Solutions for Underground Construction

Injection
Injection

Introduction

Master Builders Solutions – connecting Avoid the Unexpected

innovation and reliability for a sustainable future
Unexpected water ingress and poor ground conditions
The Master Builders Solutions brand brings all of BASF’s during underground construction and mining usually escalate
expertise together to create chemical solutions for costs, can severely influence the environment, and inevitably
new construction, maintenance, repair and renovation cause significant delays. To counteract these risks, an
of structures. Master Builders Solutions is built on the economical approach is to pre-inject the ground ahead of
experience gained from more than a century in the the advancing face to avoid water ingress occurring, or to
construction industry. use post-injection techniques as a water stopping measure,
for which a broad range of products and technologies are
The know-how and experience of a global community available. In light of the modern world’s focus on stricter
of BASF construction experts form the core of Master legislation covering the environment and workers’ health and
Builders Solutions. We combine the right elements from safety, stabilization of sands and soils requires both durable
our portfolio to solve your specific construction challenges. and safe mineral grouts and microcements.
We collaborate across areas of expertise and regions and BASF offers a complete range of injection products suitable
draw on the experience gained from countless construction for all projects, including new and existing tunnels, mines and
projects worldwide. We leverage global BASF technologies, large civil engineering projects such as dams.
as well as our in-depth knowledge of local building needs, to
develop innovations that help make you more successful and
drive sustainable construction.

Global Underground Construction Team

BASF, with its global underground construction team, is a

world leader in the provision of reliable, customer-oriented
product solutions focused on your needs in the tunneling
and mining industries. We recognise that your success is
underpinned by our ability to deliver solutions that meet or
exceed your critical needs. By accompanying you from the
start of your project and understanding the issues that are
important to you, we can contribute to your success.

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Water Ingress Reduction and Ground Rapid Water Ingress Reduction
Consolidation
The post-injection polyurethane and polyurea silicates, also
The pre-injection method can solve difficulties ahead of the known as resins, can be used to combat large water ingress
tunnel face – a simple and cost-effective approach. quickly and effectively.
Microcements and mineral grouts, the latter known as For particularly difficult cases the solution is a combination of
colloidal silica, are used in such cases. They improve working drainage and the injection of a rapid reacting foaming resin.
safety with minimal environmental consequences.

Rehabilitation of Tunnel Linings

Rapid Ground Consolidation
This post injection method can be used for rehabilitation
Quick reacting post-injection systems can immediately injection for cast concrete, segment lining and brick &
stabilize poor ground and be used to fill voids as a result of masonry lined tunnels.
cave-ins. The range of acrylate resins are particularly suitable for
The polyurethane and polyurea silicate systems are approved durable structural concrete crack injection, as well as the
for use in coal mining and are also used widely in hard rock polyurethane resin MasterRoc® MP 354 CE for concrete
mining and tunneling. repair.

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Injection

Microcement

Excavation face

Injection drillhole

Invert

Fast Setting, Fast Cycle Stable Penetrating Grout

MasterRoc MP RHEOCEM® microcements are a range of Features and benefits:

superfine portland cements specially made for injection into
rock and soils. Due to their fineness they provide extremely • Reduced time for a given result − less drilling and less
effective penetration into fine cracks in rock and fine grained pumping, with no waiting time for the cement to set
soils to give efficient water tightness, stability and durability. • Improved quality of work due to fast grout without
They represent a significant technological advantage in bleeding (w/c=1)
cementitious injection. Their unique feature is rapid and • Further reduced setting with the in-line addition of alkali-
controlled setting, allowing uninterrupted blasting rounds free set accelerators
or continued injection sequences, thereby enhancing • Excellent grout stability under high pumping pressure
productivity considerably. ensuring efficient penetration into rock and soils
MasterRoc MP RHEOCEM microcements are also available • Very good penetration into small cracks and inter-granular
as sulphate resisting versions and in different grades relating spaces
to the maximum particle size as given by the D95 values • Better working environment as MasterRoc MP RHEOCEM
illustrated in the image on page 5. contains no toxic products
• High durability
• Economical solution
• Standard cement injection equipment can be used.

4
 Injection drillhole

Aperture
0,02 mm
Colloidal Silica, MasterRoc MP MasterRoc MP MasterRoc MP Ordinary Portland Cement
MasterRoc MP 320 900 RHEOCEM 800 RHEOCEM 650 RHEOCEM CEM I 52.5
0,015 µm 9 µm 12 µm 15 µm 40 µm

Controlled Accelerated Setting of Microcement The main technical properties which can be achieved with
Suspensions this injection technology are:

The setting of grout suspensions based on MasterRoc • Controlled injection with limitation of grout spread in very
MP RHEOCEM microcements can be accelerated with permeable rock masses and soils.
a controlled dosage of alkali-free accelerator. Using this • Controllable injection with fast setting in cold groundwater
method, the open time of the grout suspension can be conditions, where conventional cements and
controlled from 1-2 minutes up to approximately 20 minutes, microcements would only cure over a long time frame
before it sets and becomes solid. (several days).

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Injection

Polyurethane and Polyurea Silicates

Water Stopping Tailor Made for Underground Use

• The MasterRoc MP 350 series of polyurethanes and the Features and benefits of MasterRoc MP injection resins:
fire resistant (according to DIN4102-B2) MasterRoc MP • All polyurethane and polyurea silicate products are solvent
360 series of polyurea silicates are designed for water free and build closed cell foams.
stopping and sealing, strata stabilization and cavity filling • Many of the products for preventing water ingress
in mining and tunneling applications, meeting the modern in tunneling can be adjusted on site to give varying
day demands of the tunneling and mining industry. performance properties to suit the conditions using
• The range varies from a convenient 1 component PU for different accelerators.
small water sealing jobs to specialist robust 2 component • The polyurea silicate range has been developed to provide
systems to effectively stop massive water ingress fire resistant properties for increased safety underground
problems. with better performance.
• All MasterRoc MP polyurethane and polyurea silicates
have been tested and certified by external institutes
Consolidation and Cavity Filling in terms of technical properties and health and safety
aspects.
• MasterRoc also provides advanced tailor-made resins for
cavity filling and ground consolidation in the demanding
coal mining industry.

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Product Reaction time Foam Applications Equipment
at 20°C factor
MasterRoc MP 350 30 ~ 100s to 8 For permanent structural crack sealing of concrete and ma- 1-component
1 component PU + Separate accelerator sonry structures, filling of dry and water bearing fissures. pump
accelerator provided to adjust
reaction time
MasterRoc MP 354 CE 160 ~ 250 mins 1 CE certified resin, especially designed for concrete repair. Can 1 and / or 2
2 component PU react with stronger expansion in presence of water. component pump
with static mixer
MasterRoc MP 355 1K 10 ~ 120s. 20 to 30 To stop water ingress in tunnels. Consolidation of gravel. Seal- 1-component
1 component PU + Separate accelerator ing cracks in concrete structures. pump
accelerator provided to adjust
reaction time
MasterRoc MP 355 1K DW 15 ~ 130s. 20 to 30 To stop water ingress in tunnels. Consolidation of gravel. 1-component
1 component PU + Separate accelerator Sealing cracks in concrete structures. DW = potable water pump
accelerator provided to adjust approval.
reaction time
MasterRoc MP 355 No Accelerator to 10 Ground consolidation and rapid water stopping in underground 2-component
2 component PU 60 ~ 70s structures. Should not be used in coal mines due to too high pump with static
reaction temperatures. Reacts with and without water. mixer
Accelerator 10 10 to 20 Use of Accelerator 10 allows increased foam factor and faster
40 ~ 60s reactions to deal with major water ingress situations.
Accelerator 15 to 8 Use of Accelerator 15 provides stiffer foam allowing more effec-
30 ~ 50s tive ground improvement properties.
Accelerator 25 to 15 Use of Accelerator 25 combines the functions of Accelerators
20 ~ 60s 10 and 15.
MasterRoc MP 355 TIX The accelerators used Fast reacting, thixotropic PU resin, used for very demanding 2-component
Highly reactive 2 component for MP 355 may also be water stopping conditions where the dilution of PU is likely. The pump with static
PU used (similar reaction resin provides immediate structural strength. mixer
times)
MasterRoc MP 358 SC 30 ~ 70s to 3 High quality foam for ground consolidation in coal mines and 2-component
2 component PU civil projects. Consolidation of fractured rock in tunnels, shafts pump with static
and longwall operations. Sealing against gas and quasi-static mixer
water. Less sensitive to water than usual polyurethanes.
MasterRoc MP 358 GS 30 ~ 70s < 1.5 Permanent consolidation of broken rock and coal in tunnels, 2-component
2 component PU shafts and longwall operations. Sealing against gas and quasi- pump with static
static water. Extremely high compressive and bonding strength. mixer
Less sensitive to water than other polyurethanes.
MasterRoc MP 364 Flex 90 ~ 120s 1 Dense glue-like resin, with good penetration properties for very 2-component
2 component solvent free effective ground consolidation of coal measures, fractured rock pump with static
urea silicate, fire resistant and gravels. No foaming in contact with water. Can be used for mixer
resin injections under water.
MasterRoc MP 367 Foam 10 ~ 60s 2 to 30 Void and cavity filling in underground construction, tunneling 2-component
2 component solvent free and mining to avoid water or gas accumulation. Consolidation of pump with static
urea silicate, fire resistant fractured rock, sand, gravel and coal. Stabilization of cavities in mixer
resin tunnels. Expands without water.

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Injection

Acrylic Resins

Crack injection in tunnel linings

Possibly leaking joints

Goal of injection:
to section and create barriers,
subsequently removing water.

Water can flow in every direction,

before and during injection.

Strong Durable Gels for Permanent Crack CE Certification

Sealing
The CE certificate specifies requirements and conformity
The MasterRoc MP 300 series is a range of high criteria for the identification, performance (including durability
performance acrylic resins for underground use. They aspects) and safety of injection products for the repair and
can strengthen weak soil and sand immediately and seal protection of concrete structures.
off water. Where water ingress must be avoided they can
permanently seal the finest cracks instantly and even Two of our latest acrylics, MasterRoc MP 303 CE and MP
accommodate limited movement due to their flexibility and 307 CE have CE certification for the “swelling fitted filling of
swelling capability. This makes them ideal products for cracks, voids and interstices in concrete”.
curtain injection behind leaking tunnel linings and diaphragm
walls. They are also widely used in major infrastructure
projects such as power stations’ generator housings for the
permanent waterproofing of concrete defects.

8
 Mastering underground
construction challenges requires
the right partner. Continuous
innovation and customized
solutions ensure that customers
using Master Builders Solutions
operate successfully, and to the
highest safety standards.

Product Reaction time Viscosity Features & Applications Equipment

at 20°C

MasterRoc 1 – 12 min 7 mPa·s Highly reactive acrylic resin with good adhesion to wet surfaces. Flexible 1 and / or 2
MP 301 gel to accommodate ground movement. Designed for stabilization of soil component pump
and heavily broken rock, including micro cracks and capillary pores of soil. with static mixer

MasterRoc 3 – 45 min 3 mPa·s Solvent free, very low viscosity acrylic resin with good adhesion to wet 1 and / or 2
MP 302 surfaces. Flexible gel to accommodate ground movement. Low swelling component pump
pressure and non-corrosive due to low pH value. Suitable for deep with static mixer
penetration into fine cracks, rock fissures and soils.

MasterRoc 10 sec – 3 min 5 mPa·s Economic acrylic resin with good penetration into fine fissures, suitable 2-component
MP 303 CE for crack injection, concrete repair etc. Good adhesion to wet and damp pump with static
surfaces. Can swell up to 200% of initial volume and is re-swellable. Very mixer
flexible: structural stability low. Stable against acidic and alkaline solutions.

MasterRoc 4 – 17 min 7 mPa·s Due to the special latex emulsion of part B, the cured system is rubber- 1 and / or 2
MP 307 CE like, strong and very flexible. Withstands high water pressure and balances component pump
ground movements. Can be used in “living cracks”. Cured material is with static mixer
not sensitive to water and stays close to its original shape (only small
shrinkage or swelling). Good chemical resistance against acids, bases,
solvents, fuels, etc.

MasterRoc 10 – 60 min 40 mPa·s Solvent free acrylic resin designed as a permanent water sealing resin for 1-component
MP 308 cracks. Suitable for injection in damp areas with excellent bonding to wet pump
surfaces. Can swell up to 150% of its initial volume. Swelling is reversible.
Resists permanent water pressure and allows for structural movement.

MasterRoc 45 sec – 8 min 30 13 mPa·s Fast setting super strong acrylic resin with good adhesion to wet rock 2-component
MP 309 and concrete surfaces. It has good chemical resistance against acids, pump with static
bases and fuels. It is a product to be used for special needs, such as mixer
consolidation in silty and sandy strata (where PU is too high in viscosity).
It neither shrinks nor swells. Not suitable for bigger voids.

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Injection

Colloidal Silica

Coalescence

OH- catalyst

OH- catalyst +H2O

Bond Formation
Between Silica
Particles

Setting Takes Place with a Physical Reaction

Si(OH)4

Entirely Natural Ingredients Effective Penetration

The MasterRoc MP 320 products (MP 320 and MP 325) Features and benefits:
are colloidal silica gels, referred to as a “mineral grouts”.
These are not chemical g ­ routs and consist only of • Colloidal silica is environmentally friendly and durable, as it
natural ingredients, making products non-hazardous is simply composed of quartz sand, water and salt.
and ecologically friendly. They are made of a stable liquid • Having a viscosity similar to water, it penetrates soils and
dispersion of discrete, nanometric spherical particles fine rock fissures very easily.
composed of 100% amorphous silicone dioxide. • The gel time can be adjusted with the addition of salt
water, and can be controlled to between 10 minutes and 2
Due to their very low viscosity, they penetrate finer fissures hours.
than any cement based products and ensure unrivalled • Unlike waterglass (sodium silicate) based products,
penetration and permanent stabilization of fine, silty sands. colloidal silica is durable and continually gains strength
over time.
The MasterRoc MP 320 products are used in jointed rock • It is extremely user-friendly as standard cement grout
and fine grained soils as a supplement to microcement equipment can be used, which is easily cleaned with
injections to achieve the final required result and where water.
durable long-term solutions for water sealing and ground • More cost-effective solution than chemical grouts.
stabilization are required.

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Know-How and Service

Training and Education Technical Services

BASF provides technical injection training courses on BASF provides more than simply a supply of products.
a frequent basis centrally located in the Hagerbach Assisting customers in selecting the right injection system
underground facility in Switzerland. In addition, tailored and setting out the injection method, as well as providing
training is organized on large projects for customers when initial supervision and site training of the customer’s
required. personnel, is an essential part of our concept.
Technical training is organized both as demonstration BASF works together with suppliers of equipment and
workshops in realistic underground settings and as practical injection accessories to provide the best, most cost-effective
injection operators’ training. and complete technology solution.
The demonstration workshops are organized as practical
“show-and-tell” sessions and aim to visualize and explain the
possible types of application and the technical performance
of our injection systems.
The practical injection operators’ training is offered
exclusively to injection customers who are working with BASF
injection systems. At this training the participants are given
the chance to work in small groups, taking part in hands-on
exercises under the supervision of experienced instructors.
The main objective is to gain practical skills for the correct
application and execution of injection works.

More brochures on our underground construction solutions are available at www.ugc.basf.com

Documentation available on request:

• Reference list
• Project reports
• Technical data sheets
• Design guidelines
• Method statements

The information given in this BASF publication is based upon the present state of our scientific and practical knowledge. As the information herein is of a generic nature, no assumption
can be made as to a product’s suitability for a particular use or application and no guarantee or warranty as to it’s accuracy, reliability or completeness either expressed or implied is given.

11
 Master Builders Solutions from
BASF for the Construction Industry
MasterAir® MasterFiber® MasterPolyheed® MasterSure®
Complete solutions for air Comprehensive solutions for Solutions for high performance Solutions for workability control
entrained concrete fiber reinforced concrete concrete
MasterTop®
MasterBrace® MasterGlenium® MasterPozzolith® Solutions for industrial and
Solutions for concrete Solution for hyperplasticized Solutions for water-reduced commercial floors
strengthening concrete concrete
Master X-Seed®
MasterCast® MasterInject® MasterProtect® Advanced accelerator
Solutions for the manufactured Solutions for concrete injection Solutions for concrete solutions
concrete product industry protection for pre-cast concrete
MasterKure®
MasterCem ®
Solutions for concrete curing MasterRheobuild® Ucrete®
Solutions for cement Solutions for superplasticized Flooring solutions for harsh
manufacture MasterLife® concrete environments
Solutions for enhanced
MasterEmaco® durability MasterRoc®
Solutions for concrete repair Solutions for underground
MasterMatrix® construction
MasterFinish ®
Advanced Rheology control
Solutions for formwork solutions for self-consolidating MasterSeal®
treatment concrete Solutions for waterproofing
and sealing
MasterFlow® MasterPel®
Solutions for precision grouting Solutions for water tight MasterSet®
concrete Solutions for retardation
control
UGC®: 03/13/Jellyfishadv

Headquarters
BASF Construction Chemicals Europe Ltd BASF Construction Chemicals BASF Australia Ltd
Global Underground Construction
23700 Chagrin Boulevard
Im Tiergarten 7 Beachwood, OH 44122, USA 11 Stanton Road
8055 Zurich, Switzerland Phone +1-216-839 7500 Seven Hills NSW 2147, Australia
Phone +41 58 958 22 11 Fax +1-216-839 8821 Phone +61 2 8811 4200
E-mail [email protected] E-mail [email protected] Fax +61 2 8811 3299

BASF Construction Chemicals UAE LLC BASF SA BASF Construction Chemicals Asia Pacific

P.O. Box 37127 Av. Brigadeiro Faria Lima, 3600 33 Tuas Avenue 11
Dubai Investment Park Andares do 8º ao 14º Singapore 639090
Al Hibab Road, Jebel Ali 04538-132 São Paulo – SP, Brazil Phone +65 6861 6766
Dubai, United Arab Emirates Phone +55 11 2718 5507 E-mail [email protected]
Phone +971 4 8090800 E-mail [email protected]