By Sunny Surlaker, Managing Director, MC-Bauchemie (India) Pvt. Ltd
Mr. Sunny Surlaker joined MC-Bauchemie, Germany in 2009 after his experience in the USA as a materials engineer. Subsequent to extensive training in Europe and Brazil, relating to various aspects of Concrete Technology, R&D, Marketing and Sales management, he has taken over the Concrete additives and cementitious materials division in MC-Bauchemie India as its Head. His pursuits include Concrete Technology, Marketing, driving local R&D and overseeing the sales and technical support structure for MC-Bauchemie. With a Bachelor’s Degree in Civil Engineering from VJTI, Mumbai, a Master’s Degree from University of Michigan, Ann Arbor, USA and his experience, he brings a fresh international perspective to the 25-year-old Construction Chemicals Manufacturer, MC-Bauchemie India. In an interaction with CE&CR, Mr. Sunny Surlaker talks about MC Bachemie in general and its expertise in Rehabilitation and Repair Techniques. At the end of it, he proves the expertise of his company through some complex cases of Heritage and masonry structures.
On Company and Product Range
MC-Bauchemie (India) Private Limited is a leading name in Construction Chemicals for over Twenty-five years in India. We manufacture over 200 construction chemicals in technical and frinancial Collaboration with MC-Bauchemie, Germany, a 50-year-old international organization. MC-Bauchemie India, an ISO 9001: 2008 certified Company, has a pan India presence through technically trained and qualified channel partners and IRP (Germany) trained applicators. Top-level technical advisors, support our distribution network. Our strength lies in Quality and Reliability. We provide free technical services to solve construction problems, alongwith detailed technical specifications and proposals. On-site, on-time delivery is our motto.
Our success is based on innovation, competence and service. These are the foundations for MC’s Quality and international market reputation. New ideas, products and technologies emphasized and developed by MC have set the standards in many key areas. MC-Bauchemie, invests 10% of manpower and resources in R&D, which is available to us, by virtue of being collaborated.
Our range of products consists of full spectrum of admixtures including PCEs for HPC & SCC, full systems for Waterproofing, Injections, Repairs, Rehabilitation, Protection and Industrial flooring. We also Specialize in low-pore-volume coatings for drinking and wastewater industry, and systems for renovation of heritage monuments, called Oxal. Our product systems are ReACh certified, solvent free and green. Our high-tech products are applied by trained specialized contractors under proper supervision of qualified Civil Engineers. To maintain high technical standards, we are one of the few companies to have a dedicated training Centre and Concrete Technology Lab in Goa for our clients. International Quality, Technical Backup and Reliability make us a successful and leading Construction Chemicals Manufacturer.
On MC-Bauchemie’s Expertise in Rehabilitation and Repair
MC-Bauchemie (India) Private Ltd. manufactures full range of construction chemicals in technical & financial collaboration with MC-Bauchemie Germany. As mentioned earlier, we are an ISO 9001:2008 certified company. Our range includes full spectrum of admixtures including PCE’S for HPC & SCC. Our strength is in providing the clients with full systems like waterproofing, Injections, Repairs & Rehabilitation systems. The clients and consultants can choose from full range of systems, which have compatible products and avoid issues of combining several products from different manufactures, wherein it is impossible for end user to decide cause of failures.
Over the years, our expertise and experience has been brought into practice to rehabilitate and safeguard different structures such as hotels, residential and commercial constructions, educational institutes, hospitals, heritage structures such as Humayun’s Tomb in Delhi, swimming pools, infrastructure like metros, bridges, tunnels, jetties, piers, ports, industrial structures and sealing and stabilization of porous soils in contact with structures. These factors, combined with the appropriate application and construction expertise, make MC-Bauchemie India a forerunner in rehabilitating and protecting our structures in the long run.
On Requirements of a Successful Structural Repair Solution
When a structure shows signs of distress or deterioration, the following steps should be taken in principle. The steps are as under:
• Preliminary investigation, detailed investigation
• Laying out specifications for repairs
• Selection of materials
• Surface preparations
• Actual repairs
• Periodical maintenance
• Maintenance of reports etc. for future repairs
In these steps, the choice of procedure, base pretreatment and materials for concrete repair will depend on the existing degree of deterioration, the mechanism of deterioration, its causes and anticipated future stress. The reasons for evident defects or damage must be explored as thoroughly as possible. Following this a thorough QA system needs to be established to ensure the durability of repairs. To provide building owners and architects with a high level of reliability in terms of durable protection and repair work, MC has developed “Quality Assurance Systems” based on:
• Long years of experience, professional competence and technical equipment for assessment of defects, damage and for establishment of repair measures.
• Recommended use of suitable and reliable products for the repair of concrete structures, from a range of successfully tested and established materials.
• Experienced professional firms who are thoroughly familiar with the repair application. For this reason, MC passes on the experience and knowledge of its staff to professional applicators. The company will advise such firms before and during the performance of repair work. Following this process stringently can definitely assist in conducting a successful repair project.
Role of Rehabilitation and Repair Techniques in Creating Green Structures
Advanced repair materials combined with state-of-the-art application technology and expertise can ensure durable repairs. Once the repairs are durable, structures will be more durable; and sustainability goes up due to use of local materials and minimal future repair.
New generation materials are environment friendly, free from solvents and harmful chemicals, and have all the essentials needed for today’s green buildings. These products are also easy to apply, can be hand-applied and require little or no mixing, making it perfectly suitable for applications in difficult, space-limited sites. Using the latest protection technologies, the life of the structures without further repairs can be tremendously increased.
Sustainable construction should aim at reducing the environmental impact of a building over its entire life cycle including construction, occupation, maintenance and demolition. In a fast developing nation like India, costs are essential and sustainable construction can help economize cost of the structure over its life cycle. While some building practices are guided by short-term economic considerations, sustainable construction is based on best practices that emphasize long-term affordability, quality and efficiency. Sustainable construction should aim at environment friendly construction, and this includes reducing repairs, rehabilitation, rebuilding and decommissioning a structure. Most of these issues can be addressed by good quality durable repair. Maintenance of durable structures is absolutely not possible without right usage of construction chemicals. This durability would define and enhance sustainability.
Some Complex Cases of Heritage and Masonry Structures
Structural repairs are basically conducted to restore structural stability of damaged structures. MC-Bauchemie India offers specialized PCC Repair products as well as innovative technology applied through our certified and trained expert applicators. Our systems are also suitable for old masonry and heritage structures in addition to modern concrete structures. Our PCC system is free from epoxies and solvents. The highlight is a one-component PCC product named Zentrifix KMH, which is a corrosion inhibitor as well as a bonding agent. This reduces the number of steps in repairs, thereby, saving time and money. All products are tested for durability.
We are doing repairs and rehabilitation of all types of structures all over India. There are scores of residential buildings where our products are used all over the country. However, our main stress is on sophisticated projects, which has real engineering challenges. We are concentrating on monuments and infrastructure projects.
In recent times our Injection & Repair systems were used in heritage buildings like Contractors Building 1922 House in Mumbai, which includes careful and controlled repairs while maintaining the heritage and structural identity. This project won prestigious award by International Concrete Repairs Institute, USA (ICRI). The work was done by our IRP, German trained applicator Kasturi Coating headed by Mr. K. R. Pai under guidance from Structwel Consultants.
Just to give an indication of the materials, technology and application methods, I would like to highlight a few projects dealing with rehabilitation of Heritage / old masonry structures and a jetty in Mumbai. This will help explain depth of our repair systems and their durability.
Case Study 1: Repair of Old Anzarle Ganpati Temple
The rehabilitation process began with a detailed survey and prepared plans for repair. Along with construction workers, skilled carvers and sculptors were also recruited who were instrumental in maintaining the original profile of the temple. In such type of repairs, the selection of products is very important. The products to be used should be compatible with the original material, durable and workable enough to produce architectural features. Hence, instead of a solvent based system, water bound cement based polymer system was used.
The work started with removal of vegetation and treatment of the areas to arrest further growth. The existing damaged sections were removed adopting the method of controlled breaking. The exposed core-face was then cleaned, wire brushed and treated. Re-plastering was done by mixing special compounds with the lime mortar manually on ground or by using ready-to-use polymer mortars with high flexural and compressive strength. For instance, the joints in the stones were filled with special non-shrinking polymer-modified cement mortar for increased bonding strength.
Ganpati Temple Before
Ganpati Temple After
Where it was not possible to expose the inner core, the method of injection grouting was used with the help of controlled-pressure-pump. Hydraulically setting, polymer modified non-shrink waterproof grout was used. This filled the inner cracks and cavities effectively. This also helped to create an internal waterproofing barrier and prevent water penetration and resulting dampness in future. It develops higher compressive and flexural strengths than normal cement grouts. This work was carried out by Jaisons Engineers, Pune under the guidance of leading Civil Engineer, Mr.Jayant Deogaonkar.
Case Study 2: Repair and Restoration of Humayun’s Tomb
Humayun’s Tomb structure was built in the year 1565. The waterways were damaged leading to deterioration of this important Heritage structure.
Around 2200 m of channels were selected for restoration, some of which required partial dismantling. The repair procedure that followed involved placing a bed of lime concrete (mix of lime, surkhi, coarse sand and brick aggregates) in a thickness of 20-25 mm. This was coated with a layer of Molasses. The finished surface was then coated over using a slurry-applied crystallization based waterproofing coating of Dichtament DS + Nafufill BB2. The coating was covered with a lime plaster. Vertical faces were covered with brick tiles 40 mm thick. The edges of the channels were done in sandstone and supported with lime mortar edging. The waterproofed surfaces were finished with a final layer of Lime Punning (Neeru Finish).
This case history has appeared in Indian Architect & Builders Volume 16 (12) August 2003 presented by Ms. Suparna Rajguru.
Case Study 3: Repair and Restoration of Old Secretariat Building – Panaji, Goa
We were approached by Goa State Infrasructure Development Corporation Limited to give them the solution to stop rising dampness at the Historical (300-year old structure) Old Goa Secretariat Building.
Owner: Goa Government
Building: 300 Years Old, Old Secretariat Building.
Agency: Goa State Infrastructure Development Corporation Limited
Products Used: Samafit VK1, Samafit VK2, MC-Einpresshilfe EH, MC-Fix ST, Dichtament DS2
Methodology: Inspection for the problems showed wet patches due to rising dampness through the internal capillaries of the walls, and dampness on the columns up to the first floor.
Secretariat Installation of Chemical Damp Proof Course
Following removal of the damp plaster, the walls were treated with a two-component chemical damp-proof course Samafit VK. Samafit VK was introduced in pre-drilled holes. The two components react in the capillaries and form gelation product which makes the capillaries non wettable. Therefore water does not rise in the capillaries against the gravity but depresses and therefore controls the rising dampness. Wherever required in cracks and hollow areas, a cementitious grout enhanced with MC-Einpresshilfe EH a non-shrink additive, was used. Following the application of the chemical damp-proof course, the holes were sealed with a quick set sealer (MC-Fix ST). After allowing the masonry to dry completely, the walls were treated with a slurry-applied crystallization based waterproofing coating of Dichtament DS + Nafufill BB2. This was followed by a waterproof plaster to complete the restoration.
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