CSL tunnels, dealing with water

ingress
What is injection or grouting?

Definition: Injection is “the introduction of a material with pressure into the ground
or a structure with the goal of waterstopping, consolidating, repair and filling of
voids, cracks and porosity”

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Why do we inject into underground structures?

Elimination of small drips or massive water inflow?

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Understanding the problem

Ground improvement injections

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Find out what you really need

How to select the right product

Viscosity : Can it penetrate into the crack?
Hardening system : Will it work at low/high temperature?
Bonding strength : Will it adhere with a high enough tensile strength?
Setting time : Can it be adapted to my needs?
Elasticity : Can it elongate, compress, swell?
Hydrophobic : Will it repel water?
Hydrophilic : Will it absorb water?
Tack : Will it stick to wet/dry surface?
Chemical resistance : Is it durable under the conditions it’s exposed to?
Environment : Is there any hazard associated with the application?

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When do we inject in underground construction?

1. Ground consolidation Under stress cracking or

fracturing occurs.
Conditions vary from site to site This can lead to:
From hard and compact rock to a roof sinking
soil based or heavily fragmented rib movement
substrate
floor heaving
Overburden pressure and rock
tunnel collapse
stress distribution create load on
the rock strata and tunnel lining

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When do we inject in underground construction?

2. Sealing against water 3. Repair 4. Void and cavity filling

and gas ingress and renovation Can occur in mines or tunnels
Entry via cracks in Damaged or erosion Needs to be stabilized using light weight
the surrounding rock of existing tunnels foams
Anticipate and deal also needs repair
Injected remotely in a controlled, safe
with before excavation and renovation
manner

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The main areas of use for injection in underground construction
and mining

Ground consolidation
Ground improvement, required within very short time (a few minutes)
A collapse situation is imminent and very high mechanical strength can immediately resolve
the situation
Water stopping
Pre- and post-injections to stop or minimize the amount of water ingress into underground
structures
Void filling
Unexpected and often uncontrolled situations where the roof collapses
Rapid reacting and foaming resins fill the cavity
Repair injections
Repair of masonry and brickwork lining
Crack injections in concrete lining

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The four main BASF UGC injection technologies

Cementitious Ordinary Portland cement, the most commonly used material which is mostly supplied locally.
grouting systems Microcement systems consist of much smaller particles for deeper crack penetration.

Mineral grout Colloidal silica, a suspension of nanometric particles for penetrating the finest cracks

Polyurethanes & Single component polyurethane systems are hydrophilic and use moisture as a curing agent for
Polyurea silicates mainly waterstopping applications.
Two component polyurethane systems with tailored properties achieved by controlled curing
systems are used to solve more complex challenges.
Polyurea silicate resins are fast setting, two component systems with excellent adhesion
properties.

Acrylates Acrylic resins are hydrogel systems which are very flexible for use in concrete repair and water
sealing applications.

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The four main BASF UGC injection technologies

Cementitious grouting systems

MasterRoc® MP 650
Fast-setting microcement for injection in tunneling and mining;
Fineness (Blaine) > 625 m²/kg
d95: 16 microns

MasterRoc® MP 800
Fast-setting microcement for injection in tunneling and mining;
Fineness (Blaine) > 800 m²/kg
d95: 14 microns

MasterRoc® MP 900
Fast-setting microcement for injection in tunneling and mining;
Fineness (Blaine) > 900 m²/kg
d95: 12 microns

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The four main BASF UGC injection technologies

Mineral grout
MasterRoc® MP 320
Mineral grout system based on colloidal silica

MasterRoc® MP 325
Mineral grout system based on colloidal silica

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The four main BASF UGC injection technologies

Polyurethanes
MasterRoc® MP 350 MasterRoc® MP 355
1-component permanent flexible water sealing Highly reactive, 2-component polyurethane injection resin
polyurethane injection grout for fine cracks and fissures MasterRoc® MP 355 THIX
in concrete and rock Highly reactive, two component polyurethane injection resin
MasterRoc® MP 354 / foam to stop very high volume water ingress
Flexible 2-component CE certified
Polyurethane resin for concrete repair
MasterRoc® MP 355 MR0
Slowly reacting, 2-component polyurethane
MasterRoc® MP 355 1K
injection resin
Watertight 1-component polyurethane injection foam for
filling holes and jointed rock, as well as cutting off MasterRoc® MP 358 GS
running water Highly reactive, 2-component nearly compact hydrophobic
MasterRoc® MP 355 1K DW polyurethane injection resin for ground stabilization
Watertight 1-component polyurethane injection foam for MasterRoc® MP 358 SC
filling voids and jointed rock, as well as cutting off Highly reactive, 2-component hydrophobic polyurethane
leaking potable water injection foam for ground stabilization

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The four main BASF UGC injection technologies

Polyurea silicates
MasterRoc® MP 368
Highly reactive 2-component polyurea silicate resin for consolidation of concrete and rock

MasterRoc® MP 367 Foam

Highly reactive, 2-component polyurea silicate foam for void filling and ground consolidation

MasterRoc® MP 368 TIX

Highly reactive, thixotropic 2-component polyurea silicate resin for consolidation of rock and
repair of concrete

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The four main BASF UGC injection technologies

Acrylates
MasterRoc® MP 303 CE MasterRoc® MP 308
Low viscosity, fast reacting acrylic resin for permanent Low viscosity, single component acrylic resin for
water sealing and layer curtaining of concrete and permanent water sealing in underground structures
masonry
MasterRoc® MP 304 MasterRoc® MP 309
Low viscosity, fast reacting and highly flexible acrylic Low viscosity, fast reacting acrylic resin with high
resin with adjustable reaction speed for permanent compressive strength for consolidation of sand and silt
water sealing, joint repair and layer curtaining of strata
concrete and masonry
MasterRoc® MP 307 CE
Low viscosity, highly flexible, fast reacting acrylic resin
for permanent water sealing and layer curtaining of
concrete and masonry

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Water ingress treatment: depending on the design

Undrained • Ful water pressure on lining

System • Full round waterproofing

• Systematically drained
Partially • Locally drained
Drained • Partial pressure relief
System • Limited water pressure

• Undrained (crown/bench)
Mixed
Systems • Drained (bench/invert)
A typical job site scenario
with damp spots
Management of wet spots

Injection
Removal of significant water seepage with
injection
in conjunction with drainage
Temporary drainage
Drill holes fitted with packers which are over
sprayed and later injected
Permanent drainage
Drainage stripes with geotextile
Drainage channels
Managing of wet spots: water stop with MasterRoc MP 355 PU resins

Fast reacting PU foam for stopping

severe water ingress
Adjustable reaction time
1K and 2K products available
Pressure relief with packers

Temporary drainage of water with drill holes,

packers and hoses.
Channel the water instead of chasing it
Temporary drainage of wet spots with small packers and subsequent
injection

Drilling of hole, installation Application of Injection of packer after

of small packer to collect membrane complete curing of
the water membrane
Injection products: MasterRoc MP 300 acrylic series

Acrylic injection range

MasterRoc MP303
10s to 3 minutes
Swellable, highly flexible
MasterRoc MP307
3 to 15 min
Flexible, high water pressure
MasterRoc MP309
1 to 9 min
Ground consolidation
Permanent drainage: Half pipe or dimpled sheet drainage system

Permanent drainage connected to the drainage system at the

invert
Mortar in order to achieve an continious MasterSeal 345
membrane afterwards
Different options available locally

Half pipe fixed with

nails

Covered with repair

mortar
Overlapping sheet membranes

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Overlapping sheet membrane / MasterSeal 345

Overlapping sheet/membrane

Connection to drainage pipe

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Solving your
Challenges in
Tunneling and
Mining