J.J.Shah Paper

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Durability of INFRASTRUCTURE PROJECTS

By

Jayakumar J. Shah
Expert : Durability, Repairs, Rehabilitation & waterproofing

ABOUT AUTHOR :
Mr. Shah was born on 18th April 1934 in a village Umadi in Maharashtra. He did his
matriculation in 1950, from Maharashtra High School, Jabalpur, inter-science in 1952,
from Ruia College Mumbai. He was awarded Gibbs prize, as he ranked first in physics
in inter-science in then Bombay University. In 1957 he received bachelor of
engineering degree in Civil Engineering from then Bombay University from then
Victoria Jubilee Technical Institute, Mumbai.
Since May 1957 to September 1990 he worked with Hindustan Construction
Company, Mumbai both in India and abroad in various fields but mainly on projects.
Later two years he was United Nations Specialist to government of Jamaica (West
Indies). After he returned from Jamaica in December 1992 he has totally devoted
himself to Repairs, Rehabilitation and Waterproofing of Existing RCC buildings and
Durability of new constructions. Second edition of his book A Handy Guide to
Repairs, Rehabilitation and Waterproofing to RCC buildings (structures) is SOLD
OUT. Third updated photo copy set with 70% updated material over the text of second
edition is made available because of heavy demand. Mr. Shah is planning to add Rate
Analysis to this set shortly. His second book A Handy Guide for Builders,
Users/Owners, Civil Engineers and Architects for constructing RCC buildings
(structures) Durable and Eco-friendly on Durability is available. He has conducted
many in-house training programmes and workshops in the subjects of his expertise,
single faculty, for full day and are continuing with great demand.

Book written by
Mr. Jayakumar J. Shah

His Biography is included in :

Various Directories of Marquis Whos Who USA

Science and Engineering in 7th, 8th, and now in 9th (2006) edition

The World in 24th edition (2007) and

The Asia in First premier edition (2007)

1. INTRODUCTION :
Preamble of Seminar leaf-let says Rapid development of proper infrastructure and assessment of existing
infrastructure are important aspects of the developmental programmes of our country. Infrastructure as a Fast
Track Development is need of the hour. The aim of this national seminar is to focus attention and deliberate on
various issues that confront engineers to tackle in a fast mode, create a forum for intense discussion on various
methodologies to purse in their implementation.
This paper focuses attention on DURABILITY of infrastructure projects.
DURABLITY is the need of the hour.
We can not continue to build structures which require Repairs, Rehabilitation and Waterproofing immediately
after construction and during the life time of the structure except for regular maintenance.

2. DURABILITY OF CONCRETE & DURABILITY OF A STRUCTURE :


What is Durability of a structure?
Durability can be defined as ability of a structure to withstand the deterioration, which is caused under the
influence of environment throughout its desired life, without the need for undue maintenance. Anon
What is Durability of a structure?
According to Mr. Peter Wright, it is resistance to physical and chemical deterioration of concrete, resulting
from:
i. interaction with environment
ii. interaction between constituents of which it is made and protection of embedded steel from corrosion
processes

Times of India published my point of view of a durable building in their supplement Times Property dated 17th
September05 as follows:
Shah defines a durable building as one in which there is no leakage, seepage and dampness anywhere.
Every unit of the building, he adds-and particularly the service pipe ducts-should be easily accessible for regular
inspection and maintenance service pipes throughout the life of the building.
If builders take pride saying that there is no leakage, seepage and dampness in their properties, they can easily
sell flats at higher rates and build up their image permanently, he adds.

3. APPOINT DURABILITY CONSULTANT FOR EVERY NEW CONSTRUCTION :


This is my totally original/new concept. I have been propagating this concept whenever an opportunity came my
way e.g. at seminars/workshops/training programmes to consultants/research institutions to work in this field
and diversify. So far to my knowledge there are no takers for this new concept. However I am working in this
field. There are many agencies on a job.
Main agencies are Architect, Design Engineer and Contractor. Owner is ignorant of the technical aspects of the
job. He needs somebody to co-ordinate with Architect, Design Engineer and Contractor to have a Durable
structure.
Durability consultant is the right agency for this job.
Durability consultant is a new concept as mentioned above and it may take some time before the importance of
such a vital functionary is understood. I had the opportunity to work as Durability consultant for Gitanjali
building standing close to the seashore at Rungta Lane, Nepean Sea Road, in a prestigious locality in South
Mumbai.
I thank the owners of Gitanjali who appreciated this concept and appointed an agency to work as Durability
consultant represented by me with the result that this totally new concept is put to practice and the building
stands a mute witness to such function
Financial institutions should advance a project only after assuring themselves that Durability Parameters are
included into the project.
Now from decades codes are available for design of buildings to cater to forces generated by earthquake. BIS
code is mandatory. Even then Government of Maharashtra thought to bring in a legislation that every building
should be designed for earthquake forces.
It is high time something is done to in- built durability into every
Should there be a separate institution to monitor Durability Parameters for every Project?

new

construction.

Should
there
be
a
legislation
to
specify durability
parameters
in
every
project?
In any case something has to be done urgently on war footing, as we cannot afford sub-standard constructions
requiring heavy funds for repairs during the lifetime of the buildings
Incorporate Durabilty Parameters In the Tender Itself
This is necessary for proper incorporation without any resistance/ objection and for proper implementation.
Design a structure with Life Cycle Cost consideration
This is necessary to avoid the astronomically high cost of RESTORATION later.
Life of all Material incorporated in the structure Must have life to match the life for which the structure
is designed.

4. TIPS ON MAKING DURABLE CONCRETE :


A. Concrete Materials
(a) Cement :

Use blended cement ONLY.

Remember 43-grade ordinary port land cement is also high grade cement.

Use as less OPC and as much more FLY ASH

(b) Aggregates :

Good rounded gravel/pebbles should be the first choice, as advised by Shri S.A.Reddi,

Use aggregates of size 20mm and down from durability considerations as advised by Shri
Dr.C.S.Viswahatha.

Round Aggregates

Crushed Sand

(c) Sand :

We may have to use manufactured sand by certain percentage in Natural sand to improve the
grading of sand.

In certain cases it may be necessary to use 100%manufactured sand.

B. Proportioning of mix

Concrete batching using ghamelas.

Concrete batching using measuring boxes.

No more 1:3:6, 1:2:4 concretes

Mix proportioning must be done in the laboratory for all concrete.

C. Water to Binder ratio

Concrete with water to binder ratio of 0.4 or less is a good


cohesive and dense concrete.

I feel all concretes should be of 0.35 water to binder ratio,


irrespective whether it is for any structural member of nonstructural member.

This makes it necessary- use of admixture in the concrete

Consider admixture as fifth important ingredient of concrete and


fourth important ingredient of mortar for plaster.

Water Meter to control water


to binder ratio.

D. Cover, Cover blocks, Reinforcement


(a) Cover
Provide sufficient cover to reinforcement
(b) Cover Blocks

Use preferably concrete cover blocks only.

Close up view of a
Cover Block.
Blockghamelas.
(c) Reinforcement

Cover Block specially designed


for sewerage project.

Proper use of cover blocks for


RCC slab.

Once we decide to have Water to Binder ratio of concrete 0.4 or less (preferably 0.35) regular
reinforcement bars without any treatment are o.k.

E. Form Oil

Do not use waste oil.

Use Mould Release Agent only available with good construction chemical companies.

Holes made on wall to support single


scaffolding.

Improper
finished holes made for supporting
scaffolding
are the entry point for water.

F. Scaffold

This has to be double legged- study, safe and self supporting.

Do not support this on Masonry by making holes in it.

Do not fix scaffold to service pipes or to safety grills.

G. Construction Joints

Prepare them properly.

Remove laitance and mortar stuck to exposed reinforcement by


water jet immediately after 2 hours of completion of concrete.

Double scaffolding.

H. Starter Lift

I.

Do away with starter lift.

This is generally rubbish unvibrated mortar.

This is provided to ensure bottom of shuttering plates do not move in.

However, this can be prevented by proper supports. Hence, do regular concrete lift without providing
any starter lift.

Chaijas, Top Balcony slabs

J.

Provide sloping slabs taken out from top of lintel beams.

Top Slab of Stair-Well

Top slab of Lift Room

Entrance Canopy

Avoid RCC slab.

Provide light weight pipe structure with roofing material of ones choice with good slope.

If in RCC, it should be doubly curved structure.

Entrance Canopy made using steel


structure.

Doubly curved stairwell slab.

K. Plumbing

This should be planned and executed properly to ensure no leakage / dampness.


Experienced Sanitary Engineer is Must.
This is an item which need utmost attention to prevent leakage / dampness in the building next to
waterproofing of terraces, over head and underground water tanks, sunken slabs, flower vases, etc.,

5. CURING :
This is the MOST IMPORTANT activity in
construction. Today rights from a labour to
Managing Director of an orgnisation talk about
CURING. Everybody knows the importance of
CURING, But nobody does CURING as is
required. This is not only limited to India but
CURING is not done as is required all over the
world.
According to Sir Adam Neville :
Wet curing is specified in majority of construction
projects but it is rarely achieved. Like batching and
mixing, curing requires close supervision, but in
my experience, not only in the United Kingdom,
but also in the desert countries, curing is left to the
man with the water hose or to no one at all.

Spraying curing compound on concrete pavement of


Mumbai Pune Expressway.

Use of plastic sheet over concrete surface is the best way to


avoid cracks which appear due to lack of early curing.
Curing is not an item in the bill of quantities and is not paid for
separately. In my view, curing should be detached from the
general items of concrete placing, and paid for by the
consumption of water or by man-hours, or in some other way.
I feel that even if curing is provided as a separate item of work
in the bill of quantities and paid separately, it will not be carried
out as specified and as required, unless where it is mechanised.
Again, curing at night is something new to building industry.

Use of hessian clothes for curing


foundation

Hence curing by the curing compound is the only solution when curing as specified and as required is not
possible. I feel that a day will come when all Durability parameters will be implemented excepting curing.
Hence, curing should be on the top of the agenda of Durability.
This has to start as early as possible. Hence, the first step is to curtail the finishing time. Start curing
immediately (say after 30 minutes or so- time is the function of temperature and humidity) after finishing is
complete and as soon as the bleed water evaporates, initially by sprinkling water and later by usual methods: by
hoses, by covering with wet hessian, by covering with plastic sheets, etc. throughout 24 hours, continuously for
minimum 14 days.
No doubt water curing is the best. But as water curing can not be done as is required unless it is mechanised as
mentioned above, hence curing by curing compound along with water curing is MUST.
This is emphasised as otherwise we will have drying shrinkage cracks in plaster and cracks in concrete. In such
circumstances we tend to blame the cement (specially blended cement if used) or the construction chemicals.
This is not the right attitude. Both are factory manufactured products and there should be NO PROBLEM with
them.

6. SHAH PLASTER :
Mix Proportions &specifications of SHAH PLASTER to the external face of masonary wall.
I started working on external plaster from 1999, initially all experiments/trials were done arbitrarily on my on
going repair jobs. Since September 2004 trials were taken in laboratory which helped me to perfect external
plaster by March05.
This is not a factory manufactured patented product. Mix has OPC cement, fly ash, acrylic polymer, naphtha
based super plasticiser, air-entraining agent, polypropylene fibers and of course water. Hence there is further
scope to improve on this by trials.
Indian concrete journal published my points of view on external plaster first in their June1999 issue and
second in their June2001 issue.

Following paras detail changes made in SHAH PLASTER as compared to conventional plaster,
i. Impermeable and crackles plaster
Generally mix proportion for external plaster is 1:4. Even leaner mixes are used.
Good masons inform that mixes leaner than 1:4 are not workable.
There are sites which claim that they use 1:6 mix. There are few who claim to use 1:8. These mixes are
not impermeable and develop drying shrinkage cracks,
Target before me was to have impermeable and crackless plaster. As the time passed one day an idea
struck me as to why both coats of plaster should be impermeable. This idea came to me from
cementitious acrylic polymer based flexible membrane waterproofing system which is a sandwich
system- sandwiched between RCC member and the protective coat. Hence now in SHAH PLASTER
first coat only is planned impermeable and second coat is planned crackless. We will discuss mix
proportions and dosages of various admixtures in a separate para later.
ii. Number of coats
Conventionally plaster is two coat plaster.
Initially it was thought- why to have two coats, why not provide single coat plaster?
Even Dr. B.S.Gupta, Deputy Director and Head-Structures, Central Building Research Institute,
Roorke (U.P) advocated single coat plaster.
But as building lack in perfect line and level this is not practical. Hence I decided to retain two coat
plaster system as is conventionally done.
iii. Interval Between First Coat and Second Coat
Conventionally this is specified as seven days. In todays fast moving world this is not acceptable. How
can we block the scaffolding for seven days and cure the same face twice once for first coat and later
for second coat.
SHAH PLASTER has Base Coat, First Coat and Second Coat. First coat is done on second day of Base
Coat and Second Coat is done on third day of Base Coat.
iv. Mix proportions of SHAH PLASTER for different coats
This mix proportions as specified now after laboratory studies is discussed below. In all the three coats
ordinary Portland cement is replaced by 45% fly ash.

Base Coat
This is 1:1 mix, 3mm to 5mm thick trowel spread with one liter of acrylic polymer per 50kg
binder. This helps in sealing all the crevices and joints of masonry wall and gives a good grip
(bond-mechanical key) to the first coat of plaster.

First Coat
This is 1:2 mix, 10mm thick.
This has 400ml to 2.5 liters of acrylic polymer-depending upon the impermeability required
and 300ml of naphtha based super plasticiser per 50 kg. binder. Polypropylene fibers at
125gms per 50kg binder is optional for this coat.

Second Coat
This is 1:3 mix, 10mm thick.
This has 300ml of naphtha based super plasticizer and 200ml of air entraining agent with 125
gms of polypropylene fibers per 50kg binder.

Earlier to laboratory studies I was specifying air entraining agent in first coat also and acrylic polymer
in second coat also. During laboratory trials it was observed that when acrylic polymer and air
entraining agent are used together in a mix then the efficiency of air entraining agent gets nullified in
presence of acrylic polymer due to consolidation effect of polymer. Thus, the first coat now has only
acrylic polymer and naphtha based super plasticizer and second coat now has only naphtha based super
plasticizer and air entraining agent.

v. Acceptance
Any new concept / idea takes time before this is accepted by any authority / institution. The concept of
Durability consultant for a new construction would have remained on paper, if this was not used by
GITANJALI building.
I am using SHAH PLASTER on my repair jobs. However, this is now specified by CIDCO for their
prestigious buildings Sea-Wood Phase-II for NRIs. It was a long way before SHAH PLASTER was
adopted by CIDCO. I had several meetings with many CIDCO officers connected with sea-wood
project.
Later, I was asked by CIDCO to present the SHAH PLASTER to many experts which included Mr.
N. N. shrikhande, Mr. R.N. Raikar, Mr. Cyrus Dordi, Mr. Shirish Patel, Mr. Hafez Contractor, Mr. B.S.
Gupta, Deputy Director from Roorkee and many CIDCO officers from various departments.
Mr. C.M. Dordi strongly supported this new concept and explained to all present as follows:
What Mr. Shah has done is to produce Masonry cement (There is a IS code for this cement, 28 days
strength specified for Masonry cement is 50kg/cm2 only) which we cement manufacturers do not
produce fearing- this may be used on a main job which may have MISHAP- which is actually the right
cement for plaster. This IS-code specifies certain percentage of air entraining agent also- which Mr.
Shah has specified. This resulted in everybody giving their acceptance to this new concept of external
plaster.
vi. Points of Interest
Last year I was co-opted by a committee (headed by Chairperson Mr. N.V. Merani) investigating substandard buildings of CIDCO. Committee interviewed many experts to find the solution
(leakage/dampness through plaster and masonry wall) to the problem. Mr. Surendra Hiranandani
Managing Director Hiranandani Constructions informed that they provide double wall on south and
west side to their towers to avoid leakage problem. I feel this is not necessary. SHAH PLASTER to
single wall is good enough. Of course, one can provide higher dosage of acrylic polymer in first coat in
prestigious buildings.
vii. CURING
After taking all the precautions as discussed in paras above, we have to take utmost care of curing.
Second coat of plaster must be cured by curing compound and later by water as additional precaution
(as suggested by an American expert in one of the ACI seminars) for crackless plaster.

7. NO HACKING ADVISED TO FRESHLY PLACED CONCRETE :


Hacking is done to freshly placed concrete RCC member now from decades. This is done to provide bond to the
plaster. I feel that the present thinking that HACKING provides bond to the plaster is purely psychological.
Hacking induces micro cracks. These micro cracks help in deterioration of the RCC member from the moment
hacking is done. I do not advise HACKING. At GITANJALI building (where I worked as durability
consultant) no Hacking is done to any RCC member, and there was NO PROBLEM. On one of the repair job,
no hacking was done to freshly placed concrete RCC columns and plaster provided de-bonded. The immediate
reaction of the contractor was that the plaster debonded as no hacking was done. Any new suggestion receives a
lot of resistance initially. Insistence and proper guidance and necessary precautions are needed to make new
suggestion acceptable. Once we accept HACKING is harmful and that it should not be specified then we can
find ways to ensure that the plaster provided to a RCC member without hacking does not de-bond.

8. THE WATERPROOFING SYSTEM :


i. Conventional waterproofing systems are:
a.

Bituminous system:
This has organic material in the system, which decays with age and exposure to sunlight.
Thus, the system becomes ineffective. This has a short life span.

b.

Brickbat coba with or without China mosaic chips:


It is projected that China mosaic topping helps in waterproofing. In fact, they do more harm
than good so far as waterproofing is concerned. Due to temperature

difference between the day and the night, the numerous joints of china mosaic open out and
water leaks into the brickbat, which is porous material. Subsequently, water leaks in the RCC
frame members and the walls, deteriorating them.
Brick is a highly porous material. Brickbat coba is used to provide slope to the top horizontal
surface of a terrace slab. Thus, the entire waterproofing depends upon :

the cement slurry spread over the terrace top or

application of sodium silicate mixed with cement over the terrace top or

application of jaggery mixed with cement over the terrace top

It is informed that the brickbat coba waterproofing system originated long back on the belief
that it absorbs water and later the water evaporates from it and thus there would be no leakage.
In fact, brickbat coba works as a reservoir of water in places where there is heavy rain, and
throws water in top storey flats during monsoon and even after that.

In buildings built in the last two decades or so, even the quality of brickbat is very poor. In
many cases it was found that the brickbat coba had virtually turned into powder, when this
was taken up for replacement. In some cases, debris is used in place of brickbat and here, the
system has not worked even for one rainy season. Even otherwise, when the quality of
material used and the work done is excellent and is carried out under proper supervision,
normally it is seen that life of this system is maximum 10 years. However, this system helps to
insulate the terrace slab from heat.
c.

Farshi type box-waterproofing:


This has joints and is not monolithic with the main structure.
In all the above conventional waterproofing system, it is observed that

They have a short span of life.

They all have some inherent problem.

They all are time consuming and extend the project time.

ii. Waterproofing system advised:


Cementitious acrylic polymer-based flexible membrane waterproofing system:

Mixing of Flexible Membrane material.

Application of Flexible Membrane.

This is the best system available as on date. It becomes one with the structure and is monolithic without
any joints. It has generally the same properties (except that the flexible membrane has hairline crack
bridging ability) as that of concrete, on which it is applied.
Moreover, it is claimed that this system has chloride and sulphate ion resistance, good carbon-di-oxide
diffusion resistance coupled with its waterproofing quantities and it acts as a protective coating against
concrete and re-bar deterioration.

This (flexible membrane) system alone,


once understood and mastered takes care
of all areas of waterproofing in a
building. For example, basements,
service ducts, lift room top slabs, sunken
slabs, water tanks, swimming pools,
terraces, chaijas, toilet blocks, entrance
canopies, stair top slabs, damp-proof
course, flower vases, etc.
The application of flexible membrane
waterproofing system has to be done by
an experienced and trained applicator
and supervised properly, as is necessary
for any construction activity. This
reduces inventory, as only one product is Waterproofing of foundation with Flexible Membrane.
to be arranged for the entire building.
Further, it is a repeat job for the entire building and the same small group of trained workers can
continue with the operation.
iii. Stamp paper guarantee for waterproofing:
It is observed that invariably this work is sub-let by the main contractor to other contractor (supposedly
an expert in waterproofing), who gives a 10 years guarantee on stamp paper and quotes the lowest.
This has not always been a good experience. Leakages/dampness are experienced even in the first year.
As mentioned above, it is absolutely necessary for the main contractor to understand the method and
the materials used. Further, with the system advised-Acrylic Polymer-based cementitious flexible
membrane waterproofing system-which takes care of all areas of waterproofing in a building, the main
contractor should attend to this himself with confidence, as he has all the expertise and experienced
staff available with him. This could work out chapter to the main contractor than what the subcontractor quotes for, with 10 years guarantee.

9. CONCLUSION :
Appoint Durability consultant right at the Concept stage.
Ensure that all Durability Parameters including curing as a separate item is included in TENDER itself, so that
there is no problem in getting them properly implemented. In short, construct any new structure with Life Cycle
Cost consideration with Sustainable Development in mind and with Holistic Approach.

JAYAKUMAR J. SHAH
203 / Wing- B / Lakshmi Apartments, Corporation Building
Behind Anand Nagar, Dahisar (East), MUMBAI 400 068.
Tel. No.:- 2848 3541 ; Mobile No:- 9819242649
Email ID : - jjshah123123@rediffmail.com

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