CPP PROJECT REPORT ON RETROFITTING DONE BY STUDENT OF GPM MALVAN CIVIL BRANCH IT WILL SURELY HELP YOU IN FUTURE

1. GOVERNMENT
POLYTECHNIC MALVAN
CAPSTONE PROJECT

2. Name of Group members –
1) 3102- Bhupal Chaugule
2) 3104- Esha Palav
3) 3111- Dip Dalvi
4) 3112- Yash Chavan
5) 3113- Justin Fernandes
6) 3118- Samrudhi Methar
7) 3135- Neha Sharbidre
8) 3138- Kaustubh Koyande
9) 3147- Rachana Manjarekar
10) 3150- Rugved Achrekar
Under the guidance of Deepak Badekar sir
TOPIC :- REPAIR AND MAINTENANCE OF MINOR CRACKS IN BEAMS

3. CONTENT OF PPT
INTRODUTION
ABSTRACT
WHAT ARE
MINOR
CRACKS IN
BEAM
CONSTRUCTION
OF BEAMS
TESTING
REPAIRING OF
THE DAMAGE
AFTER
REPAIRING

4. INTRODUCTION
WE TEN STUDENTS OF GOVERNMENT POLYTECHNIC MALVAN SELECTED THE PROJECT OF
REPAIR AND MAINTENANCE OF MINOR CRACK IN BEAM FOR CAPSTONE PROJECT. WE
SELECTED THIS TOPIC BECAUSE WE HAVE THE SUBJECT MAINTENANCE AND REPAIR FOR 6TH
SEM. FOR THIS PROJECT OUR GUIDE WERE PROF D.D. BADEKAR SIR THEY HELPED US IN
THIS PROJECT.
The objective of this project is to develop a comprehensive approach for the repair and
maintenance of minor cracks in beams. The project aims to provide effective and practical
guidelines for identifying, assessing, and repairing minor cracks in beams to prevent further
deterioration and potential structural failures.
The project will focus on minor cracks in beams, specifically those that do not pose an
immediate safety risk but still require attention to prevent future problems. The scope
includes the inspection, cleaning, preparation, application of repair materials, and finishing of
minor cracks in beams.

5. ABSTRACT
• Cracks in beams can develop over time, posing potential risks to the structural integrity of buildings, bridges, and other
structures. This project aims to address the repair and maintenance of minor cracks in beams, focusing on those that do
not present immediate safety concerns but still require attention to prevent further deterioration.
• The objective of the project is to develop a comprehensive approach for identifying, assessing, and repairing minor cracks
in beams. The project will encompass various types of beams commonly used in construction and will consider industry
best practices and recommendations. The methodology involves a systematic process that includes crack inspection,
cleaning, preparation, application of repair materials, and finishing touches.
• The project will result in a guidebook/manual that provides step-by-step instructions for repairing and maintaining minor
cracks in beams. The guidebook will include detailed procedures, safety considerations, material specifications, and
recommended tools and equipment. It will also feature illustrations and case studies to enhance understanding and
practical application of the repair methods.
• The project team, comprising experts in structural engineering, construction, and materials science, will collaborate with
industry professionals, manufacturers of repair materials, and structural consultants to ensure the accuracy and
practicality of the developed guidelines. The project timeline will be established to accommodate research,
experimentation, data analysis, and documentation.
• Through this project, professionals in the construction and maintenance industry will have access to a valuable resource
that assists them in effectively addressing minor cracks in beams. By implementing the guidelines, they can ensure the
longevity and safety of structures while minimizing potential risks associated with beam cracking.

6. WHAT ARE MINOR CRACKS IN BEAM
 Minor cracks in beams refer to small, hairline cracks that appear on
the surface of a beam. These cracks are typically shallow and do
not extend significantly into the depth of the beam. They are often
caused by various factors such as shrinkage, temperature
fluctuations, minor settlement, or the natural aging of the material.
 Minor cracks in beams are generally considered to be of lesser
concern compared to larger or more significant cracks. However, it
is essential to address them promptly to prevent further progression
and potential structural issues. If left unattended, these minor
cracks can potentially widen over time, compromising the beam's
strength, stability, and overall structural integrity.
 While minor cracks may not immediately jeopardize the safety of a
structure, they serve as warning signs of potential problems and
should be treated as indicators of underlying issues. It is crucial to
monitor and repair these cracks to maintain the durability,
performance, and longevity of the beams and the overall structure.
Prompt repair and maintenance of minor cracks help prevent them
from developing into more significant structural defects that could
necessitate extensive and costly repairs in the future.

7. CONSTRUCTION OF BEAMS
Design and Planning :- We talked to
Badekar sir about the design and
planning and sir told use to construct
12 beams of size 1000*150*150mm.
Which include steel bars of 10mm
main steel and 8mm stirups . So we
calculated the quantity of steel
required for the construction with help
of Bar Bending Schedule.
Process of Construciton beams :-
1)Purchase of Material
• 2) Purchase of Cement
• 3) Purchase of Sand and Aggregate
• 4) Reinforcement Construction
• 5) MAKING FORM WORK FOR BEAMS
• 6) PREPARATION OF CONCRETE
• 7) CASTING OF BEAMS
• 8) REMOVING FORM WORK
• 9) CURING OF BEAM
• 10) TRANSPORTATION

8. PURCHASE OF STEEL
STEEL BARS WERE BROUGHT FOR
THE REINFORCEMENT OF BEAM.
STEEL WAS PURCHASED FROM A
LOCAL STORE. THE COMPANY OF
STEEL WAS ICON STEEL TMT 500D
WE PURCHASED 10MM – 04 NOS
AND 8MM- 03 NOS 10MM WEIGHT
WAS 27.27 KG AND WEIGHT OF 8
MM WAS 14.4 KG LATER THE STEEL
WAS TRASPORTED TO THE SITE
WERE WORK WAS GOING ON

9. PURCHASE OF CEMENT BAG
CEMENT BAGS WERE
BOUGHT FROM A
LOCAL STORE THE
COMPANY OF
CEMENT WAS
ULTRATECH WE
PURCHASED 3 NOS
OF CEMENT.

10. PURCHASE OF SAND AND AGGREGATE
AGGREGATE AND SAND
WERE PURCHASED FORM
LOCAL STORE THE SIZE
OF AGGREGATE WAS
10MM AND 12MM MIXED

11. BAR BENDING
THE STEEL BARS WERE
CUT AS PER THE
REQUIRED SIZE THE
THE 10MM BAR WAS
CUT UPTO LENGTH OF
800MM AND 8MM
STIRUP BAR WAS CUT
UPTO LENGTH OF 40MM
THE SIZE OF STIRUP
WAS 10*10 MM

12. MAKING FORMWORK FOR BEAMS
PREPARING WOODEN
FORM WORK FOR
CASTING THE BEAMS
THE SIZE OF CASTING
WAS 1000*150*150 MM
WOODEN PLY AND
STEEL PLATES WERE
USED FOR FORMWORK.
THE STEEL PLATES
WERE BROUGHT ON
DAILY WAGES OF RS
3/DAY

13. PREPARATION OF CONCRETE
CONCRETE WAS
PREPARED ON
SITE OF M20
GRADE THE
PROPORTION
WAS(1 : 1.5 : 3 )
TO POUR INTO
CONCRETE

14. CASTING OF BEAMS
THE M20
CONCRETE IS
PLACED IN THE
FORMWORK AND
IS COMPACETD
USING TAMPING
ROD

15. REMOVING FORMWORK
THE
FORMWORK
WAS REMOVED
AFTER 3 DAYS

16. CURING OF BEAMS
CURING OF THE CASTED BEAM
WAS DONE BY WATERING IT. IT
WAS DONE FOR ABOUT 14
DAYS
LATER THE BEAMS WERE
BROUGHT IN COLLEGE
CONCRETE TESTING LAB AND
WERE PUT IN THE WATER POND
FOR CURING FOR NEXT 14
DAYS
TOTAL CURING WAS DONE FOR
28 DAYS

17. TRANSPORTATION
THESE CASTED BEAMS
WERE THEN MOVED
TO GOVERNMENT
POLYTECHNIC
MALVAN FORM
VENGURLA VIA
TRUCK

18. TESTING OF BEAMS
 TESTING OF BEAMS WAS DONE ON UNIVERSAL TESTING MACHINE (UTM)
 A Universal Testing Machine (UTM) is a versatile and commonly used mechanical testing device in materials science and engineering. It is designed to
perform a wide range of mechanical tests on materials, components, and structures to determine their mechanical properties, strength, and
performance characteristics.
 Key Components and Features:
 1. Load Frame: The UTM consists of a sturdy load frame that provides the structural support and stability required for conducting tests. The load frame
typically consists of a stationary base and a movable crosshead that applies the load or force to the test specimen.
 2. Force Measurement System: The UTM is equipped with a force measurement system, usually a load cell or hydraulic/pneumatic system, to accurately
measure and record the applied load or force during testing. Load cells are commonly used and can provide precise measurements across a wide range
of forces.
 3. Gripping Systems: The UTM includes various gripping systems or fixtures to securely hold the test specimen during testing. These fixtures can be
customized based on the specific test requirements and the type of specimen being tested, such as tensile grips, compression platens, bending fixtures,
or torsion grips.
 4. Control and Data Acquisition System: The UTM is equipped with a control system that allows the operator to set the test parameters, such as the load
rate, displacement rate, or strain rate. It also includes a data acquisition system to collect and record data during the test, such as load, displacement,
and time. This data is crucial for analyzing the material behavior and determining its mechanical properties.
 5. Testing Software: The UTM is typically operated using dedicated testing software that controls the testing process, captures data, and provides real-
time monitoring and analysis. The software often includes features for test method selection, data visualization, data analysis, and generation of test
reports.

19. UTM COMMMON TEST AND APPLICATIONS
 Common Tests Performed:
 The UTM can perform various mechanical tests, including:
 - Tensile Testing: Determines the tensile strength, yield strength, elongation, and modulus of elasticity of a material.
 - Compression Testing: Evaluates the compressive strength, stiffness, and deformation characteristics of materials.
 - Flexural/Bending Testing: Measures the flexural strength, modulus of rupture, and stiffness of materials.
 - Shear Testing: Determines the shear strength and shear modulus of materials.
 - Fatigue Testing: Evaluates the material's behavior under cyclic loading conditions to determine its fatigue life and durability.
 - Torsion Testing: Measures the torsional strength and shear modulus of materials.
 Applications:
 UTMs are extensively used in various industries, including aerospace, automotive, construction, manufacturing, and research laboratories. They are
employed for quality control, material characterization, product development, and research purposes. UTMs are crucial in assessing material
performance, validating design specifications, and ensuring the safety and reliability of structures and components.
 Overall, the Universal Testing Machine is a versatile and essential tool for understanding the mechanical behavior and properties of materials,
enabling engineers and researchers to make informed decisions in material selection, product development, and structural design.

20. UNIVERSAL TESTING MACHINE

21. TESTING RESULT
 IN THIS TESTING PROCESS 8 BEAMS WERE TESTED ON THE UTM MACHINE TO INTERPRETE CONDITIONS AS
PER OUR NEED
 TEST RESULTS :-
BEAM NUMBER EXTENT OF LOADING TYPE OF LOADING
BEAM NO 1 51.62 KN VERTICAL
BEAM NO 2 52 KN VERTICAL
BEAM NO 3 53 KN VERTICAL
BEAM NO 4 52 KN HORIZONTAL
BEAM NO 5 53 KN HORIZONTAL
BEAM NO 6 63.5 KN HORIZONTAL
BEAM NO 7 75 KN VERTICAL
BEAM NO 8 53 KN VERTICAL

22. TESTING

23. TESTING

24. TESTING

25. REPAIRINT THE DAMAGE
FOR REPAIR
WE USED
THREE REPAIR
MATERIAL
TOGETHER
FIRST WE
USED DR FIXIT
URP
THEN WE
USED ICFS CM
350P
INJECTION
MORTAR
AND USED
ELASTOSEAL
TO MAKE THE
CRAK WATER
TIGHT
AND LATER
COVERED IT
WITH ADITYA
BIRLA PUTTY

26. DR FIXIT URP
 "Pidicrete URP" is a product offered by Dr. Fixit, a leading brand in construction chemicals and waterproofing solutions. Pidicrete URP stands for
"Universal Repair Polymer," and it is a versatile repair mortar used for a wide range of repair and rehabilitation applications in the construction
industry.
 Key Features and Benefits of Pidicrete URP:
 1. Universal Application: Pidicrete URP is designed for various repair applications, including concrete repairs, patching, and surface leveling. It can be
used on both vertical and horizontal surfaces.
 2. Bonding Agent: Pidicrete URP acts as an excellent bonding agent between old and new concrete, ensuring strong adhesion and structural integrity in
repair works.
 3. High Strength and Durability: The product provides high mechanical strength and durability to the repaired areas, ensuring long-lasting performance
even in demanding conditions.
 4. Crack Bridging: Pidicrete URP has the ability to bridge and seal fine cracks, preventing further water ingress and protecting the underlying substrate.
 5. Shrinkage Control: The product is formulated to minimize drying shrinkage, reducing the risk of cracks and ensuring a reliable repair.
 6. Easy Application: Pidicrete URP is easy to apply using a trowel or a putty knife. It has a smooth consistency that allows for easy spreading and
leveling.
 7. Compatibility: Pidicrete URP is compatible with a variety of substrates, including concrete, masonry, and cementitious surfaces.

27. DR FIXIT URP
 Applications of Pidicrete URP:
• Concrete repairs and rehabilitation.
• Patching and leveling uneven concrete surfaces.
• Bonding agent for old-to-new concrete interfaces.
• Repairing cracks, spalls, and damaged concrete structures.
 Please note that product specifications and application guidelines may vary, so it is essential to refer to the
manufacturer's instructions and guidelines for accurate and up-to-date information on the proper usage of Pidicrete
URP for your specific project requirements.

28. DR FIXIT URP
WE USED MEDICAL
SYRIENGE TO
INJECT URP IN THE
CRACKS SO THAT
IT MAY GO DEEP IN
THE CRACK.

29. ICFS CM 350P INJECTION MORTAR
 ICFS CM 350P Injection Mortar is a specialized product used for injection grouting or repairing cracks, voids, and joints in
concrete structures. It is commonly used in the construction industry for structural repairs and waterproofing applications.
 Key Features and Benefits of ICFS CM 350P Injection Mortar may include:
 1. High Strength and Durability: ICFS CM 350P is formulated to provide excellent strength and long-term durability, ensuring
reliable repairs in concrete structures.
 2. Injection Capability: This mortar is designed to be pumpable and injectable into cracks, voids, and joints using appropriate
equipment, allowing for precise and efficient application.
 3. Excellent Adhesion: The product offers strong adhesion to various substrates, including concrete, ensuring a reliable bond and
effective sealing of cracks and joints.
 4. Shrinkage Control: ICFS CM 350P is formulated to minimize shrinkage during curing, reducing the risk of cracks and ensuring a
more robust repair.
 5. Waterproofing Properties: The mortar has water-resistant properties, enhancing the waterproofing performance of the repaired
areas and protecting the underlying structure from water ingress.
 6. Compatibility: ICFS CM 350P is typically compatible with concrete substrates, but it is important to follow the manufacturer's
guidelines and test compatibility with specific substrates before application.

30. ICFS CM 350P INJECTION MORTAR
 Applications of ICFS CM 350P Injection Mortar:
 - Injection grouting of cracks, voids, and joints in concrete structures.
 - Repairing concrete elements such as beams, columns, and walls.
 - Waterproofing and sealing of construction joints, pipe penetrations, and other vulnerable areas.
 - Structural repairs and restoration in buildings, bridges, and other concrete infrastructure.
 Please note that specific application instructions, curing times, and other details may vary depending
on the manufacturer and product formulation. It is essential to refer to the manufacturer's guidelines,
technical datasheets, and instructions for the proper usage and application of ICFS CM 350P Injection
Mortar in your specific project.

31. ICFS CM 350P INJECTION MORTAR
WE USED THE ICFS
CM 350P
INJECTION
MORTAR TO FILL
THE CRACK WHICH
INCREASE THE
STENGTH OF THE
BEAM

32. BEFORE VS AFTER
BEFORE AFTER

33. ELASTO SEAL
 In civil engineering, Elastoseal is commonly used as a waterproofing solution for various applications. Here are some common uses of Elastoseal in civil engineering:
 1. Roofs and Terraces: Elastoseal is applied as a waterproofing membrane on flat roofs, terraces, and podium decks to prevent water leakage and protect the underlying structure from
moisture damage. It forms a seamless barrier that can withstand weathering and exposure to UV rays.
 2. Basements and Foundations: Elastoseal is used to waterproof below-grade structures, such as basements and foundations, to prevent water infiltration. It helps to create a watertight
barrier, protecting the interior spaces and preventing moisture-related issues such as dampness, mold, and structural deterioration.
 3. Retaining Walls and Tunnels: Elastoseal is employed in the waterproofing of retaining walls and tunnels to prevent water penetration into the surrounding soil and the structure itself. It
ensures the stability and durability of these critical civil engineering elements.
 4. Bridge Decks and Expansion Joints: Elastoseal is utilized in the waterproofing of bridge decks to protect the underlying concrete from water and chloride ingress, which can cause
corrosion of reinforcement. It is also used to seal expansion joints in bridges, ensuring water-tightness while accommodating movement and preventing debris accumulation.
 5. Concrete Repair and Protection: Elastoseal is sometimes used as a protective coating for concrete surfaces to enhance their durability and resistance to water, chemicals, and
environmental factors. It can be applied to concrete structures such as columns, beams, and slabs to extend their service life and prevent further damage.
 6. Water Tanks and Swimming Pools: Elastoseal is utilized in the waterproofing of water tanks and swimming pools to prevent water leakage and ensure water containment. It provides a
reliable and durable waterproofing solution for these structures, which are subject to constant water exposure.
 It's important to note that the specific application guidelines and compatibility of Elastoseal may vary depending on the manufacturer and the project requirements. It is recommended to
consult with a structural engineer or a waterproofing specialist to determine the most appropriate use of Elastoseal in a specific civil engineering project.

34. ELASTO SEAL

35. ELASTO SEAL
WE USED THE ELASTO
SEAL PRODUCT SO FILL
SMALL HAIR LINE CRACKS
AND TO MAKE THE FILLED
CRACK WATER AND AIR
TIGHT SO THERE IS NO
SPACE TO AIR TO GO
INSIDE THE BEAM WHICH
WONT CAUSE
CORROSION OF STEEL

36. BEFORE VS AFTER
BEFORE AFTER

37. ADITYA BIRLA PUTTY
 Aditya Birla Putty is a popular brand of wall putty manufactured by Aditya Birla Group, one of the largest conglomerates in India. Wall putty is a white cement-based
powder that is mixed with water and applied to the interior and exterior walls before painting. It serves as a preparatory coating that provides a smooth and even surface for
paint application while also offering various other benefits.
 Here are some key features and benefits of Aditya Birla Putty:
 1. Surface Smoothing: Aditya Birla Putty helps to fill in minor surface imperfections such as cracks, dents, and undulations, resulting in a smooth and uniform surface. This
creates an ideal base for painting and enhances the aesthetic appeal of the walls.
 2. Improved Paint Adhesion: The application of wall putty improves the adhesion of paint to the walls, allowing the paint to adhere better and provide a longer-lasting finish.
This helps to prevent peeling, flaking, and blistering of the paint.
 3. Hiding Imperfections: Aditya Birla Putty has good coverage properties, which means it can effectively hide surface imperfections and blemishes. It helps to create a
flawless appearance by minimizing the visibility of stains, patches, and unevenness on the walls.
 4. Durability and Longevity: Wall putty, including Aditya Birla Putty, forms a strong and durable layer on the walls. It helps to protect the underlying surface from moisture,
weathering, and other environmental factors, thereby extending the life of the paint and the walls themselves.
 5. Ease of Application: Aditya Birla Putty is easy to mix and apply. It has a smooth consistency that allows for easy spreading and leveling on the walls. It can be applied
using a putty knife or trowel, and it dries quickly, enabling faster completion of the painting process.
 6. Suitable for Interior and Exterior Surfaces: Aditya Birla Putty is suitable for both interior and exterior walls, making it versatile for various applications. It can be used in
residential, commercial, and industrial projects to achieve smooth and aesthetically pleasing wall finishes.
 It's important to follow the manufacturer's instructions and guidelines for the correct mixing ratios, application techniques, and drying times when using Aditya Birla Putty
or any other brand of wall putty. This will ensure optimal results and the desired finish on your walls.

38. ADITYA BIRLA PUTTY

39. ADITY BIRLA PUTTY
USED ADITYA BIRLA
PUTTY ON THE
REAPAIRED BEAMS
TO INCREASE ITS
APPEARANCE

40. CONCLUSION
 In conclusion, the repair and maintenance of minor cracks in beams are essential for maintaining the structural integrity and safety
of the beams. Addressing these cracks in a timely manner can prevent further damage and potential structural failures.
 Through careful inspection and assessment, the nature and severity of the cracks can be determined, allowing for appropriate
repair methods to be selected. Whether it's through epoxy injection, crack stitching, or surface sealing, the chosen repair approach
should effectively restore the structural integrity of the beams and prevent further crack propagation.
 Proper surface preparation, including cleaning and removing loose debris, is crucial to ensure a strong bond between the repair
material and the beam surface. Following manufacturer guidelines and using high-quality repair products, such as epoxy resins or
sealants, is important to ensure durable and long-lasting repairs.
 Regular maintenance and monitoring of the repaired beams are vital to detect any emerging issues or new cracks. Implementing a
maintenance program that includes periodic inspections will help identify and address any potential problems before they escalate
into major structural issues.
 By undertaking these repair and maintenance practices, minor cracks in beams can be effectively managed, prolonging the
lifespan of the structure and ensuring the safety of occupants. Consulting with professionals and following industry best practices
will help ensure the proper assessment, selection, and implementation of repair strategies for minor cracks in beams.

41. THANK YOU