ENGINEERING SPECIFICATION FOR

WATER PROOFING WORK

FOR

NITROGEN UNIT
FOR
HINDUSTAN PETROLEUM CORPORATION LTD.
VISAKH REFINERY

DHT PROJECT
JOB NO.
DOCUMENT NO.

6261

: A-6261-A-331

TOTAL NO. OF PAGES: 13 (INCLUDING THIS PAGE)

31-03-2009

FOR BID ENQUIRY

AGR

SVP

RCN

REV.

DATE

DESCRIPTION

MADE BY

CHECKED

APPROVED

TOYO ENGINEERING INDIA LIMITED

MUMBAI

INDIA

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WATERPROOFING WORK

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CIVIL DESIGN DEPARTMENT

PAGE 2 OF 13

CONTENTS

PARA
NO.

DESCRIPTION

PAGE
NO.

1.0

SCOPE

2.0

APPLICABLE CODES

3.0

PRIORITY OF REQUIREMENTS

4.0

BITUMEN FELT BASED WATER PROOFING

4.1
4.2
4.3
4.4
4.5

Surface preparation
Treatment
Method of laying
Application areas
Manufacturers

4
4
6
6
8

5.0

CEMENT BASED WATER PROOFING

5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8

Integral Water Proofing Compounds

Surface Method
Sodium Silicate Treatment
Brick Bat Coba Treatment
Box Type Method
Injection and Grouting Method
Applications
Manufacturers

8
9
9
10
10
10
11
11

6.0
6.1
6.2
6.3

POLYURETHANE WATER PROOFING

Materials
Workmanship
Guarantee

11
11
12
13

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1.0

CIVIL DESIGN DEPARTMENT

PAGE 3 OF 13

SCOPE
This specification covers the requirement of various water proofing treatment for
water proofing of various components of structures in the buildings, Civil works
i.e. roofs, basements, water tanks, trenches etc. This specification covers supply
of labour, material, construction aids, tools and tackle etc. for water proofing and
damp proofing.

2.0

APPLICABLE CODES
Note: Wherever reference is made to IS Codes, on any page of this Technical
Specification (including annexures), applicable year of publication of IS
Code is as stated below.
The following codes applicable to this section shall include but not limited to the
following:
IS: 702-1988

Industrial bitumen.

IS: 1322-1993

IS: 1346-1991

IS: 1580-1991

IS: 1609-1991

IS: 2645-2003

Integral cement waterproofing compounds.

IS: 3036-1992

Code of practice for laying lime concrete for waterproof roof

finish.

IS: 3037-1986

Bitumastic for use in waterproofing of roofs.

IS: 3067-1988

IS: 3068-1986

IS: 3384-1986

Bitumen primer for use in waterproofing and damp proofing.

IS: 4365-1967

Code of practice for application of bitumen mastic for water

proofing of roofs.

IS: 5871-1987

Bitumen mastic for tanking and damp proofing.

IS: 6494-1988

Code of practice for water proofing of underground water

reservoirs and swimming pools.

Specification for bitumen felts for water proofing and damp

proofing.
Code of practice for waterproofing of roofs with bitumen
felts.
Specifications for bituminous compounds for water proofing
and caulking purpose.
Code of practice for laying damp proof treatment using
bitumen felt.

Code of practice for general design, details and preparatory

work for damp-proofing and water-proofing of building.
Broken brick (burnt clay) coarse aggregate for use in lime
concrete.

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3.0

CIVIL DESIGN DEPARTMENT

PAGE 4 OF 13

PRIORITY OF REQUIREMENTS
In case of any variation and discrepancy in condition between the special
conditions, this specification and codes, order of priority shall be as under :(1)
Special conditions
(2)
This specification
(3)

4.0

Codes

BITUMEN FELT BASED WATER PROOFING

The waterproofing work shall be carried out by LSTK CONTRACTORS who
have experience in doing waterproofing work and shall give a guarantee on a
stamped paper for good performance of the waterproof treatment for a minimum
of seven years period and shall, at their own cost, rectify the defects if any found
during the guarantee period.
If approved by the Engineer-In-Charge, in-situ fiberglass tissue reinforced
bitumen layers equivalent to bitumen felt may be used.

4.1

Surface preparation
Any cracks in the surface (other than hair cracks) shall be cut to V-shape,
cleaned and filled with cement mortar 1:2 or with bitumen conforming to IS 702,
as directed by the Engineer-In-Charge.
All fungus growth, moss, dust shall be removed by wire brushing.
When, a pipe passes through R.C.C. slab a cement concrete fillet shall be built
around the pipe and waterproofing taken over the fillet.
In brick parapet walls, a chase shall be made in the parapet wall to terminate the
bitumen felt. No chase shall be made in the R. C. C. parapet walls.

4.2

Treatment
Treatment shall consist of one of the following as specified, in the drawings or as
instructed by the Engineer-In-Charge.

4.2.1 Four Course Treatment

(a)

Normal Treatment

(i)

Hot bitumen applied at the rate of 1.2 kg/m2

(ii)

Hessian based self-finished felt, type 3, grade 1.

(iii)

Hot bitumen applied at the rate of 1.2 kg/m2

(iv)
of

Pea-sized gravel or grit at the rate of 0.006m3/m2 or (if specified) 2 coats

bituminous aluminum paint.

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(b)

CIVIL DESIGN DEPARTMENT

PAGE 5 OF 13

Floating Treatment
(i)

Fiber-base bitumen saturated underlay, type 1

(ii)

Hot bitumen applied at the rate of 1.2 kg/m

(iii)

Fiberglass self-finished felt type 2, grade 2.

(iv)

Hot bitumen applied at the rate of 1.2 kg/m

(v)

Pea-size gravel or grit at the rate of 0.008 m3/m2 or (if specified) 2 coats
of bituminous aluminium paint.

4.2.2 Seven Course Treatment

(a)

Floating Treatment
(i)

Bitumen primer at rate 0.08 lit/m2

(ii)

Hot bitumen applied at the rate of 1.2 kg/m2

(iii)

Fiber based felt type 2, grade 2 or Hessian based felt type 3, grade 1.

(iv)

Hot bitumen applied at the rate of 1.2 kg/m

(v)

Fiber based felt type 2, grade 2 or hessian based felt type 3, grade 1.

(vi)
Hot bitumen applied at the rate of 2.5 kg/m and 1.5 kg/m for felt and
hessian
respectively.
(vii)

(b)

3
2
Pea-sized gravel or grit at the rate of 0.008m /m or (if specified) 2 coats
bituminous aluminium paint.

Floating Treatment
(i)

Fiber-based felt saturated underlay, type 1

(ii)

Hot bitumen applied at the rate of 1.2 kg/m

(iii)

Fiber-based felt type 2, grade 2

(iv)

Hot bitumen applied at the rate of 1.2 kg/m2

(v)

Fiber based felt type 2, grade 2

(vi)

Hot bitumen applied at the rate of 2.5 kg/m2

(vii)

Pea-sized gravel or grit at the rate of 0.008m3/m2 or (if specified) 2 coats

of bituminous aluminium paint.

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4.3

CIVIL DESIGN DEPARTMENT

PAGE 6 OF 13

Method of laying
The felt shall be laid in length, at right angles to the gradient, commencing at the
lowest level and working up to the crest.
The felt shall be cut to required lengths, brushed clean of dusting material, laid
out flat on the roof to eliminate curls. It shall be laid in position and rolled up for
a distance of half its length. The hot bonding material shall be poured onto the
roof, across the full width of the rolled felt, as the latter is steadily rolled out and
pressed down. The excess bonding material shall be squeezed out, at the ends
and shall be removed as the laying proceeds.
When the first half of the strip of felt has been bonded to the roof, the other half
shall be rolled up and then unrolled onto the hot bonding material in the same
way as described above.
Minimum end and side overlaps shall be 100mm and 75mm respectively. All
overlaps shall be firmly bonded with hot bitumen.
Laying of the second layer shall be so arranged that the joints between the first
and second layer are staggered.
At the junction of vertical and horizontal, flashing of bitumen felt with minimum
overlap of 100mm shall be provided.
The grooves in the parapet wall shall be filled with cement mortar 1:2 after
completing fixing of felts.
Any ballooning observed shall be rectified.

4.4

Application areas

4.4.1 Building roofs

(a)

Membrane water proofing based on bitumen felt laying procedure as described

in 4.1, 4.2, and 4.3 above.

(b)

Multiplas, a prefabricated multilayered sandwich of polythene and polymeric

asphalt, product of Spannish water proofing may be used, if specified by
Engineer-In-charge. Multiplas Standard membrane is suitable for roofs and
sunken portion of toilets. Application of multiplas is fast and easy. Surface shall
be cleaned and prepared smooth to receive membrane. Surface is then coated
with special Multiplas Primer. Blown Bitumen shall be filled in the surface pores
to improve adhesion. Rolls of Multiplas shall be unrolled at site. Adjacent sheets
shall be lapped by 100 mm. Entire membrane is fused of substrate by means of
blowlamp torch from a homogeneous watertight layer on the surface. The
system is finally protected with mechanical topping such as cement plaster/ tiles
to provide a traversible and usable surface.

4.4.2 Toilet (Sunken Portion), As in 4.4.1 (a) and (b) above

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4.4.3 Underground Water Proofing

This specification covers the requirements of water proofing of basements,
tunnels, ducts, pits, bunkers, trenches, etc.
The material used shall be bitumen felt Type-3 of Grade-2 conforming to IS
1322, together with the specified bonding material and primer.
The number of layers of bitumen felt to be used for walls and floor, shall be as
per the drawings.
The method of laying the bitumen felts and workmanship shall in general
conform
to
IS 1609.
Water proofing work shall be taken in hand only when the site sub-soil water
level is at its lowest. The site shall be kept dry by adequate arrangements for
pumping out water till the work has been completed. For this purpose drains
shall be formed along the edges of the excavation but beyond the building line,
with suitable collecting sumps, in case of large excavation, to adequately drain
the area. Adequate arrangement shall be made to prevent the sides of
excavation from slipping when the work is in progress.
The base concrete or mud-mat shall be rendered smooth by a 20mm thick
cement sand plaster (1:6). Any sharp corner over which the waterproofing
course is to be laid shall be eased out by means of cement mortar fillets 75mm
in radius.
The surface shall be dried before the next operation is carried out. Blown
bitumen conforming to IS 702 shall be applied hot over the prepared surface at
the
rate
of
2
2
2 kg/m for the first layer and 1.6 kg/m for every other subsequent layer(s). The
laying of felt over the bitumen so applied shall always commence on the floor
and shall be carried out over the walls only after treatment of the floor is
complete. The minimum over lapping of joints for subsequent layers of felt shall
be 150mm. Joints for subsequent layers of felt shall be staggered. All joints shall
be completely sealed by blowlamp.
A protective flooring of either brick bat in cement mortar 1:3 or 60mm thick
cement concrete of grade M-15 or a coat of cement plaster (1:3) 4mm thick on
25 to 30mm thick cuddapah stone set in 1:2 cement mortar with 2% by weight of
cement water proofing compound CICCO No. 1 or approved equivalent, joints
flush pointed with same mortar, shall be constructed over the bitumen layers to
prevent damage to later during subsequent construction of the Structural floor.
The walls shall be treated in a similar way, the bitumen felts joining at the base
with the projecting felt over the mud-mat. The wall surface shall be made
smooth, where necessary with a coat of cement plaster 1:3. The felt shall be laid
as for the floor, ensuring that the surface to be treated is dry and then a
protective brick wall 115mm nominal, thickness shall be built in cement mortar

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CIVIL DESIGN DEPARTMENT

PAGE 8 OF 13

1:3 over the projecting mud mat. The space between the wall and felt shall be
grouted with cement slurry.
The treatment on the wall shall be carried 150cm above the surface of ground
and tucked into a groove 65mm wide and 40mm deep, the chase being filled
with cement mortar (1:4) Where water proofing is done to the roof of an
underground structure, such as a tunnel, it shall be done in a similar way. The
structural concrete shall be rendered smooth, hot bitumen and bitumen felts
applied on the same way as for the floor, walls and over this a protective layer
of cement concrete grade M-15, 75mm thick shall be laid.
The LSTK CONTRACTOR shall guarantee the water tightness and water
proofness of the structure for a period of 10 years. The work shall be done by a
firm of specialists in the trade approved by Engineer-In-charge.
4.5

Manufacturers
Bitumen felts Hessian based, polymeric bitumen primer etc. products are
available from following Manufacturers

4.5.1 Shalimar Tar Products - STP Ltd. - Bitumen felt etc.

4.5.2 M/S American Roofing Systems Pvt. Ltd. - SWEPCO Products for roof, wall and
floors etc.
4.5.3 F.G.P. Ltd. Fiber Glass Reinforced Plastic products - for bitumen felt F.G.P.
based for item 4.4.1 above
4.5.4 Spanish Water Proofing Co. - mulitplas Products
- Multiplas standard used for water proofing for item 4.4.1, 4.4.2 above
- Multiplas aluminum used for water proofing for item 4.4.3 above where water
proofing with heat insulation is required.
- Multiplas hiper used for water proofing of item 4.4.3 where mechanical
strength is
required.
Note: Manufacturers specifications for the above products shall be referred and
Engineer-In-charges approval shall be taken prior to its use in works.
5.0

CEMENT BASED WATER PROOFING

Various methods such as Integral Water Proofing, Surface Method, Box Type
Method, Injection and Grouting Method are used in Cement Based Water
Proofing.

5.1

Integral Water Proofing

In this method, chemicals shall be used during construction, with the objective of
water proofing and Dam proofing of concrete structure. Integral Water Proofing
Compounds (IWPC) i.e. plastizers and additives etc. shall be used to make

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concrete impermeable to water, ensuring water tightness of structural

components, so as to avoid corrosion of reinforcement inside. Use of suitable
plastizers, makes the concrete mix homogenous, cohesive and workable, easy
for placing and compaction. Bleeding and segregation is avoided.
IWPC shall be used in foundation mortar, brick/ stone masonry mortar/ plaster.
DPC at the plinth shall contain IWPC, that would not allow water to enter the
wall above plinth, in concrete for various components of structure i.e. columns,
beams, slabs etc. IWPC shall be used in concrete in water tanks, either
underground or overhead.
5.2

Surface method
The treatment shall be laid over the slab R.C.C. slab, the detailed operations are
as follows:

5.2.1 After the R.C.C. slab has been cleaned, slurry coat consisting of the neat
cement admixed with specialized imported acrylic based chemicals (or sodium
silicate treatment described below), which penetrates in the minutes of crevices
and fill up all the porosity in the structure, shall be used. In case of construction
joints between different R.C.C. members the, chemicals mixed with neat cement
slurry shall be injected at joints to make them monolithic.
5.2.2 A layer consisting of half cut brick in cement mortar 1:5 (1 cement: 5 coarse
sand), admixed with acrylic based chemicals laid to necessary gradient for
proper flow of water towards the drains. The treatment shall be extended up to
300mm height of parapet walls also. The average thickness of this brick bat
coba shall be 120mm with a minimum thickness of 75mm at the drain.
After a proper curing for about 3 days, slurry coat consisting of cement slurry
mixed with water proofing chemicals is provided to fill in the joints.
5.2.3 The top is then finished smoothly with cement mortar 1:4 (1 cement: 4 coarse
sand), with acrylic based chemicals with 300 x 500mm false rectangles and the
joints between slab and walls shall be rounded off in the form of vata.
The whole terrace shall be flooded with water for a period of 2 weeks for curing
and for final test.
5.2.4 The proportion of the chemicals to be used in respect of ordinary portland
cement shall be 1% by weight i.e. 1 kg of chemicals shall be mixed with 100 kg
ordinary cement and the quantity of cement used shall be a minimum of 5 bags
per 9.29 sq.m. of the area treated.
5.3

Sodium Silicate Treatment

This treatment consists of application of 3 coats of a solution of 1 part of silicate
of SICA to 3 parts of water, each coat being copiously applied with a soft broom
at intervals of 24 hours. Alternatively, if any other lining is specified, the same
shall be carried out as per drawings and manufacturers instruction.

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5.4

CIVIL DESIGN DEPARTMENT

PAGE 10 OF 13

Brick Bat Coba Treatment

Wherever specified, this shall consist of 100 parts of broken bricks of the sizes
of approximate 20mm to 40mm and 45 parts of lime mortar (1:2) machine mixed
or 1:6 cement mortar. The above ingredients shall be well mixed and only
sufficient water added to make the mixture plastic. The mixture shall be laid over
the concrete surface and shall be well rammed with wooden batten to the
required slope. The surface shall be trowelled smooth so as to bring the mortar
to the surface. The surface shall be kept moist for 7 days.

5.5

Box Type Method

This is an external waterproofing treatment and shall be applied to the basement
and underground water tank structure. The impregnation structure shall be
treated with the above treatment during the initial state of construction to ensure
100% water tightness.
The waterproofing layers shall be laid over the evenly laid bedding course of
concrete after cleaning the surface. Rough stone slabs are then laid side by
side, leaving a gap of about 15mm to 20mm between them. These joints thus
left are racked open and cement slurry admixed with chemicals is, grouted in
these joints. A protective layer of about 25mm thickness of cement mortar 1:5 (1
cement: 5 coarse sand) with stone chips embedded at random, is put over stone
layer. The total thickness of the water proofing layer shall be minimum 75mm.
The treatment is extended 150mm beyond the external face of the R.C.C. raft
slab and where sidewalls are laid. The treatment shall be carried over to the
sidewalls.
The impregnation treatment shall be continued of the external sides of the walls
and up to 300 mm above ground level.
Rough stone slabs of thickness 12mm to 16mm shall be fixed with the help of
cement paste, applied on the internal face of the vertical joints of the stones
leaving a gap of about 18mm between the external face of R.C.C. wall and
internal face of the rough stones. The stones are fixed side by side within 25mm
deep groove made in the bottom R.C.C. slab and the stones fixed in to ensure
the water tightness at the junction of the walls and raft, if the raft is projecting
beyond the external face of walls. Maximum of two to three horizontal layers of
rough stones is laid at a time. A coat of very rough cement plaster 1:5 (1
cement: 5 coarse sand) is applied to the external face of rough stones. After the
layer is set, the gap between the walls and the stone layer is filled with a grout
mix made up of cement slurry and cyclic based chemicals.

5.6

Injection and Grouting Method

In general the waterproofing shall be carried out as per specification of the
specialist but duly approved by the Engineer-In-Charge.

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The roof surface shall be cleaned thoroughly, watered and shall be kept wet at
least 12 hours prior to carrying out of waterproofing. If any leakage is observed,
the source of leakage shall be located and it shall be treated either by injection
grouting or by closing of the crack with application of cement mortar 1:2 after
cutting a V-shape groove. The treatment shall be continued till the leakage is
stopped.
The junction of the bottom raft with the vertical wall, is to be opened and filled
with metal aggregate of nominal size along with injection. In the wall area, all
construction joints are opened where found necessary as per site conditions.
The injections are filled with cement slurry (grouting). A layer of I.P.S. of about
50mm thick on the floor shall be provided and the vertical wall is covered with
sealproof waterproof layer of about 25mm thick.
Where specified, this work shall be carried out by the LSTK CONTRACTOR who
has specialized in carrying out this work. The LSTK CONTRACTOR shall give a
10 years guarantee on a stamped paper for good performance of his work and
shall undertake to rectify the work at his own cost if any defects are observed
during the guarantee period.
5.7

Applications

5.7.1 Surface method is used to treat concrete masonry or any other surface of roof/
terrace slab/ floor of bldgs.
5.7.2 Box type method is used to treat under ground structures viz. basement/ water
tank/ pits etc.
5.7.3 Injection and Grouting Method is used to treat existing structure for water
proofing, from inside where access to external surface is not available for under
ground water tanks, basement, pits etc.
5.8

Manufacturers

5.8.1 All India Water Proofing Company - Specialist in cement based water proofing
as described in 5.2, 5.3, 5.4, 5.5 and 5.6 above.
5.8.2 For Integral Water Proofing Compounds various manufacturers are available viz.
FOSROC, SICA QUALCRETE, MC-BAUCHEME, STP Ltd., CHEMBOND, etc.

6.0

POLYURETHANE WATERPROOFING

6.1

Materials
Materials shall consist of 2 pack clear/ pigmented Alphatic polyurethane using
polyether polyols with Iso-cynorate for rendering flame resistant characteristic.
Polyester or Castor Oil based Polyols shall not be used. The 2 pack system,
consisting of resin and hardener (Xylene /Toluene) shall be mixed in proportions

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by weight as per approved manufacturers specification. The coating shall have

high resistance to impact, abrasion and cracking. Tensile strength shall be 80
kg/cm after 4 weeks at ambient temperature. It shall be perfectly smooth, dust
free and shall retain glossy finish at least upto 3 years. It shall be resistant to
acid, alkalis and have a very low water absorption rate of 0.5% maximum at
ambient temperature after 7 days.
The packs shall not be older than 9 months after the date of manufacture and
packing.
6.2

Workmanship

6.2.1 Preparation of surface

The roof surface shall be thoroughly cleaned with a wire brush and all foreign
matter etc shall be removed. Well defined cracks on the surface shall be cut to
V section, cleaned and filled up flush with a paste of 2 component
polyurethane based crack filling compound and white cement in a ratio of 1:2.
6.2.2 Primer Coat
Primer coat shall be mixed in the ratio as per manufacturers specification. A
single coat of this primer shall be applied by brush over the prepared bed as an
adhesion coat.
The primer shall be allowed to dry for minimum of 8 hours before the successive
finishing coats of Polyurethane are applied.
6.2.3 Finishing coats
The finishing coats shall consist of three successive pigmented seating coats
each
of
2 pack polyurethane, mixed in the ratio as per manufacturers specifications.
Application shall be with brush, to a smooth and even finish. The overall dry film
thickness shall be 450 microns with a minimum covering capacity of 200 gms/m
per coat.
Ambient temperature at the time of application shall not be less than 5C and
not more than 40C.
Each coat shall be allowed to dry for minimum 8 hours or as per manufacturers
specification before applying next coat. Care shall be taken for quick application
after mixing the 2 pack primer in view of short pot life of the mix and shall be
fully consumed within the stipulated period as per manufacturers specification.
(Maximum 60 minutes at 30C).
Polyurethane coating shall be continued up the parapets/ walls for a minimum of
150mm over the finished roof surface. It shall be continued into rain water pipes
by at least 100mm.
Treated surface should be allowed to cure for minimum 72 hours.

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6.2.4 Cement Screed

The final coat of polyurethane, when tacky shall be sprinkled with 300 micron
layer of clean sand. Plain cement concrete (1:2:4) of 25mm minimum thickness
with 24 SWG chicken wire mesh shall be then laid to slope in panels not
exceeding 6 M area per panel. The joints between panels shall be raked out
neatly to a minimum 6mm x 6mm V-groove and filled up with an approved
quality elastomeric compound sealant. Drain outlet shall be provided for all
spouts/rain water pipes by suitable rounding, filling and skoping of PCC as per
drawing. At the junction of the roof and parapet or any other vertical surface, a
fillet of 75mm radius shall be formed in cement mortar 1 cement: 4 coarse sand.
6.3

Guarantee
The agency for waterproofing shall furnish a guarantee, which shall be agreed
upon in the Contract to ensure the successful performance of the Contract. The
guarantee shall be for a period of 10 years. Any work required to be carried out
as a result of any defects in workmanship during the period of the guarantee
shall be carried out by LSTK CONTRACTOR at his cost.