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Intelligent solutions from BASF Construction Chemicals Whatever your construction problem, whatever the structure is you are building, BASF Construction Chemicals has an intelligent solution to help you be more successful. Our market leading brands offer the widest range of proven technologies to help you build a better world. Emaco® - Concrete Repair Systems MBrace® - Composite Strengthening Systems Masterflow® - Precision and Structural Grouts Masterflex® - Joint Sealants Masterseal® - Coatings and Waterproofing Concresive® - Crack Injection Resins Conideck® - Hand and Spray applied Waterproof Membrane Systems Coniroof ® - PU Based Roofing Systems Mastertop® - Decorative and Industrial Flooring Solutions Ucrete® - Flooring Solutions for Harsh Environments Glenium® - Superplasticizers RheoFIT® - Waterproofing Admixtures
Head Office BASF Construction Chemicals (UK) Ltd PO Box 4 Earl Road Cheadle Hulme Cheadle Cheshire SK8 6QG Tel: 0161 485 6222 Fax: 0161 488 5220 www.basf-cc.co.uk www.pci.uk.com BASF Construction Chemicals (UK) Ltd 19 Broad Ground Road Lakeside Redditch Worcestershire B98 8YP Tel: 01527 512255 Fax: 01527 510299 www.basf-cc.co.uk www.pci.uk.com
Specifiers’ Guide to Waterproofing Systems
Masterkure® - Curing Compounds Rheofinish® - Release Agents MEYCO® - Shotcrete and Spraying Equipment Micro-Air ® - Air-entraining Agents PCI® - Tile Fixing, Cement Underlays and Waterproofing Systems
BASF is the world’s leading chemical company: The Chemical Company. Its portfolio ranges from chemicals, plastics and performance products to agricultural products, fine chemicals and oil and gas. As a reliable partner BASF helps its customers in virtually all industries to be more successful. With its high-value products and intelligent solutions, BASF plays an important role in finding answers to global challenges such as climate protection, energy efficiency, nutrition and mobility. BASF posted sales of more than € 62 billion in 2008 and had approximately 97,000 employees as of the end of the year. Further information on BASF is available on the Internet at www.basf.com.
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About BASF - The Chemical Company:
About BASF Construction Chemicals Division:
BASF is the world’s leading chemical company:
BASF’s Construction Chemicals division is the leading
The Chemical Company. Its portfolio ranges from
supplier of chemical systems and formulations for the
chemicals, plastics and performance products to
construction industry. Continuous innovation and
agricultural products, fine chemicals, oil and gas.
tailor-made solutions ensures that its customers stay
As a reliable partner BASF helps its customers to be
at the forefront of technology. Its Admixture Systems
more successful in virtually all industries.
business unit specifically helps customers in the ready-mix, precast, concrete products and underground
With its high value products and intelligent solutions,
construction industries.
BASF plays an important role in finding answers to global
Contents Introduction
2-7
Market Sector Sections
Subways, Tunnels and Shafts
8-11
Basements and Vaults
12-15
Wastewater - includes Pipes and Manholes
16-19
Potable Water
20-23
challenges such as climate protection, energy efficiency,
The Construction Systems unit offers a wide range of
nutrition and mobility. BASF posted sales of more
products for sports and industrial flooring, external
than €62 billion in 2008 and had approximately 97,000
renders and wall insulation, expansion joints and wood
employees at the end of that year.
preservatives as well as specialist repair mortars, tile
Reservoirs, Dams and Waterways
24-27
adhesives and waterproofing membranes. The division
Marine Structures and Defence
28-31
than 50 countries and achieved sales of €2.2 billion,
Swimming Pools
32-35
with approximately 7,700 employees.
Secondary Containment / Bunds
36-39
Car Parks - Exposed Decks, Multi-storey and Underground
40-43
Podium Decks
44-47
Balconies, Walkways and Terraces
48-53
Bridges
54-57
Roofing - includes Green, Cold, Warm and Inverted Roofs
58-61
operates production sites and sales centres in more
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Sustainability
62
Commitment to Research & Development
63
Degradation of Cementitious Material
64
Admixtures
65
Construction Products
66
Glossary of Terms
67
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Protect Against the Most Destructive Element
Water is the most destructive weathering element for concrete, masonry and stone structures, damaging or destroying more buildings and structures than war or natural disasters. Whether above-grade or below-grade, all building envelopes must be able to resist unwanted water in some respect, in the form of rainwater, moisture or hydrostatic pressure. Hydraulic civil structures face yet more challenges in withstanding the ongoing effects of constant immersion. Good waterproofing, or water resistance, can be the key factor in ensuring a structure’s longevity, yet the importance of this facet of structural design is not always given the attention it warrants. The majority of problems with water ingress occur in a relatively small proportion of a structure’s surface area, often where design details meet. Careful consideration at the design stage can limit cracks, leaks and potentially serious structural damage over a structure’s lifecycle, provided that trades work together at the construction stage to implement design details successfully. BASF Construction Chemicals’ holistic approach to waterproofing covers both new-build and refurbishment solutions. Driven by the belief that prevention is better than cure, we address waterproofing from first principles, including admixtures for concrete, as well as offering retrofit solutions. This reference guide is an introduction to BASF Construction Chemicals’ Waterproofing Systems for architects, engineers, owners and procurement departments, putting you in the position to specify the right BASF products. The applications outlined are by no means exhaustive, but cover most uses for our systems.
Admixture Systems
Membranes
Ground and Water Control Systems
The use of admixtures is a readily available concept, allowing the design of concrete with enhanced properties. The problem of water penetration in concrete affects ordinary and high-quality concrete, both of which contain capillaries and microcracks that allow water to pass through (capillary absorption). This takes place wherever there is a head of pressure on one side or a humidity differential between the sides, and manifests as dampness or visible seepage. Most, if not all, concrete inherently absorbs moisture and soluble contaminants from the surrounding environment. The result of water penetration is likely to be corrosion of reinforcing steel if chlorides and oxygen are present.
Our Conica liquid-applied seamless coatings for roofs, decks and other surfaces guard against water ingress, including acid rain, de-icing salts, freeze-thaw cycles and chloride ion penetration, protecting reinforcing steel. In certain applications such as use on car park decks, waterproofing benefits are combined with the prevention of unnecessary maintenance and structural damage during the structure’s lifecycle.
Unexpected water ingress during underground construction usually escalates project costs, and inevitably causes significant delays. To counteract these risks, an economical approach is to pre-inject the ground with micro-cements ahead of the advancing face. There are also instances where post-injection, stabilisation of soils and even structural repairs using high performance chemical injection products are required. BASF has the complete range of products and technical support for such situations.
BASF has developed its Watertight System as an alternative to membranes and built-up treatments: a quicker, more cost effective and more reliable solution in comparison with traditional construction methods. It combines a reactive hydrophobic pore-blocking liquid for wet or dry cast concrete and high-range water-reducing/ superplasticising admixtures. The result is inherently water repellent, non-absorptive concrete with a reduced water– cement ratio, which is also protected against soluble salts. Additional options include air-entraining admixtures which can be used to limit the effect of the freeze-thaw cycle, helping to prevent spalling and improving structural resistance to weathering. BASF admixtures for waterproofing: Glenium®, Rheocrete®, RheoFIT®, Rheofinish®, Masterkure®, micRo-air®, MASTERSEAL®, MEYCO®
For more detailed information please visit our dedicated Waterproofing website: www.basf-waterproofing.co.uk
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BASF’s elastomeric liquid membranes circumvent the perceived problem of uniformity of application as the equipment used to spray-apply these systems can guarantee a uniform thickness. A further benefit of our systems is that they are solvent free, making them already compliant with new Euro Code due to come into effect in 2010. The absence of any solvent also makes Conica systems suitable for spray application to treat foundations and for use in interior spaces with restricted ventilation. Below-grade, BASF’s MASTERSEAL® spray-applied membranes for tunnel applications are a faster, often more effective alternative to traditional sheet membranes. Applied in a sandwich construction between permanent sprayed or cast concrete shells, this waterproofing system’s strong bond to the concrete lining on either side mitigates the risk of water ingress by eliminating potential groundwater paths. BASF membranes for waterproofing: Conideck®, Coniroof®, Conica, MASTERSEAL®.
RHEOCEM® micro-cements represent a technological advance in cementitious injection work. Their relatively rapid rate of curing is a unique feature which enables blasting rounds to be prepared more quickly, resulting in enhanced productivity without the need for cycle interruptions. A full range of resin-based injection systems (acrylics and polyurethanes) is available from our MEYCO® Global Underground Construction division, offering both one and two-component polyurethane and ure-silicate foams. Our single component foam is delivered with a separate accelerator, giving the freedom to adjust the foam reaction time. Our mineral-based MEYCO® grout is stable and consists purely of natural ingredients, making it non-hazardous and ecologically friendly. Due to its very low viscosity, it penetrates finer fissures than any cement-based product and gives unrivalled penetration and permanent stabilisation of fine, silty sands. BASF ground and water control systems: RHEOCEM®, MEYCO®
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Applied Sealants
Cementitious Coatings and Renders
Concrete Repair Systems
Waterstop Systems
In damp or immersed conditions such as reservoirs, water towers, tunnels and basements, proven high-performance specialist sealants are essential. BASF’s THORO® range includes elastomeric mortars for damp substrates which allow a movement accommodation of up to 15% and are resistant to aggressive groundwater, dilute acids and alkalis. Applications span the sealing of construction joints, cracks in concrete and joints between precast concrete panels or pipe sections, as well as flexible and waterproof pointing. THORO® also offers the highly elastic pre-formed dynamic joint waterproofing system compatible with potable water, designed for a variety of substrates where a high degree of movement is expected in both vertical and horizontal directions.
BASF’s surface-applied cementitious coatings, for positive and negative applications in water-excluding and water-retaining structures above and belowgrade, protect against damp and the ingress of water, effectively becoming an integral part of the substrate. Our cementitious systems have been developed for high performance, using proprietary chemicals, with uses spanning everything from basement tanking to waterproofing structures as diverse as reservoirs, tunnels, swimming pools and pipes.
For many existing structures, remedial waterproofing and repair works are intrinsically linked. Structural restoration is often a vital preliminary stage in achieving a watertight surface, particularly in the case of concrete substrates where years of water infiltration, high in chloride content, have been a contributing factor in the corrosion of steel reinforcement.
Waterbars are not only expensive to install but can be displaced or damaged during the concreting operation. As concrete is unable to adhere to plastic waterbars a failure rate of 15-20% can be expected. As there is no maintenance opportunity, a further drawback is the potentially significant subsequent cost of repairing leaks.
Further options for wet and submerged surfaces are available: BASF’s polyurethane-based MASTERFLEX® sealants are temperature resistant from -30 to 80°C and include a sealant designed specifically for applications such as water treatment works and waterways. BASF applied sealants: THORO®, MASTERFLEX®
Whether you are looking for a basement tanking system, a façade treatment or large-scale waterproofing of a civil structure, the BASF range will have the answer. Systems include potable water solutions and a slurry system for capillary waterproofing, suitable for challenging environments such as canals, dams, coastal and other submerged structures. In most cases systems can be applied to damp substrates, ensuring that no time or money is wasted drying the area to be treated. BASF cementitious coatings and renders: THOROSEAL®, MASTERSEAL®
The BASF repair range starts with a selection of mortars: spray-applied repair mortars; a specialist DWI approved high-strength repair mortar for repairing damage caused by corroded rebars and nanotechnology-driven fast-track structural repair mortars under the EMACO® brand all complying to BS EN1504 part 3. Where structural strengthening is required, BASF’s portfolio of MBrace® carbon and aramid fibre wraps, reinforcing bars and plates supply a non-corrosive replacement for steel reinforcement. The installation of preventative measures such as cathodic protection may also be appropriate as part of a concrete repair solution. BASF has developed a special grade of its flowable replacement concrete specifically to support CP installations.
BASF’s MASTERFLEX® 900 reinjectable hose system for construction joints is the alternative to waterbars where watertight joints are essential. This preventative system can be re-tested and re-injected at any time, allowing the integrity of joints to be checked regularly. Constructed from a tough, specially formulated PVC compound, it is unaffected by weathering, low temperatures and constant immersion in water. Fast, easy installation, even with complicated design details and proven performance, make MASTERFLEX® 900 a reliable, cost-effective choice which eliminates the need for kickers. Retro-injection at any time can stop leaks caused by settlement, structural movement, damage or excessive loading. BASF waterstop systems: MASTERFLEX®
BASF concrete repair systems: Shotpatch®, THORO®, EMACO®, MBrace® Kubak, Michael T. (2000) Construction Waterproofing Handbook. McGraw-Hill
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Subways, Tunnels and Shafts Spray-applied Waterproofing
Injection
The technology used in tunnel waterproofing has remained relatively static until recently. While conventional sheet membranes have been the norm, they are often susceptible to leakages that can be notoriously difficult to rectify; moreover they are unable to accommodate complex tunnel shapes and are incompatible with the construction of permanent sprayed concrete linings.
Unexpected water ingress and poor ground conditions during underground construction usually escalate costs, influence the environment severely and inevitably cause significant delays. To counteract these risks, an economical approach is to pre-inject the ground with micro-cements ahead of the advancing face as a practical alternative to more complex post-injection techniques.
Layer of primary permanent sprayed concrete Layer of MASTERSEAL® membrane
In response to the need for a simple, effective waterproofing solution, BASF Construction Chemicals has developed the new-generation MASTERSEAL® 345 spray-applied waterproofing membrane, which is simply applied in a sandwich construction between permanent sprayed or cast concrete linings. The waterproofing system’s performance lies in the bonding properties between the membrane and concrete lining on both sides – this strong bond mitigates the risk of water ingress by eliminating potential groundwater paths. MASTERSEAL® 345 closes and isolates cracks in such a way that stresses resulting from water pressure can be transferred to the outer lining, leaving the inner lining virtually unaffected. The crackbridging properties of MASTERSEAL® 345 have been tested according to EN 1062-7:2004, demonstrating a crack-bridging capability of up to 5mm.
Layer of secondary permanent sprayed or cast concrete Rock bolt
5
Wet spot: pre-treatment, sealing or drainage Fine crack injection
1
3
Consolidation grouting
To meet increasingly strict legislation covering the environment and workers’ health and safety, stabilisation of sands and soils requires safe, durable mineral grouts and micro-cements. BASF Construction Chemicals’ MEYCO Global Underground Construction division has a complete range of injection products suitable for all projects including new and existing tunnels, mines and large civil engineering projects.
Watertight Joints
4
2
Wherever tricky joints present problems underground, in shaft junctions, within linings, cast sections or portals, BASF’s MASTERFLEX® 900 re-injectable hose system for construction joints offers a watertight solution. A preventive system that avoids the many diasadvantages of waterbars, it can be re-tested and re-injected at any time.
1. MASTERSEAL® 345 spray-applied waterproofing membrane. 2. MASTERFLEX® joint sealers. 3. MEYCO® injection resins for waterproofing. 4. MASTERFLEX® 900 re-injectable hose system for construction joints. 5. MEYCO® SA160, GLENIUM®, DELVOCRETE®, admixture solutions for successful, durable sprayed concrete according to requirements and site conditions.
Leeming, M.B. (1989). Concrete in the Oceans programmer co-ordinating report on the whole programme. Offshore Technology Report OTH 87 248, HMSO. Allen, R.T.L, Concrete in Coastal Structures
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Subways, Tunnels and Shafts
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The Challenge
Product:
Description:
Minimum tensile strength (N/mm2)
Minimum elongation (%)
MASTERFLEX® 610
Hydro-swelling waterbar
1
6.12
610
MASTERFLEX® 612
Advanced hydro-swelling gasket in paste form
1
MASTERFLEX® 611
Gun grade, hydroswelling waterbar
1
MASTERFLEX® 900
Advanced injection hose system
Precast elements
Segment rings
Filling waterbearing voids
12
Rafts and walls in tunnels
1
Construction joints exposed to hydrostatic pressure.
3.9 N/mm2
Application:
Swelling ratio (%)
Technical Data:
Minimum tear strength (N/mm)
The 1,960m Giswil road tunnel in central Switzerland is a two-lane road tunnel with an emergency escape tunnel running parallel. The main road tunnel is located in Mica Schists excavated by drill-and-blast. The final structure consists of a double shell concrete lining with drained waterproofing, utilising a PVC sheet membrane and a geotextile fleece for drainage. The emergency escape tunnel was excavated by a 4m diameter hard-rock TBM and supported by pattern rock bolting and sprayed concrete. A length of approximately 10m in each end of the tunnel was excavated by drill-and-blast. In the portal areas a cut-and-cover concrete tunnel was constructed.
Joint Sealers
No. of components
Featured Project: Giswil Emergency Escape Tunnel, Switzerland
220
l
l
l
l
l
250
l
l
l
l
l
85
l
l
l
l
l
l
l
l
l
l
Dependent on injection material
Waterproofing Injection
Stabilising coarse sand and gravel
Filling waterbearing voids l
l
l
l
l
l
l
l
l
l
l
l
Thoro ® Dryjoint
l
Thoro ® Acryl 60
Sealing off flowing water
l
Thoro® Waterplug
Emaco ® NANOCRETE R4 l
Stabilisation of jointed rock
Emaco ® NANOCRETE R2 l
l
Conipur ® M 869F
THoRO® Structurite l
Pre-injection of jointed rock
l
l
Conipur ® M 810
1
2 component pump with single mix spiral
RHEOCEM ®
1 component pump
l
Accelerator 25
l
Thoro ® flex 200
2
Accelerator 15
MEYCO MP320
Application:
l
Thoroseal ® PM
Accelerator 20-30
Thoroseal ® FX100
Separate Accelerator l
Accelerator 10
Solvent free l
Thoroseal ®
No. of components 1
®
Sprayable Waterproofing Membrane MASTERSEAL® 345 • The high bond strength to concrete meant there would be no migration of water along the membrane/substrate interface, significantly reducing the risk of water seepage even by eventual damages or holes in the membrane • Able to waterproof the invert and the interfaces between bored tunnel and drill-and-blast excavated tunnel, as well as between drill-and-blast excavated tunnel and concrete cut-and-cover tunnel • Compatibility with the PVC sheet membrane and Bikutop-system at the interfaces • Injection rather than drainage for removal of water seepages because of the undrained solution
Foam factor
PU
MEYCO ® MP355 1K
The Solution
Equipment:
Technical Data:
Thoro® Flexi-joint
Product:
Sealant type
The Engineer required a waterproofing solution in the outermost parts of the escape tunnel at both ends which supported: • No water ingress in the bored part of the tunnel • Continuous waterproofing from the bored tunnel through the blasted part of the tunnel to the cut-and-cover concrete tunnel at the portal • Compatibility between the waterproofing of the cut-and-cover concrete tunnel and the waterproofing of the rock tunnel The Engineer chose an undrained solution, with a waterproofing system that covered the entire profile, including the invert
Function Concrete re-instatement Surface finishing
References: Europe
South America
Collombey Road Tunnel, Switzerland Giswil Road Escape Tunnel, Switzerland Nordöy Sub-Sea Road Tunnel, Faroe Islands Abbottscliff Road Tunnel, United Kingdom Lausanne Metro, Switzerland
Machadinho Hydroelectric Power Station Tunnels, Brazil Zapata Highway Tunnel, Chile Lo Prado Highway Tunnel, Chile Orientales Underground Station, Santiago Metro, Chile
North America Bergen Rail Tunnel, New Jersey, USA Wolf Creek Highway Tunnel, Colorado, USA Wine Caves, Nappa Valley, California, USA
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l
l
Surface sealing Surface sealing-elastomeric
l
Expansion joint/crack sealing
l
Expansion joint/crack overbanding
l
Stopping active water
l
Repointing
Asia Pacific
Admixture
MTRC Cross Passages, Hong Kong MTRC Vent Tunnel Enlargements, Hong Kong Parramatta Rail Link Station Tunnels, Sydney, Australia
Suitable Structures
For further information visit www.basf-waterproofing.co.uk
l
l l
Reservoir roofs
l
Reservoirs-internal: hard water
l
Reservoirs-internal: soft water
l
Water towers
l
l
l
l l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l l
Subways, Tunnels and Shafts
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Basements & Vaults GLENIUM® and RheoFIT®
THOROSEAL® SUPER WHITE
Salt-inhibiting render if required
Basements and vaults have to withstand water conditions that are typically more severe than those above-grade. These include the effects of both surface water and groundwater, as well as a variation of pressures from the surrounding subsoils. Even the tiniest pinhole or crack will cause water to leak into a basement, whilst capillary action can cause delamination of flooring, mildew and staining. However, below-grade waterproofing systems need not take into account harsh environmental conditions such as wind-driven rain and ultraviolet weathering.
THOROSEAL® SUPER GREY
Optional bonding slurry coat THORO® ACRYL 60
5
6
7
4
Under the THORO® brand, BASF Construction Chemicals specialises in negative-side (internal) surfaceapplied waterproofing systems for tanking basements. These waterproofing systems are suitable for use inside any kind of basement structure and provide full protection against damp and the ingress of water. They contain no solvents, protecting both the applicator and the environment.
An alternative to tanking systems, the BASF Watertight System provides integral waterproofing that eliminates the need for external membranes and coatings. Utilising RheoFIT® permeability reducing liquid ingredient, and GLENIUM® high-range water-reducing/superplasticisers, it produces an inherently water-repellent and nonabsorptive concrete which is permanently protected against water ingress, soluble salts and acid attack. As an alternative to using the separate RheoFIT® and Glenium® components, RheoFIT® 799 is a powdered “One Bag” version of BASF’s Watertight System. RheoFIT® 799 is a high performance integral waterproofing system for wet cast concrete incorporating combined waterproofing and superplasticising components.
Watertight Joints
6
Below-grade Barrier Systems
BASF Watertight System
BASF’s MASTERFLEX® 900 re-injectable hose system for construction joints is a preventive system that avoids the many disadvantages of waterbars and eliminates kickers. Straightforward to install, it allows joints to be tested for watertightness before backfilling and can be re-tested and retro-injected at any time.
8
7
THORO® systems are equally suitable for remedial and new-build applications. Where costs and scheduling are an issue THORO® waterproofing solutions have a clear advantage over other techniques, as they can be applied to damp substrates, avoiding unnecessary delays caused by drying out the basement.
3 1
2 MASTERFLEX® 900 HOSE
THORO® WATERPLUG
With approvals from internationally respected authorities in countries including the UK, France, Germany and the USA, THORO® products are manufactured to the highest standards and are fully tested by independent laboratories approved by national building bodies.
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23331_WaterProofing.indd 13-14
Cracks THORO® FLEXIJOINT
For further information visit www.basf-waterproofing.co.uk
1. EMACO® NANOCRETE structural repair mortars, suitable for profiles and corners. 2. THORO® FLEXIJOINT elastomeric mortar for sealing movement joints and cracks in concrete/ masonry in damp/immersed conditions. 3. THORO® WATERPLUG ultra-rapid setting mortar, as a seal for wall/floor or kicker joints prior to basement tanking. 4. THORO® ACRYL 60 blended with ordinary Portland cement as a bonding slurry coat for use on dense non-porous stonework and engineering bricks. 5. GLENIUM® and RheoFIT® admixtures for durable waterproof concrete in basement applications. 6. THOROSEAL® SUPER WHITE (1st COAT) waterproof coating for spray/brush application to concrete and masonry. 7. THOROSEAL® SUPER GREY (2nd COAT) waterproof coating for spray/brush application to concrete and masonry. 8. Optional THORO® Macromix, renovation plaster to reduce surface condensation.
Basements and Vaults
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Application Spalling over small areas Cover (mm)
BASF Construction Chemicals in conjunction with the Dampstore jointly proposed that the THORO® waterproofing system be applied to the walls and floors of the basement. The solution provided was the most practical for the development of the basement areas. A close contractor/supplier working relationship, together with the back-to-back joint warranty offered by BASF, enabled the contractor to offer the end client an attractive warranty-approved basement waterproofing package.
Protection against corrosion
Can be spray applied
l
l
EMACO ® Nanocrete R3
l
l
l
l
l
l
l
l
l
l
l
EMACO ® Nanocrete R4
l
l
l
l
l
l
l
l
l
l
l
EMACO Nanocrete R4 Fluid
l
l
l
l
l
l
l
EMACO ® FAST Fluid/Fibre/Tixo
l
l
l
l
l
l
l
MASTERSEAL 524
l
l
l
l
THORO ® MACROMIX
l
l
l
l
Sealing penetrations
l
l
Permanent submersion
l
Anchoring bolts/posts
l
Corners and profiles
l
Vertical/overhead repairs
l
Waterproofing/protection
l
l
Joint waterproofing
5-10
l
l
Joint sealing
10- 25
l
l
Bonding aids
< 25
l
EMACO ® Nanocrete R2
®
The basement level of the building was to be converted into dry commercial storage, retaining the original vaulted under pavements and maintaining the original footprint of the building. When selecting a waterproofing solution, the confined working space meant that limited methods of application were possible.
The Solution:
5-10
Sprayed concrete
Polymer-modified cementitious mortars
The Challenge
SHOTPATCH ® 12
< 25
The redevelopment of the former offices of the Irish Times on D’Olier and Fleet Street in Dublin has created a new landmark development housing a mix of contemporary commercial, retail, restaurant and high-end residential units over basement car parking. The scheme allowed for the retention of listed buildings and shop fronts along D’Olier Street but permitted the removal and redevelopment of buildings along Fleet Street and the construction of a large atrium connecting the original listed buildings with a new structure facing Fleet Street. With a gross floor area of 8427m2, 2309m2 was retained floor space with 6118m² being new floor space.
10- 25
Spalling over large areas Cover (mm)
Structural crack repair
Material category
Crack sealing
Featured Project: Irish Times Building, Dublin
®
THORO ® WATERPLUG
l
l l l
l
THORO DRYJOINT THORO ® WATERPACK
Elastomeric mortar
THORO ® FLEXIJOINT GLENIUM
Admixtures
l l
®
Hydro-swelling elastic compound
l
l
l
l
l l
l
l
l
l
l
®
l
l
RHEOFIT® 790 Series
l
l
RHEOCRETE 222+ ®
l
l
Curing compounds
MASTERKURE®
l
Form-release agents
RHEOFINISH ®
l
Waterproofing admixture and slurry
MASTERTOP ® SBR 570
l
Application
Acrylic polymer liquid additive
THORO ® ACRYL 60
l
The original floor levels were reduced to increase the ceiling height and the walls were underpinned. Reinforced concrete floor slabs were cast throughout the basement. A sand/cement mortar modified with THORO® Acryl 60 was used to repair/re-level sections of underpinning. A THORO® Waterplug fillet was applied to the floor–wall interface throughout the basement.
Capillary waterproofing slurry
MASTERSEAL® 501
Two coats of Thoroseal® modified with THORO® Acryl 60 were applied to the floors and walls by hand, using a stiff bristled broom. Once cured, the Thoroseal® on the walls was protected by a sand cement render. The floors were protected and levelled with MASTERTOP® 524 cementitious screed. In total an area of 1700m2 was treated.
THORO® WATERPLUG
THOROSEAL® SUPER GREY
Polyurethane resin joint sealants
Polymer-modified coatings and membranes
l
l
l
l l
l
MASTERFLEX® 474
l
l
MASTERFLEX® 462 TH
l
l
l
THOROSEAL®
l
l
l
THOROSEAL® SUPER
l
l
l
THOROSEAL FX100 ®
l
THOROSEAL® WR
l
l
l
l
l
l
l
l
l
References:
Middle East
United Kingdom
American Embassy, United Arab Emirates
Bank of England, London Stag Cottage, Devon Plasterton Gardens, Devon The Manor House, Devon
Asia Pacific
Europe
Guang Petroleum, China Rivervale Crest Condominum, Singapore Saigon Holiday Inn Building, Vietnam St Stephen’s School, Singapore
Henry J Lyons Architects’ Office, Dublin 20mm
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THORO® WATERPLUG
For further information visit www.basf-waterproofing.co.uk
THOROSEAL® SUPER WHITE
Basements & Vaults
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Wastewater Some of the harshest and most demanding conditions for construction materials are to be found within the sewerage industry. The usual long-term problems of reinforced concrete apply: carbonation through CO2 or acid rain attack leads to concrete spalling, freeze-thaw cycles affect surface sealing and deterioration, and workmanship problems of low cover and poor concrete mix design, all affect structural integrity. In addition, wastewater and sewerage treatment installations face a whole new range of aggressive conditions. Turbulent water flows and suspended solids lead to erosion and abrasion, while chemical attack from high sulphate levels and biogenically induced acid formation create an aggressive environment. These can lead to a rapid deterioration of concrete surfaces, corrosion of concrete reinforcement and steel structures. BASF Construction Chemicals has a long history of providing repair and protection solutions in this challenging environment, including cement-based coatings, highperformance polyurethane, polyurea and epoxy coatings and screeds, joint systems, corrosion inhibitors and cathodic protection solutions.
Protective Coatings Chemically resistant coatings and linings offer a technically acceptable, cost-effective method of enhancing the performance of reinforced concrete structures, including sewers. Where thin coatings of pure or modified resins such as coal tar or pitch epoxy have been commonly used in the past to reduce water permeability, newer products resolve health concerns as they bypass the potentially carcinogenic tar component.
Cathodic Protection
Repair mortars that use low C3A cements give a high sulphate resistance, while anti-osmotic epoxy cementitious underlayments and primers give chemical resistance prior to applying PU/solvent-free epoxy coatings. Whatever the system used, it must be able to resist hydrogen sulphide, sulphuric acid at a pH value of 1.0, microbial degradation and back pressure from hydrostatic loads from groundwater, without damaging the integrity of the membrane.
Cracks and spalling
Decanting trough (Outflow)
Sludge scraper
Settling zone
Many of the technologies now used to protect concrete from water ingress and prevent corrosion were once considered to have too short a life, or be too high a risk to be appropriate for the water industry. Solutions such as cathodic protection and water quality conditioning to control corrosion were available long before the privatisation of the water industry, but were either avoided or used to a very limited extent. BASF Construction Chemicals’ EMACO® CP60 system is designed specifically for reinforced concrete applications. Comprising highly conductive coated fibres, which are tri-dimensionally distributed throughout a polymer-modified cementitious mortar, this type of system can be wet-spray applied allowing easy installation, even overhead, with current feeder wires installed every two metres.
Inlet
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Sludge zone Sludge
1. RHEOCRETE® 222+, RheoFIT® & Glenium® concrete admixtures for waterproofing/chloride/sulphate resistance. 2. THORO® WATERPACK hydro-swelling, elastic compound, used with THORO® WATERPLUG ultra-rapid setting mortar to form a watertight seal. 3. MASTERSEAL® 501 capillary waterproofing surface applied slurry system, THORO® polymer-modified coatings and membranes. Also CONIPUR M805 spray applied polyurea membrane. 4. EMACO® CP60 spray-applied cementitious conductive anode system for reinforced concrete. 5. THOROSEAL WR® cement-based waterproofing render with sulphate resistance. 6. EMACO® Nanocrete concrete repair mortars for corners and profiles. 7. THORO® STRUCTURITE DWI approved rapid-setting, high-strength structural repair mortar.
Sewerage Rehabilitation Manual, 3rd edn, Vol III Sewer Renovation
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For further information visit www.basf-waterproofing.co.uk
Wastewater - includes pipes and manholes
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For more information go to www.barbourproductsearch.info Products
Application Spalling over small areas Cover (mm)
Protection against corrosion
Can be spray applied
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EMACO ® Nanocrete R3
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EMACO Nanocrete R4 Fluid
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THORO ® STRUCTURITE
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THORO ® STRUCTURITE R4
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Bonding aids
Sealing penetrations
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Permanent submersion
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Anchoring bolts /posts
Chloride/sulphate resistance
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Corners and profiles
Vertical/overhead repairs
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Waterproofing/protection
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Joint waterproofing
5-10
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EMACO ® Nanocrete R2
Joint sealing
10- 25
SHOTPATCH ® 12
Structural crack repair
< 25
Sprayed concrete
Crack sealing
5-10
Spalling over large areas Cover (mm)
10- 25
Opened in 2009, the vast Changi Water Reclamation Plant (CWRP) project in Singapore has involved the construction of the world’s largest covered sewage treatment plant. Replacing all existing local plants in Singapore, the CWRP is a compact and closed sewage treatment plant built using the latest technology. It is designed to treat 800,000m3 of waste water daily and can be extended to a daily maximum capacity of 2,400,000m3.
Material category
< 25
Featured Project: Changi Water Reclamation Plant, Singapore
®
Located at the eastern edge of Singapore, the plant is mainly underground and stacked for maximum compactness, taking up only 55 hectares, less than a third of the land area needed for a conventional layout. The plant includes facilities such as grit removal, primary sedimentation, bio-reactors with anoxic and aerobic zones, secondary sedimentation and sludge thickening and drying. The physical and biological treatment provided by the plant produce clean water of the highest international standards, suitable for discharge into the deep sea at the Straits of Singapore. The plant effluent will be suitable for reclamation in the future.
Polymer-modified cementitious mortars
THORO ® WATERPLUG
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Hydro-swelling elastic compound
THORO WATERPACK
Elastomeric mortar
THORO ® FLEXIJOINT GLENIUM
Admixtures
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RheoFIT® 790 Series
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RHEOCRETE 222+
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The client required a waterproofing membrane suitable for flat roofs and walls that would not only provide water tightness, but also add to the aesthetics of the plant’s vast roof.
MASTERTOP SBR 570
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Acrylic polymer liquid additive
THORO ® ACRYL 60
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Capillary waterproofing slurry
MASTERSEAL® 501
The Solution
Polyurethane resin joint sealants
CWRP is part of Singapore’s award-winning Deep Tunnel Sewerage System (DTSS), a $3.65 billion scheme planned to meet the island’s used-water needs for the next 100 years. Conceptualised and managed by Singapore’s national water agency, PUB, the mammoth DTSS conveys used water from homes and industries through a 48km long deep tunnel sewer that runs from 20 to 55 metres below ground to the centralised water reclamation plant for treatment.
For further information visit www.basf-waterproofing.co.uk
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MASTERFLEX 462 TH
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THORO FLEX 200
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THOROSEAL® FX100
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THOROSEAL WR
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MASTERSEAL® 190
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CONIPUR M805
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Chemical-resistant coatings
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Polymer-modified coatings and membranes
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Waterproofing admixture and slurry
BASF Construction Chemicals supplied 62,000m2 of CONICA® waterproofing membrane (CONIPUR® M800 + CONIPUR® TC 458 Pale Green) for the flat roof and a further 40,000m2 of CONIPUR® M800 for the basement walls.
23331_WaterProofing.indd 19-20
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The Challenge
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References: United Kingdom
Americas
Avonmouth Sewage Treatment Works Crawley Sewage Treatment Works Esher Sewage Treatment Works Newbury Sewage Treatment Works Great Harwood Sewage Treatment Works RAF Welford Sewage Treatment Works
Wastewater Plant, Zipaquira, Colombia Residual Water Processing Plant, ECHO-PETROL Refinery, Colombia
Asia Pacific CLK 525 Waste Water Treatment Plant, Hong Kong Misono Sewage Treatment Plant, Japan National Sewage Treatment Plant, Malaysia
Wastewater - includes pipes and manholes
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Potable Water Specifying waterproofing systems for the clean water sector is a complex area that involves balancing current and future performance criteria against cost and installation time constraints. A well-specified solution will lead to a cleaner, safer and more durable environment for the treatment and storage of potable water.
Corner repair
Roof joints
Internal waterproofing
Overhead repair
Service reservoirs can suffer from leakage, often through failed or poorly maintained movement or construction joints; in this instance a fully bonded overbanding system is recommended. The system must be able to accommodate movement and prevent the leakage and the ingress of water.
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Our systems are applied by trained specialist applicators to ensure long-term performance and all materials are manufactured to independently audited ISO 9001:2000 quality systems.
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Waterproofed joints
Cracked concrete
23331_WaterProofing.indd 21-22
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Service reservoirs and water tower roofs require waterproofing externally to stop the ingress of groundwater and airborne pollutants. Exposed roofs in particular have greater thermal stresses exerted on them and therefore demand a membrane with high movement capabilities as well as good mechanical properties. CONIPUR® membranes have been developed and successfully applied for over 25 years in just such circumstances, and are suitable for green roof designs. BASF Construction Chemicals’ competency in supplying systems to the water industry for both refurbishment and new-build projects is based on many years of experience gained across the world in a variety of climatic and service conditions. We offer a totally integrated approach to the design and installation of waterproofing and protection systems at every stage of the process.
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Surface coatings also play an important role in the refurbishment of concrete and brick reservoirs. Cement-based coatings such as BASF’s THOROSEAL® are compatible with the substrate, will resist positive and negative water pressure and are vapour permeable, reducing the risk of blistering. Where low pH and/or soft water are encountered, waterproof coating THOROSEAL® FX 100 is able to resist its aggressive nature and protect the structure. Our range of high performance coatings and repair mortars are ideal for application in confined spaces as they contain no volatile organic compounds and are easily applied to damp substrates. Recommended cementitious coatings for this sector are easily cleaned and will withstand pressure-washing and sterilisation.
Waterproof membrane
For further information visit www.basf-waterproofing.co.uk
1. CONIPUR® spray/hand applied highly elastomeric waterproof membrane. 2. THORO® WATERPLUG ultra-rapid setting mortar for crack sealing and rapid anchoring of metalwork in damp/wet conditions. 3. EMACO® NANOCRETE, THORO® Structurite repair mortars, suitable for profiles and corners. 4. THOROSEAL® FX100 elastomeric waterproof coating for concrete/ masonry in water-retaining structures. 5. THORO® FLEX 200 dynamic joint waterproofing system approved for use with potable water. 6. THORO® DRYJOINT pointing mortar for bricks, stone and concrete. 7. THORO® STRUCTURITE DWI approved rapid-setting, high-strength structural repair mortar. 8. MASTERFLEX® 900 re-injectable hose waterstop system for construction and cold joints in concrete. 9. MASTERSEAL® 345 spray-applied waterproofing membrane (for sandwich construction). 10. Glenium® and RheoFIT® admixtures to achieve durable performance.
Potable Water
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Legionnaires Disease is a bacteria that needs humidity and heat (32-45°C) to live and grow, making it a potential risk in the provision of potable water. Adequate maintenance of reservoirs and water systems and their disinfection by professional technicians forms the fundamental basis for its prevention. A variety of processes for water disinfection are available, but generally chlorine-based products are most commonly used.
Surface finishing Surface sealing
Thoro ® Acryl 60
Thoro ® Dryjoint
Thoro® Waterplug
Thoro® Flexi-joint
Thoro ® flex 200
Thoroseal ® PM
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Stopping active water
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Suitable Structures Reservoir roofs
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During the summer of 2001 the city of Murcia had its worst ever outbreak of Legionnaires Disease. As a result, a new maintenance programme for the provision of potable water was instigated to help prevent future outbreaks: this included the cleaning and disinfection of all installations at least once a year.
Water towers
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The Solution
Roller
For further information visit www.basf-waterproofing.co.uk
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MASTERSEAL® 531, a single component waterproof coating suitable for contact with potable water, was spray applied to the internal walls of the reservoir for faster, more uniform application.
Thoroseal ® FX100
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Thoroseal ®
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Concrete re-instatement
Reservoirs-internal: hard water
After cleaning joints and ensuring the absence of moisture, backer rods were installed to support polyurethane sealant MASTERFLEX® 474, a product suitable for permanent submersion and fully tested for water migration. After the sealant had cured, a layer of MASTERSEAL® 550 polymermodified waterproof coating was applied to fibreglass mesh placed over the joint to completely cover it. Once hardened, a second layer of MASTERSEAL® 550 was applied onto the reinforcement netting.
23331_WaterProofing.indd 23-24
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Reservoirs-internal: soft water
During the construction of Lorca Reservoir in 2004, an important element was the standardisation of joints to achieve maximum waterproofing. BASF elastomeric waterproof sealant MASTERFLEX® 474, was able to accommodate structural movement where applied to expansion joints and covered with EMACO® S88C Thixotropic repair mortar.
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The Challenge
Emaco ® NANOCRETE R4
BASF Construction Chemicals’s systems were specified in the construction of Lorca Reservoir, a key reason being that the company was able to supply certification that verified its waterproofing products were suitable for use with potable water and would resist submersion in a chloride solution.
Emaco ® NANOCRETE R2
Featured Project: Lorca Reservoir, Cartagena, Spain
THoRO® Structurite
For more information go to www.barbourproductsearch.info
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References:
Europe
United Kingdom
EYDAP, Greece
Alnwickhill CTW, Scotland Boughton Service Reservoir Clandan Service Reservoir, Wales Layer De La Haye Service Reservoir Southall Water Tower St Georges Hill Service Reservoir Kilmundy Service Reservoir, Scotland
Asia Pacific
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Bukit Batok Reservoir, Singapore Hai Duong Water Supply Plant, Vietnam Tone Waterworks, Japan Shek Kei Mei Reservoir, Hong Kong Upper Pierce Reservoir, Singapore
Potable Water
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Reservoirs, Dams and Waterways Injection
Watertight Joints
Waterproofing a water-retaining structure of the magnitude of a dam begins with ensuring that seepage through the substrate is controlled. If geological conditions necessitate either curtain grouting or consolidation grouting, BASF Construction Chemicals recommends RHEOCEM® micro-cements for rock and MEYCO® MP320T Colloidal Silica for sands and soils.
Admixtures
Water-reducing agents (WRAs) such as BASF’s POZZOLITH® and GLENIUM® high-range waterreducing/superplasticising admixtures can be used to significantly reduce water demand, and our set retarding admixtures usefully delay setting times in high ambient temperatures. Alternatively, in low ambient temperatures our set accelerating admixtures can enhance the setting time of concrete. Facing concrete
BASF Construction Chemicals understands that, whatever the dam’s design, the performance characteristics of the mass concrete used is crucial. Concrete must provide satisfactory density and strength, durability, low thermal volume change, resistance to cracking, low permeability and economy.
Also appropriate for RollerCompacted Concrete (RCC), MASTERKURE® curing compounds can be applied to delay evaporation, improve finish and eliminate the occurrence of plastic shrinkage cracking whilst our RHEOFINISH® form release agents provide a smooth concrete surface.
BASF’s MASTERFLEX® 900 re-injectable hose waterstop system, for construction and cold joints in concrete, is designed as an alternative to waterbars where joints other than expansion joints are subjected to hydrostatic pressure on one or both faces of the structure. Its use prevents the passage of water through joints, recommending it for use in dams amongst other applications.
Water
MASTERFLEX® 900 eliminates the costly design, welding and installation of waterbars and, unlike traditional installations where water is in contact with the reinforcement up to the waterbar, water cannot penetrate the treated joint and rebar. Installation is fast and easy, even with complicated design details, and joints can be tested for watertightness. Offering proven, predictable performance, the system can be retro-injected to stop leaks caused subsequently by settlement or structural movement at the construction joint.
Uplift pressure relief drains
Hearting concrete
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Whilst density, strength, durability and impermeability are improved by increased cement contents and reduced water/cement ratios, thermal characteristics, volume stability and economy are improved by restricting the cement content. The use of admixtures can help to find the balance between these conflicting demands, particularly where concrete zoning is employed for increased economy. Our MICRO-AIR® air-entraining agents (AEAs) will significantly improve the concrete’s long term freeze-thaw resistance, with a further benefit being the reduction in water demand of the fresh concrete and improved handling qualities.
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For further information visit www.basf-waterproofing.co.uk
1. MICRO-AIR®, POZZOLITH®, GLENIUM® & RheoFIT® admixtures to achieve durable performance. 2. RHEOCEM® and MEYCO® systems for injection grouting. 3. MASTERKURE® curing compounds for roller-compacted concrete. 4. RHEOFINISH® form-release agents. 5. MASTERFLEX® 900 reinjectable hose system for joints. 6. EMACO® and THORO® polymer-modified cementitious repair mortars.
Novak, P., Moffat, A.I.B., Nalluri, C. & Narayanan, R. (1990) Hydraulic Structures. London, Unwin Hyman. Novak et al (1990) Hydraulic Structures. London, Unwin Hyman.
Reservoirs, Dams and Waterways
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Featured Project: Karun 3 Dam and Hydro Power Plant, Iran
Ground Conditions
The Karun 3 Dam and Hydro Power Plant generates around 4.172 MKWH of power, controls seasonal floodwater and provides agricultural water in the region. A double-arched concrete dam standing 185m high from the surface of the river and 205m from its foundations, its crest is 462m long and measures 29.5m in width at its bottom and 5.5m at its top. The construction included approximately 22km of underground tunnels and involved 2.7 million m³ of concrete. The volume of the resulting reservoir is around 3 billion m³.
Penetration in Rock
Stabilisation of Soils
Rockmass fissure size (mm)
Rockmass fissure size (mm)
The Challenge
As a safeguard for consumption of the product, an additional 20% was insured within the agreement. The client’s satisfaction with price and quality in comparison with the other tendering companies was such that, even after the concrete works were finished, they requested that the extra 20% mentioned in the agreement was still purchased and distributed amongst their other projects at the time!
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EMACO ® Nanocrete R4
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EMACO ® Fast Fluid/Fibre/Tixo
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Elastomeric mortar
THORO ® FLEXIJOINT
Product
Quantity/Consumption
Pozzolith® LD 10
More than 3 million litres
Glenium® 51
400,000 litres
Rheobuild® 1100
20,000 litres
Anti-washout admixture
RHEOMAC ® UW 450
Meyco SA 540
10,000 Kg
MASTERTOP SBR 570
Emaco® S 45
20,000 Kg
Waterproofing admixture and slurry
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References:
Admixtures for mass concrete
Polyurethane resin joint sealants
POZZOLITH ®
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South America
Sondu Miuiu Hydro Electric Power Project, Kenya
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THOROSEAL® FX100
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THOROSEAL® WR
Asia Pacific
MASTERSEAL® 501
Balambano Hydro Power Plant, Indonesia Kinta Dam, Malaysia Nathpa Jhakri Hydro Power Project, India Three Gorges Dam, China
MASTERSEAL® 345
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Africa
Polymer-modified coatings and membranes
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Glendoe Dam, Scotland, UK Mont Saint Michel Dam, France
For further information visit www.basf-waterproofing.co.uk
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THORO ® FLEX 200
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Europe
Rio Estí Hydroelectric Project, Panama Regional water system, La Rioja, Argentina Turbine foundations repair, Guadalupe IV Hydrolelectric Project, Colombia Waterways, Tuxapan Thermoelectric Power Plant, Mexico
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MASTERFLEX® 900
Curing compounds
MASTERKURE®
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Form-release agents
RHEOFINISH ®
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Reduced water demand
Can be spray applied
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Protection against corrosion
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Corners and profiles
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Vertical/overhead repairs
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Bonding aids
5-10
SHOTPATCH ® 12
Structural crack repair
< 25
10- 25
Sprayed concrete
Spalling over small areas Cover (mm)
Spalling over large areas Cover (mm)
Crack sealing
5-10
BASF was able to put forward the best price by proposing the supply of Pozzolith LD 10, in powder form, for the project and offering assistance to the contractor in assembling a liquidising unit at the job site. This eliminated the extra cost required to transport liquids to the project, about 800km away from the supply source. BASF was able to provide all the aspects of high performance concrete (HPC), using the polycarboxylic ether (PCE)-based superplasticiser Glenium® 51 to produce exceptional results for the spillway structures.
Products
< 25
The Solution
Application
Material category
10- 25
The consultant involved in the project was concerned that the admixtures to be supplied would not achieve the high-performance, high-quality concrete necessary to construct the spillway in accordance with the designed specification. BASF Construction Chemicals was one of four approved chemical supplier companies tendering, competing in a very tough, close pricing scenario.
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For more information go to www.barbourproductsearch.info
Marine Structures and Defence From seawalls to bridge piers and breakwaters, the key factor for the durability of coastal concrete is its degree of exposure, which affects the level of saturation and the frequency and rate of wetting and drying. Recent research shows that it is the presence of cracks, not their width, that has the greatest influence on durability. Water is the one common factor in the chemical/ physical deterioration of the concrete, physical damage and corrosion of reinforcement.
Construction Products
Joint
Cracks and spalling Higher concentration of salt on horizontal surfaces
Damage to sea wall from boat hulls
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Corners vulnerable to spalling
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Admixtures 9 3
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Splash
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Underw
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Increased salt concentration near bollards/ drainage channels Worst deterioration
Spray-applied mortars for large-scale refurbishment, high-performance patch repair products, joint sealants, protective coating and membranes: BASF Construction Chemicals has the solution for just about every maritime concrete repair imaginable, including the essential repair of cracks. The products we recommend for coastal use will contribute to extending the life-span of concrete in the most aggressive of environments. Cathodic protection is a tried and tested technique for maritime structures suffering from chloride ingress; products from our EMACO® Nanocrete range support this solution.
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Increasing oxygen availability
Atmosp
Increasing moisture content and chlorides
The best way to ensure durability is to start off with dense, impermeable concrete that restricts the ingress of water, using the appropriate admixtures to achieve optimum performance. Using admixtures within the mix design will help to achieve this: GLENIUM® highrange water-reducing/superplasticising admixtures and RheoFIT® waterproofing admixtures can be introduced at batching stage to provide permanent integral waterproofing and corrosion resistance. The BASF Watertight System will produce a concrete that provides protective and integral permeability reduction, producing dense, structurally sound concrete for marine environments subject to tidal and wet/dry cycling. Underwater application of concrete is possible using our anti-washout admixture RHEOMAC® UW 450.
It is hardly surprising that coastal concrete is often in a state requiring repair. As well as the usual damaging effects of sulphate attack, alkali silica reaction (ASR) and freeze-thaw cycle, it suffers from salt crystallisation and scaling to a greater degree, as well as abrasion caused by sediment in the seawater and shipping impact. Chloride ingress caused by seawater is a major contributor to the corrosion of reinforcement within the concrete.
1. EMACO®Fast rapid setting repair mortars suitable for use on pedestrian walkways in marine environments. 2. THORO® WATERPLUG ultra-rapid setting mortar for crack sealing and rapid anchoring of metalwork in damp/wet conditions. 3. THORO® and MASTERFLEX® sealants for damp/immersed joints. 4. THORO® STRUCTURITE R4 and EMACO®Fast rapid setting repair mortars suitable for use in cracked and spalled areas including the splash zone. 5. RHEOMAC® UW 450 anti-washout admixture for underwater repairs. 6. EMACO® NANOCRETE structural repair mortars, suitable for profiles and corners. 7. EMACO®Fast, SHOTPATCH® 12, EMACO® Nanocrete, THORO® STRUCTURITE R4: all suitable for large-scale concrete repairs. 8. EMACO® Nanocrete, SHOTPATCH® 12, THORO® STRUCTURITE R4: overhead concrete repairs. 9. GLENIUM®, RheoFIT® 791 Series, RHEOCRETE® 222+: admixtures for durable, waterproof concrete in marine environments.
Leeming, M.B. (1989). Concrete in the Oceans programmer co-ordinating report on the whole programme. Offshore Technology Report OTH 87 248, HMSO. Allen, R.T.L, Concrete in Coastal Structures.
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23331_WaterProofing.indd 29-30
For further information visit www.basf-waterproofing.co.uk
Marine Structures and Defence
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Using SCC by-passed these problems, as once pumped into place it needed no compaction. BASF admixtures GLENIUM® 51 and MEYCO® MS 685 were added to 10mm gravel aggregate concrete supplied by Lafarge Ready Mix, which was placed by contractor Nuttalls.
Cathodic Protection
Protection against corrosion
Can be spray applied
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
EMACO Fast Fluid Fibre Tixo
l
l
l
l
l
l
l
THORO ® Structurite R4
l
l
l
l
l
l
l
l l
®
l
l l
l l
l
l
l l
THORO ® Flexijoint
l
l
l
GLENIUM ®
l
l
RheoFIT® 790 Series
l
l
RHEOCRETE 222+
l
Anti-washout admixture
RHEOMAC UW 450
l
Waterproofing admixture and slurry
MASTERTOP ® SBR 570
®
l
l
l
MASTERFLEX® 474
l
l
MASTERFLEX 462 TF
l
l
®
®
l
l
l
®
Structural strengthening systems
l
EMACO Nanocrete R2
THORO ® Dryjoint
Polyurethane resin joint sealants
Underwater application
Permanent submersion
Anchoring bolts/posts
Corners and profiles
5-10
< 25
5-10
Pedestrian walkways
l
Vertical/overhead repairs
l
l
EMACO ® Nanocrete R4
THORO Waterplug
Admixtures
Waterproofing/protection
MBRACE Kevlar Aramid Sheet
l
®
Elastomeric mortar
Joint waterproofing
l
< 25
Polymermodified cementitious mortars
Joint sealing
l
l
®
Application Over 250m³ of SCC was poured into the area, which measured 27m x 17.5m, with a depth of 0.4m. The concrete penetrated the full 1.5m depth of the piles, displacing the residual water with no overwash. The pour was completed with a single concrete pump in just six hours. The Immingham ABP Oil Terminal SCC project was used for research by the Concrete Society Working Party on Self-Compacting Concrete.
SHOTPATCH ® 12
Bonding aids
Flexural strengthening of concrete
The Solution
Sprayed concrete
Structural crack repair
MBRACE® Carbon Fibre Wrap
The Challenge At the time of construction, the UK’s largest single pour of self-compacting concrete (SCC) took place during repairs carried out at Associated British Ports’ Oil Terminal at Immingham on the North East coast of Lincolnshire. The area to be repaired was located at the end of a jetty and was problematic because its reinforcement was extremely congested. The upstanding reinforcement prevented access for the conventional placing and compaction of concrete and, moreover, the 1.5m deep steel piles supporting the area contained residual water, also a potential obstacle.
Spalling over small areas Cover (mm)
Spalling over large areas Cover (mm)
Crack sealing
Confinement of concrete
Application
10- 25
Material category
10- 25
Featured Project: Associated British Ports’ Oil Terminal, Immingham, UK
l l l
®
MBRACE Laminated Plates ®
Polymermodified coatings and membranes Silane treatments
l
THORO ® FLEX 200
l
l
THOROSEAL FX100
l
l
®
THOROSEAL® WR MASTERSEAL® 345
l
l l
l
l
l
l
l
l
l
l
l
PROTECTOSIL® CIT
l l
l
References: United Kingdom
South America
Asia Pacific
Immingham Oil Terminal Trinity Pier, Harwich
Container Terminal, Paranaguá, Brazil International Terminal, Puerto San Antonio, Chile Pluspetrol Marine Terminal, Piso, Peru.
Redcliffe Jetty and Seawall. Australia Jebel Ali Free Zone, UAE Queen’s Pier, Hong Kong Port of Singapore Tai Chung Harbour, Taiwan
Europe Autoterminal “Port Barcelona”, Spain Container Terminal Born, Netherlands London Berth, Jersey Harbour, Channel Islands
30
23331_WaterProofing.indd 31-32
For further information visit www.basf-waterproofing.co.uk
Marine Structures and Defence
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Swimming Pools Swimming pools must not only retain water but prevent the infiltration of groundwater when fully or partially empty. Open air pools can also face problems caused by the freeze-thaw cycles. Aggressive acids, sulphates and other chemicals in the subsoil must also be taken into consideration, for instance: the organic acids in moorland water can damage concrete and cement-based mortars. Advice on dealing with difficult subsoil conditions is given in BRE Special Digest 1, Concrete in Aggressive Ground (2005).
Tanking
Pool Surrounds and Deck Areas
A comprehensive, reliable waterproofing solution is to tank the pool and surrounding area with our special permanent waterproofing system PCI Seccoral® 2K. Designed for use under ceramic coverings, Seccoral® 2K offers the advantages of a cement/polymer combination for successful waterproofing and crack
Tiled Walls Rendering and screed
Permanently wet areas such as pool surrounds and deck areas, often combined with underfloor heating, must be laid to sufficient falls of at least 2%, in accordance with BS 5385. We advise waterproofing the substrate in these areas with PCI Seccoral® 2K before tile fixing.
Tile Fixing and Grouting When specifying a suitable tile adhesive and grout for use in swimming pools, it is essential to choose the most appropriate. You have to take into account the following factors: background, type of tiles selected, chemical balance of the pool water and the intended use of the pool. BASF Construction Chemicals offer a complete range of adhesives and grouts to suit all requirements e.g. PCI Tilefast 6 Flex®, PCI Nanolight®, PCI Collastic® tile adhesives. As far as grouts are concerned BASF Construction Chemicals can offer a real alternative to an epoxy - PCI Durafug® NT; it offers high resistance to chemicals and mechanical stress and applies like any other cementitious grout. PCI Durapox® NT Plus grout is also available when only an epoxy will do.
Subsoil
8
More porous than concrete, handapplied mortars, rendering and tile adhesives are vulnerable to chemical attack and require careful specification. Once the swimming pool is in service, locating and repairing leaks is an extremely costly process, particularly if ceramic coverings have been used. BASF Construction Chemicals’ advanced product range and onestop specification service can help to prevent the likelihood of future waterproofing problems.
7
6
5
4
Watertight Joints In water-retaining structures such as swimming pools where construction joints can be waterproofed by grout injection, BASF Construction Chemicals’ MASTERFLEX® 900 re-injectable hose system offers a watertight solution. A preventive system that avoids the many disadvantages of waterbars, it can be re-tested and re-injected at any time.
bridging while allowing the passage of vapour to avoid damage from osmotic pressure. It is used in conjunction with our special waterproofing tape PCI Pecitape® for extra protection at corners and wall/floor junctions and with PCI wall and floor gaskets where required.
3
1 2
Connection joint
Concrete cast pool shell
9
1. PCI Pericret® & EMACO® Nanocrete concrete repair materials. 2. PCI Silcoferm® VE elastomeric joint sealants. 3. PCI Seccoral® waterproofing/tanking system. 4. PCI Pecitape ® special waterproofing system for waterproof corner and perimeter joints. 5. PCI Tilefast® and Nanolight series and Collastic ® tile adhesives. 6. PCI Aquafug®, Durafug NT® and Durapox NT tile grouts. 7. PCI Tilefast® and Nanolight series and Collastic ® tile adhesives. 8. PCI Aquafug®, Durafug® NT and Durapox® NT tile grouts. 9. Glenium® and RheoFIT® for durable waterproof concrete.
Perkins, Philip H, Swimming Pools 4th edn, Taylor & Francis 2000
32
23331_WaterProofing.indd 33-34
For further information visit www.basf-waterproofing.co.uk
Swimming Pools
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The Challenge The design of the National Aquatic Centre incorporated a range of facilities within the 20,000m2 project, from the international FINA standard 50m x 25m championship pool to a 25m diving pool with four diving platforms at 3m, 5m, 7.5m and 10m heights and a floating floor which could change its depth. The AquaZone, one of the most technically innovative water parks in Europe, completed the wet facilities. Reliable, high performance products were needed to ensure that each area was fully waterproofed and could accommodate various technical demands.
Bonding agent
l
l
l
Fast-track screeds
Waterproofing systems
l
l
l
l
l
l
l
l
l
l
l
PCI Seccoral ® 2K
l
l
l
l
l
l
l
PCI Pecitape ®
l
l
l
l
l
l
l
l
l
l
l
PCI Pecidur ®
l
l
l
l
PCI Pecidur ® Wellness
l
l
l
l
PCI Silcoferm ® VE
l l
PCI Silcoferm S ®
l
l
l
l
l
l
l
l
l
l
l
l
l
l l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
PCI Tilefast ® 6 Flex
l
l
l
l
l
l
l
The high profile project was a PCI specification throughout, the original specification being broken following the advice and technical support of PCI. As a result of this successfully completed prestigious project, PCI is now perceived as the experts in Ireland on swimming pool installations. PCI has since completed over 30 pool projects in Ireland, demonstrating its expertise and the ability to deliver to specification.
PCI Tilefast ® 6 Rapidflex
l
l
l
l
l
PCI Nanolight
l
l
l
l
l
l
l
l
PCI Nanolight ® Rapid
l
l
l
l
l
l
l
l
PCI Collastic
l
®
PCI Floorfast ® 20 Rapid
l l
l
l
l
l
l
l
l
l
l
PCI Aquafug ®
l*
l
l
l
l
l
l
PCI Durafug ® NT
l*
l
l
l
l
l
l
PCI Durapox ® NT Plus
l*
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
PCI Wall & Floor Grout PCI Pecilastic W ®
A
l
l
l
PCI Tilefast ® 6 + PCI Grout/Adhesive Admix
®
l
l
l
PCI Tilefast 6 Rapid
PCI Apogel® - Sealant
l l
l
The Solution
PCI Silcoferm® - Sealant
l l
l
l
PCI Elritan® - Sealant
l
l
l
Separation fabric underlay
l
l
l
PCI Seccoral® 2K - Waterproofing system
l l
l
l
Products used:
l l
l
l
Tile Grouts
l l
l
®
Tile Adhesives
l
l
PCI Novoment ® M3
PCI Pecibord ®
Silicone joint sealants
l l
l
PCI Novoment ® M1
PCI Lastogum ® X
Tileable waterproof construction boards
l l
l l
Can be spray applied
l
PCI Repahaft ®
l
Protection against corrosion
EMACO Nanocrete R4 ®
l
Levelling
l
Permanent submersion
l
Corners and profiles
l
l
Soffits
l
l
Waterproofing/protection
l
l
Joint waterproofing
l
l
Joint sealing
l
l
Steel/Metal/GRP
Outdoor use
l
EMACO ® Nanocrete R2
Structural crack repair
Indoor use
PCI Pericret ®
Crack bridging
Floors
Application
Walls
Concrete repair
Products
Adjacent rooms
The National Aquatic Centre houses the first commercial 50 metre Olympic Pool in Ireland and was the host venue for the Special Olympics in 2003. This magnificent complex brings together international championship sporting events alongside state-of-the-art family leisure. Part of an expanding government-sponsored sports campus, it cost €70 million to build.
Material category
Shell and surround
Featured Project: National Aquatic Centre, Dublin, Ireland
l
l
* Subject to water analysis report. A
Surround only.
PCI Epoxy Grout ® - Adhesive PCI Tilefast ® 6 White/Flex White - Adhesives PCI Floorfast ® 20 Rapid - Adhesive PCI Pericret ® - Levelling Compound PCI Novoment ® - Mortar
References: United Kingdom
Europe
Ashford Leisure Centre, Kent Cardiff International Pool, Wales Chelsea Football Club Training Academy, London Deptford Leisure Centre, London Durham Leisure Centre, Co. Durham
De Peppel Swimming Pool, Netherlands Villetaneuse Olympic Swimming Pool, France Thermal Spa, Glücksburg, Germany
Ireland National Aquatic Centre, Dublin Sheraton Fota Island Golf Resort & Spa Trinity College, Dublin
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23331_WaterProofing.indd 35-36
For further information visit www.basf-waterproofing.co.uk
Asia Casino, Macau, China
Ships MS Norwegian Jewel
Swimming Pools
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Secondary Containment / Bunds As a second line of defence for preventing, controlling or mitigating major hazard events, secondary containment is an essential measure for petro-chemical storage. Around 25% of all water pollution incidents involve oil and a significant proportion of these incidents involve oil storage tanks with inadequate or non-existent bunding. According to the Health & Safety Executive, maintenance of bunds is often overlooked, particularly in remote locations.
Specifying for Safety
Surface Membranes
Starting with structural design, BASF Construction Chemicals can help to ensure that concrete mix designs meet performance requirements. For example, water/ cement ratio is the most important factor and the lower the water/cement ratio the lower the permeability of the concrete. Our GLENIUM® high range water reducing/ superplasticising admixtures can be used to improve the workability of a low water content concrete mix, enabling more thorough compaction and lower permeability. Furthermore, our RheoFIT® water resisting admixtures provide a waterproof product with minimum effect on the original appearance and texture.
Joints Surface membranes Reinforced concrete
4
Clearly, structurally sound, regularly inspected secondary containment is essential to ensure the safe storage of hazardous liquids. Bunds may have to withstand both the static and dynamic loads of the liquid as well as its additional weight in the event of storage tank failure, not to mention ongoing thermal and shrinkage stress. Here defective or weak concrete can present a real risk, and CIRIA recommends that materials that can offer a minimum 50-year service life be specified. To achieve an impermeable structure, bund walls should be designed in accordance with BS 8110 (1997) or BS 8007 (1987) in combination with bund floors built to BS 8007, the recognised design code for water-retaining structures.
We can also recommend suitable waterstops and chemically resistant joint sealing compounds – here our MASTERFLEX® 900 re-injectable hose system for construction joints offers a watertight solution. A preventive system that avoids the many diasadvantages of waterbars, it can be re-tested and re-injected at any time. 4
Finally, our range of coatings and surface treatments supply additional protection: epoxy mortar renders are recommended for sumps in particular, as these areas endure more abrasion than other parts of the bund.
5
3
7 8 6 1
2 Polythene slip membrane Blinding concrete Foundation/hardcore Subsoil
1. GLENIUM® high range water reducing superplasticisers and RheoFIT® water resisting admixtures, suitable for reinforced concrete: ground slabs, walls and foundations. 2. GLENIUM® high range water reducing superplasticisers within blinding concrete under slabs/foundations. 3. MASTERFLEX® polyurethane resin joint sealants, THORO® FLEX dynamic joint waterproofing system. 4. CONIPUR® M805 chemically resistant polyurea coating. 5. EMACO® Nanocrete polymer-modified repair mortars, THORO ® Structurite rapid-setting high-strength structural repair mortars. 6. MASTERFLEX® 900 reinjectable hose system for construction joints. 7. EMACO® FAST concrete repair mortars for ultra-rapid strength build up. 8. UCRETE® RG render grade heavy-duty polyurethane screed with exceptional chemical and heavy impact-resistance.
CIRIA Report 163 Construction of Bunds for Oil Storage Tanks, p. 3 HSE Technical Measures Document: Secondary Containment CIRIA Report 163 Construction of Bunds for Oil Storage Tanks, p.30
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23331_WaterProofing.indd 37-38
For further information visit www.basf-waterproofing.co.uk
Secondary Containment / Bunds
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The solution met the expectations of the client, passed leakage testing and was approved by both internal agencies and external regulators, serving as a successful model for similar storage arrangements across Companhia Vale do Rio Doce’s other mines. Chemicals
MASTERTOP TC473
Conipur M805
UCRETE
Protection against corrosion
Can be spray applied
l
l
l
l
EMACO ® Nanocrete R3
l
l
l
l
l
l
l
l
l
l
l
EMACO ® Nanocrete R4
l
l
l
l
l
l
l
l
l
l
l
Polymer-modified cementitious mortars
EMACO Nanocrete R4 Fluid
l
l
l
l
l
l
l
l
EMACO ® FAST Fluid/Fibre/Tixo
l
l
l
l
l
l
l
l
THORO ® STRUCTURITE R4
l
l
l
l
l
l
l
l
Waterproofing admixture and slurry
MASTERTOP ® SBR 570
l
Acrylic polymer liquid additive
THORO ® ACRYL 60
l
l
l
MASTERFLEX 462 TH
Polymer-modified coatings and membranes
l
THORO FLEX 200
l
l
THOROSEAL® FX100
l
l
Heavy-duty Polyurethane screed
l
l
l
MASTERSEAL 190
l
l
l
l
l
UCRETE® RG
l
l
®
R
R
R
Diesel Fuel
R
L
R
Phosphoric Acid (10%)
L
R
R
Bund floors/walls
Standard
BS 8007
Hydraulic Oil
R
R
R
Standard
Lactic Acid (10%)
NR
R
R
Reinforced concrete: ground slabs
CIRIA Report 163 Recommendations (where given) Standard Internal
R
Hydrochloric Acid (37%)
L
R
R
Sulphuric Acid (50%)
R
L
R
R = Resistant (greater than 28 days permanent immersion) NR = Not Resistant (damage will occur in less than 24 hours) L = Limited Resistance (Resistant for up to 3 days continuous immersion)
For further information visit www.basf-waterproofing.co.uk
Concrete grade
Blinding concrete under slabs/ foundations Concrete fill to reinforced blockwork
Water/cement ratio
BASF Admixtures GLENIUM® & RheoFIT®
325
Max 0.55
C35A
325
Max 0.55 - CEM I Max 0.50 - CEM II/B-V
GLENIUM® & RheoFIT®
BS 8007
C35A
325
Max 0.55 - CEM I Max 0.50 - CEM II/B-V
GLENIUM® & RheoFIT®
Standard
BS 8500
C40
325
Max 0.55
GLENIUM® & RheoFIT®
Standard
BS 8500
RC40
340
Max 0.45
GLENIUM® & RheoFIT®
Standard
BS 8007
C35A
325
Max 0.55 - CEM I Max 0.50 - CEM II/B-V
GLENIUM® & RheoFIT®
Standard
BS 8500
GEN2
200
-
GLENIUM®
Standard
BS 8007
C20
-
-
GLENIUM®
Standard
BS 8500
GEN2
200
-
GLENIUM®
External
Reinforced concrete: walls and foundations
Min. cement content kg/m2
C30 BS 8500
Bund walls
R
l
l
Chlorinated Water
R
l
l
R
Sodium Hydroxide (50%)
l l
L
United Kingdom
l
l
NR
References:
l l
l
l
Acetic Acid (25%)
R
l l
l
R
R
l
CONIPUR® M805
L
L
l
THOROSEAL WR
R
R
l l
®
Chemical Resistant Coatings
l
l
l
THOROSEAL® ®
l
l
®
Ammonium Hydroxide (32%)
NR
l
MASTERFLEX® 474
Heavy-duty Polyurethane
R
l
THORO ® WATERPACK
Elastomeric Polyurea
Motor Oil
l
Hydro-swelling elastic compound
Polyurethane resin joint sealants
Joint sealing
®
Solvent Free Epoxy
Methanol
l
Sealing penetrations
l
Permanent submersion
l
Anchoring bolts/posts
l
Corners and profiles
l
l
Chemical resistance
l
l
Vertical repairs
5-10
l
l
Waterproofing/protection
10- 25
l
EMACO ® Nanocrete R2
Joint waterproofing
< 25
SHOTPATCH ® 12
Bonding aids
5-10
Sprayed concrete
Structural crack repair
10- 25
The oil storage tanks concerned contained supplies of diesel which amounted to 40% of the truck fleet’s fuel consumption, delivered by train via the company’s internal rail system on the site. The steel storage tanks were fixed inside secondary containment bunds constructed of concrete, linked to a concrete sump that separated the water and oil.
Following research and consultations with the client, MASTERSEAL® 515 elastomeric waterproof coating was specified as a base coat for the bund, onto which MASTERSEAL® 1390 reflective acrylic paint was applied over an area totaling 125m².
23331_WaterProofing.indd 39-40
Spalling over small areas Cover (mm)
The Challenge
The Solution
38
Application Spalling over large areas Cover (mm)
BASF Construction Chemicals needed to offer the client a product that was resistant to oil attack and also met the new regulatory requirements.
Huntsman Tioxide, Hartlepool Avecia, Redcar and Corby Ellis and Everard, Gateshead Millenium Inorganic Chemicals, Immingham Novartis Pharmaceuticals, Grimsby Shasun Pharmaceuticals, Dudley Bio diesel plant, Vivergo BP, Immingham
Products
< 25
To meet the requirements of new environmental legislation, mining company Companhia Vale do Rio Doce in Itabira, Brazil, needed to create a remote secondary waterproofed container to separate the collection of water and oil discharged from its storage tank bunds. Regulations specified that the secondary container must be waterproofed with products chemically resistant to oil.
Material category
Crack sealing
Featured Project: Remote Secondary Container, Brazil
C40
GLENIUM® & RheoFIT®
The above table is for guidance purposes only. For specific technical advice please e-mail us at:
[email protected]
Secondary Containment / Bunds
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Car Parks - Exposed Decks, Multi-storey and Underground Top Decks
Car park surfaces are constantly exposed to aggressive chemicals as a result of oil and acid spills and carbon dioxide gases. Surface salt deposits in coastal areas with a saline atmosphere, climatic conditions such as humidity, rain, and the impact of de-icing salts all contribute to a corrosive environment, the effects of which are worsened if cracks already exist in concrete decks. The use of a protective waterproofing membrane is therefore essential to reduce wholelife costs and down time caused by the maintenance of deteriorating surfaces. The function of BASF’s CONIDECK® systems extends beyond waterproofing protection to the practical considerations of skid resistance, demarcation of parking bays, traffic lanes and pedestrian walkways. Systems that vary the deck surface through the use of colours and light-reflective coatings improve usability, increase aesthetics and create a safe, welcoming atmosphere.
A single system across an entire parking structure is unlikely to be the best solution. The top deck of a car park is the structure’s most vulnerable surface, exposed to the elements as well as to oils, acids, salts and UV radiation. To withstand such severe conditions, heavy-duty, UVstable, elastomeric waterproofing systems are needed.
1
5
CONIDECK® car park systems are approved by the British Board of Agrément, fulfil the requirements of the German OS-F specification for crack-bridging coating systems designed to take traffic, and hold the French ATEX approval.
23331_WaterProofing.indd 41-42
Our solutions for car park top decks provide exceptional tensile strength and elastomeric capability. Double the thickness of most products, they use a multi-layer buildup system to ensure optimum performance, even in the harshest environments. Spray application speeds up the installation process and gives controlled thickness. CONIDECK® Systems can easily bridge cracks of up to 2.5mm in width and offer a high level of mechanical resistance, while top coats are available in a wide range of colours.
6
The CONIDECK® range of solventfree, crack-bridging and non crackbridging polyurethane membranes and wear-and-tear resistant car park deck coatings covers both exposed and covered decks. Our tough wear coats provide exceptional durability, while a coloured top coat gives design flexibility.
40
8
8
For further information visit www.basf-waterproofing.co.uk
Lower Decks Enclosed, intermediate and lower decks are protected from weather conditions to a large degree and although still exposed to aggressive de-icing salts are less susceptible to stress than top decks. A range of CONIDECK® systems for light to medium duty operations take this into account.
2 9 7
2 2
3 4 2
1
1
1. CONIDECK® elastomeric waterproof deck membranes: spray or hand applied elastomeric crack bridging membranes to provide guaranteed long term protection even in heavy-duty wear areas such as ramps and turning circles. 2. CONIDECK® intermediate car park deck coatings: solvent free and water dispersed floor coatings, available in a variety of colours. 3. EMACO® Nanocrete cementitious concrete repair systems: for small or large scale replacement of spalled or damaged concrete. 4. MASTERSEAL® protective coatings for anti carbonation and antigraffiti: aesthetic improvement and protection to delay the onset of corrosion. 5. EMACO Fast® traffic repair mortars: for rapid setting repair of potholes, joint arrises, etc. with a minimum down time and loss of revenue. 6. EMACO CP® cathodic protection systems: for the only permanent solution to heavily chloride contaminated concrete structures. 7. MASTERFLEX® structural adhesives and Concresive® resin injection systems: for repair of non-moving cracks. 8. MASTERFLOW® cementitious and resin grouts: for anchoring barriers, external cladding, etc. 9. MBRACE® systems for structural strengthening and increasing load bearing capability: carbon and aramid fibre tow sheets, laminates and rods with MBRACE® resin systems.
Car Parks - Exposed Decks, Multi-storey and Underground
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Accommodating over 2000 cars in total, the deck area covered with CONIDECK® amounted to around 60,000m². With the four parking levels situated at depths of 0.5, 3.0, 6.5 and 9.7 metres, the contractor was working with no natural daylight, and the nature of underground working meant that it was important to employ techniques that minimised the production of dust when blasting decks, particularly as deck membrane installation took place before the car park’s extraction system was operational.
The Solution With no air extraction, CONIDECK®’s solvent-free polyurethane formulation and cold working properties were ideal for the job from a health and safety perspective. Electrical rather than diesel plant was used, also for safety reasons, and no power was needed to install the CONIDECK® membranes, which were roller applied in this instance. A combination of two BASF CONIDECK® systems were used: CONIDECK® 2257 and CONIDECK® 2260, both designed for use on enclosed, intermediate and lower decks and bays. In turning circles and ramps, the areas that suffer the highest mechanical stress, a greater aggregate content increased wear resistance, producing a heavy-duty, skid resistant surface for long-term protection.
Protection against corrosion
Can be spray applied
l
l
l
EMACO ® Nanocrete R3
l
l
l
l
l
l
l
l
l
l
l
EMACO ® Nanocrete R4
l
l
l
l
l
l
l
l
l
l
l
EMACO Nanocrete R4 Fluid
l
l
l
l
l
l
l
EMACO ® FAST Fluid/Fibre/Tixo
l
l
l
l
l
l
l
l
THORO ® STRUCTURITE R4
l
l
l
l
l
l
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Sealing penetrations
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Permanent submersion
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Anchoring bolts/posts
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Corners and profiles
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Vertical/overhead repairs
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Waterproofing/protection
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Joint waterproofing
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Joint sealing
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EMACO ® Nanocrete R2
Bonding aids
5-10
Sprayed concrete
Spalling over small areas Cover (mm)
Structural crack repair
10- 25
SHOTPATCH ® 12
Spalling over large areas Cover (mm)
Crack sealing
< 25
As part of Europe’s biggest current city centre development, the nature of the vast new underground Strand Street car park structure presented unique challenges for which new installation techniques were developed. The car park provides four parking levels under Chavasse Park, a multi-functional space for recreation with a central performance area. Acting as a link between the city and the waterfront, the Park’s contoured profile allows the concealment of the four parking decks.
Application
5-10
The Challenge
Products
10- 25
The Paradise Project is an extensive £920m, 42-acre regeneration scheme creating a retail-led mixed-use development with six separate districts. Developer Grosvenor’s massive scheme included three newbuild Q-Park multi-storey car parks requiring major deck installations using BASF Construction Chemicals’ CONIDECK® systems.
Material category
< 25
Featured Project: Paradise Street, Liverpool, UK
®
Polymer-modified cementitious mortars
THORO WATERPLUG ®
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Hydro-swelling elastic compound
THORO WATERPACK
Elastomeric mortar
THORO ® FLEXIJOINT
Waterproofing admixture and slurry
MASTERTOP ® SBR 570
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Acrylic polymer liquid additive
THORO ® ACRYL 60
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Capillary waterproofing slurry
MASTERSEAL® 501
Polyurethane resin joint sealants
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MASTERFLEX® 474
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MASTERFLEX® 462 TH
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THORO ® FLEX 200
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THOROSEAL® FX100
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THOROSEAL® WR CONCRESIVE® 1380
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References:
Ireland
United Kingdom
Blackpool, Cork MSCP Douglas Shopping Centre
Ankerside Shopping Centre, Tamworth Brewer Street, London Jordangate MSCP, Macclesfield Ladysmith Shopping Centre, Ashton-Under-Lyne PalaceXchange, Enfield Silverburn Mall, South Glasgow, Scotland Sheffield Riverside, Sheffield
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Crack injection
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Polymer-modified coatings and membranes
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Europe Brussels Airport, Belgium Metro Head Office, Germany
South America Salvadorian Social Security Institute, El Salvador
Asia Pacific Harbour Front Multi-Storey Car Park, Singapore
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For further information visit www.basf-waterproofing.co.uk
Car Parks - Exposed Decks, Multi-storey and Underground
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For more information go to www.barbourproductsearch.info
Podium Decks The cost of land in cities now dictates that owners maximize their sites: as a result podiums are often a feature of contemporary commercial and domestic properties. Defined as decks which are raised above the general level of their surroundings, they can be used to create an entrance lobby, delivery areas, service areas, roadways, terraces, garden areas or car parking. Whatever the usage, waterproofing the podium deck is a key element in ensuring the integrity of the overall building envelope. Deck waterproofing systems for podiums must take into consideration the need for movement accommodation. Although concrete podium deck construction is similar in many respects to that of balconies, the greater width of podiums means that a larger area is exposed, and a higher level of thermal movement is likely, particularly if the deck is used for parking or access for traffic. In such areas of vehicular traffic, there will also be an increase in the dynamic loading of the structure. The additional weight of landscaping features such as paving and planters may also be a factor.
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For landscaped or trafficable podium decks, BASF Construction Chemicals’ CONIROOF® landscaping and podium deck systems are BBA approved and provide a surface that is fully bonded to the deck, meaning that water cannot track under the system, unlike unbonded sheet membranes which can allow water to migrate between the slab and the membrane. A robust and puncture resistant waterproofing solution, CONIROOF® avoids the need for falls in the deck and speeds up the construction process which can lead to significant cost savings across the project. Built-in root resistance to DIN 4062 standards saves the time and cost involved in installing a separate root barrier in hard and soft landscaped areas. It also removes the possibility of the separate root barrier being omitted on site. The relevant BBA certificate states that, when subjected to normal service conditions, the system will provide an effective barrier to the transmission of liquid water for the design life of the roof into which it is incorporated.
1. Optional screed to falls. 2. MASTERTOP® primers and preparation coats. 3. CONIROOF® waterproof membranes: select from systems 2110, 2111, 2103 or 2150. 4. Drainage layer with geotextile filter: CONIDRAIN® drainage board.
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For further information visit www.basf-waterproofing.co.uk
Podium Decks
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For more information go to www.barbourproductsearch.info Podium deck
CONIROOF® SYSTEMS Hand applied
1. Screed to falls
Optional
2. Preparation coat/primer 3. Waterproof membrane system
MASTERTOP® primers and preparation coats as recommended by BASF CONIROOF® 2110, CONIROOF® 2111, CONIROOF® 2113
4. Drainage layer with geotextile fabric
CONIDRAIN ® drainage board
5. Paved surfacing sharp sand bedding
Brick pavior/green roof
Products
Application
Protection against corrosion
Can be spray applied
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The Solution BASF Construction Chemicals’ CONIROOF® 2111 system was specified to waterproof the podium deck, a key factor being its root resistance. BBA tests carried out to DIN 4062 : 1978 indicate that the membrane is root resistant in accordance with the DIN standard. BBA certification also states that when buried the membrane should last the lifetime of the structure. This project was the first large-scale podium deck contract in Scotland for BASF Construction Chemicals, and the company’s podium deck system was selected for being best in terms of performance, value and service in comparison with other competitors.
Application Around 5000m² of CONIROOF® 2111 was spray applied to the podium deck. MASTERTOP® Primer P617 was first applied, followed by CONIPUR® M810 membrane without topcoat.
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Polymer-modified cementitious mortars
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THORO ® WATERPACK
Elastomeric mortar
THORO ® FLEXIJOINT
Waterproofing admixture and slurry
MASTERTOP ® SBR 570
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Acrylic polymer liquid additive
THORO ® ACRYL 60
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Capillary waterproofing slurry
MASTERSEAL® 501
Polymer-modified coatings and membranes
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THOROSEAL® SUPER THORO ® FLEX 200
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THOROSEAL® FX100
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MASTERFLEX® 462 TH
CONCRESIVE® 1380
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THOROSEAL® WR
Crack injection
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MASTERFLEX® 474
THOROSEAL
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Hydro-swelling elastic compound
Polyurethane resin joint sealants
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Sealing penetrations
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Permanent submersion
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Anchoring bolts/posts
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Corners and profiles
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Vertical/overhead repairs
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5-10
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10- 25
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Joint sealing
< 25
As the architects’ design required the installation of a podium deck to create the underground parking space without impacting on the open, green nature of the site, it was important that the podium deck waterproofing system specified could withstand both hard and soft landscaping, to include planted bamboo.
Sprayed concrete
Bonding aids
5-10
SHOTPATCH ® 12
The Challenge The site offered the opportunity to insert a modern residential development into a traditional part of Aberdeen, as well as to adjust ground levels for the incorporation of underground car parking and the provision of a high proportion of open green space. The site was particularly sensitive from a political and planning perspective. It was also constrained by the physical characteristics and issues including access and road capacity, the topography, the number of mature trees on the site, a listed building on site, a District Wildlife site, proximity to a Conservation Area and removal of playing fields.
Spalling over small areas Cover (mm)
Spalling over large areas Cover (mm)
Structural crack repair
Material category
CONIROOF® 2150
10- 25
Stuart Milne Homes’ upmarket £20 million development is positioned within a spectacularly landscaped location in a conservation area in Aberdeen’s attractive West End, on the former site of Robert Gordon University’s Kepplestone campus. It offers a selection of 52 executive apartments as well as three-storey townhouses and large luxury villas within walking distance of Aberdeen’s vibrant city centre, combining the convenience of a central location with exceptionally attractive surroundings. Parking at the development includes both underground and external facilities: with most car parking spaces being underground, over 60% of the development is either public landscaping or garden space.
Spray applied
Crack sealing
Featured Project: Kepplestone Development, Aberdeen, Scotland
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References: United Kingdom
Ireland
King’s Cross Station, London Imperial Wharf, London Berry Bros Wine Merchants, London
Apartments Georges Quay, Cork Parchment Square, Cork Royal Irish Yacht Club, Dun Laoghaire Shopping Centre, Dundrum
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For further information visit www.basf-waterproofing.co.uk
Podium Decks
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For more information go to www.barbourproductsearch.info
Balconies, Walkways and Terraces Balconies, outside terraces and communal walkways are usually constructed from concrete with asphalt as the waterproof wearing course. Without protection these substrates will inevitably crack over time. This can lead to water ingress, resulting in leaks into properties below, frost damage and corrosion of steel reinforcement, in turn causing spalling of the substrate and ultimately structural failure.
Spalled/cracked concrete 2
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Overhead repairs
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From a safety perspective, standing water on walkways can potentially be hazardous for inhabitants, however, it can also cause the less obvious problem of capillary action. Walls resting on exposed horizontal portions of an envelope, such as balcony decks and walkways, can be affected not only by evident structural defects but also by the wicking effect of capillary action. Care must be taken to ensure that the building’s design prevents this natural movement which can carry water into the underside of design details such as joints, particularly under wind loading during heavy rainstorms.
Corner repairs 2
Protective aesthetic finish Top coat
Wear coat 3 Membrane 1
Waterproof joint
For further information visit www.basf-waterproofing.co.uk
Tiling solutions from BASF Construction Chemicals’ PCI brand open up the design possibilities of ceramic and natural stone surfaces for balconies. Specified in conjunction with a suitable substrate, our advanced range of waterproofing systems, joint sealants, tile grouts and adhesives recommended for external use on balconies can be combined to create a durable, attractive tiled surface.
Remedial Treatments Where water ingress has already become an issue, restoring the building envelope through remedial waterproofing will prevent further damage to properties and extend the life of the building as a whole. Our extensive range of concrete repair materials are EN-1504 compliant, making it especially suitable for publicly funded projects.
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Protected with spray/brush applied membrane
23331_WaterProofing.indd 49-50
Vertical repairs
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The MASTERTOP® Watertight Solution
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Key advantages with MASTERTOP® balcony systems are ease of application and short drying times. Most balcony systems can be walked on after only a few hours and systems are available that can be trafficked after only one hour so that disruption is kept to a minimum.
PCI Tiling Solutions
BASF Construction Chemicals has developed a range of balcony systems, specifically designed to protect balconies against these elements, that are both functional and decorative.
The effect of weather must be taken into account both at the design stage of the structure and when selecting the balcony protection system. Criteria must include a waterproof, UV stable anti-slip finish to the surface of the balcony; this provides protection to the substrate and a safe environment for pedestrians.
Where cracks are present, then an effective crack bridging solution is a must; this is achieved by incorporating our tried and tested CONIPUR® hand or spray applied membranes into the system. Within the range of MASTERTOP® balcony systems we have a number of options available to achieve the optimum solution.
1. MASTERTOP® Balcony Systems. 2. EMACO® NANOCRETE structural repair mortars, suitable for profiles and corners. 3. MASTERFLEX® Polyurethane elastomeric joint sealants. 4. THORO® DRYJOINT pointing mortar for bricks, stone and concrete. 5. EMACO®Fast rapid setting repair mortars suitable for use on pedestrian walkway environments. 6. MASTERSEAL® anti-carbonation coatings. 7. MASTERSEAL® clear penetrating water repellent coatings.
Balconies, Walkways and Terraces
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For more information go to www.barbourproductsearch.info
Housing trust De Nieuwe Unie owns around 3,000 homes in the district and embarked on a major refurbishment programme to renovate its housing stock. BASF Construction Chemicals’ systems were specified on two of its apartment complexes where a number of walkways needed refurbishment.
Products
Application
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THORO ® STRUCTURITE R4
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THORO ® WATERPLUG
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THORO DRYJOINT ®
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THORO ® ACRYL 60
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THOROSEAL FX100
Flexible sheet membrane
Silane treatments
Protective anticarbonation coatings
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THOROSEAL® WR
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Polymer-modified coatings and membranes
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Acrylic polymer liquid additive
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Single layer
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MASTERTOP ® SBR 570
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Waterproofing admixture and slurry
MASTERFLEX® 462 TF
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THORO FLEX 200
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MASTERSEAL® 456
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MASTERFLEX® 474
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THORO ® FLEXIJOINT
Polyurethane resin joint sealants
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Elastomeric mortar
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Vapour permeable
Waterproof
Puncture resistant
Anchoring bolts/posts
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Protects against corrosion
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Suitable for cathodic protection
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EMACO ® Nanocrete R3
Horizontal use
Vertical/overhead use
Bonding aid
Waterproofing
Patch repairs
Profiles and corners
Levelling
Joint sealing
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EMACO ® Nanocrete R2
®
Polymer-modified cementitious mortars
Concrete repairs
Structural crack repairs
SHOTPATCH ® 12
Can be spray applied
Sprayed Concrete
®
The existing apartment walkways were covered with tiles, only some of which were coated. The client decided to lay a new flooring surface on top of these tiles, using a MASTERTOP® balcony system build-up. The system comprised of a thick, crack-bridging waterproof membrane layer, followed by a low-profile, fine-grained wear coat. The fine gravel surface was not coated, allowing the rainwater to run off the walkways by means of the membrane.
Properties
category
Sealing cracks
Rotterdam is the second-largest city in the Netherlands and its Pendrecht area, developed during post-war reconstruction in the fifties, is renowned for its town planning and green spaces. The small-scale nature of its architecture makes it popular with both the elderly and families.
Material
Leakage into interiors
Featured Project: Apartment Walkways Pendrecht, Rotterdam, Netherlands
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PROTECTOSIL® CIT
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MASTERSEAL 303
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MASTERSEAL® 321B
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MASTERSEAL® F1120
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MASTERSEAL® F1131
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The client, like the occupants, is very satisfied with the modern, aesthetic finish on the walkways, which has the advantage for the housing trust of requiring little maintenance thanks to its durability.
References:
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For further information visit www.basf-waterproofing.co.uk
United Kingdom
Europe
Asia Pacific
Hackney Homes New River Head Apartments Spectators’ Area, Gatwick Airport
Amena Building, Spain Apartment Postelse Hoeflaan, Netherlands De Slinge Apartment Complex, Netherlands Senior house, Czech Republic
Hyatt Hotel, Australia Marina Pinnacle, Dubai Maroubra Bay Hotel, Australia
Balconies, Walkways and Terraces
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For more information go to www.barbourproductsearch.info System (Mastertop)
System 1
System 2
System 3
System 4
System 5
System 6
System 7
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Silicone joint sealants l
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Extremely Decorative Flake Finish
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Waterproofing systems
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Extremely Decorative Quartz Finish
Anti-Slip
PCI Seccoral ® 2K + PCI Pecitape
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PCI Pecilastic ® WS + PCI Pecitape
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Flexible
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PCI Tilefast ® 6 Rapidflex
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PCI Nanolight Rapid
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Medium-bed tile adhesive
PCI Carrament ®
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PCI Floorfast ® 20 Rapid
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PCI Silcoferm ® S
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Tile Grouts
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PCI Durafug NT
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PCI Fast Track ®
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PCI Nanolight ®
Tile adhesives
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PCI Carraferm ®
PCI Carrafug
UV and Weather Resistant
Waterproofing/protection
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Joint waterproofing
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Joint sealing
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Crack bridging
Hand Applied Membrane
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Fast –track working
Spray or Hand Applied Membrane
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Natural stone tiles
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Ceramic tiles
Elastomeric
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Levelling
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Watertight
Application
category
Rapid Curing
Seamless
Products
material
Application
Large Range of Colours
Tiling
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Clear Sealer Coat Wear Coat
Wear Coat Membrane
Membrane
Void Filling Primer (Optional)
Void Filling Primer
Primer
Primer
Design Watchpoint For new-build balconies (designed and built for their intended purpose rather than as an addition to an existing construction such as a garage roof), the ideal surface to receive tiles is a sand/cement screed or a concrete substrate. Falls (drainage channels) should be formed in the substrate to ensure that ponding of water does not occur. These falls should never be formed in the adhesive layer, but always at the design stage in the substrate.
Clear Sealer Coat Clear Sealer Coat
Wear Coat Membrane Void Filling Primer (Optional) Primer
For more information on System build ups contact BASF’s Technical Department.
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For further information visit www.basf-waterproofing.co.uk
Balconies, Walkways and Terraces
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For more information go to www.barbourproductsearch.info
Bridges Bridges are constantly under stress as water, chlorides, acid rain, deicing salts and freeze-thaw cycles act on them. Seasonal and day cycle extremes of temperature, the impact of traffic and vibration place bridges under further stress. As steel reinforcing bars corrode and expand, concrete can crack and deteriorate. The costly disruption caused by resulting repair work impacts on both traffic and safety.
Bridge repairs can often amount to 10-30% of the updated construction cost, and large repairs may even exceed the updated construction cost and still be the preferred option when compared to the cost of traffic interruption and demolition. As moisture is the most significant factor in concrete deterioration, incorporating sufficient waterproofing at the design stage is by far the most cost-effective option.
Frost Damage
Crack Injection
Concrete Repair
Exposed Concrete
Where frost damage caused by the freeze-thaw cycle occurs, it is often the result of incorrect air content and pore structure of the concrete and so can be minimised through the use of admixtures. BASF admixtures designed to enhance the performance of concrete and limit the impact of the freeze-thaw cycle include: MICRO-AIR® air-entrainers to create ultra-stable bubbles, GLENIUM® superplasticisers to reduce the water-cement ratio, and RheoFIT® water-resisting admixtures which also prevent the ingress of chlorides.
Cracked concrete creates ideal conditions for deterioration as it allows the ingress of moisture or dry air. The likely degree of rust development depends on the kind of crack: macro-cracks can develop from micro-cracks and by allowing moisture ingress they encourage the possibility of alkali-silica reaction and frost damage. Designed for pressure injection grouting, low viscosity epoxy resin CONCRESIVE® 1380 can be used to structurally re-bond cracked concrete sections and offers excellent penetration of fine fissures – it can also be used as an impregnating flood coat to improve the soundness of friable screeds.
It is essential that concrete repair materials are compatible with the host concrete. BASF Construction Chemicals EMACO® Nanocrete range of flowable, hand and spray applied mortars are fully compliant with BS EN1504 Part 3, which is mandatory for all publicly funded concrete repair projects.
Untreated concrete is vulnerable to the damaging ingress of carbon dioxide, chlorides and water, which can lead to structural damage and safety issues. BASF Construction Chemicals’ MASTERSEAL® range of anti-carbonation coatings can address these problems and give long-term structural protection from environmental damage. In addition, our Protectosil® CIT advanced corrosion inhibitor can be applied to decrease the corrosion process. This organofunctional molecule penetrates concrete and inhibits the electrochemical reaction process between the reinforcement and any chloride ions, oxygen and moisture present.
Anchoring and grouting of metal rail and base plates Asphalt road surface Concrete
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1. EMACO® CP 60 ANODE high-performance spray-applied anode for cathodic protection. 2. EMACO® NANOCRETE BS EN1504 - compliant repair mortars. 3. MASTERSEAL® 303 and PROTECTOSIL® CIT Highways Agency approved silanes to BD43/03.
Cathodic protection
Mondorf, Paul E, Concrete Bridges, Taylor & Francis 2006
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For further information visit www.basf-waterproofing.co.uk
Bridges
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For more information go to www.barbourproductsearch.info Products
High levels of chloride contamination had occurred, caused by leaking water from the deck drainage which had travelled over the half joints, along the cantilevered soffits and down the deck piers. As a result of the ingress of chloride-contaminated water, the severely deteriorated structure was suffering from corroded reinforcement and spalling concrete, particularly at the half joints and cantilever soffits. The bridge required large-scale structural concrete repairs, complicated by difficult site access.
The Solution A cathodic protection system was developed using BASF’s new EMACO® CP 60 Anode mortar, its first installation onto a bridge. The system used a low current through the bridge reinforcement to create a cathode and the EMACO® CP 60 cementitious overlay, which contains nickel fibres, was applied at a thickness of 10mm as the anode. Titanium strips served as the distribution network for a current of less than 20 milliamps delivered from a streetlighting electrical feeder pillar. The reversal of the ‘electrical cell’ protected the reinforcement at the joints and soffits from further corrosion. BASF was able to offer a complete package of repair solutions in addition to EMACO® CP 60 ANODE: SHOTPATCH® 12, EMACO® S103 and NANOCRETE® R4 mortars were also supplied. A team approach giving support from the company’s Technical, Sales and Customer Services departments ensured that materials were both delivered and applied on schedule to the satisfaction of all parties. Success on the project has since lead to BASF supplying several other prestigious Highways Agency projects.
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EMACO ® FAST Fluid/Fibre/Tixo
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MASTERTOP ® SBR 570
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Acrylic polymer liquid additive
THORO ® ACRYL 60
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MASTERFLEX® 474
Crack injection
CONCRESIVE® 1380
Capillary waterproofing slurry
THOROSEAL® 501
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MASTERFLEX 462 TF
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THOROSEAL FX 100
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THOROSEAL® WR MASTERSEAL 345 ®
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GLENIUM ®
Polyurethane resin joint sealants
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RHEOMAC ® UW 450
High performance anode
Can be spray applied
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Anti-washout admixture
Silane treatments
Protection against corrosion
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RHECRETE® 222+
Coatings and membranes
Underwater application
Permanent submersion
Anchoring bolts/posts
Corners and profiles
Bridge decks
Vertical/overhead repairs
Waterproofing/protection
Joint waterproofing
Joint sealing
Bonding aids
Structural crack repair
5-10
< 25
5-10
10- 25
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Admixtures
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THORO WATERPLUG
Elastomeric mortar
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The Challenge
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SHOTPATCH ® 12
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Polymer-modified cementitious mortars
Cathodic protection
Concrete, sprayed concrete, cement-sand mortars
The Highways Agency’s River Derwent Bridge is a major road bridge carrying the A38 over the river in Derby. A three-span reinforced concrete structure, its central deck is supported at half joints by deck sections cantilevered from its piers.
Spalling over small areas Cover (mm)
Spalling over large areas Cover (mm)
Crack sealing
Application
10- 25
Material category
< 25
Featured Project: River Derwent Bridge, Derby, UK
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EMACO ® CP 60 ANODE
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References: United Kingdom
South America
River Derwent Bridge R111 Midland Links
Alencastro Bridge, Brazil Salto Grande Bridge, Brazil
Europe Apollo Bridge, Bratislava, Slovakia
Middle East
North America
Manifa Port Causeway, Saudi Arabia
Hardy Toll Road Bridge, Texas, USA Triboro Bridge, New York, USA
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Bridges
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Roofing - includes Green, Cold, Warm and Inverted Roofs Inadequate roofing affects a structure’s functionality, its maintenance and whole-life costs, with far-reaching implications for buildings insurance. A durable roof waterproofing system that is resistant to changes in temperature and environmental factors, such as pollution and acid rain, is therefore a vital part of the building envelope.
Refurbishment
Insulation options
CONIROOF® systems can be installed on most substrates, including old concrete, built-up felt, asphalt and timber substrates. They are also suitable for failed single-ply sheet, providing that the surface can be properly prepared to allow maximum adhesion. The membranes are crack bridging so existing minor cracks can be simply overcoated.
Vapour control layer Roof deck Complex/vertical details
BASF Construction Chemicals provides tailor-made solutions for flat and pitched roofs with its versatile CONIROOF® waterproofing membrane systems, which use advanced polyurethane technology to create impervious, monolithic membranes suitable for all major roof types and designs. CONIROOF® systems are multi-layered, comprising substrate sealers, primers, waterproofing membranes and protective top coats. The systems are cold applied to avoid the odour and fire risk of hot works. Custom-designed spray equipment ensures consistently high-quality membrane production and quick, uniform application. Fast curing within a few minutes speeds up installation: up to 1,000m² can be placed in a single eight hour shift. Exceptional physical properties, versatility, performance and speed of installation are combined with the reassurance of BBA and EOTA approval.
New Build Applied to new roofs, CONIROOF® membranes are waterproof and weathertight in the harshest conditions and can accept typical substrate movement without damage, preventing water ingress. CONIROOF® systems are suited to a variety of surfaces from dense concrete decks to plywood and lightweight metal panels, with different polyurethane and epoxy preparation coats and primers, for each type of substrate, optimising performance. This allows the membrane to resist wind suction, elevated temperature, thermal shock and minor structural movement.
7
BASF can supply advice on preparation and application to specific substrates and will work closely with you to produce the best specification for your requirements.
Green Roofs 1
6 5 4 3 2
CONIROOF® systems have built-in root resistance to conform to DIN 4062, eliminating the need for separate root barriers. As systems are fully bonded to the substrate, water cannot flow under the membrane coating, thus avoiding damage to the roof structure and building interior below. CONIROOF® systems will also withstand the loads imposed by landscaping for an effective, quickly installed solution for green roofs.
Complex Forms CONIROOF® systems can be applied to vertical surfaces including complex details such as penetrations, ventilators, skylights, air conditioning units and chimneys etc. Unlike sheet systems, BASF’s seamless, monolithic waterproofing systems avoid weak spots caused by laps, welds or seams, providing greater durability and protection.
1. CONIROOF® waterproofing solution: select from spray and hand-applied systems. 2. MASTERTOP® primers and preparation coats as recommended by BASF Construction Chemicals. 3. Consult BASF Construction Chemicals for advice on the most appropriate vapour control layer. 4. Insulation options: CONIROLL®, C PER® or CONITHERM®, bonded in cold adhesive or mechanically fixed. 5. CONIROOF® waterproofing membrane. 6. CONIROOF® top coat. 7. THORO® WATERPACK hydro-swelling elastic compound to seal penetrations.
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Roofing - includes Green, Cold, Warm and Inverted Roofs
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CONIROOF® SYSTEMS Hand applied
Spray applied
2150 ETA
2160 BBA
2110 BBA
2111
2102 BBA
2103 ETA
Flat/pitched
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Warm/insulated
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Inverted
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Green
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Other trades were dependent on completion of the roof membrane to begin work, so fast application and curing were important. Unusual shapes and roof openings were to be integrated into the waterproof seal effectively and reliably, without additional work or prefabricated parts, and a seamless surface compatible with hard landscaping was required.
The Solution The specification proposed the use of CONIROOF® 2110 inverted system with CONIDRAIN® insulation (extruded polystyrene) and paving on top. This system has a BBA Certificate no. 99/3660. Advantages of the system included fast-track curing (30 seconds), easy spray application, root resistance and the integration of awkward shapes and roof openings without any joints. Other important properties included crack bridging, UV and weather resistance and BBA-certification. The contractor had 12 years of experience of the system. This system was selected primarily for its speed of installation: in this case the waterproofing membrane was installed in just four days within a two week period during poor weather conditions. Other trades were able to commence as soon as 2mm of membrane were in place, allowing them to begin working in dry conditions. The client was very pleased with the results and proposed to use CONIDECK® in all future projects of a similar nature.
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For further information visit www.basf-waterproofing.co.uk
Protection against corrosion
Can be spray applied
Sealing penetrations
Permanent submersion
Anchoring bolts/posts
Vertical and horizontal repairs
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EMACO ® Nanocrete R3
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EMACO Nanocrete R4
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EMACO ® Nanocrete R4 Fluid
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EMACO FAST Fluid/Fibre/Tixo
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THORO ® STRUCTURITE R4
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®
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Hydro-swelling elastic compound
THORO WATERPACK
Elastomeric mortar
THORO ® FLEXIJOINT
Waterproofing admixture and slurry
MASTERTOP ® SBR 570
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Acrylic polymer liquid additive
THORO ® ACRYL 60
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MASTERFLEX® 462 TH
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THORO FLEX 200
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THOROSEAL® FX100
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THOROSEAL WR
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MASTERFLEX® 474
®
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®
Polymer-modified coatings and membranes
Waterproofing/protection
Joint sealing
Bonding aids
Structural crack repair
5-10
< 25
5-10
10- 25
EMACO Nanocrete R2
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THORO ® DRYJOINT
Polyurethane resin joint sealants
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®
The Challenge
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SHOTPATCH ® 12 ®
Polymer-modified cementitious mortars
Spalling over small areas Cover (mm)
Crack sealing
Application
< 25
Sprayed concrete
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Products Spalling over large areas Cover (mm)
The flat roof at the new 154-bed, 4-star Cork Airport Hotel in Ireland needed a waterproof membrane that could accommodate a range of unusual shapes and penetrations. As the roof could be accessed by hotel guests from the upstairs lobby area, the surface also had to provide a safe and durable surface for foot traffic. The solution selected for this project was the CONIDECK® inverted system, which could be combined with hard paving.
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10- 25
Material category
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Corners and profiles
Overlay
Joint waterproofing
Featured Project: Cork Airport Hotel, Ireland
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United Kingdom
Africa
Kings Cross Station Redevelopment, London
Sofitel El Gezirah Hotel, Egypt
Europe
Asia Pacific
Bakeries Blansko a.s, Czechoslovakia College Refectory, Karlsruhe, Germany Cultural Centre, Santiago de Compostela, Spain InfraServ GmbH & Co., Germany Ravensburger AG, Germany Terminal Building, Tenerife Airport Military Shelter, Sierra Nevada, Spain
Hong Kong City Office Towers, China Grand Lisaboa Hotel, Macau, China Vivocity Shopping Mall, Singapore
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Roofing - includes Green, Cold, Warm and Inverted Roofs
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Innovating for the Future Committed to UK Initiatives
Driven by dynamic innovation, BASF is fully committed to being a reliable partner that helps shape the future. To deliver on this promise, we have adopted a binding value system that forms the basis for our actions as a company and as individuals. Six core values describe our philosophy and the way in which we want to achieve our goals: sustainable profitable performance, innovation for the success of our customers, safety, health and environmental protection, personal and professional competence, mutual respect and open dialogue, and integrity.
Recognised for Sustainability BASF has gained public recognition for its sustainability and transparency – its shares have been included in the Dow Jones Sustainability Index (DJSI World), the world’s most important sustainability index, for the seventh year in succession. The companies included in the DJSI World are picked from the 2,500 members of the Dow Jones Global Index: only the top 10 percent in each industry are selected. BASF has been included in the Global 100 list compiled by the New York research house Innovest for the third year running, identifying it as one of the world’s most successful companies in the areas of environmental protection, social affairs and corporate governance. BASF Construction Chemicals (UK) was awarded the title of Sustainability Champion 2008 by the British Precast Concrete Federation after showing that the use of the company’s products can save three times more greenhouse gas emissions than the entire amount caused by their production and disposal. The award submission from the Admixtures division also highlighted the company’s progress in the field of concrete.
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For further information visit www.basf-waterproofing.co.uk
BASF Construction Chemicals is a member of the UK Green Building Council (UK-GBC), which campaigns for a sustainable built environment, and we support its belief that the challenge of sustainability is an opportunity, not a threat. The UK-GBC is part of the World Green Building Council federation, membership of which is growing as new national green building councils are established across the globe.
In the precast concrete sector, BASF’s Zero Energy System (ZES) concept has transformed production into a much more sustainable process through Zero Energy Concrete – selfplacing and compacting concrete which can fill even complex, heavily reinforced sections from one delivery location. In the manufactured concrete products (MCP) industry, the BASF FIT 4 VALUE concept assists process optimisation and the enhancement of product performance through RheoFIT® admixtures that optimise the mix design, cycle time, appearance and durability of MCPs.
Reducing Carbon Emissions BASF was honoured as Best in Class in its approach to addressing the challenges of climate change by the Carbon Disclosure Project (CDP), and has been included in the Climate Leadership Index. The CDP is an initiative of 225 institutional investors which supports the disclosure of greenhouse gas emissions by companies. Every year it selects 50 FT500 companies that are leaders in the management of the opportunities and risks of climate change.
As a leading raw material supplier to the construction industry, BASF is a key contributor to the Creative Energy Homes Project at the University of Nottingham’s School of the Built Environment. BASF, helped by its customers and partners, has built the BASF House at the university to demonstrate how its systems can be used to create an energy-efficient affordable home. Both the Admixture and Building Systems divisions of BASF Construction Chemicals assisted in the creation of the ecofriendly dwelling.
Research and Development BASF Construction Chemicals is committed to engineering quality solutions to drive the construction industry forward. Through constant research and development into new products, systems, application methods and equipment, we add value. Continuous innovation is the key to our success. Our objective is clear: to engineer materials to match the needs of the end user. From the molecular level to the finished system, enhancing the performance of construction materials for our customers is at the heart of whatever we do. Innovating for the Future
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The degradation of cementitious material by aggressive water
Admixtures and Ancillary Products
Table 1 Degree of aggression
4.5 – 5.5
4.0 – 4.5
< 4.0
Free CO2 (mg/l)
< 15
15 – 30
30 – 60
60 – 100
> 100
Ammonium (mg/l)
< 15
15 – 30
30 – 60
60 – 100
> 100
Sulphates (mg/l)
< 200
200 – 600
600 – 3000
3000 – 6000
> 6000
Magnesium (mg/l)
< 100
100 – 300
300 – 1500
1500 – 3000
> 3000
Applications
Corrosion Inhibitors
5.5 – 6.5
RheoMATRIX®
> 6.5
Rheofibre®
PH
Rheofinish ®
Very strong
Rheo-FIT®
Strong
Micro-Air®
Fair
Masterkure®
Weak
Glenium®
None
BASF Admixture Systems UK is part of BASF’s Construction Chemicals business and is the leading admixture supplier, delivering continuous innovation and added value solutions. Our market-segmented structure means that you can rely on the proximity of a regional company with the backing of a global group. With the broadest range of technologically advanced chemical admixtures and the best technical back up, we are the international market leader, ideally placed to advise on solutions for high performance concrete with integral waterproofing. The table below provides a snapshot of systems that assist performance in different applications.
Reservoirs
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Definitions
Dams
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pH
Waterways
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l
l
l
l
l
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Swimming Pools/ Wet Rooms etc.
l
l
l
l
l
l
l
l
Basements/Vaults
l
l
l
l
l
l
l
Car parks: Exposed Decks
l
l
l
l
l
l
l
l
Car parks: Multi-storey
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l
l
l
l
l
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Car parks: Underground
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l
l
l
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Dirty Water
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l
l
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l
l
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Potable Water
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l
l
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Marine Structures
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Defence Structures
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l
l
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Bunds
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l
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Roofing
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l
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Podium Decks
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Balconies
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Footbridges
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• Temperature
Stadia
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• Hardness
Bridge Decks
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l
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l
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Water quality will have a significant effect on the rate at which cement-based materials deteriorate. Medium to soft water, water containing acids, magnesium, free carbon dioxide, ammonium and sulphate salts will be more aggressive. The degree of aggression has been classified and quantified by the European Cement Association (Cem-Bureau). Table 1 is a guide only to the elements which affect water quality and does not take into consideration the influence that hardness in combination with total alkalinity, pH and temperature has on the water’s ability to attack cementitious materials. It is possible to have, for example, a swimming pool with water at pH of 7+ which could be considered to be ‘non-aggressive’ but which, because of the high temperature and low hardness, is consequently very aggressive.
Is a measure of the acidity of alkalinity of water
Alkalinity Represents the amount of bicarbonates, carbonates, hydroxides present in the water. It is a measure of the buffering capacity of the water i.e. its degree of resistance to the change in pH. Hardness Is a term used to describe the reaction between soap and water. Natural mineral salts dissolved in water reduce the ease at which soap lathers. Hardness is usually measured as calcium carbonate content.
BASF Construction Chemicals is prepared to advise on water quality when provided with the following information: • Static or replenished water • pH reading
• Alkalinity
Roller Compacted Concrete
• Chemical analysis
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Bridge Abutments
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Cooling Towers
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Diaphragm Walls
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l
l
l
l
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Retaining Walls
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l
l
l
l
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Foundations
l
l
l
l
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External Façades
l
l
l
l
l
l
l
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Storm Tanks
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l
l
l
l
l
l
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Sustainable Underground Drainage Systems (SUDS)
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l
l
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Construction Products
Glossary
Prestigious new-build and refurbishment projects rely on materials from BASF Construction Chemicals’ Construction
Above-grade waterproofing
Freeze-thaw cycle
Products division for performance and durability. Our tailor-made solutions present systems that improve, preserve or
Prevention of water ingress into exposed structural elements using materials not subject to hydrostatic pressure but exposed to weathering and pollutants.
The process of water freezing then thawing, related to building components.
repair, helping structures to stand the test of time. From composite strengthening systems and cathodic protection to sealants, coatings, concrete repair materials and grouts – BASF’s innovative construction systems extend the service life of structures, adding value through whole-life cost savings. The table below outlines which of our brands can assist performance in different waterproofing applications.
Hydrostatic pressure Admixtures
THORO ®
MASTERFLEX®
MASTERSEAL®
MASTERSEAL® 900
MASTERTOP ®
Pressure exerted by a fluid due to the force of gravity. Hydrostatic pressure increases in proportion to depth measured from the surface because of the increasing weight of fluid exerting downward force.
EMACO NANOCRETE®
Materials added to the concrete mix to enhance/improve its performance.
Reservoirs
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Capillary admixtures
Dams
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Negative waterproofing system
Waterways
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Swimming Pools/Wet Rooms etc.
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Basements/Vaults
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Admixtures that react with concrete or masonry to form microscopic crystalline growth in the capillaries resulting from hydration – this fills the capillaries to prevent further capillary action.
Capillary action
Positive waterproofing system
A wick-like migration of water created by surface tension or molecular attraction.
A system applied to the substrate side with direct exposure to water or a hydrostatic head.
UCRETE®
PCI ®
Below-grade waterproofing MBrace ®
CONIROOF®
CONIDECK®
Application
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Prevention of water ingress using materials that withstand hydrostatic pressure, not exposed to weathering.
Membrane A flexible/elastomeric waterproofing material applied to a building envelope.
A below-grade system applied to the interior (negative) side of a structure, away from direct exposure to groundwater.
Car parks: Exposed Decks
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Car parks: Multi-storey
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Car parks: Underground
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Construction joint
Seepage
A stopping place in the process of construction.
In soil engineering, movement of water in soils, often a critical problem in building foundations.
Wastewater Potable Water
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Marine Structures
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Bunds
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Roofing
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Podium Decks
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Balconies Footbridges
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Stadia
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Bridge Decks
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Bridge Abutments
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Cooling Towers
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Diaphragm Walls
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Retaining Walls
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Foundations
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External façades
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Storm Tanks
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Sustainable Underground Drainage Systems (SUDS)
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Contraction joint (also Control joint) A joint placed to control random cracking.
Waterbar/Waterstop
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Damp proofing
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Systems resistant to dampness or the effects of dampness, acting as a back-up to primary waterproofing materials.
A continuous strip of waterproof material placed at concrete joints designed to control cracking and limit moisture penetration.
Expansion joint (also Isolation joint)
Weep hole A hole in a sill, retaining wall, or similar for draining off accumulated moisture, as from condensation or seepage.
Used to relieve flexural stresses caused by vertical movement of slab-on-grade applications that adjoin fixed foundation elements such as columns, building or machinery foundations.
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For further information visit www.basf-waterproofing.co.uk
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