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Special Repair Techniques for Masonry and Heritage Structures

Article · January 2015

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Aditya Gangane Pravin Khandve

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 Special Repair Techniques for Masonry and
Heritage Structures
Aditya S. Gangane * Pravin V. Khandve Sarang M. Dhawade
Research scholar, Research scholar, Assistant Professor,
PRM College of Engg and Mgmt, PRM College of Engg and Mgmt, PRM College of Engg and Mgmt,
Badnera, Badnera, Amravati (MS) India. Badnera,
Amravati (MS) India. [email protected] Amravati (MS) India.
Abstract: Civil engineering not only deals with construction of various structures but also
works for their maintenance. Present era demands efficient and sustainable methods for any
job. In this paper brief about conventional repair techniques are explained and the
methodology of special repair techniques is discussed. Paper highlights the potential of newer
philosophy generated by the use of chemicals and admixtures. Use of new chemicals is very
well explained for various components of building in order to mitigate the ill effects of
dampness and so on. In this paper procedure adopted for special repair techniques using
special product material for grouting, waterproofing, protective coatings and chemical
adhesive are discussed. Guidelines to evaluate structure under consideration, Testing and
investigation procedure, requirement of site preparation, cleaning systems, rectifying
measures are described. Special Technique executions for non structural repairs and
structural repairs with require Management approach special repair work is also given. This
will certainly help in enhance the performance of civil engineering project where similar kind
of repair and maintenance work is require to be executed.
Keywords: Non Structural Repairs, Special Material, Admixtures, Chemicals, Special Repair.

1.0 INTRODUCTION structure, improves aesthetics. Because of

sentimental attachment with structure repair is

S tructures hold an inevitable position in

human life. With evolution of humankind it
underwent numerous changes. With each little
sometime require which may expand useable
space if restricted due to non repair. Projects for
the repair and restoration of existing structures
change the demand for protecting the structure are rarely easy. There are many, and sometimes
also increased which raised the concepts like conflicting, demands; there is a wide range of
repair, restoration, retrofitting and so on. mechanisms that cause deterioration and a
Rehabilitation of old masonry buildings or holistic approach, encompassing all factors,
Restoration of Heritage structures presents a must be taken.
special case for repair. In such cases, natural
materials like sand, lime, wood, etc. are used
against the contemporary materials. Thus, water
or any other source of dampness coming in
contact of structures leads to biological elements
like weed and plants to grow. Further, the attack
of acid rains due to pollution has accelerated the
process of deterioration. Every problem of
dampness has its own unique cause and it leads
to various defects on the structure. As causes
are unique the solution to mitigate also vary due
to this it need complete and detailed study in the
reference of causes and measures to put in
action. All factors such as age of structure, local
climate, construction techniques and ground
conditions should be considered to develop an
individual and specific repair programme. The
decisions for initiating repairs are generally
limited. Repair enhances value the value of Fig.1: Distressed Plaster

* Corresponding Author
 However, change is permanent and various
firms are working to elevate this work pattern in
various perspectives viz. methodology,
techniques used and materials used. One of the
leading company MC-Bauchemie have given a
new attitude to tackle issues related to repair
and restoration of structures, on the same theme
following methodology can be implemented to
achieve the desired goal.

Fig.2: Rising Dampness

Fig.4: Plaster With Hexagonal Mesh

Fig.3: Efflorescence

1.1 Traditional Methods for Repair of

Masonry Structures

i. Removal of old plaster and laying new

plaster - It is simple method in which poor
plaster is removed by tools and new plaster Fig.5: Cement Paint
is done

ii. Oil paint i.e. Cement paint - In this, the

cement water paste is done which can be
sprayed off or painted with brush.

iii. Cement slurry grouting with water proof

compound - This method does grouting
where there are cracks in the walls and so
on .in this waterproof compound are added
as per standards for further safety.

iv. Plaster with hexagonal mesh - As name

suggest it is done using mesh, first the old
plaster is removed for high output cleaned,
and mesh of specific material is sandwiched
in between structure and new plaster above. Fig.6: Oil Paint coating
 2.0 METHODOLOGY v. Once the decision is been made about the
selection of cleaning, job site test should be
Special repair of any structure revolves conducted on small test area to determine
around some basic procedures. Step-1: the effectiveness.
Investigation – Guidelines to Evaluate Structure,
Step-2: Testing and Investigation, and Step-3:
Site preparation. These three important steps
are described below.
2.1 Guidelines to Evaluate Structure
First and foremost it should be checked that
overall structure is structurally sound. This may
not be a factor as most old buildings were
normally designed with higher safety factors.
Some of the key factors to be observed:
i. If column have cracks or poor joints at base

ii. If iron oxides are found

iii. If there are major water ingress problems

due to rain water
Fig.8: Moisture checking
iv. If there is flooding at the bottom of the
structure due to level differences between
the new roads and the old structures.

v. If dampness, rising dampness as well as

growth of fungus and vegetation is observed
in basement / plinth areas.

vi. If there is dampness or condensation or

deterioration associated with biological
growth.
Cracks are normally observed on masonry
walls, veranda pillars etc. which are made of soft
sand stone. In addition, the balustrades of
stones or wood are mostly in deteriorated stage
if not properly maintained. The roof
waterproofing systems fail and the new
waterproofing system installed are sometimes
incompatible with materials like bitumen etc. Fig.9: Core testing
Lime plasters are damaged and have to be
replaced with waterproof plaster made of either
lime or cement depending upon the limitations
specified by conservation architects.
2.2 Testing and Investigation
Before any repair programme following
testing should be done
i. Preliminary observation and investigation.
ii. Determine whether the damage is structural
or non structural in each element
iii. Determining the degree of deterioration of
natural stone as well as porosity.

iv. Non-destructive tests or coring can be

conducted to determine existing strengths
and chemical profile of structure. Fig.10: Injection for masonry
2.3 Site Preparation

Surface Selection of Dampness Water Rendering &

Cleaning
Preparation Material Barrier proofing Finishing

After determining cause of deterioration iv). Low compressive strength of repair material,
and investigative testing, for successful repair, matching the substrate
the following steps need to be taken:
Restoration works done in various parts of
Cleaning Systems India are worthy to guide the depth of positive
effects of admixtures, and chemicals. In
Utmost care should be exercised in design following special repair technique admixtures,
of suitable cleaning system for cleaning the chemicals and grouts proposed by MC
existing stone masonry and facades. There are Bauchemie India Pvt. Ltd. Mumbai are used and
three basic methods of cleaning of masonry executed by the firm itself. This paper is
surfaces. a) Water /steam cleaning; b) Abrasive highlighting some of the vital works and
cleaning; and c) Chemical Cleaning strategies using following three product
Depending upon the degree of strength and manufactured by the company. Materials used
porosity of the stones one should make a are i) special mortar ready to use polymer, ii)
decision to use the combination of one or more non shrinking polymer-modified cement mortar
of the above methods. Pros and Cons of each and iii) hydraulically setting Polymer modified
method should be borne in mind such as if grit non –shrink water proof grout. Brand names of
blasting is done the stone may get irreversibly these products are not mentioned here.
damaged. Therefore, this method should be
used only in cases where the stones are strong 3.0 EXECUTION TECHNIQUES
and non-porous. With certain chemically inert The special repair techniques for historical
stones, a chemical cleaning agent can be used masonry structures consists of two types of
or certain chemical biocides can be used to repairs namely non structural repairs and
remove vegetation growth. structural repairs. It should be understood that,
Rectifying Measures before considering all repairs structural stability
should be considered in parallel. The overall
Rehabilitation of old buildings with historic repair project should be in consultation with
significance is different compared to normal structural engineer recommendations.
repair of concrete structures as the materials
used in construction are natural and the 3.1 Non Structural Repairs
rehabilitation or restoration is to be done by Once the right material is chosen for the
maintaining the architectural aesthetics and correct application, the following steps can be
ambience. One should be able to blend new followed for repairs.
materials and new structural concepts with old
building materials and structural designs. It i). Clean and remove the existing biological
should be borne in mind that primary growth in the structure. Coat the affected
responsibility is not only to regain the areas with appropriate fungicide or
architectural aesthetics but also to make the old weedicide to avoid the recurrence of plant
buildings perform their new roles with total growth.
safety. The new building material must be
compatible with the existing old material. It is ii). Rising dampness should be treated by
preferable for the building materials to possess creating a chemical damp proofing course
the same properties throughout – at any time: by using Gelling / setting injection materials.
now and when ageing. Some of the key On the surfaces where there is existing
properties to be considered before starting repair dampness, the plaster and overcoats should
are: be removed, and a coat of mineral based
waterproofing slurry should be applied.
i). E-Module of repair material matching the
iii). Final Step would be to apply a waterproof
substrate
plaster / render. This material should ideally
ii). Low resistance to water vapour diffusion and be a ready-made product, but this type of
high degree of water-tightness, in short waterproof protective plaster can also be
breathability prepared on-site by incorporating correct
type of waterproofing and air entraining
iii). UV-resistant and similar joint colours admixtures into the plaster mortar
iv). The bottoms of the pillars can be repaired vii). The joints should be raked and should be
using epoxy mortars, if needed. These refilled by using the correct polymer modified
mortars can be formulated using solvent free waterproof joint mortars. The properties of
(to keep our heritage structures green) two- these waterproofing, plasters and mortars
component epoxy resin and selected fillers. should be matching the existing substrate as
discussed earlier.
v). In areas where major repairs are to be done
one can also resort to using polymer mortars viii). For waterproofing and sealing purposes one
by incorporating correct acrylic polymers or can resort to injection grouting by using
SBR based repair polymers suitable grouting systems.
ix). After completion of all repairs, the structure
vi). Roofs can be re-waterproofed and protected should be coated with water repellent
by using polymer-based flexible transparent coatings to preserve the
waterproofing systems. It can be easily over restoration done. Ready to use colourless
coated with the required final finish. Figure hydrophobic impregnating coating with deep
shows external treatments, the same penetrating properties on silicone basis can
procedure can be applied to roof structures. be used.

Fig.11: Restoration Type - 1

Fig.12: Restoration Type - 2

 Fig.13: Restoration Type-3

Fig.14: Structural Injection

3.2 Structural Repairs iii). Verandah pillars and balustrades should be

either replaced or repaired with appropriate
i). The cracks in structural elements should be epoxy or polymer modified mortars
injected with two-component low viscosity
epoxies or the appropriate cement based iv). RCC slabs should be repaired using the
polymer-modified grout formulated for the appropriate Concrete Repair systems. On
purpose, depending upon the width of the the other hand they should be replaced if
crack. Figure 3.4 shows structural injections. found to be structurally inadequate.

ii). The bottom portion of the building should be v). Finally it should be remembered that these
grouted with polymer-based grout or the are mostly old heritage structures, we are
correct type of structural resin grouts, to dealing with and appropriate consideration
restore the structural integrity of the building. should be provided to the skill of applicators
 / workers and final aesthetics of the pertaining to 4M’s will certainly leads to good
structure. Figures 3.5 and 3.6 shows a result oriented work with economy and
heritage structure before and after the sustainability.
restoration process.
References
4.0 MANAGEMENT ASPECT FOR SPECIAL [1] Sunny Surlaker Repair Systems for Masonry
REPAIR WORK and Heritage Structures 2nd Edition of
International Construction Chemicals
In order to implement the knowledge to
Conference .Master Builder December 2013
harness the most of the investment requires
pages 172-178
sound management. Dealing with heritage
structure requires high accuracy with no space [2] Carlier, J. P., C. Kao, and I. Ginzburg” Field
for mistake in any way. Management in any Scale Modeling Of Subsurface Tile Drained
project concludes with the management of 4 M’s Soils Using An Equivalent-Medium
i.e. Man; Material; Money; and Machine. This Approach” Journal Of Hydrology, Volume
management comprises of following managerial 341, Issues 1-2, 20 July 2007, pages 105-
task. 115.
i. Preliminary investigation schedule [3] Waterproofing Sika Solutions For Below
Ground Structures
ii. Material required for the job
[4] ACI Committee 212, Guide for the Use of
iii. Quantity calculation for work High-Range Water Reducing Admixtures
(Super plasticizers) in Concrete, ACI
iv. Scheduling of repair and maintenances
212.4R-93 (Reapproved 1998), American
work
Concrete Institute, Farmington Hills,
v. Procurement of special material Michigan, 1998.

vi. Management of training to the site workers [5] Tagnit-Hamou, Arezki, and Aítcin, Pierre-
Claude, “Cement and Superplasticizer
vii. Arranging scaffolding and foam work Compatibility,” World Cement, Palladian
Publications Limited, Farnham, Surrey,
viii. Providing safety guide and equipments England, August 1993, pp 38-42
ix. Actual execution in stages [6] Sunny Surlaker MC-Bauchemie: A
Forerunner in Protecting Heritage and
x. Final finishing and cost accounting.
Masonry Structures CE&CR June 2014
pages 50-54
5.0 CONCLUSION
The primary cause of masonry or heritage [7] Nmai, Charles K.; Schlagbaum, Tony; and
structure needing repair is dampness and salt Violetta, Brad, “A History of Mid-Range
which find its way through the structural Water-Reducing Admixtures,” Concrete
elements itself .the causes need to be verified International, American Concrete Institute,
the strategy required for purpose can be Farmington Hills, Michigan, April 1998,
finalised. Here the old plastering should be pages 45 to 50.
removed and fresh plastering should be done in
order to avoid the bridge among the plasters. [8] Nmai, Charles K.; Tomita, Rokuro; Hondo,
These techniques are new and involve Fumiaki; and Buffenbarger, Julie,
appreciable amount of money generating the “Shrinkage-Reducing Admixtures,” Concrete
need of trained skilled labours and supervision International, American Concrete Institute,
by trained personnel. The demand of restoration Farmington Hills, Michigan, April 1998,
can be achieved very well enhancing the life and pages 31 to 37.
look of the structure provided all the work done
is as per standards. In such type of special [9] Chaitanya Raj Goyal Construction Materials:
repair work, good quality of special chemicals, Composites Get ‘Thumbs-Up’ From The
admixtures, grouts material should be used. Industry The Masterbuilder - May 2012
Systematic management of all activities pages 44-48

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