Proposed SSR Items: Specifications and Uses
1. Wall Paneling With Perforated Gypsum Board
1.1 Introduction
Perforated gypsum board Wall Paneling is an appropriate solution to achieve Noise Reduction required in large Spaces like Auditoriums. It can be painted to achieve any desired finish. The Noise Reduction Coefficient is high.
1.2 Design Details
Wall deflection limit L/240 for wall systems & shall not be greater than 30 mm for general areas. Deflection Limit is decreased to L/360 or L/720 base on the application area and types of loadings Internal wind pressure considered is 0.20KPa
1.3 Method Statement
1.3.1 Base/ Surface Preparation
Scrub brush must be used for cleaning the area by removing dust & other particles, where the system has to be installed.
Checking as to whether floor & soffit surface are smooth & even or not, for uneven surface screening should be done.
While setting out the lining, it must be ensured that the lining is placed at the correct position as per the drawing and it shall be installed vertically upright. Taking the plumb is very important for this.
Starting shall be always marked on end wall, column, soffit & floor slab.
1.3.2 Method Statement
Perimeter Channel shall be fixed to floor slab and soffit using rawl plugs with screw. The fixing points shall be a maximum of 50mm from both ends and all other fixings shall be at not more than 600mm intervals.
Universal section shall be cut 5mm shorter than the floor to soffit height and installed into Perimeter Channel at 610mm maximum intervals. Universal section shall be aligned by screw fixing to Wall Bracket fixed to masonry substrate at 800 mm centre to centre is vertical directions..
1.3.3 Boarding:
12mm thick Echo Bloc plasterboards shall be installed leaving a 5 to 10mm gap at floor level (for projected or without skirting places), this will ensure that any moisture/damp in the floor shall not pass into the plasterboard.
Boards shall be fixed to studs by using 25mm Plasterboard Self Tapping screws. All boards shall be fixed @ 200mm maximum centers around the board edge and @ 300mm maximum centers for the middle area of the board.
All plasterboard joints must be staggered at a distance not less than 300mm.
1.3.4 Perimeter Sealing:
The perimeter of the partition wall and any gaps must be sealed using acrylic sealant to maintain acoustic performance.
1.4 Precautions during execution
Before starting the work ensure that the following is ready with the Installation Team
Safety Equipment
Equip them with right set of tools
Preparing the shop drawing before hand to avoid & plan about any obstructions at site.
Clear idea of the Installation location
MEP Service
Openings must be treated with proper acoustic sealan
Loadings if any
Performance Requirement
Material availability at site before Installation
1.5 Limitation
This weld paneling is 3 times faster than conventional construction.
It follows dry construction, saves water & is lighter in weight. Overall dead weight on the structure is reduced by 30 percent.
The Gypsum Boards are non-combustible due to the crystalline water molecules present in gypsum which prevents the fire from spreading in the unlikely event of the fire hazard.
Back sides of the boards come with Acoustic Fleece which enhance the Acoustic Performance.
The chances of imperfections in the lining become less as almost 24 sq ft can be covered with a single sheet of gypsum board.
1.6 Advantages of this new method process.
It is easier & faster to install.
Different types of Perforations are available for achieving required performance & aesthetics.
Jointing application is simple without the usage of jointing tapes. Only a sealant gun is required to fill the joints.
Gives a seamless finish with through & through perforations.
Re-paintable without any loss of acoustics & functionality.
The whole construction process is dry hence save water.
The chances of imperfections in the lining become less as almost 24 sq ft can be covered with a single sheet of gypsum board. This in turn results in minimizing performance deficits.
Areas of application
2. Gypsum board False Ceiling
2.1 Introduction :
Gypsum Board False ceilings are very durable and are more flexible to any design. Gypsum board designs provide a seamless look & assist in concealing Services. Gypsum board False ceiling gives you better Thermal Insulation and also insulates against noises.
2.2 Benefits of Gypsum Ceiling :
Gypsum Ceiling helps in uniform light distribution through ceiling lights. It helps to provide better thermal insulation so cool building spaces which reduce need of air conditioning with dropped ceiling.
It follows dry construction saves water, lighter in weight and can be erected faster.
The Gypsum Boards are non combustible due to the crystalline water molecules present in gypsum which will prevent the fire from spreading.
It gives a uniformly smooth surface without any undulations that too in perfect line and level is and it is easy to paint.
2.3 Method Statement
Mark the area of the false ceiling on the soffit slab with points at distances of maximum 1200 mm each side. Drill a 10mm hole at each of these points. Mark base points on the walls at the height where the false ceiling will be suspended below the main ceiling.
Fix Fastener in each hole and fix a soffit cleat then fix ceiling angle to the soffit cleat with help of nuts and bolts. These installations become the anchor points of the false ceiling. Fix the perimeter channel with Nylon sleeves & steel screws on the walls at the 12.5mm above height where the false ceiling will be suspended below the main ceiling. This acts as the frame for the false ceiling.
Providing and fixing of Universal section /Intermediate section as main channel in either direction at 1200mm max centers and connecting the free ends of the L angle strips to the Universal section / intermediate channels with wafer head metal-to-metal screws. The first and last Channel should not be more than 300mm centers. Overlapping of Sections or connectors to be used for large spans.
Snug-fit the Universal Section / Ceiling section to the perimeter channel and it is placed perpendicular to the universal section / intermediate channels, at distances of 457mm c/c. The ceiling sections are then connected with universal section /intermediate channel using connecting clip or four point connector. These form the framework for fixing plasterboards. This offers a strong and flexible joint, facilitating easy installation of plasterboards. For length more than 3.66mtr required overlapping of sections or a connector to be used as per manufacturer recommendation.
Fixing of 12.5mm thick standard gypsum plasterboards or moisture resistant gypsum plaster boards are to be fixed in the direction of ceiling section with 25mm self-tapping screws at 150mm centers at periphery and cutouts and 230mm centers in rest of the areas. All plasterboard joints need to be sealed with paper tape & APJC (All purpose jointing compound) jointing compound with three-layer application to be carried out to reinforce the board joints as per recommendation of manufacturers.
Application Area
False ceilings can be used in all types of buildings (Healthcare, Institutional, Offices, Residential) to give a seamless finish better thermal and sound insulation.
Typical Drawings
3. Glass Fiber Reinforced Gypsum Board False Ceiling
3.1 Introduction :
"Glass fiber reinforced perforated gypsum board ceilings are robust have high pressure resistance, durable. These Glass fiber reinforced perforated gypsum board ceilings have air purification property with Cleaneo technology. These perforated Gypsum board False ceiling gives you better Noise Reduction Coefficient and are made of Safe, natural material
and 100% recyclable."
3.2 Benefits of Perforated Glass Fiber Reinforced Gypsum Ceiling
It provides Acoustics, Clean Air with cleaneo technology and desired aesthetics.
It follows dry construction saves water, lighter in weight and can be erected faster.
The ggypsum boards are non combustible due to the crystalline water molecules present in gypsum which will prevent the fire from spreading.
3.3 Method Statement
Mark the area of the false ceiling on the soffit slab with points at distances of maximum 1200 mm each side. Drill a 10mm hole at each of these points. Mark base points on the walls at the height where the false ceiling will be suspended below the main ceiling.
Fix Fastener in each hole and fix a soffit cleat then fix ceiling angle to the soffit cleat with help of nuts and bolts. These installations become the anchor points of the false ceiling. Fix the perimeter channel with Nylon sleeves & steel screws on the walls at the 12.5mm above height where the false ceiling will be suspended below the main ceiling. This acts as the frame for the false ceiling.
Providing and fixing of intermediate section as main channel in either direction at 1200mm max centers and connect the free ends of the L angle strips to the intermediate channels with wafer head metal-to-metal screws. The first and last channel should not be more than 300mm centers. Overlapping of sections or connectors to be used for large spans.
Snug-fit the ceiling section to the perimeter channel and it is placed perpendicular to the intermediate channels, at distances of 300mm/ 333mm c/c. The ceiling sections are then connected with an intermediate channel using a connecting clip or four-point connector. These form the framework for fixing plasterboards. This offers a strong and flexible joint, facilitating easy installation of plasterboards. For length more than 3.66mtr required overlapping of sections or a connector to be used as per manufacturer recommendation.
Fixing of perforated glass fiber gypsum plaster boards are to be fixed in the direction of ceiling section with recommended self-tapping screws at 200mm centers. The board joints to be finished with uniflott jointing compound as per manufacturer's recommendation as recommended by architectural finishes.
Application Area
False ceilings can be used in all types of buildings (Healthcare, Institutional, Offices) to give better acoustics, clean Air with Cleaneo Technology and desired aesthetics.
Typical Section
4. Drywall
4.1 Introduction :
Drywall are light-weight non load bearing walls with high performance. Drywalls can be designed to achieve any height with desired fire rating and sound insulation. Drywall partitions offer a wide range of design options to suit various architectural styles and preferences. They can be finished with different textures, paints, wallpapers etc.
Drywall partitions can contribute to energy efficiency within a building, it helps in maintaining temperature control and reducing energy consumption. This leads to cost savings on heating and cooling bills while creating a comfortable and energy-efficient environment for occupants.
It consists of a GI steel frame encased with gypsum plasterboards on either side fixed through self drilling drywall screws. The joints are then taped and finished with gypsum jointing compound.
4.2 Benefits of Drywall
Dry construction saves water, is lighter in weight and can be erected faster and this makes a difference to the energy costs during their construction.
It reduces building loads and hence saves steel
It is fire resistant due to the crystalline water molecules present in gypsum which will prevent the fire from spreading.
It gives a uniformly smooth surface without any undulations that too in perfect line and level and it is easy to paint drywall.
4.3 Method Statement
Base/ Surface Preparation
The floor & soffit surface should be smooth & even, if there is any undulations or any uneven surface screeding should be done.
Pre-treatment: - The surface should be cleaned with scrub brush removing dust & other particles.
Installations procedure – Partition:- While installing the partition one must ensure that each partition is placed in the correct position as per the drawing.
Ensuring 90 degree angles: -
The appropriate method used to ensure 90 degree angles is the “The builder square method “. This method uses the ratio of 3:4:5. If used correctly this will guarantee partition are installed square at 90 degree with each other.
The following examples show the 3:4:5 builder square method using multiple of 100, 200, 300, 400 allowing you to make the size of builder square suitable for your needs.
Design Details
The Drywall should be designed for a height that should withstand the lateral wind pressure of 200 Pa with deflections limited to L(Span)/240 criteria.
4.4 Method Statement
Mark the drywall location from the layout drawing to the floor & ceiling.
The marking of ceiling and soffit should be in plumb with the floor layout.
Then the ultraframe floor & ceiling U channel shall be screw fixed to the floor & soffit slab with anchor fasteners @ 600mm centers with the first & last fasteners shall be 50mm from the end of the drywall.
Ultraframe C studs are inserted in the floor & ceiling U channels with all stud facing in the same directions. The spacing between the stud and overlaps for extension shall be as per specification. Ensure that no horizontal joints of the boards coincide with the overlap. Fixing channel / nogging channel to be fixed as per the specification.
All services like electrical conduits run through the predetermined slots in the metal studs.
Single layer/ Double layer boarding of plasterboard shall be fixed vertically to both sides of the metal C stud with 25mm drywall screw @ 300mm Centers with 25mm & 38mm long Drywall Screws at 300mm centers. All cut ends & boards at the junction, wall perimeter need to be secured at 150mm centers with 25mm drywall screws. All vertical & horizontal joints shall be staggered.
No vertical joints of the plasterboard should coincide vertically with the periphery of doors/windows or any openings.
Insulation in the cavity of drywall with insulation hold strap and appropriate sealants in the junctions to be applied as per the specification to be used to achieve the desired performance of drywall as per specification.
All plasterboard joints need to be sealed with paper tape & APJC (All purpose jointing compound) jointing compound with three-layer application to be carried out to reinforce the board joints as per recommendation of manufacturers.
4.5 Application Area
Drywall can be used in all types of buildings (Healthcare, Institutional, Offices, Residential) to create light weight non load bearing walls with desired performances in fire rating, sound insulation and stability.
Typical Section
MCON LWP is a fine cementitious powder to be mixed with concrete and cement mortar mixes to improve their work ability, increase the yield and also make them waterproof.
MCON LWP is a traditional admixture to fill natural pores within the concrete or mortar matrix to reduce porosity and improve water tightness.
Coverage :-
• 500 gm of MCON LWP for every 50 kg bag of cement.
Technical Specifications
• Add LWP integral waterproofing powder in the mortar course with the dosage of 500 gms per bag of cement and mix the dry materials until an even colour is obtained
• The product should be confirming to IS 2645
• The product should be certified with ISI & CE Certification
4.6 ADVANTAGES:
● Easy to use – Simple application familiar to site operations..
● High quality– It reduces the permeability as it disrupts the capillaries within concrete.
● Work ability – Improves work ability.
● Reduce mortar dropping , when used in plaster.
4.7 Limitations
● The traditional method is subjective to physical damage or deterioration
● It does not help to reduce shrinkage cracking
● The traditional method does not provides a reliable secondary barrier against rainwater, moisture and ground water ingress into the concrete
● There is nothing that makes the mix more workable (improves the slump) hence improving the final output and finish of the top IPS/surface
4.8 Method Statement
● Dosage: With normal concrete and sand/cement mortar mixes use 500 GM of MCON LWP for every 50 kg bag of cement.
● Hand mixing : Measure out the required quantity of sand/aggregate, followed by the cement. Sprinkle the correct quantity of MCON LWP evenly over the cement .
● Mix the dry materials until an even colour is obtained. Add the normal measured quantity of water and mix as usual.
● Machine mixing : Add the measured quantity of sand/aggregate into the drum and mix continuously.
● Add the cement and sprinkle in the correct quantity of MCON LWP at the same time. Mix the dry materials for 2 minutes. Add the normal measured quantity of water and mix to completion.
5. Waterproofing Bridge Deck, Deck Slabs Of Viaducts, Flyovers, Major And Minor Bridges
5.1 Application:
For all bridges, interchanges, viaducts, FOB, culverts and other similar structures having deck slabs, the bare/parent concrete surface of decks shall be provided with very low viscous high molecular weight waterproofing MMA monomer. The monomer must impregnate the concrete to seal it and further strengthen it. The application shall be done at a coverage of 1Kg/Sqm. The bridge deck waterproofing monomer should conform to the following specifications: Viscosity at 25°C (Brookfield): ≤5 cP, Specific Gravity at 25°C (ASTM-D-1963): 0.95-1.00, Compressive Strength (ASTM-D-695) (7 days): 60 MPa, Flexural Strength (ASTM-D-790) (7 days): >20 Mpa, Tensile Strength (ASTM-D-638-91) (7 days): 20MPa, Elongation (ASTM-D-638-91) (7days): 8%, Pull off Bond test with VG 30 BC (ASTM D4541) shall be >3 Mpa , Bond with concrete (ASTM C 882): 10.5 MPa.
5.2 Advantages:
By virtue of extremely low viscosity, it permeates through the pore structure of the concrete. This impregnation action also makes it almost an inseparable part/layer having very high durability.
It can permeate through the fine hairline cracks of even 0.025mm.
It strengthens the concrete matrix by improving the binding between the cement and aggregates.
Due to its high elasticity, it has enough flexibility to withstand the cyclic loading and has excellent crack bridging ability as well.
Its high compressive strength coupled with its high elasticity effectively protects the top layer of the deck from developing cracks.
5.3 Method Statement :
As per method statement:
Bridge repair: SSR item no.: 19.32
Structural Strengthening: SSR item no. 47.17
Structural Strengthening: SSR item no. 47.18 (to be deleted - duplicate of SSR 47.17)
5.4 Application:
Old RCC bridges, existing marine structures, old RCC residential structures and all existing reinforced concrete structures which need corrosion inhibition of reinforcement bars. To supply and insert the metal seeking corrosion inhibiting inserts which upon insertion into the concrete diffuse active molecules towards the embedded reinforcement. These are specifically designed for RCC structures like bridges, flyovers and marine structures wherein deep penetration is required Corrosion inhibiting molecules traverse through the dense concrete to form a nano molecular later on the rusting steel rebars to inhibit the process of corrosion, in both cathodic and anodic sites. Tablet is Inserted by drilling 20-22 mm diameter holes into the concrete at a depth of 30-40 mm and inserts to be covered by epoxy putty. The insertion should be done as per the method statement of the manufacturer. Inserts shall inhibit corrosion with an inhibition efficiency of 98% (when added 0.03 % by weight) against control samples evaluated by the Tafel polarization method. Depth of penetration for effective corrosion protection shall be 120mm. Spacing of insert shall be: (a)For RCC Columns- 1 Units in a single drilled hole at a spacing of 1 m c/c from two opposite faces in staggered fashion (b) For RCC Beams- 1 Units in a single drilled hole at a spacing of 1m c/c from two opposite faces in staggered fashion (C) RCC Slab- 4 Units in a single drilled hole in 1 sqm area in a grid pattern.
5.5 Advantages:
Ensures uniform corrosion protection of rebars throughout the concrete matrix.
Easy to insert during repair works of existing RCC structures.
TTCI Penetrates towards rebars over a prolonged period and arrests corrosion of rebars.
Effective even in the presence of high amount of chlorides
5.6 Method Statement :
As per method statement:
6. Corrosion Inhibiting Admixture
6.1 Application:
Traversing Type Corrosion Inhibiting (TTCI) additive to be used in all reinforced concrete structures like pile foundations, raft foundations, retaining walls, bridges, flyovers, jetties, sewage plants (STP), swimming pools, pumping stations, effluent treatment plants (ETP), water retaining structures, pipeline pedestals, admixture to repair mortars, micro-concrete and all marine structures. TTCI powder additive is added to green concrete which imparts significant corrosion resistant properties to concrete to protect rebars. It is compatible with all types of cements like OPC, PPC, slag cement without altering the basic characteristics of concrete mix. TTCI powder has high vapour pressure. These vapours have high affinity towards the embedded steel rebars and they traverse through densest concrete to reach the rebars and form a mono-molecular later on the rebars. This layer effectively breaks the cycle of corrosion by inhibiting corrosion at both poles (anodic and cathodic) simultaneously. Admixture should have evaluated test reports from a reputed research institution like Institute of Chemical Technology, Mumbai, demonstrating a corrosion rate of zero coulombs after 40 test cycles as per ASTM G 109, Corrosion inhibiting additive shall be tested as per ASTM G59 with a minimum of 85 % inhibition efficiency, the Vapour Inhibiting ability test as per NACE TMO 208 shall be of Grade 4. Exact minimum dosage would be determined based on mix design considerations and exposure conditions by the additive manufacturer as directed by the Engineer in Charge.
6.2 Advantages:
Ensures uniform corrosion protection of rebars throughout the concrete matrix
TTCI Penetrates towards rebars over a prolonged period and arrests corrosion of rebars
Effective even in the presence of high amount of chlorides
Does not affect bond strength of new concrete to reinforcement bars
Does not affect the mechanical strength characteristics of concrete
6.3 Dosing Procedure:
TTCI should be added either at the batching plant or in the transit mixer.
7. Integral Waterproofing Powder For Concrete And Plaster
7.1 Introduction:-
A fine cementitious powder to be mixed with concrete and cement mortar mixes to improve their work ability, increase the yield and also make them waterproof.
A traditional admixture to fill natural pores within the concrete or mortar matrix to reduce porosity and improve water tightness.
Coverage :-
❖500 gm of MCON LWP for every 50 kg bag of cement.
Technical Specifications
❖integral waterproofing powder in the mortar course with the dosage of 500 gms per bag of cement and Mix the dry materials until an even colour is obtained
❖The product should be confirming to IS 2645
The product should be certified with ISI & CE Certification
Limitations with Conventional Method
The traditional method is subjective to physical damage or deterioration
It does not help to reduce shrinkage cracking
The traditional method does not provides a reliable secondary barrier against rainwater, moisture and ground water ingress into the concrete
There is nothing that makes the mix more workable (improves the slump) hence improving the final output and finish of the top IPS/surface
7.2 ADVANTAGES:
Easy to use – Simple application familiar to site operations..
High quality– It reduces the permeability as it disrupts the capillaries within concrete.
Work ability – Improves work ability.
Reduce mortar dropping , when used in plaster.
7.3 Method Statement
Dosage: With normal concrete and sand/cement mortar mixes use 500 GM of MCON LWP for every 50 kg bag of cement.
Hand mixing : Measure out the required quantity of sand/aggregate, followed by the cement. Sprinkle the correct quantity of MCON LWP evenly over the cement .
Mix the dry materials until an even colour is obtained. Add the normal measured quantity of water and mix as usual.
Machine mixing : Add the measured quantity of sand/aggregate into the drum and mix continuously.
Add the cement and sprinkle in the correct quantity of MCON LWP at the same time. Mix the dry materials for 2 minutes. Add the normal measured quantity of water and mix to completion.
8. Solvent Free Food Grade Epoxy Coating- Epoxy Fg Paint + 2k Primer
8.1 Introduction
EPOXY FG PAINT:
❖MCON EPOXY FG PAINT is high build and fast drying food grade epoxy coating. Excellent coating for internal / external linings of potable water pipelines.
❖Internal coating for concrete / steel potable water storage.
❖MCON EPOXY FG PAINT provides long term protection to cement and concrete substrates
❖Conformance to BS: 6920: 2014, IS 16676:2017 (Clauses 4.3 & 9.1) and AWWA C-210: 2003 and CFTRI approved
2K Epoxy primer:
MCON 2K Epoxy primer is two component, epoxy-based primer is suitable for priming concrete / metal surfaces, including walls, prior to the application of any epoxy flooring, epoxy coating and epoxy repair mortar
EPOXY FG PAINT :
Nature: Epoxy resin and selected fillers
Appearance: Coloured viscous liquid
Mix Density: 1.3 ±0.2
Solid%: > 98%
Mixing Ratio (Pack A: B), by wt.: 5:1
Pot life: 60 mins
Drying time: Touch dry 3 hrs Hard dry 6-8 hr
Abrasion Resistance, 1000 cycle ASTM D 4060: <100 m
Adhesion pull-off after 7 Days, MPa ASTM D 4541: On Concrete >3; On Steel > 10
❖Immersion test, 30 days AWWA C 210 DIW 1% H2SO4: No blistering / peeling / disbanding 1% NaOH
Solid%: > 98%
Mixing Ratio (Pack A: B), by wt.: 5:1
Pot life: 60 mins
Drying time: Touch dry 3 hrs Hard dry 6-8 hr
Abrasion Resistance, 1000 cycle ASTM D 4060: <100 m
Adhesion pull-off after 7 Days, MPa ASTM D 4541: On Concrete >3; On Steel > 10
❖Immersion test, 30 days AWWA C 210 DIW 1% H2SO4: No blistering / peeling / disbanding 1% NaOH
2K EPOXY PRIMER :
Nature: Epoxy resin and selected fillers
Appearance: Colourless viscous liquid
Mix Density: 1.2 ±0.2
Solid%: 50-55%
Mixing Ratio (Pack A: B), by wt.: 2:1
Pot life: 2 hrs
Drying time: Touch dry 2 hrs Hard dry 6-8 hr
8.2 Advantages
❖Contains no VOC
❖Excellent bond on freshly prepared concrete surfaces can be applied to damp concrete without any loss of adhesion.
❖Excellent coating for internal / external lining of pipelines where abrasion / chemical resistance is of major concern. Cured film is very hard and abrasion resistant.
❖Ideal as a body coat in protective coating systems. Particularly suited to quick repair situations like maintenance work.
Excellent food grade properties.
8.3 Limitations with Conventional Method
There is no conventional method available which was food grade certified
No proper bonding with the surface of the substrate
The conventional method does not increases the aesthetics of the structure
Different types of materials were required for different surfaces which was difficult to manage and costly
8.4 Method Statement
Concrete must be at least 28 days old. Any cement laitance must be removed.
Concrete surfaces must be clean, dry or matt damp, free from standing water, ice, dirt, oil, grease, laitance, surface treatments, all loose particles and any other surface contaminants that could affect adhesion of the adhesive.
Stir container of each component thoroughly for uniformity.
For best result, use a variable speed drill mixer with a spiral type blade at the bottom of stirrer rod. The speed may be 400-600 rpm.
Mix only sufficient materials for immediate requirements. Leave the mixed material to stand for 2- 3 minutes to enable entrapped air, if any, to escape from the mix and then use as quickly as possible.
MCON EPOXY FG PAINT may be applied by a soft nylon brush or roller.
If the concrete surface is very porous, more than two coats may be required to seal all surface pores otherwise air bubbles may appear on the next coat.
AREAS OF APPLICATION
9. Corrosion Inhibiting Admixture
9.1 Introduction :
It is a bipolar corrosion inhibiting admixture in liquid form for reinforced concrete and mortar.
It provides outstanding resistance against corrosion of rebars.
By using MCON CI 300 the life expectancy and durability will be substantially increased.
Dosage :- 1 - 3% of cement weight.
Specifications
Providing & Supplying corrosion inhibiting admixture in concrete to protect steel bars for all concrete in every part CI 300 of approved make& approved by Engineer in charge migrating, non-nitrite based corrosion inhibiting admixture shall be added at a dose of 3 kilograms per cubic meter of concrete.
The admixture should protect both cathodic and anodic sites.
Admixture should have evaluated test as per ASTM G 1-03 2017 & JIS Z 1535.The admixture should have followed guidelines as per IS: 9103-2007 and ASTM C-494-2010(Type-D).PH of admixture should be alkaline in nature, specific gravity of 1.03 ± 0.2, colour :Yellow coloured liquid.
The contractor must intimate the engineer in charge prior to addition in concrete for recording. If the admixture is put in the concrete mix at the batching plant, a written record of the amount of admixture used shall be supplied to the engineer. The engineer must ensure that the specified dosage of admixture is added in the concrete mix. (Material Cost Analysis only)
Limitations with Conventional Method
9.2 Advantages
Corrosion protection for embedded reinforcing steel, especially from chloride attack
Protection from the destructive influences of reinforcement corrosion
No negative influences on the properties of both the fresh and the hardened concrete
Adsorbs onto the reinforcing steel to form a corrosion-resistant protective film
Extended service life of reinforced concrete structures
9.3 Method Statement
MCON CI 300 is mixed with the gauging water or added at the same time into the concrete mixer.
It may also be added to the concrete in the transit mixer at the point of discharge
In this case, an additional mixing time of at least 1 minute per cubic meter concrete must be observed.
Before discharging it, check the concrete visually for uniform consistency.
The quantity of MCON CI 300 in the mix design should be taken into consideration when determining the quantity of water for a specific W/C ratio.
MCON CI 300 is not to be mixed with dry cement.
AREAS OF APPLICATION
10. Polyacrylic Fiber Reinforced Waterproof Liquid Membrane - MCON MAGIC COAT FLEXI
10.1 Introduction :
A fiber reinforced, modified poly-acrylic, liquid-applied coating that is composed of specially developed polymers, and properly selected and graded fillers.
It cures by reaction with atmospheric moisture to give a tough elastomeric waterproof
membrane.
10.2 Coverage :-
25 - 35 Sq. ft. / kg in 2 coats.
10.3 Technical Specifications
Appearance: Thixotropic liquid
Color: White
Odor: Styrene acrylic
Viscosity: 1.6 - 3.5 poise at 25°C
Density: 1.45 - 1.52 g/cm
Solids: 50 - 60 %
Solvent: Water
10.4 ADVANTAGES:
Elastomeric – On that accommodate cracks up to 2 mm with an elasticity of
100-150%.
Low water permeability – excellent resistance to ingress of water.
Adhesion – excellent adhesion to concrete and masonry surfaces.
No curing required.
10.5 Limitations
Need to add cement separately for doing the waterproofing.
There is almost no elongation of the waterproofing chemical.
The dft of the traditional waterproofing chemical is in microns which is very low.
The traditional method requires water curing separately.
In case of EPDM membranes, there are a lot of joints in the waterproofing system which may become an entry point for water.
Also, EPDM membrane requires skilled labours which is costly.
10.6 Method Statement
All surfaces to be waterproofed should be sound, clean and dry and free of any laitance, grease and oil, dirt and other loose materials.
Algae and fungi must be removed physically. After treatment leave for 2 - 3hrs and then wash down thoroughly with clean water and allow to dry completely.
MAGIC COAT FLEXI should be applied by brush, trowel, and airless spray in two coats maintaining the spreading rate to achieve the desired DFT of 1 mm. The material consumption shall be approximately 0.2 to 0.3 kg / m per 2 coats.
In critical applications where film thickness is of paramount importance and desired than the stated one then two coats should be applied with quantities per coat gauged to give the specified final film thickness.
On a vertical surface if high film build-up is desirable then additional coat may be required.
If the coated surface is to be further subject to abrasion then sprinkle sand on the surface when the coating is in wet condition. This will ensure protection of the membrane.
The coating will get fully cured into the membrane in 7 days. If a water ponding test is to be run, the membrane should be fully cured.
AREAS OF APPLICATION
11. Polyurethane Waterproof Liquid Membrane
11.1 Introduction :
It is a modified polyurethane, liquid-applied coating that is composed of a specially developed polyurethane compound.
It cures by reaction with atmospheric moisture to give a tough elastomeric waterproof
membrane.
11.2 Coverage:-
15 - 20 Sq. ft. / kg in 2 coats.
11.3 Technical Specifications
Color: White, Grey
Tack Free Time @ 28° C: 12 Hours
Time to Full Cure @ 28°C : 72 Hours
Solid Content: 50 - 60 %
Elasticity: 400%
Elongation @ Break: > 1365 % (ASTMD 412 - 98)
Viscosity (Spindle No: 7; RPM: 10 25 C): 50000 – 70000 CPS
Water vapor Transmission ( g/h – m² ): 0.46 (ASTME 96 – 95)
11.4 Advantages
Cold curing, cures to a tough, flexible, and abrasion-resistant coating.
Bonds strongly on cement concrete, asbestos, mild steel, and cement-plastered applied surfaces.
Thermal stability Irreversible chemical cure eliminates melting and flow at high temperatures.
Excellent protection against corrosive soil conditions, resistance against saline water, mild.
Acids and alkalies, and high sulphate resistance.
11.5 Limitations
Need to add cement separately for doing the waterproofing.
There is almost no elongation of the waterproofing chemical.
The dft of the traditional waterproofing chemical is in microns which is very low
The Traditional method is not UV stable.
The traditional method requires water curing separately.
In case of EPDM membranes, there are a lot of joints in the waterproofing system which may become an entry point for water.
Also, EPDM membrane requires skilled labours which is costly.
11.6 Method Statement
All surfaces to be waterproofed should be sound, clean and dry and free of any laitance, grease and oil, dirt and other loose materials.
Algae and fungi must be removed physically. After treatment leave for 2 - 3 hrs and then wash down thoroughly with clean water and allow to dry completely.
Apply MAGIC COAT PRIMER with the help of a brush and allow it to dry for 3-4 hours. (Depending on the temperature).
MAGIC COAT PU should be applied by brush, trowel, and airless spray in two coats maintaining the spreading rate to achieve the desired DFT of 0.5mm.
The material consumption shall be approximately 15 - 20 Sq.ft / per kg in 2 coats. The first coat has to be diluted with 10 % water, mixing it thoroughly.
Allow first coat to dry for 24 Hours. The second coat has to be applied perpendicular to the first coat with no dilution.
In critical applications where film thickness is paramount and desired than the stated one then two coats should be applied with quantities per coat gauged
to give the specified final film thickness.
On a vertical surface if high film build-up is desirable then an additional coat may be required.
The coating will get fully cured into membrane in 7 days. If a water ponding test is to be run, the membrane should be fully cured.
Note : If coating is further subjected to screed/tiling sprinkle some sand on 2nd coat when coating is wet.
AREAS OF APPLICATION
12. Deco Floor Systems (Stamp Concrete)
12.1 Introduction
MCON Deco floor systems are unique decorative solutions for external paving.
Its durable and long lasting as compared to the traditional system
It gives monolithic seamless surface with numerous designs and patterns
It can be used in pavements, building lobbies, parking areas, gardens podium areas etc.
12.2 Specifications
Stamp Concrete of 75mm Thickness - Providing and Laying in-situ M30 Grade unreinforced plain concrete of 75mm thickness pavement over a prepared sub base with 43 grade cement, coarse and fine aggregate, as per design mixed in a batching and mixing plant / non tilting mixer and weigh batcher as per approved mix design, admixtures, transporting to site, spreading, laying, compacted and finished in a continuous operation, finishing to lines and grades.
Providing and applying colour hardener Mcon Deco Hard floor @ 2.75 kg per square meter in 2 pass, over concrete of Grade M 30, and finishing with aluminum bull float followed by steel floater to get smooth and even finish.
Applying release powder of Mcon Deco Release of desired shade @ 0.113 kg per square meter, placing, pressing and removing PU stamp of desired pattern, over release covered concrete. Removal of the release powder by water after 24 hours by using little bit detergent.
Curing the surface for at least 7 days by covering with wet gunny bags with assurance that surface remains damp for 24 hours.
Providing and applying sealer coat of Mcon Deco Sealer in 2 coats with interval of 1 hour as approved by Engineer-in-charge or Landscape architect etc. complete, Control joints shall be cut in between 24 to 72 hours
12.3 Advantages
Unlimited designs.
Unlimited colour combinations
Tear and wear resistance double than original concrete.
Easy to install
Natural stone look with strength of concrete.
Out put is more than other system.
Monolithic pavement.
12.4 Limitation
Limitations of existing paving system:
Limited designs.
Limited colours
Limited thickness.
Artificial look.
Very close joints.
Possible only where source is near.
Time consuming
Poor strength
12.5 Method Statement
STEP 1: PUMPING / LAYING & LEVELLING OF CONCRETE
STEP 2: APPLICATION OF ON FLOOR
STEP 3: RELEASE
STEP 4: STAMPING
STEP 5: WASHING OF THE SURFACE
STEP 6: APPLICATION OF SEALER
Finished items
13. Ready to Use Self Cure Waterproof Plaster (Green Product)
13.1 Introduction
Ready to plaster of any known company of repute is (Self Cure) a ready mix plaster reinforced with Fibre , ready to use plastering mortar for internal & external plastering with Self Curing Mechanism. It is convenient, easy to use, strong and binds better to its substrate.
This product is composed of good quality cement, properly selected aggregates, fibres &
additives with additional Self Curing Compound as the integral part of the product.
The waterproofing and bonding polymers give the plaster a better bonding with water tight
characteristics.
13.2 Coverage :-
16 – 18 sq. ft per 40 kg bag at 10 – 15 mm thickness .
13.3 Technical Specifications
Binder : Grey Portland Cement 53 Grade
Dry Density : 1.7 - 1.8 Kg/Ltr
Wet Density : 1.9 - 2.0 Kg/Ltr (mixed with water)
Water Intake : 150 – 200 ml per kg (approx 6 - 8 Ltr in a bag of 40 Kg)
POT Life : 25 to 30 Minutes
Thickness : 10 – 15 mm per single coat
13.4 ADVANTAGES:
Crack free & firm surface that preserves beauty of building for longer time.
Better bond than conventional cement-based mortar hence ideal for use in Plastering machines.
Self-curing hence reduces labour cost for curing and also saves water.
Moisture resistant - Offers excellent resistance to moisture ingress.
13.5 Limitations
Need potable water for curing.
Difficult to maintain or check if the water curing is done properly and if not, it may lead to
formation of cracks on the surface
Difficult to cure the plaster in patch work plastering resulting into cracks.
No option for water curing in areas with water scarcity.
13.6 Method Statement
Clean the substrate, free from all loose particle, oil & grease, paints or free sand.
Water jet cleaning is advisable.
Wet the surface before application of the plaster.
Mix one bag of 40 kg of MCON READY PLASTER (Self Cure) with 6 to 8 ltr of water using a mechanical mixer.
Small quantity can be mixed using a trowels and a bucket. All care should be taken that the mixing is done thoroughly.
Use the mixture within 40 Min after addition of water. .
No Curing is required. Plaster can be over coated with other material after 3 days of plastering. For tiling you need to leave the surface for 14 days.
It is important to pre-wet the wall surface before application of MCON READY PLASTER (Self Cure). In very high temperature, humid areas light spraying of water (curing) for 7 days would be necessary.
13.7 AREAS OF APPLICATION
14. Cement Sand Thin Section Render
14.1 Introduction
MCON READY PLASTER RENDER of any known company like MCON etc. is a cement sand fiber reinforced, ready to use product for doing thin section plaster render internal & external surface corrections purpose. It is convenient, easy to use, strong and binds better to its substrate.
This product is composed of good quality cement, properly selected aggregates, fibres &
additives. Its well graded aggregates which are clean and silt free ensure that the plaster has a very cohesive and smooth finish.
The waterproofing and bonding polymers give the plaster a better bonding with water tight
characteristics. READY PLASTER RENDER is easy to use as it can be applied with
trowel.
14.2 Coverage :-
50 - 60 sq. ft per 40 kg bag at 5 - 6 mm thickness.
14.3 Technical Specifications
Binder : Grey Portland Cement 53 Grade
Dry Density : 1.6 Kg/Ltr
Wet Density : 1.9 Kg/Ltr (mixed with water)
Water Intake : 150 – 200 ml per kg (approx 6 - 8 Ltr in a bag of 40 kg)
POT Life : 30 - 45 Minutes
Thickness : 5 - 6 mm per single coat
14.4 ADVANTAGES:
Crack free & firm surface that preserves beauty of building for longer time.
Moisture resistant - Offers excellent resistance to moisture ingress.
Sufficiently flexible to accommodate thermal & physical movements.
Better bond than conventional cement-based mortar.
14.5 Limitations
Not possible to do thin section plastering on the surface.
No added polymers making it difficult to get proper bond strength.
Unable to get desired finished surface.
Unable to maintain proper mixing ratio as per IS Standards
14.6 Method Statement
Clean the substrate, free from all loose particle, oil & grease, paints or free sand.
Water jet cleaning is advisable.
Wet the surface before application of the plaster.
Mix one bag of 40 kg of MCON READY PLASTER RENDER with 6 - 8 ltr of water using a mechanical mixer.
Small quantity can be mixed using a trowels and a bucket. All care should be taken that the mixing is done thoroughly.
Use the mixture within 30 - 35 min after addition of water.
Curing of the plastered surface can be done after 10 – 12 hrs and should be done for 2 – 3 days.
14.7 AREAS OF APPLICATION
15. Flowable Structural Repair Concrete With Integral Corrosion Inhibitor
15.1 Introduction
Micro Concrete Antirust is a flowable, shrinkage-compensated repair concrete product. It is designed for large volume repairs, including structural elements.
It has a unique formulation that provides excellent bond, resistance to sulfates and
chlorides, high electrical resistivity, low permeability, high-compressive strengths, and
protection from corrosion. It replace the broken fateguard concrete.
15.2 Coverage :-
1.5 Sq.Mtr @ 10 mm thickness
15.3 Technical Specifications
Physical Appearance: Grey Powder
Water : Powder Ratio: 12 - 14 %
Working Time: - 90 min
Mixed Density: 1.80 - 1.90
Setting Time: Initial 4 hrs Final 6 hrs
Compressive strength (ASTM C 39): 1 day 20 Mpa, 7 days 35 Mpa, 28 day 40 MPa
Flexural strength (ASTM C 348): 7 days 6MPa, 28 days 7 Mpa
Rapid chloride Permeability (ASTM C 1202): 28 days 718 coulombs
15.4 ADVANTAGES:
In fresh state: cohesive, flowing and self-levelling
Already admixed with integral corrosion inhibitor.
Abrasion resistant for repairs requiring protection from vehicular traffic.
Pre-mixed with pea gravel, ready-to-use.
Shrinkage compensated, minimizing cracking from drying shrinkage reducing stress at the bond line. In fresh state: cohesive, flowing and self-levelling
Low permeability with excellent freeze-thaw resistance.
15.5 Limitations
Need to provide additional anti corrosive treatment to the steel rebars before casting/ placing the concrete.
Difficulty in maintaining/checking if the anti-rust treatment is done uniformly.
There are high chances of leaving pin holes on the steel during coating manually.
Multiple labours are to be associated hence its time consuming and costly.
15.6 Method Statement
Concrete surfaces must be structurally sound, free of loose or deteriorated concrete and free of dust, dirt, paint, efflorescence, oil and all other contaminants.
Expose fully any corroded steel in the repair area and remove all scale and corrosion deposits. Apply MCON STEEL RR for rust free bars.
The product of any reputed company is ususally available in the 25 kg bags and may be mixed with a drill and “jiffy” mixer.
Use a horizontal shaft, paddle type mortar mixer for mixing multiple bags simultaneously.
Add the appropriate amount of water, Use 12-14% water by weight of Antirust concrete, for the batch size and then add the dry product. Mix for minimum of 3 minutes.
Do not add water to the surface during the finishing operation
For most practical purposes, cure the antirust concete with water for 7 days.
15.7 AREAS OF APPLICATION
16. High Performance Plaster Bonding Agent
16.1 Introduction
The PLASTER BOND is a polymer based bonding agent from selected synthetic
copolymers to perform as a Chemical and Mechanical bonding coat to create strong
bond of Cement Sand Plaster on any cementitious substrate including high quality
concrete surfaces.
It comes in Blue colour and hence is easily traceable for application. It provides a strong
chemical bonding coatand also a mechanical bonding substrate.
16.2 Coverage :-
35 - 40 Sq.ft per Kg for Single Coat
16.3 Technical Specifications
Physical Appearance: Blue Paste
Setting Time @ 30° C: 4 hours (Initial) , 8 hours (Final)
Service Temp.: - 50 C to + 900 C
Density: 1.40 - 1.50 Per Kg.
Ph: 7 - 9
Bond Strength: 1 Mpa at 28 days
Solid Content: 65 - 70
16.4 ADVANTAGES:
Twenty times faster than hacking and also more effective.
No chat plaster needed , can do direct plastering on the coated surface.
Works well for sand-cement plaster.
Excellent adhesion to most building substrates.
16.5 Limitations
Hacking is difficult in case of high grade concrete
Difficulty in maintaining uniform and proper hacking of the surface
Other bonding agents in the market get dried if the dash coat is not done in 15 mins
Due to transparent colour of the other bonding agents, its difficult to identify whether
the coating is done or no
Multiple labours are to be associated hence its time consuming
16.6 Method Statement
Surface preparation is vital for effective adhesion and bonding of MCON PLASTER BOND.
To start with, free the surface from laitance, loose dust particles, oil, grease and other dirt
Stir constantly until all the solid contents are uniformly distributed throughout the solution of MCON PLASTER BOND and slurry of uniform consistency is achieved.
Apply this slurry on the substrate using a soft 4 - inch wide paint brush or a cotton roller.
Apply the slurry in one direction only and that too in single coat.
The coating will dry in 4 hours and you can overcoat it with Cement Sand plaster after 08 hours and within 10 days from date of application of MCON PLASTER BOND.
16.7 AREAS OF APPLICATION
17. SINGLE COMPONENT HYDROPHOBIC PU GROUT
17.1 Introduction
MCON MAGIC GROUT PU is a hydrophobic grout based on polyurethane
After coming in contact with water, Mcon Magic Grout PU reacts to closed cell rubber-like foam while expanding its volume up to 27 times.
The cured material is of a constant volume.
Since water is not a component of the foam structure, the cured material is essentially
not affected by water or dryness.
17.2 Packing :-
10 & 20 Kgs
17.3 Technical Specifications
Color: Ivory
Form: Liquid Type
Solubility in Water: Hydrophobic
Viscosity (KS F 4923): 100-200 mPa-s
Density (g/ml): 1.12
Tensile Shear Strength :4 N / mm2 (230 C), (KS M 3705)
Appearance: Light Yellow Polyurethane Foam
Corrosiveness: Non-Corrosive
Chemical Resistance: Resistant to more organic Solvent , Mild Acids , Alkali
17.4 ADVANTAGES:
Negative side application possible.
Inert after curing, constant volume, no shrinkage.
Good adhesive strength , tolerant of movement.
Foam increases in volume to fill cavities and voids.
17.5 Limitations with Conventional Method
It cannot be used for negative side waterproofing
Traditional waterproofing cannot stop running water leakages
Traditional waterproofing cannot fill the voids and cracks from which there may be a
chance of a leakage in the future
The traditional type waterproofing does not make the structure completely watertight
The traditional system cannot be used for basement and lift pit waterproofing
17.6 Method Statement
MAGIC GROUT PU Application is depending according to individual site. Sometimes the grouting maybe on floor or in ceilings.
Need to remove the existing IPS or Tile floor up to mother slab. Need to drill holes at certain intervals(approximately 1 mtr distance depends on site and leakage).
Insert MS Nozzles and fix them in drilled holes. Need to wait for 24 Hrs.
Now MCON PU Grouting Can be done with the help of machine shown below.
After grouting(approximately after 24 hrs), Ineed to remove the nozzles with the help of a cutter machine and fill the holes with MCON MAGIC COAT INSTANT. Further surface is ready for IPS or Tiling.
MAGIC GROUT PU Application is depending on the individual site. Sometimes the grouting may be on the floor or in ceilings.
17.7 AREAS OF APPLICATION
18. Tile On Tile Grey Adhesive For Ceramic & Vitrified Tiles
18.1 Introduction
MCON NSA GREY is a pre packed cementitious tile adhesive which mainly consists of high-strength cements, selected silicon/quartz mineral charges and specific additives.
It is ideal for concrete, plaster and also tile substrates.
It is an adhesive for the permanent fixing of ceramic tiles both in damp and submerged conditions.
18.2 Coverage :-
20 kg of MCON NSA GREY will cover 3.5 to 4 m² with recommended thickness of 3
to 4 mm.
18.3 Technical Specifications
Bed Thickness : 3 - 4 mm
Wet Density: 1.70 - 1.75 g/cc
Dry Density: 1.50 - 1.55 g/cc
Temperature Resistance: -5˚ C to 80˚ C
Initial Setting Time: Approx. 50 min
Pot Life: 60 Minutes
Open Time: Min. 10 minutes
Can be subjected to traffic: *After 24-36 h
Compressive strength: 14 N/mm2
Creep on a vertical wall: 0 mm °
Surface can be used: *After 14 d
Wall tiles can be grouted: *After 4-6 h
Floor tiles can be grouted: *After 24-36 h
18.4 ADVANTAGES:
Excellent adhesion - hence can be used for tile on tile applications apart from fixing tiles on concrete and plaster substrates.
Excellent waterproofing characteristics.
Gives sufficient time to set the tiles.
Good slip resistance & Spreads quickly and easily.
18.5 Limitations
Unable to control the heat of hydration resulting in cracking of the tiles
Ordinary cement slurry made with a mixture of water and sand, it creates an uneven surface and leaves voids beneath the tiles upon drying and shrinking. This causes inefficient bonding which translates into cracks
Difficulty in fixing wall tiles
Unable to get proper bond strength
Difficult to fix large format tiles
Difficulty in fixing tiles on external walls / facades
18.6 Method Statement
MCON NSA GREY should be mixed with water in the ratio of 1 Bag : 3 to 4 Ltr by volume with the help of slow speed drill having paddle attachment.
Blend until a homogeneous, lump-free mixture is obtained.
After mixing, 3-4 mm thick bed of MCON NSA GREY should be spread with the help of trowel and grooves shall be shaped zig-zag using a scraper.
The product obtained is a creamy paste that can be easily applied with a trowel and tha possesses optimum thixotropy.
Tiles should be fixed keeping line and length into consideration. Excess adhesive should be removed before material has set.
Joint grouting may be commenced 24 hours after laying of tiles.
Curing: Joint grouting of tiles laid on MCON NSA GREY can be done after 24 hrs.
18.7 AREAS OF APPLICATION
19. Acoustical Perforated Metal Clip-in In False Ceiling With NRC of 0.7
19.1 Introduction
Acoustical Clip-in Modular False ceiling in Metal finish.
Monolithic appearance, Concealed suspension system.
Can be used for Semi-Exterior Areas.
100% downward accessibility with panel removal tool
Good acoustic performance with 0.7 NRC
Ideal for Applications like Porch, Lobbies, Offices, Education, Transportation etc.
19.2 Base Preparation
19.3 Method Statement
Modular Ceiling gives benefit for easy access to plenum for services without requirement of any ceiling installer.
Simple and safe installation
Can be used for Semi-Exterior Areas.
Good Acoustic performance with 0.7 NRC
19.4 Advantages
Fast & Dry Installation – No requirements of Nails and Glue.
Factory finished
Can be removed and reinstalled in other location
Easy access to Services above ceiling for maintenance
19.5 Precautions during execution
Suspension: M6 threaded rod to be used for suspension of Clip-In system with appropriate anchor.
Perimeter: Use 19X32mm Wall Moulding for Clip-In system.
Distance of the first suspension point should not be more than 300mm from the perimeter and maximum distance of 1200mm centre to centre between suspension in both the directions.
Place the first primary steel angle section (C - Channel) at a distance not greater than 300mm with on centre distance between two steel angle not greater than 1200mm.
20. Metal Pelmet For Curtain
20.1 Introduction
Metal Pelmet system for Curtain.
Perfect match in color with ceiling Grid system.
Direct Integration with False Ceiling.
No Carpentry work on site, Pelmet comes factory finish.
Ideal for Applications like Offices, Education, Hospitality, Healthcare etc.
20.2 Base Preparation
20.3 Design Details
20.3 Method Statement
20,4 Advantages
Fast & Dry Installation – No requirements of Nails and Glue.
No Carpentry work on site, Pelmet comes factory finish.
Can be removed and reinstalled in other location.
Custom profile, slotting, available for large projects
20.5 Limitation
Pre-engineered Pelmet trims integrate perfectly with False Ceiling suspension systems.
Better quality control at the perimeter and reduces risk associated with field fabrication.
Improves construction efficiency.
20.6 Precautions during execution
Knauf Axiom Pelmet system should be installed to comply with all standards and Knauf recommended guidelines.
21. Glazing Channel for Glass Partition from False Ceiling
21.1 Introduction
Glazing Channel for Glass Partition from Ceiling.
Offers fully concealed integration with all Knauf acoustical and drywall ceiling systems.
Coordinated fit and finish ensures delivery of design intent
Offers clean installed visual so that glass can disappear into the plenum
21.2 Base Preparation
Glazing Channel is Installed with False Ceiling Suspension System.
21.3 Method Statement
21.4 Advantages
Fast Installation
Glass disappearing into the ceiling.
No field fabrication
Preferred solution for fast-track project.
21.5 Limitation
Pre-engineered Glazing Channel integrates perfectly with False Ceiling suspension systems.
No Carpentry work required on site.
Saving -Less Labour
Fast & Dry Installation – No requirements of Nails and Glue.
Improves construction efficiency.
21.6 Precautions during execution
Knauf Glazing Channel should be installed to comply with all standards and Knauf recommended guidelines.
22. Custom Made Plain Metal Ceiling
22.1 Introduction
Interior and Semi-exterior custom False Ceiling solutions in metal
Versatile system and simple design
Panel dimensions 300 - 750mm (w) & upto 3000mm (l)
Concealed grid for a monolithic effect
Ease of installation (alignment) and fully demountable
Ideal for Applications like Porch, Lobbies, Offices, Education, Transportation etc.
22.2 Base Preparation
22.3 Method Statement
22.4 Advantages
Fast & Dry Installation – No requirements of Nails and Glue.
Factory finished
Can be removed and reinstalled in other location
Easy access to Services above ceiling for maintenance
Most versatile custom system for metal plank design, suitable for regular and staggered patterns
22.5 Limitation
Modular Ceiling gives benefit for easy access to plenum for services.
All panels are fully accessible without the use of tools
Simple and safe installation
Can be used for Semi-Exterior Areas.
Factory cutouts available on request for services
22.6 Precautions during execution
U-prole are installed 1200mm on center with a maximum distance of 460mm to perimeter walls.
U-prole are suspended with 2.5mm galvanized wire, wires must be within 460mm of the perimeter wall. then1200mm on center.
Hanger wire must be wrapped tightly with 3 full wraps within 75mm of the U-prole.
Level U-prole to within 6mm in 3000mm. U-prole will be 95mm above the finished ceiling height.
23. Acoustical Custom-Made Perforated Metal Ceiling With NRC Upto 0.7
23.1 Introduction
Interior and Semi-exterior custom False Ceiling solutions in metal
Versatile system and simple design
Panel dimensions 300 - 750mm (w) & upto 3000mm (l)
Concealed grid for a monolithic effect
Ease of installation (alignment) and fully demountable
Ideal for Applications like Porch, Lobbies, Offices, Education, Transportation etc.
23.2 Base Preparation
23.3 Method Statement
23.4 Advantages
Fast & Dry Installation – No requirements of Nails and Glue.
Factory finished.
Can be removed and reinstalled in other location.
Easy access to Services above ceiling for maintenance
Most versatile custom system for metal plank design, suitable for regular and staggered patterns
23.5 Limitation
Modular Ceiling gives benefit for easy access to plenum for services.
Superior Acoustical Performance with NRC upto 0.7
All panels are fully accessible without the use of tools.
Simple and safe installation
Can be used for Semi-Exterior Areas.
Factory cutouts available on request for services
23.6 Precautions during execution
U-prole are installed 1200mm on center with a maximum distance of 460mm to perimeter walls.
U-prole are suspended with 2.5mm galvanized wire, wires must be within 460mm of the perimeter wall. then1200mm on center.
Hanger wire must be wrapped tightly with 3 full wraps within 75mm of the U-prole.
Level U-prole to within 6mm in 3000mm. U-prole will be 95mm above the finished ceiling height.
23.7 Areas of applications
24. Custom Made Acoustical Wall Panel With NRC Of 0.85
24.1 Introduction
Acoustical Custom wall panel give option for end-to-end installation.
Fire Rated – Class A as per ASTM E-84
Versatile system and simple design
Ease of installation (alignment) and fully demountable
Ideal for Applications like Atriums/Lobby, Theatres and Auditoriums, Conference Room, Offices etc.
24.2 Base Preparation
24.3 Design Details
24.4 Method Statement
24.5 Advantages
Fast & Dry Installation – No requirements of Nails and Glue.
Factory finished.
Can be removed and reinstalled in other location.
Available in wide range of custom size to meet individual design requirements.
Easy to install over existing walls.
24.6 Limitation
Panel comes factory finish with proper edge details.
Superior Acoustical Performance with NRC upto 0.85
Simple, safe and fast installation
Fire Rated – Class A as per ASTM E-84
24.7 Precautions during execution
24.8 Areas of applications
25. Waterproofing to existing terrace using Sunkote
25.1 Introduction :
Ready to use 400 % elongable acrylic system for waterproofing of existing terrace, podium etc. without removal of brick bat coba.
Using Polymeric cementitious membrane (MPBP) membrane (Polyalk WP) +
Acrylic (TMPBP) Membrane (Sunkote)
25.2 Base Preparation
Break open the existing IPS (which is having cracks and leading to leakages) and expose the brick bat coba’s top surface.
If there are any voids or gaps in brick bat coba, fill the same by pouring cement slurry of 1 part of cement and 3 parts of water. Add one pouches of 330 grams each Shrinkage compensating admixture per 50 kg of cement. Fill the joints with cement mortar 1:4.
Since the exposed brick bat coba surface is very rough, give a leveling course of 10 to 15 millimeters cement mortar (1:4 ratio) and cure it properly.
Since the vatta portion is also important part of waterproofing. Similar care and treatment shall be to vatta portion.
25.3 Design Details
Ready to use 400% elongable acrylic system for waterproofing of existing terrace without removal of brick bat coba Polyalk WP + Sunkote
25.4 Method Statement
Mix 1 part of 2-(methoxycarbonyl)-1-propene-Butyl-2 propenoate (MPBP) membrane Polyalk WP and 0.30 part of cement by weight using a low speed mechanical stirrer to form slurry lump free consistency.Apply this as primer coat up to parapet walls.
After the primer coat is set, apply first coats of pure enoate based polymer titanium dioxide based 2-(methoxycarbonyl)-1-propene-butyl-2 propenoate (TMPBP) and 2-(methoxycarbonyl)-1-propene-Butyl-2 propenoate (MPBP) single Component, UV Resistant, Elastomeric, High Build Waterproof Coating (Sunkote)waterproof coating surface.
After the first coat is dried apply 2nd coat of above material.
Sprinkle quartz sand on the 2nd coat when it is tacky.
After 24 hours provide 25 mm thick IPS of M 20 grade as top coat and finish the same using shrinkage compensating admixture 330 gram pouch per bag of cement use
25.5 Advantages of Methodology
Only removal of IPS is recommended. No need of removal of entire existing BB coba & other material up to mother surface of Slab.
User friendly.
It is in liquid form, after application it forms a seamless membrane.
The cementitious waterproof primer has elongation property of 100%. This has excellent adhesion with the matrix.
The pure enoate based polymer titanium dioxide based 2(methoxycarbonyl)-1-propene-butyl-2 propenoate (TMPBP) waterproofing material is having elongation property of 400 %.
These two materials will not allow the penetration of water.
Use of Shrinkage compensating admixture in mortar & IPS will reduce cracking.
Guaranteed waterproofing.
25.6 Limitations
Normally waterproofing is done of Brick bat coba covered with IPS. Admixtures are used to reduce shrinkage in joints & top layer. Over a period cracks are developed in the top surface & water starts percolating in the BB coba. Once the bricks are saturated, leakages are started through existing waterproofing system.
In the proposed technology, only removal of top IPS is to be done. After removal of IPS hollow joints of BB coba to be refilled & rough surface to be leveled & primer of polymeric cementitious membrane followed by 2 coats of Acrylic membrane is to be applied & then to be covered with IPS as protection screed. Use shrinkage compensating Polymeric admixture in the mortar as well as IPS.
25.7 Precautions during execution
The joints of BB coba shall be refilled where ever necessary.
After providing leveling course over BB coba, it shall be cured.
The surface shall be clean & dry before application of primer & subsequent coating.
It shall be ensure that vatta is also properly covered.
It shall be ensure that sufficient rainwater down take pipes are provided and are properly fixed & its joints are filled up properly.
All safety measures strictly followed.
26. Waterproofing to new terrace using Sunkote
26.1 Introduction
Ready to use 400% elongable acrylic based system for
waterproofing of new terrace
Polymeric cementitious membrane (MPBP) membrane(Polyalk WP) + Acrylic ((TMPBP)Membrane (Sunkote
26.2 Base Preparation
Clean the existing surface / terrace thoroughly to remove dirt, loose particles, laitance etc. by vacuum cleaner or high pressure jet or wire brushing as per requirement.
Fill the cracks if any with acrylic polymeric non-shrink crack filler putty as approved by Engineer in charge a pure aliphatic, acrylic, polymer modified ready to use paste.
Allow the surface to dry for atleast 24 hrs.
Since the vatta portion is also an important part of waterproofing. Similar care and treatment shall be to vatta portion.
26.3 Design Details
26.4 Method Statement
Mix 1 part of 2-(methoxycarbonyl)-1-propene-Butyl-2 propenoate (MPBP) Polymeric membrane and 0.30 part of cement by weight using a low speed mechanical stirrer to form slurry lump free consistency. Apply this as primer coat up to parapet walls.
After the primer coat is set, apply first coats of pure enoate based polymer titanium dioxide based 2-(methoxycarbonyl)-1-propene-butyl-2 propenoate (TMPBP) and 2-(methoxycarbonyl)-1-propene-Butyl-2 propenoate (MPBP) single Component, UV Resistant, Elastomeric, High Build Waterproof Coating waterproof coating surface.
After the first coat is dried apply 2nd coat of above material.
Sprinkle quartz sand on the 2nd coat when it is tacky.
After 24 hours provide 112 mm thick 25 mm thick IPS of M 20 grade as top coat and finish the same using shrinkage compensating admixture 330 gram pouch per bag of cement use
26.5 Advantages
The Polymeric paste for crack filling has auto suction property, hence gets sucked up to bottom of crack. Repeat the crack filling till crack is fully bridged.
User friendly.
It is in liquid form, after application it forms a seamless membrane.
The cementitious waterproof primer has elongation property of 100%. This has excellent adhesion with the matrix.
The pure enoate based polymer titanium dioxide based 2(methoxycarbonyl)-1-propene-butyl-2 propenoate (TMPBP) waterproofing material is having elongation property of 400%.
These two materials will not allow the penetration of water.
Use of Shrinkage compensating admixture in mortar & IPS will reduce cracking.
Guaranteed waterproofing.
26.6 Limitation
Normally waterproofing is done of Brick bat coba covered with IPS. Admixtures are used to reduce shrinkage in joints & top layer. Over a period cracks are developed in the top surface & water starts percolating in the BB coba. Once the bricks are saturated, leakages are started through existing waterproofing system.
In the proposed technology, primer of polymeric cementitious membrane followed by 2 coats of Acrylic membrane is to be applied & then to be covered with BB coba for maintaining slope with IPS as protection screed. Use shrinkage compensating Polymeric admixture in the mortar as well as IPS.
Very effective in heavy rainfall areas.
26.7 Precautions during execution
The surface shall be clean & dry before application of primer & subsequent coating.
It shall be ensure that vatta is also properly covered.
It shall be ensure that sufficient rainwater down take pipes are provided and are properly fixed & its joints are properly filled up.
All safety measures strictly followed.
27. High performance impregnating coating to RCC/PCC using Polyalk 2M1P
27.1 Introduction
Protection to RCC/ PCC surface in saline or chemical conditions using high performance Low-Viscosity, Transparent, Solvent-Free, Three Component, 2-(Methoxycarbonyl)-1-Propene Base impregnating coating
27.2 Base Preparation
The surface shall be made free of oil, grease, dust or any foreign material & complete dry.
27.3 Method Statement
Empty entire pre packed and pre-weighed contents of ‘B’ Component into a pail containing ‘A’ Component. Mix for 30 seconds with a low speed stirrer. (400- 600 rpm). After proper mixing of component ‘A’ and ‘B’, now empty entire pre- packed and pre weighed part ‘C’ component into the mix and using a mechanical stirrer mix all the components for 1-3 minutes with a low speed stirrer. (400-600 rpm) (Polyalk 2M1P)
Make only as much material as can be used by the available manpower within 15 - 20 minutes.
Apply the first coat of this material within 15 to 20 minutes after mixing.
Make sure that the surface is fully dry before applying the first coat.
After 1 st coat is dried, apply the 2nd Coat.
27.4 Advantages
All coatings are applied on the surface which forms a barrier between substrate & liquid or chemicals
whereas this material impregnates into a matrix of concrete & fills all porosity & voids.
Thus, ingress of any chemicals in to the matrix is stopped.
Enhances the life of the structure.
27.5 Limitation
All coatings are applied on the surface and form a film on it whereas this material impregnates into matrix of concrete.
27.6 Precautions during execution
The Concrete substrate shall be cured & fully dry.
All safety measures shall be strictly followed.
28. Anti corrosive, chemical resistant food grade epoxy coating
28.1 Introduction
Anti corrosive, chemical resistant Food grade epoxy coating to RCC water storage structure, tanks using high build food grade epoxy.
28.2 Base Preparation
Clean the surface by water jetting, scrapping & removing oil, grease, any other foreign material.
Surface shall be fully dried.
28.3 Method Statement
Mix 2 parts Resin & 1 part of hardener of LCNR Epoxy primer and apply one coat on the concrete/ steel surface using brush/ roller/spray. Allow it to set for 24 hours.
Mix 4 parts Resin & 1 part of hardener of High build Food grade Epoxy and apply 1st coat on the primed surface using brush/ roller/spray. Allow it to set for 24 hours.
Apply 2nd coat on the surface using brush/ roller/spray. Allow it to set for 24 hours.
28.4 Advantages
User friendly.
A barrier is formed on the substrate which protects the RCC from attack of chlorides or chemicals used during purification of water.
Enhances life of the structure.
28.5 Limitation
Normally anti corrosive & chemical resistant coatings are not applied. Hence there are cases of damage to RCC due to presence of chlorides in the water.
With application of Epoxy LCNR primer & Food grade high build epoxy coating a barrier is formed on the surface.
28.6 Precautions during execution
Surface shall be free from oil , grease, any foreign material & fully dry.
Ensure no pin hole is left out on the coat.
All safety measures shall be strictly followed.
29. Ready to use anti wash out micro concrete Sunhydrocrete
29.1 Introduction
Ready to use anti washout micro concrete for underwater works :-
29.2 Base Preparation
Surface shall be clean
29.3 Method Statement
Mix 10 to 14% of water in the material & stir it well using a mechanical mixer and place the same at desired location.
Make only as much material as can be used by the available manpower within 20 - 30 minutes.
Keep the consistency of mortar between stiff and workable.
29.4 Advantages
Saving a large amount of cement which otherwise would have been washed out.
Will make construction of hydraulic structures lot easier.
29.5 Limitation
Ordinary concrete washes away when used for underwater works.
This material prevents washing away of concrete.
29.6 Precautions during execution
Mix the material as only can be used immediately.
All safety measures shall be strictly followed.
30. Anti washout admixture for under water concrete (sunplast AWA)
30.1 Introduction
Anti washout admixture in concrete for underwater works, where the problem of ingredient like cement, fine aggregates may get washed under the capillary upward pressure of the under ground water.
30.2 Base Preparation
Shuttering as required for concreting
30.3 Method Statement
Admix 400 ml - 750 ml per 50 kg bag of cement.
Dosage depends on cement content, water-cement ratio and degree for washout resistance required. Varying concrete temperature, ambient temperatures or designed concrete mix containing special admixtures may require varied dosage.
Trials may be conducted to determine the suitability of dosage under such cases.
30.4 Advantages of Methodology
Anti Washout Polymer compound formulated to provide highly fluid, easily placed and consolidated concrete that will resist washout and segregation during placement and curing under water, thereby protecting the mechanical properties of the concrete structure.
30.5 Limitation
Ordinary concrete washes away when used for underwater works.
This admixture in concrete prevents washing away of concrete.
31. Suncrete PU MF polyurethane flooring for parking, godowns, industries
31.1 Introduction
Polyurethane concrete flooring PU MF to resist wear & tear for car parking, godowns, industrial floors etc.
31.2 Base Preparation
Remove all dust, debris, grease, oil, dust, residual curing compound, mould release agent or other contaminants that could impair adhesion.
Ensure that the compressive strength of floor concrete is at least 25MPa.
The concrete slabs (directly in contact with the ground) shall have a proper vapour barrier installed.
It shall be ensured that the moisture content in the floor shall not be more than 4% by using suitable moisture detection techniques.
31.3 Method Statement
Mix the 3 components of PU MF using a mechanical stirrer. The materials are supplied in a pre-measured container.
All surfaces treated should be primed with PU MF (mixed as per instruction) as a scratch coat of 1 mm shall be applied immediately to the prepared substrate using stiff brushes and/or rollers.
The primer should be well ‘scrubbed’ into the substrate to ensure full coverage, care should be taken to avoid over application.
Allow the scratch coat of PU MF to dry completely before applying any screed or top coat. Suncrete PU MF Top coat.
Install PU MF of cove base as required.
The material should be applied onto the prepared and primed substrate as soon as mixing is complete. Screed or trowel apply the mixed material onto the floor. Hand trowel or power trowel the material to compact and level the topping to the required thickness of 3 mm.
Immediately after laying, the material should be rolled, using a spiked nylon roller, to assist air release. The rolling should be carried out using a ‘back and forth’ technique along the same path. An overlap of 50% with adjacent paths is recommended. Further light rolling may be required to remove surface imperfections, or for subsequent release of trapped air, but should be prior to the setting of the product.
Flooring should be protected and left to cure for a minimum of 7 days after laying of final coating.
31.4 Advantages of Methodology
Very tough & abrasion resistant flooring to resist wear & tear down to movement of vehicles etc.
31.5 Limitation
Very tough & abrasion resistant flooring useful in car parking, godowns.
Maintenance free
31.6 Precautions during execution
Ensure to remove all dust, debris, grease, oil, dust, residual curing compound, mold release agent or other contaminants that could impair adhesion
Use mechanical devices for mixing of material.
Follow manufacturers instructions
Follow safety norms
32. Ready to use admixture for sealing porosity, capillaries in concrete (Suncrystalmix)
32.1 Introduction
Ready to use integral crystalline waterproofing admixture in concrete for basement, water/liquid retaining structures
32.2 Method Statement
The crystalline mix shall be used 0.80% of the cementitious material or as per manufacturer's specifications in concrete.
32.3 Advantages
Crystalline mix contains Portland cement, very fine treated silica sand and various active, proprietary chemicals. These active chemicals react with the moisture in fresh concrete with the by-products of cement hydration to cause a catalytic reaction, which generates a non-soluble crystalline formation throughout the pores and capillary tracks of the concrete to permanently seal against the penetration of water or liquids from any direction.
33. Elastomeric decorative paint
33.1 Introduction
Ready to use 100% acrylic Elastomeric decorative paint for external wall surface of the buildings.
33.2 Base Preparation
Clean the surface to remove dirt, loose particles.
Examine the surface closely for any cracks.
Clean the cracks.
Provide and fill a pure acrylic, polymer modified ready to use paste
Apply acrylic primer
33.3 Method Statement
Surface Cleaning:
Clean the RCC/ concrete/ plastered surface with wire brush and finally by compressed air jet or even the suction pump can be used to remove all the dust.
This operation exposes the cracks on the surface and also removes loose cement slurry, laitance etc.
This is an important step as it helps in improving the adhesion of polymeric treatment to surface to enhance the efficacy of waterproofing.
Crack Filling:
The cracks on the bare slab shall be cleaned, and shall be injected with auto suction, non-shrink, ready to use polymeric paste. The same process shall be repeated till the crack is fully filled up.
Apply primer Coat on the surface as follows:
Wash the surface with a water jet and ensure that there is no standing water.
Mix 1 litre of ‘100 % acrylic’ paint with approximately 700 ml of water to adjust the requisite film thickness. Stir well and apply one coat by brush/ roller/ spray at an interval of 24 hrs.
Applying top coats:-
Apply two coats of Elastomeric paint without dilution by brush or roller at a time interval of 6-8 hours. DFT of 2 coats shall not be less than 100 microns.
33.4 Advantages
Protecting and waterproofing exterior masonry substrates with excellent flexible, Waterproof, Anti-fungal, Anti-carbonation, dust resistant, highly UV resistant coating.
33.5 Limitation
Cement based paints were used for exterior wall painting of the buildings.
33.6 Precautions during execution
Proper surface preparation
Crack filling
Proper mixing & application
Following safety norms
34. Epoxy flooring using Sunepoxy underlay & SL top coat
34.1 Introduction
Self-leveling epoxy flooring for all laboratory/ operation theaters of hospitals/ clean rooms/ computer labs etc
34.2 Base Preparation
Remove all dust, debris, grease, oil, dust, residual curing compound, mould release agent or other contaminants that could impair adhesion.
Ensure that the compressive strength of floor concrete is at least 25 Mpa.
The concrete slabs (directly in contact with the ground) shall have a proper vapour barrier installed.
It shall be ensured that the moisture content in the floor shall not be more than 4% by using suitable moisture detection techniques.
Cleaning joint area, if any, and sealing joint area with specially formulated heavy duty, high strength, self-curing, non shrink, fast track repairing grade EPOXY LCNR epoxy resin rich mortar and making joint area properly sealed and smooth.
Repairing major defects in basic concrete floor area with specially formulated heavy duty, high strength, self curing, non shrink, fast track repairing grade epoxy lcnr mortar and making basic floor properly prepared.
34.3 Design Details
34.4 Method Statement
Priming the surface with epoxy primer : Epoxy LCNR
EPOXY LCNR has a 2:1 resin: hardener ratio. Mix one batch at a time. Pour half Kg of the hardener into One Kg resin into a bucket.
Mix the materials thoroughly using a slow speed (300-500 rpm) flame proof or air driven drill fitted with a mixing attachment.
Mix the materials thoroughly using a slow speed (300-500 rpm) flame proof or air driven drill fitted with a mixing attachment.
Apply the one coat of EPOXY LCNR mix by roller as the priming coat.
34.5 Comparison with conventional materials
Tough & abrasion resistant flooring
Maintenance free
Chemical resistant
Hygienic conditions can be maintained
34.6 Application of Base Coat - Epoxy SL Underlay
EPOXY SL UNDERLAY flooring is supplied in three pre-weighed packs (base, hardener, aggregate) which are ready for immediate on-site use. Mixing should be carried out using a slow speed power mixer.
First Mix Part A & Part B, thereafter, the contents of the graded aggregate pack (Part C) should be slowly added and mixing carried out for a further 3 minutes until a completely homogeneous material is obtained.
Application:-
The material should be poured onto the prepared and primed substrate as soon as mixing is complete. It should be spread to the required thickness of 2 mm using a serrated trowel; with care taken not to overwork the resin, spreading evenly and slowly.
Immediately after laying, the material should be rolled, using a spiked nylon roller, to remove slight trowel marks, and to assist air release. The rolling should be carried out using a ‘back and forth’ technique along the same path.
An overlap of 50% with adjacent paths is recommended. Further light rolling may be required to remove surface imperfections, or for subsequent release of trapped air, but should be done prior to the setting of the product.
34.7 Advantages of the product when used.
Upon application the epoxy resin coating forms a smooth and level texture on the surface of the floor. The coating tends to automatically fill any uneven parts of the floor.
When laid on the floor it provides an aesthetic, smooth, monolithic, light reflective surface
Easy to apply. Flowable
Self leveling, glossy
Excellent resistance to wide range of chemicals
Excellent abrasion resistance
Provides a dense, impervious seamless floor surface
Hygienic surface
Available in wide range of colors to enhance the working environment
34.8 Precautions during execution
Proper surface preparation
Proper mixing in the proportion given by manufacturer
Uniform application
Follow safety noms
35. Enhancing strength of concrete using (Polytancrete NGT) admixture
35.1 Introduction
Admixture for reducing water & enhancing strength of concrete
35.2 Method Statement
Application procedure for admixture only : It can be added at batch mix plant or in transit mixer or at site of work and mix it thoroughly.
Doses: It shall be 150 to 400 ml per 50 kg of cement in concrete, but dose to be adjusted depending up on the required workability as per mix design.
35.3 Advantages of Methodology
Reduces water requirement & enhances strength of concrete.
35.4 Limitation
Higher dose of admixture required to achieve higher strength of concrete.
36. Basement waterproofing using Sunprufe HDPE sheets
36.1 Introduction
Ready to use Sunproof HDPE sheet waterproofing system for basement
36.2 Base Preparation
Surface Preparation:
Substrates should be uniform with no gaps or voids greater than 12 mm. Where these exist fill with a material of sufficient strength to support the membrane. All substrates must be free of loose aggregate and sharp protrusions. Where possible, avoid rounded concrete blinding.
The surface does not need to be dry, but standing water must be removed. Substrates must have sufficient rigidity not to move during the concrete pour. Boarded substrates must be close butted to provide support and not more than 12 mm out of alignment.
36.3 Method Statement
All below ground concrete shall be fully encapsulated with one layer of pre-applied fully bonded HDPE waterproofing membrane 1.2 mm (min.) thick. Place the membrane with the zip strip facing towards the concrete pour. Kick out or roll out the membrane with HDPE film side to the substrate. End laps should be staggered to avoid a buildup of layers. Leave zip strips on the membrane until the overlap procedure is completed. Accurately position succeeding sheets to overlap the previous sheet 80 mm along the marked edge. Peel back and remove both the zip strips in the overlap area to achieve an adhesive-to-adhesive bond at the overlap. Ensure a continuous bond is achieved without creases and roll firmly with a heavy roller.
HDPE membrane shall be projected by 250 mm on all sides of concrete structures from PCC top level.
SEAL TAPE is an 80 mm-wide tape to be used in detail areas including end laps and various tie-ins. It is also used to patch damaged areas in the HDPE membrane.
On completion of the installation, ensure complete removal of the plastic zip strips from all overlaps.
Ensure there are no creases or trapped air in the laying of membrane.
36.4 Advantages of the product :
HDPE membrane is a pre-applied fully bonded HDPE self-adhesive waterproofing membrane that bonds to the wet concrete.
Chemical Stability against common organic and inorganic acids, alkalis, salts and organic solvents.
No protection layer required with a material of sufficient strength to support the membrane. All substrates must be free of loose aggregate and sharp protrusions. Where possible, avoid rounded concrete blinding.
36.5 Limitation
Conventional method : Box type waterproofing treatment. Consumes a lot of time. Skilled workers are rare now. Unavailability of good quality fine aggregates for mortar.
HDPE membrane can be laid very fast & cost effective in terms of time required.
36.6 Precautions during execution
Laying to be done as per manufacturer's directions for effective use.
37. Acoustic Cellulose Fibre Spray – 20mm Thick
37.1 Introduction
Supply and installation of Acoustic Cellulose Fibres AchoSpray having 20mm thick Eco-friendly, Fire resistant, Thermal resistant; a cellulosic acoustic insulation, sprayed using Cyanoacrylate Insta-Bond GRADE-2, with a sound absorption of NRC 0.80, or higher as per EN ISO 354 Standards, made of fire resistive material that achieves a flame spread rating of B-s1,d0 (Euro Standards) when tested in accordance with EN13501-1:2009 Standards, with thermal conductivity W/m-K 0.037 as per ISO 8302:2002-4 Standards. Material should have achieved class BA:0 Standards for Bacteria & Fungal test as per EN 15101-1:2013 Standards. The material shall be applied on fully cured concrete/gypsum/Lath/metal ceiling surface at site using necessary supports, including scaffolding upto 3.5 m ceiling height ( Above 3.5 m height extra charges for scaffolding shall be applicable), system to be installed by skilled labour as directed by Engineer in Charge.
37.2 Specifications
Acoustic Cellulose Fibre Spray – 20mm Thick
Cellulose fibres spray contains natural fibres is made from recyclable wooden pulp and papers, through a special processing machine to form green environmental protection building material which are with porous in structure. They can absorb sound energy effectively, reduce and eliminate noise and can be sprayed on the underlying surface of the building directly, but don't affect the original configuration of the space where it is applied. It also has the property of fire prevention, Thermal insulation, etc.
CEILING/WALL PREPARATION FOR CELLULOSE SPRAY
The surface of wall or ceiling/deck slab/other, to be painted shall be prepared plumb/levelled and dust free to the satisfaction of the Architect, and then needs to be applied with two coats of primer, two coats of readymade putty and touch up putty if required to achieve smooth finish. Thereafter we can start acoustic spraying works.
37.3 Advantages
Sound Absorption (NRC) can be achieved upto 1.0
Thermal Resistivity of 0.0386 W/m.K
Can be spray on any form of structure and Hard Surface material.
Resistant to Fire and Humidity
Different color and texture options
Easy and fast to apply
Seamless appearance
Reduces reverberation
Sustainable
Hygroscopic
38. Acoustic PET/Non-Woven Standard Tiles
38.1 Introduction
Providing and Fixing Acoustical Polyethylene Terephthalate Standard Tiles of various colours having size 595mm x 595mm, made from compressed polyester fibre of 13 mm thickness, 2000 GSM Density. The Polyethylene Terephthalate Panel should be Highly resistance to humidity (RH:99%), water vapour diffusion resistance (as per ISO-12572-2016 standards), zero mold growth (as per EN-15101-1 standards), Highly versatile and (Class A) flame retardant (as per BS-3119 standards, IS-15061 standards) and Thermal conductivity (as per EN12667 standards). 25mm RGB sheet (Density 48 kg/m3) and high quality 1mm freudenberg acoustic fleece
should be placed above the false ceiling tiles. The Panel should have an Avg NRC of 0.80. The tiles should be fixed on pre-coated SS T-Grid of 15mm, having the grid work of 600x600mm with suspension, wall angles, runners and all other accessories, including scaffolding upto 3.5 m ceiling height (Above 3.5 m height extra charges for scaffolding shall be applicable). system to be installed by skilled labour as directed by Engineer in Charge.
38.2 Specifications
For Acoustic PET/Non-Woven Standard Tiles, CNC Machines is used for cutting, perforations, profiling and various other design required as per architects choice
Indosonic Acoustic Non Woven Fibre Panel
Size: 1220x2420mmm,
Thickness: 13mm, other sizes also available
Density of polyster fibre board: 1100gsm-3600gsm
Fire protection: ASTM E84
Environmental protection: E1 polyester acoustical panels
Acoustic performance: NRC 0.8 or higher
Colors and patterns: normal, 3D, printed, textured, 16 standard colours.
Packing: plastic bags and cartons
GI/WOODEN Framing for Walls and Ceiling are to be made
38.3 Design & Execution Details
For Acoustic PET/Non-Woven Standard Tiles
1 Preparation of production planning report as per sales order no, given by sales back office team to production manager in accordance to the final specifications defined by customer suitable to site conditions quantity and delivery schedule.
2 Preparation of manufacturing schedule /bar chart using pert / cpm combination method being production and construction scope involved in works.
3 Selection of non woven /pet board as per requirement for 8'x4' size board by selecting density out of 1500 kg/m3, 1800 kg/m3, 2000 kg/m3, 2500 kg/m3 and thickness of available size of 10mm, 13mm, 15mm, 18mm, 20mm, 22mm, 25mm (nrc value varies as per this selection) also to see verging or recycled material, colour and Indian or international standards compliance for various physical, chemical and mechanical properties of this material.
4 Preparation of drawing to be fed to cnc lesser cutting machine for required design, cutting, making groves, tiles or panels formation, perforation (micro, helmhotz , square et.c) colour , designs -shapes etc
5 Formation of tiles or panels of required sizes
6 Packings with lldpe film wrapped over panels and kept stacking positions in godown or tiles products wrapped by film and kept in carton boxes as per quantity, set of 10,20,30,40,50 nos, each, this is standard size of packing.
7 Manufacturing of panels or tiles for wall mounted and ceilings at site is defined
38.4 Advantages
Made from 100 % Recycled material
Light weight, Flexible & Easily Customizable
Easy Installation & Maintenance
High Resistance to Humidity, Moisture & Chemicals
Does not aid to the spread of fire
Mold-free product
Safety all along – Causes no irritation nor any allergies
39. Acoustic Non-Woven/PET Ceiling Baffles
39.1 Introduction
Providing & Fixing of Acoustic Ceiling Baffles made of 100% Polyethylene Terephthalate material having size of panel 150mm(H) x 50mm(W) x 1200mm(L), Colour should be as per approval from the Architect/Engineer in charge, with impregnated bolts for hanging vertically from ceiling, achieving 0.95 NRC/equivalent 1 Metric Sabin. Bolts supported from ceiling using SS wire of min. 1mm dia. Each baffle must be hung vertically using 2 suspension bolts only and levelled in perfect plane having interspacing distance of 100mm. Highly resistance to humidity (RH:99%), water vapour diffusion resistance (as per ISO-12572-2016 standards), zero mold growth (as per EN-15101-1 standards), Highly
versatile and (Class A) flame retardant (as per BS-3119 standards, IS-15061 standards) and Thermal conductivity (as per EN12667 standards). Including leveling, scaffolding upto 3.5 m ceiling height ( Above 3.5 m height extra charges for scaffolding shall be applicable) etc complete. system to be installed by skilled labour as directed by Engineer in Charge.
39.2 Specifications
Acoustic Non-Woven/PET Ceiling Baffles
Made from PET/Non-Woven Sheet of Size: 1220x2420mmm,
Thickness: 10mm - 50mm, other sizes also available Density of polyster fibre board: 1100gsm-3600gsm
Fire protection: ASTM E84
Environmental protection: E1 polyester acoustical panels
Acoustic performance: NRC 0.8 or higher
Colors and patterns: normal, 3D, printed, textured, 16 standard colours.
Shapes : Linear and non-linear (Wavy) Patterns shapes
Packing: plastic bags and cartons
39.3 Design Details
Framework: The material used for the purpose of preparing the baffles are the made up of PET and is quite light in weight.
Adjustable Cable- The roof hanging that takes place through the acoustic assembling possess an adjustable cable. It offers you with complete amount of flexibility as well as make sure that you are able to have the hanging which is full of cable hanging kit.
PET Casing- The products are well prepared through the PET casing that will help to provide you with a better kind of fabric. It will make sure that you will have to get some
of the best experience that will impart you with the great variety of noise control.
39.4 Execution Details
1 Preparation of production planning report as per sales order no, given by sales back office team to production manager in accordance to the final specifications defined by customer suitable to site conditions quantity and delivery schedule.
2 Preparation of manufacturing schedule /bar chart using pert / cpm combination method being production and construction scope involved in works.
3 Selection of non woven /pet board as per requirement for 8'x4' size board by selecting density out of 1500 kg/m3, 1800 kg/m3, 2000 kg/m3, 2500 kg/m3 and thickness of available size of 10mm, 13mm, 15mm, 18mm, 20mm, 22mm, 25mm (nrc value varies as per this selection) also to see verging or recycled material, colour and Indian or international standards compliance for various physical, chemical and mechanical properties of this material.
4 Preparation of drawing to be fed to cnc lesser cutting machine for required design, cutting, making groves, tiles or panels formation, perforation (micro, helmhotz , square et.c) colour , designs -shapes etc
5 Formation of tiles or panels of required sizes
6 Packings with lldpe film wrapped over panels and kept stacking positions in godown or tiles products wrapped by film and kept in carton boxes as per quantity, set of 10,20,30,40,50 nos, each, this is standard size of packing.
7 Manufacturing of panels or tiles for wall mounted and ceilings at site is defined
40. Acoustic PET/Non-Woven Wall Panel
40.1 Introduction
Providing and fixing in position Acoustic Polyethylene Terephthalate Wall Panel of various colours having size 2400mm x 1200mm, made from compressed polyester Fibre of 13mm thickness, 2000 GSM Density. The Polyethylene Terephthalate Panel should be Highly resistance to humidity (RH:99%), water vapour diffusion resistance (as per ISO-12572-2016 standards), zero mold growth (as per EN-15101-1 standards),
Highly versatile and (Class A) flame retardant (as per BS-3119 standards, IS-15061 standards) and Thermal conductivity (as per EN12667 standards), The product should have an acoustical performance of 0.80 NRC. The Panel should be fixed on Anodised Aluminium framework of 50mm x 50mm x 1.5mm equally spaced and welded at distance of 600x600mm center to center, Anodised Aluminium hollow space section
should be filled with Polyurethane sound resistance chemical. The wall should be treated with 2mm Mass Loaded Vinyl Membrane and Suitable Wall Isolators should be fixed to the frame to achieve the STC of 30dBA. The frame infill should be of 50mm Polysynth (density 1000 GSM). The framework should be finished with 10mm Marine-ply as per IS 710 standard having 22 to 25mm Helmholtz perforations. The
exposed surface of the ply should be treated with finishing material of 13mm Polyethylene Terephthalate panel by using Cyanoacrylate Insta-Bond Standard. The paneling shall be finished as per the design, sizes, colour, cut-outs, joints and all other elements as directed by the architect / Engineer in Charge. Including leveling, scaffolding upto 3.5 m ceiling height ( Above 3.5 m height extra charges for scaffolding shall
be applicable) etc complete. system to be installed by skilled labour as directed by Engineer in Charge.
40.2 Specifications
Size: 1220x2420mmm,
Thickness: 10mm - 50mm, other sizes also available
Density of polyster fibre board: 1100gsm-3600gsm
Fire protection: ASTM E84
Environmental protection: E1 polyester acoustical panels
Acoustic performance: NRC 0.8 or higher
Colors and patterns: normal, 3D, printed, textured, 16 standard colours.
Packing: plastic bags and cartons
40.3 Execution
1 Preparation of production planning report as per sales order no, given by sales back office team to production manager in accordance to the final specifications defined by customer suitable to site conditions quantity and delivery schedule.
2 Preparation of manufacturing schedule /bar chart using pert / cpm combination method being production and construction scope involved in works.
3 Selection of non woven /pet board as per requirement for 8'x4' size board by selecting density out of 1500 kg/m3, 1800 kg/m3, 2000 kg/m3, 2500 kg/m3 and thickness of available size of 10mm, 13mm, 15mm, 18mm, 20mm, 22mm, 25mm (nrc value varies as per this selection) also to see verging or recycled material, colour and Indian or international standards compliance for various physical, chemical and mechanical properties of this material.
4 Preparation of drawing to be fed to cnc lesser cutting machine for required design, cutting, making groves, tiles or panels formation, perforation (micro, helmhotz , square et.c) colour , designs -shapes etc
5 Formation of tiles or panels of required sizes
6 Packings with lldpe film wrapped over panels and kept stacking positions in godown or tiles products wrapped by film and kept in carton boxes as per quantity, set of 10,20,30,40,50 nos, each, this is standard size of packing.
7 Manufacturing of panels or tiles for wall mounted and ceilings at site is defined
41. Acoustic Sliding & Folding Partition Panel
41.1 Introduction
Providing and fixing of 100-110mm thick Manual sliding folding Indosonic partition of required Width and Height up to ceiling level having sound insulation of 47-52dB STC as per manufacturer's specifications with required components, fittings, accessories and detachable handle for operations, all complete as per manufacturer’s specifications, drawings and direction of Engineer-In-Charge.
Partition system: The partition system should be comprises of; series of individual flat panels, manually operated, top supported with retractable top and bottom seals, travelling along a ceiling track and assembled to form a solid wall. Each100mm thick panel should consist of welded internal steel frame. Each panel should be fabricated with 1.2 mm extruded natural anodized Aluminum track, vertical member, top & Bottom etc. resiliently secured to the tubular frames with appropriate insulation to achieve specified Noise Reduction Class. Also to provide the entire panel fabrication, FR Grade Material, dimensionally stable, with no protruding parts. The void should have proper Insulated with suitable FR Grade and Acoustic properties material inside the panel. The panels should have cladded on both sides with high quality HDHMR panel to incorporate with other finishing materials. It should have Natural anodized extruded Aluminium sections vertical side’s fitted with
double acoustical seals. The panel should have designed to be suspended and center-hung by high grade steel ball bearing encased with DuPont delrin polyformaldehyde (POM) material.
41.2 Execution
INSPECTION OF EACH PANEL IS REQUIRED BEFORE INSTALL
USE CORRECT TOOLS & SAFETY PROCEDURES:
Required tools: Tape measure, spirit level, string line, fine-tooth panel saw, electric / battery drill, posidrive extension bit, end sealer and panel spacer blocks (end-sealer provided with all orders).
End sealer is not for touching up the face of the panels, only end-sealing.
Health & Safety: Wear a dust mask, safety glasses and ear protection when using power tools and sawing.
PREPARE THE SURFACE & ALLOW FIXING POINTS
POSITION THE ACOUSTIC PANEL
LOCATE THE FIXING PLATES
FIX ACOUSTIC PANEL TO WALL OR CEILING
USE SPACER BLOCK FOR LOCATION POSITION OF ACOUSTIC PANELS
END-SEALING MAY BE REQUIRED
FIXING THE TRIM
For PET /Non-Woven Panels:
The sound-absorbing effect of the sound-absorbing panel is not constant. It has a lot to do with the installation method and the pre-safety treatment. Therefore, when installing the sound-absorbing panel, you must not be sloppy. You must figure out how to install it. The sound-absorbing effect of the sound-absorbing board is the best.
1. Sound-absorbing board treatment: non-porous sound-absorbing board should be glued to the joints of the sound-absorbing board with seam adhesive tape, and the perforated sound-absorbing board should be sealed with a thin film on the inner side of the sound-absorbing board.
2. The walls covered by the sound-absorbing panels must be installed with Frames according to the requirements of the design drawings or construction drawings, and the Frame must be leveled. The surface of the Frame should be flat, smooth, free of rust and deformation. The structural walls must be pre-construction processed in accordance with the building specifications, and the arrangement of the Frame must be compatible with the arrangement of the sound-absorbing panels. The Frame spacing should be less than 300mm, and the light steel Frame spacing should not be greater than 600mm. The installation of the Frame should be perpendicular to the length of the sound-absorbing board; the distance from the surface of the Frame to the base layer is in accordance with the specific requirements, generally 50mm. The flatness and verticality error of the Frame side surface should not be greater than 0.5mm; if fillers are needed in the Frame gap, they should be installed and treated in advance according to the design requirements, and ensure that the installation of the sound-absorbing panel is not affected.
The choice of Adhesive for sound-absorbing board pasting: first consider using Adhesive that meets the national environmental protection requirements. Different types of adhesives can be selected according to the bonding base; the cement or wood base can be benzene-free with neoprene as the raw material., you can choose recommended Adhesive by manufacturer as raw material.
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