasteners
c) 12 mm dia anchor fasteners
d) 16 mm dia anchor fasteners

each
each
each
each
each
each
each
each

Item
No.

Description of item

Unit of
Measurement

CHAPTER 2: CRACK/HONEYCOMB AREA REPAIR


8.2.1 Providing and inserting 12mm dia Aluminium/ galvanized iron
injection nipples along crack lines or honey-comb area, including
i) drilling holes of required diameter up to depths from 40mm
to 80mm or half the thickness of member (whichever is less),
at required spacing but not exceeding the thickness of member
or 300 mm
ii) Making grooves of size 12mm x 12mm along the crack line.
iii) Making the crack dust free by blowing compressed air and
then washing with water.
iv) Sealing the distance between the injection nipples with
approved putty (Polymer modified cement mortar /polyester
putty/epoxy putty) etc and allow it to cure.
v) If cementitious grout material proposed to be used, washing and
saturating the cracked surface with water by pumping from top
most nipple and down wards complete as per the direction of
Engineer-in-charge.( The rate shall include all material, labour
and all operations above). Quantity of grout material for payment
purposes shall be taken on the basis of actual quantity consumed
A In concrete work
B In masonry work.
8.2.1 a Supply of approved crack/honeycombed area sealing material/
admixture.
A Approved Emulsified acrylic Polymer (Rates shall be in terms
of solid contents of polymer)
B Approved Emulsified SBR Polymer (Rates shall be in terms
of solid contents of polymer)
C Approved epoxy (Total weight of Resin & hardener in
proportion specified by manufacturer)
D Shrinkage compensating cement

each
Each

kg
kg
kg
kg

Item
Description of item
Unit of
No.
Measurement
8.2.2 Injecting approved grout in appropriate proportion excluding cost
of such grout material covered under item No. 8.2.2a into cracks/
honey-comb area of concrete/masonry by suitable gun/pump at
required pressure including cutting of nipples after curing etc.
complete as per directions of Engineer-in-charge. (The payment
shall be made on the basis of actual weight of approved grout
injected).
A Epoxy grout in
a) Concrete/ RCC work
b) Masonry Work

Kg
Kg

B Stirrer mixed acrylic Polymer modified cement slurry made


with shrinkage compensating cement in
a) Concrete/RCC work
b) Masonry Work

Kg
Kg

C Stirrer mixed SBR Polymer modified cement slurry made


with shrinkage compensating cement in
a) Concrete/RCC work
b) Masonry Work

Kg
Kg

D Stirrer mixed shrinkage compensating plain cement slurry in

a) Concrete/RCC work
b) Masonry work
Stirrer mixed shrinkage compensating cement sand slurry in
RCC/PCC/Masonry in proportion
a) 1:0.5 (1- cement and : 0.5-specified grade of sand by
weight)

Kg
Kg

b) 1:1 (1- cement and : 1-specified grade of sand by weight)


c) 1:1.5 (1- cement and : 1.5-specified grade of sand by
weight)
Kg
d) 1:2 (1- cement and : 2-specified grade of sand by weight) Kg

Kg
Kg

Item
No.

Description of item

Unit of
Measurement

8.2.2a Supply of approved grout material/admixture


A Approved Emulsified acrylic Polymer (Rates shall be in terms
of solid contents of polymer)
B Approved Emulsified SBR Polymer (Rates shall be in terms
of solid contents of polymer)
C Approved epoxy (Total weight of Resin & hardener in
proportion specified by manufacturer)
D Approved shrinkage compensating cement
E Approved Ordinary Portland Cement of Grade 43
F Approved Ordinary Portland Cement of Grade 53

Kg
Kg
Kg
Kg
Kg
Kg

CHAPTER 3 BONDING COATS


Item
Description of item
Unit of
No.
Measurement
8.3.1 Mixing and applying bonding coat, including cost of material,
on prepared non-metallic surface of parent material as per
specifications and direction of Engineer-in-Charge complete.
A. Acrylic polymer modified cementitious bond coat @ 2.2 Kg
cement per sqm. of surface area with specified proportion of
polymer admixed (Rate shall include cost of cement,tools &
plants, etc)
sqm
B. SBR polymer modified cementitious bond coat @ 2.2 kg
cement per sqm of surface area with its proportion as specified
sqm
C. Approved epoxy adhesive.
sqm
8.3.1a Supply of approved bonding material for prepared non-metallic
surface
A Approved Emulsified acrylic Polymer (Rates shall be in terms
of solid contents of polymer)
Kg
B Approved Emulsified SBR Polymer (Rates shall be in terms
of solid contents of polymer)
Kg
C Approved epoxy (Total weight of Resin & hardener in
proportion specified by manufacturer)
Kg
D Ordinary Portland Cement 43 Grade
Kg
8.3.2 Applying alkaline passivating & bonding coat of approved adhesive
including the cost of material over reinforcement duly approved by
Engineer-in-Charge with.
A Approved CPCC material, a two coat patented system of CECRI
on
a) Steel reinforcement bars

Kg

B Two coats of approved acrylic polymer and cement in the ratio of


1:5 (1-solid contents of acrylic polymer and 5-cement) by weight
at an interval not less than 4 hours
a) Steel reinforcement bars

Kg

Item
No.

Description of item

Unit of
Measurement

Epoxy phenolic IPN-RB, an epoxy based, CBRI patented coating


system, including sprinkling silica sand (no 10) for:
a) Steel reinforcement bars
Kg
D Approved epoxy bonding coat as per manufacturer's specifications
including sprinkling silica sand (no 10) for;
a) Steel reinforcement bars
Kg
8.3.2a Supply of approved bonding / passivating adhesive for reinforcement
A Emulsified acrylic Polymer (payment shall be made for the
weight of solid contents of polymer)

litre

B CPCC coating material (excluding the weight of cement)

Kg

i) Primer coat
ii) Sealer Coat
C

litre

Epoxy phenolic IPN-RB, a CBRI licensed product (Payment shall Litre


be for quantity of Resin plus hardener in manufacturer specified
proportion)

D Approved epoxy (payment shall be for total weight of Resin plus


hardener in manufacturer specified proportion)

Kg

E Ordinary Portland Cement 43 Grade

Kg

CHAPTER 4 STRUCTURAL REPAIR


CHAPTER

4A

Refer Introductory and General Notes along with the following Chapter Notes :
Chapter Notes :
GENERAL :
Structural Rehabilitation is a specialized subject in itself. As such before undertaking the
structural repair of a building, following principles may please be clearly understood.
(i)

Detailed inspection and distress mapping of a structure is necessary. In distress


mapping every part of structure is inspected & the extent of damage & its location
needs to be marked on a drawing.

(ii)

In case visual inspection is not found to be sufficient NON DESTRUCTIVE TESTS


need to be carried out to assess the extent of damage & residual life of a structure.

(iii)

Structural Rehabilitation with construction chemicals are expensive. As such cost


benefit analysis should be prepared before undertaking repair.

(iv)

These repairs are basically Design Repairs. Like a building is designed before
undertaking construction, these repairs are required to be Designed before
undertaking rehabilitation. As such maximum Data should be collected through visual
inspection, NDT & material testing to prepare design of repair.

(v)

The aim of rehabilitation should be extend the life of structure by at least 30 years

INFORMATION FOR GUIDENCE


Typical steps involved in repairing R.C.C. structures which have spalled concrete due to
corrosion of reinforcement is as follows:
(i)
Remove the loose concrete & expose the corroded reinforcement. Concrete if strong
need not be broken, however at the same time, it should also be ensured that no loose
concrete, which can be removed is left.
(ii)

Clean the corroded bars with mechanical means like wire bush, sand paper etc.

(iii)

Apply rust removing chemical solution.

(iv)

Apply rust prevention (Protection from corrosion) chemical.

(v)

Apply bond coat on concrete area to be repaired

(vi)

Apply polymer/Epoxy/repair mortar

(vii)

Finish the complete surface with ordinary plaster as a finishing coat.

The above guideline is very brief and generic. Many other alternatives like rust converters,
migratory corrosion inhibitors, cathodic protection techniques, bond coats of several types, ready mix
polymer mortars etc. are available. Hence, detailed study should be undertaken for deciding the
methodology of repair.
IMPORTANT
There are large number of companies manufacturing construction chemicals. The products
of each company is typical. While approving the product, it should be ascertained that minimum
technical standards as given in Specification are fulfilled. Further necessary tests should be ordered to
ascertain quality as required.
MEASUREMENT
In all cases of repairs by construction chemicals, the required quantity of chemicals shall be
first supplied in depot, which shall be recorded in MB by Sectional / Sr. Sectional Engineer. This shall
be further 100% test checked by ADEN. The quantity then shall be issued back to contractor for repair
work. The day to day consumption record shall be maintained as is done for cement.
PRECAUTIONS
Construction chemicals are manufactured by more than 50 companies and their numbers are
increasing. Every company has its own brand names. Due to this, it is difficult to determine the
product which will be economical as well as technically correct choice. However, some basic
principles can be applied in this regard.
i)

It is better to have a company with ISO 9001 certification.

ii)

Generally IS codes/standards are not available for repair chemicals. In such cases,
appropriate ASTM standards/B.S. Standards should be referred. A sample should be got
tested according to these standards. The schedule items for testing is given in the chapter
of Material Testing.

iii)

In no case any acidic base material shall be used as it helps corrosion process. Materials
shall be ALKALINE BASED

iv)

Item
No.

1.
25101

25102

25103

25104

Clear meaning of the terms POLYMER, EPOXY, RUST REMOVER etc. must be
understood. E.g. all epoxys are polymers but a polymer may not be epoxy because
polymer is a Generic name based on the molecular structure of the material. Word
Epoxy is also a generic name. More than 300 (Three Hundred) various formulations of
epoxies are available.
Therefore, it is important to choose the construction chemical after studying various
technical aspects of the material.
Description of work

2.

Unit

Standard Rates for

3.

Mumbai Other
Division Divisions
of C. Rly.
4.
5.

Exposing existing RCC members such as columns, beams, slabs,


lintels etc. up to the main reinforcement carefully by means of chisel
& hammer, hard wire brushes or any other mechanical means, so as to M2
remove all loose concrete and cleaning the surface to remove all rust
particles etc. and make the surface ready for further chemical
treatment in bone dry condition.
Removing existing corrosion in reinforcement by means of tapping,
wire brushing etc. and then applying approved ALKALINE BASED
construction chemical for residual rust removal as per manufactures
specification and making the surface ready for treatment, as per Litre
direction of Engineer In-charge with all Contractors labour, material,
tools & plants, scaffolding , leads & lifts etc. (Item to be used in
structural repair works & not for new construction. The rust remover
should not be acid based as it initiates further corrosion).
Providing and applying Zinc based Epoxy protective coating on
reinforcement as per manufactures specification including all
contractors labour material, tools & plants, scaffolding, leads & lifts Kg
etc. complete.
Providing alkaline based protective coating on reinforcement bar as
per manufactures specification including all contractors labour, Litre
material, tools & plants, scaffolding, leads & lifts etc. complete.

19.50

14.60

113.60

107.90

319.50

319.50

171.10

171.10

Qty.
of
Ceme
nt
bags

R
e
m
a
r
k
s

6.

7
.

25105

Providing and applying cementatious polymer based bond coat


prepared by mixing approved construction chemical with cement in
the specified proportion and applied as per manufactures
specification to achieve good adhesive and high mechanical strength.
Item includes all contractors material, labour, lead, lift etc. complete.
(Item to be used for all normal building repairs).
25106 Providing and applying solvent free epoxy resin based bond coat
prepared by mixing components as per manufactures specification to
achieve good adhesive and mechanical strength. The epoxy resin
should have the properties of application on damp surface also.
(Generally to be used in the areas subjected to heavy dynamic loading
like Girder bridges etc.). (In market solvent based bond coats are
available, which are much cheaper but not suitable for the purpose.
Care needs to be taken to differentiate between the two).
25107 Providing and laying in all positions reinforced cement concrete of
M-25 grade controlled concrete for jacketing of existing columns,
strengthening of beams & other such structural repair work in all
locations including applying modified cement based bond coat &
including centering and shuttering, scaffolding, mixing of concrete in
concrete mixers, laying and compacting with proper required type of
vibrators with all contractors material, labour, leads, lifts etc.
complete including Contractors concrete mix design, casting of cubes
at the rate of 3 cubes per 5 m3 of concrete and testing of cubes.
(Cement @ 425 Kg/m3 minimum). (The item is specifically for
structural repair work and shall be operated only when existing
structure is being repaired and not for new works.

M2

36.50

36.50

M2

99.40

99.40

M3

3230.20

2584.20

25108

25109

25110

Providing and applying polymer modified cement mortar prepared by


adding approved ACRELIC BASED POLYMER LATEX additive
as per manufacturer specifications. The mortar shall be prepared by Per
mixing polymer, cement and quartz sand as per manufactures Kg
of
specification. Rate includes labour, scaffolding, material, tools and
plants etc. complete. The application procedure shall be as per Mort
ar
manufactures directives & approved by Engineer-In-Charge. (For
General building repair work).
Providing and applying EPOXY MORTAR prepared by adding
approved quality Epoxy and graded quartz sand as per manufacturers
specification. Rate includes labour, scaffolding, material, tools and
plants etc. complete. The application procedure shall be as per
manufacturers directives & approved by Engineer-In-Charge.
Per
NOTE :- Item to be used for heavy structural repairs subjected to Kg
dynamic loadings like Girders, RCC Deck slab etc.
of
Mort
ar
Providing and applying polymer modified cement based READY Per
MIXED coarse or fine mortar as directed by Engineer-In-charge Kg
including mixing and applying as per manufactures specification for
of
concrete or masonry repairs at all locations. The rate includes labour, Mort
scaffolding, tools and plants etc. complete in all respect.
ar

18.80

18.80

26.45

26.45

23.30

23.30

25111

25112

25113

25114

Plastering with cement mortar 1:3 using quartz sand (2.36 mm and
down graded) in place of ordinary sand with water cement ratio 0.40
and finishing the surface smooth in proper line, level & plumb in all
positions. The rate includes use of required admixtures as per
manufacture specification for achieving desired water cement ratio:
(Generally to be used in exterior finishing and in areas, which are
subjected to heavy rain lashing or dampness etc.)
a) 15mm Thick
M2
b) 20mm Thick
M2
M2
c) 25mm Thick
Providing and fixing G.I. weld mesh of 12 SWG, 50 mesh of
approved quality on existing concrete surface with the help of nails,
binding wire etc. with all contractors, labour, material, tools & plants,
leads, lifts, scaffolding etc. complete in all respects. The mesh is to be
fixed to concrete surface by drilling holes and fixing U hooks to hold
the mesh and shall not be tied to the corroded reinforcement.
M2
Providing and fixing chicken mesh of 20mm opening and 21 SWG of
approved quality on existing concrete surface with the help of nails,
binding wire etc. with all contractors labour, material, tools & plants,
leads, lift, scaffolding etc. complete in all respects. The mesh shall be
fixed to the concrete surface and not to the existing corroded M2
reinforcement.
Removing existing Nahanis completely including breaking masonry,
flooring iron Nahani trap etc. and removing the debris to the nearest
Municipal Dump Site complete as directed. Care to be taken to ensure
least damage to existing tiles, with all contractors tools & plants, Each
labour, material, leads, lifts etc. (For repairing leaking Toilet floors)

123.15
160.10
209.25

110.80
144.10
188.30

74.50

74.50

30.25

30.25

26.60

21.30

25115

25116

Removing existing water proofing layer in bath, WC Mori, water


tanks etc. including removing Brick Bat Coba, Nahani traps, IPS,
bottoms & side plaster and making the surface ready for further
treatment and removing the debris to the nearest Municipal Dump
M2
Site complete in all respects with contractors labour, material, tools
& plants, leads and lifts etc.
Grouting ready to use approved quality cementatious grout as
Per
directed by Engineer In-charge in RCC slab, columns, beams,
Kg.
of
masonry etc. as follows :
dry
1. Drill holes of specified diameter to a depth of minimum 40mm
grout
with the help of drills.
materi
2. Fixing grouting nipples with epoxy putty.
al
3. Cleaning & pre-soaking the surface to be grouted by injecting
water under pressure through the nipples before 24 hrs. prior to
actual grouting.
4. Grouting the RCC members with ready to use non-shrink free
flow cementatious grout through the spouts at a pressure of
minimum 4 kg. per cm2 and repeating the process till the voids
are filled.
5. Removing the pipe spouts and sealing the holes with epoxy
mortar to ensure that they do not become source of water
penetration. Item includes all contractors labour, material, tools
& plants, lead and lift etc.
NOTE:- The total quantity of ready grout shall be supplied to the
Railways first which shall be recorded and test checked as specified
in Chapter notes. The grout material shall then be issued to the
contractor for use.

19.00

15.20

18.45

18.45

25117

Grouting water based Epoxy Grout as directed by Engineer In-charge


in RCC slab, columns, beams etc. as follows :
1. Drill holes of specified diameter to a depth of minimum 40mm
with the help of drills.
2. Fixing grouting nipples with epoxy putty.
3. Cleaning & pre-soaking the surface to be grouted by injecting
water under pressure through the nipples before 24 hrs. prior to
actual grouting.
4. Grouting the RCC members with low viscosity water based
epoxy grout.
5. Removing the pipe spouts and sealing the holes with epoxy mortar
to ensure that they do not become source of water penetration.
Item includes all contractors labour, material, tools & plants, lead
and lift etc.
NOTE:- The total quantity shall be supplied to the Railways first and
shall be recorded & test checked as specified in Chapter Notes. The
epoxy grout shall then be issued to the contractor. It should be
proposed only for structural cracks like cracks in bed block,
prestressed girders, etc. No masonry grouting shall be done with this
item.

Kg

235.45

235.45

\
25118

25119

Providing and laying water proofing treatment in Bathroom, WCs


and Moris of upper floors to attend leakages down below as under:M2
1. Remove all loose concrete, tile etc. and expose the slab portion.
Remove plaster on the side walls up to a height of minimum
20cm.
2. Clean the surface thoroughly, so that no loose particle remains.
The cleaning shall be done with air blower.
3. Apply as per manufactures specification two coats of flexible
acrylic polymer modified cement based water proofing coating.
4. After setting of the coat 40 mm thick 1:11/2:3 C.C I.P.S. floor to be
laid without joints with C.M. 1:3. Plaster on the verticle surface
and all finished smooth. The junction of verticle and horizontal
surface be provided with hauler in concrete.
5. After initial setting time fill the water & test for leakage for 7
days.
The item includes all contractors labour, material, tools & plants,
leads & lifts etc. complete.
Providing & fixing strong non teak, wooden ballie props of minimum
100 mm diameter at middle in single piece up to 4.0 mts, height to Each
support distressed flooring beams, walls, galleries balconies or other
portion of dilapidated bldg. by propping including top and bottom
plates/planks, wedges etc. as necessary including all labours, materials
& as per direction of Engineer In-charge. The props shall be fixed in
workman like manner to ensure safety of structure without disturbing
adjoining structure etc. complete as directed. (The props shall be
taken over by the railways after the structure is repaired and the props
are released).

1291.65

1033.30

122.35

110.10

Item
No.

Description of item

Unit of
Measurement
CHAPTER 4 B STRUCTURAL REPAIR ITEMS
8.4.1 Providing and placing in position Micro-concrete, which shall be
cement based prepacked single component, chloride free, non-shrink,
free flow, self compacting, ready to use after mixing water in specified
proportion obtained from approved manufacturer as per specification
and directions of Engineer in charge (Payment under this item shall be
made only after proper wet curing has been done and surface has been
satisfactorily evaluated by sounding/tapping with a blunt metal
instrument)
A Grade M25
cum
B Grade M30
cum
C Grade M40
cum
D Grade M50
cum
E Grade M60
cum
8.4.2 Shotcreting R.C.C. columns, beams and slabs etc. in layers with
approved design mix concrete having the specified minimum
characteristic compressive strength [with ordinary portland cement,
coarse sand and graded stone aggregate of 10 mm maximum size
in proportion as per design criteria] including the cost of centering
and shuttering at edges and corners etc. as directed by Engineerin-Charge The rates shall include the providing necessary ground
wires etc. The levelling gauges, if used, shall be paid separately.
(Payment under this item shall be made only after proper wet curing
has been done and surface has been satisfactorily evaluated by
sounding/tapping with a blunt metal instrument)
A Upto a height of 15m above plinth level.
a) 25 mm thick in Grade M 20 with cement content not
less than 320 Kg per Cu M
b) 50 mm thick in Grade M 20 with cement content not
sqm
less than 320 Kg per Cu M
c) 75 mm thick in Grade M 20 with cement content not
sqm
less than 320 Kg per Cu M
d) 25 mm thick in Grade M 25 with cement content not
sqm
less than 350 Kg per Cu M
e) 50 mm thick in Grade M 25 with cement content not
sqm
less than 350 Kg per Cu M
f) 75 mm thick in Grade M 25 with cement content not
sqm
less than 350 Kg per Cu M
g) 25 mm thick in Grade M 30 with cement content not
sqm
less than 400 Kg per Cu M

Item
No.

Description of item

Unit of
Measurement
sqm

h) 50 mm thick in Grade M 30 with cement content not


less than 400 Kg per Cu M
i) 75 mm thick in Grade M 30 with cement content not
sqm
less than 400 Kg per Cu M
B Deduct for every 10 mm thickness provided less than the specified
thickness of shotcrete.
a) in Grade M 20 with cement content not less than 320 Kg
per Cu M
sqm
b) in Grade M 25 with cement content not less than 350 Kg
per Cu M
sqm
c) in Grade M 30 with cement content not less than 400 Kg
per Cu M
sqm
C Extra for every additional height of 3 metre or part thereof
beyond 15 metre height for every 25 mm thick layer or
part thereof
8.4.3 Providing and laying plain/reinforced concrete jacket for the
structural members e.g. columns, pillars, piers, beams etc with
concrete having the specified minimum characteristic compressive
strength [with ordinary portland cement, coarse sand and graded
stone aggregate of 10 mm maximum size in proportion as per design
criteria] with specified average thickness all-round existing core
of RCC member. Rates shall be for finished surface area of concrete
and shall include the cost of making holes in existing RCC slab, if
required, centering and shuttering, strutting, propping for pouring
concrete in shuttering mould of jacket and appropriate approved
super-plasticiser for rendering concrete flowable, self compacting etc
but shall exclude cost of reinforcement, bond coat, shear keys,
(Payment under this item shall be made only after proper wet
curing has been done and surface has been satisfactorily evaluated
by sounding/tapping with a blunt metal instrument)
A a) 150 mm thick in Grade M 20 with cement content not
less than 320 Kg per Cu M
b) 100 mm thick in Grade M 20 with cement content not
less than 320 Kg per Cu M
c) 75 mm thick in Grade M 20 with cement content not
less than 320 Kg per Cu M

sqm

sqm
sqm
sqm

Item
No.

Description of item
d) 50 mm thick in Grade M 20 with cement content not
less than 320 Kg per Cu M
e) 150 mm thick in Grade M 25 with cement content not
less than 350 Kg per Cu M
f) 100 mm thick in Grade M 25 with cement content not
than 400 Kg per Cu M
g) 75 mm thick in Grade M 25 with cement content not
less than 350 Kg per Cu M
h) 50 mm thick in Grade M 25 with cement content not
less than 350 Kg per Cu M
i) 150 mm thick in Grade M 30 with cement content not less
than 400 Kg per Cu M
j) 100 mm thick in Grade M 30 with cement content not less
than 400 Kg per Cu M
k) 75 mm thick in Grade M 30 with cement content not less
than 400 Kg per Cu M
l) 50 mm thick in Grade M 30 with cement content not less
than 400 Kg per Cu M

B Extra for every 10 mm thickness of jacket over the specified


thickness
a) Grade M 20 with cement content not less than 320 Kg
per Cu M
b) Grade M 25 with cement content not less than 350 Kg
per Cu M
c) Grade M 30 with cement content not less than 400 Kg
per Cu M
8.4.4

Unit of
Measurement
sqm
sqm
sqm
sqm
sqm
sqm
sqm
sqm
sqm

sqm
sqm
sqm

Providing and laying an overlay of plain/reinforced concrete


sqm
over prepared surface of existing concrete slab with concrete [as
per design mix criteria] of [specified] average thickness as per the
direction of Engineer-in-Charge. Rates shall be for finished surface
area of concrete and shall include the providing necessary ground
wires etc. the cost of appropriate approved super-plasticiser for
rendering concrete as flowable self compacting, centering and
shuttering, strutting, propping, etc but shall exclude cost of

Item
No.

Description of item

Unit of
Measurement

reinforcement, bond coat, shear keys, levelling gauges (if used),


(Payment under this item shall be made only after proper wet curing
has been done and surface has been satisfactorily evaluated by
sounding/tapping with a blunt metal instrument)
sqm
8.4.5 Reinforcement for R.C.C. work including Cutting bending,
binding, straightening and placing in position &/or welding with
the existing bars wherever necessary complete.
A MS bars
B Cold twisted CTD bars
kg
C TMT bars
kg
D Hard drawn hot dipped galvanized steel wire fabric
kg
E Hot dipped galvanized Wire
kg
8.4.6 Providing structural connections including necessary formwork
kg
for concreting, wherever required, as directed by Engineer-incharge by :
i) Chipping of concrete and exposing the reinforcement to the
required extent.
ii) Welding necessary dowels to the existing exposed main
reinforcement.
iii) Providing shear keys/ mechanical anchors
iv) Applying a bonding coat of approved epoxy resin on the substrate
as per manufacturer's specifications
v) Concreting the joint along with new structural member within the
pot life of epoxy bonding coat.
Costs of concrete, reinforcement, welding, shear key/mechanical anchors
and formwork shall be paid under the relevant items separately. Under
this item, finished surface area at interface of the connection shall be
measured for payment. Rates shall include cost of all the operations
mentioned above. (Payment under this item shall be made only after
proper wet curing has been done and surface has been satisfactorily
evaluated by sounding/tapping with a blunt metal instrument)
8.4.7 Providing, mixing and applying polymer modified cement mortar
in layers, each layer not exceeding 10mm thick, including trowelling
sqm
with wooden tools etc. complete as per specifications and directions of
Engineer-in-charge (cost of polymer shall be bear by contractor) For
payment purposes, pre-measurement of thickness shall be done just
after the surface preparation is completed. (Payment under this item
shall be made only after proper wet curing has been done and surface
has been satisfactorily evaluated by sounding/tapping with a blunt metal
instrument)

A Cement Sand mortar in proportion of 1:2 (1-cement: 2-graded

.
Item
No.

Description of item

Unit of
Measurement

coarse sand) with polymer admixed in proportions approved


by Engineer-in-charge. (75mm size cube crushing strength
at the end of 28-day to be not less than 30 N/sqmm)
a) 25 mm average thickness for slabs

sqm

b) 50 mm average thickness for Beams

sqm

c) Deduct/Add for every less/extra 10 mm thickness

sqm

B. Cement Sand mortar in proportion of 1:2.5 (1-cement: 2.5


graded coarse sand) with polymer admixed in proportions
approved by Engineer-in-charge. (75mm size cube crushing
strength at the end of 28-day to be not less than 25 N/sqmm)
a) 25 mm average thickness for slabs

sqm
sqm

b) 50 mm average thickness for Beams

sqm

c) Deduct/Add for every less/extra 10 mm thickness

sqm

(C) Cement Sand mortar in proportion of 1:3(1-cement: 3- graded


coarse sand) with polymer admixed in proportions approved
by Engineer-in-charge. (75mm size cube crushing strength
at the end of 28-day to be not less than 20 N/sqmm)
a) 25 mm average thickness for slabs
b) 50 mm average thickness for Beams
c) Deduct/Add for every less/extra 10 mm thickness
8.4.7a Supply of Polymer for polymer modified mortar
A Emulsified Acrylic Polymer (Rates shall be in terms of solid
contents of polymer)
B Emulsified SBR Polymer (Rates shall be in terms of solid
contents of polymer)
Note The mortar shall be prepared by mixing polymer, cement and
quartz sand as per manufacture specification. Rate include labour,
scaffolding, material, tools and plants etc complete the application
procedure shall be as per manufacture directives & approved by
engineer in charge

sqm
sqm
sqm
sqm

kg

Item
No.
8.4.8

Description of item

Unit of
Measurement
Mixing and applying epoxy mortar using approved epoxy resin,
kg
hardener and silica sand in proportions as per manufacturer's
recommendation complete. (The rate shall include the cost of silica
sand. The epoxy shall be paid separately on the basis of actual
consumption of the resin and hardener by weight and nothing extra
shall be paid for silica sand.
(priming/ bonding coat of epoxy to be paid separately as per the
sqm
relevant item in the schedule)
Rate include labour, scaffolding, material, tools and plants etc
complete the application procedure shall be as per manufacture
directives & approved by engineer in charge
A 25 mm average thickness for slabs

B 50 mm average thickness for Beams


C Deduct/Add for every less/extra 10 mm thickness
8.4.8a Supplying approved epoxy for epoxy mortar(payment shall be for
total weight of Resin plus hardener in manufacturer specified
proportion)
8.4.9 Providing, mixing and applying dry pack mortar 1:2.5
(1-cement: 2.5- graded sand passing 1.18 mm size sieve) by weight.
Priming/ bonding coat required to be applied shall be paid
separately as per manufacture directives & approved by engineer in
charge. . For payment purposes, pre-measurement of volume shall

sqm
sqm
sqm
Kg

be done just after the surface preparation is completed. (Payment


under this item shall be made only after proper wet curing has been
done and surface has been satisfactorily evaluated by sounding
/tapping with a blunt metal instrument& approved by engineer in charge)
8.4.10 Providing Pre-placed Aggregate Concrete (PAC) with well
compacted or hand packed aggregates of size not less than 20 mm
with self flowing grout of cement sand mortar, to be injected as
per specified proportions [neither leaner than 1:2 (1-cement: 2
clean sand passing 1.18 mm size sieve) nor richer than 1:1(1cement : 1 clean sand passing 1.18 mm size sieve)]. The water
cement ratio shall be not more than [to be specified but not
exceeding 0.5) but with approved super plasticisers admixed to
achieve required flowability etc complete. For payment purposes,
pre-measurement of volume shall be done just after the surface

cum

Item
No.

Description of item

Unit of
Measurement

preparation is completed. The rates shall include all necessary


labour, materials, T&P including grout pumps etc for executing the
job as per specifications. and site incharge Shuttering and priming/ bonding
coat, if applied, shall not be be paid separately as per the relevant
item in the schedule. (Payment under this item shall be made only
after proper wet curing has been done and surface has been
satisfactorily evaluated by sounding/tapping with a blunt metal
instrument)
8.4.11 Strengthening RCC structural member (Beam/Column/Slab/etc) sqm per layer
with hybrid fabric system of a reputed firm comprising of E-glass
and Kevlar fibres woven in the two orthogonal directions soaked in
epoxy complete. Rate shall include cleaning surface, patching up surface
irregularities, rounding of the corners to min. radius of 20 mm, precutting the fabric according to dimensions required, mixing the epoxy
with high speed mixer for 5 minutes, saturating the fabric with epoxy
manually or using the mechanical saturator, wrapping the member with
the saturated the fabric material after priming the surface with epoxy
and curing for 24 hours at ambient temperatures including applying
cement plaster finish over the outermost layer etc complete. Removing
plaster from the parent surface, if involved, shall be paid for separately
under the relevant item. (The rates shall be for finished surface area and
shall cover the cost of a minimum of 100 mm over laps).
8.4.12 Strengthening RCC structural member (Beam/Column/Slab/etc)
with unidirectional high strength fibres comprising of E-glass fibre sqm per layer
wrapped over prime coated surface with special epoxy, saturated after
wrapping with saturant epoxy complete. Rate shall include cost of
cleaning surface, patching up surface irregularities Removing plaster
from the parent surface if involved, rounding of the corners to
min. radius of 20 mm, pre-cutting the fibres according to
dimensions required, mixing the epoxy with high speed mixer for 5
minutes, saturating the fibres with epoxy manually or using the
mechanical saturator, wrapping the member with the high strength
fibres after priming the surface with epoxy and curing for 24 hours
at ambient temperatures including applying cement plaster finish
over the outermost layer etc complete.(The rates shall be for
finished surface area and shall cover the cost of over laps, if any).

Item
No.

Description of item

Unit of
Measurement

CHAPTER 5 CURING
8.5.1Wet curing of shotcreted or plastered surface or RCC work as per sqm per layer
specifications by keeping it continuously wet for a minimum period
of seven days
A With regular sprinkling of water by keeping the surface
continuously wet.
B Using pre-tested and approved water based concrete curing
compound
a) Using non-pigmented wet curing compound
b) Using pigmented wet curing compound
8.5.1a Supplying pretested and approved water based concrete curing
compound
A Non-pigmented wet curing compound
B Pigmented wet curing compound

sqm
sqm
litre
litre

Item
No.

Description of item

Unit of
Measurement

CHAPTER 6 CHHAJJA/SUN SHADES


Providing and fixing [40 mm or to be specified] thick [red
sqm
sandstone or to be specified] chajja over door/window/ventilator
in MS angle iron [40x40x6mm or to be specified] frame pre-painted
with a coat of zinc rich epoxy primer and two coats of tar-epoxy
paint. The stone slab shall be supported on three sides of the frame,
the fourth side of the stone slab to be supported on brick wall as
which could be modified as per site specific requirements
. The angle iron are to be embedded in brick wall as shown in
drawing in cement concrete block of specified size including
providing gola as per Railway specification along the wall
face. Measurements shall be done for the funished projected
chhajja in sqm correct to second place of decimal. Rates shall
include cost of all labour and materials. (The size of angle iron
frame could be modified as per structural requirement
depending upon the size of chhajja)
8.6.2 Providing and constructing average 25mm thick Ferro-cement
Chhajja/ weather shade, reinforced with 2 layers of 21 gauge
galvanised Iron orthogonally woven wire mesh of 12x12mm size,
sandwiching a layer of 3.15 mm dia M.S. weld mesh of
sqm
100x100mm size, grouted to full depth with cement mortar 1:2.5
(1-cement: 2.5 graded sand, conforming to zome-II of IS:383,
admixed with polymer admixture @ 2 Kg per 50 Kg of cement)
and a cover of 4 mm of same mortar at top and bottom and with
necessary fixing on beam/drop pardi etc. complete with water drip
course (cost of polymer admixture, shuttering, and structural steel
supports to be paid separately). Ferro-cement units must be vibrated
during casting using modified vibrator or orbital vibrators.
8.6.2a Supply of Polymer admixture for Ferro-cement Chhajja/weather shade
A Emulsified Acrylic Polymer (Rates shall be in terms of
solid contents of polymer)
Kg
B Emulsified SBR Polymer (Rates shall be in terms of solid
contents of polymer
Kg
8.6.1

CHAPTER 7 WATER PROOFING & PROTECTIVE COATINGS


Item
No.
8.7.1

Description of item

Unit of
Measurement

Providing, mixing and applying two coats of polymer based


protective, waterproofing and anticarbonation coating with
manufacturer's recommended admixed dose in cement mixed with
minimum quantity of additional water to make mix workable over
exposed surface at all heights as per specifications. Mixing to be
done by a vertical stirrer type grout mixer. (The cost of polymer
shall be bear by contractor.)

8.7.1a Supply of Polymer admixture for waterproofing and anti


carbonation coating
A Emulsified Acrylic Polymer (Rates shall be in terms of solid
contents of polymer)
B Emulsified SBR Polymer (Rates shall be in terms of solid
contents of polymer)
8.7.2 A Applying an appropriate priming coat of standard primer
compatible to the substrate (bituminous or cementitious)
surface including injection grouting the cracks, filling the
voids, undulations etc. complete using quantity not less than
theoretical consumption as per manufacturer's specifications
and directions of Engineer-in-Charge. The rates shall include
the cost of carrying out repairs to concrete surface, (if required)
and also the injection grouting.
B Applying two or more coats of ready mixed UV resistant
acrylic polymer based water proof coatings with broad
brush or roller over prepared and primer applied surface using
not less than theoretical consumption as per the manufacturer's
specifications and directions of Engineer-in-Charge (time gap
between two coats of coatings shall be not less than 8 hours).
8.7.2a Supplying appropriate primer for bituminous/cementitious
substrate for water proof coating with UV resistant acrylic
polymer manufactured by reputed manufacturer as approved
by the Engineer in charge in sealed containers.

sqm

kg
kg

sqm

sqm

sqm

8.7.2b Supplying ready mixed UV resistant acrylic polymer based water


proof coating manufactured by reputed manufacturer as approved kg
by the Engineer in charge in sealed containers.

Item
No.

Description of item

Unit of
Measurement

8.7.3 Providing and laying ferrocement water proofing treatment


comprising of layers of hot dip galvanised 22 gauge orthogonal
kg
woven wire mesh with 12 mm size mesh openings stretched and fixed
to substrate with 100 mm overlaps in both directions at a clear spacing
of 4 mm and also maintaining a clear bottom cover of 4 mm complete
with plasticiser and polymeric pore sealant admixed in appropriate
approved proportions to 1:2 cement mortar (1-Cement : 2-graded
coarse sand) applied over a bond coat of polymer modified cement
sand slurry, finished with mechanical vibratory orbital trowel. The bottom
cover and the gap between the layers shall be maintained with 4mm dia
GI wire with one layer of wire mesh stretched in the one direction &
fixed with GI wire nails/clamps at 450 mm c/c and another set of 4 mm
GI wires stretched in the other direction and second layer of mesh
stretched over and fixed with GI wire nails/clamps at a spacing of 450
mm c/c. The fixing with G.I. wire nail/clamps shall be done with epoxy
in drilled holes complete as per standard specifications and directions
of Engineer-in-Charge. The rates shall include cost of all materials,
labour, T&P involved, woven wire mesh, polymer admixed as pore
sealant and bond coat
A
B
C

15 mm thick with two layers of woven wire mesh


20 mm thick with three layers of woven wire mesh
25 mm thick with three layers of woven wire mesh

8.7.3a Supplying hot dip galvanised 22 g orthogonal woven wire mesh

sqm

with 12 mm size mesh openings in rolls with widths 750 mm to

sqm

1200 mm as may be approved by Engineer-in charge

sqm

8.7.3b Supply of Polymeric pore-sealant for ferrocement water proofing


traetment
A Emulsified Acrylic Polymer (Rates shall be in terms of solid
contents of polymer)
B Emulsified SBR Polymer (Rates shall be in terms of solid
contents of polymer)

sqm

Item
Description of item
Unit of
No.
Measurement
8.7.4 Providing and laying polymeric water proofing compound
kg
admixed cement plaster 1:4 (1-cement : 4-graded coarse sand
conforming to zone-II of IS : 383) (specify thickness 12 mm to
18 mm kg thick) mm thick in layers with the water proofing
compound mixed in proportions as per manufacturer's
recommendations including preparation of surface and application
of bond coat etc. complete over all vertical and inclined surfaces
of RCC work/ Brick Masonry/ block masonry including necessary
scaffolding, clearing the site complete as per. directions of Engineerin-Charge. The rates shall include cost all materials, labour and
operations but shall exclude the cost of bond coat, which shall
be paid separately

sqm

8.7.5 Providing injection type post construction water proofing to


concrete structures such as under ground tanks, swimming pools
etc by installing minimum 12/15 mm dia aluminium or GI nozzles
Sqm
at specified intervals and mechanically injecting machine mixed water
proofing polymer modified cement slurry at the minimum pressure of 3
kg/sqcm. Water proofing polymeric compound and shrinkage
compensating admixtures shall be added in proportion as per
manufacturer's recommendations. The rate shall include all materials,
labour and operations and finishing etc complete but shall exclude the
cost of providing, fixing and cutting off nozzle projections grouting holes,
which shall be paid separately. (Only treated surface area measurement
to be measured).

Item
No.

Description of item

Unit of
Measurement
CHAPTER 8 : MASONRY REPAIR
8.8.1Cutting, removing, and rebuilding the decayed/damaged masonry with
A Brickwork of 2nd sort in superstructure
a) Cement Sand Mortar 1 : 4 (1-Cement : 4-Coarse Sand
b) Cement Sand Mortar 1 : 5 (1-Cement : 5 Coarse Sand)
c) Cement Sand Mortar 1 : 6 (1-Cement : 6 Coarse Sand)

cum
cum
cum

In situ concrete 1:2: 4 (1-cement: 2-coarse sand : 4-12 mm Per brick or part
and downsized graded stone aggregate) in part section of a
thereof
brick or part there of.
C Build up by guniting in thickness
a) up to 25 mm
sqm
b) Above 25 mm but not exceeding 50 mm
sqm
D Applying bonding coat, providing & fixing GI wire mesh
and building up the masonry section to required thickness
sqm
on existing surface with the help of nails ,binding wire etc.
with all contractor, labour ,material, tools & plant ,all lead &
lift scaffolding etc complete in all respect by providing
polymer mortar 1:3 (1-Cement : 3-Sand Conforming to zone-III
as per IS : 383) in layers not more than 12mm in thickness
or part there of.
Note : The wire mesh shall be fixed to the concrete surface and not to
the existing corroded reinforcement.
8.8.1aSupply of polymer for polymeric bond coat and/or polymer mortar
A Emmulsified Acrylic Polymer (rates shall be in terms of solid
Kg
contents of polymer)
B Emulsified SBR polymer (Rates shall be in terms of solid

contents of polymer
8.8.2 Repair of cracks in 115 mm/230 mm thick masonry wall by
cutting the masonry, and providing and fixing precast RCC runners

in M20 concrete and packing with stiff cement mortar 1:4


A 600mm x 115mm x 75mm with 2 nos.6mm MS bar
B 600mm x 230mm x 75mm with 2 nos. 6mm MS bar
8.8.3 Repair of cracks in 115/230 mm thick masonry wall by cutting the
masonry, and providing cast in-situ RCC runners in M20
concrete with the help of contractors material, tools & plant etc.
and as per site engineer .
A 600mmx115mmx70mm with 2 nos. 6mm MS bar
B 600mmx230mmx70mm with 2 nos. 6mm MS bar
C 1200mmx230mmx70mm with 2 nos. 10mm CTD/T

Kg

Kg

Each

Item
No.
8.8.4

Description of item

Unit of
Measurement

Dismantling removing and cleaning damaged masonry and


Providing cast in-situ RCC Bed Blocks in M20 concrete
including scaffolding & shuttering complete, including
reinforcement, if any with the help of contractors material,
tools & plant etc. and asper site engineer .Disposal of waste
material shall be done by contractor beyond railway area.

8 .8.5 Raking of joints , washing and applying salt peter antidote


and replastering with cement plaster 1:4 (1 cement :4 coarse
sand). with the help of contractors material, tools & plant etc.
and as per site engineer .Disposal of waste material shall be
done by contractor beyond railway area.
8 .8.6 Chipping off the area and removing the plaster ,cleaning
wetting and applying a layer of polymer mixed bonding coat
covering the joint with one layer of 20 gauge hot dipped
galvanised wire mesh strip in plaster area extending it 75 mm
on both sides of the joint and replastering in cement mortar
1:4. Polymer shall not be paid separately

cum
cum

sqm

8 .8.7 Supply of polymer for polymeric bond coat and/or polymer mortar
A Emmulsified Acrylic Polymer (rates shall be in terms
Kg
of solid contents of polymer)
B

Emulsified SBR polymer (Rates shall be in terms of solid

contents of polymer

8 .8.8 Wrapping of Masonry structure


Application Nitowrap 30 primer which shall have density of 2.0gm/cm3
and a pot life of 20 mins @ 35 deg at a coverage of 5.5 m2/Kg and then
application of Nitowrap 410 which shall have a density of 1.12-1.16gm/cm3
and shall have pot life of 2hours@ at 30 deg at a coverage of 2.5 m2/Kg
and application of NitowrapEP CF which shall have weight of 200gm/m2
and the fibre thickness of 0.111mm and ultimate elongation(%) of 1.5 and
shall have a tensile strength of 3500N/mm2 and tensile modulus of
285x103 N/mm2 in 2 layers by applying one coat of Nitowrap 410
saturant after wrapping with NitowrapEP CF 2nd layer and then
application of Nitowrap UR 512 UV resistant top coat shall be
applied in 2 coats at a coverage of 6.5 m2/Kg/coat all complete as
specified and directed by the Engineer-In-Charge.

Kg

sqm

CHAPTER 9 : TESTING OF MATERIALS AND PRE /

POST REPAIR TESTING OF STRUCTURE (NON-DESTRUCTIVE TESTS)


Refer Introductory and General Notes along with the following Chapter Notes :
Chapter Notes :
General :
The chapter of non-destructive tests is being introduced for developing scientific system of
determining the health of structure based on data collected through tests. The items included in this
chapter are related to reinforced cement concrete, Prestressed concrete or cement mortar works. The
scope of this chapter is limited at present but can be extended gradually over a period of time.
Some tests like load test on piles etc. has been included in the relevant chapters though they can
also be termed as non-destructive tests.
Agency for conducting NDT :
The relevant notes from the chapter of Material testing shall also be applicable for this
chapter.
The testing shall be carried out by the contractor only through authorized agencies, which are
personally approved by Sr. DEN(Co-Ordination).
Rate includes :
(i)

All preparatory works like transportation & installing of equipment at site, providing
staging, scaffolding, Jhoola etc. as required
at site.

(ii)

Carrying out the work during block timing, if required in cases like bridges etc.

Item
No.

Description of item

Unit of
Measurement

8.9.1 Ultrasonic Pulse Velocity (UPV) measurement in accordance


with IS: 13311 Part-1-1992 & railway specification to detect cracks,
voids, honeycombs & other discontinuation in concrete by deploying
portable ultrasonic non destructive digital test equipment. The test
shallbe carried out by placing two transducers at predetermined
location son concrete directed by site in-charge. The rate shall
include the surface preparation including its smoothening and
making it flat, application of petroleum jelly, etc necessary for
intimate contact of the transmitter & receiver with the concrete
surface, recording the minimum & stable reading, necessary ,
marking on structure with 5 cm size lettering in yellow paint for
easy identification of location of tests scaffolding and platform,
presentation of results in an acceptable format etc all complete.

sqm

The NDT report shall be submitted to the Engineer in-charge


along with sketch indicating the location of the test.

8.9.2

Measurement of Rebound Index in accordance with IS: 13311

Part-2-1992 for a location on concrete surface with calibrated

Each

rebound hammer placed perpendicular to the surface and taking


required number of rebound readings to ascertain the compressive
strength and possible local deterioration of concrete. The rate shall
include surface preparation, which shall cover removal of surface
plaster, if any, with chisel etc, removal of cement slurry layer from
concrete surface with grinding stone, making surface even & smooth,
marking on structure with 5 cm size lettering in yellow paint for easy
identification of location of tests necessary scaffolding and platform,
presentation of results in an acceptable format etc all complete.

The NDT report shall be submitted to the Engineer in-charge


along with sketch indicating the location of the test.
8.9.3

Measuring the Half Cell Potential readings at the nodes of premarked grid on concrete surface for determining the probability
of corrosion activity of embedded steel reinforcement in concrete with

specified half cell electrode in accordance with ASTM C876-1980

after moistening the concrete surface with water. The rate shall include
surface preparation, moistening concrete surface, marking on structure
with 5 cm size lettering in yellow paint for easy identification all the
operations and materials enumerated above, necessary scaffolding

and platform, presentation of each location results in an acceptable


format etc all complete. The test shall be carried out at location
indicated by site in-charge.

Each

Item
Description of item
No.
A i) With Copper-Copper Sulphate Half Cell Electrode

Unit of
Measurement

ii) With Silver-silver chloride Half Cell Electrode


iii) With Calomel Electrode
B Plotting the half cell potential readings in graphical
presentation with potential contours plotted in acceptable
format
8.9.4 Measuring the Half Cell Potential readings with wheel electrode

at the nodes of pre-marked grid points on concrete surface in a


suitable grid for determining the probability of corrosion activity
of embedded steel reinforcement in concrete with specified half
cell electrode in accordance with ASTM C876-1980 after
moistening the concrete surface with water. The rate shall include
surface preparation, moistening concrete surface, marking on
structure with 5 cm size lettering in yellow paint for easy identification
of location, all the operations and materials enumerated

above, necessary scaffolding and platform, presentation of results


in an acceptable format etc all complete. The test shall be carried
out at location indicated by site in-charge.
A.

8.9.5

i) With Copper-Copper Sulphate Half Cell Electrode


ii) With Silver-silver chloride Half Cell Electrode
iii) With Calomel Electrod
B. Plotting the half cell potential readings in graphical
presentation with potential contours plotted in acceptable
format
Cutting and extracting undisturbed concrete core of specified
diameters (25 to 100mm) preferably with its length finished
after end preparation equal to twice the diameter but in any case
not less than the 150mm, without encountering any steel
reinforcement from the RCC members at specified locations
by site in-charge with portable power driven core cutting
equipment as per railway specification. After the core has been
extracted, the hole shall be made good by plugging with epoxy

mortar and finished as as per the existing finish. The rate shall
include preparing the sketch indicating the location of the test &
marking on structure with 2 inches size lettering in yellow paint
for easy identification of location and necessary scaffolding &

Platform and cost of all the operations, scanning


T& P and Materials etc complete
-

Each
Each
Each
Each

Item
No.
A
B

A
B
i)
ii)
iii)
iv)
v)

8.9.6

Description of item

Unit of
Measurement

(i)
50 mm diameter
Each
( ii)
75mm diameter
Each
(iii)
100 mm diameter
Each
Testing the extracted concrete cores of any diameter for
i)
Evaluating compressive strength
Each
ii)
Determining density of concrete
Each
(iii)
Determining depth of carbonation with
Each
phenolphthale indicator
iv)
Determining the total acid soluble chloride contents in
concrete as per BS 1881:Part 124
Each
v)
Determining the total sulphate contents in concrete
expressed as sulphate buy mass of concrete as per BS Each
1881:Part 124
T& P and materials etc complete
(i) 50 mm diameter
Each
(ii) 75mm diameter
Each
(iii) 100 mm diameter
Each
Testing the extracted concrete cores of any diameter for
Evaluating compressive strength
Each
Determining density of concrete
Each
Determining depth of carbonation with phenolphthalein
Each
indicator
Determining the total acid soluble chloride contents in
Each
concrete as per BS 1881:Part 124
Determining the total sulphate contents in concrete
Each
expressed as sulphate buy mass of concrete as per BS
1881:Part 124
Determining depth of carbonated cover concrete by spraying
phenolphthalein pH indicator with physicians injection syringe
(or other fine spraying equipment) over freshly broken/drilled

Each

concrete surface (after blowing away dust, if any, due to drilling

operation). The test shall be carried out at location indicated by


site in-charge The rate shall include cost of all the operations,
marking on structure with 5 cm size lettering in yellow paint for easy
identification of location, T&P and materials including making good

the surface damaged with dry pack concrete, etc as approved by


Engineer-in-charge. The NDT report shall be prepared and submitted
to the Engineer in-charge along with sketch indicating the location of the test.

Item
No.
8.9.7

Description of item

Unit of
Measurement

Scanning the concrete surface with standard non-destructive


embedded metal detecting instrument and plotting the
reinforcement scan, determining its diameter and concrete
cover thickness as per site in-charge. The NDT report shall
be prepared and submitted to the Engineer in-charge along
with sketch indicating the location of the test. The rate
include marking on structure with 5 cm size lettering in yellow
paint for easy identification of location.

8.9.8

8.9.9
8.9.10
8.9.11
8.9.12
8.9.13

A Plot of reinforcement
sqm
B Cover Thickness
Each
C Bar diameter
Each
Determination of relative density of samples of fluid, Pyknometer
or relative density bottle for polyester resins, etc according to
Annex-F of IS:6746:1994 Part 4) 1992. The test report shall be
prepared and submitted to the Engineer in-charge.
Each
Determination of relative density samples of liquid admixtures
using hydrometer and according to Annex-E of IS:9103:1999
Determination of solid content of samples of polymer according
to IS 13435 (Part 1) 1992
Each
Determination of pH value of sample using pH meter electrode
conforming to IS:2711:1979 and testing done according toIS13435 Each
Determination of viscosity of samples of polyester resin by
Brookfield viscometer, expressed in centipoises according to
Each
Annex-A of IS 6746:1994
Determination of percentage of air entrained in hardened
concrete/mortar due to an admixture with reference to standard
concrete/mortar without admixture considered as reference by
casting standard 75 mm size concrete cubes, three nos. each of
admixed and standard mortar samples respectively prepared and

weighing them after 28 days of standard curing procedure.

Each

8.9.14

Determination of water soluble chloride content in samples of

admixtures according to IS:6925-1973

Each

8.9.15

Determination of total acid soluble chloride content of concrete


/mortar, expressed as percent of mass, according to BS 1881:

Each

Determination of total acid soluble sulphate content of concrete


/mortar, expressed as percent of mass, according to BS 1881:Part

Each

Part 124

8.9.16

124

Item
No.

Description of item

Unit of
Measurement

8.9.17

Determination of gel time

resins, according to Annex-D of IS 6746:1994

Each

8.9.18

Determination of air content of freshly prepared concrete /


mortar, expressed as percent of mass, according to IS:1199-1959

Each

8.9.19

Conducting tests for uniformity tests (dry material content, ash

expressed in minutes, of polyester

Each
according to Annex E of IS:9103-1999.
Determination of resistance of concrete against freezing and
thawing according to Annex B of IS:9103-1999.
Each
Determination of flow of concrete of high workability concrete
according to Annex C of IS:9103-1999.
No.
Determination of bleeding of concrete according to Annex D of
IS:9103-1999.
No.
content, relative density, chloride ion content &pH) on admixtures

8.9.20
8.9.21
8.9.22

@ the projected length of shear key shall be more than 10 times its
diameter plus half the thickness of cover concrete plus bend l

CHAPTER 10 MATERIAL TESTING


Refer Introductory and General Notes along with the following Chapter Notes:
Chapter Notes :
1. This chapter is being introduced to ensure that the materials are tested before their use in
construction.
2. A list of mandatory tests is given in the Railway Specification for all types of works. These
tests are compulsory and no work shall be executed without ensuring the quality of material by
conducting the mandatory tests. Unless specified otherwise the cost of mandatory tests is
included in the item of work. However, additional tests as ordered by Engineer shall be carried
out by contractor, which shall be paid as per the items given in this chapter.
Material Testing by Contractor and Department
It shall be the responsibility of the contractor to ensure that mandatory material testing as detailed in
the Railway Specification is carried out before commencement of work. In addition as mentioned in
para two above Engineer can order additional tests during execution of work, which shall be paid
under appropriate item of this chapter. Engineer may also decide to get the material tested from any
other agency as per his discretion.
ADENs shall ensure that while finalizing all the proposal appropriate item of material testing is
include in the tender schedule, as required.
Test Laboratories
For every Division DEN/ Sr. DEN shall finalize a list of Govt./ Non-Govt. institutions where material
testing can be carried out. This list shall be circulated to Engineers and contractors in the division. Sr.
DEN (Co) shall inspect the facilities available in the laboratory and based on the reliability, will list
these institutions. In case no such laboratory is available in the division, the list of adjoining division
shall be obtained & circulated.
Rate includes :
(i)
Collecting samples in required quantity as per specified procedure.
(ii)
In case of soil testing for earthwork, taking disturbed or undisturbed samples as
required.
(iii) Transportation of samples to laboratories & submission of test results in 3 copies.

MATERIAL TESTING CEMENT MORTER / CONCRETE


Ite
m
No
.
1.
27
10
1

Description of work

Unit

2.
Carrying out material testing from approved laboratory as per Railways
Specification, relevant I.S. Codes as specified and test procedures
including collecting and labeling samples, transporting to laboratory and
submitting the test reports in 3 copies.

3.

Standard
Rates for
BB & other
than BB
4

Remark
s
5

(I)

CEMENT

Per Test

(A) Physical Test


(i) Initial / final setting time (Both)
(ii) Soundness
(iii)
Specific Gravity
(iv)
Fineness
(v) Compressive strength
(B)
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
(x)
(xi)
(xii)
(xiii)

154.50
154.50
103.00
103.00
515.00

Chemical Analysis
SO2
Tetra Calcium Alumina Fernite (C,AF)
Silica (SiO2)
Alumina (Al2O3)
Magnesia (MgO)
Iron (Fe2O3)
Lime (CaO)
Chloride (CI)
Specific surface
Total Alkalies (N3O + K2O)
Tri Calcium Aluminate (C3A)
Tri Calcium Silicate (C3S)
Di calcium Silicate (C2S)

154.50
154.50
206.00
206.00
206.00
180.25
231.75
103.00
103.00
128.75
309.00
824.00
824.00

(II)

AGGREGATES

(A)

Fine Aggregates
Physical Tests

(i)
(ii)
(iii)
(iv)
(v)
(vi)

Sieve Analysis / Fineness modulus (Both)


% silt by weight
% silt by volume
Bulkage
Moisture Absorption
Specific Gravity

(B)

Per Test

103.00
51.50
51.50
51.50
51.50
51.50

Coarse Aggregates
Physical Tests

(i) Sieve Analysis / Fineness modulus (Both)


(ii) Flakiness / Elongation Index
(iii) Los Angeles abrasion Value
(iv) % silt by weight
(v) % silt by volume
(vi) Impact value
(vii) Moisture Absorption
(viii) Specific Gravity
(ix) Crushing Value

103.00
103.00
103.00
51.50
51.50
51.50
51.50
51.50
77.25

(C ) FINE / COARSE AGGREGATES


Chemical Tests
(i)
Soundness
(ii)
Alkali (Aggregate reactivity)
(iii)
Organic Importion

206.00
154.50
103.00

(III)
(A)

CONCRETE

Per Test

Physical Tests (Concrete blocks)


(i)
(ii)
(iii)
(iv)
(v)
(vi)

Compressive strength
Moisture content
Water Absorption
Density
Drying Shrinkage
Moisture movement

92.70
41.20
61.80
51.50
154.50
154.50

( B ) Chemical Analysis
(i)
(ii)
(iii)
(iv)
(v)
(C)

103.00
103.00
103.00
154.50
206.00

Compression Testing of cubes / cylinders


(i)
(ii)

(IV)

pH
Chloride
Alkalinity
Sulphate
Sulphur Trioxide

Cubes (Set of 3) (Rate of complete set)


Cylinders (set of 3)

77.25
77.25

BRICKS
(i)
(ii)
(iii)
(iv)

Per Test
41.20
61.80
20.60
51.50

Water Absorption
Compressive strength
Density
Efflorescence

(V)

MARBLE MOSAIC /CHEQUERED (CONCRETE)


TILES
(i)

Abrasion

(iii)
(iv)

Transverse
Acid resistance test

(ii)

(VI)

(VII)

(VIII)

Per Test

Crazing
Water Absorption
Impact

103.00
41.20
41.20

WOOD
(i)
(ii)
(iii)
(iv)

Per Test
Moisture Content
Density
Sp. Gravity
Retroactivity

103.00
103.00
103.00
257.50

FLUSH DOOR
(i)
(ii)
(iii)
(iv)

103.00
41.20
41.20
309.00

Water Absorption

CERAMIC TILES
(i)
(ii)
(iii)

Per Test

Per Test

Thickness
End Emerson Test
Glue adhesion test
Knife test

41.20
206.00
206.00
103.00

(IX)

(X)

PLY WOOD
(i)
Density & Moisture Content
(ii)
Water resistance
(iii)
Mycrological Test
(iv)
Tensile strength
(v)
Resistance to dry head
(vi)
Glue shear strength
(vii)
Test for Adhesion of Plies
STEEL
(A)
(i)
(ii)
(iii)
(iv)
(v)

Physical Tests (Dia 28mm 300/Bar)


Density
% Elongation
Tensile strength
Bend
Re-bend

(B)

Physical Tests ( Dia 28 mm 400/Bar)

(i)
(ii)
(iii)
(iv)
(v)
(C )
(i)
(ii)
(iii)

Per Test

Per Test

206.00
206.00
206.00
206.00
103.00
154.50
154.50

51.50
30.90
103.00
61.80
61.80

Density
% Elongation
Tensile strength
Bend
Re-bend

61.80
41.20
154.50
77.25
77.25

Chemical Analysis
Carbon
Sulphur
Phosphoras

103.00
103.00
103.00

(XI)

SOIL
(A) Physical Tests

Per Test

(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
(x)
(xi)
(xii)
(xiii)
(xiv)
(xv)
(xvi)
(xvii)
(xviii)
(xix)

Bulk Density
Moisture Content
Specific Gravity
Sieve Analysis
Shrinkage Limit
Hydrometer Analysis
Unconfined Compression
Liquid Limit / Plastic Limit (Both)
Standard Proctor
Modified Proctor AASHO
Consolidation
California Bearing Ratio (Un-soaked)
Triaxial Compression Unconsolidated un-drained
Triaxial Compression unconsolidated drained
Triaxial consolidated drained
California Bearing Ratio (Soaked)
Permeability
Lab vane shear
Direct Shear (Un-drained)

51.50
103.00
103.00
103.00
103.00
206.00
206.00
257.50
721.00
824.00
618.00
618.00
463.50
927.00
1030.00
875.50
226.60
154.50
283.25

(B)
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)

Chemical Analysis
PH
Chloride
Silica (SiO2)
Alumina (Al2O3)
Loss of Ignition (LOI)
Sulphate
Calcium Oxide(CaO)
Magnesium Oxide(MgO)

103.00
103.00
103.00
103.00
103.00
154.50
154.50
154.50

(XII) ROCK

Per Test

(A)

Physical Test

(i)
(i)
(ii)
(iii)
(iv)

Density
Specific Gravity
Water Absorption
Unconfined crushing Strength
Porosity

(B)

Chemical Tests

(i)
(ii)
(iii)

Sulphate
Chloride
PH value

(XIII)

51.50
103.00
103.00
257.50
154.50

206.00
103.00
103.00

HYDRATED LIME (Neeru / Quick lime)


(A)
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)

Per Test

Chemical Tests
Insoluble residue
Silica
Alumina
Lime(CaO)
Magnesia (MgO)
Loss on Ignition (LOI)
Residue by sieve analysis

77.25
128.75
128.75
154.50
154.50
103.00
257.50

(XIV) CONSTRUCTION CHEMICALS


(i)
(ii)
(iii)

Per Test

pH
Chloride
Phosphate

103.00
103.00
103.00
-

(XV) CLAY & REFRACTORIES


(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
(x)

Per Test

Alumina (Al2O3)
Silica (SiO2)
Sulphur trioxide(SO3)
Iron Oxide (Fe2O3)
% Loss on Ignition
Chloride (CI)
Sodium Oxide (Na2O)
Potassium Oxide (K2O)
Calcium Oxide (CaO)
Magnesium Oxide (MgO)

206.00
206.00
206.00
154.50
103.00
103.00
133.90
133.90
257.50
257.50

(XVI)

ANTICORROSIVE TREATMENT SOLUTIONS

Per Test

(A) Derusting Solutions (Acid)


103.00
103.00

(i) Weight loss of standard mild steel specimen


(ii) Specific Gravity
(B) Phosphating Jelly
(i)
(ii)
(iii)
(iv)
(v)
(vi)

309.00
103.00
103.00
103.00
154.50
154.50

Coating Weight (Procedure A)


Density
PH
Nail scratch
Presence of fungicide
Presence of phospheting Chemical (Ammonium molybdate)

(C ) (C ) Inhibitor Solution (A)


(i) Specific Gravity
(ii) PH
(iii) Chloride (by titration method)

103.00
103.00
103.00

(D ) Sealing treatment Solution (B)


Specific Gravity

103.00

(XVII) PLASTICIZER
(i)
(ii)
(iii)
(iv)
(XVIII)

pH
Chlorides
Sulphates
% total Solids / Concentration

WATER
(i)
(ii)
(iii)
(iv)
(v)
(vi)

Per Test
103.00
103.00
103.00
206.00
Per Test

Chlorides
pH
Alkalinity
Suspended Solids
Sulphates
Total Hardness

103.00
103.00
103.00
103.00
154.50
154.50

CHAPTER 11 : GENERAL REPAIRS TO BUILDING WORKS

Refer Introductory and General Notes along with the following Chapter Notes :
Chapter Notes:(i)
(ii)

This chapter is introduced for repair works only & shall not be used in any new construction work.
The documentation of repair/maintenance work shall be maintained meticulously. The following procedure
shall be adopted for recording the measurement of items included in these chapters:
(a) Sectional Engineer /Sr. Sectional Engineer shall open a numbered separate register called Zonal Petty
Repair/Maintenance Register (ZPRR) which shall be in the following format.

Division ____________

Section ______________ Sr. Section Engineer __________ Cont. Agt. No._________

(b) The above Zonal Petty Repair Register shall be maintained in two copies. One with Section Engineer and
the other copy with the Contractor. Occupants/users signature shall be obtained on contractors copy, as it
will be the responsibility of the contractor to obtain the signature in token of satisfactory work done.
(c) The measurements shall be recorded in the MB after completion of the work & the same shall be test
checked as per the extant instructions. However, the recorded measurement shall also be cross-checked with
the ZPRR.
(d) In case the occupant/user refuses to acknowledge the repairs, Section Engineer/Sr. Sectional Engineer in
addition to his usual inspection & certification of work will again satisfy himself about the quality & quantity
of the work and shall pass the remark I have personally inspected the work again in addition to my normal
inspection & satisfied myself with quantity and quality of work done in (name the work and location). The
complaint of the occupant is therefore not genuine & the measurement of the work is to be recorded without
occupant/users signature.

(iii)

As far as possible Sectional Engineer/Sr. Sectional Engineer shall club the repair works planned to be done in a
month and shall give the instructions through register once in a month, for facilitating execution of the work by
the contractor. However, it shall not be binding on the railways to do so and instructions as and when repairs
are required shall be given.

(iv)

This register shall be known as ZPRR (Zonal Petty Repair Register).

Rate includes :i)


ii)
iii)
iv)

All lead, lift.


Disposing off the released debris & other disposable material to the nearest municipal dump.
Scaffolding, Jhoola & other such arrangements for carrying out the repairs.
Carrying out the work in specified time according to the convenience of the occupant/passenger/user, etc. as
directed by Engineer-in-Charge

It Description of work
e
m
N
o.

1.
2.
2 Repairs to plaster of thickness 12mm to 20mm in
8 patches of area 5.0 sq. meters or less including

CEMENTATIOUS REPAIRS
Unit

Standard Rates for

Mumbai
division
3.

4.

Other
divisions of
C. Rly.
5.

Qty.
of
Ceme
nt
bags

Remark
s

6.

7.

1
0
1
2
8
1
0
2

2
8
1
0
3
2
8
1
0
4
2
8
1
0

cutting the patch in proper shape, preparing and


plastering the surface of the walls complete including
disposal of rubbish to the nearest municipal dump
beyond railway area.
a) With cement mortar 1:4
Patch repairs to cement concrete flooring upto 100
mm thick and 5.0 sq.m. or less by cutting the patch in
square/rectangle, minimum 75mm deep, cleaning it
thoroughly, applying cement slurry as bond coat and
repairing the same with cement concrete 1:2:4 with
10 mm crushed aggregate including finishing smooth
to match the adjoining existing flooring & curing as
per specification.
Repairs to existing polished stone flooring of all
types like Kotah, Shahabad kadappa, etc. in buildings
& platforms by filling up the exposed joints with
epoxy putty as per specification including repairing
cracked and chipped portion of the stone so as to give
neat finished surface.
Cutting holes up to 45x45cm in walls including
finishing the same with cement plaster 1:4 for fixing
exhaust fans or similar other purpose.

Cutting holes up to 15x15cm in R.C.C. floors and


roofs for passing drain pipe etc. and repairing the
hole after insertion of drain pipe with cement
concrete 1:2:4 including finishing complete so as to

M2

75.05

63.75

M2

196.85

177.15

M2

41.75

37.60

Per hole

60.35

54.30

Per hole

56.55

50.90

5
2
8
1
0
6
2
8
1
0
7

make it leak proof.


Machine cutting groove 10 mm wide and 60 mm
deep in the concrete surface for expansion joints and
longitudinal joints.
Repairs to RCC chajja by plastering with 20mm thick
c.m. 1:4 finished smooth along with repairing leaking
junction between chajja and walls by exposing the
junction by breaking plaster upto a height of 20 cm
on the wall and providing a C.C. 1 : 2: 4 curved
hauler of 15 cm x 15 cm. The work also includes
finishing side edges (patta) and providing drip
course. Rate includes all lead, lift, scaffolding etc.
complete. (The item shall be operated only when the
chajjas are to be repaired in isolation and not when
complete plastering of outside walls of a building is
being carried out.)

References:

(1)
(2)
(3)
(4)

Per meter

45.90

45.90

M2

210.70

189.65

Concrete Repair Manual-Vol.I & II(2nd edition year 2003) of American Concrete Institute(ACI)
Handbook on repair and rehabilitation of RCC buildings issued by CPWD
Schedule of Rates(2002) of Central Railway
N.S. items of S.C.Rly