DATE: 11th August, 2014.

STRUCTURAL AUDIT REPORT

OF

Industrial Building located on

Plot no. A – 130, Phase-I, MIDC,
Dombivli (E).
Owner:- Dr. P.K.Chopade.

Submitted by:

ENTECH ENGINEERS
Consulting Civil and Structural Engineers
Office address : RP-26, Near Ganesh Visarjan Talao, Milapnagar, M.I.D.C.
Residential Zone, Dombivli – East.

Contact no. : 0251-2438181/ 26454511

Email address : design@entechengineers.co.in

 STRUCTURAL AUDIT REPORT

Date: 7th Aug. 2014.

A) General Building Information:

Industrial Building located on

Building Name and
1. Plot no. A – 130, Phase-I, MIDC,
Address
Dombivli (E).
1238 sq.m. (R.C.C. Structure).
2. Total Area
15 sq.m. (Load Bearing Structure).
1971 – Construction of 1000 sq. ft. factory area &
Year of
3. load bearing structure.
Construction
1978 – Construction of remaining part.
4. Year of Additions As mentioned above.
No. of Wings and One factory building G + 2
5.
floors One load bearing structure.
6. Current use Industrial
Type of
7. R.C.C Framed Structure and Load bearing.
Construction
8. No. of Staircases 2
Structural members repaired time to time with sun-
History of recent
9. mix & Polyalk EP however reinforcement corroded
repairs
and reduced in diameter not repaired.
Heavy leakage from certain external faces & terrace
10. Effect of Monsoon
slab
Nature of
11. Visual & by use of light tapping hammer
Inspection

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 12. Plinth level 12” above ground level

Thickness of wall
9” thk.
RCC Part- Internal
13. 12” thk.
-External
12” thick Load bearing walls with 15” thk. Brick
Load bearing part-
pillars.
- 3.75m. for all floors in RCC structure
Floor to floor - 5.00m. total height of Load bearing Structure
14.
height with Mezzanine floor 2.4m. from ground
level.

B) Detailed Information:

Location Observations

1. Heavy leakage from certain external

2. Plaster & paint in door condition
External Periphery 3. Structural members in poor condition with
reinforcement exposed & corroded
4. Growth of vegetation at certain locations.
1. Cracks in Terrace china-chip waterproofing.
Terrace 2. Cracks in parapet wall.
3. Growth of vegetation at certain locations.
1. Mumty slab poor in condition with reinforcement
exposed and corroded.
Staircase
2. Cracks in waist slab at certain location with
reinforcement exposed and corroded.

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 Location Observations

1. Leakage observed at bottom slab of water tank.

2. Major structural cracks in beam & column supporting
water tank
Overhead Water tank
3. Cantilever slab at bottom of OHT projected 5feet wide
in poor condition with reinforcement exposed &
corroded.
1. Major Structural Cracks in Ground Floor Columns
with reinforcement exposed and corroded at multiple
locations in external columns.
2. Structural cracks observed in beams and slab at certain
Ground floor
locations.
3. Drainage in poor condition in toilet.
4. Cracks and bulges in waist slab of Staircase-1 (as
indicated in drawings attached alongwith).
1. External chajjas poor in condition with reinforcement
exposed & corroded
2. Major structural cracks & bulges observed in external
columns & beams.
3. Minor cracks observed in beam due to earlier leakage
First floor from open terrace part above.
4. Cracks in lintel above windows with reinforcement
exposed and corroded at certain location. M.S. Grill
fitted on windows bent due to failure of lintel at
certain locations.
5. Structural cracks observed in internal beams.

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 Location Observations

1. Heavy leakage from terrace above

2. Major structural cracks observed in external columns
3. Major structural cracks observed in beam & slab with
Second floor
reinforcement exposed & corroded at multiple
4. External chajjas poor in condition with reinforcement
exposed & corroded.
1. Cracks observed in parapet wall & terrace
waterproofing causing leakage in slab below.
Terrace
2. Major cracks in columns extended above staircase
level.
1. No major cracks observed in load bearing walls or
brick pillars provided at junctions.
2. External and internal paint and plaster found
Load Bearing Structure
satisfactory.
3. Ground floor level exactly at compound level causing
entry on rainwater into ground floor.

C) Observation Summary:

1) Columns specified in particular locations marked on plan observed to be poor

condition with major structural cracks showing up. Certain columns were
observed to be weak in condition as the cracks were showing up in same
column from ground floor to first floor.
2) Major structural cracks were observed in some of beams and slab, particularly
external and cantilever beams and slab exactly below terrace level.
3) Bulges and minor cracks were observed in slabs and beams at certain locations.
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4) Minor cracks were observed in Terrace in china chip water proofing causing
leakage at certain locations.
5) Growth of vegetation was observed at certain locations at terrace level and
external faces.
6) Storm water drain and W.C. and Bath drain pipes in poor condition causing
leakage and absorption of water in to the structure.
7) Compound paving and plinth protection improper causing dampness in external
side of structure.

(Note: - For exact location of problems, refer detailed observation, plan showing
affected members and adjoining photos.)

D) Recommendations:

1) Columns which have undergone major structural cracks should to be rebuilt

with polymer modified mortar. Steel reinforcement if corroded and reduced
more than 20% of its actual size then it needs to be replaced with new
reinforcement of same size and diameter. The work must be carried out as per
methodology specified.
2) Minor cracks observed in structural members like Column and Beam need to
be opened out and treated with polymer modified concrete and sealed off
immediately. If cracks are major and steel reinforcement is exposed and
corroded, the section must be repaired as done in point no.-1.
3) Slabs where bulges are observed need to be treated by removing loose plaster
and lean concrete and replacing with micro concrete and covered with new
plaster. Reinforcement Bars which are corroded & diameter is reduced by more
than 20% of its original diameter needs to be replaced with new reinforcement
bars which will be welded to existing bars which are intact in size & location.

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4) Cracks in Terrace waterproofing and parapet wall need to be opened out and
filled with crack sealant. Apply a coat of waterproofing chemical and cover the
surface with any suitable flooring. The complete procedure requires removal of
existing china-chip flooring.
5) The cracks in external walls to be filled with suitable flexible membrane and
covered with new plaster. Care must be taken to ensure removal of loose
material and plaster which is good in condition need not be damaged.
6) Any kind of vegetation developed near drain pipes & walls must be removed
immediately to avoid development of their roots further into structure. W.C.
and bath drain pipes although not operational at first and second floor yet it is
necessary to get it repaired as they can be a reason growth of vegetation. It is
also advised to carry out regular maintenance and check for leakages in pipes
fitted at face of building as it is the most severely affected area, causing
leakages in internal faces of building. It is advised to hold the pipes at certain
distance from walls by use of clamps.
7) Cantilever slab where major structural cracks are observed with reinforcement
exposed and corroded to be repaired with polymer modified mortar as per
methodology suggested for repairing of slabs.
8) All vacant units must be regularly maintained to avoid untimely damage to
structural as well as non structural members.

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E) Remarks:

The building consists of cracks in majority of structural members especially in

Columns. It is observed that timely repairs have been carried out by the owner by
use of Construction Chemicals, however Steel reinforcement is corroded reduced
and almost absent at majority of parts which has not been attended to.

It is hence suggested to carry out major repairs in the structure as per

methodology suggested at earliest. In absence of proper maintenance or suggested
repairs, the building can be termed unsafe to be used for the purpose it is intended
for.

Notes and Limitations:

1) The report is based on visual inspection of accessible area and data provided by
client. This report serves a basis of preliminary health checkup of building and
should not be treated as Stability certificate of the building.
2) Due to absence of design data and as built R.C.C. detailed drawing, resistance
of structure for earthquake/wind forces cannot be assessed.
3) Inspection of Substructure was not possible and hence condition of structure
below plinth cannot be commented on.

***

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LEGENDS

- CRACKS IN STRUCTURAL MEMBER

- CRACKS IN STRUCTURAL MEMBER WITH

REINFORCEMENT EXPOSED AND CORRODED.

- LEAKAGE FROM SLAB

LEGENDS

- CRACKS IN STRUCTURAL MEMBER

- CRACKS IN STRUCTURAL MEMBER WITH

REINFORCEMENT EXPOSED AND CORRODED.

- LEAKAGE FROM SLAB

LEGENDS

- CRACKS IN STRUCTURAL MEMBER

- CRACKS IN STRUCTURAL MEMBER WITH

REINFORCEMENT EXPOSED AND CORRODED.

- LEAKAGE FROM SLAB

LEGENDS

- CRACKS IN STRUCTURAL MEMBER

- CRACKS IN STRUCTURAL MEMBER WITH

REINFORCEMENT EXPOSED AND CORRODED.

- LEAKAGE FROM SLAB

 01) Cracks and damage in column at Ground Floor. 02) Cracks in Column At First Floor.

04) Column below overhead tank repaired by Construction

03) Reinforcement exposed and corroded in external Column.
chemicals.
 05) Cracks in beam at Ground floor. 06) Cracks and Reinforcement exposed in beam at second floor.

07) Cracks in beam supporting O.H.T. 08) Sagging of Grill due to failure of R.C.C. lintel above.
09) Mumty slab Reinforcement exposed and corroded. 10) Rendorcement in Cantilever slab exposed and corroded.

11) Reinforcement corroded in slab above second floor. 12) Growth of vegetation near storm drain outlet.
 METHODOLOGIES FOR REPAIR OF
DISTRESSED MEMBERS
CASE – 1
FOR COLUMN AND BEAM REPAIR (WHERE MEMBER HAS NOT
REDUCED IN CROSS SECTION BY MORE THAN 1/3RD)

Step 1- Surface Preparation

a) Remove all the loose material by small chisel and by hammer weighing
not more than 1kg.

b) Remove the exiting binding wires for proper removal of scales and rust.

c) Remove the scales and rust by suitable mechanical tools.

d) Finally clean the surface by vacuum cleaner/blower/water jet.

Kindly ensure that all loose material is removed (but good concrete is not touched)
and all binding wires are removed, and that rebars are thoroughly cleaned by
mechanical means and totally free of rust and scales.

Step 2- Protection against corrosion

a) Coat exiting re-bars by SUNEPOXY ZINC RICH, anti corrosive primer.

b) In case where the diameter of the exiting re-bars is reduced by more than
20% or so, provide new re-bars coated with PROCOAT SNZ either by
welding or by drilling holes and anchoring them by SUNEPOXY 358
(EPOXY based anchor grout).

c) Touch up where necessary by SUNEPOXY ZINC RICH.

Step 3- Building up the section

There should be started within 24 hrs of step 2

a) Coat/spray the entire surface with POLYALK EP. Wait for the required time
to ensure that the BOND COAT is TACKY before proceeding with the next
step.

b) Provide protective coat of polymer mortar, of (1:3) mix, one binder material
and three sand with POLYALK EP as admixture at 1 litre per 5kg of binder
material to cover the reinforcement. Water just enough to have stiff mix.
Place the polymer mortar in position by hand with pressure. Do not use
trowel.

c) The balance portion of the member should be built in 15mm to 20mm thick
layers or so. Coat/spray POLYALK EP bonding agent over the previous
layer before placing every new layer. From durability consideration the free
water to binder material ratio of 4/10 or less is advisable for these layers.

Step 4- Curing

Curing to be done to complete area for atleat 14 days from date of building
the section. If curing is not possible properly, spray the complete area with
SUNPOLICURE (curing compound) and resume normal curing.
CASE – 2
FOR COLUMN AND BEAM REPAIR (WHERE MEMBER HAS
REDUCED IN CROSS SECTION BY MORE THAN 1/3RD)

Step 1 and Step 2 as above for case no. 1

Step 3: Building up the section

This is to be started within 24 hrs of step 2.

a) Coat/spray entire surface with bonding agent POLYALK EP.

b) Pour POLYCRETE A – a ready to use micro concrete in WATER TIGHT

and RIDGID FORMWORK when the bonding agent is tacky.

One can add maximum 10 mm size aggregates to micro concrete maximum up

to 25% of micro concrete.

Step 4: Curing – same as above for case-1

CASE- 3
FOR REPAIR OF SOFFIT SLABS

Step 1 and 2: same as above for case – 1

Step 3:

This is to be started within 24 hrs of step 2

a) Coat the surface to be built up by section POLYALK EP.

b) Build up the section as per treatment detailed in Case-1- step 3(b) within 6
hrs. (Each layer should not be more than 25mm thk.)
c) Start building the next layer of section next day after application of BOND
COAT over the layer placed earlier.

Step 4: Curing – same as above for case no. 1

CASE- 4
FOR REPAIR OF CRACKS IN INTERNAL AND EXTERNAL PLASTER.

Step 1: Surface preparation

a) Makes a ‘V’ groove on the crack, preferably by cutter.

b) Remove all the loose material.
c) Clean the surface by water suitable for construction and moisten the surface
before commencing next procedure.

Step 2: Applying protective coating

a) Fill the crack with POLYFILL AR using spatula or a putty knife.

b) While applying avoid formation of cavity or bubbles.
c) After filling, allow the surface to dry for at least 24 hrs.
d) Apply in layers at 24 hours interval, if the depth of the crack is more than
10mm.

Step 3: Curing

The treated areas as above are localized and are spread over. Hence spray
SUNPOLICURE on the finished surface immediately and resume with normal
curing.
CASE- 5
FOR REPAIR OF INTERNAL AND EXTERNAL PATCH PLASTER.
It is likely that the existing bad plaster at some location may give way while
making ‘V’ grooves along the cracks. It is advised to remove all hollow, de-
bonding, unsound existing plaster as suggested below:

Step 1: Surface preparation

a) Check the bad plaster by hammer sounding and then mark it by paint.
b) Make a groove all along paint mark by cutter and then remove bad plaster by
chisel and hammer weighing less than a kg.
c) Clean the surface finally by water jet.
d) Wet the surface for 3 days or so. Keep the surface moist before proceeding
to the next step

Step 2: Replace the plaster as detailed below

From durability considerations (to achieve CRAKLESS and IMPERMEBLE

PLASTER) the mix of the plaster will be continuously improved to bring down the
free water to binder material ratio to 4/10 or less and to make the mix as much
leaner as possible.
EXTERNAL PLASTER AND PARAPET PLASTER
- Bond coat: Thin plaster (say 5mm or so)
- Mix proportion: 50kg binder material +50kg sand + 1 litre of POLYALK EP +
required water
- First coat-1:2
- Second coat-1:3
INTERNAL PLASTER
Only single coat: 1:3
POLYALK EP: 100ml for 50kg of binder material

Step 3: Curing

Use Jute bags to kep the surface moist by placing them over the treated surface. If
treated areas as above are localized and are spread over, spray SUNPOLICURE on
the finished surface immediately and resume with normal curing.
CASE- 6
FOR REPAIRS, REHABILITATION AND WATERPROOFING OF
WATER TANKS.
(A) OVER HEAD TANK:

Step 1: Make alternate arrangement for storage and supply of water.

Step 2: Empty the water tank.

Step 3: Surface preparation:

Remove existing inside plaster completely and all the loose concrete from inside
the rank and only bad plaster and loose concrete from outside the tank.

Step 4: Treatment to outside of the tank

Treatment to all four sides and to bottom of the tank from outside.

a) Cracks or spalling of the concrete due to the structural distress shall be done as
per CASE-1
b) Cracks in the plaster to be treated as per CASE-4.
c) Hollow, unsound plaster to be treated as per methodology mentioned in
CASE-5.

Step 5: Treatment to inside of the tank

Treat the inside surface for any structural distress as per the methodology no.1.
(Specially check the bottom of the top slab for any structural distress.) Fill the
crevices and pockets and level all the inside faces by polymer mortar. Seal the
separation gaps at location marked ‘C’ and ‘D’ by polymer mortar as per
methodology mentioned above in CASE-4.

Step 6: Application of Flexible Membrane waterproofing system

- Remove all curing compounds and sealers.

- Scrub and clean the surface.
- Remove laitance, dirt, paint, loose flakes or particles or other foreign matter
etc. using a vacuum cleaner or high pressure water jet or wet sandblasting or
wire brushing.
- Ensure that the concrete surface possesses an open surface texture.
 - Fill hairline cracks with POLYFILL AR, large cracks with POLYALK EP.
- Moisten the surface with water jet 24 hours prior to the application of
POLYALK WP.
- Mix 1 part of POLYALK WP and 1.25 parts fresh white or grey cement by
weight using a low-speed stirrer, to form a slurry.
- Continuous hand-mixing to a lump-free consistency may also be adequate.
- Keep the mix continuously stirred.
- Apply the slurry by brush to the damp surface.
- Apply two more coats of similar slurry at 24 hrs intervals.
- Allow to set for 48 hours.
- Cure the coating for 7 days by sprinkling water three times a day on the
vertical surface (external walls) and using moist gunny bags on the
horizontal surface (terraces).
- For best results, it is necessary to sandwich the cured coating of POLYALK
WP with a screed layer.

(B) TOP OF THE TANK

Step 1: Surface preparation.

- Remove all loose materials.

Step 2: Building the section

- Build section as mentioned in CASE-3.

Step 3: Curing

- Same as CASE-3

(C) UNDER GROUND TANK

Treatment on the same lines as above for ‘overhead tank’ is advised.

CASE- 7
FOR WATERPROOFING THE TERRACE SLAB WITH FLEXIBLE
MEMBRANE WATER PROOFING SYSTEM.
It is advised to attend to the following points at appropriate time.
a) Provide supports if necessary.
b) Check all the rainwater pipes and repair / replace them if required. If
necessary provide additional RW pipes.
c) Bring the RW pipes beyond the inside face of the parapet as per sketch
no.1 and seal the gaps around the pipes in the parapet as per Methodology
No.2 (A).
d) Replace rusted GI pipes as per details in sketch no.2
e) Water can find access through YOP BALCONY SLABS and TCHAJJAS
also. Hence it is advisable to waterproofing system.

TERRACE WATERPROOFING:

Step 1: Take up the surface preparation for attending to the structural distress to
theTerrace slab and beams from inside of the flats, to top balcony slabs and to
top chajjas to be attended first as per the methodology no.1.

Step 2: Remove all brickbat koba, china mosaic chips, bitumen, cement tiles,etc.
by Small chisel and small hammer completely. Care should be taken to do this
work slowly and watchfully so that there is no damage to the structure and to the
belonging insides the flats. Take up surface preparation for attending to structural
distress to the terrace slab from top. It is advised that the surface preparation for
items no.1 & 2 to be done together.

Step 3: Clean the surface by vacuum cleaner / blower / water jet.

Step 4: Restore the terrace slab and beams from inside the flats as per CASE-1,2,3.

Step 5: Restore the top of the slab for any structural distress as CASE-3.

Step 6: Fill the crevices and pockets and level the surface as per CASE-4. Dry
cement should not be used to give smooth finish to the surface.

Step 7: Grouting to be done by Polymer modified cement slurry at location from

where leakage is observed in the flats below.
Step 8: Coat the surface with FLEXIPROOF PU in two coats. Second coat at right
angle to the first as per the note on Application.

Step 9: Protect the membrane coats by trowelling thin layer of plaster.

Before proceeding with further steps to protect the same from any damage from
further work to be taken up over the same subsequently.

Step 10:

(a) Provide binder material mortar / binder material concrete screed to Protect the
above film (8) from abrasion and Rainwater to flow. Calculate the thickness of the
screed at the crown as per the specified slopes, keeping the thickness of the screed
at parapet joint as only 5mm or so.. Screed will be cast in ONE OPERATION
only. Top surface will not be finished by sprinkling dry cement powder. Strictly no
rope markings should be provided to top surface of screed. The mix design of the
screed mortar shall be as per in CASE-5 as per for External plaster.

(b) Alternately Brickbat koba or suitable tiles can be provided in place of concrete
screed / mortar screed. The mix of the mortar for above as per CASE-5 as per for
External plaster.

(c) Alternately the protective coat of concrete with good quality brick bat
aggregate available from terrace debris with free water to binder material ratio of
0.35 is advised.

Step 11: Spray SUNPOLYCURE immediately on completion of the screed, which

keeps the heat away from the concrete and ensures proper curing.
CASE- 8
FOR REPAIR OF PARAPET WALL AND CHAJJAS WATERPROOFING /
TOP BALCONY SLAB WATERPROOFING:

PARAPET WALL:
- SAME AS CASE-4 & 5 FOR EXTERNAL PLASTER.
PARAPET TOP:
Provide 150mm thick PCC coping or alternately, provide 25mm thick cuddapa
stone slabs with drip moulds, properly anchored by anchor fasteners.

CHAJJAS WATERPROOFING / TOP BALCONY SLAB WATERPROOFING

Step 1: Follow steps 1 to 9 of terrace waterproofing as mentioned in CASE-7

above.

Step 2: Provide mortar screed similar to step 10 (a) of terrace Waterproofing with
wata at the joints and with specified slope. Use polyfibre to improve the quality of
mortar.

Step 3: Spray SUNPOLYCURE as directed.