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Product Evaluation of MASTERSEAL® 345 Mott MacDonald
Assessment, Application and Specification MEYCO Global Underground Construction
239368/006/E/June 2009 P:\Budapest\TPE\NEW FOLDER STRUCTURE\239368 BASF Lining report\H Reports and Drawings\H.02 Outgoing Reports\Masterseal 345 Report Final.doc
MEYCO Global Underground Construction
Division of BASF Construction
Chemicals Europe Ltd
110 Vulkanstrasse
Zurich
CH-8048
Product Evaluation of MASTERSEAL® 345
Assessment, Application and Specification
June 2009
Mott MacDonald
St Anne House
20-26 Wellesley Road
Croydon
Surrey
CR9 2UL
UK
Tel : 44 (0)20 8774 2000
Fax : 44 (0)20 8681 5706
Product Evaluation of MASTERSEAL® 345 Mott MacDonald
Assessment, Application and Specification MEYCO Global Underground Construction
239368/006/E/June 2009
P:\Budapest\TPE\NEW FOLDER STRUCTURE\239368 BASF Lining report\H Reports and Drawings\H.02 Outgoing Reports\Masterseal 345 Report Final.doc
Product Evaluation of MASTERSEAL® 345
Assessment, Application and Specification
Issue and Revision Record
Rev Date Originator
Checker
Approver
Description
01 06/02/04 PAD/BB EMC/AHT DBP First Draft – for comment
02 12/03/04 PAD/EMC AHT DBP Second Draft – for comment
03 24/05/04 E M Casson A H Thomas D B Powell Final Issue
04 12/07 BJH/MWGy A H Thomas D B Powell Updated Issue
05 26/08 L Forgo A H Thomas D B Powell Updated Issue
06 19/06/09 L Forgo P Duarte D B Powell Updated Issue
This report has been prepared exclusively for the party commissioning it and no liability can be accepted by the writers
towards users of the product or any other person who seeks to rely on it to the full extent that such liability can be excluded
by law.
This document has been prepared for the titled project or named part thereof and should not be relied upon or used for any
other project without an independent check being carried out as to its suitability and prior written authority of Mott
MacDonald being obtained. Mott MacDonald accepts no responsibility or liability for the consequence of this document
being used for a purpose other than the purposes for which it was commissioned. Any person using or relying on the
document for such other purpose agrees, and will by such use or reliance be taken to confirm his agreement to indemnify
Mott MacDonald for all loss or damage resulting therefrom. Mott MacDonald accepts no responsibility or liability for this
document to any party other than the person by whom it was commissioned.
To the extent that this report is based on information supplied by other parties, Mott MacDonald accepts no liability for any
loss or damage suffered by the client, whether contractual or tortious, stemming from any conclusions based on data
supplied by parties other than Mott MacDonald and used by Mott MacDonald in preparing this report.
.
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List of Contents Page
1 Introduction 7
2 Product evaluation 8
2.1 Description of product 8
2.2 Water Absorption and Water Tightness 9
2.3 Structural Bonding 10
2.4 Performance of MASTERSEAL®345 in Fire 11
2.5 Track record 12 2.5.1 Giswil Tunnel, Switzerland 12 2.5.2 MTRC Disney Tunnels, Hong Kong 12 2.5.3 Ash Vale, Aldershot, UK 12 2.5.4 Extension of Prague Metro, Czech Republic 12 2.5.5 Metro M2 Lausanne, Switzerland 12 2.5.6 Nordöy Road Tunnel, Faeroe Islands 13 2.5.7 Chekka Road Tunnel, Northern Lebanon 13 2.5.8 Wine caves, California, USA 13 2.5.9 Wolf Creek, Colorado 13 2.5.10 Abbotscliffe Tunnel Repair, UK 14 2.5.11 Stormwater Management and Road Tunnel (SMART), Kuala Lumpur 14 2.5.12 Machadino Hydroelectric Power Station, Brazil (MASTERSEAL
® 340) 14
2.6 Assessment of claimed properties 15
2.7 Safety (COSHH-Control of Substances Hazardous to Health) 17
2.8 Summary 17
3 Guidelines for application 19
3.1 General 19
3.2 Groundwater conditions 20 3.2.1 Design 20 3.2.2 Managing Water Ingress Encountered During Construction 20
3.3 Substrate 22 3.3.1 Substrate preparation 22 3.3.2 Optimising sprayed concrete surface texture 23
3.4 Application 24 3.4.1 Spraying equipment 24 3.4.2 Spraying technique 25 3.4.3 Thickness 26
3.5 Water content 26
3.6 Temperature and humidity 29
3.7 Curing 29
3.8 Joint details 30 3.8.1 Jointing of MASTERSEAL
®345 and MASTERSEAL
® DR1 30
3.8.2 Jointing of MASTERSEAL® 345 and a sheet membrane 31
3.8.3 Joint between adjacent sections of MASTERSEAL® 345 31
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3.8.4 Waterproofing Over Fixings 32
3.9 Secondary (internal) lining 33 3.9.1 Design 33 3.9.2 Construction 34
3.10 Durability 35 3.10.1 Elevated temperature 36 3.10.2 Ultraviolet (UV) light 36 3.10.3 Chemical resistance in aqueous solutions 36
3.11 Maintenance and repair 37
3.12 Environmental aspects & demolition 37
4 Quality control during application 38
4.1 Preconstruction trials 39
4.2 Performance tests 40 4.2.1 Pull - off tests 40 4.2.2 Water penetration test 40
4.3 Coverage 41
4.4 Thickness 41 4.4.1 Cutting patches 41 4.4.2 Measuring quantity 41 4.4.3 Thickness: Wet and dry film test methods 42
4.5 Defects 42
4.6 Generic specification 43
5 Conclusions and recommendations 44
Appendix A Risk Assessment A-1
Appendix B Material Safety Data Sheet B-1
Appendix C Past Projects using MASTERSEAL ® 340 and MASTERSEAL
® 345 C-1
Appendix D Inspection Report D-1
Appendix E MASTERSEAL® 345 Data Sheet E-1
Appendix F Specification F-1
Appendix G Hard Ground/Soft Ground; Drained/Undrained G-1
Appendix H Examination of composite single shell action H-1
Appendix I Reference List I-1
Figures
Figure 1 - Flow of Water Vapour through MASTERSEAL®345.......................................................... 10
Figure 2 - Bonding between MASTERSEAL®345 and concrete.......................................................... 11
Figure 3 - Reverse when sprayed onto wood ........................................................................................ 11 Figure 4 - Management of wet spots using geotextile membranes (left) or drainage channels (right) . 21
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Figure 5 - Flowchart to determine suitability of MS 345 based on the water ingress through the
substrate ............................................................................................................................ 22 Figure 6 - Combined grading for sprayed concrete............................................................................... 24 Figure 7 - Different substrate roughness .............................................................................................. 24 Figure 8 - Manual Spraying of MASTERSEAL
® 345........................................................................... 25
Figure 9 - Mechanised Spraying of MASTERSEAL®
345 with MEYCO ®
LOGICA ......................... 26 Figure 10 - MASTERSEAL
® 345 sprayed too dry, front (left) and reverse sprayed onto plastic film
(right) ................................................................................................................................ 27 Figure 11 - Surface of MASTERSEAL
®345 at 0.4 (left) and 0.6 water-powder ratio (right)............... 28
Figure 12 - Reverse on plastic membrane at 0.4 (left) and 0.6 (right) water-powder ratio ................... 28 Figure 13 - Surface of MASTERSEAL
®345 with 0.6 water-powder ratio showing pinholes and cracks
in the fire retardant filler ................................................................................................... 28 Figure 14 - MASTERSEAL
® 345 applied in conjunction with MASTERSEAL
® DR1 Fleece .......... 31
Figure 15 - MASTERSEAL ®
345 applied in conjunction with sheet membrane................................. 31 Figure 16 - Jointing of adjacent sections of MASTERSEAL
® 345...................................................... 32
Figure 17 – Movement joint detail ........................................................................................................ 32 Figure 18 - Application of sprayed membrane around steel insertion .................................................. 33 Figure 19 - Width of expending crack................................................................................................... 35 Figure 20 - Properties of MASTERSEAL® 345 in changing water conditions ................................... 36 Figure 21 - Coring the membrane ......................................................................................................... 41
Tables Table 1 - Comparison of claims 17 Table 2 - Advantages and disadvantages of MASTERSEAL
® 345 17
Table 3 - Curing status of MASTERSEAL ®
345 according to Shore A 30 Table 4 - Possible test methods for quality control of MASTERSEAL
® 345 application 39
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Executive Summary
In 2004 UGC International (UGC), a division of BASF Construction Chemicals Ltd (formerly
Degussa) commissioned Mott MacDonald to produce a product evaluation and generic specification
for MASTERSEAL® 345, a spray applied waterproofing membrane. This is an update to that report
that includes the latest application knowledge, experience and project testimonies. MASTERSEAL®
345 is a spray applied polymeric waterproofing membrane modified with cement. It is based on an
ethylene-vinyl acetate copolymer mixed with rapid hardening cement1
which forms a layer that acts as
a barrier to water ingress. It has been designed specifically for use in underground structures.
Test data and other information provided by UGC have been reviewed critically and previous
applications have been summarised. The product and the application and testing procedures have been
reviewed in the light of current engineering practice for waterproofing of underground structures. In
the course of this study tests have been carried out to establish the properties of the material in shear
and the information provided has been assumed to be an accurate and fair account as well as the
results of the tests / projects undertaken previously by others.
The principal conclusion of this report is that the product, MASTERSEAL® 345, meets the stated
claims, as far as it has been possible to verify them. MASTERSEAL® 345 is suitable as a spray
applied waterproofing membrane for use in sandwich construction in underground structures. An
internal lining is required to resist any external water pressure.
MASTERSEAL® 345 has been proven to have an excellent resistance to water ingress in laboratory
tests, tested up to 20 bar for a period of 1 year. As with any material constructed in-situ, there remain
residual concerns about quality control and workmanship. To address these concerns, a generic
specification has been produced as a guide for specifying this product. Each project must complete and
amend the specification to suit the particular application. It is also believed that the majority of
application concerns can be addressed by the use of the MEYCO® LOGICA robotic spraying
manipulators, which removes many sources of human error and can apply the membrane at a very
regular and consistent thickness. Recommendations for quality control test methods have been made
and it is considered that a robust quality control system can be implemented on site. Pre-construction
trials and use of trained operatives are vital for a successful application.
While MASTERSEAL® 345 is not a panacea for waterproofing underground structures, it is
considered to be a useful addition to the armoury of measures available to resist water ingress. It is
particularly suitable to situations where there is transient water or water under a low pressure in either
drained or undrained tunnels. MASTERSEAL® 345 has a proven resistance up to 5 bar for large scale
samples, and evidence from site and the laboratory suggests that it could be used in higher pressure
environments. However, each application should be considered on its own merits, with due regard to
the implications of any failure in the waterproofing composite system.
MASTERSEAL® 345 has been seen to be quick and simple to apply. By virtue of being a spray
applied membrane it is ideal for structures with complex geometries, such as tunnel junctions and local
enlargements, and also for blasted rock tunnel profiles where significant profile smoothing would
otherwise be required for the installation of traditional sheet membranes. The bond between the
primary lining and secondary lining offers savings through the option of adopting a “single shell”
design, in which both linings act as a composite. The viability of this depends on the exact loading
conditions prevalent in each situation. The relatively strong bond characteristic between the membrane
and concrete lining may allow a significant reduction in the development of groundwater paths to the
inner surface of the underground structure. Consumption rates and the risk of inadequate coverage
increase as the roughness of the substrate increases. This should be investigated during the pre-
construction field trials and a shotcrete smoothing layer, applied to the substrate, may be required.
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This report has been prepared exclusively for the party commissioning it and no liability can be
accepted by the writers towards users of the product or any other person who seeks to rely on it to the
full extent that such liability can be excluded by law.
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Assessment, Application and Specification MEYCO Global Underground Construction
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1 Introduction
The scope of this study is to evaluate the suitability of using MASTERSEAL®
345, a spray applied
waterproof membrane manufactured by UGC International (UGC), a division of BASF – Construction
Chemicals Europe Ltd, for use as a permanent waterproofing system for tunnels.
This report consists of a direct evaluation of the product’s claimed performance against the available
test data. Tests have also been commissioned as part of this report to examine the properties of the
product in shear, with the results used in a numerical analysis to examine the behaviour of the
membrane in composite structures.
The use of MASTERSEAL® 345 is discussed in a section on guidelines for application. This includes
the practical details of installation as well as design. Previous projects that have made use of
MASTERSEAL® 345 are summarised and the role of MASTERSEAL
® in the project highlighted.
Finally, testing and quality control of installation is assessed.
A generic specification for the product is included, covering materials, equipment and workmanship. It
should be noted that the specification will need to be modified to suit each specific project’s
requirements.
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2 Product evaluation
2.1 Description of product
MASTERSEAL® 345 is a spray applied polymeric waterproofing membrane modified with cement. It
is based on an ethylene-vinyl acetate copolymer mixed with rapid hardening cement, which forms a
polymer (plastic) layer that acts as a barrier to water ingress. Water may diffuse through the membrane
in vapour form but if water pressure is applied the long chain polymers are pushed closer together and
water movement is prevented. MASTERSEAL® 345 is a powder-based spray applied membrane that
can be covered in another concrete layer in less than 24 hours3 (depending on water content and
environmental conditions). It has been designed specifically for use in underground structures.
The main difference between this product and its predecessor, MASTERSEAL®
340, is that the latter
is a water based dispersion of a styrene acrylate copolymer. Hence, MASTERSEAL®
340 took longer
to cure and was applied in two layers instead of one. Difficulties in the application of
MASTERSEAL®
340 led to the development of MASTERSEAL®345. Although there are differences
in the application method and curing time between MASTERSEAL®
340 and MASTERSEAL®
345,
the main characteristics of the finished product are identical. Therefore some data on the performance
of MASTERSEAL®
340 may be used in the evaluation of MASTERSEAL®
345.
Spray applied waterproofing membranes have been used successfully in the past under high water
pressure conditions. MASTERSEAL®
340 has been used successfully on the Machadinho
Hydroelectric Power Station Project in Brazil (see Section 2.5.12) under a water pressure of up to 10
bar. This project was completed in the year 2000. A maintenance inspection of the completed tunnels
was carried out in the summer of 2003 and no leaks were observed during this inspection.
The following claimed properties have been extracted from information provided by UGC and
summarise its performance:
1. MASTERSEAL®
345 can resist water pressures of up to 15 bar (based on a 12 month test at
20 bar at the Swiss Federal Laboratories for Materials Testing and Research (EMPA))2.
2. It bonds well on both sides of the substrate and to material placed on top of it. Bond strengths
to concrete are 1.2 ± 0.2 MPa1. Bond strengths to metals range from 0.5 to 1.2 MPa.
4
3. Due to the bonded nature of the membrane, water migration along the membrane/substrate
contact is prevented.
4. The elasticity is 80% to 140% between -20°C and +20°C.1
5. MASTERSEAL® 345 can be applied to wet (i.e. no running water) or damp surfaces.
1
6. Water is added during spraying; the required water content (by weight of product) is between
30% and 50%.1
7. Concrete can be sprayed or cast against it once the chemical hardening process is complete
and the Shore hardness is adequate (See Section 3.9.2).
8. The membrane can be sprayed straight onto steel insertions (e.g. anchored reinforcement,
drainage pipes, etc.).1
9. It is compatible with plain and steel fibre reinforced concrete on either side of the membrane. 1
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10. It can be used in combination with traditional sheet membranes.1
11. It contains no toxic components.1
12. It is self-extinguishing (according to DIN 4102-B2).1
13. The application thickness required is a minimum of 3mm, and can be applied to a thickness of
10mm at a typical consumption rate of 1.0 kg/mm per m2.
14. It can be applied using simple equipment in a temperature range of between +5°C to +40°C.1
15. The membrane can be applied to most complex geometries at a rate of 50m2 per hour by three
operatives3 or at rates of 150-180m² per hour by 2 operatives using the latest MEYCO
®
LOGICA robotic spraying equipment.3,5
16. The shelf life is 12 months if stored in unopened bags in a dry storage area between the
temperatures of +5°C to +40°C.1
As well as the claims listed above, general observations have been made during its use by UGC. There
can be a saving in cost due to quick application, reduced excavation profile and the reduced risk of
water ingress, due to high bond strength of MASTERSEAL®
345 onto the substrate.
2.2 Water Absorption and Water Tightness
MASTERSEAL®345 is a polymer colloid containing many long chain polymers. In liquid form it
contains stabilisers that stop particles coagulating. The evaporating water overcomes these stabilising
forces and the particles coalesce to form a film. Many polymers absorb water into the voids in their
chemical structure to a greater or lesser degree; MASTERSEAL®345 is no different. Water in both
the liquid and the vapour state has a very strong attraction to MASTERSEAL®345 and it absorbs
water by up to 24% by weight. If enough water is present it takes about 1 hour for a 3mm thick
section of MASTERSEAL®345 to become fully saturated. When absorbed into the
MASTERSEAL®345 the water becomes chemically bonded to the polymer chains or is captivated by
capillary forces and is held very strongly within the material
Once bonded into the structure release of the water molecules in the form of vapour occurs very
slowly (at around 0.05 l/m²day, depending on environmental factors).4 Attempts have been made by
several bodies to quantify the amount of permissible water ingress into a tunnel and what constitutes a
watertight tunnel. The most well known test for water tightness is the water conductivity test; Swiss
Engineers and Designers Society Standard SIA 162/1, test no. 5. This standard defines watertight
concrete as a 25cm thick piece of concrete with a maximum vapour release of 0.26 l/m²day. The
German Research Association for Underground Transportation (STUVA) defines the allowable
quantity of daily water ingress for a frost endangered section of road tunnel as 0.05 l/m²day. This level
of water ingress corresponds to conditions in which “The wall of the lining must be so tight that only
slight isolated patches of moisture can be detected on the inside (e.g., as a result of discolouration).
After touching such slightly moist patches with a dry hand, no traces of water should be detectable on
it. If a piece of blotting paper or newspaper is placed upon a patch, it must on no account become
discoloured as a result of absorbing moisture”. Placed in the context of the above standards
MASTERSEAL®345 forms a watertight barrier and will ensure that a dry tunnel is achieved.
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.
Figure 1 - Flow of Water Vapour through MASTERSEAL®345
2.3 Structural Bonding
A spray applied membrane provides a bond between the primary and secondary linings so that they act
compositely. With MASTERSEAL®345 the bond strength to concrete is high, in the range of 1.0 to
1.4MPa, which provides a fully bonded waterproof membrane. Sprayed concrete can be directly
applied onto the MASTERSEAL®345 membrane after it has dried out sufficiently (when the Shore
hardness has reached a minimum 30). The sprayed concrete will bond to the membrane surface in a
similar manner as when spraying onto rock or concrete.
MASTERSEAL®345 fully encapsulates the surface roughness of sprayed concrete forming a fully
bonded homogenous watertight membrane. The two slides in Figure 2 show the interface between the
MASTERSEAL®345 and concrete, the rough appearance of the membrane is due to the diamond
cutting in the sample preparation.
Water vapour in the air
Water is absorbed into the fabric
of the MS354 lining until
saturation is reached at 24%
Water vapour is released at
a rate of 50g/m²day
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Figure 2 - Bonding between MASTERSEAL®345 and concrete
MASTERSEAL®345 has also been sprayed onto wood to demonstrate its penetration into fine
roughness structures as shown in Figure 3.
Figure 3 - Reverse when sprayed onto wood
Tests carried out in the course of this study examined the behaviour of the material bond in shear.
Results from these tests have been used in a finite difference model, examining the option of adopting
a “single shell” tunnel design, where the primary and secondary linings, although separated by a layer
of MASTERSEAL®345, can still be said to act as a composite.
2.4 Performance of MASTERSEAL®345 in Fire
MASTERSEAL®345, like many long chain polymers, melts when heated. The polymer used is
thermoplastic, becoming soft and liquid at temperatures above 200°C and at 250°C
MASTERSEAL®345 decomposes completely.
The membrane itself is self extinguishing and provides no risk of combustion during a fire once it has
been applied to the substrate. The product may burn but should not catch fire.
MASTERSEAL®345 MASTERSEAL
®345
Concrete Concrete
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2.5 Track record
MASTERSEAL®
345 was launched on the market in May 2003. Since then it has been used on a
number of tunnelling projects. A selection of some of these projects are summarised below. Further
listings, including of MASTERSEAL®
340 can be found in Appendix C.
2.5.1 Giswil Tunnel, Switzerland
An escape tunnel in Giswil, Switzerland (2003) required the construction of a 4m diameter tunnel
using a TBM (for the entire 1966m length) with Drill and Blast methods used for the portal areas
(approximately 10m tunnel length). The tunnel was bored through schist and hard rock utilising a
single shell sprayed concrete lining. In the region of 1900m2 of tunnel was waterproofed using
MASTERSEAL®345 (130m of bored tunnel and 10m of blasted tunnel).
5
2.5.2 MTRC Disney Tunnels, Hong Kong
The tunnel to the new Disney Theme Park in Hong Kong, built in 2003, is 710m long and goes
through massive granite. During construction occasional water seepage was observed. The running
tunnels are 6.2m in diameter and utilised a PVC membrane on a sprayed concrete primary lining as the
waterproofing method. MASTERSEAL®345 and MASTERSEAL
® DR1 was used on two inner
concrete lining vent fan enlargements, both 16m in diameter (one is 39m long, the second is 43m
long). A 150mm thick, Steel Fibre Reinforced Shotcrete (SFRS) lining was used with
MASTERSEAL®DR1 installed due to the requirements for a drained tunnel. The final lining included
a 200mm SFRS layer with a 50mm smoothing coat. 5
2.5.3 Ash Vale, Aldershot, UK
MASTERSEAL®345 was applied as a waterproofing to a sprayed concrete lining for a pedestrian
underpass through a shallow railway embankment (2003). After the inner concrete lining was cast
leaks were observed. Some cracking of the membrane had been observed during application, possibly
due to differential shrinkage induced by variable water content. An investigation determined that the
cold temperatures (at or below +5°C) during application were the main reason for unsuccessful
application; the underpass is very short and is exposed to the prevailing weather along its entire length.
The leaks were successfully sealed by crack injection.
2.5.4 Extension of Prague Metro, Czech Republic
The construction started in May 2004 and is planned to be finished by the year 2007-2008. The new
part of the metro is 4.6km long and consists of 3 stations, 2.4km of which are excavated according to
NATM principles and the rest are cut-and cover structures. The tunnels are excavated at a depth of 20-
30m depth below the surface in grey-black clay stone with sandstone interbeds. In addition to keeping
the water out of the tunnel the owner required the waterproofing material to be an electrical insulator.
UGC were able to recommend MASTERSEAL®345 to fulfil these requirements in areas with complex
geometries such as the pump stations. A total of 1100m² of spray applied waterproofing was
successfully applied at two structures.5
2.5.5 Metro M2 Lausanne, Switzerland
The new M2 Metropolitan Railway Line will cross Lausanne from South to North. The total length of
the tunnel is 6 km and the line has 14 intermediate stations. The urban sections were built in 8 tunnels
using “cut and cover” construction techniques. The line runs just beneath the surface and at depths
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down to 25m. Two of the tunnels were waterproofed with MASTERSEAL®345. This enabled
significant cost and time savings as the inner lining could be of sprayed fibre-reinforced concrete
rather than a cast-in-situ lining. Pre-sealing of water ingress was carried out using MEYCO® MP 308
and MASTERSEAL®845.
5
2.5.6 Nordöy Road Tunnel, Faeroe Islands
The tunnel is entirely located in rock and passes under the fjord between the two islands. The length of
the tunnel is 6155 m with a cross section of 64 m² (two lanes). The maximum depth under the sea is
150 m with a minimum rock cover of approximately 40 m. The tunnel was constructed by traditional
drill - and – blast excavation with rock support based on the single shell lining method with sprayed
concrete and rock bolts. MASTERSEAL®345 was used in a sandwich structure between the sprayed
concrete rock support and an inner layer of sprayed concrete. Hence the final lining consists of a
composite waterproof liner; a 3mm thick layer of the spray applied membrane in between the two
layers of sprayed concrete. 5
2.5.7 Chekka Road Tunnel, Northern Lebanon
The Chekka Road Tunnel was constructed in 1977 and comprises two parallel tubes accommodating
three traffic lanes each. The waterproofing of the original tunnel lining was in a state of deterioration.
MASTERSEAL®345 was used in a sandwich structure between the original cast concrete and a new
inner lining of fibre reinforced sprayed concrete. The inner lining of sprayed concrete had a thickness
of 4cm and was applied as a separate operation after installation of the sprayed waterproofing
membrane. The actual spray application of the MASTERSEAL®345 membranes was achieved using
the latest state-of-the art computerized spraying robot, the MEYCO®LOGICA POTENZA.
5
2.5.8 Wine caves, California, USA
The first Napa Valley wine cave construction dates back to the late 1800’s. Throughout the 20th
Century hundreds of wine caves were built. Being so close to the surface has the advantages of
minimizing development but may create other potential problems. One is surface water ingress; the
other is expansion-retraction of rock cover due to season temperature variances. Water from the
atmosphere may flow through rock joints or cracks and in the wine cave. The second problem is that
ambient temperature can vary substantially from day to night, especially in the winter months. Two
newly mined caves have been covered by MASTERSEAL®345 and waterproofing of an older cave
has begun. 6
2.5.9 Wolf Creek, Colorado
On the Wolf Creek highway tunnel in Colorado, a contractor with limited previous tunnelling
experience was contracted to apply only the final lining. As such, the lining contractor had no control
over the quality of the substrate of rockbolts and primary support shotcrete as installed by the project’s
Part 1 excavation contractor. Preparation of the surface for application of the membrane incurred
significant time and cost overruns, claims for which eventually went to arbitration. The ruling found in
favour of the contractor, the court awarding extra payment for application of the sprayed-on
waterproofing membrane. The ruling found no fault with the membrane concept itself and the tunnel
(now in operation) remains waterproofed with the Masterseal sprayed-on membrane as part of its
composite-shell lining.
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2.5.10 Abbotscliffe Tunnel Repair, UK
The Abbotscliffe Tunnel is a 19th Century brick arch tunnel on the railway between Folkestone and
Dover in Kent. A seasonal high water ingress, known as the Lydden spout, led to frequent closure of
the tunnel, which resulted in difficulties for its owners, Network Rail. During the remediation of the
whole tunnel in 2006 the Lydden Spout section was covered with a MASTERSEAL® 345
waterproofing membrane and relined. Drainage was also installed to intercept water behind the lining.
2.5.11 Stormwater Management and Road Tunnel (SMART), Kuala Lumpur
The SMART tunnel is an innovative solution to the Malaysian Capital’s long term traffic and
stormwater management problems. The 9.7km single bore tunnel connects two holding ponds, which
will contain and divert the yearly flood water away from the city. A 3km central stretch of the tunnel is
used as a two deck motorway to relieve the congestion at the southern gateway to the city. During
heavy storms (once or twice a year) a switch is made, the road tunnel is closed to traffic, and the full
tunnel section with a combined capacity of 3 million cubic metres becomes available to divert the
dramatically increased flows. The tunnels and cross-passages have been excavated in Karstic
Limestone. MASTERSEAL® 345 was used for waterproofing the crown areas of the cross passages
from springer level up and is jointed with sheet membrane. Whilst leaks were identified it is believed
that these were dues to tears in the sheet membrane rather than problems with the spray applied
membrane.7
2.5.12 Machadino Hydroelectric Power Station, Brazil (MASTERSEAL® 340)
The 1140MW Machadino hydroelectric power station in the south of Brazil required the construction
of three, 100m high, inclined, water intake shafts. In two of the intake shafts, overburden was small
and there was, therefore, a risk of excessive hydraulic fracturing of the surrounding rock mass. To
prevent the water escaping from the inclined shafts to the rock mass, it was proposed to waterproof
two of the sprayed concrete lined shafts to resist water pressure of 10 bar.
Following a review of the traditional waterproofing solutions available, including PVC sheet
membranes and steel liners, the MASTERSEAL® 340F spray applied membrane was chosen.
MASTERSEAL®
340F was successfully applied to a total area of 7000m2 and provided time savings
on the project. It also enabled easy application in the complex geometries of the shafts.
This project was completed in 2000. An inspection 3 years after completion of this project concluded
that there were no problems with waterproofing system.5
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2.6 Assessment of claimed properties
Table 1 compares the claims made by UGC, as detailed in Section 2.1, against available test data
provided by UGC. No comments can be made regarding the independence or quality of the tests
commissioned by UGC.
No. Claim Yes, No,
UTV*
Comments
1. Resists 15 bar of
water pressure
Yes Tests at EMPA Laboratory for Concrete and Construction
Chemistry in Switzerland have verified that a 3mm thick
sample of the membrane can resist water pressures of up to 20
bar over a period of 12 months without any discernible
leakage.2
NB: this refers to small samples prepared in a laboratory and
may not reflect the performance of the membrane under
normal construction conditions.
2. Bond strengths to
concrete and steel
Yes Concrete: 1.2 ± 0.2 MPa.8
Steel: 0.65± 0.05 MPa – some data presented shows lower
values than claimed.
3. Water migration
along the
membrane/substrate
contact
Yes Testing carried out at the University of Innsbruck.9 As the
membrane bonds to the surface (following contours), water
migration along the membrane/substrate contact will be low.
4. Elasticity Yes Tests show that at breakage (plastic deformation)
MASTERSEAL® 345 elongates by 80-170% between -20°C
and +20°C.
5. Application to wet
surfaces (i.e. damp
but no running
water)
Yes With the use of a drainage fleece (such as MASTERSEAL®
DR1), MASTERSEAL®
345 can be applied to wet or damp
surfaces. MASTERSEAL®
DR1 has a hydrophobic side
(facing the water), an impervious membrane and a hydrophilic
side facing the MASTERSEAL®345. Alternatively local
measures can be applied as appropriate.
6. Water Content
(during
application)
UTV The exact water content should be determined on site as it will
depend on environmental conditions.
7. Time period to
application of
secondary lining
Yes The secondary lining can be applied once the Shore hardness
of the membrane has reached 30; usually after less than 24
hours depending on the environmental conditions. The
membrane should not be left unduly exposed (see section 3.6).
The minimum time before application of the secondary lining
and maximum time that the membrane can be left exposed
should be specified for each project, with the aid of UGC
representatives.
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No. Claim Yes, No,
UTV*
Comments
8. Spraying onto
steel insertions
Yes MASTERSEAL®
345 can be sprayed onto steel insertions (see
point 2).
9. Compatibility with
concrete
Yes Fibre reinforced sprayed concrete and plain shotcrete can be
sprayed onto MASTERSEAL®
345. Alternatively, a cast
concrete secondary lining may be used.
10. Compatibility with
PVC sheet
membranes
Yes MASTERSEAL®
345 can be used with PVC membranes, but
as the PVC membrane is hydrophobic, it can be difficult to
obtain a good bond between the two. Tests show that after
approximately 56 days, a bond strength of between 0.8-0.9
MPa was achieved (with 30% water content) between the two
membranes.
11. No toxic
components
Yes According to the UGC Material Safety Data Sheet, in terms of
ingestion, inhalation or eye contact there are no anticipated
problems (copious amounts of water in each case coupled with
medical advice are recommended). Repeated contact with the
skin may cause irritation due to its cementitious nature.
MASTERSEAL®
345 is not considered to contain any
environmentally harmful products including disposal after
destruction.10
It is recommended that MASTERSEAL®
345 is
not disposed into drains and sewers since high alkalinity can
harm aquatic life forms.
12. Self extinguishing Yes Once applied to the substrate MASTERSEAL®
345 does not
catch fire. MASTERSEAL®
345 is self extinguishing,
according to DIN 4102-B2. There is very low risk of dust fire
at concentrations of 249g/m3(dry dust) and the minimum
ignition temperature is 470°C.11
13. Application
thickness and
consumption rate
UTV The thickness values given in the MASTERSEAL®
345 data
sheet are based on a flat surface (i.e. no roughness). Page 3 of
the data sheet (See Appendix E) shows the consumption rates
for different roughness concrete used (4, 8 and 16mm).
14. Equipment and
temperature range
Yes Sections 4-9 (inclusive) of the May 2007 Revision of the
Method Statement for MASTERSEAL®
345 should be
followed. The tensile strength of MASTERSEAL®
345
decreases from over 7MPa (at +5°C) to just over 2MPa (at
+40°C). Extremes of temperatures and cyclic temperatures
during the membrane curing period have been known to
damage the membrane – the temperature should be between
+50C and +40
0C for at least five days after application and
cyclic temperatures during this period should not exceed 100C.
15. Application rate
over complex
geometries
Yes For MASTERSEAL®
345 application rates between 50-100m2
per hour can be expected with manual application and 150-
180m² per hour using robotic application methods.
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No. Claim Yes, No,
UTV*
Comments
16. Shelf life UTV Although the shelf life of MASTERSEAL®
345 has not been
proven for the temperature range of +5°C to +40°C, at a
temperature of +20°C and relative humidity of 65%, the
product has a shelf life of greater than one year.
* UTV = Unable To Verify
Table 1 - Comparison of claims
2.7 Safety (COSHH-Control of Substances Hazardous to Health)
Appendix A contains a generic risk assessment for the use of MASTERSEAL®
345 and concludes that
there are no unacceptable health and safety risks inherent in the use of the product. However, users of
MASTERSEAL® 345 must perform their own risk assessment to take into account the particular
conditions of their usage.
Appendix B contains a copy of the Material Safety Data Sheet for MASTERSEAL®
345.
2.8 Summary
The selection of MASTERSEAL®
345 as a waterproofing membrane depends on the specific project
requirements and characteristics. Hydrological conditions, construction method and the final use of
tunnel, are only a small number of factors influencing the decision on what type of waterproofing
membrane is most suitable for a project.
General advantages and disadvantages of MASTERSEAL®
345 are summarised in Table 2.
Advantages Disadvantages
Easy application under difficult geometric
conditions.
Surface has to be cleaned thoroughly for
application. The smoothness of the substrate
may need to be improved to reduce
consumption rates.
A bond strength to concrete of around
1.2±0.2MPa which results in composite action
between primary and secondary linings –
producing a more efficient structure.
Water needs to be managed prior to spraying
the membrane. Cannot be used where there is
active water ingress, i.e. free-flowing water.
Fast initial curing time (overlying concrete can be
applied once the Shore hardness has reached 30,
usually in less than 24 hours depending on
environmental conditions).
Consumption rates are high if the surface is
rough, leading to high costs (although a
smoothing layer can be used).
Can be applied directly onto various substrates –
concrete, sprayed concrete, steel, copper,
aluminium, iron, brass (with varying bond
strengths).
Difficult to test the integrity of the final
product.
Fully bonded system with no migration of water Limited track record due to recent introduction
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along the membrane/substrate interface. of product into tunnelling market.
Environmentally friendly. Potential production of dust during mixing if
equipment not used properly.
Safe application (no toxic components). Performance based on operator skill. Hence it
is recommended to use approved operatives
only.
Fast application rates (approximately 50m2/hour
with manual spraying, up to 180m²/hour with
robotic application).
Vulnerable to extremes of temperature during
curing.
Potential of reduced volume excavation for tunnel
profile and lining thickness (if using a composite
lining).
The membrane must be given sufficient time to
cure prior to secondary lining application.
Membrane can withstand high water pressures.
Compatible with other waterproofing systems.
Can be applied using robotic spray boom.
Does not require a high level of tunnel profile
evenness as required with sheet membranes (e.g.
smoothing of irregular profiles of rock tunnels
and rock bolt or anchor heads).
Table 2 - Advantages and disadvantages of MASTERSEAL® 345
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3 Guidelines for application
3.1 General
MASTERSEAL®
345 is a spray applied, cement modified polymer waterproofing membrane designed
for application in a sandwich construction. It offers an alternative to traditional waterproofing systems
such as sheet membranes.
MASTERSEAL® 345 can be used in both open face construction methods, using drill and blast or road
header excavation techniques, and in soft and hard rock TBM tunnelling.12
As MASTERSEAL®
345 is
a sprayed membrane it can easily be applied to underground structures with complex profiles and
geometries. Due to the good bond strength between MASTERSEAL®
345 and steel, it can provide an
effective seal around steel elements, such as rock anchor heads or starter bars.
One of the major advantages MASTERSEAL®
345 has over traditional sheet membranes is its high
bond strength to underlying and overlying concrete linings. This makes it particularly suitable for use
in composite shell permanent sprayed concrete lining design, where the primary sprayed concrete
layer and the secondary sprayed concrete layer act as a composite lining. The use of a composite shell
design can result in time and cost savings as a result of a reduced excavation profile and lining
thickness.12
MASTERSEAL®
345 is also suitable for use in double shell linings, either sprayed or cast. It can also
be applied onto pre-cast concrete segments in conjunction with a final layer of sprayed or cast concrete
for architectural or fire protection requirements.12
MASTERSEAL®
345 is a versatile product that can be applied under many conditions, including
application on wet or damp substrates. However, careful preparation of the substrate is necessary to
ensure the effectiveness of the waterproofing system. The surface onto which it is to be applied must
be free of loose particles and cleaned thoroughly. The substrate must be thoroughly pre-wetted,
cleaned using compressed air and water jetting as well as removing any standing water.3
As with all spray applied waterproof membranes, it is not possible to use the membrane to seal against
any active water ingress through the substrate. Where active water inflow is present this must be pre-
sealed or managed using a drainage system prior to application of the waterproofing membrane.3
It is likely that joints will exist in the substrate onto which MASTERSEAL®
345 will be applied. Each
joint has the potential to provide a path for water ingress to reach the substrate/waterproof membrane
interface. Due to the high bond strength between MASTERSEAL®
345 and the underlying and
overlying layers, the possibility of any water ingress passing through joints in the substrate, and
migrating along the substrate/membrane interface until it reaches a defect in the membrane, is very
remote. This assumes that the substrate is generally impermeable except at the joints or cracks.
MASTERSEAL®
345 releases no toxic products during the application process and is, therefore,
highly suitable for use in confined spaces. MASTERSEAL®
345 is supplied as a dry powder. In order
to prevent any possible build up of dust when it is being applied in a confined space, the use of
spraying equipment equipped with a dust filter system is recommended.
MASTERSEAL®
345 can be sprayed by trained operatives either manually, or using robotic spray
booms, making it suitable for use in areas where man access is difficult.
Further details of projects where MASTERSEAL®
345 and its predecessor MASTERSEAL®
340 have
been used as the waterproofing layer are attached as Appendix C.
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3.2 Groundwater conditions
3.2.1 Design
The watertightness of MASTERSEAL® 345 has been tested by UGC, with additional testing also
performed at the EMPA (Federal Institute of Material Testing, Switzerland)2 and at BMI (Institute of
Concrete Structures, Building Materials and Building Physics) at the Technical University of
Innsbruck (Austria13
). A 3mm layer of MASTERSEAL®
345 membrane, embedded in concrete was
exposed to water pressures of 20 bar for 12 months without any leakage observed. MASTERSEAL®
345 was successfully tested at pressures up to 6 bar in large scale composite panel tests and proved
impermeable.9 When tested in a large scale trial with no internal lining MASTERSEAL
® 345 was
generally able to resist water pressures up to 10 bar, although delamination was evidenced by
blistering; and some blisters leaked. It should be noted that it is not recommended that
MASTERSEAL®
345 be used without an internal lining and so this test is unrealistically onerous.
The membrane’s ability to resist water pressure is highly dependent on its bond to the substrate, which
is influenced by the quality and cleanliness of the substrate. Experience has shown that the
performance of the finished product depends heavily on proper surface preparation and the integrity of
any joints in the membrane.
Another important factor for resistance to concentrated groundwater pressure is the thickness of the
secondary lining. If the tunnel is designed as un-drained, then the secondary lining must be designed to
withstand the full hydrostatic pressure. Therefore, for practical reasons tunnels are rarely designed to
be undrained (i.e. fully watertight) for water pressures greater than 6 bar (60m of water head).
Laboratory tests of a large sample (of MASTERSEAL®
345 embedded between 2 layers of concrete)
have shown that it is suitable for undrained tunnels in the normal operating range of 0 to 6 bar.
MASTERSEAL®
345 is suitable for drained tunnels in the same pressure range.
3.2.2 Managing Water Ingress Encountered During Construction
As with all spray applied waterproof membranes, it is not possible to apply the membrane effectively
in areas with active water ingress through the substrate. Quite low rates of seepage can result in
hydrostatic pressure developing at the concrete/membrane interface causing it to fail before it has
cured sufficiently to achieve adequate adhesion.
Where active water inflow is present this must be pre-sealed, or a suitable temporary or permanent
drainage system used to channel away the water inflow, prior to application of the sprayed membrane.
The following water management methods are recommended:
• Collection of water inflow via hoses fixed into the sprayed concrete layer prior to application
of MASTERSEAL®
345, with grout injection of the hoses after application of the secondary
lining. This method is suitable for localised water inflow.
• Installation of half-round drainage channels fixed to the surface of the sprayed concrete. This
method is also suitable for use with localised water inflow.
• Installation of a drainage fleece (e.g. MASTERSEAL®
DR1). This can be applied locally or
globally depending upon the water inflow conditions. It should be noted that consumption of
the product is higher when spraying onto a drainage fleece.
Two of the possibilities for permanent drainage are shown in Figure 4. The geotextile membrane
would be continued down from the wet spot to a drain in the invert, with the edges securely fastened
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by strips of metal. A drainage channel, such as a half pipe could also be used and once again fixed
from the wet spot to the invert. For a composite shell lining design drainage should be as narrow and
infrequent as possible in order to limit the area of the system that is not fully bonded.
Figure 4 - Management of wet spots using geotextile membranes (left) or drainage channels (right)
In areas where extensive water inflow is present or expected, it may be necessary to design some form
of pre-grouting or post-grouting to seal the water inflow before the use of MASTERSEAL®
345 can be
considered. Depending upon the residual water inflow after water control measures have been
performed, MASTERSEAL® may be applied directly to the substrate or in combination with a
drainage system. It should be noted that although MASTERSEAL®
345 is a versatile product, it may
not be suited for every condition, and its use should be carefully evaluated in all cases.
It may be useful to combine the drainage measures listed above with a priming layer of a faster curing
sprayable membrane than MASTERSEAL®
345, such as MASTERSEAL®
855A. This can block
smaller water seepages or be used for the closing around drainage channels or strips where small water
seepages may occur.
The following flowchart can be used as guidance in determining the suitability of MASTERSEAL®
345 as a waterproofing membrane.
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Note: Water ingress classes 1 to 5 are based on ITA Report, Water Leakages in Subsurface Facilities14
.
However, classes in the flowchart above refer to the initial state of water ingress through the substrate before
membrane application, not the desired tightness class as in the ITA report.
Figure 5 - Flowchart to determine suitability of MS 345 based on the water ingress through the substrate
3.3 Substrate
MASTERSEAL®
345 is suitable for application on all types of concrete substrates and with all types
of secondary linings, including steel fibre reinforced sprayed concrete and cast in-situ concrete.
MASTERSEAL®
345 is also suitable for application on brick substrates and masonry, provided that
the normal surface preparation is carried out.
3.3.1 Substrate preparation
Quality of the finish and cleanliness of the substrate onto which the sprayed membrane is to be applied
is fundamental to ensuring the effectiveness of the finished waterproofing system.
Prior to application it is essential that any active water inflow has been sealed or managed using a
suitable drainage system and that the surface is clean and free from any loose particles. All laitance,
dust, loose aggregate, curing liquids, compounds and membranes and other debris which may impair
Consideration of MS 345 as a waterproofing
systems for a structure
Class 1: Completely Dry
What is the water ingress class?
Class 2: Substantially Dry
Class 5: Trickling Water
Over
Class 3: Capillary Wetting
Class 6: Extensive Water
Inflow
Class 4: Weak Trickling
Water
MS 345 Applied Directly to Primary
Lining
Single Shell Lining Design Possible (Sprayed Concrete Primary & Secondary
Lining Acting compositely)
Double Shell Lining Design Possible
Benefits of Spray Applied Membrane & Potential Project Savings Using
Single Shell Design
Extensive Use of DR1 Followed by
MS 345. Need Careful
Evaluation of This Approach
Double Shell Design Lining
MS 345 Probably not Competitive on Long
Standard Tunnel Geometries
Is the Tunnel Already Built?
Promote Pre-Injection
Techniques
Implement Injection
Approach
Promote Post-Injection
Techniques
No Yes
Management of Active Water Inflow Necessary: e.g. a) MS 345 Applied Directly to
Primary Lining With DR1 Fleece Applied Locally
b) Sealing of Water Inflow Locally Using Quick Setting Leak Sealing Mortar
c) Localised Chemical Injection d) Temporary Drainage Pipes
Consider Also Sheet Membrane
Consider Use of MS 345 in Non-Standard Tunnel
Sections (e.g. Niches, Cross Passages)
Need to Consider Injection
Techniques to Manage Water
Inflow
MS 345
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adhesion of the membrane to the substrate must be removed. The substrate should also be damp ( but
not soaking wet) to ensure good application. A dry surface is likely to lead to poor results.
Another advantage of MASTERSEAL® 345 over traditional sheet membranes is that it can be applied
to substrates with varying surface profiles such as those in Drill and Blast (D & B) tunnels. Surface
profiles can be quite hummocky (with peaks and troughs) and additional work is often required to
achieve an adequately smooth profile for application of a sheet membrane. This substrate preparation,
to regulate the tunnel profile, is not required prior to spraying of MASTERSEAL®345. However,
MASTERSEAL® 345 should not be applied directly to rock, and it is recommended that a 25mm thick
sprayed concrete sealing layer is provided to ensure a smooth, unbroken surface before application of
MASTERSEAL® 345.
3.3.2 Optimising sprayed concrete surface texture
The large fluctuations in surface profile described above are not problematic for MASTERSEAL®
345.
However fluctuations in surface profile on a smaller scale, e.g. an excessively rough substrate, will
result in higher consumption rates of MASTERSEAL®
345, slower progress rates, and subsequently
higher costs. For cost-effective application of MASTERSEAL®
345 it is recommended that the
substrate is as smooth as possible (although screeding or a floated surface is not necessarily required).
Careful selection of the sprayed concrete properties can help reduce the time and cost of the spray
applied membrane. The following guidelines will help to achieve a substrate surface suitable for the
application of MASTERSEAL®
345:
• Ensure a good combined grading of the sprayed concrete aggregates. A maximum aggregate
size of between 4 and 8mm is recommended as indicated in Figure 6 (the dashed lines indicate
the recommended zone for aggregate gradation by EFNARC and the shaded area shows the
recommended zone for grading curves).
• Employ an accelerator-cement combination for the primary lining which ensures suitable
setting characteristics when sprayed. An incorrect combination will result in an excessively
rough substrate surface.
Where it is not possible to adjust the sprayed concrete properties to achieve the desired surface
characteristics and the finished surface of the substrate is excessively rough, it may be necessary to
apply a thin mortar smoothing layer. This smoothing layer will significantly reduce the consumption
of MASTERSEAL®
345 and is more economic than excessive amounts of MASTERSEAL® 345. The
smoothing layer can be of simple sand and cement composition which will provide good coverage
rates (providing a fast and cheap solution).
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11
22
37
55
73
100
26
50
72
90
100 100
0.0
75
0.1
5
0.3
0.6
1.1
8
2.3
6
3.3
5 56
.3 10
14
20
37
.5
4
90
12
16
84210.5
0.2
5
0.1
25
0
10
20
30
40
50
60
70
80
90
100
0 .0 1 0 .1 1 1 0 1 0 0
Particle size (mm)
Pe
rce
nta
ge
pa
ss
ing
BS Sieve
ISO Sieve
Figure 6 - Combined grading for sprayed concrete3
Figure 7 shows the finished texture of MASTERSEAL®345 after application on the indicated substrate
aggregate thickness.
Figure 7 - Different substrate roughness 3
3.4 Application
MASTERSEAL®
345 is applied using the dry mix spraying method. The use of a dry mix rather than a
wet mix method allows the water content to be minimised resulting in shorter curing times. The use of
a dry mix also provides better penetration of the membrane into the irregular substrate surface.
Thereby the problems of pinholes and voids experienced with MASTERSEAL®
340 are eliminated.
3.4.1 Spraying equipment
MASTERSEAL®
345 is applied using the dry spraying method with either an air or electrically driven
pump, such as a MEYCO® PICCOLA or similar.
Application can be by manual spraying or using a
robotic spraying boom.
The MEYCO®
LOGICA15
is an example of spraying robot technology. It can be used for the
application of sprayed concrete for ground support, fire protection, thin support liners and membranes.
Using its 8 freedoms of movement, the manipulator system can control and keep constant the
predefined distance and angle to the substrate as well as the speed of movement: independent of the
visibility or surface features. This results in a higher output and a consistent membrane thickness.
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With a correct angle of application and constant spraying distance, a reduction in rebound and
therefore savings in cost is achieved. The operator can use the machine in either manual, semi-
automatic and automatic modes using the remote control and computer system.
The spray equipment must be fitted with a dust collection filter, or similar dust collection system. Care
should be taken not to create excessive dust when filling the hopper of the pump. The floor area
should be dampened with water during the application process to suppress any dust production. The
specified order of activating the pumping equipment outlined in the method statement must be
observed.
A spraying nozzle, diameter 32mm, with a water ring with a minimum of 16 holes is recommended. It
is a requirement to use two valves on the water line on the nozzle. The first valve is a needle valve for
fine control of water dosage and the second is a ball valve for on-off control. This is to ensure that
once the optimum water settings have been determined during pre-construction trials, they are not
changed by the operative during application. When spraying, the nozzle should be angled to ensure
that any holes are filled, and then orientated to make certain appropriate coverage is achieved.
Compressed air supply is frequently full of condensation water. Such water will cause problems by
build-up of hardened MASTERSEAL® 345 in the nozzle, spraying hose and pump. Such build-up may
be very difficult to remove and can cause unnecessary practical problems. A complete equipment set-
up must always include a water separator with sufficient capacity to dry out all air used for the
spraying operation. Such a water separator can be part of a complete equipment delivery from BASF
UGC. Furthermore, it is recommended that the compressors are fitted with water separators (as is the
case with most modern compressors).
3.4.2 Spraying technique
Spraying distances for both manual and robotic applications should typically be between 1.5 and 2.5m
as can be seen in Figure 8 and Figure 9.
Figure 8 - Manual Spraying of MASTERSEAL® 345
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Figure 9 - Mechanised Spraying of MASTERSEAL® 345 with MEYCO ® LOGICA
It is recommended that a minimum of three operatives are employed for the manual application of the
membrane; one to control the nozzle, the second to manage the delivery hoses for the nozzleman,
control membrane thickness and identify any mistakes during the application, and the third to operate
the pump.
An application of MASTERSEAL®
345 with MEYCO®
LOGICA fully computerised robotics can be
operated by a two man crew, one operator and one utilities pump operator. The application procedure
then consists of the following elements:
• The spraying nozzle is mounted on to a robotic manipulator (boom) which is controlled
remotely.
• The surface which is to be sprayed is digitally recorded in bay lengths of 3m along the tunnel
• The surface to be sprayed is pre wetted by the spraying of water through the nozzle
• The application of the membrane is completed in fully automatic mode (with pre determined
parameters for nozzle distance, lance and pump speed) with the spraying manipulator which
will apply the membrane onto the scanned surface with a consistent amount of
MASTERSEAL ®
345.
Where MASTERSEAL®
345 is to be applied over large areas it is recommended that it is sprayed in
alternate panels, in a so called “hit and miss” approach, with the intermediate areas sprayed later.
3.4.3 Thickness
The minimum thickness recommended by the manufacturer is 3 mm and the practical upper limit for
application is stated as 10 mm. Above 10 mm the self-weight of the membrane may cause debonding
during application. No guidance is given on merits or disadvantages of applying layers that are thicker
than 10 mm. Applying a thicker layer should reduce the risk of localised areas of thicknesses less than
3 mm.
3.5 Water content
Water should be added at a rate between 30% and 50% of the dry product weight. It is crucial that
preliminary site tests are undertaken with the actual equipment to be used for the project, to allow the
optimum water to powder ratio to be determined. The trial can be carried out on existing concrete test
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panels that have been made. Once the optimum settings for water to powder ratio have been
determined, it is vital that these are not altered during the spraying process.
Potable water should be used for spraying. Under no circumstances should saltwater, river, lake or
ground water be used for mixing and spraying the MASTERSEAL® 345 membrane.
Testing has revealed that inhomogeneous water content, as a result of inconsistent water addition or
mixing during application, can result in cracking of the membrane. Hence fixed nozzle settings and the
correct equipment is necessary. If the powder is applied too dry the polymer particles are not
adequately dissolved. Instead they form conglomerates on the substrate to create a porous, non-
homogenous material. This effect is seen in the Figure 10 below, where porosity can be seen all the
way through.
Figure 10 - MASTERSEAL® 345 sprayed too dry, front (left) and reverse sprayed onto plastic film (right)
A water-powder ratio >0.3 is essential for the correct curing of the membrane. When the correct ratio
is used, fillers, mainly fire retardants, accumulate in the spray valleys (white areas as shown in Figure
11). They form a “skin” on the membrane surface of pure mineral based products and are not flexible
like the membrane. With a higher water-powder ratio they accumulate even more at the surface
providing a fire-protecting layer. The white filler surface “skin” is very thin and has a brittle nature,
which causes cracks, and pinholes that can be seen in the surface. (see Figure 13) The flexible
membrane remains intact underneath. During spraying it is possible to see if too little water is being
used as the polymer comes out of the nozzle as a powder. Above a water-powder ratio of 0.6 the
polymer becomes too liquid and flows down the tunnel wall.
The quantity of water applied also affects the curing time of the membrane. Adding the minimum
recommended water content of 30% results in an initial curing time (Shore hardness 15-25) of
approximately 4 hours (depending on site conditions). An increase in water content results in an
increase in curing time.
When sprayed onto a plastic film the intact nature of the polymer surface can be seen with no pinholes
or cracks evident. The polymer film itself is translucent so that cement particles inside the membrane
are seen (brown and dark grey spots) – see Figure 12.
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Figure 11 - Surface of MASTERSEAL®345 at 0.4 (left) and 0.6 water-powder ratio (right)
Figure 12 - Reverse on plastic membrane at 0.4 (left) and 0.6 (right) water-powder ratio
Figure 13 - Surface of MASTERSEAL®345 with 0.6 water-powder ratio showing pinholes and cracks in the fire retardant filler
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3.6 Temperature and humidity
Another major factor for successful membrane performance is the environmental conditions on site at
the time of application. Temperature and atmospheric humidity can have a significant effect on
application and curing behaviour. During application it is important to ensure adequate monitoring of
temperature (ambient and concrete), air speed, and humidity, to ensure they remain within the
recommended limits.
The manufacturer recommends that the substrate and ambient temperature at the time of application of
the sprayed membrane are between +5°C and +40°C.
The optimum relative humidity during
application is below 90%. It is also important that ventilation is applied during spraying, although very
little dust is generated if the correct equipment is used.
MASTERSEAL®
345 cannot be applied directly to a frozen substrate and should not be allowed to
freeze during application or during the full curing period.
3.7 Curing
The curing time of the MASTERSEAL® 345 membrane is affected by the water content of the applied
membrane. An increase in the water content results in an increase in the required curing time. The
final stage of curing involves the loss of excess water through the membrane surface. As the surface
area of the membrane is constant, increasing the water quantity during spraying results in an increase
in the excess water present and hence the time required for it to evaporate.
An increase in the thickness of the applied membrane also results in an increase in the required curing
time. This is due to the increase in the excess water in the thicker membrane without a resulting
increase in the membrane surface area and evaporation rate.
The relative humidity of the surrounding environment affects the curing rate. The first stage of curing
is the reaction of the cement with the water, while the polymers form long chains and cross links. As
stated above, the final stage of curing involves the loss of the excess water by evaporation through the
membrane surface. If the relative humidity is 100% no evaporation can take place and the curing is
stopped. For optimal curing it is recommended that relative humidity is below 90% and air speed is a
minimum of 0.5m/s, otherwise water will be retained within the membrane, although this should not
impair its impermeability. Humidity in the substrate below the membrane does not affect the curing.
To monitor the curing on site it is recommended to measure the Shore A hardness of the applied
membrane according to DIN 53505 or ASTM D2240. Table 3 gives the curing status in typical
conditions.3
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Shore A Curing status of
MASTERSEAL ® 345
Time taken to achieve at 20°C,
65% relative humidity
Not measurable First skin, very soft 1 hour
5-10 Skin slightly sticky, still pasty 2 hours
15-25 Sufficient adherence is
achieved, material is not a
homogenous membrane yet but
partly pasty
6 hours
30-40 Homogenous fully cured
membrane. High residual water
amount softens the material.
20 hours
75-85 Fully cured and dried
membrane.
> 10 days
Table 3 - Curing status of MASTERSEAL ® 345 according to Shore A
To ensure proper curing, care must be taken to ensure that, for five days after application, the ambient
temperature remains between +5oC and +40
oC and cyclic temperatures do not exceed 10
oC. Presence
of a further layer of concrete (inner lining) may increase the time taken but will not effect the
membranes ability to reach a fully cured state.
3.8 Joint details
It is possible that MASTERSEAL® 345 will interface with a drainage system or another type of
waterproofing system, such as a sheet membrane. In this situation the joint between the two systems
presents a possible water path, so an effective water tight joint is vital to the success of the overall
waterproofing sytem. Suggested joint details for application of MASTERSEAL® 345 in conjunction
with drainage systems and sheet membranes are shown in below.
3.8.1 Jointing of MASTERSEAL®345 and MASTERSEAL® DR1
MASTERSEAL® 345 is fully compatible with MASTERSEAL
® DR1 drainage fleece. To prevent
voids forming behind the fleece or water escaping around the edges it is recommended that a suitable
method to hold down the edges of the fleece during application is used. Examples of particular details
are given in Figure 14.
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Figure 14 - MASTERSEAL ® 345 applied in conjunction with MASTERSEAL ® DR1 Fleece
3.8.2 Jointing of MASTERSEAL® 345 and a sheet membrane
MASTERSEAL® 345 can be applied in combination with traditional waterproofing systems, such as
PVC sheet membranes. MASTERSEAL® 345 can be sprayed directly onto sheet membranes (e.g.
Enkadrain, Sarnafil and Sikaplan) to form an overlapping joint. A reduction in bond strength (see Table
1, point 10) can be experienced when MASTERSEAL® 345 is applied over a sheet membrane due to its
hydrophobic nature. It may be necessary to enhance the joint (e.g. by integrating a water stop) to
compensate for the lower bond strength to the sheet membrane. See Figure 15 for details.
Figure 15 - MASTERSEAL ® 345 applied in conjunction with sheet membrane
3.8.3 Joint between adjacent sections of MASTERSEAL® 345
When joining adjacent sections of MASTERSEAL® 345, an overlap of 200 to 300mm should be
employed to ensure the integrity of the joint (see Error! Reference source not found.). When
applying MASTERSEAL® 345 adjacent to a cured layer of MASTERSEAL
® 345, preparation of the
cured underlying layer is important. The underlying layer should be cleaned of all loose material and
dust prior to the application of the overlapping layer. In some cases, depending on conditions,
overlying layers can be applied approximately 6 hours after application of the previous layer.
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Figure 16 - Jointing of adjacent sections of MASTERSEAL ® 345
Figure 17 shows a possible joint detail where movement is expected at the joint.
MASTERSEAL 345
Masterflex 3000
Concresive 1402
Figure 17 – Movement joint detail
3.8.4 Waterproofing Over Fixings
MASTERSEAL®345 is suitable for direct application over steel insertions, such as rock anchor heads
and starter bars. The bond strength between MASTERSEAL®345 and steel is around 0.65±0.05MPa
and a waterproof seal is easily achieved. Where steel insertions are present, application must ensure
that no excessive bridging of the membrane occurs across gaps between the insertion and the substrate.
In this case a smoothing layer should be applied over the steel insertion prior to application.
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Figure 18 - Application of sprayed membrane around steel insertion
3.9 Secondary (internal) lining
3.9.1 Design
To resist the external water pressure, a lining has to be installed inside the membrane. Ideally this
secondary lining will act as a composite with the primary sprayed concrete lining due to the bond
between the membrane and the concrete. Only a few published studies have addressed the question of
the bond strength required at the interface between the primary and secondary lining to permit the
composite action required in so-called “single-shell” linings. These studies suggest that relatively
modest bond strengths are necessary, typically greater than 0.5MPa (Figure 16, Figure 17). This is
well within the achievable bond strengths for MASTERSEAL® 345 to concrete. However, each
project must consider the prevailing load conditions before coming to a judgement on whether or not a
single-shell lining solution is achievable. To assist in this, an investigation of this “single shell”
behaviour was performed by Mott MacDonald using a numerical model to simulate the composite
action and examine the boundaries of its applicability.
The properties of the interfaces between the concrete and the waterproofing membrane were taken
from the back-analysis of shear test data gathered by Professor Blumel in Graz. The original shear test
curves were replaced with curves derived from FLAC simulations of the shear tests. The curve of the
original test Specimen No. 00 was approximated by the curve named “Rough” and the Specimen No.
03 by the curve “Smooth”, see Figure H-2. For their FLAC input parameters see Model 1 and Model 2
respectively in Table H-1. The exact parameters for the interface elements may vary depending on the
theory implemented in each numerical modelling program. Therefore it is recommended that the input
parameters for the model are derived by first back-analysing test data and calibrating the numerical
model.
The base model was created using FLAC (Fast Lagrangian Analysis of Continua) and represents a 1m
thick length of composite tunnel lining (280mm thick primary lining, a 3mm layer of
MASTERSEAL® 345 and a 145mm thick secondary lining). By using symmetry one quarter of the
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ring is modelled. An external pressure was applied to the ring, simulating a vertical stress of 500kPa
and a horizontal stress of 1000kPa (i.e. the ratio of horizontal to vertical stresses, K, = 2). This
represents a highly loaded tunnel lining, subjected to bending as well as compression. Most tunnels
would experience lower loads than this.
Nonetheless, in all the models run, there was no shear failure on the interface between the membrane
and the concrete linings. In other words, the lining functioned as a single shell. The model was
checked by comparing the displacements predicted against an elastic analytical solution based on the
no-slip case calculation after Duddeck and Erdmann (1985)16
. The results agreed to within about 6%
which is acceptable.
In Models 7 and 8 lower properties were used for the interface to mimic poor quality installation in an
attempt to find a point at which load sharing – single shell behaviour – would cease. For their shear
test simulation curves see Figure H-1, “Smooth but 50% weaker” and “Smooth but 75% weaker”.
Even if the membrane only has 25% of the expected shear strength, there is a successful load sharing
and no shear failure occurs on the interface (Table H-1).
The loading was also varied. Even increasing the loads by 24 times or applying the load to only half of
the ring did not produce any failure at the membrane interface.
This numerical modelling study showed that the single shell structure is possible with MS345 and that
the performance is relatively insensitive to the precise strength or stiffness values of the bond between
the MS345 and the concrete.
3.9.2 Construction
Sprayed concrete can be directly applied onto the MASTERSEAL® 345 membrane after it has dried
out sufficiently (once the Shore hardness has reached 30). The sprayed concrete will bond to the
membrane surface in a similar manner as when spraying onto rock or concrete. Normal curing
procedures should be used to minimise the risk of shrinkage of the membrane.
According to UGC International, the use of steel fibre reinforced sprayed concrete as the secondary
lining will not cause any damage to the membrane. Alternatively, a cast concrete secondary lining may
be used.
Sheet membranes make use of the lack of bond on their surfaces to allow shrinkage of inner cast in-
situ linings – reducing the occurrence of longitudinal tension cracks generated if concrete is restrained
during the cooling phase. This early age cracking of the secondary lining can lead to loss of water
tightness and aesthetic issues. Although providing a greater restraint to the concrete, MASTERSEAL®
345 is able to bridge cracks on the inner surface and thus maintain its waterproofing capability (see
Figure 19).4
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Figure 19 - Width of expending crack
Crack creation is traditionally reduced through the optimisation of the concrete properties and by
reinforcement. By allowing the primary and secondary linings to work together as a composite,
MASTERSEAL ®
345 allows for greater optimisation of the secondary lining. For example, sprayed
concrete can be used as the inner lining (either for the whole lining or only for the tunnel crown where
surface reflectance of the concrete is of less importance) and the linings can be thinner which reduces
the propensity for crack generation.
3.10 Durability
MASTERSEAL® 345 is designed to be spray-applied in a sandwich system between layers of sprayed
or cast concrete. This composite system is the key to optimum durability. For example, in most
applications this should limit the temperatures to which the membrane is exposed during its life and
prevent exposure to UV radiation. Because this product has been on the market for a relatively short
time definitive statements on durability cannot be made. However, this type of polymer has been used
in construction for many years and is very stable chemically.
Due to the nature of the bond between the polymer and water, unlike other polymers such as PVC,
over time the ethylene-vinyl acetate copolymer does not become increasingly brittle. The transitions
illustrated in Figure 20 are believed to carry on without degrading throughout the polymers life span
independent of how many times the situation is reversed.4
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Figure 20 - Properties of MASTERSEAL® 345 in changing water conditions
3.10.1 Elevated temperature
No data has been provided regarding stability of the product at elevated temperatures (i.e. > 40ºC).
However in the Journal of Polymer Science: Polymer Letters 1973 Volume 11, p.521-523“Thermal
degradation of ethylene-vinyl acetate copolymer” it was found that with an activation energy of 180kJ,
at 60°C 1 out of 100 000 bonds will break within 45 years but at 250°C 50% of bonds decompose
within 2 hours.
Each project should consider this issue in light of the likely exposure during the lifetime. It should be
noted that sheet membranes will also degrade at similar temperature elevations.
3.10.2 Ultraviolet (UV) light
The polymers used in MASTERSEAL® 345 have been chosen specifically to provide the finished
product with the characteristics required for a waterproofing membrane for use in an underground
environment i.e. with a low incidence of UV light. The specific polymers used are less stable in UV
light than those which may be present in a product designed for use in works above ground. However,
in sandwich construction the membrane is protected from UV light.
3.10.3 Chemical resistance in aqueous solutions
MASTERSEAL® 345 has been tested for the effects of water containing a relatively high
concentration of sodium sulphate solution for up to 6 months at room temperature, with no detrimental
effects being observed.17
The effects of exposure of MASTERSEAL® 345 to both strongly base
solutions and mineral acids in tests have also shown no detrimental effects.
Samples of a fully cured MASTERSEAL® 345 membrane were immersed at room temperature in the
following:18
1) Water (pH=7)
2) A saturated salt solution (Na2SO4)
3) An acid (0.1% H2SO4) (pH<3)
4) An alkali (Cement Lime) (pH>10)
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MASTERSEAL® 345 displayed the expected water absorption of 10-23% by weight. A constant value
was reached after approximately two weeks. At this time the membrane appeared to be saturated and
an osmotic equilibrium was achieved. As there are inorganic fillers in MASTERSEAL® 345, the
osmotic pressure is highest in pure water and lowest in saturated Na2SO4- solution. Cement lime and
0.1% H2SO4 lie in between. In line with the theory of osmotic pressure, the water absorption was
observed to be highest in water and lowest in Na2SO4. Although the polymer underwent a moderate
softening by absorbing liquid, the membrane maintained its water tightness properties after 4 months.
It should be borne in mind that since the membrane is applied in a sandwich construction between
concrete layers, its exposure to the chemicals is likely to be reduced unless the concrete is very
cracked.
Each project should consider which chemicals the membrane may be exposed to and carry out tests to
examine the durability, if deemed necessary. It may be noted that chemicals with a similar
composition (for example, hydrocarbons) may dissolve the membrane.
3.11 Maintenance and repair
If defects are identified prior to the application of the secondary lining, they can be repaired easily by
simply spraying additional layers of membrane as necessary, a simpler and quicker solution than the
repair of sheet membranes by welding on patches. Moreover, stopping water ingress from a failed
sheet membrane using chemical injection is expensive, partly because of the difficulty in locating the
source of the leak. With MASTERSEAL® 345, and the bonded solution, water ingress at any point is
confined to a limited location in the secondary lining where the membrane has failed. A typical repair
method is to drill and inject through a small packer with chemical resin (e.g. acrylic resin) in the same
way as for a mass concrete lining.
Alternatively, the damaged waterproofing membrane can be repaired by cutting back the overlying
lining until the damaged section of membrane is found (taking care to ensure the drainage fleece, if
used, is not damaged) and then reapplying MASTERSEAL® 345. The overlying lining should be cut
back sufficiently to allow 200 – 300mm overlapping to the existing membrane in accordance with the
manufacturer’s recommendations.
If necessary for repairs, small quantities of MASTERSEAL® 345 can be mixed by hand with about
50% by weight of water.
3.12 Environmental aspects & demolition
The environmental impact of MASTERSEAL® 345 has been considered by BMG
19, according to the
Swiss Ordinance on Waste. It was concluded on the basis of the laboratory test results that
MASTERSEAL® 345 does not pose any hazards to humans or the environment. It was noted that in
normal circumstances, such as demolition waste, the membrane will be mixed up with much larger
quantities of rock or concrete. Excavated material or concrete containing MASTERSEAL® 345 can be
classified as “not contaminated” according to the requirements of the Swiss Aushubrichtlinie
(Excavation Directive), provided that the content of MASTERSEAL® 345 is sufficiently small (i.e. >
1 %).
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4 Quality control during application
The prime objective of testing MASTERSEAL® 345 is to assure the client that the product will
perform its job of waterproofing the structure to the specified standard during the working life of the
structure. The essential features of the applied waterproofing membrane which are required to be
tested are as follows:
• Water content
• Performance
• Coverage - has the membrane entirely covered the required area?
• Thickness - is the membrane of the required minimum thickness throughout?
• Defects
These points are the main indicators of quality of the application of MASTERSEAL® 345. They can
be checked by a variety of methods and Table 4 summarises possible test methods for
MASTERSEAL® 345. The table has been designed to highlight the properties of each test to enable
selection of appropriate test methods for each individual project.
It is recommended that inspection sheets are generated on site to record each application of
MASTERSEAL®
345 in the tunnel. As a minimum, recording of the following information is
recommended.
• Section of substrate (chainage, bay number, etc.)
• Date
• Shift
• Operative
• Pre-spraying checks (surface condition, surface drainage system, cleanliness, environmental
conditions etc.)
• Thickness checks (Elcometer, patches, etc.)
• Post spraying checks (ensure coverage by marking areas for respray)
• Repair report
• Inspection before application of secondary lining
An example inspection sheet is attached in Appendix E.
Critical to the success of cast application is the use of approved operators who have been trained by
the manufacturer.
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Subject Test Method In-
Situ
Trials Damage Additional
information
Relevant
Standards
Membrane
Hardness
Shore
Durometer
Yes Yes None DIN53505
ASTM2240
Coverage Visual Check Yes No None This check should
be performed by
the engineer as a
quality check
-
Thickness/
Coverage
Patches Yes Yes Destructive, but
can respray the
patches.
- -
Thickness Covermeter Yes Yes None. Bond to
steel lower than
that to concrete.
Potential rust
issue
- -
Thickness Needle
penetrometer
Yes Yes Pinhole created.
MASTERSEAL®
340 in paste form
can fill in the hole
- -
Thickness Measurement
of volume
sprayed
Yes Yes None Only for robotic
spraying.
Calibration in trials
required.
Impermeability
Water
penetration
test
Yes Yes - Cored samples
taken from test
panels.
BS EN
1542: 1999
Bond Strength Pull-off Test No Yes 50mm cores Cored samples
taken from test
panels.
BS EN
12390
8:2000
Table 4 - Possible test methods for quality control of MASTERSEAL ® 345 application
4.1 Preconstruction trials
A trial with MASTERSEAL® 345 should be performed before applying it to the tunnel interior. The
trial enables the operator to adjust the amount of water added until the desired consistency is achieved.
This water content should then be maintained throughout application. In the trial MASTERSEAL®
345 should be sprayed onto a substrate constructed using an identical mix and equipment to that used
in construction. Ideally, horizontal and vertical orientations (representing tunnel walls and crown)
should be tested to optimise the application characteristics in all situations.
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4.2 Performance tests
Performance tests to determine the properties of the final product are detailed in this section.
4.2.1 Pull - off tests
In order to determine the tensile bond strength of the MASTERSEAL® 345 membrane to the
underlying substrate it is possible to employ a test which involves pulling off a “dolly” bonded to the
surface of the membrane (according to BS EN 1542: 1999).
Before the pull-off tests are performed, and before the dolly is applied to the membrane, the membrane
should be allowed to cure for a minimum of 28 days. Because of this curing period this test would
normally be performed on test panels, to avoid delaying the application of the secondary lining.
Following the curing period the specimen is prepared by fixing the steel dolly to the membrane surface
using a rapid hardening epoxy adhesive. Once the adhesive has cured, a sharp instrument is used to cut
into the substrate around the dolly. Test equipment complying with EN 24624 is then used to apply a
tensile load to the dolly until failure occurs. The tensile load should be applied continuously and
evenly at a rate of 0.05±0.01 MPa/s until failure occurs. The failure load is then recorded and the mean
diameter of the failure face determined, by taking the average result of measurements taken
perpendicularly across the core using vernier callipers. The location of failure should also be recorded,
as adhesive failure is also possible.
The tensile bond strength is calculated using the following formula:
hf =2
4
D
Fh
π
Where hf is the bond of the test specimen, in MPa
hF is the failure load, in N
D is the mean diameter of the test specimen in mm
4.2.2 Water penetration test
There are two methods for establishing the water resistance:
1. Taking a core from the permanent works (i.e. in-situ core)
2. Taking a core from a test panel sprayed using with the same shotcrete mix and membrane to
be used in the tunnel and using the same equipment
The second option is preferable as it will not compromise the integrity of the in-situ membrane (taking
a core will puncture the membrane). As the test panel is sprayed with the same concrete and
membrane mixes to be used in the tunnel, it will be representative of in-situ conditions and a good
indication of the final water resistance. A core (concrete-membrane-concrete sandwich) is taken from
the test panel and tested under the required water pressure (according to BS EN 12390 8:2000). No
more moisture than 0.05l/m² per day should penetrate through the lining.
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Figure 21 - Coring the membrane
4.3 Coverage
In order to ensure that the membrane has fully covered the required area, a visual check can be
performed. The light yellow colour of MASTERSEAL® 345 contrasts sufficiently well with the grey
of the concrete behind it to enable this check to be easily carried out.
4.4 Thickness
The minimum membrane thickness recommended by the manufacturer is 3 mm and the practical upper
limit for application is stated as 10 mm. The following sections highlight possible methods of
measuring the thickness of the membrane.
4.4.1 Cutting patches
The thickness of the membrane can be checked by cutting out patches at regular intervals along the
length of the tunnel, and physically measuring the thickness using mechanical methods such as a
micrometer. To ensure water tightness the membrane can be sprayed over areas where patches have
been taken. The patches should be cut out, using a knife, within 12 hours of membrane application but
after initial curing has occurred. The later the patches are cut, the higher the bond strength, leading to
difficulties in removal of the patch. In a recent project in Wolfe Creek, Colorado, USA the thickness
of the membrane was successfully tested by taking patches.
This method provides a good indication of the thickness of the membrane applied. Although it is
possible to take patches from areas where MASTERSEAL®
DR1 (drainage fleece) is installed, there is
a risk of puncturing the fleece. If the fleece is punctured then the area can not be re-sprayed because
there may be running water on the surface. Therefore, it is recommended that the areas containing
MASTERSEAL®
DR1 are recorded and care is taken to avoid these areas to reduce the risk of damage
to the drainage layer when cutting patches.
4.4.2 Measuring quantity
The quantity of MASTERSEAL® 345 that is being used over a given area can be recorded to give an
indication of the membrane thickness. UGC give approximate guidelines on product consumption
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rates per m2 for substrates of different roughnesses. The data sheet (Appendix E) indicates that typical
consumption rates are 0.72 kg/mm/m². Therefore, once the consumption over an area is known, the
thickness can be estimated. It should be noted that, as this method is approximate. It should be used as
an extra check to back up the more direct methods.
If the project uses robotic spraying such as the MEYCO® LOGICA (as described in 3.4.1) this method
will be more accurate. Field trials can be used to optimise the spraying quantities required to achieve
the required thickness. The applied quantity per m² determined in the field trials can then be used
during the works as a measure of thickness.
4.4.3 Thickness: Wet and dry film test methods
These methods are summarised below:
Wet film test methods (EN ISO 2808:2001) employ the use of “combs” and are utilised on liquid
applied waterproofing products for bridge decks. Combs are not appropriate for MASTERSEAL® 345
as it is sticky when first sprayed, and because the use of the comb damages the membrane.
Needle penetrometers with micrometer gauges can be used, possibly with a pad through which the
needle penetrates. On previous projects thickness has been measured simply by pushing a nail into the
membrane. A needle with a micrometer gauge is effectively an “intelligent” nail. The hole made by the
needle must be repaired. It is possible and easier to carry out the repair by applying MASTERSEAL®
340 by hand over the area. The cured membrane is the same but the product has a longer pot life once
mixed.
Dry film thickness tests (EN ISO 2808:2001) are also available. A dry film thickness gauge may be
helpful as a spot check when a smoothing coat has been applied. Dry film thickness tests are mostly
destructive tests and not practical to use on site (most are aimed at “take-away” lab tests). The
following tests are those deemed feasible for testing MASTERSEAL® 345:
• EN ISO 2808:2001 Section 8 – Method number 3, Measurement of dry-film thickness by
direct measurement of sample. A micrometer can be used to measure thickness where patches
are being cut out from the membrane, as described in section 4.4.1.
• EN ISO 2808:2001 Section 11 – Method number 6, Magnetic method. This non-destructive
test is similar to that using the Elcometer 456.
4.5 Defects
Large defects, such as an accidental scratch on the membrane, can be found during a visual inspection
and repaired by re-spraying. In the case of any smaller defects, that are not visible to the naked eye,
the risk of water ingress is mitigated by the high bond strength between the membrane and the
concrete lining which limits the migration of water along the contact surfaces between the membrane
and the substrate. In contrast, water can migrate freely along the contact surface between the concrete
and sheet membranes. Therefore the bonded nature of the spray applied membrane may reduce the
impact of the presence of small holes on the watertightness of the overall structure.
Defects become more problematic when using a drainage fleece (MASTERSEAL®
DR1) as the fleece
provides a drainage path behind the membrane. If there is a crack in the primary lining, there is a
greater chance of the water finding its way to the defect in the membrane as it can migrate along the
fleece. Nevertheless the water is still restricted by the bond between the membrane and the inner
lining.
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4.6 Generic specification
The recommended options for testing are contained in the generic specification (see Appendix F). The
generic specification must be amended to suit the specific requirements of each project.
The specification must also be integrated with the other project specifications. Items which must be
addressed include, but are not limited to:
• Watertightness criteria
• Thickness of membrane
• Frequency of testing
• Type of thickness testing
The test regime should be defined for each project separately with due regard to the type and size of
the application. The generic specification does not cover issues such as tolerances or payment.
Pre-construction field tests form a vital part of the application strategy. They serve two purposes:
1. To ensure the correct proportions of water and powder are set before commencing spraying
(see section 3.5)
2. To perform tests such as the water penetration tests (as described in Section 4.2.2)
The field tests can be performed either in the tunnel or on test panels. By using a pre-construction field
trial to determine the correct water content, the water feed to the spray nozzle can then be locked for
the duration of application, and a consistent mixture used throughout. By doing so, problems such as
local shrinkage and cracking (due to varying water content in adjacent sections) should be avoided.
A test panel is useful for water penetration tests as the in-situ lining and membrane are not
compromised by taking cores. A representative sample is possible by constructing the test panel using
the same mixes (concrete and MASTERSEAL®
345) and equipment as to be used in the final
application.
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5 Conclusions and recommendations
The principal conclusion of this report is that the product, MASTERSEAL® 345, meets the stated
claims (see Table 1). MASTERSEAL® 345 is suitable as a spray applied waterproofing membrane for
use in sandwich construction in underground structures.
MASTERSEAL® 345 has been proven to have an excellent resistance to water ingress in laboratory
tests, tested up to 20 bar for a period of 1 year. As with any material constructed in-situ, there remain
residual concerns about quality control and workmanship. However, it has been successfully used on a
number of projects (see section 2.5). A generic specification has been produced (Appendix F) as a
guide for specifying this product. Each project must complete and amend the specification to suit the
particular application. Recommendations for quality control test methods have been made and it is
considered that a robust quality control system can be implemented on site. Pre-construction trials and
training of operatives are vital for a successful application.
While MASTERSEAL® 345 is not a panacea for waterproofing underground structures; it is
considered that it is a useful addition to the armoury of measures available to resist water ingress. It is
particularly suitable to situations where there is transient water or water under a low pressure (i.e. < 1
bar), in either drained or undrained tunnels. MASTERSEAL® 345 has a proven resistance up to 6 bar
for large scale samples and evidence from site and the laboratory suggests that it could be used in
higher pressure environments. However, as with all waterproofing measures, each application should
be considered on its own merits with due regard to the implications of any failure in the waterproofing
layer.
MASTERSEAL® 345 has been seen to be quick and simple to apply. Consumption rates and the risk
of inadequate coverage increase as the roughness of the substrate increases. This should be
investigated during the pre-construction field trials and a smoothing layer may be required in the
tunnel. By virtue of being a spray applied membrane it is ideal for structures with complex geometries,
such as tunnel junctions and local enlargements, and also for blasted rock tunnel profiles where
significant profile smoothing would otherwise be required for the installation of traditional sheet
membranes. The bond between the primary lining and secondary lining offers the option of adopting a
composite “single shell” design, in which both linings act together. The viability of this depends on the
exact loading conditions prevalent in each situation.
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Appendix A Risk Assessment
abc
Likelihood Categories Severity Categories (Health, Safety & Environment) Risk Level ActionScore
123 • Minor revenue loss4 • Public relations embarrassment5
Risk Profile • Significant revenue loss• Minor security alert• Re-routing city access
• Effects of a facility closure• Major city impact
• Cost to Project (£100's k)
Risk Type: S= Safety, E= Environmental, O= Operational
1)2)3)
1) 1) 1)
2) 2)
3)4)
1) 1)2) 2)3) 3)
4)1) 1)
2) 2)
3)
1) 1)
2)
1) 1)
1) 1)2)
2) 2) 3)
1) 1)2)
1) 1)
2) 2)
3)
1)2)3)4)
1) 1) 1)2) 2)
1) 1)
2)
1) 1) 2)3)
Contractor
Contractor
Contractor ContractorContractor
Contractor
ContractorContractor
3
Contractor
1
Masterseal 345 Waterproofing Membrane
3 Low
1
4Handle as for normal cementitious products
Use non-alkali accelerator Designer / Contractor
Contact with cementitous material in Masterseal 345
Use non-alkali accelerator for sprayed concrete
Ignition of MS345 in dry powder form
Fire in tunnel
Fire in tunnel
Falls from height during spraying or testing
Ignition of MS345 membrane on substrate
Smoking in tunnel
Welding and cutting (burning)
1
Contractor
Contractor
Contractor
Contractor
Contractor
2
2
Contractor
3 Low
1 2 Low
2 Low
Ensure adequate ventilation
Contractor
Low2
Wear suitable PPE
Contractor
Use remote control for spray boom operation
Control access to spraying location
1 3 Low
1 3 Low
1 3 Low
1 3 Low
1 1
1 4
2 4
3
Chemical burns to skin and eyes from smoothing layer
Injury resulting from use of high pressure water jetting equipment
Use robotic spray boom
Wear fall arrest system
Employ normal procedures for working at height
SA
F
M.12
M.09
M.10
M.11
SA
F
M.07
SA
F
Masterseal 345 Waterproofing Membrane
M.06
M.08
Masterseal 345 Waterproofing Membrane
Masterseal 345 Waterproofing Membrane
SA
F
Masterseal 345 Waterproofing Membrane
M.04
M.03 SA
F
Masterseal 345 Waterproofing Membrane
M.05
SA
F
Masterseal 345 Waterproofing Membrane
Masterseal 345 Waterproofing Membrane
Masterseal 345 Waterproofing Membrane
Masterseal 345 Waterproofing Membrane
2 3 4 5
Descriptor Description
Probable more likely to happen than not
Score Health, Safety & Environment Impact Financial Impact Operational Impact Risk Level Health, Safety & Environment Risks
• £1000's extra cost
Financial Risks Operational RisksImprobable about 1 in 1000Remote about 1 in 100Occasional about 1 in 10
1• Minor Injuries/ Inconveniences• Operative can continue work
Low
• Operative Requires First Aid Treatment Post / Pre RCM
Frequent expect it to happen • Short term local damage • Check that no further risks can be eliminated by modifications of design • Seek alternative, and assess cost to benefit of mitigation measures in relation to severity of risk
2
• Minor Injuries
• £10's k extra cost
• Proceed with Design
Post / Pre RCMLikelihood
Score
Severity Score • Stops Work
Medium
• Consider Alternative Design or Construction Method • Disseminate risk assessment information to senior management, affected stake holders and third parties as appropriate
1 • Medium term local damage or short term regional damage Severity / Risk • If Alternatives are not available, specify precautions to be adopted Severity / Risk
• List residual hazards in risk register
5
4
Comments / Constraints
Sev
erity
3• Reportable / Lost Time Injury or Illness
4• Major injury or illness with long term effects
Hea
lth, S
afet
y &
E
nviro
nmen
t
Fina
ncia
l• Delay in Project of Several Months (on Critical Path) • Major effects to infrastructure
• Potential to close down the project • Loss of transport link
Hea
lth, S
afet
y &
E
nviro
nmen
t
Fina
ncia
l
Ope
ratio
nal
• Long term local damage
High
• Seek alternative solutions • List residual hazards in risk register• If Alternatives are not available, specify precautions to be adopted and advise senior management and planning supervisor (where applicable)
3• Long term systematic damage • List residual hazards in risk register
• Cost to Project (£1M's)
Ope
ratio
nal
• Delay in Project of Several Weeks (on Critical Path)
Like
lihoo
d
2 5• Fatalities• Permanent damage
Cause
1
Ris
k
Sev
erity
Ris
k
Sev
erity
Ris
k
Sev
erity
Ris
k
Sev
erity
Ris
k
Like
lihoo
d
Communication / CompletionRisk Control Measures in Design (RCM)
Sev
erity
Ris
k
Residual Hazards Owner
Masterseal 345 Waterproofing Membrane
M.01 SA
F
M.02
SA
F
1 3 Low
Ensure adequate ventilation Use of dusr filter on pumping equipmentUse of water spraying for dust suppresion
Contractor
Contractor
1 3 Low
1 3
3 3
Med
ium
Med
ium
Contractor
Med
ium
Isolate storage area from general workign area
Low
Hig
h
Wear suitable PPE
ContractorContractor
Ensure adequate ventilation
2
4
Wear suitable PPE
Ensure good personal hygiene
Prohibit eating in the tunnel
Use tools with vibration dampers
2
Med
ium
3
Med
ium
3
3
1 2 Low
ContractorContractor
Med
ium
Med
ium
Contractor
Contractor
LowContractorTrain operatives in manual handling procedures
Limit distance bags need to be carried
Falls from heightEnsure protective guards are fitted to pumping equipment
Use anti-vibration glovesUtilise rotation of workers to limit exposureMedical surveillance
Med
ium
Med
ium Ensure operatives are trained in operation of pumping equipment
2
Med
ium
Masterseal 345 Waterproofing Membrane
M.13 SA
F
2 3
Employ normal procedures for use of compressed air equipment
Employ normal procedure for use of high pressure water jetting equipment
ContractorContractor
Contractor
Contractor
Contractor
Contractor
Contractor
Hand injury
Manual handling
SA
F
Inhalation of dust
SA
FS
AF
SA
F
Ingestion
Hand Arm Vibration (HAV)
3 3
2
4
Injury resulting from use of compressed air equipment
Hit by spraying boom
Vibrating tools
Cleaning of substrate
1)
Spraying Plant
Contamination of food
Drilling equipment
4
Prohibit smoking in tunnel
Lifting bags of MS345Spraying of smooting layer
Bags are 25kg
Trapping of hand in pumping equipment
Ensure adequate lighting
Handling of MS345 in dry powder form
As for normal cementitious products
ContractorContractor
1)Welding and cutting (burning)
Powder will ignite if it comes into contact with hot surface or naked flame
Ensure suitbale fire-fighting equipment is located nearby
Limit amount of MS345 stored in tunnel
1)
Cleaning of substrate
1)
Spraying of membrane from "cherry-picker" or working platformCollapse of working platform
Spraying of MS 345
Spraying of MS345 mebrane
1)
Contact with accelerator for smoothing layer
Masterseal 345® Product Evaluation
High concentration of MS345 in powder form
1) MS345 dust did not ignite during testing1)Masterseal 345 Waterproofing Membrane
Explosion
Activity / Element Risk No. & Type Hazard
Ensure all underground personnel are trained in use of fire-fighting equipment
5)
MS345 is only used in sandwich construction and will be covered by secondary lining.
2)
Low
Test have shown MS345 to be self extinguishing
Prohibit smoking in tunnel
Undertake burning work at surface or use cold cutting process
Employ hot work permit to work systemEnsure suitbale fire-fighting equipment available
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abc
Likelihood Categories Severity Categories (Health, Safety & Environment) Risk Level ActionScore
123 • Minor revenue loss4 • Public relations embarrassment5
Risk Profile • Significant revenue loss• Minor security alert• Re-routing city access
• Effects of a facility closure• Major city impact
• Cost to Project (£100's k)
Risk Type: S= Safety, E= Environmental, O= Operational
2 3 4 5
Descriptor Description
Probable more likely to happen than not
Score Health, Safety & Environment Impact Financial Impact Operational Impact Risk Level Health, Safety & Environment Risks
• £1000's extra cost
Financial Risks Operational RisksImprobable about 1 in 1000Remote about 1 in 100Occasional about 1 in 10
1• Minor Injuries/ Inconveniences• Operative can continue work
Low
• Operative Requires First Aid Treatment Post / Pre RCM
Frequent expect it to happen • Short term local damage • Check that no further risks can be eliminated by modifications of design • Seek alternative, and assess cost to benefit of mitigation measures in relation to severity of risk
2
• Minor Injuries
• £10's k extra cost
• Proceed with Design
Post / Pre RCMLikelihood
Score
Severity Score • Stops Work
Medium
• Consider Alternative Design or Construction Method • Disseminate risk assessment information to senior management, affected stake holders and third parties as appropriate
1 • Medium term local damage or short term regional damage Severity / Risk • If Alternatives are not available, specify precautions to be adopted Severity / Risk
• List residual hazards in risk register
5
4
Comments / Constraints
Sev
erity
3• Reportable / Lost Time Injury or Illness
4• Major injury or illness with long term effects
Hea
lth, S
afet
y &
E
nviro
nmen
t
Fina
ncia
l• Delay in Project of Several Months (on Critical Path) • Major effects to infrastructure
• Potential to close down the project • Loss of transport link
Hea
lth, S
afet
y &
E
nviro
nmen
t
Fina
ncia
l
Ope
ratio
nal
• Long term local damage
High
• Seek alternative solutions • List residual hazards in risk register• If Alternatives are not available, specify precautions to be adopted and advise senior management and planning supervisor (where applicable)
3• Long term systematic damage • List residual hazards in risk register
• Cost to Project (£1M's)
Ope
ratio
nal
• Delay in Project of Several Weeks (on Critical Path)
Like
lihoo
d
2 5• Fatalities• Permanent damage
Cause
1
Ris
k
Sev
erity
Ris
k
Sev
erity
Ris
k
Sev
erity
Ris
k
Sev
erity
Ris
k
Like
lihoo
d
Communication / CompletionRisk Control Measures in Design (RCM)
Sev
erity
Ris
k
Residual Hazards Owner
Masterseal 345® Product Evaluation
Activity / Element Risk No. & Type Hazard
1) 1)2)
3)
1) 1)
2)3)4)
1) 1) 1)
M.17
SA
F
1)
3 1 Low
1)
2 2 Low
1) 1) 1)
2) 2)
3)
Masterseal 345 Waterproofing Membrane
ContractorContractor
Note:This document provides a risk assessment review of the health and safety issues involved with the use of Masterseal 345. The risk assessment focuses on hazards particular to the application, repair and demolition of Masterseal and therefore does not include general risks associated with tunnelling and underground works.
Contractor
Follow recommended disposal procedures
Ensure adequate lighting
Accoustic screening around plant
Contractor
Contractor
Contractor
Med
ium
3
Med
ium
3
Low
Use appropriate PPE
Route hoses to avoid access routes
Contractor
M.14
Masterseal 345 Waterproofing Membrane
Masterseal 345 Waterproofing Membrane
Masterseal 345 Waterproofing Membrane
Masterseal 345 Waterproofing Membrane
M.15
M.16
4
Plant
Disposal of waste
3 1
2
SA
FS
AF
Tripping
Noise
Disposal of demolition waste
MS345 has high alkalinity
SA
F
Contamination
Pollution
Low
Low
1 3 Low
ContractorFollow typical disposal procedures for alkali materials
Plant to undergo regular maintenance checksUse plant with low noise levels
1 3
1 2Contractor
Ensure good housekeepingHoses
M.18Leaching during operation
Leaching of demolition waste
Membrane is sandwiched between concrete. Leaching during operation is unlikely
Spillage of MS345 during cleaning of lines or rebound
Contamination of water course
SA
F
Demolition waste classified as "not contaminated" according to the requirements of the Swiss Aushubrichtlinie (Excavation Directive)
4 2
Med
ium
Follow recommended disposal procedures
Contractor
Low2 2
Contractor
Contractor
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Appendix B Material Safety Data Sheet
HD-MASTERSEAL 345
Material Safety Data Sheet
Revised : 22/09/2006
MASTERSEAL® 345Supersedes : 09/08/2006
1. IDENTIFICATION OF THE SUBSTANCE/PREPARATION AND THE COMPANY/UNDERTAKING
Product InformationMASTERSEAL® 345Product name
Use of the Substance/PreparationProduct for underground applicationsRecommended use
Manufacturer, importer, supplierUGC International, Division of BASF Construction Chemicals(Switzerland) Ltd , Vulkanstrasse 110, 8048 Zurich, Switzerland,Tel.: +41 58 958 22 11, Fax: +41 58 958 34 10, www.ugc.basf.com
Company
BASF AG Ludwigshafen WerkfeuerwehrTel.: 0049 621 60 43333Fax: 0049 621 60 92664e-mail: [email protected]
Emergency telephone number
2. COMPOSITION/INFORMATION ON INGREDIENTS
Formulation containing a vinyl acetate/ethylene copolymerChemical nature of the preparation
Hazardous components CAS-Nr. Weight % OEL*, mg/m³Calcium sulfoaluminate 37293-22-4 5 - 10 % 5
Xi,R36/38Calcium oxide 1305-78-8 < 2 % 2
Xi,R41
* Occupational Exposure Limit, mg/m³
3. HAZARDS IDENTIFICATION
Not classified as hazardous according to directive 1999/45/EC
Mixing with water results in an alkaline suspension. Simultaneoushardening with emission of hydration heat occurs.
physico-chemical properties
4. FIRST AID MEASURES
Remove eye lenses immediately. Rinse thoroughly with plenty ofwater for at least 15 minutes and consult a physician.
- Eye contact
Wash off immediately with soap and plenty of water removing allcontaminated clothes and shoes. Put cream on the skin carefully.Get medical attention if irritation persists.
- Skin contact
Remove affected person to fresh air. In case of breathing difficultyor distress, get medical attention.
- Inhalation
Rinse mouth. Do not induce vomiting. If accidentally swalloweddrink plenty of water and obtain medical attention.
- Ingestion
5. FIRE-FIGHTING MEASURES
1 / 5Page :Version nr : 8.00
Pollux6®©CH-8048 Zurich, Switzerland
Tel. : +41 58 958 22 11Fax : +41 58 958 34 10
UGC InternationalDivision of BASF Construction Chemicals (Switzerland) LtdVulkanstrasse 110
HD-MASTERSEAL 345
Material Safety Data Sheet
Revised : 22/09/2006
MASTERSEAL® 345Supersedes : 09/08/2006
Extinguishing mediaAll extinguishing media can be used.- Suitable extinguishing mediaHigh volume water jet- Extinguishing media which must not be
used for safety reasonsCollect contaminated fire extinguishing water separately. This mustnot be discharged into drains.
Specific methods
Use self-contained breathing apparatus for fire fighting.Special protective equipment forfirefighters
May form acetic acid in a slightly oxygeneated atmosphereUnder fire conditions:
6. ACCIDENTAL RELEASE MEASURES
Use personal protective equipment. See # 8. Ensure adequateventilation. Danger of dust explosion. Remove all sources ofignition. Avoid formation of dust. Do not inhale dust.
Personal precautions
Do not discharge into drains and sewers because of high alkalinity.Environmental precautionsTake up mechanically and collect in suitable container for disposal .Clean up promptly by sweeping or vacuum. Dispose as per 13.Flush down rest with water. Discharge of only after neutralisation.
After spillage/leakage/gas leakage
7. HANDLING AND STORAGE
HandlingProvide adequate ventilation or air evacuation at workplace.Observe the usual precautions when handling chemicals. Duringprocessing, dust may form explosive mixture in air. Keep away fromsources of ignition - No smoking. Mechanical energies, hot surfacesand naked flames may ignite the dry powder.In underground applications, as specified in the Technical DataSheet, no ignition of dust was observed in presence of a burner.The wet powder is not combustible. Spray only wet material. Keepfloors around the mixing equipment wet. Blocked pipes should beblown on wet surfaces.
Technical measures/Precautions
Avoid formation of dust. Do not inhale dust. Avoid contact with skinand eyes.
Safe handling advice
StorageStore in original container. Keep containers tightly closed and dry.Store away from wet and humid areas. Do not store in directsunlight. Protect against frost.
Technical measures/Storage conditions
Store away from acidsIncompatible products13: Non-combustible solidsStorage class (VCI)Danger of dust explosion. Dusting of dry powder should be avoidedProtection against fire and explosion
8. EXPOSURE CONTROLS / PERSONAL PROTECTION
10 mg/m3 for respirable dust (copolymer of vinylacetate & ethylene)Exposure limit(s)5 mg/m3 for respirable dust (Calcium sulfoaluminate CAS Nr.37293-22-4)
2 / 5Page :Version nr : 8.00
Pollux6®©CH-8048 Zurich, Switzerland
Tel. : +41 58 958 22 11Fax : +41 58 958 34 10
UGC InternationalDivision of BASF Construction Chemicals (Switzerland) LtdVulkanstrasse 110
HD-MASTERSEAL 345
Material Safety Data Sheet
Revised : 22/09/2006
MASTERSEAL® 345Supersedes : 09/08/2006
Provide adequate ventilation. Where reasonably practicable thisshould be achieved by the use of local exhaust ventilation and goodgeneral extraction. If these are not sufficient to maintainconcentrations of particulates and solvent vapour below the OEL,suitable respiratory protection must be worn.
Engineering measures
Personal protective equipmentWear respiratory equipment when entering the spray area masks /respirators (filter P1, EN 143)
- Respiratory protection
Gloves: polyvinyl chloride (PVC, EN 374)- Hand protectionSafety goggles / face shield- Eye protectionOverall for medium risks chemicals, Class II (EN 468)- Skin and body protectionObserve the usual precautions when handling chemicals. Washhands before breaks and after finishing work. Change contaminatedclothes immediately. Do not eat, drink or smoke at workplace.
Hygiene measures
9. PHYSICAL AND CHEMICAL PROPERTIES
powderFormgreyColournoneOdour585 ± 90 g/l (20° C)Bulk density11 - 12.5pHinsolubleWater solubilityca. 300 °CDecomposition temperature22.5 ± 2.5 % Ash contentOther dataDry dust at concentrations equal or greater than 249 g/m3 mightlead to a dust fire (see also #7). Minimum ignition temperature of adust cloud 470 grad. C (BAM method). Minimum ignition energywithout induction for the dry powder > 300 mJ (MK3 method).
10. STABILITY AND REACTIVITY
Stable under normal storage and application temperatures.StabilityAvoid contact with strong acidsMaterials to avoidExothermic reaction with strong acidsHazardous reactionsMay form acetic acid in a slightly oxygeneated atmosphere underfire conditions.
Hazardous decomposition products
Risk of dust explosionFurther information
11. TOXICOLOGICAL INFORMATION
No toxicological data is available for the finished product. The LD50/LC50 values mentioned refer to individualraw materials. (IUCLID)
Aluminium hydroxide CAS Nr. 21645-51-2Component:Copolymer of vinylacetate & ethylene
Acute toxicity> 5000 mg/kg Aluminium hydroxideLD50/oral/rat => 2000 mg/kg Copolymer of vinylacetate & ethyleneRepeated prolonged contact may cause irritation.SensitisationProduct may cause irritation.Eye irritation
3 / 5Page :Version nr : 8.00
Pollux6®©CH-8048 Zurich, Switzerland
Tel. : +41 58 958 22 11Fax : +41 58 958 34 10
UGC InternationalDivision of BASF Construction Chemicals (Switzerland) LtdVulkanstrasse 110
HD-MASTERSEAL 345
Material Safety Data Sheet
Revised : 22/09/2006
MASTERSEAL® 345Supersedes : 09/08/2006
Product may cause irritation.Skin irritation
12. ECOLOGICAL INFORMATION
No eco-toxicological data is available for the finished product. The EC50/LC50 values mentioned refer toindividual raw materials. (IUCLID)
Calcium oxide CAS Nr. 1305-78-8Component:Copolymer of vinylacetate & ethyleneNo negative effect expectedBioaccumulationElimination through activated sludge absorbtionBiological eliminationDo not discharge product into drains, surface and/or ground watersor onto surface soils. Must pass neutralization plant prior todischarge into drains and sewers.
Ecotoxicity effects
1070 mg/l (C. carpio, Calcium oxide)LC50/96h/fish => 1000 mg/l (C. carpio, Copolymer)German WPC (water polution class) = 1 (low hazard to water)Water pollution class
13. DISPOSAL CONSIDERATIONS
Eliminate the product and its package in agreement with the locallegislation. The end user of the product is responsible for the waste(product and package). May be under observance of localregulations, admitted into sewage treatment plant, or incinerated insuitable plant.
Waste from residues
After neutralization the unused product can be disposed off as 1603 04 (unused inorganic wastes other than 16 03 03)
Waste disposal number
14. TRANSPORT INFORMATION
Road/rail transportADR/RIDSea transport IMDGAir transport ICAO-TI and IATA-DGRIATA-DGRCEFIC
This product is not classed as a dangerous good in any transportregulation.
Other information
15. REGULATORY INFORMATION
Labelling according to EU directives concerning preparations: Nohazard symbol required. This product is not a dangerouspreparation.
Labelling
noneSymbol(s):noneR-phrase(s)noneS-phrase(s)
16. OTHER INFORMATION
R36/38 - Irritating to eyes and skin.Text of R phrases mentioned in Section 2R41 - Risk of serious damage to eyes.DEAApproved:
4 / 5Page :Version nr : 8.00
Pollux6®©CH-8048 Zurich, Switzerland
Tel. : +41 58 958 22 11Fax : +41 58 958 34 10
UGC InternationalDivision of BASF Construction Chemicals (Switzerland) LtdVulkanstrasse 110
HD-MASTERSEAL 345
Material Safety Data Sheet
Revised : 22/09/2006
MASTERSEAL® 345Supersedes : 09/08/2006
DEAChecked:This data sheet conforms to standards defined by directives 91/155& 93/112/EECData sheet required pursuant to Art.10 of directive 88/379/EEC.The information in this Data Sheet applies only to the productsdesignated herein and produced or supplied by us. It is based onour experience and on the data available to us at the time of itsissue and is accurate to the best of our knowledge.
REMARKS:
5 / 5Page :Version nr : 8.00
Pollux6®©CH-8048 Zurich, Switzerland
Tel. : +41 58 958 22 11Fax : +41 58 958 34 10
UGC InternationalDivision of BASF Construction Chemicals (Switzerland) LtdVulkanstrasse 110
Product Evaluation of MASTERSEAL® 345 Mott MacDonald
Assessment, Application and Specification MEYCO Global Underground Construction
Page C-1 of 56 239368/006/E/3 June 2008
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Appendix C Past Projects using MASTERSEAL ® 340 and MASTERSEAL ® 345
Project Machadino Hydroelectric Power Station, Brazil, Inclined water intake shafts, 8-10m dia
KCRC Tseun Wan to Kwai Ching Cross Passage Tunnels
Colombey Road Tunnel, Switzerland Dual lane highway 850m long
Zapata 2 and Lo Prado 2 Road Tunnels, Chile
Warrington Water Treatment Works, UK Filter bed wall refurbishment
Bergen Rail Tunnel, New Jersey Transit, USA Refurbishment of tunnels and shafts
Zapata 2 and Lo Prado 2 Road Tunnels, Chile
Warrington Water Treatment Works, UK Filter bed wall refurbishment
Bergen Rail Tunnel, New Jersey Transit, USA Refurbishment of tunnels and shafts
Wolfe Creek, Colorado, USA Dual lane highway tunnel
Product Used Masterseal 340 Masterseal 340 Masterseal 340 Masterseal 340 Masterseal 340 Masterseal 340 Masterseal 340 Masterseal 340 Masterseal 340 Masterseal 340
Excavation Method Drill and blast Tunnels EPBM TBM 8.6m diameter Hand Excavated Cross Passages
Cut-and-cover (alluvial deposits below groundwater table) Drill and blast (rock)
Geology/Hydrogeology
10 bar pressure. Randomly jointed hard rock.
Below water table Applied below groundwater table
Locally percolating through jointed hard rock ground mass
Below water table Hard rock with fissures, local seepage
Locally percolating through jointed hard rock ground mass
Below water table Hard rock with fissures, local seepage
Hard rock with fissures and local groundwater seepage
Substrate Sprayed concrete Sprayed concrete Sprayed concrete Sprayed concrete Brickwork Brickwork Sprayed concrete Brickwork Brickwork Sprayed concrete
Smoothing Layer Applied
Applied as required Sprayed concrete, max aggregate grain size 4mm
Total Thickness of Waterproofing Membrane Applied
3mm 2mm 3mm (min) 3mm (min) 3mm (min) 3mm (min) 3mm (min) 3mm (min) 3mm (min)
Number of Layers 2 2 to 3 (low temperatures 8°C 90%RH)
Application Method Sprayed with mono pump at approx 50m2/hr
Sprayed with mono pump at approx 50m2/hr
Sprayed (Specialist contractor Scandinavian Rock Group (SRG)) 50 to 100m2 per hour
Sprayed with mono pump at approx 50m2/hr
Sprayed with mono pump at approx 50m2/hr
Sprayed with mono pump at approx 50m2/hr
Sprayed with mono pump at approx 50m2/hr
Sprayed with mono pump at approx 50m2/hr
Sprayed with mono pump at approx 50m2/hr
Sprayed with mono pump at approx 50m2/hr
Total Area Covered 7000m2 1200m2 (800m2 on sprayed concrete surface / 400m2 on fleece)
20000m2 (15000m2 on shotcrete surface / 5000m2 on fleece)
20000m2 (15000m2 on shotcrete surface / 5000m2 on fleece)
Drainage Temporary drainage pipes in areas of active water inflow
Masterseal DR1 Locally in areas with drips, Masterseal DR1
As required Masterseal DR1
As requiredMasterseal DR1
DR1 applied locally
Testing Visual (contrasting coats) Wet-film thickness
Visual Wet-film thickness
Visual Wet-film thickness
Visual (contrasting coats) Wet-film thickness
Wet-film thickness Visual (contrasting coats) Wet-film thickness
Wet-film thickness Cutting test squares Visual
Final Lining 25mm mortar protective lining, reinforced concrete
Initial 75mm sprayed concrete followed by further 125mm sprayed concrete
Cast in-situ concrete Sprayed concrete Sprayed concrete Fibre reinforced sprayed concrete
Sprayed concrete Sprayed concrete Fibre reinforced sprayed concrete
Sprayed concrete
Comments Applied over steel insertions, temporary drainage pipes, pre-injection pipes. Complex geometry, irregular profile. Completed 2000. Inspected 2003 no problems found.
Single shell design. 100% dry specification. Complex geometry. Bond of 1.0N/mm2
with segmental lining required. Completed 2000. No problems reported to-date.
Compatibility with PVC membrane and bitumen membrane. Completed 2002. Inspected and no problems found
Sprayed over steel insertions. Completed 2002. No problems reported to-date.
Completed 2003. No problems reported to-date.
Completed 2003. Minor curing issues in portal zones due to ground freezing conditions. No other problems reported to-date.
Sprayed over steel insertions. Completed 2002. No problems reported to-date.
Completed 2003. No problems reported to-date.
Completed 2003. Minor curing issues in portal zones due to ground freezing conditions. No other problems reported to-date.
Due for completion end 2003. No problems experienced to-date.
Project Parramatta Rail Tunnels,
Sydney, Australia Single lane highway tunnel
Andorra Highway Tunnel, Andorra Single lane highway tunnel
MTRC Tunnels to new Disney Park, Hong Kong
Giswil Emergency Escape Tunnel, Switzerland
Extension of Prague Metro, Czech Republic
Metro M2 Lausanne, Switzerland
The Nordöy Road Tunnel, Faeroe Islands
The Chekka Road Tunnel, Northern Lebanon
Wine caves, California
Product Used Masterseal 340 Masterseal 345 Masterseal 345 Masterseal 345 Masterseal 345 Masterseal 345 Masterseal 345 in sandwich structure
Masterseal 345 Masterseal 345
Excavation Method Drill and blast 2,4km NATM principles and the rest are cut-and-cover.
Cut-and-cover Drill and Blast Refurbishment Project Pick and shovel, Drill and Blast, Mechanical means (Road header)
Geology/Hydrogeology Sandstone, below water table in some locations
Hard rock, limited ground water seepage
Sandstone, below water table
Below water table Below water table (Max. depth under sea level 150m)
Melted snow and rain water
Substrate Sprayed concrete Sprayed concrete Sprayed concrete Sprayed concrete Sprayed concrete Sprayed concrete Sprayed concrete Cast in situ concrete Sprayed Concrete
Smoothing Layer Applied
Sprayed concrete, maxaggregate grain size 4mm
Improvements to the sprayed concrete surface texture where necessary.
Total Thickness of Waterproofing Membrane Applied
3mm (min) 3mm (min) 3mm 3mm
Number of Layers
Application Method Sprayed with mono pump at approx 50m2/hr
Sprayed Sprayed MEYCO PiccolaSprayed concrete machine was used approx 70-80m2/hr
Computerized sprayingmachine, the MEYCO LOGICA POTENZA
Computerized spraying machine, the MEYCO LOGICA POTENZA
Total Area Covered 1900m2 First structure 350m2 ,Second structure 750 m2
5500m2 40000m2 18000m2 20000m2
Drainage Lightweight geotextile DR1 Undrained solution. Remaining water seepages through the substrate removed by small scale injection MEYCO MP308 acrylic grout.
Undrained solution, with a waterproofing system that covered the entire profile, including the invert.
The sprayed concrete layers were sealed by injecting acrylic gel MEYCO MP 308.
Drainage systems applied where required.
Testing Visual Wet-film thickness
Wet-film thickness Visual Wet-film thickness
Final Lining Sprayed concrete Sprayed concrete Sprayed concrete Unreinforced sprayed concrete lining 10 cm thick.
Cast-in-place lining. Cast in-situ concrete Sprayed concrete Cast in-situ concrete Sprayed Concrete
Comments Due to start in last quarter 2003
Due to start in December 2003
Due to start in October/November 2003. Further information requested from UGC.
Single shell design 100% dry specification. Compatibility between the waterproofing the cut-and-cover concrete tunnel and bored tunnel.
Fast application in area of complex geometry. Due for completion 2007-2008.
Single shell design 100% dry specification. The membrane showed bonding properties to sprayed concrete and cast in-situ concrete.
Some difficulties where water penetrated through in areas where a continuous membrane was not achieved. Corrected by local injection works.
The original tunnel lining was in a state of deterioration regarding waterproofing. Structurally, the original concrete lining was still intact.
To be used in new mines as well as to repair existing caves in the coming years.
Product Evaluation of MASTERSEAL® 345 Mott MacDonald
Assessment, Application and Specification MEYCO Global Underground Construction
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Appendix D Inspection Report
Project Name:
Site Manager:
Company:
Chainage
Date Shift Operative Pre-
spraying
checks
Thickness
checks
Post
spraying
checks
Repair
report
Inspection
before
application
of
secondary
lining
Product Evaluation of MASTERSEAL® 345 Mott MacDonald
Assessment, Application and Specification MEYCO Global Underground Construction
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Appendix E MASTERSEAL® 345 Data Sheet
MASTERSEAL® 345 22/05/04
Elastic, waterproofing membrane for spray application in a sandwich structure with sprayed or cast in-situ concrete Product description MASTERSEAL® 345 is a sprayable membrane for the waterproofing of concrete structures. MASTERSEAL® 345 is spray applied in a sandwich construction between layers of sprayed or cast concrete. It has good bond strength characteristics to the substrates on both sides of the membrane and behaves elastically. As a fully bonded system, this promotes excellent watertightness characteristics to the underground structure, preventing the development of water migration on both concrete-membrane interfaces. MASTERSEAL® 345 undergoes a chemical hardening between 4 and 6 hours (depending on environmental conditions) sufficient to allow a further structural sprayed concrete lining to be placed, thereby preventing disruption to standard construction sequences. As with all spray applied products, it is not possible to seal against active water ingress through the substrate. In such cases the MASTERSEAL® DR1 drainage system is recommended to be used in combination with MASTERSEAL® 345, or local management using drainage pipes. Please refer to the MASTERSEAL® DR1 Technical Data Sheet for details. However, MASTERSEAL® 345 can be applied to damp and wet (no running water) substrate. Steel fibre reinforced sprayed concrete can be used on both sides of the MASTERSEAL® 345 membrane. Fields of application • Sprayed concrete structures • Replacement of waterproofing sheet
membranes • In sandwich structures
(concrete/membrane/concrete) • Single shell permanent tunnel linings
constructed of sprayed concrete
• Underground structures with complex profiles and geometry
• Drill and blast substrates, saving the smoothening layer of sprayed concrete required for sheet membranes
• Can be applied directly over steel insertions, such as rock anchor heads, starter-bars for internal structures and ventilation supports
Features and benefits • No toxic components • No classification needed for transport • Ready for use • Fast curing • Application by spraying, simple equipment • Elasticity 80% to 140% between -20 0C
and +20 0C • Two-sided bond with sprayed concrete
allowing monolithic behaviour and providing excellent watertightness properties
Packaging MASTERSEAL® 345 is available in 25 kg bags Technical data Form Powder Colour light brown Water pressure resistance (max) 15 bar Bulk density (+20°C) 590 g/l ± 100 g/l
Theoretical consumption per mm per m2 0.72kg Application thickness 3 to 10mm Application temperature +5°C to +40°C Failure stress (at +20°C, at 28 days) 1.5 to 3.5 MPa Failure strain (at +20°C, at 28 days) > 100% Bond strength to concrete (28 days) 1.2 ± 0.2 MPa Shore hardness 80 ±5 Flammability self-extinguishing (in
accordance with DIN 4102-B2) Compatibility MASTERSEAL® 345 can be applied onto all types of concrete, provided that the surface is clean and without loose particles. Sprayed concrete and cast concrete with or without steel fibres may be placed against the applied membrane surface, once it has cured.
MASTERSEAL® 345 can also be applied in combination with traditional waterproofing sheet membrane system approaches.
Application procedure MASTERSEAL® 345 shall be applied by the dry spraying method with a MEYCO® Piccola or similar, with the following additional equipment:
• Rotor 12 round hole 90 mm high • Rotor base 90 mm coupling • Rotor dust collector 90 mm high coupling • Spraying nozzle DIA 32 mm (plastic tip
with collar/conical) with minimum 16 hole water ring (18 holes is recommended)
• Spraying hose DIA.32 mm The MEYCO® Piccola or chosen spray equipment must be fitted with a dust collection filter, or similar dust collection system, as shown below.
Figure 1: MEYCO Piccola dry spray unit with dust filter
. Surface preparation Before applying the membrane, the concrete surface has to be thoroughly pre-wetted. Any contamination of the surface, such as dust, oil, soot, loose particles etc., must be removed. The substrate and ambient temperature during application must be above +5ºC. Care should be taken not to create excessive dust when filling the hopper of the pumps. The floor areas near the pump should be soaked with water during the application process.
The following procedure should be implemented for all applications:
• Start water • Start air • Start MASTERSEAL® 345 feed • Apply • Shut-off MASTERSEAL® 345 feed • Finally, turn-off air • When clear, shut off water
NOTE: Under no circumstances should MASTERSEAL® 345 be sprayed without the addition of water at the nozzle. Water addition should be between 30 and 50% by product weight. MASTERSEAL® 345 should be sprayed in the ambient temperature range of +5°C and +40°C, and cyclic variations shall not exceed 10°C within this range. Spraying technique Spraying distance should be between 2 - 2.5m. Manipulation of the nozzle should be such as to promote the full coverage of the MASTERSEAL® 345 into the surface texture of the substrate. If blockages occur, blow out lines into barrel of water to prevent excessive dust. Curing The rate of curing is dependant on the site specific environmental conditions. However, typically the MASTERSEAL® 345 may be over-sprayed within 8 hours (or shorter). For a minimum of 5 days following application, the membrane shall not be exposed directly to temperatures outside the temperature range of +5°C and +40°C, and cyclic variations shall not exceed 10°C within this range. Consumption As a guide, the following chart gives consumption rates for an average thickness of 3mm per m2 for three varying roughness sprayed concrete substrates.
Dust filter unit
If the roughness of a sprayed concrete surface requires more than 6 kg/m² of MASTERSEAL® 345, a smoothening layer of cementitious mortar should be considered. It is recommended that the smoothening mortar should have maximum aggregate size of 4mm. The mortar layer will reduce MASTERSEAL® 345 consumption significantly. If an external curing agent has been applied to the sprayed concrete, this must be thoroughly removed before applying the membrane and the cleanliness checked. Active water must be either pre-sealed, collected in hoses through the membrane, or be covered by MASTERSEAL® DR1 sheets fixed to the concrete surface, for diversion to the drainage system behind the membrane. A practical solution must be adapted to each individual case, and must be strictly implemented on site. Inner concrete lining application Sprayed and cast in-situ concrete can be constructed directly onto the MASTERSEAL® 345 membrane after it has cured sufficiently (normally between 4 and 6 hours depending on environmental conditions).
The MASTERSEAL® 345 should receive the inner lining of concrete as soon as practically possible or if unduly adverse conditions are expected, such as high water ingress, temperatures below 5°C, or hydrostatic loads exceeding the bond strength of the membrane to the substrate. The installation of the inner concrete lining within hours of membrane application will inhibit the bond strength development of the membrane. However, within 56 days the designed bond strength should be achieved. Cleaning The dry spray machine and delivery lines should be cleaned with compressed air. The nozzle and injector should be cleaned with water. For removal of membrane build-up in the equipment, dry sand may be sprayed through the equipment. Storage MASTERSEAL® 345 has a shelf life of 12 months if stored in original, unopened bags between +5 °C to +40°C. The storage area must remain dry. Safety precautions The product has no toxic components. The use of gloves, eye protection and a mask when spraying are recommended. Care must be given to the reduction of dust during application as described in this Technical Data Sheet and advice given in the Material Safety Data Sheet. For further information please refer to the Material Safety Data Sheet.
3
4
6
0
1
2
3
4
5
6
Consumption of dry powder
for average 3mm thick membrane
(kg)
4mm 8mm 16mm
Degree of surface roughness
The information given here is true, represents our best knowledge and is based not only on laboratory work but also on field experience. However, because of numerous factors affecting results, we offer this information without guarantee and no patent liability is assumed. For additional information or questions, please contact your local UGC representative. Headquarters: UGC International Division of BASF Construction Chemicals Europe Ltd Vulkanstrasse 110 8048 Zurich, Switzerland Phone +41-58-958 22 11 Fax +41-58-958 32 46
For more information: Visit us: www.ugc.basf.com Contact us: [email protected]
Product Evaluation of MASTERSEAL® 345 Mott MacDonald
Assessment, Application and Specification MEYCO Global Underground Construction
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Appendix F Specification
Generic Specification Mott MacDonald for MASTERSEAL® 345 UGC International
UGC International Division of BASF Construction Chemicals Europe Ltd Vulkanstrasse 110 CH-8048 Zurich
Generic Specification
for MASTERSEAL® 345
September 2007
Mott MacDonald St Anne House 20-26 Wellesley Road Croydon Surrey CR9 2UL UK Tel : 44 (0)20 8774 2000 Fax : 44 (0)20 8681 5706
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Generic Specification Mott MacDonald for MASTERSEAL® 345 UGC International
Generic Specification
for MASTERSEAL® 345
Issue and Revision Record Rev Date Originator
Checker
Approver
Description
01 05/02/04 EMC AHT/DL DBP First Draft
02 11/03/04 EMC AHT DBP Second Draft
03 24/05/04 E M Casson A H Thomas D B Powell Final Issue
04 09/07 T J Ireland / B J Haig A H Thomas D B Powell Updated Issue
This document has been prepared for the titled project or named part thereof and should not be relied upon or used for any other project without an independent check being carried out as to its suitability and prior written authority of Mott MacDonald being obtained. Mott MacDonald accepts no responsibility or liability for the consequence of this document being used for a purpose other than the purposes for which it was commissioned. Any person using or relying on the document for such other purpose agrees, and will by such use or reliance be taken to confirm his agreement to indemnify Mott MacDonald for all loss or damage resulting therefrom. Mott MacDonald accepts no responsibility or liability for this document to any party other than the person by whom it was commissioned. To the extent that this report is based on information supplied by other parties, Mott MacDonald accepts no liability for any loss or damage suffered by the client, whether contractual or tortious, stemming from any conclusions based on data supplied by parties other than Mott MacDonald and used by Mott MacDonald in preparing this report.
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Generic Specification Mott MacDonald for MASTERSEAL® 345 UGC International
This Specification is a model document intended to serve as a basis for materials, the equipment and workmanship requirements for the application of a spray applied waterproofing membrane.
1 General Requirements
An elastic spray applied waterproofing membrane shall be used as designated on the Drawings.
At least 30 days prior to commencement of application of the spray applied waterproofing membrane, details of the system shall be submitted to the Designer for approval. The details shall include, but not be limited to, the following:
1. Manufacturer
2. Type of system
3. Testing methods
4. Method of application
5. Jointing details (if applicable)
6. Waterstop details (if applicable)
7. Protection from damage after spraying
8. Method of repair
9. Details of personnel training
The spray applied waterproofing membrane shall only be installed by the manufacturer of the product or his approved applicator. The Contractor shall submit a method statement, prepared in conjunction with the applicator and endorsed by the manufacturer of the product, describing the details of the waterproofing works including protective measures at all stages.
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Generic Specification Mott MacDonald for MASTERSEAL® 345 UGC International
2 Materials
The Contractor shall furnish an elastic polymeric waterproofing membrane, such as BASF MASTERSEAL®345 or an approved equivalent, for waterproofing the tunnel as a spray applied layer as shown on the Drawings.
Storage conditions of the product shall comply with the manufacturer’s recommendations.
Only potable water shall be used for spraying. Under no circumstances shall saltwater, river, lake or ground water be used for mixing and spraying the waterproofing membrane.
The product shall conform to the performance requirements in Table 1 and be applied in accordance with the manufacturer’s instructions.
Property Test Method Requirement
Hydrostatic pressure without leakage BS EN 12390-8:2000 To be defined by project
Minimum Thickness See section 4.1 To be defined by project
Application Thickness See section 4.1 Up to 10mm in one pass
Application temperature +5oC to +40oC
Tensile strength (at 20oC, at 28 days) DIN 53504 >1.5MPa
Elongation at break (at 20oC, at 28 days) DIN 53504 >100 %
Bond strength to substrate (28 days) BS EN 1542:1999 >1.0MPa at 28 days
Shore hardness >75
Water absorption SIA V 280/13 <25%
Fire rating BS EN 11925-2
Class B2 -DIN 4102 Self-extinguishing
Table 1 – Performance requirements
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Generic Specification Mott MacDonald for MASTERSEAL® 345 UGC International
3 Preparation
The surface shall be prepared in accordance with the manufacturer’s instructions.
If a cementitious product is used, the surface shall be thoroughly pre-wetted before application of the membrane.
3.1 Surface Cleaning
Before application of the membrane, the sprayed concrete surface shall be thoroughly cleaned using compressed air and water (without oil contamination). When commencing the application of membrane, no free standing water should be visible, however the surface should be damp.
All other surface contamination, such as dust, oil, loose particles, etc., shall be removed.
Any external curing agent applied to the sprayed concrete shall be thoroughly removed, using a method approved by the Engineer, before application of the membrane.
3.2 Surface Texture
In areas where the surface roughness may prevent complete coverage with the specified thickness (greater than 6mm projection from the surface) a smoothing layer shall be applied to the sprayed concrete surface, as required by the Engineer. The requirement for a smoothing layer may be determined on the basis of field trials and the advice of the manufacturer.
The smoothing layer shall be 5 to 10mm thick and shall use sand (with a grading of 0 to 4mm) as the aggregate. The primary lining substrate shall be inspected in the presence of the Engineer to confirm that the surface texture complies with these clauses.
3.3 Active Water Treatment
Active water ingress shall be pre-sealed by resin injection or managed by drainage systems so that there is no running water on the surface during application. This drainage shall be maintained throughout the membrane installation works and shall be arranged such that excess water pressure cannot develop behind the membrane. For each area of active water ingress, counter-measures shall be submitted to the Engineer for approval.
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Generic Specification Mott MacDonald for MASTERSEAL® 345 UGC International
4 Quality Assurance and Control
4.1 Field Trials
Field trials shall be made to demonstrate the capability of the equipment, workmanship, materials and application methods under field conditions. Field trials shall be performed in the presence of the Engineer.
Trials shall be carried out as specified in Table 2.
The testing program shall be started sufficiently early (at least 2 months prior to spraying the membrane) to ensure that the required thickness, impermeability and bond to substrate can be achieved. All trials and acceptance tests are to be completed satisfactorily by the time spraying the membrane commences.
The Engineer reserves the right to witness laboratory tests.
Field trials may be carried out in the tunnel or using test panels (e.g. panels prepared for sprayed concrete field trials). The membrane shall be applied using the same equipment and methods and by the same approved personnel as those designated for the permanent works.
All actions for thickness control will be trialled during the field trials and a reliable method determined for use during the works. This shall be included in the construction method statement.
4.1.1 Surface Roughness
The trials shall be carried out on the full range of surface roughness to be encountered during application of the permanent works. This trial will confirm the requirement or otherwise of smoothing layers.
4.1.2 Water: Powder Ratio
Trials shall determine the optimum water: powder ratio for each of the conditions in which the membrane is to be used. For example: in a dry area, in a damp area and in an area with drained active water ingress.
4.1.3 Bond to Substrate Testing shall be in accordance with BS EN 1542:1999, Products and systems for the protection and repair of concrete structures - Test methods - Measurement of bond-strength by pull-off, or an approved equivalent. Testing shall be carried as specified in Table 2.
4.1.4 Permeability
Pre-construction trials shall be carried out to assess the water resistance of the spray applied membrane from a core taken from a test panel sprayed with the same shotcrete mix and membrane to be used in the works and using the same equipment. A core (concrete-membrane-concrete sandwich) is taken from the test panel and tested under the required water pressure.
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Generic Specification Mott MacDonald for MASTERSEAL® 345 UGC International
Testing shall be in accordance with BS EN 12390-8:2000 Testing hardened concrete – Part 8: Depth of penetration of water under pressure, as specified in Table 2. No moisture should penetrate the spray applied membrane.
4.1.5 Coverage
A visual inspection of the membrane shall be carried out as specified in Table 2. Areas in which the substrate is still visible, or where the membrane is damaged, shall be marked up and an additional layer of membrane applied with a minimum lap of 200mm around the area.
4.1.6 Thickness – Patches
Patches shall be cut from the membrane at the frequency and locations specified in Table 2. The patches shall be 50mm x 50mm in area. The minimum and maximum thickness of the patch shall be measured using a micrometer and results and location of the test recorded.
Where the field trials are carried out in the tunnel, the membrane shall be repaired as for a defect, as detailed in Section 5.3 of this Specification.
4.1.7 Thickness - Needle Penetrometer
Wet film thickness measurement shall be carried out using a needle penetrometer with micrometer gauge. Measurement shall be carried out at the frequencies specified in Table 2, and for each test the thickness and location of the test shall be recorded.
All holes created during the test shall be repaired immediately after the test is carried out.
4.1.8 Thickness - Cover Meter
Thickness measurement shall be carried out using a cover meter, such as Elcometer 456 Coating Thickness Gauge or an equivalent approved by the Engineer. Small metal discs or strips shall be fixed to the substrate prior to spraying and after spraying the thickness of membrane covering the metal shall be measured. Measurement shall be carried out at the frequencies specified in Table 2. The cover meter shall be calibrated as recommended by the supplier.
4.1.9 Thickness – Measuring Quantity
If applied robotically the applied thickness may be assessed by measuring the quantity applied and the area over which is has been applied. The purpose of field trials will be to optimise the spraying quantities required to achieve the required thickness. The applied quantity per m² determined during field trials will be used during the works as a measure of thickness.
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Generic Specification Mott MacDonald for MASTERSEAL® 345 UGC International
Parameter Test Method Frequency Pass/Fail Criteria
Bond to substrate
Pull-off test – BS EN
1542:1999 3 No. tested at 28 days >1.0MPa at 28 days
Permeability BS EN 12390-8:2000 1 No. tested at 28 days Zero penetration of water
through membrane.
Coverage Visual
A visual inspection to be carried out continuously while the membrane is applied and after application is complete.
100% coverage
Option 1 – Patches As required by Engineer. As defined by project
Option 2 - Needle
Penetrometer As required by Engineer. As defined by project
Option 3 - Cover Meter As required by Engineer. As defined by project
Thickness
Option 4 – Measurement of volume sprayed
Throughout spraying As defined by project
Table 2 – Field trials for spray applied waterproofing membrane
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Generic Specification Mott MacDonald for MASTERSEAL® 345 UGC International
4.2 Construction Testing
The quality of the membrane shall be tested using the combination of methods specified in Table 3, and as directed by the Engineer.
The project shall specify the testing regime according to its requirements.
4.2.1 Bond to Substrate Testing shall be in accordance with BS EN 1542:1999, Products and systems for the protection and repair of concrete structures - Test methods - Measurement of bond-strength by pull-off, or an approved equivalent. Testing shall be carried as specified in Table 3.
Testing may be carried out in the tunnel or using test panels sprayed under representative conditions.
4.2.2 Permeability
Testing shall be in accordance with BS EN 12390-8:2000, Testing hardened concrete – Part 8: Depth of penetration of water under pressure, or an approved equivalent. Testing shall be carried as specified in Table 3.
Testing may be carried out in the tunnel or using test panels sprayed under representative conditions.
4.2.3 Coverage
A visual inspection of the membrane shall be carried out as specified in Table 3. Areas in which the substrate is still visible, or where the membrane is damaged, shall be marked up and an additional layer of membrane applied with a minimum lap of 200mm around the area.
4.2.4 Thickness – Patches
Patches shall be cut from the membrane at the frequency and locations specified in Table 3. The patches shall be 100mm x 100mm in area. The minimum and maximum thickness of the patch shall be measured using a micrometer and results and location of the test recorded. The membrane shall be repaired as for a defect, as detailed in Section 5.3 of this Specification.
The location of the tests shall be determined to give even distribution around the entire lining (i.e. samples from crown, axis and invert).
4.2.5 Thickness - Needle Penetrometer
Thickness measurement shall be carried out using a needle penetrometer with micrometer gauge. The equipment used shall be approved by the Engineer. Measurement shall be carried out at the frequencies specified in Table 3 and for each test the thickness and location of the test shall be recorded. All holes created during the test shall be repaired immediately after the test is carried out.
The location of the tests shall be determined to give even distribution around the entire lining (i.e. samples from crown, axis and invert).
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Generic Specification Mott MacDonald for MASTERSEAL® 345 UGC International
4.2.6 Thickness – Measuring quantity
If applied robotically the applied thickness may be assessed by measuring the quantity applied and the area over which it has been applied.
4.2.7 Thickness - Cover Meter
Thickness measurement shall be carried out using a cover meter, such as Elcometer 456 Coating Thickness Gauge or an equivalent approved by the Engineer. Small metal discs or strips shall be the substrate prior to spraying and after spraying the thickness of membrane covering the metal shall be measured. Measurement shall be carried out at the frequencies specified in Table 3. The cover meter shall be calibrated as recommended by the supplier.
The location of the tests shall be determined to give even distribution around the entire lining (i.e. samples from crown, axis and invert).
Parameter Test Method Frequency Pass/Fail Criteria
Bond Pull-off test – BS EN
1542:1999
3 per 100 linear metres of tunnel length
>1.0MPa at 28 days
Permeability BS EN 12390-8:2000
1 per 100 linear metres of tunnel length
Zero penetration of water through membrane.
Coverage Visual A visual inspection to be carried out continuously while
the membrane is applied.
100% coverage
Option 1 - Patches
One test per 100m2 As defined by project
Option 2 - Needle
Penetrometer
Ten tests per 100m2 As defined by project
Option 3 - Cover Meter
Ten tests per 100m2 As defined by project
Thickness
Option 4 – Application
Quantity Measurement
Per batch Kg/m² to match minimum applied quantity determined
during field trials
Shore A Hardness
DIN 53505 or ASTM D 2240
3 tests per 100m² 50
Table 3 – Construction testing for spray applied waterproofing membrane
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Generic Specification Mott MacDonald for MASTERSEAL® 345 UGC International
5 Application
The elastic spray applied waterproofing membrane shall be installed in accordance with the manufacturer’s instructions, as indicated on the Drawings, and shall be subject to the approval of the Engineer.
During application the ambient temperature, and the temperature of the substrate, waterproofing membrane and water supply, shall be between +5oC and +40oC. For five days after application, the ambient temperature shall remain between +5oC and +40oC, and cyclic temperatures shall not exceed 10oC.
Ventilation shall be around 1m/s to provide optimal application and curing conditions.
When spraying the membrane no other works shall be carried out in the vicinity which may cause personnel or equipment to intentionally or accidentally come into contact with the membrane before it has sufficiently cured. If it is likely that excessive dust will be generated in the vicinity of the works (vehicle movements etc.) then measures shall be put in place to minimise dust and dust suppression measures shall be incorporated.
5.1 Equipment
Application of the membrane shall be in accordance with the recommendations of the manufacturer. The spraying equipment shall be capable of feeding materials at a regular rate and ejecting the product from the nozzle at velocities which allow adherence of the materials to the surface with minimum rebound and maximum adhesion.
If the sprayed membrane is to be applied robotically the equipment used shall be approved by the manufacturer. The equipment should use laser guided automated application methods to ensure that a uniform thickness is applied over the entire substrate.
The air and water supply system shall be capable of supplying the delivery machine and hose at the pressures and volumes recommended by the manufacturer of the machine.
The air supplied to the pump, delivery hoses and nozzle shall be dry air. This shall be facilitated by the use of compressors and/or spray equipment fitted with adequate water separation devices. Air supply systems that deliver air contaminated by oil shall not be used.
The placing equipment shall be configured so that the nozzle can be placed 1.50m to 2.50m from the surface receiving the membrane in such a manner as to place the membrane onto the wall with minimum rebound. Equipment shall be furnished to allow application of the membrane to surfaces with the nozzle at the specified distances from the Work.
Typically application will be by the dry spraying method using a MEYCO Piccola concrete-spraying machine or similar approved by the Engineer, with the following additional equipment:
• 32mm diameter spraying nozzle (plastic tip with collar/conical) with a minimum of 16 hole water ring (18 holes recommended) to ensure proper mixing.
• Dust collection system installed where it is envisaged that works elsewhere in the tunnel will cause excessive dust in the vicinity of the works.
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Generic Specification Mott MacDonald for MASTERSEAL® 345 UGC International
• Two valves (one fine adjustment valve and one on-off valve) for water content control to enable the setting to be fixed during pre-construction trials and remain constant throughout application.
5.2 Temporary Construction Joints
Where the membrane is sprayed in alternate bays, or there is an interruption in spraying of more than 6 hours, there shall be a minimum overlap of 200mm with the existing membrane and the surface shall be cleaned prior to application.
5.3 Defective membrane
Areas of the membrane which lack uniformity, exhibit lamination or cracking, lack adequate bonding, lack watertightness, or fail to meet the specified strength and toughness requirements shall be regarded as defective membrane. Where an area is deemed defective the section shall be removed, cleaned and resprayed with a minimum overlap of 200mm from the boundaries of the defect.
The Engineer reserves the right to halt further placement of the membrane not meeting specified requirements or to order removal and replacement of defective membrane and any associated water ingress control measures or smoothing layer without additional cost. The cause of the problem is to be rectified before playing any further membrane.
6 Secondary Lining Construction
Prior to secondary lining construction, the membrane shall be visually inspected for defects, pinholes and 100% coverage in the presence of the Engineer.
Secondary lining sprayed concrete shall not be applied until the membrane has cured sufficiently to achieve a Shore A hardness of 50. As soon as practicably possible after the membrane has been installed it shall be protected by the construction of the secondary lining.
7 Disposal of material
Disposal of all waste shall be in accordance with any legal or local Engineer requirements.
8 References: Test Standards
DIN 53504: 1994 Prüfung von Kautschuk und Elastomeren; Bestimmung von Reißfestigkeit, Zugfestigkeit, Reißdehnung und Spannungswerten im Zugversuch (Determination of tensile strength at break, tensile stress at yield, elongation at break and stress values of rubber in a tensile test)
DIN 4102 Brandverhalten von Baustoffen und Bauteilen (Fire behaviour of Building Materials and Elements)
BS EN 1542:1999 Products and systems for the protection and repair of concrete structures - Test methods - Measurement of bond-strength by pull-off
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BS EN 12390-8:2000 Testing hardened concrete - Part 8: Depth of penetration of water under pressure
BS EN 11925-2:2002 Reaction to fire tests - Ignitability of building products subjected to direct impingement of flame. Single-flame source test
SIA 162/1 Swiss Society of Engineers and Architects “Ouvrages en beton”
DIN 53505 Shore A and Shore D hardness testing of rubber
ASTM D2240 Standard test method for rubber property – Durometer Hardness
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Product Evaluation of MASTERSEAL® 345 Mott MacDonald
Assessment, Application and Specification MEYCO Global Underground Construction
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Appendix G Hard Ground/Soft Ground; Drained/Undrained
Hard Rock, Drained Soft Ground, Drained
Hard Rock or Soft Ground, Undrained
Grouted rock mass if
necessary
Low permeability
rockLow permeability soft ground
Drainage strips (local or systematic) to relieve water pressure
Drains in case of minor seepage
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Appendix H Examination of composite single shell action
Figure H-1. Shear test results of Specimen No. 00 and No. 03 and their approximation in the FLAC
numerical model, labelled as Rough and Smooth respectively.
Figure H-2. Composite tunnel lining with MASTERSEAL® 345 interface in the FLAC 3D model.
Smooth
Rough
Smooth
Smooth
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Table H-1. Input parameters of the FLAC models and the key results
Model 1
Rough
(Spec. 00)
Model 2
Smooth
(Spec. 03)
Model 5
Smooth
overloaded
24x
Model 6
Smooth
partly
loaded
Model 7
Smooth
but 50%
weaker
Model 8
Smooth
but 75%
weaker
Interface friction
[angle]
43 24 24 24 15.12 8.4
Interface cohesion
[MPa]
1.05 0.5 0.5 0.5 0.315 0.175
Ks – interface shear
stiffness [MPa/m]
220 100 100 100 45 20
Kn– interface normal
stiffness [MPa/m]
4000 8730 8730 8730 8730 8730
Dilation [angle] 32 20 20 20 12.6 7
Vertical load [kPa] 500 500 12000 4000 500 500
K – ratio of horiz. to
vertical loads [−]
2 2 2 2 2 2
Lining stiffness
[GPa]
35 35 35 35 35 35
Poisson ratio of lining
[−]
0.2 0.2 0.2 0.2 0.2 0.2
Horiz. displacement
[mm]
-1.54 -1.64 -38.53 -22.77 -1.63 -1.64
Vertical displacement
[mm]
1.38 1.42 34.00 22.43 1.44 1.45
Max. interface shear
stress [kPa]
68.54 32.70 785.30 498.80 15.08 6.78
Interface
shear failure
No No No No No No
Max. shear stress
[kPa]
3397 3404 81729 39436 3412 3489
Max. horiz. stress
[kPa]
6007 6431 154540 137500 6541 6593
Interface
normal failure
No No No Yes No No
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Appendix I Reference List
1 MS 345 Technical Data Sheet, Version 4, 21/05/2004
2 Technical Document “EMPA Test Report”, Trindler, W
3 Method Statement “Application of MASTERSEAL ® 345 spray applied waterproofing membrane”
Brandenberger, R., Holter, K.G. and Kothe, T. May 2007. 4 Technical Document “MASTERSEAL
® 345 a spray applied membrane from a chemists point of view” Kothe,
T 5 Website www.ugc.basf.com/DCCUGC/EN/downloads/ugconline/
6 UGC, Personal Communication, August 2007, Dimmock, R
7 Website www.tunnels.mottmac.com/
8 Test data, “Membranes MASTERSEAL
® 845/345, World-Wide Mining Task Force Meeting”, Kothe, T
9 Test Report, “MASTERSEAL
® 345 Laboratory tests/practical tests”, BMI Innsbruck, Department of Concrete
Technology and Material Testing, December 2003 10
Test Data, “BMG MS 345 Classification – Ecotox” 11
MS 345 Material Safety Data Sheet, 22/09/2006 12
Technical Document “Sprayable Membrane Systems”, Dimmock, R 13
Technical Document, “BMI – MASTERSEAL® 345 Laboratory tests/Practical tests”, December 2003
14 ITA Report, Water Leakages in Subsurface Facilities: Required Watertightness, Contractual Matters and
Methods of Redevelopment, Tunnelling and Underground Space Technology, Vol 6, No. 3, pp 273-282, 1991. 15
Website, www.meyco.basf.com/Meyco/EN/ 16
Duddeck, H. & Erdmann, J. “On Structural Design Models for Tunnels in Soft Soil“ Underground Space Vol.
9. pp. 246-259., 1985 17
Test Data, “Spray Applied Waterproofing Membrane-MASTERSEAL® 345:Resistance to Salt Water and
Mineral Acids” 18
Test Data, “Chemical Resistance of Spray Applied Polymer Based Waterproofing Membrane
MASTERSEAL® 345 in Aqueous Solution”
19 Technical Report, Klassierung von Tunnelausbruch gemässSchweizer Abfallrecht nach Einsatz der
Polymermembran MASTERSEAL® 345, 27/08/2003