The Challenge: Severe RCC Corrosion & Spalling

In early 2026, a prominent 10-story housing society in Borivali approached Urban Civil Services. The building had received a 'C-2A' notice from the BMC, indicating that while the building was repairable, it required immediate structural intervention. Residents were witnessing large chunks of concrete falling from the external columns, exposing heavily rusted 20mm reinforcement bars.

Our Diagnostic Approach

Before touching a hammer, our engineering team conducted a Rebound Hammer Test and Ultrasonic Pulse Velocity (UPV) scan. We discovered that while the core concrete was strong, the 'cover' had failed due to carbonation. The proximity to the creek had accelerated salt-water damage to the steel rebars.

The Solution: Step-by-Step Restoration

• Propping & Shoring: We installed heavy-duty MS props to take the load off the distressed columns before starting work.
• Mechanical Rust Removal: We used wire-brushing and sand-blasting to clean the rusted steel to a 'bright metal' finish.
• Zinc-Rich Primer: Applied a two-component epoxy-zinc coating to prevent future rusting of the reinforcement.
• Jacketing with Micro-Concrete: We used self-compacting, non-shrink micro-concrete to reconstruct the columns, increasing their load-bearing capacity by 25%.
• External Polymer Plaster: The entire building was finished with a fiber-reinforced polymer mortar to create a waterproof shield.

The Result

The project was completed in 120 days. A follow-up structural audit moved the building from 'Distressed' to 'Safe.' The society's property valuation increased by an estimated 15% following the restoration and fresh painting.