ITAtech Design Guidance for Spray Applied Waterproofing Membranes

Summarized by Tarcsio B. Celestino

Aug. 2013

Problems due to water Ingress into tunnels

Durability Functionality Aesthetics Safety Comfort

1970s sheet membranes 2000s spray applied membranes

Cost-Benefit

Typical Inflow Problems

Cracks and fissures Reinforcement shades in shotcrete Low compaction zones Steel sets Interface between top heading and bench

Objectives of the Document

Assessment of the project condition; potential benefits of the spray applied membranes Limitations of spray applied membranes for water proofing Potential impact on the structural design - composite shell Guide for technical specifications

Appendices - Example specification - Training certification - Generic detail drawings - Case studies

Properties
Non reactive-curing by hydration or air-drying Reactive systems - curing by polymer reaction Produced and installed in situ against primary lining Secondary lining or protective layer (mortar or sprayed concrete) Sandwich-structure (concrete-membrane-concrete) is a quasi-monolithic structure Not a panacea but offers viable solution for a specific window of ground and hydrological conditions

Features
Benefits in complex geometry (niches, cross passages, portals, etc.) Use of final lining shotcrete No need for mesh to build up shotcrete as required by sheet membranes Application by means of equipment already available on site 50-100m/h manually by 3 operators; 180m/h with robotic spraying Applied in limited sections (e.g. crown) or continuous waterproofing Continuity without discrete joints (no need for weld, injection tubes, etc.) No welded seams simply connected by overlapping Easier and quicker location and repair of leaks

Features (cont.)
Can be combined with other waterproofing systems Compatible with all concrete placement methods and reinforcement No folding or stretching during casting or spraying of the secondary lining

Installation Limitations
Exposed to tunnel environment (temperature, water) which may interfere with curing process Vulnerable to poor workmanship Training and accreditation of applicators required Close quality control required Surface preparation (some systems) Not appropriate to install when high levels of water inflow are expected Appropriate only for isolated areas with trickling or running water, tunnels through dewatered or pre-grouted rock masses Substantially wet: sheet membrane recommended

Waterproofing Approach Based on Water Ingress

Waterproofing Systems
1. Withstand full water pressure (submarine system) 2. Withstand partial water pressure (Umbrella system) 3. Fully drained (no pressure on lining)

Spray applied membranes adequate for 1 and 2

Use of Submarine Systems

Environmental restrictions to any water level lowering Settlement restrictions due to consolidation Eliminate pumping costs Isolation of groundwater and tunnel (e.g. sewer tunnels)

Drained and Undrained Tunnels

Systematic drainage system

Drains installed at 5-10 m intervals Dimpled sheets strips onto primary lining connected to invert drain Regulating shotcrete applied prior to waterproofing membrane Secondary lining

Localized drainage System

Impermeable rock with water through some cracks Dimpled drainage strips Drilled drainage holes, if required

Mixed System
Drainage as in previous cases Membrane only in crown

Combination with Sheet Membrane

Overlapping in dry areas Substrate treated with mortar Sheet membrane properly fixed and well stretched Minimum overlap 40cm or according to suppliers instruction Compatibility between materials should be tested Not to align structural joints with waterproofing transition

Bonding
Water tightness promoted by: bonding between membrane and substrate bonding between membrane and secondary lining minimum thickness leakage only if defects aligned easy to treat defect

Remedial Measures in Case of Leakage

Leak identification Drill hole (18-25mm) 50mm deep to primary concrete Inject acrylic resin Observe and repeat injection if needed Remove packers and repair surface

Dealing with water pressure during construction

Option 1 Divert flow to invert through dimpled drainage strips, covered by shotcrete. All surfaces covered with membrane Option 2 Insert packers with drainage tubes. Take drainage to drainage system. Spray membrane to all surfaces. Inject through packers or allow drainage to continue in permanent case Option 3 Spray membrane to all surfaces other than area of ingress. Allow membrane to cure fully. Inject water sealing resins, complete spraying membrane.
Time between membrane and secondary lining

Time between membrane and secondary lining

If pressure relieved permanently or during membrane installation, not critical If membrane will withstand pressure, make sure membrane is cured before Curing characteristics of membrane may vary from product to product

Bonding
Essential for waterproofing Good for structural reasons Minimum value required: 0,5 MPa Double bonding Reduction of total lining thickness due to monolithic behavior of composite shell lining

Crack bridging
Bridging cracks of up to 2.5mm. Performance depends on elongation and tensile strength Wider cracks require increased membrane thickness and agreement of manufacturer Structural and economic consequences of thicker membranes

Durability
Chemical aggressivity of groundwater should be known beforehand Possible to deal with some degree of aggressivity

Flammability
Avoid fire risk during spraying and before secondary lining

Trials and Testing

If required, Certificates of compliance to ITAtech Example Specification shall be provided, or other special requirements Suitability of materials, equipment, grouting gear and fixings Compatibility with first and second lining

Application Requirements
Spraying equipment feeding material at regular rate at velocities which promote adhesion, and minimum rebound Meet required pressures, volumes and ratios of product components Spraying operatives with certified training according to ITAtech scheme Equipment maintenance and cleanliness Approved Quality Audit System Correct surface preparation, if required

Substrate preparation

Surface preparation
Closed surface No trapped air Time needed for preparation Material consumption Regulating layer: 1 to 3cm with 4mm maxaggregate

Substrate surface finishing

Shotcrete Layer of gunite (4mm aggregate) Smooth finished

Potential causes of failure

Poor application, poor workmanship, lack of training Damage to membrane before final lining Two colored layers useful to detect damage Exceptionally rough surfaces Excess of water (running) Exposure to heat, freezing, UV.

All conditions addressed in specification and QC

Quality Control
Coverage
Visual inspection for defects Substrate visible Membrane not suitably opaque Damage

Spray paint Additional layer of membrane with 200mm overlap

Thickness
Depth of wet film: gage during application. Number of locations as specified. Correction if needed.

Average thickness from quantity sprayed and area

Thickness
Two layer application Two colors

Thickness
Cut-out inspection patches Randomly located Typically 50mm Repaired by overs praying

Bond do Substrate
min 0.5 MPa within 28 days In case of water, diversion must be maintained during 28 days

Integrity Testing
Non-destructive Holiday detection, Verification and Spark Testing Continuity

Design Aspects
Single Shell Lining (SSL) Composite Shell Lining (CSL) Double Shell Lining (DSL)

DSL typical for deep tunnels which anticipate high water pressure

Composite Shell Lining

2nd lining: shotcrete or cast in situ concrete Quasi-monolithic behavior like single-shell lining

Structural Behavior
SSL OK but poor waterproofing CSL Test at SINTEF Design should limit shear stress acting on the joint as a function of membrane thickness (research underway). Numerical analyses

Watertightness classes

Properties of Spray Applied Membrane

Watertightness Test

Application Requirements
Substrate temperature between + 5C and +40C Ventilation according to usual needs No other works carried out in the vicinity, dust suppression measures, if needed. Sufficient lighting Fire detection and suppression Personal protective equipment Exclusion zones Eye wash and first aid facilities

Defects
Inspection detects and marks defects If after repairs defects still persist, membrane shall be removed and replaced. Adjacent sections of membrane shall overlap by a minimum as defined by manufacturer.

Quality Control Testing During Construction

Details Drained Road Tunnel

Details Undrained Road Tunnel

Details Membrane overlapping

Details Interface with sheet membrane

Details Metal Insertions

BASF

BASF

NORMET

NORMET

Stirling Lloyd

Stirling Lloyd

Mapei

Mapei

Thank you! tarcisio@themag.com.br tbcelest@usp.br