Product Evaluation of MASTERSEAL® 345 Assessment

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



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.

.



Page i of 56 239368/006/E/June 2009/i of i


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



Page iii of 56 239368/006/E/June 2009/iii of iii


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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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.



16 of 56 239368/006/E/19 June 2009/


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.



22 of 56 239368/006/E/19 June 2009/


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



23 of 56 239368/006/E/19 June 2009/


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).



24 of 56 239368/006/E/19 June 2009/


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.



25 of 56 239368/006/E/19 June 2009/


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



27 of 56 239368/006/E/19 June 2009/


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.



28 of 56 239368/006/E/19 June 2009/


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



29 of 56 239368/006/E/19 June 2009/


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.



32 of 56 239368/006/E/19 June 2009/


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.



33 of 56 239368/006/E/19 June 2009/


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



34 of 56 239368/006/E/19 June 2009/


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



35 of 56 239368/006/E/19 June 2009/


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



36 of 56 239368/006/E/19 June 2009/


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)



37 of 56 239368/006/E/19 June 2009/


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.



39 of 56 239368/006/E/19 June 2009/


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.



41 of 56 239368/006/E/19 June 2009/


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



42 of 56 239368/006/E/19 June 2009/


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.



44 of 56 239368/006/E/19 June 2009/


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.



Page A-1 of 56 239368/006/E/19 June 2009


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


M.06

M.08



SA

F


M.04

M.03 SA

F


M.05

SA

F





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


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


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


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


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


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


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

210231/1/A/24 May 2004M:\210231_sprayonMembrane_AHT\Reports\Report\Reportfinal.doc A-3 of 65

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)



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





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

210231/1/A/24 May 2004M:\210231_sprayonMembrane_AHT\Reports\Report\Reportfinal.doc A-3 of 65



Page B-1 of 56 239368/006/E/19 June 2009


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


Revised : 22/09/2006


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)



Tel. : +41 58 958 22 11Fax : +41 58 958 34 10


HD-MASTERSEAL 345


Revised : 22/09/2006


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



Tel. : +41 58 958 22 11Fax : +41 58 958 34 10


HD-MASTERSEAL 345


Revised : 22/09/2006


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:



Tel. : +41 58 958 22 11Fax : +41 58 958 34 10


HD-MASTERSEAL 345


Revised : 22/09/2006


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:



Tel. : +41 58 958 22 11Fax : +41 58 958 34 10




Page C-1 of 56 239368/006/E/3 June 2008


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








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.



Page D-1 of 56 239368/006/E/19 June 2009


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



Page E-1 of 56 239368/006/E/19 June 2009


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]



Page F-1 of 56 239368/006/E/19 June 2009


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

239268/001/D/September 2007 \\Server\common\NEW FOLDER STRUCTURE\239368 BASF Lining report\H Reports and Drawings\H.02 Outgoing Reports\End of Phase 1 issue to RD and TK for comments\Appendix H Generic Specification.doc/BJH


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.



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.



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



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.



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.



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.



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



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.




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.


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



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.



• 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



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




Page G-1 of 56 239368/006/E/19 June 2009


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



Page H-1 of 56 239368/006/E/19 June 2009


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



Page H-2 of 56 239368/006/E/19 June 2009


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



Page I-1 of 56 239368/006/E/19 June 2009


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

Documents

Product Evaluation of MASTERSEAL® 345 Assessment