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GAMMON INDIA LIMITED

JOB: 20 BRIDGES ON NH-60 @ OR/WB-I
METHODOLOGY FOR REPAIR & REHABILITATION OF EXISTING STRUCTURE:

BOQ Item No. 5.01:

Repairing of R.C. Deck slab / Girder by chipping or peeling off loose
concrete, cleaning reinforcement, treating the exposed surface with
epoxy paint and filling the affected area with non-shrink concrete mix not
lesser than 1:1.5:3 by using 12mm down coarse aggregate including the
coat of epoxy paint, non-shrink admixture, formwork, centering, curing
etc.
Material Resource:
S.No.
1
2
3
4

Name of Material
Armatec 108
Sikadur 32
Sikatop 77
Antisol E

Description
Anti-corrosive Paint
Epoxy Bonding Agent
Acrylic Polymer
Curing compound.

Man Power
1. Engineer 01 No.
2. Foreman 01 No.
3. Khalasis 04 Nos.
Methodology:
1. The damaged concrete portion of Deck slab / Girders & spalling & honey
comb portion shall be identified & shall be chipped off thoroughly.
2. The exposed Reinforcement bars shall be brushed thoroughly with Wire
brush / Salt Paper to remove completely the loose concrete sticking to the
bars & shall be cleaned thoroughly with water.
3. The dia of the existing bars shall be checked, if the dia of the bar gets
reduced by 25% of own dia, then it shall be cut out, & replaced by welding
new reinforcement bars of same dia by providing appropriate shear
connectors.
4. The newly fixed reinforcement bars shall be painted with Armatec-108 as
an anticorrosive agent.
5. Proportioning & Mixing of Armatec-108 is as follows:
1. Name of Compound
: Sika top Armatec 108
2. Form of Compound
: Comp. A- Liquid ,
Comp. B Solid
3. Mixing Ratio
: 1: 4 by weight [Comp A:B]
4. Mixing Density
: Approx. 2.12 Kg/ Litre

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6. Epoxy Bonding Agent Sikadur-32 [Comp. A:B is 2:1] shall be mixed and
then painted on the concrete surface before applying Mortar.
7. Then Sikatop-77 shall be mixed @ 5% weight of Cement with 1:2:4
concrete in the. The prepared concrete mix shall be placed manually with
proper finishing.
8. Curing compound Antisol E shall be applied over the repaired surface.

BOQ Item No. 5.03:

Peeling off of damaged plastered area from existing structure, raking out joints
and roughening of old surface to receive new plaster, using polymer modified
mortar of 15mm thickness.

Material Resource:
S.No.
2
3
4

Name of Material
Sikadur 32
Sikatop 77
Antisol E

Description
Epoxy Bonding Agent
Acrylic Polymer
Curing compound.

Man Power
1. Engineer 01 No.
2. Foreman 01 No.
3. Khalasis 04 Nos.
Methodology:
A. Arrangement for Identification /Repairing of Damaged
Damaged Areas shall be inspected & marked conspicuously jointly with the
Engineer.
The Damaged Girders / Deck slab portion shall be inspected & identified by
Gantry Arrangement for River spans.
For other than River spans, Scaffolding Arrangement shall be made for
Estimating the extent of repair.
B. Surface Preparation:
The Marked Portion shall be watered thoroughly to completely free of loose
material, unsound concrete, dust or any other deleterious material.
C. Application Procedure.
2. Epoxy Bonding Agent Sikadur-32 [Comp. A:B is 2:1] shall be mixed and
then painted on the concrete surface before applying Mortar.

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3. The Mortar [1:3 cement: sand] has to mixed with Sikatop 77 @ max. 4%
weight of cement shall be placed manually with proper finish at the marked
locations.
4. Curing compound Antisol E (WP) shall be applied over the repaired
surface as per the manufacturers specification.

BOQ Item No. 5.08 & 5.09

Providing & inserting nipples with approved fixing compound after drilling holes for
Cement & Epoxy grout.
Sealing cracks by injection process through nipples with Cement & Epoxy grout.

Material Resource:
1. Sika 4A / Sikadur 31. For sealing Nipples.
2. Sikadur 52 For Epoxy grouting.
3. Interplast N-200 for Cement grouting.
Machine Power:
1. Hand grouting Machine.
2. Drilling Machine.
3. Other Hand tools.

Man Power
1. Engineer 01 No.
2. Foreman 01 No.
3. Khalasis 04 Nos.
Location:
Epoxy Grout : Beam Soffit, Deck soffit & other prime sub structures where cracks
are visible.
Cement Grout :
Non important locations / As per the instruction of Engineer.
Methodology:
A. Arrangement for Identification /Repairing of Damaged
Damaged Areas shall be inspected & marked conspicuously jointly with the
Engineer.
The Damaged Girders / Deck slab portion shall be inspected & identified by
Gantry Arrangement for River spans.
For other than River spans, Scaffolding Arrangement shall be made for
Estimating the extent of repair.

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B. Providing Nipples:
1. Identify the cracked locations & do holes of 12mm dia by
drilling machine up to the depth of 150 mm for nipples. The
spacing of nipples shall be 1 m c/c.
2. Fix the nipples by Sikadur-31 / Sika 4A [Part A & B in the ratio
2:1 by weight ] at the holed locations, Once sealing material
gains full strength, cement /Epoxy injection shall be started.
3. Epoxy Grout:
Expoxy grouting shall be continued till refusal by Sikadur-52
[Comp. A:B 1:2 in weight].
After completion of grouting, Nipple ends to be sealed with
concrete surface.
4. Cement Grout:
Cement grouting shall be continued till refusal by Interplast
N200 @ 0.4% to be mixed with 0.45 w/c ratio..
After completion of grouting, Nipple ends to be sealed with
concrete surface.

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