Benefits Of Cement Grouting - Le Fong Business Services | Waterproofing Contractor Singapore

Grouting Singapore

Le Fong possess a wide range of specialist grouting Singapore plant that is able to operate at a range of pressures up to 1000psi, and, are proven with a variety of specialist cementitious grout mix designs, including sand:cement, cement bentonite and plasticizes. Water reducing agents and plasticisers are regularly used within our day-to-day grouting operations to improve work-ability and reduce bleed.

We provide the following grouting services:

Chipping Concrete Pressure Grouting
Foam, PU, Epoxy & Cementitious Grouting
Acrylic Gel Grouting for Soil Reinforcement
Leakage Investigation & Repair
Shotcreting
Tunnel Repairs

A range of proven cementitious grouting techniques are available in-house including:

Ground improvement and soil stabilisation grouting for enhancement of the mechanical properties of the soil and remediate problems associated with subsidence
Under-slab grouting and re-levelling
Bentonite/cement grouting to impregnate open soil
Fissured rock grouting typically performed in downward phases
Void filling to eliminate collapses, sink holes or depressions associated with deformation of the ground surface
Tube-a-manchette grouting to improve uplift resistance of bridge substructures and foundations (the tube-a-manchette is first sealed in place followed by grouting via a double-packer located over discretely positioned valves within the tube-a-manchette)
High-pressure (5MPa) post-grouting in weak soils to improve the bond capacity of ground anchors and soil nails
Structural steel and foundation grouting
Precast concrete grouting for panels, barriers, and columns and associated connections

We provide a full range of specialist construction services in the fields of grouting, ground anchoring, soil nailing, post-tension and drilling. Our reputation as a construction company in Singapore has been built on providing practical and cost effective solutions and we have the right mix of people, resources and expertise required to make your next project a success.

Over the years, a tradition of excellence in civil and structural engineering and construction has become one of our top priorities. Our continually developing technology, operational performance and willingness to innovate, together offers our clients a service of the highest quality and the benefit of sustainable assets.

Shrinkage compensated, super flow micro-concrete

For grouting of gaps with thicknesses ranging from 50 mm to 250 mm.

Some application examples

Structural reinstatement of reinforced concrete beams and pillars.
Restoring the lower flanges of pre-stressed concrete beams of viaducts.
Reinstatement of floor beams and slabs after scarification of deteriorated areas.
Restoring concrete floors (industrial, road and airport).
Grouting of machine baseplates, bridge bearing.

Technical Characteristics

It is a ready-mixed powder composed of high strength cement, selected aggregates and special additives with an expansive agent prepared according to a formula developed in research laboratories.

It once mixed with water, becomes a fluid mortar, suitable for pouring into form-work without separation of the aggregates even when forming great thicknesses.

It once cured, has the following qualities:

very high flexural and compressive strength;
modulus of elasticity and coefficients of thermal expansions and permeability to water vapour similar to those of high quality concrete;
waterproof;
high adhesion to old concrete, providing it has been saturated with water beforehand, and to reinforcing rods especially if they have been treated, two-component and one component;
high resistance to wear due to abrasion

It is recommended for voids up to 250 mm for single placing.

Recommendations

Do not use it on smooth concrete surfaces; roughen them well and insert reinforcing rods if needed.
Do not use it for precision anchorages.
Do not use it for applications by spray or trowel.
Do not add cement or additives to it.
Do not add water after the mix has begun to set.
Do not use it if its packing has been damaged or if it has been opened prior to use.

Preparing the substrate

Remove degraded and loose concrete until the substrate is solid, resistant and rough. Any previous restoration work which is not soundly bonded should also be removed.
Clean the concrete and reinforcing rods by sandblasting, to remove all dirt, rust, cement laitance, grease, oil and previously applied paints.
Soak the substrate with water.
Allow the excess water to evaporate before pouring in the mix; if necessary, use compressed air to facilitate the removal of the free water.

Preparing the mortar

Pour 3.3-3.5 litres of water into a concrete mixer.

Start the mixer and slowly and continuously pour in.

Mix for 1-2 minutes, scrape any unmixed powder off the sides of the mixer and remix for another 2-3 minutes until the mix is fluid and free from lumps.

Depending on the quantity being prepared, a mortar mixer or drilling machine with a stirrer attachment can be used.

Avoid stirring an excess of air into the mix. Only in exceptional circumstances should the slurry be mixed by hand. Only where it is absolutely necessary, prepare small quantities and mix for at least 5-6 minutes until the slurry is completely smooth and even. It should be remembered that manual preparation requires greater quantities of water, which are detrimental to some of its characteristics, such as mechanical strength, shrinkage, waterproofing, etc

The expansion has been calculated to compensate for hygrometric shrinkage.

In order to be effective, the forces of expansion must be countered with suitable reinforcement or form-work around the substrate.

The expansion phase is completed during the first days of curing.

Applying the mortar

To facilitate the expulsion of air, pour it continuously into the moulds.

Water from it must not be absorbed by the formwork, which should be treated with a form-release oil.

The pour does not need to be vibrated. Make sure that all the parts have been filled. If necessary, use sticks or rods to tamp the slurry into particularly difficult areas.

As an option, it can be applied on the surfaces to enhance the protection against oils and acids.

Precautions to be observed during application and curing

No special precautions need to be taken when the temperature is around +20°C.

In hot weather, it is advisable to prevent the material from being exposed to the sun and to use cold water for preparing the mix.

When the temperature is low, the water used for the mix should be around 20°C.

Once poured, it must be cured very carefully. The surface of the mortar exposed to air must be protected against the rapid evaporation of water particularly in warm and windy environments, as this will cause surface cracks due to plastic shrinkage.

Spray water onto the surface during the first 24 hours of curing or apply a suitable anti-evaporation product.

Cleaning

Before hardening, the slurry can be cleaned from tools with water. After setting, cleaning is very difficult and it can only be removed mechanically

Consumption

20 kg/m2 per cm of thickness.

Packaging

25 kg bags.

Storage

12 months in original packaging in a dry place.

Product Identification

Type: powder

Colour: grey

Maximum aggregate diameter (mm): 6

Density (kg/m3 ): 1300

Dry solid content (%): 100

Hazard classification according to EC 1999/45: Irritant. Before using, refer to the “Safety Instruction for the preparation and application” paragraph and the information on the packaging and safety data sheet.

Customs code: 38245090

Application Data

Colour of the mix: grey

Mixing ratio:one 25 kg bag with 3.3-3.5 litres of water

Consistency of mix: fluid

Density of mix (kg/m3 ): 2250

pH of the mix: >12

Application temperature range: from +5ºC to +35ºC

Pot life at +23ºC and 50% R.H.: 60 minutes

Maximum thickness per application (mm): 250

Final Performance

Mechanical characteriostics:
(according to EN 196/1 – mixing water 13.5%) Compressive strength MPa):

– after 1 day: > 25

– after 7 days: > 55

– after 28 days: > 75

Flexural strength (MPs):

– after 1 day: > 6

– after 7 days: > 8

– after 28 days: > 9

Adherence to substrate (MPs):
(measured by pull-off test on damp concrete):

– after 7 days (+23ºC and 50% R.H.): > 3 (concrete failure)

– after 21 days (7 days at +23ºC and 50% R.H. + 21 days at +60ºC: > 3 (concrete failure)

– after 28 days (7 days at +23ºC and 50% R.H. +21 days at +20ºC: > 3 (concrete failure)

Rapid Chloride Permeability (Coulombs) < 1000

Consistency: Fluid

Slump (%) According to uni norm 7044/72: ≥ 160

Litres of water per 25 KG Bag: 3.3 – 3.5

Non-shrink Grout – ST-NSG

General purpose shrinkage compensated cementitious grouting material with superior flow-ability, high compressive strength and non-shrink properties.

Product Description

ST-NSG is a dry packed proprietary premixed shrinkage compensating cementitious precision grout. It is specially designed for the use of grouting at gaps, holes and base plates, etc. where excessive shrinkage is prohibited for the filling material. It can also be used, when mixed to a lower work-ability, as a patching material for minor repairs for honeycombs or for filling up tie-holes in concrete. ST-NSG is composed of Ordinary Portland cement, graded sand and non-shrink additives, which impart controlled expansion in both the plastic and hardened states.

Features & Benefits

Expansion at early stage and shrinkage compensated at ultimate stage
High early strength and ultimate strength
Can be mixed to plastic, flow-able and fluid states with different water addition
Free from chlorides, nitrates and sulphates
High ultimate strength & low permeability
Hydrogen free gaseous expansion
No bleeding or segregation

Substrate Preparation

The substrate surface must be free from oil, grease, or any kind of loose particles. Interfaces must be patched up to avoid scales, coatings, recessives, pockets, etc. to avoid hindrance of the flow/spread of grout. Bolt holes or fixing pockets must be blown clean to get rid of any dirt or debris. Pressure relief holes/exit should be provided to allow venting of isolated high spots. At appropriate time before grouting, normally several hours, interfaces must be pre-soaked with fresh water and clear up all free water on surfaces thereafter. When levelling shims are used and are to be removed after the grout goes hardened, they should be treated with a thin layer of grease before installation. Form-work should be leak-proof. Rubber/polystyrene stoppers or sealants can be used at joints or bolt holes.

Area of Application

Filling up gaps between reinforced concrete and/or precast concrete elements
Patching material for concrete repairs
Structural concrete repair by grouting
Filling up tie-holes in concrete
Bridge bearings
Machine base plates, etc.
Applying underwater or in tidal zone
Consult Score Tech’s staff for other suitable applications

Mixing & Installation

Mix ST-NSG with electric drill in bucket or all-in-one grouting pump until the required consistency is achieved homogeneously.
When mixing with electric drill for grouting purpose, mix the material with 80% of the recommended quantity of water for at least 3-4 minutes and then add the remaining water and mix for another 1-2 minutes to achieve the best effect of flow-ability.
Sufficient grout must be made available in order to ensure continuous grout pour is achieved. The mixed grout should be poured only from one side to the other side to reduce entrapment of air.
For large volume of grouting, ST-NSG can be applied by pump such as heavy-duty diaphragm pump, screw feed pump or piston pump.

Curing

Under normal circumstances, natural air curing is proved adequate for ST-NSG. However, water mist curing is beneficial to ensure the best performance of ST-NSG under dry or windy condition.

Area of Application

Filling up gaps between reinforced concrete and/or precast concrete elements
Patching material for concrete repairs
Structural concrete repair by grouting
Filling up tie-holes in concrete
Bridge bearings
Machine base plates, etc.
Applying underwater or in tidal zone
Consult Score Tech’s staff for other suitable applications

Package: 30 kg bag

Shelf Life: ST-NSG has a shelf life of 12 months if well kept in dry condition on lifted floor.

Health & Safety

Wear NIOSH approved face mask or equivalent personal protective equipment when handling the material. ST-NSG contains cement which may cause an allergic effect or irritation to eyes and skin. When contact with eyes, flush immediately with large quantity of water.

Reference Standards

British Standard: BS 6319; BS 1881;
Amercian Standard: ASTM C827; ASTM C1090; ASTM C939
Hong Kong Standard: ArchSD General Specification; HKHA MTS Spec. Part D; Product Certificate PCCS-RM; CS1:2010

Technical Data

StoPox IH BV

(formerly known as StoJet IH-BV)
Two-components solvent-free, epoxy resin

Characteristics

Functionality

Low viscosity
Economical
Resistant to wide range of chemicals
Virtually impermeable therefore protecting the concrete against carbonation
High compressive and tensile strength
High slant shear bond strength

Application

Apply by roller / squeegee as a primer or injection method when repairing cracks

Area of use

Structural repair of cracked concrete by injection
Repair and filling of small hairline cracks in reinforced concrete structures
Primer for solvent-free coating/topping systems • Sealer for cement-based surfaces
Steel-plate bonding

Technical Data

The values stated are average values. Due to the use of natural raw material in our products, the actual value determined on an individual delivery may deviate slightly, without compromising product suitability.

Application

Substrate preparation

The substrate to be treated must be sound, dry and free from any contaminants which may prevent good adhesion.

If necessary, the surface should be prepared by mechanical means.

Substrate preparation (cont’d)

When used as a primer/sealer, the maximum moisture content of the substrate should be < 4%, and the pull-off strength of pre-treated substrate should be > 1.5 N/mm2.

Material preparation

Stir the individual components of StoPox IH BV thoroughly. Pour both components into a mixing vessel and mix for approximately 5 minutes using slow-speed drill and paddle until a homogeneous mixture is obtained. Transfer the contents to a clean container and re-mix. Use the product as quickly as possible after mixing.

Coating procedure

As a primer or sealer:

StoPox IH BV can be applied by means of a squeegee, roller or sprayed in one layer as a primer or two layers as a sealer.

If necessary, scatter each freshly applied layer Sto Filler 30/60 @ approximately 1.0kg/ m2, otherwise remove surface gloss with a mechanical grinder.

As an injection system for crack repair:

Prepare surface by removing laitance, dust, paint, skim coat etc, along the crack for a width of approximately 50mm.

Attach the injection nipple by applying a bead of Sto epoxy crack sealer on the back and then stick it at approximately 300mm c/c along the crack.

Seal the remaining parts of the cracks with Sto epoxy crack sealer. It should be applied in strips of approximately 50mm width and 2mm thickness along the length of the crack. Allow the sealer to cure overnight.

Begin injection at the lowest nipple upward or from one end of the crack if it is horizontal. Once StoPox IH BV has fully cured/hardened, remove the injectors and sealer by grinding.

Working Life

At 10°C approx. 2 hours

At 23°C approx. 90 mins

At 30°C approx. 45 mins

Curing Time

At 23°C

Tack free 6 hours

Re-touchable 24 hours

Overcoat 24 hours

Full cure 7 days

Consumption

When use as a primer or sealer, coverage rate is approximately 200 – 300g/m2, depending on porosity of the substrate.

Application Temperature

Minimum application temperature +15°C

Maximum application temperature +45°C

Cleaning of Tools

Tools must be cleaned immediately after use with thinner.

Delivery

Colour: Colourless

Packing: StoPox IH BV is available in 1kg, 4kg and 15kg set.

Storage

Storage Life/conditions: The shelf life of StoPox IH BV is approximately 12 months if stored in cool dry conditions.

Special Notes

Safety Precautions:

After full curing, StoPox IH BV is physiologically harmless. Keep the resin and hardener away from eyes, mouth and skin. Do not inhale vapour. Protective gloves should be used when handling this product. If skin contact with resin occurs, cleaned immediately with soap and plenty of water. DO NOT use solvent. The use of goggles is recommended, however, should accidental eye contamination occur, rinse thoroughly with plenty of clean running water and seek medical treatment immediately.

Technical Support:

Please consult Sto Technical Service Department or the local sales office for further information and any site assistance required.

Disclaimer:

Sto Products are guaranteed against defective materials and manufacture and are sold subject to its standard terms and conditions. Whilst efforts are made to ensure that any advice, recommendation, specification or information STO SEA may give is accurate and correct, it cannot accept any liability either directly or indirectly arising from the use of its products as it has no direct or continuous control over where or how the products are applied, whether or not in accordance with any advice, specification, recommendation or information given by it. If any product fails to conform, STO SEA will replace the product at no cost to the buyer. Replacement of any products shall be the sole and exclusive remedy available and buyer shall have no claim for incidental or consequential damages. Any warranty claim must be made within six months from the date of the claimed breach. Buyers shall be solely responsible for determining the suitability of products for their intended use.

HA Cut AF : longevity of cured material

Introduction

This report describes tests to estimate the longevity of cured HA Cut AF; the principle is to expose cured HA Cut AF to higher temperatures (80°C and 50 °C) and to monitor the decrease in compressive strength under both storage conditions until a critical level is reached. In this experiments the critical level of the compressive strength is 80 % of the original value. If the decrease in both conditions is different, the results can be put in an Arrhenius plot. With this equation it will be possible to extrapolate the time needed to decrease the tensile strength to 80 % of the starting value at e.g. 20°C.

Method

HA Cut AF is cured in confined conditions in a stainless steel mold. The cured product is cut in blocks of 4 cm x 4 cm x 4 cm. In total 60 blocks were made. The blocks are stored in sand 0,2–0,4 mm; half of the samples is stored in a closed recipient at 50 °C and the other half is stored at 80 °C. At regular time intervals 4 samples of each test condition are tested on compressive strength. This monitoring is done until a decrease of the compressive strength of 20 % in one or both conditions can be observed. The difference in the rate of decrease in both conditions allows to put the data in an Arrhenius plot. With the Arrhenius plot an extrapolation can be made of the time needed to reach a decrease of 20 % in compressive strength at normal conditions, eg. 20°C. The test started on 07/09/2016 and ended on 07/12/2017.

Results

The following graph shows the results of the compressive strength measurements. The results are expressed as % of the starting value; the starting compressive strength was 55 MPa. Each data point is the average of 4 individual measurements.

With the equations of both trend lines the time for the compressive strength to drop to 80 % of the starting value can be calculated. The following Arrhenius plot can be made by putting the temperatures in 1/K * 1000 and taking the logarithm of the time in hours.

In this way it can be calculated how long it would take at 20°C for the compressive strength of HA Cut AF to drop to 80 % of the starting value : the result of this calculation is more than 120 years.

Conclusion

In order to try to assess the life expectancy of cured HA Cut AF, a product property has to be monitored and a critical value is to be chosen; in the reported experiments the monitored property is the compressive strength of HA Cut AF samples stored in wet sand at 50°C and 80°C, and the criticial value is set at 80 % of the starting compressive strength.

The evolution of the compressive strength was monitored during 15 months. Out off the difference of the evolution of the compressive strength of samples stored at 50°C and 80°C an Arrhenius plot can be made; this plot enables to extrapolate the time required for the compressive strength to drop until 80 % of the starting value at ambient temperatures. The outcome of the tests in this report is that it takes at least 120 years for the compressive strength of HA Cut AF to drop to 80 % of the original value when in contact with wet sand at 20°C.

Hydro Active® Cut CFL AF

Next generation, phthalate free, closed cell, 1-component, high performance, low viscosity, hydrophobic, hydro-active, semi-rigid polyurethane injection grout for cutting off gushing water leaks with a high flow rate and/or high hydrostatic pressure in applications where both high strength and flexibility are required.

Product Description

In its uncured form, Hydro Active® Cut CFL AF (hereby referred to as HA Cut CFL AF) is a dark brown, non-flammable liquid without phthalate plasticisers. HA Cut CFL AF is a next generation 1- component injection resin with improved waterproofing and water cutting performance. When it comes in contact with water, the grout expands and quickly (depending on temperature and the amount of catalyst HA Cut Cat AF used) cures to a tough, semi-rigid, closed-cell polyurethane foam that is generally unaffected by corrosive environments.

Field of Application

Designed for cutting off gushing water leaks with a high flow rate and/or high hydrostatic pressure in moving or non-moving joints or cracks.
Used to block leaks into diaphragm walls.
Filling large voids such as rock fissures, crushed faults, gravel layers, joints, cracks and honeycombs in concrete structures that are subjected to small settlement or movement.
For curtain injections behind tunnel segments.
For screen injection behind porous structures when high velocity water streams are present.

Product Advantages

• ADR free transport

• Next generation resin with improved waterproofing performance

• Improved cell structure of the cured compound resulting in better mechanical properties and durability

• Phthalate free resins, REACH compliant

• Improved performance at temperatures below 5°C, no crystallisation of HA Cut Cat AF

• Fast, Extra-Fast and Super Extra-Fast catalysts available for applications where the standard catalyst reaction speed is insufficient due to low temperatures or very high water flow (See respective Technical Data Sheet)

• HA Cut CFL AF forms a semi-rigid gasket with high strength and a small amount of flexibility in the joint or crack

• Non-flammable, solvent free

• User friendly: 1-component material

• Controllable reaction times: by using catalyst curing times can be reduced

• Cured compound is resistant to most organic solvents, mild acids, alkalis and micro-organisms (*)

(*) For chemical resistances please contact your local GCP representative.

Application

Before commencing the injection, consult the Technical Data Sheets and Material Safety Data Sheet (MSDS) in order to be familiar with the materials at hand. Always shake the HA Cut Cat AF well before use.

1. Surface Preparation

• Remove surface contaminants and debris to establish the pattern of the crack or joint. Active leaking cracks larger than 3mm need to be sealed with an approved method.

• Drill holes of the correct diameter for the selected packer. Drill at an angle of 45°. Preferably the holes should be drilled staggered around the crack to insure good coverage of the crack in case it is not perpendicular to the concrete surface.

• The depth of the bore should be approximately half of the thickness of the concrete. As a rule of thumb the distance of the drill point from the crack is half the wall thickness.

• Distance between holes can vary by 15 to 90cm, depending on the actual situation.

• Insert the correctly sized packer into the hole up to 2/3 of its length. Tighten with a wrench or spanner by turning clockwise until sufficient tension has been reached to keep the packer in place during injection.

• Flush the crack with water before injecting with resin. This will flush out dust, debris and prime the crack for the injection resin and improve penetration of the product into the crack. Water in the crack will activate the resin.

2. Resin and Equipment Preparation

• Prepare the resin with the predetermined amount of catalyst. Shake HA Cut Cat AF well before use.

• No reaction with the resin will occur until the resin comes into contact with water.

• Protect the resin from water, since this will trigger a reaction in the container used and might cause the resin to harden or foam prematurely within the injection equipment.

• It is highly recommended to use separate pumps for the water and the resin injection to prevent cross contamination and blockages.

• The pumps should be thoroughly primed with Washing Agent Eco to lubricate and dry the system before injection. We recommend the use of pneumatic or electric 1-component pumps.

3. Injection

• Start the injection at the first packer.

• Start injecting at the lowest pressure setting of the pump. Slowly increase the pressure until the resin begins to flow. Pressures may vary from 14 bars to 200 bars depending on the size of the crack, the thickness of the concrete and the general condition of the concrete.

• A little leakage of resin through the concrete or crack is useful in showing the extent of resin travel. Large leaks should be plugged with rags, wait for the resin to set, then inject again.

• During the injection water will first flow from the crack, followed by foaming resin. After this, pure resin will flow from the crack.

• Stop pumping when the pure resin reaches the next packer.

• Move to the next packer and repeat the procedure.

• After injecting through a few of the packers, go back to the first one and re-inject with resin.

• After the resin injection, water can be re-injected into the ports to cure resin left behind.

• Let the resin cure thoroughly before removing packers. The resulting holes can be filled with hydraulic cement.

• When the injection is finished, clean all tools and equipment which have been in contact with the resin with Washing Agent Eco. This should be done within 30 minutes. Do not use solvents or other cleaning products since they give less positive results and can create hazardous situations.

• Products should be disposed off according to local legislation.

Technical Data / Properties

4. Reactivity

Appearance

HA Cut CFL AF: Dark brown liquid.

HA Cut Cat AF: Red liquid.

Consumption

Has to be estimated by the engineer or operator and depends on the size of the cracks and voids which need injecting, and on the expansion rate of the chosen resin.

Storage

HA Cut CFL AF is sensitive to moisture and should be stored in original containers in a dry area. Storage temperature must be between 5°C and 30°C. Once the packaging has been opened, the useful life of the material is greatly reduced and should be used as soon as possible.

Shelf life: 2 years.

Packaging

HA Cut CFL AF

5kg, 25kg or 200kg metal drums

1 Pallet:

180 x 5kg drum 24 x 25kg drum 4 x 200kg drum

HA Cut Cat AF

0.5 or 2.5L plastic bottle or 20kg metal drum

1 box = 8 x 0.5L

1 box = 5 x 2.5L

1 Pallet:

84 boxes with 0.5L bottles

40 boxes with 2.5L bottles

24 x 20kg metal drums

Accessories

To be ordered separately

• IP 1C – Manual hand pump.

• IP 1C – Compact electric airless diaphragm pump.

• IP 1C – Pro electric airless diaphragm pump.

• Packers and connectors. (Please consult the relevant data sheet).

Health and Safety

HA Cut CFL AF is classified as harmful.

HA Cut Cat AF is classified as irritant.

In case of spills and accidents, refer to the Material Safety Data Sheet of the products or when in doubt contact your local representative.

Always wear protective clothing, gloves and protective goggles when handling chemical products.

For full information, consult the relevant MSDS.

Hydro Active® Flex LV AF/Flex SLV AF

Next generation, phthalate free, closed cell, 1-component high performance hydrophobic, hydroactive, flexible polyurethane injection grouts for waterproofing leaking joints and cracks.

Product Description

In its uncured form, Hydro Active® Flex LV AF/Flex SLV AF (hereby referred to as HA Flex LV AF/Flex SLV AF) are white or yellow, non-flammable liquids without phthalate plasticisers. HA Flex LV AF/Flex SLV AF are next generation 1-component injection resins with improved waterproofing performance. When they come in contact with water, the grout expands and quickly (depending on temperature and the amount of accelerator HA Flex Cat AF used) cures to a tough, flexible, closed-cell polyurethane foam that is essentially unaffected by corrosive environments.

Field of Application

HA Flex LV AF /Flex SLV AF

• Designed for grouting joints or stopping water leaks in concrete structures, which are subject to settlement and movement.

• Used for protective waterproofing and gap filling around the brush tails of the TBM and for repairing the waterproof gasket.

• For stopping water leaks through joints between tunnel segments.

• For injection of the LDPE or HDPE membrane in tunnel constructions.

• For curtain injections behind tunnel segments.

HA Flex SLV AF (Specific fields of application)

Specifically developed for injection of fine and ultra fine crack and joints.

Joint and Crack Dimensions

• Always select a resin based on the crack or joint size to be injected.

• Small cracks will require low or ultra-low viscosity resins to ensure good crack penetration.

As a general recommendation, the following crack dimensions can be used:

HA Flex LV AF: Cracks > 0.5mm

HA Flex SLV AF: Cracks < 0.5mm

Product Advantages

• ADR free transport

• Next generation resin with improved waterproofing performance

• Improved cell structure of the cured compound resulting in better mechanical properties and durability

• Phthalate free resins, REACH compliant

• Improved performance at temperatures below 5°C, no crystallisation of HA Flex Cat AF

• HA Flex LV AF /Flex SLV AF form a flexible gasket or flexible plug in the joint or crack

• Non-flammable, solvent free

• Choice of different expansion rates

• User friendly: 1 – component product

• Controllable reaction times: by using catalyst curing times can be reduced

• Cured compound is resistant to most organic solvents, mild acids, alkalis and micro- organisms (*)

Application

• Before commencing the injection, consult the Material Safety Data Sheet (MSDS) in order to be familiar with the materials at hand.

• Always shake the HA Flex Cat AF well before use.

1. Surface Preparation

• Remove surface contaminants and debris to establish the pattern of the crack or joint. Active leaking cracks larger than 3mm need to be sealed with an approved method.

• The depth of the bore should be approximately half of the thickness of the concrete. As a rule of thumb the distance of the drill point from the crack is half the wall thickness.

• Distance between holes can vary by 15 to 90 cm, depending on the actual situation.

2. Resin and Equipment Preparation

• Prepare the resin with the predetermined amount of catalyst. Shake HA Flex Cat AF well before use. No reaction with the resin will occur until the resin comes into contact with water.

• Do not prepare more resin than can be injected within 4 hours after mixing HA Flex Cat AF in the resin. Avoid mixing full drums, it is recommended to batch mix smaller quantities in a separate pail or in the pump reservoir.

• Protect the resin from water, since this will trigger a reaction in the container used and might cause the resin to harden or foam prematurely within the injection equipment.

• It is highly recommended to use separate pumps for the water and the resin injection to prevent cross contamination and blockages.

• The pumps should be thoroughly primed with Washing Agent Eco to lubricate and dry the system before injection. We recommend the use of pneumatic or electric 1- component pumps.

3. Injection

• Start the injection at the first packer.

• A little leakage of resin through the concrete or crack is useful in showing the extent of resin travel. Large leaks should be plugged with rags, wait for the resin to set, then inject again.

• During the injection water will first flow from the crack, followed by foaming resin. After this, pure resin will flow from the crack.

• Stop pumping when the pure resin reaches the next packer.

• Move to the next packer and repeat the procedure.

• After injecting through a few of the packers, go back to the first one and re-inject with resin.

• After the resin injection, water can be re-injected into the ports to cure resin left behind.

• Let the resin cure thoroughly before removing packers. The resulting holes can be filled with hydraulic cement.

• When the injection is finished, clean all tools and equipment which have been in contact with the resin with Washing Agent Eco. This should be done within 30 minutes. Never leave the pump filled with resin overnight or for periods beyond 1 shift. Do not use solvents or other cleaning products since they give less positive results and can create hazardous situations.

• Products should be disposed off according to local legislation.

• Refer to Material Safety Data Sheet (MSDS) for general recommendations. In case of spills and accidents, refer to the MSDS of the products or when in doubt contact your local GCP representative. Always wear appropriate protective gear for the job at hand according to local guidelines and regulations. We recommend that gloves and protective goggles are worn when handling chemical products. See MSDS for further recommendations.

4. Reactivity

Technical Data / Properties

Appearance

HA Flex LV AF: Yellow liquid

HA Flex SLV AF: Yellow liquid

HA Flex Cat AF: Grey transparent liquid

Consumption

Has to be estimated by the engineer or operator and depends on width and depth of the cracks and voids which need to be injected, and on the expansion rate of the chosen resin.

Packaging

HA Flex LV AF /Flex SLV AF

5kg, 25kg or 200kg metal drums

1 Pallet: 180 x 5kg drum

24 x 25kg drum

4 x 200kg drum

HA Flex Cat AF

0.25 or 1L plastic bottle or 20kg metal drum

1 box = 15 x 0.25L

1 box = 16 x 1L

1 Pallet: 84 boxes with 0.25L bottles

24 boxes with 1L bottles

24 x 20kg metal drums

Storage

HA Flex LV AF/Flex SLV AF are sensitive to moisture and should be stored in original containers in a dry area. Storage temperature must be between 5°C and 30°C. Once the packaging has been opened, the useful life of the material is greatly reduced and should be used as soon as possible.

Shelf life: 2 years.

Accessories

To be ordered separately

• IP 1C – Manual hand pump.

• IP 1C – Compact electric airless diaphragm pump.

• IP 1C – Pro electric airless diaphragm pump.

• Packers and connectors. (Please consult the relevant data sheet).

Health and Safety

HA Flex LV AF/Flex SLV AF resins are classified as harmful.

HA Flex Cat AF is classified as irritant.

In case of spills and accidents, refer to the Material Safety Data Sheet of the products or when in doubt contact your local GCP representative. Always wear protective clothing, gloves and protective goggles when handling chemical products. For full information, consult the relevant MSDS.

Hydro Active® Safefoam NF

Environmentally friendly, phthalate free, low viscosity hydrophilic polyurethane injection resin designed for moving non-structural cracks. Hydro Active Safefoam NF can be used as a 2-component 1:1 ratio system with water as second component

Product Description

Hydro Active® Safefoam NF (hereby referred to as HA Safefoam NF) is a single component, phthalate free, low viscosity, hydrophilic, polyurethane resin. After curing HA Safefoam NF forms an inert, flexible, close cell foam with very good tensile and adhesion properties. HA Safefoam NF can be used as a 2-component system with a 1:1 ratio water for injection into dry cracks.

Field of Application

• For sealing dry, moving, non-structural cracks as a 2-component system with a 1:1 ratio with water.

• For sealing moist, moving non-structural cracks as a 1-component system.

• For sealing water leaks between the joints of concrete tunnel segments.

• For curtain injections behind tunnel segments.

• For sealing moving, leaking cracks.

• Filling of honeycombs below ground water level.

• For waterproofing man and non-man accessible sewer pipes.

• For expansion joints or annular joints in combination with oil-free dry oakum or open cell foams.

Product Advantages

• ADR free transport

• Phthalate free resin, REACH compliant

• Non-flammable

• High bond and tensile strength

• Withstands thermal movement, wet-dry cycles, freezethaw cycles and crack movement without degradation

• Good all-round chemical resistance (*) (*) For chemical resistances please contact your GCP representative.

Application

HA Safefoam NF can be used as a 1-component system for injection into moist conditions or as a 2-component system with a 1:1 ratio with water for injection in dry conditions.

Before starting the injection, consult the Technical Data Sheets and Material Safety Data Sheet (MSDS) in order to be familiar with the materials at hand.

Injection

• Drill holes of the correct diameter for the selected packer. Drill at an angle of 45°.

• Preferably the holes should be drilled staggered around the crack to insure good coverage of the crack in case it is not perpendicular to the concrete surface. The depth of the bore should be approximately half of the thickness of the concrete. As a rule of thumb the distance of the drill point from the crack is half the wall thickness.

• Distance between holes can vary by 15 to 90cm, depending on the actual situation.

• Insert the correctly sized packer into the hole up to 2/3 of its length.

• Tighten with a wrench or spanner by turning clockwise until sufficient tension has been reached to keep the packer in place during injection.

• Start the injection at the first packer. Start injecting at the lowest pressure setting of the pump. Slowly increase the pressure until the resin begins to flow. Pressures may vary from 4 bars to 200 bars depending on the size of the crack, the thickness of the concrete and the general condition of the concrete. A little leakage of resin through the concrete or crack is useful in showing the extent of resin travel. Large leaks should be plugged with rags, wait for the resin to set, then inject again.

• Stop pumping when the pure resin reaches the next packer. Move to the next packer and repeat the procedure. After injecting through a few of the packers, go back to the first one and re-inject with resin. Let the resin cure thoroughly before removing packers. The resulting holes can be filled with hydraulic cement.

• When the injection is finished, clean all tools and equipment, which have been in contact with the resin with HA Washing Agent Eco. This should be done immediately. Do not use solvents or other cleaning products since they give less positive results and can create hazardous situations.

Technical Data / Properties

• Products should be disposed off according to local legislation. Refer to MSDS for general recommendations.

• In case of spills and accidents, refer to the MSDS of the products or when in doubt contact your local Grace representative.

• Always wear appropriate protective gear for the job at hand according to local guidelines and regulations. We recommend that gloves and protective goggles should be worn when handling chemical products. See MSDS for further recommendations.

Appearance

HA Safefoam NF: Pale yellow liquid.

Consumption

Has to be estimated by the engineer or operator and depends on width and depth of the cracks and voids which need to be injected.

Packaging

HA Safefoam NF

25kg metal drum

1 pallet: 24 drums

Storage

HA Safefoam NF is moisture sensitive.

HA Safefoam NF should be stored in a dry and frost free area, free from ground.

Storage temperature must be between 5°C and 30°C.

Once the packaging has been opened, the useful life of the material is greatly reduced and should be used as soon as possible. Shelf life: 2 years.

Accessories

To be purchased separately

• IP 1C – Manual hand pump.

• IP 1C – Compact electrical airless diaphragm pump.

• IP 1C – Pro electrical airless diaphragm pump.

• IP 2C – Gel pneumatic twin piston pump.

• Packers and connectors.

(See relevant data sheets).

Health and Safety

HA Safefoam NF is classified as harmful.

All persons in contact with the materials should wear the appropriate protective clothing and gloves. Spills should be washed immediately with abundant quantities of clean water.

For full information, consult the relevant MSDS.

HA Cut AF + HA Cut Cat SXF – behavior injected in Ice at -30°C

Scope

To check the reaction properties and exothermic effects of HA Cut AF+ HA Cut Cat SXF AF on ice and frozen soils a mixture of the resin is reacted in ice samples the reacted

Sample preparation: 4 Samples prepared

2x Approx. 800 ml of salt water (containing 3,5% NaCl) is frozen at -30°C

2x A mixture of 1500 g sand + 300 ml salt water is frozen at -30°C

In the middle of the samples a cylindrical hole is drilled with a 13mm and 24mm diameter and a 6 to 7 cm depth.

Volume of the hole in sample 1/3: approx. 10ml, volume of the hole in sample 2/4: approx. 30 ml

Sample 1 & sample 3 prior to injection

Test procedure

– In the samples with a 13mm diameter hole 5 ml of precatalyzed resin (HA Cut AF + 10% HA Cut Cat SXF AF is injected simultaneously with 0,75 ml water.

– The resin + water is mixed for approx. 10” and left to react.

– The foaming is monitored

– After foaming the excess foam is removed and the properties of the drilled cylinder examined to check the foam quality, and to check whether any signs of melting, deformation or cracking has occurred to the frozen material.

Left: climate chamber at -30°C

Middle: sample 2 is injected with 10 ml catalyzed resin+ 1,5 ml water, and then mixed

Right: sample 2 during foaming/while reacting

Test results

Left to right: sample 2, 3 &4 after foaming

Sample examination

Directly after the foaming, the excess foam on top of the sample is removed, the integrity of the sample and the diameter of the opening is checked, to know whether there was any sings of melting, or physical movement of the ice / soil around the injected foam mass.

Left& middle: sample 4 after partial removal of the foam.

Right: the diameter of the samples does not change during the test (photo: sample 2)

– The foams are relatively dense.

– None of the samples shows signs of deformation or melting.

– The aspect and size of the injected holes is not affected by the injection of the resin.

Conclusion

The exothermic reaction of free foam HA Cut AF + HA Cut SXF AF does not thaw the surrounding ice or frozen soil.

The cold temperatures slow down the reaction of the resin with water, the resin foams to form a good quality foam (but with lower foam factor compared to free foam in ambient temperature conditions)

CROSS TUNNEL PROJECT

INFLUENCE OF STORAGE AT -30°C ON REACTED RESINS

PROJECT

Cross tunnel between 2 metro line at a depth of 30 meter.

Initially a grout fan ( arch ) will be made where after they’ll need to apply ground freezing.

SAMPLES

Cured samples of HA CUT AF and HA SOIL AF, pure and injected in sand. Half of the samples are stored at 20°C and the other half are stored for 4.5 days at -30°C, microscopic pictures will be taken before and after.

SAMPLES

HA CUT AF pure before / after 4.5 days storage at -30°C

HA SOIL AF pure before and after 4.5 days storage at -30°C

HA CUT AF injected in sand before / after 4.5 days storage at -30°C

HA SOIL AF injected in sand before and after 4.5 days storage at -30°C

RESULTS

CONCLUSION

Microscopic observation shows that the structure of the pure-resin-samples and resin injected in sand samples does not change after 4.5 days storage at -30°C. This applies both to HA CUT AF and HA SOIL AF.

Compressive strength measurement does not show any detrimental effect of storage at -30°C during 4.5 days.

De Neef®

Gelacryl acrylate injection resins

Gelacryl resins

Poly-acrylate resins
Gelacryl
Gelacryl SR
Gelacryl Superflex
Special systems / resins
CementGel W
AR systems for wet-dry applications
GASFAR for open joints

Poly-acrylate resins

2-component systems

Comp 1
(Water)
Gelacryl Accelerator (TE300)

Comp 2
Water, use only tap water Initiator (SP200)

2-component pump IP 2C-Gel
NON CORROSIVE

GELACRYL

2-component
Water soluble
Gel
No strength
Flexible
Very low viscosity
No expansion
No pressure
Very good penetration
Short injection distance
Very small cracks (0,05 mm)
Light and UV sensitive

1-comp PU

1-component
Water reactive
Foam
High strength
Flexible or hard
Low to medium viscosity
Expansion
Pressure
Very good penetration
Short to long injection dinstance
Small to large cracks
Moisture sensitive

Gel needs to remain moist at all times => shrink of the gel

Can be countered by using AR systems

GELACRYL V 1-comp PU

REACTION PROFILE

60 % of injections = screen injection in soil behind the structure.

Well suited for masonry: no pressure build-up
Gel remains moist and flexible due to soil humidity.

40 % of injections = Injection of screen between layers of the structure

=> Between concrete pours
=> Filling voids between walls
=> PVC tunnel liner with injection ports

Crack injection in concrete and masonry.

Very efficient for small cracks < 0.5 mm
In concrete this is a CE application : Gelacryl Superflex AR
Optimum is injection through the crack so that the Gelacryl
Forms a screen between structure and soil

Gelacryl crack injection

PRINCIPAL OF INJECTION

Multiple layer construction
Screen needs to be on the outside behind:
Isolation layer
Existing membrane
Prevent filling of void between layers
Use specially adapted packers with elongation tubes.
Packers which seals the drill hole at the back to
prevent resin from coming back.

PRINCIPAL OF INJECTION

Hollow brick walls
Consumption can be high due to the voids in the bricks.
Fill up with cement grout before injection of Gelacryl screen.
Injection under floor slabs
Use packers where the rubber seal close the drill hole at the bottom
This keeps the hole open to be filled with cement or epoxy after the injection
Make sure to maintain the structural integrity of the slab

Gelacryl resins overview

Low viscosity : Excellent penetration
Elongation / elasticity : Depends on application
Post expansion : Extra waterproofing due to build up of pressure against structure’s surface
Adhesion : Extra waterproofing due to adhesion of gel against the structure

GELACRYL / GELACRYL SUPERFLEX APPLICATIONS

Screen injections behind structure for waterproofing
Screen injections behind masonry structures
Soil stabilisation (= coagulation)
Screen injections behind tunnel segments
Sealing tunnel liners (Superflex)
Moving cracks (elongation)
Waterproofing expansion joints
Sealing capillaries with small movements

Gelacryl SR soil injections

RENOVATION PROJECT BRUSSELS

Soil injection with Gelacryl SR
Existing slab needs to be lowered 50 cm
High ground water level
Water needs to be stopped before excavation
Installation of a grid with plastic strainer pipes
Injection with Gelacryl SR, 5’ geltime
Build up of waterproof soil encasement.
Core drills showed little water