WARWANTI WATER TREATMENT PLANT

Structural condition
assessment report
PREPARED BY
M/S TANDON AND ASSOCIATES

2014

L AT U R C I T Y M U N I C I PA L C O R P O RAT I O N
T A L . D I S T. L A T U R , M A H A R A S H T R A

INDEX

1.
2.
3.
4.
5.
6.
7.
8.

Methodology of condition assessment

List of structures
List of non destructive tests
Observations
Conclusion
Reasons for distress
Methodology of repair
References

1 Methodology of Condition Assessment

All the sites were visited and structures were visually inspected.
The overall structural system was studied. All visual signs of distress were studied and
noted. The crucial members were identified for non destructive testing .
Visual observations/distress mapping is carried out as per following procedure
Following distress is observed specifically
a.
b.
c.
d.
e.
f.
g.
h.
i.

Structural cracks
Corrosion cracks
Spalling of concrete
Reinforcement corrosion
Reinforcement buckling
Leakage
Deflection
Structural steel corrosion and reduction in thickness
Joint failure in structural steel structures
Non destructive testing was carried on various members of all structures

2 List of structures
A layout plan of Warwanti WTP showing all the structures is given in annexure A
Overall the system is composed of

Aeration fountain

Inlet channel

Flash mixer

CLF

filter house

Pure water sump

The structural condition of following structures were assessed

1.
2.
3.
4.
5.
6.
7.

Aeration fountain
Inlet channel
Flash Mixer
CLF
Chemical house
Filter House
Pure water sump

3. List of non destructive tests carried out

i) Rebound hammer test
The test is performed as per IS 13311(part 2). In this test the rebound number is
measured, which is correlated to compressive strength of concrete.
Spring-driven mass strikes surface of concrete and rebound distance is given in Rvalues. Surface hardness is measured and strength estimated from calibration
curves.
Equipment details
Make-Proceq Switzerland
Methodology of test

Plaster is removed at test locations

For testing smooth, clean dry surface without any defect like honeycombing, crack or
hollow sound is selected

Area of approx 300x300 mm is rubbed with carborandum stone to remove loosely

adhering scales etc

In this area points at approximately 30 mm apart are selected in grids

By holding the rebound hammer at right angles to the surface of the concrete
member 12 readings are taken at selected points

Abnormally high and low results are neglected and average of balance readings is
worked out

Corrected rebound number is worked out after considering moisture, carbonation

,test location ,direction of test

Compressive strength of concrete is obtained from graph

Statistical analysis is carried out for this set of values

ii) Ultra sonic pulse velocity test
This test is performed as per 13311(part 1). In this test, the velocity of ultrasonic
waves through concrete is measured, and is related to concrete quality.

It operates on principle that stress wave propagation velocity is affected by quality of

concrete. Pulse waves are induced in materials and the time of arrival measured at
the receiving surface with a receiver. Ultrasonic pulse velocity is influenced by elastic
modulus and strength of concrete.
Methodology of test
Plaster is removed at test locations
For testing smooth ,clean dry surface without any defect like honeycombing,
crack or hollow sound is selected
Area of approx 300x300 mm is rubbed with carborandum stone to remove
loosely adhering scales etc
Two points are marked on the opposite faces of the concrete members for
direct transmission of ultrasonic pulses
Grease is applied as a coupling medium to ensure proper contact of the
transducers with concrete surface so that ultrasonic pulse is transmitted
through the medium without much disturbance
Both the transducers are held at correct test locations by applying constant
pressure and ultrasonic pulses are transmitted through the concrete
The velocity is calculated from the readings
Following is the criteria as per IS code
Sr no Ultrasonic pulse velocity(km/sec)

Concrete quality grading

Above 4.5

Excellent

3.5 to 4.5

Good

3 to 3.5

Medium

Below 3

Doubtful

4 Observations
The NDT results are given in Annexure B
1. Aeration Fountain- the walkway is heavily deteriorated.
2. Inlet Channel- side walkway is deteriorated
Side wall has cracks. The side channel is showing leakages.
3. CLF clariflocculators launder covers are broken . Main walls are showing minor
leakages at some points. launder base slab and wall is showing slight leakages.

4. Chemical house
The RCC sections of this chemical house shows various signs of distress as porosity,
hollowness, paint peeling, fungus , loose pocket plaster, seepage marks on walls and slab
area due to leakage from the tank. The tank top slab is showing major distress . Bottom
slab has leakage and dampness
.
5. Filter Beds
leakages, paint peeling is observed in side walls
6. Filter House
Some distress is observed in this structure. Roof slab is deteriorated. Beams are
showing structural cracks, there are leakages.
7. Pure water sump
The pure water sump is UCR masonry structure. The top slab is deteriorated.

Conclusions

Pure water sump is stone masonry structure. The top slab is showing
heavy distress. The pump house is deteriorated.
For long term
performance it is recommended to dismantle the structure and construct
new Pure water Sump in RCC M 30
All other structures are showing cracking of RCC components and
require dismantling and constructing it new.
Plastering and painting for all structures is suggested to protect them for
future use

6 Reasons for distress

All concrete in service is subjected to loads and attack by environmental factors. In almost all
cases penetration of water and aggressive chemicals is the primary reason for the distress.
Deterioration is caused by corrosion of reinforcing bars (carbonation, chloride ingress),
sulphate attack, and alkali silica reaction
Corrosion
Once the water enters into the structure and the reaches reinforcement corrosion starts.
Concrete has a pH of approximately 12.5, and this provides a protective environment for the
steel reinforcement because a thin film of passivating iron oxide forms over the surface of
the steel. However, two processes lead to a breakdown of the passivating film and initiation
of corrosion:
An acidic environment develops when carbon dioxide from the air mixes with water in the
concrete pores (carbonation) that removes the passivating layer.
The passivating layer can become permeable due to the presence of chloride ions that
penetrate into the concrete from marine environments and chloride in sand and aggregates.
The corrosion of reinforcements has resulted to be one of the most frequent causes of their
premature failures, which can set in, as early as 3 months depending on the surroundings.
Carbonation
Carbonation is a process in which carbon dioxide from the atmosphere diffuses through the
porous concrete and neutralizes the alkalinity of concrete. The carbonation process will
reduce the pH to approximately 8 or 9 in which the oxide film is no longer stable. With
adequate supply of oxygen and moisture, corrosion will start.
The reaction of Ca (OH) 2 with CO2 takes place by first forming Ca (HCO3)2 and finally
CaCO3, the product precipitates on the walls and in crevices of the pores. This reduction in
pH also leads to the eventual breakdown of the other hydration products, such as the
aluminates, C-S-H gel and sulfoaluminates.
The relative humidity with which the pore solution is in equilibrium greatly affects the rate of
carbonation.
Consequently carbonation occurs at a maximum rate between 50 and 70 percent relative
humidity. In addition to atmospheric conditions, carbonation rate is also influenced by the
permeability of the concrete, and the cement content of the concrete. Cement content of
approximately 15 percent produces a concrete relatively resistant to carbonation.

The two most common causes of reinforcement corrosion are (i) localized breakdown of the
passive film on the steel by chloride ions and (ii) general breakdown of passivity by
neutralization of the concrete, predominantly by reaction with atmospheric carbon dioxide.
Sulphate attack- The sulphate attack on concrete on concrete manifests itself in the form of
expansion, cracking, loss of mass and disintegration. Expansion and cracking is generally
associated with the product ettringite formed due to reaction between sulphate ions and the
hydration products C3A present in Portland cement paste.

7 Repair Methodology
Cement grouting
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, strength, etc.
on 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 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 and the 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 handled 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, admixtures to Portland cement grout
mixtures may be added for delaying the setting time, increasing flow ability, minimizing
segregation and shrinkage.
2 Preparations
The surface shall be cleaned with wire brush and compressed air, 15 m dia and 150 to 200
mm deep holes along the length of the cracks at a spacing of 500 mm may be drilled by wet
drilling using rotary percussion drills and nipples inserted in these holes.
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 add 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.
4 Application
Highest practical pressure within the limits 100-400 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. Grouting is to be done by attaching a packer (consisting of expansible tube of rubber)
to the end of the grout supply pump through the holes and nipples.
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 until refusal. 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.
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.

References

IS 13311 (Part 1): 1992, Non-Destructive Testing of Concrete Methods of Test,

Part 1, Ultra Sound Pulse Velocity, Bureau of India Standards.

IS 13311 (Part 2): 1992, Non-Destructive Testing of Concrete Methods of Test, Part
2, Rebound Hammer, Bureau of India Standards.

CPWD Handbook on Repair and Rehabilitation of RCC Structures, Central Public

Works Department (CPWD), Government of India, New Delhi, 2002.

IS 456 2000 Plain and reinforced concrete- code of practice(fourth revision)

IS 516-1959 Method of test for strength of concrete