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
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Product Evaluation of MASTERSEAL® 345 Mott MacDonald
Assessment, Application and Specification MEYCO Global Underground Construction
® 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
Financial Risks Operational RisksImprobable about 1 in 1000Remote about 1 in 100Occasional about 1 in 10
1• Minor Injuries/ Inconveniences• Operative can continue work
Low
• Operative Requires First Aid Treatment Post / Pre RCM
Frequent expect it to happen • Short term local damage • Check that no further risks can be eliminated by modifications of design • Seek alternative, and assess cost to benefit of mitigation measures in relation to severity of risk
2
• Minor Injuries
• £10's k extra cost
• Proceed with Design
Post / Pre RCMLikelihood
Score
Severity Score • Stops Work
Medium
• Consider Alternative Design or Construction Method • Disseminate risk assessment information to senior management, affected stake holders and third parties as appropriate
1 • Medium term local damage or short term regional damage Severity / Risk • If Alternatives are not available, specify precautions to be adopted Severity / Risk
• List residual hazards in risk register
5
4
Comments / Constraints
Sev
erity
3• Reportable / Lost Time Injury or Illness
4• Major injury or illness with long term effects
Hea
lth, S
afet
y &
E
nviro
nmen
t
Fina
ncia
l• Delay in Project of Several Months (on Critical Path) • Major effects to infrastructure
• Potential to close down the project • Loss of transport link
Hea
lth, S
afet
y &
E
nviro
nmen
t
Fina
ncia
l
Ope
ratio
nal
• Long term local damage
High
• Seek alternative solutions • List residual hazards in risk register• If Alternatives are not available, specify precautions to be adopted and advise senior management and planning supervisor (where applicable)
3• Long term systematic damage • List residual hazards in risk register
• Cost to Project (£1M's)
Ope
ratio
nal
• Delay in Project of Several Weeks (on Critical Path)
Like
lihoo
d
2 5• Fatalities• Permanent damage
Cause
1
Ris
k
Sev
erity
Ris
k
Sev
erity
Ris
k
Sev
erity
Ris
k
Sev
erity
Ris
k
Like
lihoo
d
Communication / CompletionRisk Control Measures in Design (RCM)
Sev
erity
Ris
k
Residual Hazards Owner
Masterseal 345 Waterproofing Membrane
M.01 SA
F
M.02
SA
F
1 3 Low
Ensure adequate ventilation Use of dusr filter on pumping equipmentUse of water spraying for dust suppresion
Contractor
Contractor
1 3 Low
1 3
3 3
Med
ium
Med
ium
Contractor
Med
ium
Isolate storage area from general workign area
Low
Hig
h
Wear suitable PPE
ContractorContractor
Ensure adequate ventilation
2
4
Wear suitable PPE
Ensure good personal hygiene
Prohibit eating in the tunnel
Use tools with vibration dampers
2
Med
ium
3
Med
ium
3
3
1 2 Low
ContractorContractor
Med
ium
Med
ium
Contractor
Contractor
LowContractorTrain operatives in manual handling procedures
Limit distance bags need to be carried
Falls from heightEnsure protective guards are fitted to pumping equipment
Use anti-vibration glovesUtilise rotation of workers to limit exposureMedical surveillance
Med
ium
Med
ium Ensure operatives are trained in operation of pumping equipment
2
Med
ium
Masterseal 345 Waterproofing Membrane
M.13 SA
F
2 3
Employ normal procedures for use of compressed air equipment
Employ normal procedure for use of high pressure water jetting equipment
ContractorContractor
Contractor
Contractor
Contractor
Contractor
Contractor
Hand injury
Manual handling
SA
F
Inhalation of dust
SA
FS
AF
SA
F
Ingestion
Hand Arm Vibration (HAV)
3 3
2
4
Injury resulting from use of compressed air equipment
Hit by spraying boom
Vibrating tools
Cleaning of substrate
1)
Spraying Plant
Contamination of food
Drilling equipment
4
Prohibit smoking in tunnel
Lifting bags of MS345Spraying of smooting layer
Bags are 25kg
Trapping of hand in pumping equipment
Ensure adequate lighting
Handling of MS345 in dry powder form
As for normal cementitious products
ContractorContractor
1)Welding and cutting (burning)
Powder will ignite if it comes into contact with hot surface or naked flame
Ensure suitbale fire-fighting equipment is located nearby
Limit amount of MS345 stored in tunnel
1)
Cleaning of substrate
1)
Spraying of membrane from "cherry-picker" or working platformCollapse of working platform
Spraying of MS 345
Spraying of MS345 mebrane
1)
Contact with accelerator for smoothing layer
Masterseal 345® Product Evaluation
High concentration of MS345 in powder form
1) MS345 dust did not ignite during testing1)Masterseal 345 Waterproofing Membrane
Explosion
Activity / Element Risk No. & Type Hazard
Ensure all underground personnel are trained in use of fire-fighting equipment
5)
MS345 is only used in sandwich construction and will be covered by secondary lining.
2)
Low
Test have shown MS345 to be self extinguishing
Prohibit smoking in tunnel
Undertake burning work at surface or use cold cutting process
Employ hot work permit to work systemEnsure suitbale fire-fighting equipment available
210231/1/A/24 May 2004M:\210231_sprayonMembrane_AHT\Reports\Report\Reportfinal.doc A-3 of 65
Financial Risks Operational RisksImprobable about 1 in 1000Remote about 1 in 100Occasional about 1 in 10
1• Minor Injuries/ Inconveniences• Operative can continue work
Low
• Operative Requires First Aid Treatment Post / Pre RCM
Frequent expect it to happen • Short term local damage • Check that no further risks can be eliminated by modifications of design • Seek alternative, and assess cost to benefit of mitigation measures in relation to severity of risk
2
• Minor Injuries
• £10's k extra cost
• Proceed with Design
Post / Pre RCMLikelihood
Score
Severity Score • Stops Work
Medium
• Consider Alternative Design or Construction Method • Disseminate risk assessment information to senior management, affected stake holders and third parties as appropriate
1 • Medium term local damage or short term regional damage Severity / Risk • If Alternatives are not available, specify precautions to be adopted Severity / Risk
• List residual hazards in risk register
5
4
Comments / Constraints
Sev
erity
3• Reportable / Lost Time Injury or Illness
4• Major injury or illness with long term effects
Hea
lth, S
afet
y &
E
nviro
nmen
t
Fina
ncia
l• Delay in Project of Several Months (on Critical Path) • Major effects to infrastructure
• Potential to close down the project • Loss of transport link
Hea
lth, S
afet
y &
E
nviro
nmen
t
Fina
ncia
l
Ope
ratio
nal
• Long term local damage
High
• Seek alternative solutions • List residual hazards in risk register• If Alternatives are not available, specify precautions to be adopted and advise senior management and planning supervisor (where applicable)
3• Long term systematic damage • List residual hazards in risk register
• Cost to Project (£1M's)
Ope
ratio
nal
• Delay in Project of Several Weeks (on Critical Path)
Like
lihoo
d
2 5• Fatalities• Permanent damage
Cause
1
Ris
k
Sev
erity
Ris
k
Sev
erity
Ris
k
Sev
erity
Ris
k
Sev
erity
Ris
k
Like
lihoo
d
Communication / CompletionRisk Control Measures in Design (RCM)
Sev
erity
Ris
k
Residual Hazards Owner
Masterseal 345® Product Evaluation
Activity / Element Risk No. & Type Hazard
1) 1)2)
3)
1) 1)
2)3)4)
1) 1) 1)
M.17
SA
F
1)
3 1 Low
1)
2 2 Low
1) 1) 1)
2) 2)
3)
Masterseal 345 Waterproofing Membrane
ContractorContractor
Note:This document provides a risk assessment review of the health and safety issues involved with the use of Masterseal 345. The risk assessment focuses on hazards particular to the application, repair and demolition of Masterseal and therefore does not include general risks associated with tunnelling and underground works.
Contractor
Follow recommended disposal procedures
Ensure adequate lighting
Accoustic screening around plant
Contractor
Contractor
Contractor
Med
ium
3
Med
ium
3
Low
Use appropriate PPE
Route hoses to avoid access routes
Contractor
M.14
Masterseal 345 Waterproofing Membrane
Masterseal 345 Waterproofing Membrane
Masterseal 345 Waterproofing Membrane
Masterseal 345 Waterproofing Membrane
M.15
M.16
4
Plant
Disposal of waste
3 1
2
SA
FS
AF
Tripping
Noise
Disposal of demolition waste
MS345 has high alkalinity
SA
F
Contamination
Pollution
Low
Low
1 3 Low
ContractorFollow typical disposal procedures for alkali materials
Plant to undergo regular maintenance checksUse plant with low noise levels
1 3
1 2Contractor
Ensure good housekeepingHoses
M.18Leaching during operation
Leaching of demolition waste
Membrane is sandwiched between concrete. Leaching during operation is unlikely
Spillage of MS345 during cleaning of lines or rebound
Contamination of water course
SA
F
Demolition waste classified as "not contaminated" according to the requirements of the Swiss Aushubrichtlinie (Excavation Directive)
4 2
Med
ium
Follow recommended disposal procedures
Contractor
Low2 2
Contractor
Contractor
210231/1/A/24 May 2004M:\210231_sprayonMembrane_AHT\Reports\Report\Reportfinal.doc A-3 of 65
Product Evaluation of MASTERSEAL® 345 Mott MacDonald
Assessment, Application and Specification MEYCO Global Underground Construction
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.
UGC InternationalDivision of BASF Construction Chemicals (Switzerland) LtdVulkanstrasse 110
HD-MASTERSEAL 345
Material Safety Data Sheet
Revised : 22/09/2006
MASTERSEAL® 345Supersedes : 09/08/2006
Extinguishing mediaAll extinguishing media can be used.- Suitable extinguishing mediaHigh volume water jet- Extinguishing media which must not be
used for safety reasonsCollect contaminated fire extinguishing water separately. This mustnot be discharged into drains.
Specific methods
Use self-contained breathing apparatus for fire fighting.Special protective equipment forfirefighters
May form acetic acid in a slightly oxygeneated atmosphereUnder fire conditions:
6. ACCIDENTAL RELEASE MEASURES
Use personal protective equipment. See # 8. Ensure adequateventilation. Danger of dust explosion. Remove all sources ofignition. Avoid formation of dust. Do not inhale dust.
Personal precautions
Do not discharge into drains and sewers because of high alkalinity.Environmental precautionsTake up mechanically and collect in suitable container for disposal .Clean up promptly by sweeping or vacuum. Dispose as per 13.Flush down rest with water. Discharge of only after neutralisation.
After spillage/leakage/gas leakage
7. HANDLING AND STORAGE
HandlingProvide adequate ventilation or air evacuation at workplace.Observe the usual precautions when handling chemicals. Duringprocessing, dust may form explosive mixture in air. Keep away fromsources of ignition - No smoking. Mechanical energies, hot surfacesand naked flames may ignite the dry powder.In underground applications, as specified in the Technical DataSheet, no ignition of dust was observed in presence of a burner.The wet powder is not combustible. Spray only wet material. Keepfloors around the mixing equipment wet. Blocked pipes should beblown on wet surfaces.
Technical measures/Precautions
Avoid formation of dust. Do not inhale dust. Avoid contact with skinand eyes.
Safe handling advice
StorageStore in original container. Keep containers tightly closed and dry.Store away from wet and humid areas. Do not store in directsunlight. Protect against frost.
Technical measures/Storage conditions
Store away from acidsIncompatible products13: Non-combustible solidsStorage class (VCI)Danger of dust explosion. Dusting of dry powder should be avoidedProtection against fire and explosion
8. EXPOSURE CONTROLS / PERSONAL PROTECTION
10 mg/m3 for respirable dust (copolymer of vinylacetate & ethylene)Exposure limit(s)5 mg/m3 for respirable dust (Calcium sulfoaluminate CAS Nr.37293-22-4)
UGC InternationalDivision of BASF Construction Chemicals (Switzerland) LtdVulkanstrasse 110
HD-MASTERSEAL 345
Material Safety Data Sheet
Revised : 22/09/2006
MASTERSEAL® 345Supersedes : 09/08/2006
Provide adequate ventilation. Where reasonably practicable thisshould be achieved by the use of local exhaust ventilation and goodgeneral extraction. If these are not sufficient to maintainconcentrations of particulates and solvent vapour below the OEL,suitable respiratory protection must be worn.
Engineering measures
Personal protective equipmentWear respiratory equipment when entering the spray area masks /respirators (filter P1, EN 143)
- Respiratory protection
Gloves: polyvinyl chloride (PVC, EN 374)- Hand protectionSafety goggles / face shield- Eye protectionOverall for medium risks chemicals, Class II (EN 468)- Skin and body protectionObserve the usual precautions when handling chemicals. Washhands before breaks and after finishing work. Change contaminatedclothes immediately. Do not eat, drink or smoke at workplace.
Hygiene measures
9. PHYSICAL AND CHEMICAL PROPERTIES
powderFormgreyColournoneOdour585 ± 90 g/l (20° C)Bulk density11 - 12.5pHinsolubleWater solubilityca. 300 °CDecomposition temperature22.5 ± 2.5 % Ash contentOther dataDry dust at concentrations equal or greater than 249 g/m3 mightlead to a dust fire (see also #7). Minimum ignition temperature of adust cloud 470 grad. C (BAM method). Minimum ignition energywithout induction for the dry powder > 300 mJ (MK3 method).
10. STABILITY AND REACTIVITY
Stable under normal storage and application temperatures.StabilityAvoid contact with strong acidsMaterials to avoidExothermic reaction with strong acidsHazardous reactionsMay form acetic acid in a slightly oxygeneated atmosphere underfire conditions.
Hazardous decomposition products
Risk of dust explosionFurther information
11. TOXICOLOGICAL INFORMATION
No toxicological data is available for the finished product. The LD50/LC50 values mentioned refer to individualraw materials. (IUCLID)
Aluminium hydroxide CAS Nr. 21645-51-2Component:Copolymer of vinylacetate & ethylene
Acute toxicity> 5000 mg/kg Aluminium hydroxideLD50/oral/rat => 2000 mg/kg Copolymer of vinylacetate & ethyleneRepeated prolonged contact may cause irritation.SensitisationProduct may cause irritation.Eye irritation
UGC InternationalDivision of BASF Construction Chemicals (Switzerland) LtdVulkanstrasse 110
HD-MASTERSEAL 345
Material Safety Data Sheet
Revised : 22/09/2006
MASTERSEAL® 345Supersedes : 09/08/2006
Product may cause irritation.Skin irritation
12. ECOLOGICAL INFORMATION
No eco-toxicological data is available for the finished product. The EC50/LC50 values mentioned refer toindividual raw materials. (IUCLID)
Calcium oxide CAS Nr. 1305-78-8Component:Copolymer of vinylacetate & ethyleneNo negative effect expectedBioaccumulationElimination through activated sludge absorbtionBiological eliminationDo not discharge product into drains, surface and/or ground watersor onto surface soils. Must pass neutralization plant prior todischarge into drains and sewers.
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:
UGC InternationalDivision of BASF Construction Chemicals (Switzerland) LtdVulkanstrasse 110
HD-MASTERSEAL 345
Material Safety Data Sheet
Revised : 22/09/2006
MASTERSEAL® 345Supersedes : 09/08/2006
DEAChecked:This data sheet conforms to standards defined by directives 91/155& 93/112/EECData sheet required pursuant to Art.10 of directive 88/379/EEC.The information in this Data Sheet applies only to the productsdesignated herein and produced or supplied by us. It is based onour experience and on the data available to us at the time of itsissue and is accurate to the best of our knowledge.
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.
Elastic, waterproofing membrane for spray application in a sandwich structure with sprayed or cast in-situ concrete Product description MASTERSEAL® 345 is a sprayable membrane for the waterproofing of concrete structures. MASTERSEAL® 345 is spray applied in a sandwich construction between layers of sprayed or cast concrete. It has good bond strength characteristics to the substrates on both sides of the membrane and behaves elastically. As a fully bonded system, this promotes excellent watertightness characteristics to the underground structure, preventing the development of water migration on both concrete-membrane interfaces. MASTERSEAL® 345 undergoes a chemical hardening between 4 and 6 hours (depending on environmental conditions) sufficient to allow a further structural sprayed concrete lining to be placed, thereby preventing disruption to standard construction sequences. As with all spray applied products, it is not possible to seal against active water ingress through the substrate. In such cases the MASTERSEAL® DR1 drainage system is recommended to be used in combination with MASTERSEAL® 345, or local management using drainage pipes. Please refer to the MASTERSEAL® DR1 Technical Data Sheet for details. However, MASTERSEAL® 345 can be applied to damp and wet (no running water) substrate. Steel fibre reinforced sprayed concrete can be used on both sides of the MASTERSEAL® 345 membrane. Fields of application • Sprayed concrete structures • Replacement of waterproofing sheet
membranes • In sandwich structures
(concrete/membrane/concrete) • Single shell permanent tunnel linings
constructed of sprayed concrete
• Underground structures with complex profiles and geometry
• Drill and blast substrates, saving the smoothening layer of sprayed concrete required for sheet membranes
• Can be applied directly over steel insertions, such as rock anchor heads, starter-bars for internal structures and ventilation supports
Features and benefits • No toxic components • No classification needed for transport • Ready for use • Fast curing • Application by spraying, simple equipment • Elasticity 80% to 140% between -20 0C
and +20 0C • Two-sided bond with sprayed concrete
allowing monolithic behaviour and providing excellent watertightness properties
Packaging MASTERSEAL® 345 is available in 25 kg bags Technical data Form Powder Colour light brown Water pressure resistance (max) 15 bar Bulk density (+20°C) 590 g/l ± 100 g/l
Theoretical consumption per mm per m2 0.72kg Application thickness 3 to 10mm Application temperature +5°C to +40°C Failure stress (at +20°C, at 28 days) 1.5 to 3.5 MPa Failure strain (at +20°C, at 28 days) > 100% Bond strength to concrete (28 days) 1.2 ± 0.2 MPa Shore hardness 80 ±5 Flammability self-extinguishing (in
accordance with DIN 4102-B2) Compatibility MASTERSEAL® 345 can be applied onto all types of concrete, provided that the surface is clean and without loose particles. Sprayed concrete and cast concrete with or without steel fibres may be placed against the applied membrane surface, once it has cured.
MASTERSEAL® 345 can also be applied in combination with traditional waterproofing sheet membrane system approaches.
Application procedure MASTERSEAL® 345 shall be applied by the dry spraying method with a MEYCO® Piccola or similar, with the following additional equipment:
• Rotor 12 round hole 90 mm high • Rotor base 90 mm coupling • Rotor dust collector 90 mm high coupling • Spraying nozzle DIA 32 mm (plastic tip
with collar/conical) with minimum 16 hole water ring (18 holes is recommended)
• Spraying hose DIA.32 mm The MEYCO® Piccola or chosen spray equipment must be fitted with a dust collection filter, or similar dust collection system, as shown below.
Figure 1: MEYCO Piccola dry spray unit with dust filter
. Surface preparation Before applying the membrane, the concrete surface has to be thoroughly pre-wetted. Any contamination of the surface, such as dust, oil, soot, loose particles etc., must be removed. The substrate and ambient temperature during application must be above +5ºC. Care should be taken not to create excessive dust when filling the hopper of the pumps. The floor areas near the pump should be soaked with water during the application process.
The following procedure should be implemented for all applications:
• Start water • Start air • Start MASTERSEAL® 345 feed • Apply • Shut-off MASTERSEAL® 345 feed • Finally, turn-off air • When clear, shut off water
NOTE: Under no circumstances should MASTERSEAL® 345 be sprayed without the addition of water at the nozzle. Water addition should be between 30 and 50% by product weight. MASTERSEAL® 345 should be sprayed in the ambient temperature range of +5°C and +40°C, and cyclic variations shall not exceed 10°C within this range. Spraying technique Spraying distance should be between 2 - 2.5m. Manipulation of the nozzle should be such as to promote the full coverage of the MASTERSEAL® 345 into the surface texture of the substrate. If blockages occur, blow out lines into barrel of water to prevent excessive dust. Curing The rate of curing is dependant on the site specific environmental conditions. However, typically the MASTERSEAL® 345 may be over-sprayed within 8 hours (or shorter). For a minimum of 5 days following application, the membrane shall not be exposed directly to temperatures outside the temperature range of +5°C and +40°C, and cyclic variations shall not exceed 10°C within this range. Consumption As a guide, the following chart gives consumption rates for an average thickness of 3mm per m2 for three varying roughness sprayed concrete substrates.
Dust filter unit
If the roughness of a sprayed concrete surface requires more than 6 kg/m² of MASTERSEAL® 345, a smoothening layer of cementitious mortar should be considered. It is recommended that the smoothening mortar should have maximum aggregate size of 4mm. The mortar layer will reduce MASTERSEAL® 345 consumption significantly. If an external curing agent has been applied to the sprayed concrete, this must be thoroughly removed before applying the membrane and the cleanliness checked. Active water must be either pre-sealed, collected in hoses through the membrane, or be covered by MASTERSEAL® DR1 sheets fixed to the concrete surface, for diversion to the drainage system behind the membrane. A practical solution must be adapted to each individual case, and must be strictly implemented on site. Inner concrete lining application Sprayed and cast in-situ concrete can be constructed directly onto the MASTERSEAL® 345 membrane after it has cured sufficiently (normally between 4 and 6 hours depending on environmental conditions).
The MASTERSEAL® 345 should receive the inner lining of concrete as soon as practically possible or if unduly adverse conditions are expected, such as high water ingress, temperatures below 5°C, or hydrostatic loads exceeding the bond strength of the membrane to the substrate. The installation of the inner concrete lining within hours of membrane application will inhibit the bond strength development of the membrane. However, within 56 days the designed bond strength should be achieved. Cleaning The dry spray machine and delivery lines should be cleaned with compressed air. The nozzle and injector should be cleaned with water. For removal of membrane build-up in the equipment, dry sand may be sprayed through the equipment. Storage MASTERSEAL® 345 has a shelf life of 12 months if stored in original, unopened bags between +5 °C to +40°C. The storage area must remain dry. Safety precautions The product has no toxic components. The use of gloves, eye protection and a mask when spraying are recommended. Care must be given to the reduction of dust during application as described in this Technical Data Sheet and advice given in the Material Safety Data Sheet. For further information please refer to the Material Safety Data Sheet.
3
4
6
0
1
2
3
4
5
6
Consumption of dry powder
for average 3mm thick membrane
(kg)
4mm 8mm 16mm
Degree of surface roughness
The information given here is true, represents our best knowledge and is based not only on laboratory work but also on field experience. However, because of numerous factors affecting results, we offer this information without guarantee and no patent liability is assumed. For additional information or questions, please contact your local UGC representative. Headquarters: UGC International Division of BASF Construction Chemicals Europe Ltd Vulkanstrasse 110 8048 Zurich, Switzerland Phone +41-58-958 22 11 Fax +41-58-958 32 46
For more information: Visit us: www.ugc.basf.com Contact us: [email protected]
Product Evaluation of MASTERSEAL® 345 Mott MacDonald
Assessment, Application and Specification MEYCO Global Underground Construction
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 Mott MacDonald for MASTERSEAL® 345 UGC International
Generic Specification
for MASTERSEAL® 345
Issue and Revision Record Rev Date Originator
Checker
Approver
Description
01 05/02/04 EMC AHT/DL DBP First Draft
02 11/03/04 EMC AHT DBP Second Draft
03 24/05/04 E M Casson A H Thomas D B Powell Final Issue
04 09/07 T J Ireland / B J Haig A H Thomas D B Powell Updated Issue
This document has been prepared for the titled project or named part thereof and should not be relied upon or used for any other project without an independent check being carried out as to its suitability and prior written authority of Mott MacDonald being obtained. Mott MacDonald accepts no responsibility or liability for the consequence of this document being used for a purpose other than the purposes for which it was commissioned. Any person using or relying on the document for such other purpose agrees, and will by such use or reliance be taken to confirm his agreement to indemnify Mott MacDonald for all loss or damage resulting therefrom. Mott MacDonald accepts no responsibility or liability for this document to any party other than the person by whom it was commissioned. To the extent that this report is based on information supplied by other parties, Mott MacDonald accepts no liability for any loss or damage suffered by the client, whether contractual or tortious, stemming from any conclusions based on data supplied by parties other than Mott MacDonald and used by Mott MacDonald in preparing this report.
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 Mott MacDonald for MASTERSEAL® 345 UGC International
This Specification is a model document intended to serve as a basis for materials, the equipment and workmanship requirements for the application of a spray applied waterproofing membrane.
1 General Requirements
An elastic spray applied waterproofing membrane shall be used as designated on the Drawings.
At least 30 days prior to commencement of application of the spray applied waterproofing membrane, details of the system shall be submitted to the Designer for approval. The details shall include, but not be limited to, the following:
1. Manufacturer
2. Type of system
3. Testing methods
4. Method of application
5. Jointing details (if applicable)
6. Waterstop details (if applicable)
7. Protection from damage after spraying
8. Method of repair
9. Details of personnel training
The spray applied waterproofing membrane shall only be installed by the manufacturer of the product or his approved applicator. The Contractor shall submit a method statement, prepared in conjunction with the applicator and endorsed by the manufacturer of the product, describing the details of the waterproofing works including protective measures at all stages.
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Generic Specification Mott MacDonald for MASTERSEAL® 345 UGC International
2 Materials
The Contractor shall furnish an elastic polymeric waterproofing membrane, such as BASF MASTERSEAL®345 or an approved equivalent, for waterproofing the tunnel as a spray applied layer as shown on the Drawings.
Storage conditions of the product shall comply with the manufacturer’s recommendations.
Only potable water shall be used for spraying. Under no circumstances shall saltwater, river, lake or ground water be used for mixing and spraying the waterproofing membrane.
The product shall conform to the performance requirements in Table 1 and be applied in accordance with the manufacturer’s instructions.
Property Test Method Requirement
Hydrostatic pressure without leakage BS EN 12390-8:2000 To be defined by project
Minimum Thickness See section 4.1 To be defined by project
Application Thickness See section 4.1 Up to 10mm in one pass
Application temperature +5oC to +40oC
Tensile strength (at 20oC, at 28 days) DIN 53504 >1.5MPa
Elongation at break (at 20oC, at 28 days) DIN 53504 >100 %
Bond strength to substrate (28 days) BS EN 1542:1999 >1.0MPa at 28 days
Shore hardness >75
Water absorption SIA V 280/13 <25%
Fire rating BS EN 11925-2
Class B2 -DIN 4102 Self-extinguishing
Table 1 – Performance requirements
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Generic Specification Mott MacDonald for MASTERSEAL® 345 UGC International
3 Preparation
The surface shall be prepared in accordance with the manufacturer’s instructions.
If a cementitious product is used, the surface shall be thoroughly pre-wetted before application of the membrane.
3.1 Surface Cleaning
Before application of the membrane, the sprayed concrete surface shall be thoroughly cleaned using compressed air and water (without oil contamination). When commencing the application of membrane, no free standing water should be visible, however the surface should be damp.
All other surface contamination, such as dust, oil, loose particles, etc., shall be removed.
Any external curing agent applied to the sprayed concrete shall be thoroughly removed, using a method approved by the Engineer, before application of the membrane.
3.2 Surface Texture
In areas where the surface roughness may prevent complete coverage with the specified thickness (greater than 6mm projection from the surface) a smoothing layer shall be applied to the sprayed concrete surface, as required by the Engineer. The requirement for a smoothing layer may be determined on the basis of field trials and the advice of the manufacturer.
The smoothing layer shall be 5 to 10mm thick and shall use sand (with a grading of 0 to 4mm) as the aggregate. The primary lining substrate shall be inspected in the presence of the Engineer to confirm that the surface texture complies with these clauses.
3.3 Active Water Treatment
Active water ingress shall be pre-sealed by resin injection or managed by drainage systems so that there is no running water on the surface during application. This drainage shall be maintained throughout the membrane installation works and shall be arranged such that excess water pressure cannot develop behind the membrane. For each area of active water ingress, counter-measures shall be submitted to the Engineer for approval.
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Generic Specification Mott MacDonald for MASTERSEAL® 345 UGC International
4 Quality Assurance and Control
4.1 Field Trials
Field trials shall be made to demonstrate the capability of the equipment, workmanship, materials and application methods under field conditions. Field trials shall be performed in the presence of the Engineer.
Trials shall be carried out as specified in Table 2.
The testing program shall be started sufficiently early (at least 2 months prior to spraying the membrane) to ensure that the required thickness, impermeability and bond to substrate can be achieved. All trials and acceptance tests are to be completed satisfactorily by the time spraying the membrane commences.
The Engineer reserves the right to witness laboratory tests.
Field trials may be carried out in the tunnel or using test panels (e.g. panels prepared for sprayed concrete field trials). The membrane shall be applied using the same equipment and methods and by the same approved personnel as those designated for the permanent works.
All actions for thickness control will be trialled during the field trials and a reliable method determined for use during the works. This shall be included in the construction method statement.
4.1.1 Surface Roughness
The trials shall be carried out on the full range of surface roughness to be encountered during application of the permanent works. This trial will confirm the requirement or otherwise of smoothing layers.
4.1.2 Water: Powder Ratio
Trials shall determine the optimum water: powder ratio for each of the conditions in which the membrane is to be used. For example: in a dry area, in a damp area and in an area with drained active water ingress.
4.1.3 Bond to Substrate Testing shall be in accordance with BS EN 1542:1999, Products and systems for the protection and repair of concrete structures - Test methods - Measurement of bond-strength by pull-off, or an approved equivalent. Testing shall be carried as specified in Table 2.
4.1.4 Permeability
Pre-construction trials shall be carried out to assess the water resistance of the spray applied membrane from a core taken from a test panel sprayed with the same shotcrete mix and membrane to be used in the works and using the same equipment. A core (concrete-membrane-concrete sandwich) is taken from the test panel and tested under the required water pressure.
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Generic Specification Mott MacDonald for MASTERSEAL® 345 UGC International
Testing shall be in accordance with BS EN 12390-8:2000 Testing hardened concrete – Part 8: Depth of penetration of water under pressure, as specified in Table 2. No moisture should penetrate the spray applied membrane.
4.1.5 Coverage
A visual inspection of the membrane shall be carried out as specified in Table 2. Areas in which the substrate is still visible, or where the membrane is damaged, shall be marked up and an additional layer of membrane applied with a minimum lap of 200mm around the area.
4.1.6 Thickness – Patches
Patches shall be cut from the membrane at the frequency and locations specified in Table 2. The patches shall be 50mm x 50mm in area. The minimum and maximum thickness of the patch shall be measured using a micrometer and results and location of the test recorded.
Where the field trials are carried out in the tunnel, the membrane shall be repaired as for a defect, as detailed in Section 5.3 of this Specification.
4.1.7 Thickness - Needle Penetrometer
Wet film thickness measurement shall be carried out using a needle penetrometer with micrometer gauge. Measurement shall be carried out at the frequencies specified in Table 2, and for each test the thickness and location of the test shall be recorded.
All holes created during the test shall be repaired immediately after the test is carried out.
4.1.8 Thickness - Cover Meter
Thickness measurement shall be carried out using a cover meter, such as Elcometer 456 Coating Thickness Gauge or an equivalent approved by the Engineer. Small metal discs or strips shall be fixed to the substrate prior to spraying and after spraying the thickness of membrane covering the metal shall be measured. Measurement shall be carried out at the frequencies specified in Table 2. The cover meter shall be calibrated as recommended by the supplier.
4.1.9 Thickness – Measuring Quantity
If applied robotically the applied thickness may be assessed by measuring the quantity applied and the area over which is has been applied. The purpose of field trials will be to optimise the spraying quantities required to achieve the required thickness. The applied quantity per m² determined during field trials will be used during the works as a measure of thickness.
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Generic Specification Mott MacDonald for MASTERSEAL® 345 UGC International
Parameter Test Method Frequency Pass/Fail Criteria
Bond to substrate
Pull-off test – BS EN
1542:1999 3 No. tested at 28 days >1.0MPa at 28 days
Permeability BS EN 12390-8:2000 1 No. tested at 28 days Zero penetration of water
through membrane.
Coverage Visual
A visual inspection to be carried out continuously while the membrane is applied and after application is complete.
100% coverage
Option 1 – Patches As required by Engineer. As defined by project
Option 2 - Needle
Penetrometer As required by Engineer. As defined by project
Option 3 - Cover Meter As required by Engineer. As defined by project
Thickness
Option 4 – Measurement of volume sprayed
Throughout spraying As defined by project
Table 2 – Field trials for spray applied waterproofing membrane
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Generic Specification Mott MacDonald for MASTERSEAL® 345 UGC International
4.2 Construction Testing
The quality of the membrane shall be tested using the combination of methods specified in Table 3, and as directed by the Engineer.
The project shall specify the testing regime according to its requirements.
4.2.1 Bond to Substrate Testing shall be in accordance with BS EN 1542:1999, Products and systems for the protection and repair of concrete structures - Test methods - Measurement of bond-strength by pull-off, or an approved equivalent. Testing shall be carried as specified in Table 3.
Testing may be carried out in the tunnel or using test panels sprayed under representative conditions.
4.2.2 Permeability
Testing shall be in accordance with BS EN 12390-8:2000, Testing hardened concrete – Part 8: Depth of penetration of water under pressure, or an approved equivalent. Testing shall be carried as specified in Table 3.
Testing may be carried out in the tunnel or using test panels sprayed under representative conditions.
4.2.3 Coverage
A visual inspection of the membrane shall be carried out as specified in Table 3. Areas in which the substrate is still visible, or where the membrane is damaged, shall be marked up and an additional layer of membrane applied with a minimum lap of 200mm around the area.
4.2.4 Thickness – Patches
Patches shall be cut from the membrane at the frequency and locations specified in Table 3. The patches shall be 100mm x 100mm in area. The minimum and maximum thickness of the patch shall be measured using a micrometer and results and location of the test recorded. The membrane shall be repaired as for a defect, as detailed in Section 5.3 of this Specification.
The location of the tests shall be determined to give even distribution around the entire lining (i.e. samples from crown, axis and invert).
4.2.5 Thickness - Needle Penetrometer
Thickness measurement shall be carried out using a needle penetrometer with micrometer gauge. The equipment used shall be approved by the Engineer. Measurement shall be carried out at the frequencies specified in Table 3 and for each test the thickness and location of the test shall be recorded. All holes created during the test shall be repaired immediately after the test is carried out.
The location of the tests shall be determined to give even distribution around the entire lining (i.e. samples from crown, axis and invert).
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Generic Specification Mott MacDonald for MASTERSEAL® 345 UGC International
4.2.6 Thickness – Measuring quantity
If applied robotically the applied thickness may be assessed by measuring the quantity applied and the area over which it has been applied.
4.2.7 Thickness - Cover Meter
Thickness measurement shall be carried out using a cover meter, such as Elcometer 456 Coating Thickness Gauge or an equivalent approved by the Engineer. Small metal discs or strips shall be the substrate prior to spraying and after spraying the thickness of membrane covering the metal shall be measured. Measurement shall be carried out at the frequencies specified in Table 3. The cover meter shall be calibrated as recommended by the supplier.
The location of the tests shall be determined to give even distribution around the entire lining (i.e. samples from crown, axis and invert).
Parameter Test Method Frequency Pass/Fail Criteria
Bond Pull-off test – BS EN
1542:1999
3 per 100 linear metres of tunnel length
>1.0MPa at 28 days
Permeability BS EN 12390-8:2000
1 per 100 linear metres of tunnel length
Zero penetration of water through membrane.
Coverage Visual A visual inspection to be carried out continuously while
the membrane is applied.
100% coverage
Option 1 - Patches
One test per 100m2 As defined by project
Option 2 - Needle
Penetrometer
Ten tests per 100m2 As defined by project
Option 3 - Cover Meter
Ten tests per 100m2 As defined by project
Thickness
Option 4 – Application
Quantity Measurement
Per batch Kg/m² to match minimum applied quantity determined
during field trials
Shore A Hardness
DIN 53505 or ASTM D 2240
3 tests per 100m² 50
Table 3 – Construction testing for spray applied waterproofing membrane
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Generic Specification Mott MacDonald for MASTERSEAL® 345 UGC International
5 Application
The elastic spray applied waterproofing membrane shall be installed in accordance with the manufacturer’s instructions, as indicated on the Drawings, and shall be subject to the approval of the Engineer.
During application the ambient temperature, and the temperature of the substrate, waterproofing membrane and water supply, shall be between +5oC and +40oC. For five days after application, the ambient temperature shall remain between +5oC and +40oC, and cyclic temperatures shall not exceed 10oC.
Ventilation shall be around 1m/s to provide optimal application and curing conditions.
When spraying the membrane no other works shall be carried out in the vicinity which may cause personnel or equipment to intentionally or accidentally come into contact with the membrane before it has sufficiently cured. If it is likely that excessive dust will be generated in the vicinity of the works (vehicle movements etc.) then measures shall be put in place to minimise dust and dust suppression measures shall be incorporated.
5.1 Equipment
Application of the membrane shall be in accordance with the recommendations of the manufacturer. The spraying equipment shall be capable of feeding materials at a regular rate and ejecting the product from the nozzle at velocities which allow adherence of the materials to the surface with minimum rebound and maximum adhesion.
If the sprayed membrane is to be applied robotically the equipment used shall be approved by the manufacturer. The equipment should use laser guided automated application methods to ensure that a uniform thickness is applied over the entire substrate.
The air and water supply system shall be capable of supplying the delivery machine and hose at the pressures and volumes recommended by the manufacturer of the machine.
The air supplied to the pump, delivery hoses and nozzle shall be dry air. This shall be facilitated by the use of compressors and/or spray equipment fitted with adequate water separation devices. Air supply systems that deliver air contaminated by oil shall not be used.
The placing equipment shall be configured so that the nozzle can be placed 1.50m to 2.50m from the surface receiving the membrane in such a manner as to place the membrane onto the wall with minimum rebound. Equipment shall be furnished to allow application of the membrane to surfaces with the nozzle at the specified distances from the Work.
Typically application will be by the dry spraying method using a MEYCO Piccola concrete-spraying machine or similar approved by the Engineer, with the following additional equipment:
• 32mm diameter spraying nozzle (plastic tip with collar/conical) with a minimum of 16 hole water ring (18 holes recommended) to ensure proper mixing.
• Dust collection system installed where it is envisaged that works elsewhere in the tunnel will cause excessive dust in the vicinity of the works.
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Generic Specification Mott MacDonald for MASTERSEAL® 345 UGC International
• Two valves (one fine adjustment valve and one on-off valve) for water content control to enable the setting to be fixed during pre-construction trials and remain constant throughout application.
5.2 Temporary Construction Joints
Where the membrane is sprayed in alternate bays, or there is an interruption in spraying of more than 6 hours, there shall be a minimum overlap of 200mm with the existing membrane and the surface shall be cleaned prior to application.
5.3 Defective membrane
Areas of the membrane which lack uniformity, exhibit lamination or cracking, lack adequate bonding, lack watertightness, or fail to meet the specified strength and toughness requirements shall be regarded as defective membrane. Where an area is deemed defective the section shall be removed, cleaned and resprayed with a minimum overlap of 200mm from the boundaries of the defect.
The Engineer reserves the right to halt further placement of the membrane not meeting specified requirements or to order removal and replacement of defective membrane and any associated water ingress control measures or smoothing layer without additional cost. The cause of the problem is to be rectified before playing any further membrane.
6 Secondary Lining Construction
Prior to secondary lining construction, the membrane shall be visually inspected for defects, pinholes and 100% coverage in the presence of the Engineer.
Secondary lining sprayed concrete shall not be applied until the membrane has cured sufficiently to achieve a Shore A hardness of 50. As soon as practicably possible after the membrane has been installed it shall be protected by the construction of the secondary lining.
7 Disposal of material
Disposal of all waste shall be in accordance with any legal or local Engineer requirements.
8 References: Test Standards
DIN 53504: 1994 Prüfung von Kautschuk und Elastomeren; Bestimmung von Reißfestigkeit, Zugfestigkeit, Reißdehnung und Spannungswerten im Zugversuch (Determination of tensile strength at break, tensile stress at yield, elongation at break and stress values of rubber in a tensile test)
DIN 4102 Brandverhalten von Baustoffen und Bauteilen (Fire behaviour of Building Materials and Elements)
BS EN 1542:1999 Products and systems for the protection and repair of concrete structures - Test methods - Measurement of bond-strength by pull-off
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Generic Specification Mott MacDonald for MASTERSEAL® 345 UGC International
BS EN 12390-8:2000 Testing hardened concrete - Part 8: Depth of penetration of water under pressure
BS EN 11925-2:2002 Reaction to fire tests - Ignitability of building products subjected to direct impingement of flame. Single-flame source test
SIA 162/1 Swiss Society of Engineers and Architects “Ouvrages en beton”
DIN 53505 Shore A and Shore D hardness testing of rubber
ASTM D2240 Standard test method for rubber property – Durometer Hardness
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Product Evaluation of MASTERSEAL® 345 Mott MacDonald
Assessment, Application and Specification MEYCO Global Underground Construction