2800

REPAIR OF
STRUCTURES
Repair of Structures Section 2800

2801 DESCRIPTION

Repair of structures shall be carried out in accordance with the repair plans and these
Specifications or as directed by the Engineer. Where repair work is not covered by these
Specifications, special specification may be framed.

Implementation of repair schemes shall also conform to provisions of IRC:SP:40,

IRC:SP:74 and IRC:SP:80.

2802 GENERAL

2802.1 Environmental Aspect

Care shall be taken to ensure suitable mitigation measures against noise and dust, pollution
and damages to the environs whether temporary or permanent.

2802.2 Phasing

The sequence of work shall be in accordance with the drawings or as directed by the
Engineer.

2802.3 Traffic Management

Traffic management, signage, signaling, barricading, and lighting arrangement shall be in

accordance with Section 100 of these Specifications.

2802.4 Safety Precautions

Adequate precautions shall be taken for safety of personnel, road users and existing
services.

2802.5 Dismantling and Removal of Material

Dismantling of any bridge component and removal of materials shall conform to Section 200
of these Specifications and as shown on the drawings or as directed by the Engineer.

2803 SEALING OF CRACKS BY INJECTION OF EPOXY RESIN

2803.1 General

The work of structural bonding of concrete using epoxy adhesive shall conform to these
Specifications.

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Section 2800 Repair of Structures

2803.2 The Contractor shall furnish a method statement giving details of

methodology of construction, sources of supply of materials, tools, equipment, and
appliances to be used on work, personnel and supervision.

2803"3 Personnel

The Contractor's personnel shall be qualified and experienced in epoxy injection process.

2803.4 Material

The material for injection shall be suitable two-component low viscosity epoxy resin, having
the required characteristics of bonding with concrete and resistance to moisture
penetration. Epoxy mortar or polysulphide resin may be used for sealing the surface.

The material for epoxy injection shall conform to the following:

i) The resin and hardener shall be mixed by weight and the mixing ratio
shall generally be between 1 pbw (parts by weight) to 50 pbw subject
to manufacturer's recommendation.
ii) Neither the mixed epoxy adhesives nor their individual component
shall contain solvents and thickeners.
iii) The components shall be free of lumps or foreign material. The
viscosity of the individual components shall not change more than ±15
percent kept in closed containers at 25°C after two weeks.
iv) Consistency of mixed adhesive shall satisfy the requirements given in
Table 2800 -1.

Table 2800-1: Consistency of Adhesive

Standard Version low Viscosity

(cps) Version (cps)
i) Viscosity of Mixed Adhesive at 25°C (200-300) (100-190)
ii) Pot Life of mixed adhesive at 25°C 1 hour ± 15 minutes *
iii) Set time of mixed adhesive at 25°C 3 - 6 hours

* In the case of two component injection system where resin and hardener get mixed at point
of injection pot life at 25°C shall be not greater than 15 minutes ± 10 minutes.

2803.5 Equipment for Injection

The equipment shall be portable positive displacement type pumps with interlock to provide
positive ratio control of exact proportions of the two components at nozzle. The pumps shall
be generally electrically powered and shall provide in-time metering and mixing. The
tolerance

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on mix ratio shall be 5 percent by volume. The injection equipment shall have automatic
pressure control capable of discharging mixed adhesive at any pre-set pressure within the
prescribed limits and shall be additionally equipped with a manual pressure control.

The injection equipment shall be equipped with sensors on both the components A and B
reservoirs that will automatically stop the machine when only one component is being
pumped to the mixing head.

If considered appropriate, suitable compressed air operated epoxy injection gun can be
used with prior approval of the Engineer for manual injection of mix when resin and
hardener had been mixed in a separate unit.

28036 Preparation

Surfaces adjacent to cracks or other areas of application shall be cleaned of dirt, dust,
grease, oil efflorescence or other foreign matter by brushing/water jetting/sand blasting.
Acids and corrosives shall not be permitted for cleaning.

Entry ports shall be provided along the crack at intervals of not more than the thickness of
concrete at the location.

Surface seal shall be applied to the face of the crack between the entry ports. For through
cracks, surface seal shall be applied to both faces.

Before proceeding with the injection, it shall be ensured that the surface seal has gained
adequate strength corresponding to concrete strength of the member and to withstand the
injection pressure.

2803.7 Epoxy Injection

Injection of epoxy adhesive shall begin at the lowest entry port and continue until the epoxy
adhesive appears at the next adjacent entry port. The injection shall then be discontinued at
the first entry port which shall be sealed. Thereafter, epoxy injection shall be carried out
from the next adjacent port and continued successively from each port until the crack is
completely filled.

If travel of epoxy adhesive from one port to the next does not occur, the work shall be
stopped immediately. In case the volume of the injected material exceeds 2 litres for a
particular entry port, the work shall be stopped and the specifications may be reviewed.

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2803.8 Precautions for Application

a) Temperature of components A and B, i.e., resin and hardener shall

be between 10°C and 35°C at the time of mixing unless otherwise
specified.
b) Temperature of structural member during epoxy injection shall be
between 10°C and 35°C unless otherwise specified.
c) Immediately prior to use, each component shall be thoroughly mixed
with a clean paddle. The paddle shall be of a type that does not propel
air into the material. Separate clean paddle must be used for each
component.
d) Any heating of the adhesive components shall be done by application
of indirect heat, in case the work is to be done in cold climate.
e) Just before use, the two components shall be thoroughly mixed in the
ratios specified by the manufacturer. The mixing time shall be strictly
in accordance with manufacturer's recommendations. When
adhesives with different coloured components are mixed, the mixture
shall have a uniform colour without streaks.
f) The use of solvents and thinners shall not be permitted except for
cleaning of equipment.

2803.9 Testing

2803.9.1 Material Testing

Prior to approval of material, the following tests shall be carried out by the Contractor at site
or in an authorised laboratory for each batch of resin and hardener and each combination.

i) Viscosity test for resin and hardener and the mix: three specimens
each.
ii) Pot life test: three specimens each.
iii) Bond test: three specimens each.
iv) Shear test: six specimens each, 3 after 24 hours and the other three
after 72 hours of curing.

Subsequent tests shall be carried out as directed by the Engineer. Procedure for tests shall
be as below:

i) Pot life Test

a) 500 gm of resin formulation shall be prepared by thoroughly
mIxIng the resin and hardener/ accelerator/ catalyst
component in proposed proportion in a 1 kg capacity
hemispheric

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porcelain bowl by means of a spatula or any other agitating

device and time and the ambient temperature noted.
b) The resin formulation shall be applied with a clean dry 25 mm
size painter's brush, on a clean dry surface such as cement
concrete over 150 mm - 200 mm length, starting immediately
after mixing the formulation and repeating the operation every
five minutes. When it becomes just difficult to spread the resin
properly with the brush, the time is noted. The time elapsed
since completion of mixing of resin formulation, is taken as its pot
life.
c) One pot life test shall be performed on commencement of work
and the same shall be repeated every four hours.
d) In case the material fails to satisfy the pot life test, it shall not be
used for injection.
Where the resin and hardener get mixed at point of injection, the pot
life is not important and no tests may be required.
ii) Bond Test
A standard 150 mm diameter and 300 mm long concrete cylinder shall
be cast in 2 pieces by providing a separating medium at an axis of
45 degrees to the longer axis of the cylinder as shown in Fig. 1 of
Appendix 2800/1.
Three such split cylinders shall be prepared. Two pieces of each
cylinder shall be joined with epoxy mortar at four points to give a
clear gap of about 0.2 mm, which will be injected with epoxy resin at
site. After epoxy has been cured, load test shall be carried out on the
cylinder. The failure shall not take place at the joint injected with
epoxy resin. Also the strength of cylinder at failure shall not be less
than 80 percent of the 28 days cube strength of the concrete mix.
iii) Shear Tests
Two steel plates, minimum 3 mm thick, shall be bonded with epoxy at
site using the same resin mix as used/proposed to be used for
injection. The assembly shall be kept in mechanical clamp till epoxy is
cured. A total of six specimens shall be prepared for each batch of
materials. Three test specimens shall then be subjected to a shear
force along the axis after 24 hours and the minimum shear strength
before failure shall not be less than 1 MPa (Refer Fig. 2 of Appendix
2800/1).
The remaining test specimens shall be similarly tested after 72 hours
of curing. The shear strength before failure shall not be less than
2.5 MPa.

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2803.9.2 Core Test

If directed by the Engineer, cores shall be tested for the acceptance of the work. The
selection of the location of cores shall be as directed by the Engineer in such a way that
damage in critical/stressed areas of the structure is avoided.

The Contractor shall obtain 50 mm diameter initial core samples in the first 50 linear
metres. Thereafter, frequency of core sampling shall be as specified or as agreed by the
Engineer. The depth of the core shall normally be less than 200 mm.

Tests and Acceptance Criteria shall be as follows:

a) Penetration-Visual examination of the core should show epoxy

adhesive filling a minimum of 90 percent of the crack.
b) Bond Strength- When tested for bond, concrete failure should occur
before adhesive failure. Also, minimum bond strength of 40 MPa
should be developed with no failure of either concrete or adhesive.

If the cores taken in first 50 m length pass tests as specified above, epoxy adhesive
injection work at area represented by cores will be accepted.

If cores fail either by lack of penetration or bond strength, work shall not proceed further
until the areas represented by the cores are re-injected and re-tested for acceptance.

Filling of Core Holes

Two-component bonding agent shall be applied to surfaces of cored holes followed by

filling of non-shrink cement grout mix placed by hand trowel, thoroughly rodded and tamped
in place. The surface shall be finished to match the finish and texture of existing concrete to
the satisfaction of the Engineer. Materials to be used and procedures for filling core holes
shall be got approved by the Engineer before proceeding with work.

2803.9.3 Test for Injection Equipment

At all times during the course of the work, the Contractor shall keep complete and accurate
records and make available to the Engineer, the results of the pressure ancl ratio tests
specified below so that the efficacy and accuracy of the injection equipment is verified.

The Engineer at any time may direct the Contractor to conduct additional tests in his
presence.

a) Pressure Test
The mixing head of the injection equipment shall be disconnected
and the two adhesive component delivery lines shall be attached to

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the pressure check device, which shall consist of two independent

valved nozzles capable of sensing the pressure. The check
device shall be closed and equipment operated until the gauge
pressure in each line reads 5 MPa. The pumps shall be stopped
and the gauge pressure shall not drop below 4 MPa within
2 minutes.
The pressure test shall be run for each injection unit at the beginning
and after break of every shift.
b) Ratio Test
The mixing head of the injection equipment shall be disconnected
and the two adhesive components shall be pumped simultaneously
through the ratio check device, which shall consist of two independent
valved nozzles. There shall be a pressure gauge capable of controlling
back pressure by opening or closing valved nozzles capable of
sensing the back pressure behind each valve.The discharge pressure
shall be adjusted to read 5 bar for both adhesive components,
which shall be simultaneously discharged into separate calibrated
containers during the same time period. The amounts thus discharged
shall be compared to determine whether the volume/discharge
conforms to the manufacturer's recommended ratio for applicable
material.

2804 REPLACEMENT OF SPALLED CONCRETE BY EPOXY MORTAR/

POLYMER MORTAR

2804.1 Epoxy Mortar

2804.1.1 Material

The epoxy resins for use in the mortar shall be obtained from a reputed manufacturer and
shall conform to the following:

Pot Life 60 minutes at 30°C

Bond Strength 12 MPa
Tensile 16 MPa
Strength
The Contractor/user shall carry out tests on the samples to demonstrate that the above
requirements are met.

The sand to be used in the mortar shall be graded quartz sand.

2804.1.2 Proportioning and Mixing

The resin and hardener shall be first mixed. Thereafter, dry filler shall be added and again
mixed thoroughly. The resultant mix shall be free of lumps of dry filler and shall be of uniform

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colour. For a total weight of 1kg or less, the components shall be mixed for 3 minutes in a
slow speed (400-600 rpm) mixer. The stirrer shall be moved up and down and along the
sides until uniform colour without streaks, is obtained. While stirring, it shall be ensured that
excessive amount of air is not entrapped. If no power is available, a flat putty knife may be
used to reach into the corners of the can and hand mixing done for at least 5 minutes.

2804.1.3 Surface Preparation

Two general methods of surface preparation shall be followed:

a) Mechanical that includes grinding, grit blasting, water blasting and

scarification.
b) Chemical that includes acid etching with 15 percent by weight of
hydrochloric solution, followed by repeated flushing with high pressure
stream of water

Contaminants, such as oil, grease, tar, asphalt, paint, wax, curing compounds, surface;
impregnants like linseed oil or silicons and laitance, loose material and unsound concrete,
shall be removed from the surface on which epoxy mortar is to be placed.

2804.1.4 Application

The epoxy primer coat which acts as a bonding agent, shall consist of resin and hardener
mixed in the proportions as given by the manufacturer. Epoxy bonding agent shall be
applied only on a dry surface and shall not be applied when it rains or in standing water.
The overlay, whether epoxy or cement based, shall be done within the pot life of the epoxy
primer coat. Epoxy primer coat shall be applied with the help of stiff nylon bristle brushes or
hard rubber rollers or spray gun, depending upon the nature of surface and extent of work
area. As far as possible, the coating shall be uniformly thick.

Before the primer coat is fully cured, epoxy mortar shall be applied by means of trowels
and floats. The interval between the application of primer coat and epoxy mortar shall be
approximately 15/30 minutes depending upon the ambient temperature.

Seal coat shall be applied 24 hours after curing and mild roughening of the surface of the
mortar.

2804.1.5 Coverage

The coverage of resin mix would depend on the system of resin used. However, as a
general guideline the coverage area shall be as under:

a) Primer Coat. An area of 3-6 square metres will be covered by 1 kg of

resin hardener mix, depending on the finish of the concrete.

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b) Epoxy Mortar. One square metre of surface requires approximately

20-24 kg of epoxy mortar, when laid to a thickness of 10 mm.
c) Seal Coat. An area of 4 to 6 square metres will be covered by 1 kg
depending on the temperature of application.

2804.1.6 Cleaning and Maintenance of Equipment

Tools and equipment are best cleaned immediately after use since the removal of cured
resin is difficult and time consuming. The bulk of resin shall be removed using a scraper
and remainder washed away completely using solvents such as toluene, xylene or acetone.
Equipment shall always be cleaned before the epoxy hardens. Solvents used for this
purpose may be Acetone (flammable), Methyl Ethyl Kethone (flammable), Methyl Chloride
(non flammable). Cured epoxies may be removed using Methylene Chloride

2804.1.7 Testing

Epoxy used for making mortar shall conform to all requirements and testing procedures as
laid down in Clause 2803.9.

2804.1.8 Personnel and Environment Safety

Any skin contact with epoxy materials, solvents and epoxy strippers should be avoided.
Epoxy resins and particularly epoxy hardeners (B component) may cause a rash on the
skin. The official toxicity classification on the container labels may be looked at before
starting work.

Rubber gloves, with a cloth liner, and protective clothing shall be worn. Barrier creams are
recommended but are not substitutes for protective clothing. Eyes shall be protected where
splashing could occur while spraying or mixing. Good ventilation shall be ensured and
inhalation of vapours avoided. If materials are sprayed, a respirator shall be used.

If contact occurs with the skin, it shall be immediately washed with a cleaner, followed by
soap and water. Should eye contact occur, it shall be flushed immediately with plenty of
water for 15 minutes and a doctor called for.

If contact occurs with the clothing, it shall be immediately changed lo prevent further skin
contact, and if the contact occurs with components A or B, the clothing shall be thrown
away. Hardened epoxy is not harmful but will break the clothing.

All emptied, used buckets, rags and containers shall be removed from site. These shall be
stored in waste disposal bags and suitably disposed of.

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2804.2 Polymer Mortar

2804.2.1 Material

The latex acrylic polymer for use in the polymer modified cementitious mortar (PMC) shall be
obtained from a reputed manufacturer and shall conform to the following:

Pot Life
Compressive strength at 28 days
Flexural strength at 28 days
Addition to concrete (slant
shear)
60 minutes at 30°C
18.20 N/mm2
3.0 N/mm2 to 5.0 N/mm2
3.1 N/mm2 to 5.0 N/mm2

The sand to be used in the mortar shall be graded quartz sand and the sand content shall
be in accordance with the desired consistency.

2804.2.2 Proportioning and Mixing

A dry mortar of quartz sand and cement (OPC) shall be prepared as per the proportions
recommended by the manufacturer. The quantity of polymer shall be measured by
measuring jars and shall be added to dry mortar. It shall be mixed with trowel or by hand so
that no lumps remain in the mixed mortar.

2804.2.3 Surface Preparation

Same as in Clause 2804.1.3.

2804.2.4 Application

The polymer bond coat shall consist of a mix of polymer and cement as per
recommendations of manufacturer and shall be applied in the same manner as indicated in
Clause 2804.1.4 for epoxy primer coat.

The cement and sand shall be dry mixed and then mixed with liquid polymer, adding the
required amount of water in prescribed proportions as per manufacturer's recommendation.
The mortar shall be mixed till it attains a smooth consistency. The mix shall be applied over
the polymer bond coat by hand and finished by trowel.

2804.2.5 Coverage

a) An area of 3 to 4 square metres will be covered by 1 litre of polymer

bond coat, depending on substrata conditions.
b) An area of 1 square metre of surface will be covered by
approximately 21-22 kg of polymer mortar when laid to a thickness of
10 mm.
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2804.2.6 Testing

The polymer used in making polymer mortar, shall be tested for all requirements
as indicated by the manufacturer and lo satisfy requirements given in
Clause 2804.2.1.

2805 EPOXY BONDING OF NEW CONCRETE TO OLD CONCRETE

2805.1 Epoxy resin used for bonding shall be obtained from a reputed
manufacturer. The pot life of such bonding epoxy shall not be less than 60 minutes at
normal temperature.

2805.2 The entire surface of the existing concrete member should be thoroughly
cleaned by wire brush and then with compressed air to remove dust and loose particles
from the surface. Any crack or spalling of concrete shall be sealed by epoxy injection/epoxy
mortar/grouting as decided by the Engineer. A coating of suitable epoxy resin at the rate of
0.8 kg/sq.m (minimum) should then be applied on the surface of the existing concrete
members. Fresh concrete shall then be placed within the pot life of the resin system.

2805.3 Testing

2805.3.1 Epoxy used for bonding work shall satisfy the criteria mentioned in
Clause 2803.9.

2805.3.2 Two concrete cubes of 150 mm size cast as per approved design mix shall
be placed at a distance of 150 mm from each other, as shown in Fig. 3 of Appendix-2800/1.
Epoxy resin system suggested for bonding new to old concrete shall be applied on the
opposite faces of the cubes.

Fresh cement concrete cube of grade as per approved design mix shall be cast with water
cement ratio of 0.4 or less in the manner shown in Fig. 3 of Appendix 2800/1. The assembly
shall be cured in water for 28 days and steel spacer removed thereafter.

The cube assembly shall be subjected to compression load after 28 days of curing, thereby
subjecting the bond to shearing load. Failure must not occur at this joint

2806 CEMENT GROUTING

2806.1 Material

Grouting shall normally be performed with a mixture of neat Portland cement and water.
Other additives and admixtures may be added to improve the impermeability and strength,
with the approval of the Engineer. The size of the particles and the consistency of the grout
must be suited to the passageways it must follow. Neat grout will not flow freely into holes
smaller
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than about three times the largest cement particle. Except in large cavities where thick
mortar can be placed, the sand should all pass the 28-mesh sieve and have a large portion
passing the 50-mesh and 100-mesh sieves. The proportions of Ordinary Portland cement to
sand will depend upon the size of the spaces to be filled and will vary from a neat grout to
about 1:1 mix. The amount of water to be added depends upon the consistency required.
Grouts with as little as 16 litres of water per bag of cement could be used and it should
seldom be necessary to use more than 35 to 40 litres of water per bag of cement.

Where necessary and approved by the Engineer, additives and admixtures may be added
to Portland cement grout mixtures for improving impermeability and strength, delaying the
setting time, increasing flowability and minimizing segregation and shrinkage.

2806.2 Preparation

The surface shall be cleaned with wire brush and compressed air. Thereafter holes of 15
mm dia and 150 mm to 200 mm deep may be drilled along the length of the cracks at a
spacing of 500 mm by wet drilling using rotary percussion drills and nipples shall be
inserted in these holes.

2806.3 Proportioning, Mixing and Equipment for Grouting

The cement grout shall be mechanically mixed using a system of power-driven paddles
of high speed centrifugal pump. The grout pump to be used shall permit close control of
pressures to allow a flexible rate of injection with minimum clogging of valves and ports.
The most satisfactory equipment for injecting grout is a pump of the double-acting flexible
reciprocating type giving a steady flow. The grout pump shall be so placed as to reduce the
waste in cleaning lines. It is preferable to put 50 percent or more of the mixing water into
the mixer before adding the dry ingredients and then the remaining water. A continuous
supply of grout is preferable to an intermittent one. Consistency of the grout may be
determined by trials starting with thin grout i.e. about 40 litres of water per bag of cement
and progressively decreasing the water content to about 15 litres per bag of cement.

Where the mixer and pump are combined in one unit, the dry material shall be screened
before mixing. If the mixer and pump are in separate units, the grout shall pass through a
screen before it enters the pump.

2806.4 Application

Highest practical pressure within the limits of 100 kPa - 400 kPa should be used in order to
force the surplus water from the grout. As the pressure may be distributed hydraulically
over considerable areas, vigilance must be exercised to prevent damage or needless waste
of grout. Adequate precaution shall be taken to ensure that leakage of grout does not
occur.

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Pressure shall be steady to ensure a continuous flow of grout. Grouting shall not be
continued till the hole consumes mix at the rate of not less than 30 litres in 20 minutes or
until refusal at the grouting pressure of 400 kPa at any hole. Should the grout escape from
an adjacent nipple, it should be plugged or capped. Any seam, crack or joint through which
grout escapes shall be caulked with epoxy mortar as soon as thick grout appears.

2806.5 Cleaning of Equipment

After completion of each grouting operation or temporary shutdown, it is advisable to force

clear water through the pump until the discharge line shows no colour, after which the
pump covers shall be removed and the valve chambers thoroughly cleaned.

2806.6 Testing

Percolation test done at the end of grouting operation shall give a value of less than 2
lugions. For specialised treatment like polymer modified cementitious grout injection,
manufacturer's literature and specification shall be followed.

2807 GUNITING/SHOTCRETING

2807.1 The gunite shall comprise 100 parts by weight of cement, 300 parts by
weight quartz sand, 35-50 parts by weight water and 2 parts by weight approved quick
setting compound. In general, dry mix shotcrete shall be used.

2807.2 Ordinary Portland cement conforming to IS:269 shall be used in guniting.

2807.3 Sand for guniting shall comply with the requirements stipulated in IS: 383.
In general, sand should neither be too coarse to increase the rebound nor too fine to
increase the slump. Sand should preferably have moisture content between 3 to 6 percent.

The grading of sand shall lie within the limits given below:

IS Sieve Percent Passing the Sieve

Designation
4.75 mm 95-100
2.36 mm 65-90
1.18 mm 45-75
600 micron 30-50
300 micron 10-22
150 micron 2-8
2807.4 For thick sections it may be advantageous to incorporate coarse aggregate
in the mix provided adequate guniting equipment is available. Coarse aggregate, when
used,

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shall conform to grading given in Table-1 of IS:9012. The percentage of coarse aggregate
may normally be kept as 20 to 40 percent of the total aggregate and the mix shall be
suitably designed.

2807.5 Water/cement ratio for guniting shall fall within the range of 0.35 to 0.50 by
mass; wet enough to reduce the rebound. Drying shrinkage may be between 0.06 percent
and 0.10 percent. The quick setting compound shall be added at the nozzle with water just
before guniting.

2807.6 Workmanship

The cement and sand shall be batched and mixed and conveyed through a hose pipe with
the help of compressed air. A separate line shall bring the water under pressure. The
cement, sand and water mix shall be passed through and intimately mixed in a special
manifold and then projected at high velocity to the surface being repaired. The density of
gunite shall not be less than 2000 kg/cu.m. The strength of gunite shall not be less than 25
MPa. For effective guniting, the nozzle shall be kept 600 mm to 1500 mm away from the
surface, preferably normal to that surface. While enclosing reinforcement bars during
repairs the nozzle shall be held closer at a slight angle and the mix shall be wetter than the
normal.

2807.7 Test panels simulating actual field conditions shall be fabricated for
conducting preconstruction testing. The procedure for testing the cubes or cylinders taken
from the panels stipulated in Clause 6 of IS:9012 shall be followed.

2807.8 It should be ensured from tests that strength of about 25 MPa at 28 days is
available for the mortar/concrete mix.

2807.9 The defective concrete shall be cut out to the full depth till sound concrete
surface is reached. Under no circumstances should the thickness of concrete to be
removed be less than clear cover to the main reinforcement. No square shoulders shall be
left at the perimeter of the cut-off portion and all edges shall be tapered. Thereafter, all
loose and foreign materials should be removed and the surface sand blasted to make it
rough to receive shotcrete after applying a coat of epoxy bonding as per recommendation
of the manufacturer at the rate of 1.0 kg per 1.5 sq.m. of surface area.

2807.10 The exposed reinforcement shall be thoroughly cleaned free of rust, scales
etc. by wire brushing. Wherever the reinforcements have been corroded, the same shall be
removed and replaced by additional reinforcement. Before application of gunite, a coat of
neat cement slurry should be applied on the surface of the reinforcement.

2807.11 Sufficient clearance shall be provided around the reinforcement to permit

encasement with sound gunite. Care shall be taken to avoid sand pockets behind the
reinforcement.

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2807.12 A thickness of 25 mm to 40 mm of gunite can normally be deposited in one

operation. If, for some reason, the total thickness is to be built up in successive operations,
the previous layer should be allowed to set but not become hard before the application of
the subsequent layer. Guniting shall always be done on a damp concrete surface.

2807.13 Where required, welded wire fabrics 50 mm x 50 mm x No. 10 gauge shall

be provided in the first layer of guniting. The fabric shall be tied properly. In case the
damage to the concrete member is very deep, the specifications for guniting as well as
requirement of placement of wire mesh, has to be decided as per field conditions.

2807.14 The stipulations given in IS:9012 regarding application of gunite should be

followed so as to keep the rebound to the minimum. The quality of guniting and
workmanship shall be such that the percentage of rebound mentioned in IS:9012 can be
adhered to. In no circumstances shall the rebound material be re-used in the work.

2807.15 It would be desirable that green gunite is moistened for at least 7 days.
Guniting work shall not be done during windy or rainy conditions.

2808 PROTECTIVE SURFACE COATING OF CONCRETE BY ACRYLIC

ElASTOMERIC COATING

2808.1 The acrylic elastomeric coating shall be water based (solvent free),
modified with selected mineral fillers applied over the prepared surface. The coating should
have anti-carbonation and water vapor diffusion property and should be resistant to action
of ultra violet (UV) radiation. It should be waterproof and capable of bridging crazings and
cracks. The shelf life for such coatings shall not be more than 6 months.

2808.2 It is necessary that the system should be capable of protecting the surfaces
of pre-stressed and reinforced concrete members from all deleterious elements such as
chlorides and sulphates. The protective treatment should allow excess water vapour in the
concrete to evaporate out (breathing) without rupturing itself due to vapour pressure. The
protective system itself should not deteriorate from exposure to UV rays and weathering.

The acrylic elastomeric coating system shall satisfy the requirements given in
Table 2800-2.

Table 2800-2: Properties of Acrylic Elastomeric Coating

SI.No. Parameter Requirement Reference

1) Specific Gravity 1.4±0.05 IS:345
2) Solid contents 70±3% IS:345
3) UV resistance No colour change ASTM-G-53/DIN-EN-
150-105

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SI.No. Parameter Requirement Reference

4) IR-Speclrum As per Acrylic Polymer IR-Spectrometer
standards
5) Adhesion with concrete 1.5 N/m2 ASTM-D-4541-02/
DIN500014
6) Dry film thickness 200-225 Microns (for
minimum 2 coats)
7) Coverage 400-450 gm /m2 (2 Coats)
8) Physical properties Diffusion Equivalent air layer DIN 53122 Part-I
resistance against carbon thickness S0 CO2 shall be
dioxide >50 m
9) Diffusion resistance against Equivalent air thickness DIN 52615
water vapour S H.0 <4 m
10) Water proofing characteristics Percentage reduction in flux
should be>50%
11) Re-coa!ability Min. 2h to 72 h or as per
manufactures specification
with the approval of the
Engineer in charge.

he primer shall satisfy the following requirements

i) System
Single component universal polymer primer
ii) Base Acrylic Resin dispersion
iii) Curing
Air Curing
iv) Colour
Milk white, transparent application
v) Shelf life
6 months from date of manufacturing in tightly
sealed container.
vi) Coverage
75 gm/m2 to 100 gm/m2 (depending upon
smoothness and absorption of concrete surface)
2808.3 Quality Assurance

The Acrylic elastomeric material should be tested in GOI accredited laboratories where
such laboratories are available, otherwise in other standard laboratories where similar
facilities exist for properties specified above. Random samples during execution shall be
taken from consignments brought to site to verify that the test results match with the earlier
certificates produced before approval of the product. Both the test results (prior to approval
and during execution), shall conform to the requirements as per Table 2800-1, failing which
the consignment shall be rejected. It shall be made mandatory that the stock register for the
materials are maintained al site and signed by the Engineer periodically.

774
Repair of Structures Section 2800

2808.4 Surface Preparation

The work shall commence after carrying out any repair to the concrete surface as directed
by the Engineer. The concrete surface shall be free from all adhesion inhibiting substances
such as oil, grease release agents as well as laitance and dust. The surface shall be
cleaned by wire brushing, mechanical scraping and any loose material shall be removed by
chiseling with small hammer and washed with clean water. The substrata shall be
structurally sound for effective bond of the acrylic polymer with the concrete surface. All pin
holes shall be filled with non-shrink polymer modified fine repair mortar.

2808.5 Application

After preparing the surface and filling the pin holes, primer coat (75-100 gm/sq.m.) shall be
applied with brush/lambskin roller/spray gun and shall be cured for 60 minutes or as
specified by the manufacturer.

Subsequently, 1st and 2nd coats of polymer coating shall be applied with brush/spray gun/
roller keeping the time between coats not less than 2 h and not more than 72 h.
Consumption per coat shall be 200-225 gm/m 2• The total dry film thickness of the protective
coating for all coats shall be in the range of 200-225 microns. The wet film thickness shall
be measured at a number of selected locations at the time of application with painting
gauges. For measuring the dry film thickness, suitably located painting gauge shall be
used. At least one gauge shall be located on each face of superstructure in each span but
not less than one gauge/100 sqm. For the given solid content in the application, the dry film
thickness to wet film thickness ratio should be established by prior testing in the laboratory
using appropriate panels like glass plates, flat concrete, steel plates (300 x 300 mm)with
similar coatings. Alternatively, the dry film thickness may be calculated from the measured
wet film thickness by multiplying with the solid contents per unit volume.

2808.6 Performance Guarantee

This type of protective coating shall be executed only through authorized technical
applicators of standard manufactures who have requisite work experience for having
carried out similar type coating works. The Engineer shall take performance guarantee from
the agency responsible for the execution of the work for a minimum period of 5 years.

2809 PROTECTIVE SURFACE COATING OF CONCRETE BY PATENTED

SYSTEMS OF COATING

Patented system of protective coating like epoxy polyurethane painting system, epoxy
phenolic protective system and other systems shall be used only with the approval of
Engineer after the assessment of the performance of the product, backed by certificates
from users, acceptance tests as per published standards, pertinently to cover the material,
processes,

775
Section 2800 Repair of Structures

carbonation resistance, water vapour diffusion property, crack bridging properties, and UV
resistance. The Engineer shall take performance guarantee from the agency responsible
for the execution of the work for a minimum period of 5 years.

2810 REPLACEMENT OF BEARINGS

2810.1 Necessary repair/replacement of bearings shall be carried out as indicated

in the repair plan or as directed by the Engineer. Care shall be taken to plan the execution
of repair in the shortest possible time.

2810.2 Lifting of superstructure spans may be carried out by jacking up from below
or by lifting the span from top. Where jacks are employed, their location/number and size
shall be selected in such a manner so that no undue stresses are created in the structure.
Jacks may be placed on piers/pier caps or specially erected trestles in accordance with
the approved methodology for lifting of superstructure. All jacks shall be operated from one
control panel by a single control lever. The system shall have provision for manual override
to control the loads of any particular jack. The jacks should be so synchronized that
differential lift between individual jacks does not exceed 1 mm.

2810.3 Precautions during Lifting of Girders for Rectification of Bearings

Walkie talkie system or similar audio arrangements should be available for communicating
instructions during lifting of girders for rectification/replacement of bearings. In the event of
replacement it shall be ensured that the new bearing fits into the available space.

2811 REPAIR AND REPLACEMENT OF WEARING COAT

2811.1 Repair of Wearing Coat

Repair of bituminous and cement concrete wearing coat shall be as per Section 3000 of
these Specifications.

2811.2 Replacement of Wearing Coat

i) The existing wearing coat shall be dismantled before laying fresh

wearing coat.
ii) Overlay shall not be provided on existing wearing coat on bridge
decks unless its structural adequacy to carry extra load of overlay is
assured and certified by the Engineer.
iii) Before commencing dismantling, the nature and condition of the
wearing coat shall be ascertained.
iv) Dismantling of wearing coat shall be carried out using jack

776
Repair of Structures Section 2800

hammers or suitable manual/mechanical methods as approved by the

Engineer. Care should be taken to avoid any damage to the existing
structure including concrete, reinforcement or pre-stressing
anchorages for cables, if any, located in the deck slab.
v) The existing expansion joint assemblies shall be removed carefully
along the entire width of the carriageway if included under the scope
of work or as directed by the Engineer. In such cases, the deck slab
for a width of 400 mm on either side should be removed for placing of
reinforcement, anchor rods, anchor bolts and other fixing assemblies
for the new expansion joints and pouring of fresh concrete. The gap
between the girders over the piers should be cleared of all debris. A
temporary platform under the gap at the end of girders shall be
erected to collect the materials falling down during concreting and
fixing of expansion joints.
vi) After dismantling the existing wearing coat fresh wearing coat shall be
provided as per Section 2700 of these Specifications. The expansion
joint assembly, wherever dismantled shall also be fixed in position
true to lines and levels.

2811.3 Precautions during Dismantling Work

For general guidelines, reference may be made to Section 100 of these Specifications.

Dismantling work shall not be carried out at night, or during storm or heavy rain. A warning
device shall be installed in the area for warning the workers in case of mishap/emergency.

Safety helmets conforming to IS:2925 shall be used by the workmen engaged in

dismantling work. The sheds and tool boxes should be located away from the work site. To
protect eyes and face from injuries from flying pieces, dirt, dust etc., celluloid goggles and
gas masks shall be worn at the time of dismantling, especially where tools like jack
hammers are deployed. Leather or rubber gloves shall be worn by the workers during the
demolition of RCC work. Screens made of GI sheets shall be placed wherever necessary to
prevent flying pieces from injuring the workers.

Water should be sprayed to reduce the dust while removing concrete wearing course with
jack hammer. No work shall be taken up under the span when dismantling work is in
progress.

2812 EXTERNAL PRESTRESSING

2812.1 Material

H.T. Strands/wires shall conform to Section 1000 of these Specifications.

777
Section 2800 Repair of Structures

HDPE Sheathing shall conform to IS:4984 suitable for a working pressure of 6 bars. Its
density shall be 955 kg/cu.m, shore hardness D63, yield stress 24 MPa and ultimate tensile
strength 35 MPa.

As necessitated by the profile of the external cable, suitable strand/wire deviator block
fabricated from M.S. sections shall be provided and securely fixed at the required locations.
The block shall be sand blasted and given a coat of suitable paint (preferably epoxy based).

Depending upon the pre-stressing force, suitable anchorages and wedges shall be used
conforming to relevant codes and Section 1800 of these Specifications.

2812.2 Workmanship

a) Stressing of cables shall be carried out as per instruction given in the

drawings, and conforming to Section 1800 of these Specifications.
b) Care should be taken to avoid any damage to the existing structure by
way of stress concentration or any other reason during fixing of the
deviator blocks and after stressing of cable. The deviator blocks shall
be so fixed as not to allow any movement due to pre-stressing forces.
Radius of curvature of the surface of the deviator block interfacing with
the cable shall be minimum one metre.
c) The anchorages shall be sealed with suitable epoxy mortar system
after the stressing of cables. A minimum cover of 50 mm shall be
provided for the anchor plates and anchorages.
d) Suitable grouting inlet points and vent points shall be provided by way
of HDPE "T' vent connections to the sheathing.
e) Grouting of cables shall be carried out as per provisions of
Section 1800 of these Specifications.

2812.3 It shall be ensured that no part of the existing structure is

damaged/distressed due to the external pre-stressing.

The behaviour of the girder shall be monitored by measurement of deflection so that only
required amount of external pre-stressing is imparted to the girder. Care shall be taken to
avoid excess pre-stressing and impairment of the girders.

2813 TESTS AND STANDARS OF ACCEPTANCE

The material shall be tested in accordance with these Specifications and shall meet the
prescribed criteria.

The work shall conform to these Specifications and shall meet the prescribed standards of
acceptance.

778
Repair of Structures Section 2800

2814 MEASUREMENTS FOR PAYMENT

a) For epoxy grouting measurement for sealing of cracks and injection

shall be made by weight of epoxy consumed in kg for epoxy grouting.
For provision of nipples required for grouting, the payment shall be for
number of nipples inserted.

b) For cement grouting measurement for sealing of cracks and injection

shall be made by weight of cement consumed in kg.

c) Measurement for application of epoxy mortar/protective surface

coating of concrete for specified thickness shall be in square metre of
surface area of application.

d) Bonding of old and new concrete by epoxy mortar shall be measured

in square metre of surface area of interface.

e) Guniting/shotcreting shall be measured in square metre of surface

area of application.

f) Replacement/rectification of bearings shall be measured in number of

bearing assembly replaced/rectified.

g) Dismantling of wearing coat shall be measured in square metre of

area of wearing course dismantled.

External pre-stressing shall be measured in tones of H.T. steel strand/wire measured from
anchorage to anchorage before stressing.

2815 RATE

The contract unit rate for sealing of cracks and injection of cement grout shall include cost
of all materials, labour, tools and plant, placing in position, testing, curing and other
incidental expenses for the satisfactory completion of the work as per these Specifications.

The contract unit rate for application of epoxy mortar/protective surface coating for
specified thickness shall include cost of all materials, labour, tools and plant, placing in
position, testing and other incidental expenses including surface preparation for the
satisfactory completion of the work as per these Specifications and as shown on the
drawings.

The contract unit rate for guniting/shotcreting shall include cost of all materials, labour, tools
and plant, placing in position, testing, curing, surface preparation and other incidental
expenses including the provision of nipples for the satisfactory completion of the work as
per these Specifications.

779
Section 2800 Repair of Structures

The contract unit rate for replacement/rectification of bearings shall include cost of all
materials, labour, tools and plant, placing in position, site welding/riveting/bolt connections,
operation of jacks and other incidental expenses for the satisfactory completion of the work
as per these Specifications and as shown on the drawings.

The contract unit rate for dismantling of wearing coat shall include cost of all materials,
labour, tools and plant, traffic management, signages, safety precautions and other
incidental expenses including removal of existing expansion joints, if included as a part of
the work by the Engineer for the satisfactory completion of the work as per these
Specifications.

The contract unit rate for external pre-stressing shall include cost of all materials, labour,
tools and plant, temporary works, testing, curing and other incidental expenses including
careful monitoring of the deflection of girders being externally pre-stressed for the
satisfactory completion of the work as per these Specifications and as shown on the
drawings.
780
r
3000
MAINTENANCE OF
ROAD
Maintenance of Road Section 3000

3001 GENERAL

The Specifications shall apply to all items of road maintenance works as required to be
carried out under the Contract or as directed by the Engineer. The works shall be carried
out in conformity with the relevant Specifications to the required level, grade and lines using
approved materials. The works shall be carried out using appropriate machinery. Wherever
the Specifications are not given for an item, sound engineering practice shall be adopted to
the satisfaction of the Engineer.

3002 RESTORATION OF RAIN CUTS

3002.1 Scope

The work shall consist of earthwork for restoration of rain cuts in the embankment and
shoulders, using suitable material, and compacting the same.

3002.2 Materials

The material used for restoration of rain cuts shall consist of soil conforming to
Clause 305.2.

3002.3 Construction Operation

The area affected by rain cuts shall be cleared of all loose soil and benched. The width of
the benches shall be at least 300 mm and they shall extend continuously for a sufficient
length. The height of the benches shall be in the range of 150-300 mm.

Fresh material shall be deposited in layers not exceeding 250 mm loose thickness and
compacted so as to match with the benching at a moisture content close to the optimum.
Compaction shall be carried out using suitable equipment such as plate compactors and
rammers or by suitable implements handled manually. The finished work shall conform to
alignment, levels and slopes as indicated in the drawing or as directed by the Engineer.

3002.4 Measurements for Payment

The earthwork for restoration of rain cuts shall be measured in cubic metres.

3002.5 Rate

The Contract rate for the item of earthwork for restoration of rain cuts shall be payment in full

789
Section 3000 Maintenance of Road

for carrying out the required operation including full compensation for:

i) Supply of labour, equipment and material including all leads and lifts
and the cost of arranging land for borrow pits;
ii) Setting out;
iii) Removal of loose material from the rain cuts;
iv) Benching of old earthwork; and
v) Compacting after adding required quantity of water.

3003 MAINTENANCE OF EARTHEN SHOULDER

3003.1 Scope

The work of maintenance of earthen shoulder shall include making up the irregularities/loss
of material on shoulder to the design level and cross-fall by adding fresh approved soil and
compacting it with appropriate equipment or to strip excess soil from the shoulder surface
as per the requirement of these Specifications.

3003.2 Material

The material to be added to the shoulder, if required, shall be a select soil conforming to
Clause 305.

3003.3 Construction Procedure

This work shall involve:

i) Making up of the earthen shoulder by adding extra soil and

compacting the same; and/or
ii) Stripping a layer of soil to achieve the required grade and level.

Wherever extra earth is required to be added, the earthen shoulder shall be stripped and
loosened to receive fresh soil. The deficiency of thickness shall be made up in layers of
loose thickness not exceeding 250 mm. Water shall be added, if required, to attain the
optimum amount and the layer compacted by a smooth wheel roller, vibratory roller, hand
roller, plate vibrator or hand rammer to obtain atleast 97 percent of the maximum dry
density in accordance with IS:2720 (Part 8). The finished surface shall have the specified
cross slope and line in accordance with the drawing or as directed by the Engineer. The
side slopes shall be trimmed to the required slope with the help of grader or manual
methods using hand tools.

Wherever the earth is required to be stripped from the shoulder, this shall be done either
using equipment like grader or by manual means using hand tools. The resulting surface
shall be uniform and have a field density of atleast 97 percent of maximum density obtained

790
Maintenance of Road Section 3000

in accordance with IS:2720 (Part 8). If the surface is not uniformly compacted, it shall be
excavated to a depth of 150 mm and the soil mixed with water if required and compacted at
a moisture content close to the optimum to achieve 97 percent of maximum density as
stated above.

3003.4 Measurement for Payment

Maintenance of earthen shoulder shall be measured in sq. metres.

3003.5 Rate

The Contract unit rate for maintenance of earthen shoulder shall be payment in full
compensation for :

i) furnishing earth required for making up of shoulders including all leads

and lifts, compaction to the required density and cost of arranging land
for borrow pits;

ii) excavation and stripping of earth as required and disposal of the earth
at the location approved; and

iii) all labour, tools, equipment and incidentals to complete the work in
accordance with these Specifications.

3004 BITUMINOUS WORK IN CONNECTION WITH MAINTENANCE AND

REPAIR

3004.1 General

The scope and type of maintenance work to be carried out shall be in accordance with the
provisions of the Contract or as instructed by the Engineer.

Maintenance treatments required under the Contract or instructed by the Engineer may
include pothole and patch repair, crack-sealing, fog spray, dusting, slurry sealing, surface
dressing, overlays and specialist repairs.

The materials (particularly patching and overlay materials) used in maintenance operations
shall be of a standard not less than those specified for the original construction.

Traffic control during maintenance operations shall conform to the requirements of the
Contract and Section 100.

791
Section 3000 Maintenance of Road

3004.2 Filling Potholes and Patch

Repairs 3004.2.1 Scope

This work shall include repair of potholes and patching of all types of bituminous pavement
and paved shoulders.

The work shall include the removal of all failed material, in the pavement courses and, if
necessary, below the pavement, until the root cause of the failure is removed, the trimming
of the completed excavation to provide firm vertical faces; the replacement of material of
at least as high a standard as that which was originally specified for the pavement layer;
the application of tack coat on to the sides and base of excavations prior to placing of any
bituminous materials and the compaction, trimming and finishing of the surfaces of all
patches to form a smooth continuous surface, level with the surrounding road.

3004.2.2 Materials

All materials used for the pothole and patch repair of bituminous surface and underlying
layers shall be in accordance with these Specifications and shall be of the same type as
specified for the original construction. A mix superior to the one on the existing surface may
also be used for repair work. An emulsified bitumen/modified bitumen mix compatible with
the existing layer shall also be considered appropriate.

Materials used for patching shall not be of lesser bearing capacity nor of a greater porosity
than the adjacent previous construction. Non-bituminous material shall not be used for
patching bituminous materials.

Ready patch mix material can also be used with the specific approval of the Engineer.

3004.2.3 Preparation of the Area for Pothole and Patch Repair

Each pothole and patch repair area shall be inspected and all loose and defective material
removed. The area shall be cut/trimmed to a regular shape either with jack hammers or with
hand tools suitable for the purpose.

The edges of the excavation shall be cut vertically. The area shall be thoroughly cleaned
with compressed air or any appropriate method approved by the Engineer to remove all dust
and loose particles. Layers below the level of the bituminous construction shall be filled
using material of the equivalent specification to the original construction, which shall
particularly include the specified standards of compaction. The area and sides for
bituminous construction shall be applied with a tack coat conforming to Clause 503 of these
Specifications before back filing operation.

792
Maintenance of Road Section 3000

3004.2.4 Backfilling Operation

The mixture to be used in bituminous patching shall be either a hot mix or a cold mix in
accordance with the appropriate Clauses of these Specifications or any other approved
patching material. Mixing shall be done in a plant of suitable capacity. The bituminous
mixture shall be placed in layers of thickness not more than 100 mm (loose) and shall be
compacted in layers with roller/plate compactor/hand roller/rammer to the compaction
standards defined in the appropriate Clauses of these Specifications. While placing the final
layer, the mix shall be spread slightly proud of the surface so that after rolling, the surface
shall be flush with the adjoining surface. If the area is large, the spreading and levelling
shall be done using appropriate tools and equipment During the process of compaction, the
surface levels shall be checked using a 3 m straight edge.

3004.2.5 Measurement for Payment

Filling of potholes and patch repair shall be measured in sq m or by weight in tonnes.

3004.2.6 Rate

The contract unit rate for filling of potholes and patch repair shall be payment in full for :

i) furnishing all materials required;

ii) all works involved including excavation, trimming, filling with any non
ituminous layers required, applying tack coat, and back filling with
bituminous materials;
iii) all labour, tools, equipment and incidentals to complete the work in
accordance with the Specifications.

3004.3 Crack Sealing

3004.3.1 General
Section 3000 Maintenance of Road

these Specifications, and shall consist of an application of emulsified bitumen, without any
aggregate cover for sealing fine hair-cracks or for rejuvenating oxidised bituminous
surfaces. Areas having cracks with less than 3 mm width shall be considered for this
treatment, unless otherwise instructed by the Engineer.

3004.3.2.2 Material

Bituminous emulsion for fog seal shall conform to the requirements of Clause 513 of these
Specifications.

3004.3.2.3 Application

The area to be treated with fog seal shall be thoroughly cleaned using compressed air,
scrubbers, etc. The cracks shall be cleaned with a compressed air jet to remove all dirt,
dust, etc. The fog seal shall be applied at the rate of 0.5-1.0 litre/sq.m of emulsion, or as
otherwise instructed by the Engineer, using equipment, such as, a pressure tank, flexible
hose and spraying bar or lance. Traffic shall be allowed on to the surface only after the seal
has set to a non-tacky and firm condition so that it is not picked up by the traffic.

3004.3.2.4 Measurement for Payment

The fog seal work shall be measured in sq. metres, calculated from the dimensions of work
instructed in the Contract or by the Engineer.

3004.3.2.5 Rate

The contract unit rate for application of fog seal shall be payment in full for :

i) supplying of fog seal material and all the operations for applying it;
and
ii) all the labour, tools, equipment and incidentals to complete the work
in accordance with these Specifications.

3004.3.3 Crack Filling

3004.3.3.1 Scope

Crack filling shall be carried out using a binder of a suitable viscosity, normally a slow-curing
bitumen emulsion, as instructed by the Engineer. For wider cracks, in excess of an average
of 3 mm in width, the application of emulsion shall be preceded by an application of crusher
dust, or other fine material or a suitable premix acceptable to the Engineer.

794
Maintenance of Road Section 3000

3004.3.3.2 Materials

Bitumen for use in crack sealing shall be of a slow curing type as instructed by the
Engineer. Dust for crack sealing, when used, shall be crusher dust or some other suitable
fine material approved by the Engineer, passing the 2.36 mm sieve but with a maximum of
10 percent passing the 0.075 mm sieve.

3004.3.3.3 Construction

If crusher dust or other graded fine material is to be used it shall be placed in the cracks
before the application of binder and the cracks filled to a level approximately 5 mm below
road surface level. The surface of the road shall be swept clear of dust prior to the
application of binder or premix. Binder shall be poured into the cracks, taking care to
minimise spillage. If spillage onto the road surface does occur, dust shall be applied to the
excess bitumen until it is blotted up. Where a crack-filling mix is used, a squeegee shall be
used to force the premix into the cracks wider than 10 mm.

3004.3.3.4 Measurement

The work of crack sealing in areas where patching is to be done subsequently shall be
measured in sq.m. Isolated cracks where no patching is to be done subsequently shall be
measured in linear metre.

3004.3.3.5 Rate

The contract unit rate for crack sealing shall be payment in full for :

i) supplying all necessary materials and for the work of applying them;
ii) all labour, tools, equipment and all incidentals necessary to complete
the work according to these Specifications.

3004.3.4 Crack Prevention Courses

Where specified crack prevention courses shall conform to Clause 517.

3004.4 Dusting

3004.4.1 Scope

Dusting shall consist of the application of crusher dust or other fine graded material approved
by the Engineer to areas of road where bleeding of excess bitumen is occurring.

795
Section 3000 Maintenance of Road

3004.4.2 Material

Dust shall consist of crusher dust or other graded fine material acceptable to the Engineer,
and shall generally be finer than 2.36 mm with not more than 10 percent passing the
1.75 mm sieve.
3004.4.3 Dust shall be spread by manual application, to the areas of road defined by
the Engineer. Dust shall generally be applied during the hottest part of the day and, when
so instructed by the Engineer, surplus dust displaced by passing traffic shall be manually
swept back onto the area where further bleeding of excess bitumen is apparent. Dust shall
be applied at a nominal rate of 2.5 kg per square metre.

3004.4.4 Measurement

Dusting shall be paid for by the square metre of road surface instructed to be dusted by the
Engineer.

3004.4.5 Payment

The Contract unit rate for dusting shall be payment in full for :
i) supplying all necessary materials and for the work of applying them;
ii) all labour, tools, equipment and all incidentals necessary to complete
the work according to the Specifications.

3004.5 Slurry Seal

Slurry seal for use in maintenance work shall conform to the requirements of Clause 512.

3004.6 Surface Dressing for Maintenance Work

Surface dressing for maintenance applications shall be carried out in conformity with the
requirements of Clause 509, except that the use of small and portable equipment shall be
permitted provided that it can be demonstrated, to the satisfaction of the Enginetir, that it
can produce work consistently in accordance with the requirements of these Specifications.

3004.7 Special Treatments

3004.7.1 Special treatments include repairs of localized areas of damage to

materials for which repairs using normal hot-mix or cold-mix patching materials are
inappropriate. Such special treatments will include repairs to mastic asphalt and stone
matrix asphalt.

3004.7.2 In such cases, pothole and patch repairs shall be carried out in accordance

796
Maintenance of Road Section 3000

with the provisions of Clause 3004.2 above, except that the treatment to the mastic asphalt,
stone mastic asphalt or other special material layer shall be carried out in accordance with
the provisions of the appropriate Clauses of these Specifications.

3005 MAINTENANCE OF CEMENT CONCRETE ROAD

3005.1 Repair of Joint Grooves with Epoxy Mortar or Epoxy Concrete
3005.1.1 Scope

The work shall consist of repair of spalled joint grooves of contraction joints, longitudinal
joints and expansion joints in a concrete pavement using epoxy mortar or epoxy concrete.

3005.1.2 Materials

The type/grade of epoxy compatible with the coefficient of thermal expansion of concrete
shall be used with either processed fine aggregate or fine stone chips to produce a dry mix
for repairing spalled or damaged edges.

3005.1.3 Repairing Procedure

Spalled or broken edges shall be shaped neatly with a vertical cut with chisels into the
shape of rectangle. Small pneumatic chisels also may be used, provided the cutting depth
can be controlled. The depth of the cut shall be the minimum to effect repair. After shaping
the spalled area, it shall be cleaned and primed. The epoxy mortar/concrete is then applied
using hand tools like trowels, straight edges, brushes etc. The repaired edge shall be in line
with the joint groove and shall be flush with the concrete slabs. During the repair work, any
damage noticed to the joint sealant shall be made good by raking out the affected portion
and resealing.

3005.1.4 Traffic

Although the epoxy mixes set in 2-3 hours time, it is desirable to divert the traffic for 12 hours
or as per the recommendation of the manufacturer.

3005.1.5 Measurements for Payment

Repair of joint grooves shall be measured in linear metres.

3005.1.6 Rate

The Contract unit rate for repair of joint grooves with epoxy mortar or epoxy concrete shall
be in full compensation for :

i) supply and application of epoxy primer, epoxy mortar or epoxy

concrete;

797
Section 3000 Maintenance of Road
1
ii) all tools, equipment and incidentals to complete the work in
accordance with the Specifications.

3005.2 Repair Involving Removal of Old Joint Sealant and Sealing with Fresh
Sealant in Cement Concrete Pavements
3005.2.1 Scope
The repair of sealant of contraction, longitudinal or expansion joints shall include removal of
the existing sealant and resealing the joint with fresh sealant material.

3005.2.2 Material

Sealant material to be replaced shall be either hot poured rubberised bitumen or cold-
poured polysulphide or silicone sealant as per Clause 602.2.10. As per the
recommendation of the manufacturer, appropriate type of primer shall be applied.

3005.2.3 Repairing procedure

The existing sealant shall be raked out with the help of a metal raker such that most of the
sealant is removed. Subsequently, the sealant stuck to the sides of the grooves shall be
removed thoroughly either by using saw cutting machine so that grooves may be widened
by 1 mm or by sand blasting. In no case the old sealant shall be present during resealing
operation. If joint grooves are found inadequate in depth, they shall be deepened as
directed by the Engineer. The edges of the groove shall be chamfered. Any spalls of the
joint shall be made good by epoxy mortar.

Before commencing the sealing operation, compressed air shall be used to clean the joint
grooves. A heat resistant, paper backed compressible debonding strip or tape and backer
rod should be inserted in accordance with the requirement of Clause 602.10.2. Sealant may
be poured either using hand held pourer or using mechanized sealing machines. Sealants
should not be heated directly but in double jacketed machine. All precautions and
arrangements shall be taken not to spill the sealant on the concrete pavement. The sealant
may be poured to a depth of 3 mm from the pavement surface.

3005.2.4 Measurements for Payment

Repair of joint sealant shall be measured in linear metres.

3005.2.5 Rate
Contract unit rate for repair of joint sealant shall be in full compensation for :

a) removal of old sealant, regrooving or sand blasting the sealing groove

and placing of debonding strip or tape.
b) all tools, equipments and incidentals to complete the work in
accordance with the Specifications.

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