FAILURE OF GOVERNMENT BUILDINGS AT EARLY AGE

By Sri P.Suresh Babu.B.Tech.,

In the past few years, i t i s observed that Ma!ri"y !# "he
G!$er%&e%" Bui'(i%)s 'i*e Sch!!' Bui'(i%)s, +!s"e' Bui'(i%)s,
Resi(e%"ia' ,uar"ers a%( !"her Ma!r s"ruc"ures c!%s"ruc"e( by
$ari!us E%)i%eeri%) De-ar"&e%"s .hich .ere c!%s"ruc"e(
u%(er "he su-er$isi!% !# ,ua'i#ie( ci$i' E%)i%eers a%( .e''
e/-erie%ce( 0i$i' E%)i%eers are sh!.i%) si)%s !# #ai'ure a" a
$ery ear'y a)e !# 12 years.
In thi s case I Prefer to i nform si)%s !# #ai'ure &ea%s 'i*e
e/-!sure !# S"ee' Rei%#!rce&e%" i% R!!# s'ab, R!!# Bea&s,
0!'u&%s !# Bui'(i%), crac*s i% '!a( beari%) .a''s3 %!% '!a(
beari%) .a''s e"c. It does not mean that the structure i s total l y unfi t
and has to be di smantl ed. Even though these structures are not total l y
col l apsed, but the i nmates and General Publ i c fear about the structure
col l apse, as i" #ai'e( "! sa"is#y "he ser$iceabi'i"y cri"eri!% as
s"i-u'a"e( i% IS 0ODE42567888.
In such a si tuati on many Engi neers prefer to di smantl e the total
structure and reconstruct the structure. But i t i s hi gh ti me to anal yze
and thi nk why the structures are showi ng si gns of fai l ure at such an
earl y age of ! years agai nst the mi ni mum sti pul ated l i fe of !" #ears.
$i th my e%peri ence as a &i vi l Engi neer i n 'oads and Bui l di ngs
(epartment si nce )*+, the fol l owi ng are the general omi ssi ons
responsi bl e for earl y si gns of fai l ure.
9SMALL T+INGS IF TA:EN 0ARE ;ILL LEAD TO
PERFE0TION. BUT PERFE0TION IS NOT A SMALL
T+ING.<
,he above proverb needs to be kept i n mi nd by al l &i vi l Engi neers
whi l e constructi ng structures l i ke Bui l di ngs and Bri dges. It i s my
personal opi ni on that the premature si gns of fai l ure i n Government
Bui l di ngs is %!" (ue "! 'ess usa)e !# ce&e%" i% c!%s"ruc"i!%, bu"
(ue "! i%a(e=ua"e care a%( su-er$isi!% !# De-ar"&e%"
E%)i%eers. -t the same ti me the structures constructed by i ndi vi dual
house owners ad.oi ni ng our Government Bui l di ngs, whi ch were
constructed under the supervi si on of un/ual i fi ed masons are doi ng
wel l compared to Government Bui l di ngs. ,hi s poi nt i s to be e%ami ned
very careful l y by us and we have to be more careful and meti cul ous to
avoi d publ i c cri ti ci sm. ,he fol l owi ng are the few observati ons duri ng
my fi el d i nspecti on of recentl y constructed Government Bui l di ngs of !
years age.
>1? E/-!sure !# S"ee' Rei%#!rce&e%" i% R!!# S'ab a%( R!!#
Bea& "!"a''y !r -ar"ia''y.
>7? 0rac*s i% .a''s a%( se""'e&e%" !# F'!!ri%),
>@? Da&- -a"ches i% .a''s a%( -ee'i%) !# P'as"eri%).
>4? Lea*a)es i% R!!# s'ab a%( -'u&bi%) !i%"s
(ue to the above mentioned defects, everyone feels that the structure is
'i*e'y "! c!''a-se i% sh!r" "i&e .hich is %!" "rue i% &a%y cases. Even then is
it not our responsibility to avoid such complications, to build confidence of
occupants when an un/ualified mason0s Building is well and looking good. If the
same situation continues no person prefer to approach Government (epartment
Engineers. Even some of the Buildings are being entrusted to consultants who are
less /ualified i.e., (iploma holders or others. 1any of us say that it is all due to
corrosion of steel. 1y /uestion is that when the same steel is used by private
owners why the steel is not getting corroded.

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,he above 6uarters are now proposed for di smantl i ng the total
structure and reconstruct the same wi th huge Publ i c E%che/uer.
,he fol l owi ng are some of the reasons whi ch are responsi bl e, for
poor condi ti on of Government Bui l di ngs.
1? I%a(e=ua"e c!$er !r %! c!$er "! Rei%#!rce&e%".
I8 ?!+@:""" has gi ven very hi)h i&-!r"a%ce "! c!$er !#
Rei%#!rce&e%". But many of us do not understand the seri ousness of
i t. ,he cover to rei nforcement is a (!&i%a%" #ac"!r "! be a""e%(e(
$ery care#u''y (uri%) c!%s"ruc"i!% !# Bui'(i%)s. $e must cast
cover bl ocks of si ze !"%!"%?" mm wi th &ement mortar 9A:< wi th a
smal l bi ndi ng wi re pi ece pl aced i n each bl ock, not l ess than ! days i n
advance to casti ng of concrete. ,hat means cover bl ocks must be
avai l abl e at si te i n advance and shoul d be cured for mi ni mum ! days,
before they are pl aced under rei nforcement, for casti ng of concrete.
,here are pl asti c cover bl ocks avai l abl e i n the market and are
recommended by I8 codes very wel l . ,he provi si on of ade/uate cover
as sti pul ated i n I8 &2(E prevents i ngress of moi sture i n to concrete
and avoi d corrosi on of steel . Because we do not pl an cover bl ocks i n
advance whi ch l ooks very si mpl e and easy, we pl ace some stones
under rei nforcement whi l e starti ng of concrete and they get di spl aced
due to movement of concrete workers, fi nal l y the rei nforcement
touches the centeri ng sheets wi thout any cover. $e cast concrete
wi thout noti ci ng thi s l apse and i t creates the bi ggest probl em. -fter :
days we re&!$e "he ce%"eri%) shu""ers a%( "he% !%'y .e %!"ice
"ha" "here is %! c!$er "! rei%#!rce&e%" a%( s"ee' is e/-!se(
-ar"ia''y .hich is su--!se( "! be i%si(e !# c!%cre"e. As a
s!'u"i!% .e -'as"er "his sur#ace .i"h ce&e%" &!r"ar and forget
the matter. But nature wi l l not al l ow us to forget the matter. It
(ischar)es i"s !b !# se%(i%) &!is"ure i% "! c!%cre"e .hich
ca%%!" be -re$e%"e( by -'as"eri%) and fi nal l y l eads to corrosi on of
steel . It i s an astoni shi ng fact that the Bui l di ngs far away from sea
coast l i ke 7dayagi ri etc are al so showi ng corrosi on i n rei nforcement of
'oof sl ab because of thi s l apse. 4rom thi s we can concl ude that a
smal l negl i gence i s maki ng al l the di fference and bri ngi ng very bad
name to Government (epartment Engi neers. 8o we must adhere to
thi s procedure of provi di ng cured cover bl ocks under rei nforcement.

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>7? Usa)e !# P!!r ,ua'i"y !# ;a"er i% &i/i%) !#
c!%cre"e a%( 0uri%) !# c!%cre"e
IS 42567888 cl earl y speci fi ed that .a"er used for mi %i ng of
concrete and &uri ng of concrete sha'' ha$e a P+ Va'ue &!re "ha%
5, whi ch means that water shoul d not be hard and aci di c. General l y
Potabl e $ater 9dri nki ng water< i s sui tabl e for mi %i ng and curi ng of
concrete. But i n many vi l l ages good /ual i ty water wi l l not be readi l y
avai l abl e and at ti mes scarci ty of dri nki ng water may be there or may
be avai l abl e far away from si te. In such a si tuati on the contractors for
the work prefer to use the water avai l abl e nearer to si te, wi thout
veri fyi ng the sui tabi l i ty for concrete. 3atural l y the Ground water ei ther
from bore or from wel l i s hard and have a P= of l ess than + and not
sui tabl e for concrete. $e too do not bother to test and use the water.
,hi s gi ves ri se to poor strength of concrete and more corrosi on of
steel . In such si tuati ons when the Bui l di ngs are l ocated near sea
coast, or i n pl aces where good /ual i ty of water i s not avai l abl e, "he
c!%"rac"!r sha'' be -ai( e/"ra .a"er 'ea( a%( i%sis"e( "! bri%)
)!!( =ua'i"y !# .a"er i% "he i%"eres" !# "he 'i#e !# "he
s"ruc"ure. Ma%y E%)i%eers (! %!" -re#er "! a''!. "his e/"ra
-ay&e%" and as* "he c!%"rac"!r "! &ee" i% "he !$erhea(
char)es -r!$i(e( i% "he (a"a .hich is %e$er c!%si(ere( by "he
c!%"rac"!r and fi nal l y for the sake of thi s smal l amount i n thousands
we are sacri fi ci ng the l i fe of structure and i n turn wasti ng the publ i c
money and getti ng bad reputati on.
In some cases many Engi neers feel that good /ual i ty water i s
re/ui red for mi %i ng onl y and water used for curi ng need not be that
much good whi ch i s a wrong noti on and responsi bl e for earl y damage
of Bui l di ngs.

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>@? I&-r!-er c!&-ac"i!% !# c!%cre"e a%( e/cess
.a"er ce&e%" Ra"i!
Everyone shoul d keep i n mi nd that mi ni mum water shal l be used
for mi %i ng of concrete .i"h .a"er ce&e%" ra"i! ra%)i%) be".ee%
8.@2 a%( 842. =owever i n practi ce many fi el d offi cers prefer to use
more water for easy workabi l i ty and easy fi ni shi ng. Because of thi s, i t
i s easy for masons for fi ni shi ng, but i t i s detri mental to concrete. -s
per code the -rese%ce !# 2A $!i(s i% c!%cre"e re(uce "he
c!&-ressi$e s"re%)"h !# c!%cre"e by @8A. ,he presence of voi ds
may be due to more water@ cement 'ati o or due to i nade/uate
compacti on.
In remote l ocati ons the contractors do not have vi brators for
compacti on of concrete and prefer to use more water i n mi %i ng so that
i t fl ows and fi ni shi ng can be done wi th a hand trowel by mason. -l l of
us shoul d keep i n mi nd that compacti on of concrete by vi brators i s
compul sory and concrete shal l be compacted wi th mi ni mum water@
cement 'ati o to achi eve ma%i mum densi ty wi thout any voi ds. ,hi s hi gh
water@ cement 'ati o i s responsi bl e for l eakages due to presence of
more voi ds i n concrete and l ess compressi ve strength and al so
responsi bl e for corrosi on of steel .
>4? De'aye( 0uri%) !# c!%cre"e a%( curi%) #!r sh!r"
-eri!( !# 'ess "ha% 7B (ays
Every one of us knows that concrete shal l be cured for a
&i%i&u& -eri!( !# 7B (ays "! achie$e re=uire( c!&-ressi$e
s"re%)"h. &oncrete re/ui res more water i n the fi rst ?* hours after
casti ng, as i" achie$es 41A !# (esire( c!&-ressi$e s"re%)"h. But
i n practi ce curi ng wi th water i s started on the B
r d
day nearl y after B+
hours of casti ng concrete, due to vari ous reasons. Because of thi s
del ayed curi ng the concrete shal l not achi eve i ts desi gned strength
and i s of poor /ual i ty. Even thi s curi%) c!&&e%ce( $ery 'a"e is
(!%e #!r !%e .ee* a%( #ur"her curi%) is s"!--e( by "he
c!%"rac"!r. -s per I8 &ode the concrete attai ns C?.:!D of i ts desi red
compressi ve strength i n C days i f curi ng i s commenced i mmedi atel y
after : hours of casti ng of concrete. General l y we commence curi ng
l ate and stop curi ng earl y, fi nal l y gi vi ng a concrete of l ess strength.
=ence al l of us shoul d c'!se'y &!%i"!r "he c!&&e%ce&e%" !#
curi%) and the curi ng shal l be conti nued for :* days i rrespecti ve of
Grade of cement wi th potabl e water. 7nl ess we i nsi st for thi s, i t i s not
possi bl e to achi eve re/ui red strength and dense concrete.

>2? Da&- -a"ches i% .a''s (ue "! 'ea*a)es a" r!!# 'e$e'
!r (ue "! 'ea*a)es i% !i%"s !# P'u&bi%)3 (ue "! %!"
-r!$i(i%) (ri- ba%( a'' r!u%( r!!# s'ab3c!%"i%u!us
'i%"e'.
In many Bui l di ngs .e !bser$e (a&- -a"ches i% .a''s due to
i ngress of moi sture i n to the wal l s ei ther from roof or due to i mproper
.oi nti ng of pl umbi ng pi pes. Because of thi s damp patches pl asteri ng i s
peel ed off and wetness i n wal l s take pl ace. ,hi s probl em of 'ea*a)es
ca% be arres"e( by c!%(uc"i%) s&!*e "es" i% -'u&bi%) -i-es
be#!re "hey are c!%cea'e( i% .a''s. But none of us conduct thi s
test whi ch causes dampness i n wal l s and peel i ng of pl asteri ng.
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In some cases the fi el d Engi neers forget to provi de dri p band al l
round the roof sl abEl i ntel and water dropl ets come up to the Bri ck
1asonry wal l duri ng rai ny season and causes dampness i n wal l s. It i s
&y -ers!%a' !-i%i!% that i t i s preferabl e to -r!$i(e -r!ec"i!% i%
R!!# s'ab "! a .i("h !# 8.C8&, to avoi d rai n showers up to the wal l
even i t costs a l i ttl e bi t i n thousands but i t hel ps to prevent the
damage to the structure i n a bi g way.
8o far we di scussed about the mi stakesEomi ssi ons general l y
commi tted by us i n constructi on of Bui l di ngs and I feel i t i s our 8oci al
responsi bi l i ty to repai rE 'ehabi l i tate such Bui l di ngs whi ch have shown
si gns of fai l ure at earl y age for the mi stakes commi tted by us. ,he
'epai rE 'ehabi l i tati on of such structures are costl y and re/ui re
speci al i zed materi al s and techni cal e%perti se to i mprove the l i fe of
such structures i nstead of total l y di smantl i ng the structure and
reconstruct the same wi th huge publ i c e%che/uer.
This (!es %!" &ea% "ha" "he s"ruc"ures c!%s"ruc"e( by
G!$er%&e%" De-ar"&e%"s !%'y are sh!.i%) si)%s !# #ai'ure a"
a% ear'y a)e !# 18 "! 12 years.
S!&e !# "he Ma!r s"ruc"ures c!%s"ruc"e( by re%!.%e(
c!%su'"a%"s are a's! sh!.i%) a 'i""'e bi" &!re !r 'ess
-er#!r&a%ce i% "he sa&e &a%%er.
In one case, a #!'(e( -'a"e "y-e R!!# s'ab #!r a G!$er%&e%"
s-i%%i%) &i'' under constructi on l ocated nearer to sea coast
(esi)%e( by a .e'' es"ab'ishe( c!%su'"a%", #ai'e( !% re&!$a' !#
ce%"eri%) i"se'# .hich re&ai% u% %!"ice( by Pub'ic !r
Bureaucra"s a%( "he "!"a' R!!# s'ab .as re-aire( .i"h hu)e
Pub'ic e/che=uer.
I# "he sa&e #ai'ure "a*es -'ace i% a%y Pub'ic .!r*s
De-ar"&e%", i" .!u'( ha$e bec!&e a bi) issue a%( e$eryb!(y
sh!u'( ha$e -!i%"e( !u" a%( &a(e a bi) issue by &e(ia. Fi%a''y
"he Bureaucra"s .!u'( ha$e sus-e%(e( s!&e #ie'( e%)i%eers,
#!r c!%(uc"i%) e%=uiry "ha" are i% %! .ay c!%%ec"e( "! "he
&is"a*e i% Desi)%. I" &ay "a*e years a%( '!" !# &e%"a' a)!%y
u%"i' "he e%=uiry is c!&-'e"e(. S!&e"i&es i" &ay s-!i' !ur
#i%a%cia' s"abi'i"y.
But as we are readi l y avai l abl e to Bureaucrats and General Publ i c,
the cri ti ci sm i s more and has to face the wrath and bend our heads
before some non techni cal persons as the end product i s not to the
re/ui rement of Publ i c. #es, we must accept thei r cri ti ci sm as we are
pai d wi th Publ i c money and there i s some l apseEl ethargy on our si de.
3o Probl em, we are the !%'y E%)i%eers e%c!u%"ere( .i"h "he
u%*%!.% %a"ure a%( u%*%!.% -r!-er"ies !# %a"ura' #!u%(a"i!%
s!i's .hich $aries a'ar&i%)'y #r!& !%e si"e "! !"her si"e a%( i%
s!&e cases #r!& !%e -!i%" "! !"her -!i%" i% "he sa&e si"e !#
'ar)e -r!ec". In case of other Engi neeri ng branches l i ke 1echani cal
Engi neeri ng, El ectri cal Engi neeri ng, El ectroni cs and communi cati on
Engi neeri ng where we have defi ni te, preci se and perfect properti es of
1ateri al s and unl ess the i nput materi al s are to the re/ui red
speci fi cati on, those Engi neers wi l l not make a si ngl e move and fi nal l y
the end product i s to re/ui rement, wi th very l i ttl e fai l ures. But we the
0IVIL E%)i%eers ha$e "! a(!-" '!ca''y a$ai'ab'e %a"ura'
&a"eria's a%( #i%a''y a'' !ur s"ruc"ures sh!u'( res" !% %a"ura'
s!i' .h!se -r!-er"ies ca% %!" be assesse( -recise'y "! 188A
-er#ec"i!% a%( .e &us" &a*e s!&e assu&-"i!%s i% 0IVIL
ENGINEERING a%( &us" -r!cee( "! c!%s"ruc" s"ruc"ures #!r a''
"he ab!$e E%)i%eers !# !"her bra%ches "! )i$e she'"er a%( "!
-er#!r& "heir !b. In that way we must be proud we are the
Engi neers .h! are )i$i%) she'"er a%( .!r*i%) E%$ir!%&e%" #!r
!"her Bra%ch E%)i%eers, "he s! ca''e( -er#ec"i!%is"s. Even i f we
are gi ven Perfect products unconnected to 3ature and wi th defi ni te
and preci se properti es for materi al s we can al so gi ve ""D perfect
products.
3ow l et us di scuss how the l i fe of Bui l di ng structures are
i mproved when they have shown some premature si gns of damage at
very earl y age.

>1? REPAIRS TO EDPOSED REINFOR0EMENT IN
ROOF SLAB, ROOF BEAMS, 0OLUMNS
It i s a general probl em of E%posure of 'ei nforcement i n 'oof
sl ab, 'oof Beams i n al most al l Government Bui l di ng structures l ocated
near 8ea &oast and wi thi n :! >1 (i stance from sea. ,he corrosi on of
'ei nforcement i s due to presence of 1ari ne atmosphere and the
corrosi on takes pl ace very easi l y i n such atmosphere. ,hi s probl em
ca% be -re$e%"e( by -r!$i(i%) Fusi!% b!%(e( E-!/y c!a"i%) to
'ei nforcement before casti ng concrete of 'oof sl ab and 'oof Beams,
even though i t i s a bi t costl i er. ,hi s e%tra cost i s very nomi nal when
compared to fai l ure of structure at an earl y age. ,he Bui l di ng 88'
speci fi es a rate of '8 E1,. ,hi s comes as preventi ve
measure as we al l know that Preventi on i s al ways better than cure.
It i s very i nteresti ng to observe that the Rai'.ay au"h!ri"ies
.hi'e c!%s"ruc"i%) R!a( O$er Bri()es %ear Sea c!as" a(!-" "his
&e"h!( a'!%) .i"h c!%cre"e sur#aces c!a"e( .i"h E-!/y Resi%s,
but we don0 t even attempt to copy thei r procedure when our
counterpart Engi neeri ng wi ng i s adopti ng i t. $e must note thi s whi l e
we construct structures i n 1ari ne -tmosphere. $e wake up after the
structure has shown si gns of damage after few years. Even at thi s
stage .e (! %!" "a*e i" seri!us'y a%( .e si&-'y -'as"er i" .i"h
0e&e%" M!r"ar i# %!"ice( !r 'e#" u%a""e%(e( #!r s!&e &!re
years as -r!b'e& is i%crease( "! a'ar&i%) c!%(i"i!% !#
e/-!si%) a'' "he Rei%#!rce&e%" and by that ti me we do not have
ade/uate funds, as 'epai rs are costl y. =ere al so we forget the basi c
pri nci pl e that a s"i"ch i% "i&e sa$es %i%e. I a& a's! %!" a%
e/ce-"i!% "! "ha". -s I al so commi tted the same mi stakes and faced
the mental agony i n repai r of &oncrete, I a& )i$i%) "his re-air
&e"h!( "! -re$e%" res"'ess%ess, a%( %i)h"&arish e/-erie%ce "!
&y c!''ea)ues a%( I a& %!" a -er#ec" 0IVIL ENGINEER, "!
"each !"hers.
TO REPAIR SU0+ DAMAGED STRU0TURES, ;E MUST ADOPT
T+E FOLLO;ING PRO0EDURE
9< 4i rst re&!$e a'' "he '!!se c!%cre"e ei"her s-a''e( !r
crac*e( wi th =ammer as much as possi bl e.
9:< 'emove the sca'e #!r&e( !$er Rei%#!rce&e%" "!"a''y and
cl ean the 'ei nforcement wi th hard metal wi re brushes.
9B< 'emove or b'!. a.ay "he (us" #!r&e( (uri%) "he ab!$e
-r!ce(ure and keep i t dry. In remote vi l l ages the P!.er S-rayers
are general l y avai l abl e wi th farmers 9as they use the power sprayers
for sprayi ng Pesti ci des to crop protecti on<.
9?< 3ow we have to start our repai rE 'ehabi l i tati on process wi th
Epo%y compounds. E-!/y is a c!%s"ruc"i!% che&ica' .hich ca% be
use( #!r c!a"i%) !# Rei%#!rce&e%", b!%(i%) !'( c!%cre"e "! %e.
c!%cre"e3-'as"eri%).
9!< ,he Epo%y comes i n two components vi z. Resi% a%(
+ar(e%er. 2ne of the Epo%y 'esi ns known to me are LAPOD BRAND
EPODY 1anufactured by &EIB-@GEIG# &ompany and the performance
of thi s product i s up to the mark as I mysel f have used thi s product
and some other brands used di d not perform wel l . This (!es %!"
&ea% I a& -r!ec"i%) "his -r!(uc" as a sa'es &a%a)er .i"h
$es"e( i%"eres". I ca% h!%es"'y say "ha" I use( "his -r!(uc"
!%'y a%( &y *%!.'e()e is $ery 'i&i"e( i% c!%s"ruc"i!%
che&ica's a%( I a& %!" e/-!se( "! !"her "y-e !# -r!(uc"s.
-nyone can adopt other known products al so and use them and check
thei r performance and recommend i t to our fel l ow Engi neers. $hi l e
usi ng these products pl ease fol l ow the i nstructi ons sti pul ated by the
manufacturer scrupul ousl y.
9+< 4i rst take 7 -ar"s !# E-!/y a%( 1 -ar" !# +ar(e%er by
.ei)h" and mi % i t thoroughl y for few mi nutes, around ten mi nutes. If
we conti nue mi %i ng for some more ti me, i" bec!&es har( 'i*e a
s"!%e !%ce i# "he Reac"i!% is s"ar"e(. ,hi s i s one i mportant poi nt
to be kept i n mi nd. In general .he% "he c!'!ur !# &i/"ure "ur%s "!
ye''!., i" ca% be c!%s"rue( "ha" i" is "he "i&e "! a--'y i"
.i"h!u" #ur"her (e'ay.
9C< -fter &i/i%) is c!&-'e"e( "he E-!/y -r!(uc" is "! be
a--'ie( i&&e(ia"e'y as "he -!" 'i#e !# c!&bi%e( &i/"ure is 'ess
"ha% ha'# a% h!ur. =ence we have to take l i ttl e /uanti ti es l i ke :""gm
of Epo%y and "" gm of =ardener each ti me and perform our .ob
i nstead of mi %i ng l arge /uanti ti es and waste i t.
9*< The c!&bi%e( -r!(uc" is a--'ie( .i"h Pai%" Brush !%
"he sur#ace !# c'ea%e( Rei%#!rce&e%" a%( a(!i%i%) c!%cre"e.
This c!&-'e"es "he #irs" s"e-.
9)< 3ow &i/ sec!%( ba"ch !# E-!/y c!&-!u%( i% "he ab!$e
&a%%er. Be#!re .e -re-are "his sec!%( ba"ch, *ee- rea(y rich
0e&e%" M!r"ar >1E7? Mi/ #!r a--'yi%) "he sa&e.
9"< 3ow a--'y "he sec!%( c!a" !$er "he a'rea(y E-!/y
"rea"e( sur#ace and l eave i t for ! mi nutes and a--'y ce&e%"
s'urry. Immedi atel y after the &ement 8l urry i s pai nted start doi ng
Pl asteri ng to the 'oof sl ab and 'oof Beams as usual and l eave i t.
Pl ease note that the combi ned Product of Epo%y and =ardener i s
sol ubl e i n $ater unti l i t i s hardened and once i t i s hardened on
reacti on i t i s stronger than 1?" &oncrete and cannot be broken. -s
such "he brushes a%( !"her i"e&s use( i% &i/i%) are "! be
c'ea%e( #re=ue%"'y .i"h .a"er, *e-" i% a buc*e" %earby, a%(
&a(e (ry .i"h c'!"h e"c !"her.ise "hey bec!&e $ery har( a%(
%!" use#u' #!r sec!%( c!a" a--'ica"i!%.
,hi s compl etes the process and thi s one c!s"s a--r!/i&a"e'y
Rs 18883s=&, whi ch i s undoubtedl y very costl y and we are l eft wi th
no other al ternati ve and we must pay for our earl i er menti oned
omi ssi onsE 1i stakes.

>7? REPAIR TO LEA:Y ROOF SLAB
It i s common practi ce to l ay I&-er$i!us 0!a" !$er "he R!!#
s'ab 78&& "hic* .i"h ce&e%" M!r"ar >1E7? "! (rai% !## .a"er
easi'y a%( "! a$!i( 'ea*a)es wi th ade/uate sl ope l eadi ng the water
to 'ai n water pi pes pl aced. But i n practi ce i t i s a common mi stake that
we i gnore the fact s'!-e sh!u'( be -r!$i(e( i% ce%"eri%) i"se'#
be#!re -'aci%) Rei%#!rce&e%". General l y i t i s l eft to the centeri ng
l abour and we vi si t the si te after the steel i s wrought and kept i n
posi ti on and check thei r spaci ng and other aspects as per the
approved desi gns. -t thi s stage even i f we noti ce that the sl ope i s not
ade/uate, i t i s di ffi cul t to recti fy the centeri ng and the contractor
convi nce us that he wi l l obtai n re/ui red sl ope i n Impervi ous coat even
though i t i s l oss to hi m.
I% !r(er "! achie$e "he -r!)ress !# .!r*, .e "!! acce-"
"he c!%"rac"!rF s re=ues" a%( acc!r( -er&issi!% "! 'ay "he
c!%cre"e. -fter casti ng the concrete the contractor commences
Impervi ous coat on the ne%t day and at thi s stage the &as!% 'ays
ce&e%" &!r"ar 'e$e' b'!c*s .i"h s!&e s'!-e a%( %!"ices "ha"
"he 78&& "hic*%ess i% I&-er$i!us c!a" is %!" a(e=ua"e a%(
e/"ra "hic*%ess is re=uire( "! ha$e a(e=ua"e s'!-e "! (rai% !##
.a"er. As a c!&&!% -rac"ice "he c!%"rac"!r .!r*s !u" "he
Re=uire&e%" !# 0e&e%" #!r I&-er$i!us c!a" .i"h ce&e%"
&!r"ar >1E7? #!r 78&& "hic*%ess !%'y and try to i ncrease the sand
content thereby reduci ng the proporti on of &ement mortar to >1E4?
!r e$e% 'ea% .hich ca%%!" -re$e%" 'ea*a)es and at ti mes thi s
absorbs water due to l ean cement mortar mi % as i t i s more pervi ous to
'ai n water and .a"er is "ra--e( be".ee% "his I&-er$i!us c!a"
a%( R!!# s'ab.
In one Ma!r Bui'(i%) NEARER TO SEA 0OAST i t i s noti ced
duri ng the 6.& i nspecti on al ong wi th 8uperi ntendi ng Engi neer 9'FB<
6.&, that "he "hic*%ess !# I&-er$i!us c!a" is G2 && .hich
&ea%s "ha" "he ce%"eri%) shee"s .ere %!" -'ace( "! re=uire(
s'!-e a%( "he c!%"rac"!r -re#erre( "! bri%) "he re=uire( s'!-e
i% I&-er$i!us c!a" !%'y, but wi thout i ncreasi ng the &ement
content, thus maki ng very l ean Impervi ous coat. ,hi s Impervi ous coat
as i t i s l ean was comi ng out wi th a screw dri ver and we can say thi s
type of Impervi ous coat does &!re har& i%s"ea( !# PREVENTING
-erc!'a"i!% !# rai% .a"er i% "! r!!# s'ab a%( i" i%creases (ea(
'!a( !# s'ab, abs!rbs a%( re"ai% .a"er i% i". Because !# "his
e%"ra--e( .a"er, .a"er (r!-'e"s c!%"i%ue #!r s!&e &!re (ays
e$e% a#"er rai% is s"!--e( as "he e%"ra--e( .a"er has %! .ay
"! c!&e !u" e/ce-" "hr!u)h "he $!i(s i% R!!# s'ab. ,hi s
i ncreases corrosi on i n 'ei nforcement and i ncreases the vol ume of
'ei nforcement and pushes down the cei l i ng pl asteri ng and thi n cracks
may devel op i n 'oof sl ab.
4rom the above we can understand how a s&a'' &is"a*e !# %!"
$eri#yi%) "he s'!-e !# ce%"eri%) shee"s, be#!re Rei%#!rce&e%"
is *e-" i% -!si"i!%, creates deadl y probl em of corrosi on and
E%posure of 'ei nforcement. ,hi s coul d have been chec*e( .i"h a
si&-'e ".i%e a%( 'e$e's )i$e% -r!-er'y .hich "a*es 7 "! @ h!urs
#!r us. Even though i t seems si mpl e i t i s one of the reasons for
l eakages i n 'oof sl abs and show si gns of fai l ure at earl y age whi ch i s
not due to l ess use of cement i n 'oof sl ab but due to Poor
$orkmanshi p.
In such case when there i s l eakage i n 'oof sl ab, INSPE0T
"h!r!u)h'y "he "!- !# I&-er$i!us c!a" a%( i# i" is 'ea%er "ha%
>1E7? -r!-!r"i!% a%( 'ar)e %u&ber !# hair 'i%e crac*s are
!bser$e(, re&!$e "he e%"ire I&-er$i!us c!a" and cl ean the
surface thoroughl y that there i s no dust. -gai n i%s-ec" "he r!!# s'ab
&e"icu'!us'y .he"her "here is a%y (e#i%e( crac* a" "he "!- !#
r!!# s'ab. I# "here is a $isua' crac* c!%"i%u!us'y .e ha$e "!
arres" 'ea*a)e #r!& "his crac*. F!r "his .e ca% a(!-" sa&e
E-!/y c!&-!u%( e/-'ai%e( i% "he ab!$e -!i%". As "his "y-e !#
crac*s are $ery "hi% "he E-!/y c!&-!u%( (!es %!" #'!. i%"!
crac* u%'ess i" is .i(e%e(.
In order to al l ow the Epo%y compound i n to the crack, a shar-
chise' &ay be use( "! s'i)h"'y .i(e% "he crac* "! @&& .i("h a"
"!- a%( re&!$e a'' "he (us", (ry "he sur#ace.
9< Re&!$e a'' (us" .i"h Pressure -u&-3P!.er s-rayer and
keep the surface dry.
9:< 3ow "a*e 788 )& !# E-!/y Resi% a%( 188 )& !#
+ar(e%er and mi % i t thoroughl y i n the same way as e%pl ai ned earl i er.
9B< 3ow -!ur "he E-!/y &i/"ure .i"h a #u%%e' i% "! "he
crac* and al l ow i t to fl ow deep i n to the crack unti l the crack i s fi l l ed
total l y wi th Epo%y mi %. ;he% "he crac* is "!"a''y #i''e( i" s"ar"s
c!&i%) "! si(es !# crac* a%( .e ca% s"!- "he -r!cess.
9?< ;eave i t for one day and veri fy the ne%t day .he"her "he
crac* is "!"a''y #i''e( a%( "here are %! $isib'e )a-s.
9!< -ppl y ce&e%" s'urry !$er "he r!!# s'ab to the e%tent that
the i mpervi ous coat can be l ai d i n B" mi nutes.
9!< N!. s"ar" 'ayi%) i&-er$i!us c!a" .i"h 0e&e%" &!r"ar
>1E7? a%( c!&-'e"e i% !%e si%)'e !-era"i!%.
9+< 0uri%) sha'' be s"ar"e( .i"hi% 5 "! B h!urs a#"er 'ayi%)
i&-er$i!us c!a" a%( c!%"i%ue i" #!r %!" 'ess "ha% 7B (ays
irres-ec"i$e !# )ra(e !# ce&e%" use( by -!%(i%).
9C< It i s al so to be kept i n mi nd by "he user (e-ar"&e%"s "!
i%s-ec" "he r!!# s'ab be#!re !%se" !# &!%s!!% a%( re&!$e a''
"he (ebris, (ry 'ea$es #a''e% !$er "he r!!# as "his (ebris .i''
b'!c* "he rai% .a"er -i-es a%( cause s"a)%a"i!% !# .a"er !$er
r!!#. In some cases the di kes 9cement mortar bunds< l ai d for curi ng
were not removed and water was stagnated over the roof even after
year and the User De-ar"&e%" sh!u'( a's! "a*e care "! &ai%"ai%
"he s"ruc"ure by (!i%) -r!-er &ai%"e%a%ce.
9*< 1ust provi de !%e IRON LADDER "! i%s-ec" "he r!!# by
"he user De-ar"&e%" as a%( .he% 'ea*a)es are !bser$e( !r #!r
a%y -eri!(ica' i%s-ec"i!% by "he &ai%"e%a%ce (e-ar"&e%", a%(
"hey &us" be e/-'ai%e( !# "his -r!b'e& a%( %!" "! b'a&e "he
c!%s"ruc"i!% De-ar"&e%" .i"h!u" &ai%"ai%i%) "he s"ruc"ure a%(
a""e%( re-airs i&&e(ia"e'y "! a$!i( #ur"her (a&a)e.
,hi s compl etes the repai r to l eaky roof.
>@? MINOR 0RA0:S IN LOAD BEARING3PARTITION ;ALLS
General l y i n many Bui l di ng structures i t i s a common phenomenon
that some &i%!r hair 'i%e crac*s are %!"ice( s"ar"i%) #r!& Li%"e'
'e$e' (!.%.ar(s3u-.ar(s. It i s not cl earl y establ i shed as to why
these cracks appear. 8ome desi gn Engi neers opi ne that these are due
to sl i ght defl ecti on of beams on l oadi ng. It i s advi sed that the
parti ti on wal l s i n case of 4ramed structures may be constructed after a
month after removal of centeri ng for 'oof BeamsE 'oof 8l ab so that
the Beams take l i ttl e defl ecti on. ,hese s&a'' hair 'i%e crac*s (! %!"
ha$e a%y i&-ac" !% s!u%(%ess !# s"ruc"ure, but a smal l
di scontent i n the 2wners of the structure that thei r own house i s
showi ng cracks wi thi n a short peri od. ,hi s probl em i s seen both i n the
Government Bui l di ngs and i n the Pri vate Bui l di ngs and need not be
consi dered as a si gn of damage. In case of Pri vate owners, they try to
hi de these cracks wi th fre/uent pai nti ng. But i n case of Government
Bui l di ngs as nobody bothers about them, they are l eft open and offer
cri ti ci sm by everyone.
It i s my personal opi ni on that these smal l cracks need not be
bothered. =owever i f anyone wants a sol uti on for thi s, i t i s advi sabl e
to use ;ALL PUTTY #!r sea'i%) !# "hese crac*s a%( "he% a--'y
-ai%" as usua'. I" &ay recur a#"er #e. years.



>4? Se""'e&e%" !# F'!!ri%)
,hi s probl em i s general l y observed i n Bui l di ng structures
constructed i n E/-a%si$e s!i's 'i*e B'ac* 0!""!% s!i's .here -i'e
#!u%(a"i!% is )e%era''y a(!-"e(. -s per I8 code air )a- sha'' be
-r!$i(e( be".ee% "he P'i%"h Bea& a%( Na"ura' Gr!u%( "! a''!.
#!r e/-a%si!% !# c'ayey s!i's. ,hi s smal l ai r gap general l y of C!mm
has to be protected wi th a smal l pro.ecti on under the beam outer si de.
,hi s i s not general l y adhered by the fi el d engi neers duri ng
constructi on and al l ows fi l l i ng materi al to be eroded due to seasonal
vari ati on i n Bl ack cotton soi l s. In order to avoi d thi s -'i%"h
Pr!"ec"i!% a'' r!u%( "he Bui'(i%) i% "he #!r& !# s&a'' .a'' a" a
(is"a%ce !# 8.58& #r!& "he &ai% .a''. ,he foundati on of thi s smal l
wal l shal l be taken bel ow the Ground l evel by ".B"m and rai sed up to
pl i nth l evel so that there wi l l not be any l oss of materi al and al l the
fi l l i ng materi al shal l be i ntact. ,he space between the mai n wal l and
protecti ve shal l be fi l l ed preferabl y wi th non cohesi ve soi l s l i ke sandE
Gravel and at top >adapa sl ab fl oori ng l ai d wi th sl i ght sl ope outwards,
so that the rai n water drai n off easi l y.
In some cases some &ontractors use the e%cavated e%pansi ve soi l
as fi l l materi al under fl oori ng to some hei ght and then use 8and for
fi l l i ng. Because of the E%pansi ve nature of Bl ack &otton soi l s, the
fl oori ng wi l l be settl ed duri ng dry season and heave up i n rai ny season
due to i ngress of moi sture. =ence avoi d fi l l i ng under fl oori ng wi th
e%pansi ve soi l s. ,hi s probl em recurs i f proper care i s not taken whi l e
doi ng fi l l i ng. I% case !# c!''e)es3sch!!'s .hich are '!ca"e( i% a
#ar a.ay is!'a"e( '!. 'yi%) si"es #r!& $i''a)e, "here is e$ery
-!ssibi'i"y !# I%u%(a"i!% !# si"e a'' r!u%( "he bui'(i%) a%( i" is
$ery easy #!r i%)ress !# M!is"ure i% '!. 'yi%) si"es. I" is a'.ays
(esirab'e "! -r!$i(e -'i%"h -r!"ec"i!% "! -re$e%" i%)ress !#
&!is"ure a%( "his i%)ress !# &!is"ure #r!& )r!u%( 'e$e' &ay
cause (a&-%ess i% .a''s (ue "! ca-i''ary ac"i!% !# e/-a%si$e
cl ays. ,hi s i s al so another probl em whi ch gi ves very shabby
appearance due to peel i ng of Pai nti ng and Pl asteri ng. It al so damage
the heal th of the resi dents.
In some cases when the sand i s of poor /ual i ty wi th sal ts al so
may create thi s probl em. It i s desi rabl e ri ver sand Esand obtai ned
away from sea shal l be used i n Pl asteri ng work. It does not mean that
the sand nearer to 8ea can be used for other i tems of work. P'ease
re&e&ber "ha" "he Sa%( use( ei"her #!r c!%cre"e3 -'as"eri%)3
Mas!%ry sha'' be #ree #r!& a%y "y-e !# sa'"s.
In some cases the user (e-ar"&e%" sha'' %!" "a*e u- a%y
&ai%"e%a%ce as they feel that i t i s botherati on of Engi neeri ng wi ng
and s&a'' -'a%"s 'i*e'y "! )r!. i% "he "i%y )a-s !# !i%"s and the
user (epartment shal l take no responsi bi l i ty to remove them i n the
begi nni ng stage i tsel f, unti l they become trees wi th thei r roots gone
deep i n to the wal l s. $e are al so not e%cepti on to i t, as we al so al l ow
pl antati on to grow at the E%pansi on .oi nts of Bri dge structures. $e
see and 'ea$e i" as a R!!# )ar(e% !$er -ier ca-s. P'ease e/cuse
&e i# &y .!r(s are harsh. I thi nk i t i s hi gh ti me to anal yze
oursel ves to l earn from mi stakes i nstead of bl ami ng one another that
i t i s the responsi bi l i ty of the -ssi stant E%ecuti ve Engi neer and they are
not di schargi ng thei r duty properl y. $e have to /uesti on oursel ves
that h!. &uch a&!u%" is se-ara"e'y *e-" #!r Re-airs3
Rehabi'i"a"i!%.

P;-3,8 BE&-1E ,'EE8 -8 ,=E# -'E 32, 'E125E( I3 E-';# 8,-GE
B# 78E' (EP-',1E3,
Even the Bri dges whi ch are vi tal i n transporti ng men and materi al
duri ng di sasters are not l ooked i n to and thei r mai ntenance i s l eft to
ai r unti l they are col l apsed. $e don0 t have money even to pai nt them
fre/uentl y unti l a &hi ef 1i ni ster vi si ts. It i s my personal opi ni on that
&a%y Bri()es %earer "! sea c!as" are (a&a)e( ba('y (ue "! %!
&ai%"e%a%ce e/-!si%) a'' "he Rei%#!rce&e%" a" B!""!& (ue "!
i%a(e=ua"e c!$er a%( &ari%e a"&!s-here, and l eft unattended for
decades. In case of one bri dge the total steel i s separated from
concrete due to corrosi on and the pl ai n concrete i s onl y taki ng heavy
Grani te bl ocks wei ghi ng more than !"mt and nobody knows when wi l l
i t col l apse.
4i nal l y we can say that the above si mpl e omi ssi ons are
responsi bl e for earl y fai l ure of Government Bui l di ngs .hich i%$!'$es
%! e/"ra #i%a%cia' c!&&i"&e%" and i f they are taken care duri ng
constructi on, many probl ems i n Bui l di ng structures can be el i mi nated.
If regul ar mai ntenance of Bui l di ngs i s attended by user (epartments
i .e., removal of debri s i n rai n water pi pes before monsoon, attendi ng
mi nor repai rs i mmedi atel y, as i t i s a wel l known fact that a sti tch i n
ti me saves ni ne, the structures constructed by (epartmental Engi neers
l ast l ong and we can rai se our head wi th pri de.


;IS+ING YOU ALL T+E BEST.
T+AN:ING YOU RESPE0TED ENGINEERS.

DETAILS OF AUT+OR

NAME E PAMART+I SURES+ BABU
,UALIFI0ATION E B.Tech >0IVIL? FROM NAGRHUNA UNIVERSITY
DESIGNATION E DEPUTY EDE0UTIVE ENGINEER
>GOVERNMENT OF AND+RA PRADES+?
ROADS AND BUILDINGS DEPARTMENT
UDAYGIRI, NELLORE DISTRI0T.
EDPERIEN0E E ;OR:ING IN T+E DEPARTMENT SIN0E 1CB5.
0ONSTRU0TED MAHOR BRIDGES.
PURPOSE E TO IMPROVE T+E PERFORMAN0E IN
0ONSTRU0TION OF GOVERNMENT BUILDINGS
ADDRESS E FLAT NO.784, S:Y LINE TO;ERS, 4
T+
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+ARANAD+PURAM, NELLORE627488@
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E6MAIL E sb-a&ar"hiI)&ai'.c!&
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