Waterproofing for Toilet & Kitchen Sunken Area
Waterproofing for Toilet & Kitchen Sunken Area
(Elastomeric acrylic reinforced
cementitious, composite coating system)
Table of Contents
2
Scope of Work
3
Reference Documents
4
Materials
5
Equipment’s
6
Personal Protective Equipment’s and Safety Equipment’s
7
Methodology
8
Quality Control and Assurance
9
Responsibilities
10
Check Sheet for sunken area waterproofing
1.0 INTRODUCTION
It is two-component polymer modified cementitious coating in pre-packaged
form. The product is designed to be easily mixed on site using a slow speed
drill fitted with a mixing paddle. and then applied to the substrate using a
trowel for best results. Coating shall be applied by brush, roller or trowel.
2.0
SCOPE OF WORK
The Scope of Work includes
1.
The method statement is applicable to the waterproofing work for toilet
and kitchen sunken area by using two coats of Elastomeric acrylic
reinforced cementitious Cementitious composite
coating system.
3.0
REFERENCE DOCUMENTS:
Ø Contract
specifications.
Ø Relevant GFC
drawings.
Ø Manufacturer’s
specifications.
Ø Indian Standard
Codes.
Ø CPWD specifications.
4.0
MATERIALS
4.01 Elastomeric Acrylic Cementitious Waterproofing (BASF Masterseal
551/ FOSROC Nitocote CM210/ SIKA SikaTop Seal 109 hi or approved equivalent)
EWP is ready to use two components coating based on cement with carefully graded aggregates in combination with selected admixtures and synthetic resins. EWP is highly recommended to waterproof concrete. For pot life of EWP refer manufacturer data sheet.
4.02 Cement
Cement to be used in
sunken area waterproofing works shall be Ordinary Portland cement (OPC-43
grade) conforming to IS: 269.
Contractor shall obtain test certificates on the physical and chemical
properties of cement from the manufacturer for each batch of cement received to
ensure conformity with relevant Indian Standard specifications and keep the
certificates on record with a copy to GPL. In addition, with a view to cross
check the manufacturers' test results, samples from first consignment of a
particular brand shall be tested from GPL approved and NABL-accredited material
testing laboratory. Periodic validation of the manufacturers' test results
shall be carried out by testing the physical and chemical properties of cement
in GPL approved and NABL-accredited lab at every six months per source.
4.03 Sand
Sand to be used in sunken area
waterproofing Works shall conform to IS:383 (Zone – II). The sand shall be
hard, durable, chemically inert and free from adherent coatings, organic matter
and harmful impurities. The sum of the percentages of all deleterious material
shall not exceed 5%. The maximum quantity of silt content in sand shall not
exceed 3% by weight.
4.04 Coarse
aggregate (4.75mm to 12.5mm)
Coarse aggregate to be used shall
conform to IS: 383 and IS 2386. The aggregate shall be hard, durable,
chemically inert and free from adherent coatings and harmful impurities.
4.05 Water
Water used for mixing of mortar
and curing shall be clean and free from injurious quantities of alkalis, acids,
oils, salts, sugar, organic materials, vegetable growth or other deleterious
substances. Potable water is generally considered satisfactory for mixing. The
Ph value of water shall not be less than 6. Water from each source shall be
tested before the commencement of work and thereafter as per frequency
specified in Inspection Test Plan or once in a six months for concrete works till the completion of the work. Water from approved
sources only shall be used. Water shall conforms to IS-456 for RCC works.
4.06 Cementitious Non shrink grout for injection grouting (BASF Masterflow
150/ FOSROC Cebex 100/ SIKA Intraplast EP or approved equivalent)
Cementitious non shrink grout is a plasticized and
non-shrink Injection / Pressure Grout specially formulated non-shrink polymeric
compound for injection cement grouting. It is for addition to neat cement-water
mix its strong plasticizing properties allowing the mix for substantial
reduction in water content without affecting the fluidity, thus improving the
strength and impermeability of the grout. During the setting period of the
grout it produces controlled expansion to compensate the normal plastic
shrinkage of cement. This ensures complete filling of voids and prevent
formation of porous sections add Cementitious Non shrink grout to cement dosage
as per manufacturer technical data sheet.
4.07 Epoxy Primer (BASF Masterseal P2525/ FOSROC
Nitoprime25/ SIKA Sikadur 32LP or approved
equivalent)
Epoxy primer is solvent free low viscosity two component
product based on epoxy base (resin) and reactor (hardener) to improve their
adhesion to existing concrete substrate. Epoxy primer is used to bond resin
coatings to concrete and other materials since it is non-tainting. Mixing
Ratio, as per manufacturer’s technical data sheet. Pack A & Pack B are
pre-measured quantity of Resin and Hardener and need only mixing at site.
4.08 SBR Latex (BASF Master Emaco SBR-2/ FOSROC Nitobond SBR Latex/
SIKA Latex or approved equivalent)
It is a
Styrene-Butadiene co-polymer latex liquid, produced from styrene and butadiene
by high pressure emulsion polymerization with high dispersive properties. When
used with cement, concrete and plaster, it reduces the mixing time through high
dispersion of the polymer and improves waterproofing, new to old
concrete/plaster bonding and strength characteristics and reduces shrinkage and
cracking of the mix.
4.09 Micro Concrete (BASF MasterEmaco S 346 / FOSROC Renderoc RG/ SIKA
SikaRep Microrete 4 or approved equivalent)
It is a shrinkage compensated,
flowable micro concrete for concrete repairs and filling area
around pipe penetration. Micro
concrete is a pourable mortar
is a dual shrinkage compensated, high flow, and high strength formulation for
structural concrete repairs.
It is suitable for placing in thicknesses/ gap of 25mm to 200 mm.
Micro-concrete is a ready to
use dry powder which requires only addition of clean water at site to produce a
free flowing non shrink repair micro concrete. It is composed of good quality
cement, properly selected aggregates & additives. It is used & designed
for repairing of damaged reinforced concrete elements like columns, beams &
structure where the areas are restricted or not easily accessible for proper placement
of concrete using vibrator. Micro Concrete has excellent flowability,
workability & proper particle size to reach small & congested
reinforcement.
For
repair of sections generally wider and deeper than 100mm it may be necessary to
mix the micro-concrete with properly graded 5mm to 12mm silt-free coarse
aggregate to minimize temperature rise. The quantity of aggregate required may
vary depending on the nature and configuration of the repair location
(generally it is 50% by weight of micro-concrete). Where the addition of graded
coarse aggregate is required it should be added after the water and
micro-concrete are properly mixed. Mixing should then continue for a further at
least 1 minute to ensure proper dispersion.
4.10 Non-shrink, shrinkage compensating cementitious
grout (BASF Masterflow 718/ FOSROC Conbextra GP2/ SIKA Sikagrout 214 or approved
equivalent)
An
expanding non-ferrous grout, consisting of a dry pre-mixed blend of special
grade cement, siliceous aggregate with set regulating and reactive chemical
compounds in powder form. Only water needs to be added. It contains no Calcium
Chloride.
Contractor shall obtain test
certificates from the manufacturer for each batch of material received to
ensure conformity with relevant Standard specifications and keep the
certificates on record.
4.11 Integral Water proofing compound (BASF MasterPel 777/ FOSROC
Conplast WL/ SIKA Plastocrete Plus or approved equivalent)
Integral Water
Proofing compound is Liquid Waterproofing and Plasticizing Admixture, integral
waterproofing compound to be used in cement slurry /mortar in proportion as per
manufacturer technical data sheet. Integral water proofing compound shall
conform to IS: 2645 and shall be tested before commencement of work and
thereafter as and when required by GPL project In-charge or once in a six
month. Dosage of Integral waterproofing compound 100ml per bag of cement or
shall be as per maximum quantity specified in their technical data sheet.
Contractor shall obtain test
certificates from the manufacturer for each batch of material received to
ensure conformity with relevant Standard specifications and keep the
certificates on record.
4.12 Epoxy Putty/ mortar (BASF Masterbrace ADH 2200 or Masterflow 410/
FOSROC Nitomortar S/ SIKA Sikaguard 694
F(I) or approved equivalent)
Epoxy Putty is solvent free,
fast curing three component system made of resin, hardener and special filler
(Graded Silica Sand). It is a non-shrink epoxy based repair material. Ensure
that concrete should be at least 28 days old. Mix Comp A, B & C in the
ratio as per manufacturer data sheet (depending on area of application % of
silica sand can be reduced after approval of GPL project Incharge). The system
is insensitive to the presence of moisture, thus allowing application on damp
concrete surfaces. The cured resin possesses high mechanical strength,
excellent adhesion, non-shrinking properties and a chemical resistance typical
of all epoxy resin.
5.0 EQUIPMENTS
i.
Electric Air Blower
ii.
Pressure Grout Pump
iii.
Electric Stirrer
iv.
Weigh balance
v.
Wire Brush
vi.
Measuring Jar
vii.
Paint Brush
viii.
As mentioned in the manufacturers specification
and procedure agreed with the specialized agency.
ix.
Other Small Tools as per Requirements for
convenience.
6.0 Personal
Protective Equipment and Safety Equipment
i.
Helmets
specified for designated personnel
ii.
Gloves
for manual work.
iii.
Safety
footwear
iv.
Use
goggles and nose mask during application.
v.
Safety
Barricades, Caution tape, etc.
vi.
Clean hands with warm water
after application.
vii.
Other Safety Arrangements –
As per Site Specific Safety Plan and MSDS of waterproofing chemical
manufacturer.
7.0 METHODOLOGY
7.1 Surface Preparation.
1. All the chasings or cuttings in the floor and
walls for sanitary, electrical and other services shall be carried out prior to the commencement of waterproofing treatment.
2. All surfaces must be cleaned with compressed
air and soft / wire brushes, free of loose materials, oils, form release agents
and other contaminants.
3. All surface imperfections, construction
joints, cracks, protrusions, structurally unsound and loose concrete must be
removed / repaired with SBR Latex modified cementitious mortar, comprising of SBR
Latex, Cement and river sand in the ratio of 1:5.15 PBW (proportion by weight)
and water content usually equal to SBR latex depending on required consistency
of mortar.
4.
Treatment to
Construction joint and Junctions/ cracks, chasing and opening the construction
joints to form a “U” shaped groove of approx.20mm width and 20 mm depth. Apply
cement slurry admixed with SBR latex as a primer coat prior to seal Joints/
cracks. Sealing the construction joints/ cracks by using SBR Latex modified
cementitious mortar, comprising of SBR Latex, Cement and river sand in the
ratio of 1:5.15 PBW (proportion by weight) and water content usually equal to
SBR latex depending on required consistency of mortar .
5.
Followed by
making 35mm x 35mm corner fillets at the junctions of floor and walls by using
polymer modified cementitious mortar, comprising of SBR Latex, Cement and river
sand in the ratio of 1:5.15 PBW (proportion by weight) and water content
usually equal to SBR latex depending on required consistency of mortar.
6.
Filling of Tie
rod holes: Completely remove PVC sleeves if any, increase the dia of hole by surface breaking 50mm x 50mm
followed by filling and compaction with SBR Latex, Cement and river sand in the
ratio of 1:5.15 PBW (proportion by weight) and water content usually equal to
SBR latex depending on required consistency of mortar.
7.
It is mandatory
that all works of plumbing and sanitation must be complete before taking up
application of any chemical coating. Treatment to pipe within the Waterproofing
area from internal side.
8.
PIPE PENETRATION TREATMENT: On PVC Pipe, apply a coat of epoxy primer coat on the specified
length on core/ bore hole this is to provide the mechanical key for better
adhesion, sand sprinkle over the pipe area whilst the primer coat is still
tacky. After the complete curing of primer application, fill the core area with
prepacked non-shrink cementitious , free flow, high strength grout material for
width upto 25mm or use microconcrete for width more than 25mm to seal the
annular gap around pipe periphery and core cut in the slab/ wall as follows;
Ø Pour
the prepared grout/ micro concrete in the core area upto the concrete surface and a 15mm x 15mm groove to be formed at
junction of pipe and micro concrete; Sealing junction of pipe and micro
concrete with epoxy mortar/ putty. MIXING RATIO for Component A, Component B
and Component C of epoxy putty are as per manufacturer’s technical data sheet.
For sections generally wider than 100 mm it may be necessary to mix the micro
concrete with properly graded 4.75 mm to 12.5 mm coarse aggregate to
minimize temperature rise. The quantity of aggregate required may vary
depending on the nature and configuration of the repair location generally
micro concrete:coarse aggregate in a proportion of 2:1 (refer manufacturer
technical data sheet for exact proportions and required flow) .
9. Brick/
Block masonry wall surface shall be prepared by joint filling, racking of
joints and plastering with 6mm thick plaster admixed with integral water
proofing compound in a proportion of 1:4 (one part cement & four part
coarse sand) application up to height of 300mm above finished floor level.
10. Pre-Pond
Test: Treatment area unit will be subjected to water ponding test for the floor
for 24hrs. The entire floor should be flooded to 100mm of water / atleast 50mm
above the top of corner fillet (junction of Horizontal & vertical surface).
11. PMC/
GPL team will verify whether there are any leakages at the immediate unit below
the ponded unit. Leakage observation if any from Outside/ Bottom Surface of
structure shall be checked and marked. Leakages/Seepages found from
construction joints, junctions and core cut locations which are in waterproofing
contractors scope shall be treated by contractor. In case of leakages/seepages
from cracks or other defects in the structure are found, such points shall be
highlighted to main civil contractor for treatment as part of main civil
contractor scope of work. The leakage arresting process as below.
7 2 Application of Elastomeric
cementitious composite coating
7.2.1 All concrete surfaces shall be thoroughly pre-wetted for at least one hour prior to the application of cementitious elastomeric coating by pouring water on flat surface or by vigorously spraying water on vertical surfaces. When placing cementitious elastomeric coating, water should be removed so that surface is only damp. In no case there should be standing water or a shiny wet surface.
7.2.2 cementitious elastomeric Acrylic shall be mixed in a clean container as it is supplied in pre-measured units and should be mixed on site utilizing clean containers. Slowly add the powder to the liquid and mix, using a slow speed drill fitted with a suitable paddle. Mix until a homogeneous lump free consistency is obtained. Leave the mixed material to stand for 5 minutes to allow for full saturation to take place. Remix to restore the consistency. Do not mix more material than can be used in half an hour. DO NOT RE-TEMPER WITH WATER.
7.2.3 Always apply cementitious elastomeric Acrylic slurry
coating to pre-dampened surface Application of first coat of cementitious
elastomeric Acrylic slurry coating on the sunken floor over rendered surface;
turned up and finished upto 300mm above finished floor level.
Ø First Coat: Brush the mix firmly onto the pre dampened, prepared
surface. Care must be taken not to spread the material too thinly. When the
material begins to drag or “ball”, do not add more liquid/water but dampen the
surface again.
Ø Second Coat: Allow at least overnight to cure before applying
subsequent coats. Dampen the first coat and remove excess moisture. Brush or
broom the mix onto the surface (as above) finishing in the opposite direction
to the first coat.
7.2.4 After complete curing for 3 days, the sunken
area shall be filled with water, for 3 days to test water tightness.
Post-Pond Test: Water ponding area shall be cleaned properly closing
of outlet points. Water filling up to 50mm above top of corner fillet for
72hrs. Leakage observation if any from outside/bottom Surface of structure
shall be checked and marked. Dewatering of water from structure. All such
leaking points shall be grouted with Vinyl Ester Methacrylate resin of BASF
Masterseal 901 or approved equivalent. Post repairing retesting to be re done
for seepages and leakages.
7.2.5 Protect coating by application of 12mm thick
protective plaster in a proportion of 1:4 (1 part cement : 4 part coarse sand)
by mixing an integral waterproofing compound to mortar in proportion as per
manufacturer specification over horizontal surface and vertical surface.
In-case vertical surface is masonry (Bricks / AAC blocks) protect PMC slurry
coating by application of 6mm thick protective plaster in a proportion specified
above. Plastered surface shall be cured for minimum seven days.
7.2.6 Test MEP pipes for leakages after success of
leakage test haunching to be done by MEP contractor over the laid pipes with
Concrete mix and thickness as specified in BOQ of MEP contractor.
8.0 QUALITY
CONTROL & ASSURANCE
Ø In addition to providing step-by-step
procedures for Contractors, this Method statement is also meant to provide
Quality Control and Quality Assurance with the knowledge needed to ensure that
appropriate procedure is implemented.
Ø Proper attention to implementation of each
step in the water proofing process is critical to successful application. The
first step is ensuring that the contractor is using approved materials. Correct
proportioning and mixing is also critical. A common mistake is for Contractors
to “eyeball” or guess at proper proportions when using multi-part mixes. GPL/
PMC Project Engineer should verify that contractors are measuring, all individual
components prior to mixing, either by volume or weight.
Ø All the material used for water proofing shall
be checked prior to the commencement of work.
Ø Net consumption of material in entire coats
should be checked as per manufacturer recommendations and recorded in the form
of register.
Ø cementitious elastomeric Acrylic slurry
coating to be applied within its Pot life generally 30 minutes at 30 degree Celsius,
refer manufacture data sheet for exact value.
Ø Inspection
to done before each stage and documented in the form of register.
Ø Checklist
report shall be maintained as record.
Ø Record
for receipt and consumption of cement and water proofing material shall be
maintained at site.
Ø After
complete curing, the sunken area shall be filled with water, for 3 days to test
water tightness. Fill water
minimum 50mm above top of corner fillet.
Ø All
coats should be applied at right angle to the previous one this way second coat
will cover any blemishes (if any) of the previous coat.
9.0 RESPONSIBILITIES
PROJECT
INCHARGE – Shall Report to Operations Head; shall be Responsible
for Control, Supervision & Direction for Implementation of this Procedure.
PROJECT ENGINEER –
Shall report to Site In-Charge; shall carryout the work as per the approved
drawings & specifications and make sure that all the required tests &
checks are done.
QUALITY ENGINEER
–Shall Report to Quality In-charge; Quality Engineer shall Assist in Carrying
out Field / Lab Test; shall conduct Audit / Observation of the work done and
Inform Site In-charge / Site Engineer about the Non-Compliances when found in
the Work Done.
9.1 Responsibility for Material Quality &
Workmanship
Contractors Quality Engineer along with their Project
In-charge with the use of Site / External approved material testing laboratory
is responsible for ensuring the quality of material supplied /delivered at site.
Ø It is the Contractor’s responsibility to use materials
specified in this method statement and contract document.
Ø Store materials on job site according to
material manufacturer’s requirements, preventing direct exposure to sunlight
and moisture.
Ø Materials exceeding their shelf lives shall
not be used.
Ø Check materials to ensure that they are
appropriate for the given application. Material should either be on preapproved
lists or approved by the GPL prior to use.
Ø Ensure that the Contractor is following the
procedures outlined in this method statement.
Ø Verify that all damaged material has been
removed and that the remaining surface is clean and sound prior to the
Contractor proceeding with water proofing activity.
Ø Confirm that material performance is
acceptable through testing. Sample should not exhibit leakages when tested as
specified in this method statement.
Ø Material to be applied within its Pot life,
refer manufacture data sheet for exact value. Inspection to be done before each
stage and documented in the form of register. Checklist report shall be maintained
as record. Record for receipt and consumption of material for water proofing
shall be maintained at site.
9.2 Sampling & Tests
·
The
tests shall be done In accordance with referenced codes and CPWD
Specifications.
·
Regular
Site checks for each area of application.
·
Material
testing as and when desired by GPL Project In-charge.
·
Manufacturer
test certificate is required with each lot of material supplied at site.
9.3 Storage of Material
All material shall be stored as per IS: 4082 (Indian
standard code of practice for stacking and storing of construction material at
site) and as per manufacturers recommendations / specifications so as to
prevent deterioration. If these precautions are neglected material will be
rendered less effective or useless.
RESPONSIBILITY
TABLE
|
Sl.
No. |
Procedure |
Responsibility |
Check
By |
Records |
|
1 |
Material
received at site is inspected |
Site Engineer |
QC Engineer |
Material Inspection
Report (MIR) & Checklist |
|
2 |
Clearance
from Services |
Site Engineer |
Site Engineer |
Checklist |
|
3 |
Injection
Grout Process |
Site Engineer |
QC Engineer |
Checklist |
|
4 |
Surface
Preparation |
Site Engineer |
QC Engineer |
Checklist |
|
5 |
Application
of cementitious elastomeric Acrylic slurry coating Slurry coat |
Site Engineer |
QC Engineer |
Checklist |
|
7 |
Sealing
of pipes junction with Epoxy putty/ mortar and non shrink shrinkage
compensating cemintitious grout or micro
concrete. |
Site Engineer |
QC Engineer |
Checklist |
|
8 |
Application
of Protection plaster |
Site Engineer |
QC Engineer |
Checklist |
|
9 |
Curing
done after Plastering |
Site Engineer |
QC Engineer |
Checklist |
|
10 |
Water
tightness test |
Site Engineer |
QC Engineer |
Checklist |
|
CHECK
LIST FOR SUNKEN AREA (TOILET / KITCHEN) WATERPROOFING |
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DATE : |
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STRUCTURE : |
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FLOOR LEVEL : |
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LOCATION : |
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REFERENCE DRAWING NO. : |
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Sl. No. |
Description |
REQUIRED |
ACTUAL |
Remarks |
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PRE CHECK |
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1 |
All Inspected &
Approved Brand of Material Received. |
Yes / No |
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2 |
Clearance from
Services (electrical conduits/ MEP pipes or other embedment’s). |
Yes / No |
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3 |
Surface thoroughly
cleaned of all dust, mortar dropping and other foreign materials. |
Yes / No |
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4 |
Preparation of construction
joints, tie rod hole filling, corner fillet and bore packing with micro
concrete done. |
Yes / No |
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5 |
Joints of pipes with concrete should be sealed with epoxy
putty/ mortar.
|
Yes / No |
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6 |
Joint Filling &
Racking upto 300mm above FFL on Brick/Block masonry Wall is done with 6mm
thick plaster 1:4 (one part cement & four part coarse sand) |
Yes / No |
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7 |
Seepage / leakage test. Area to be
flooded with water for 12 hours duration and at least 50mm above corner
fillet. |
Yes / No |
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8 |
Base
Surface shall be wet for at least 01 Hr. |
Yes / No |
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Signature
of Contractor |
Signature
of Client |
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PROCESS CHECK |
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9 |
First coat of Elastomeric cementitious slurry application. |
Yes / No |
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10 |
Second coat of Elastomeric cementitious slurry
application.
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Yes / No |
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11 |
Seepage / leakage test Area to be flooded with water for
72 hours duration and at least 50mm above top of corner fillet. |
Yes / No |
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12 |
Application of 12mm thick protective plaster 1:4 (1 cement
: 4 coarse sand) by mixing an integral waterproofing compound. |
Yes / No |
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Signature
of Contractor |
Signature
of GPL/ PMC |
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POST CHECK |
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14 |
Curing of protection
plaster. |
Yes / No |
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15 |
Haunching of soil and waste water surface drain pipes as
per good for construction drawing. |
Yes / No |
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Signature
of Contractor |
Signature
of Client |
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